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This invention relates to a rake attachment used on a skid steer and particularly a rake attachment used for grading, filling, leveling and scarifying soil.
BACKGROUND OF THE INVENTION
Grounds preparation for seeding and lawn installation is a part of most building and construction projects. Preparing soil for seeding and lawn installation involves grading, filling, leveling and scarifying the soil around buildings, side walks, trees and other obstacles. Conventional industrial and commercial earth moving equipment is designed to operate in large open areas, thus they are not well suited for operation in confined areas or around the edges of buildings and other structures. Consequently, most of the finishing work around buildings and confined areas is still performed by laborers with hand tools. Utilizing conventional skid loaders or skid steers as they are commonly known has decreased the amount of hand work involved in lawn and grounds preparation. As a small utility loader, the skid steer is well adapted for precision earth moving operations in confined areas. Skid steers have hydrostatic transmissions with four independent wheels, which allows the skid steers to pivot in place. Skid steers also include hydraulic controlled lift arms and pivoting attachment assembly, which can be operated simultaneously while driving skid steers.
A skid steer can be fitted with various attachments to perform a variety of earth moving functions; however, no single skid steer attachment has been developed to address all the operational needs of the lawn or grounds preparation industry. Bucket attachments are ideal for transporting loads of soil to low lying areas, but are ill suited for spreading the soil radially across the low lying area. The conventional blade type attachment allows the skid steer to grade but does not drag soil or scarify effectively. The bulk of conventional buckets and blade type attachments obstruct the operators view of the ground being worked. Mechanical scarifying rakes have been developed for use with skid steers; however, these scarifying rakes have complex mechanical parts, which are often subjected to stress, which results in damage and often failure. The articulated mechanical scarifying rakes are large and cumbersome, which makes them difficult to operate in confined areas, such as around building and other obstacles. The operator's view of the ground being worked is obstructed by the bulk of the mechanical attachments. Furthermore, the scarifying rakes are ineffective at moving soil to low lying areas. Since no single attachment is suitable for all the lawn preparation functions; namely grading, filling, leveling and scarifying, the skid steer attachments must be frequently interchanged during use at the job site. Transporting multiple attachments is cost ineffective.
SUMMARY OF THE INVENTION
The rake attachment of this invention allows a conventional skid steer to be used for all lawn preparation functions: grading, filling, leveling and scarifying. The design of the rake attachment allows the skid steer to push as well as pull soil. Consequently, the rake attachment can be used to grade soil off of high areas, to push soil into low areas, and to scarify the soil to a seeding ready finish. The rake attachment eliminates the mechanical complexity of other attachments and the inconvenience of frequently changing attachments to perform various earth moving functions. The design of the rake attachment also maximizes the operator's field of vision for precision operation around buildings and other confined areas.
This rake attachment includes a frame and a replaceable elongated toothed rake blade having a row of rigid spaced teeth along its forward edge. The frame includes a mounting plate for connecting the frame to the pivot plate of the skid loader and a forward lateral support member connected by a pair of spaced side members. The rake blade is mounted to the forward support member. The positioning of the rake blade and the open configuration of the frame provide the operator an unobstructed view of the ground being worked.
Accordingly, an object of this invention is to provide for a novel and unique multi-purpose rake attachment for use with a skid steer loader.
Another object is to provide a rake attachment for a skid steer, which is suitable for pushing and pulling soil during grading, filling, leveling and scarifying.
Another object is to provide for a low maintenance rake attachment for a skid steer, which reduces the complexity and number of components and allows a clear line of vision to the ground being worked.
Other objects will become apparent upon a reading of the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
A preferred embodiment of the invention has been depicted for illustrative purposes only wherein:
FIG. 1 is a perspective view of a skid steer with the rake attachment of this invention;
FIG. 2 is a top plan view of the rake attachment;
FIG. 3 is a side elevation view of the rake attachment;
FIG. 4 is a side elevational view of the skid steer with the rake attachment grading soil in a push/pull position;
FIG. 5 is a side elevation view of the skid steer with the rake attachment dragging soil in a push/pull position;
FIG. 6 is a side elevation view of the skid steer with the rake attachment in a elevated position above a pile of soil; and
FIG. 7 is a side elevation view of the skid steer with the rake attachment performing a scarifying operation.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred embodiment herein described is not intended to be exhaustive or to limit the invention to the precise form disclosed herein. It is chosen and described to explain the principles of the invention and its application and practical use to enable others skilled in the art to utilize its teachings.
FIGS. 1-7 show the rake attachment 20 of this invention used with a conventional skid loader or skid steer 2. Rake attachment 20 is shown used on a skid steer 2 manufactured by Melroe Company under the trademark "BOBCAT" although rake attachment 2 can be adapted for use with any make or model of skid steer.
Skid steer 2 includes a chassis 4, which has an operator's compartment 5. Skid steer 2 preferably uses the conventional hydrostatic transmission with four independently driven wheels 8. The transmission is operated by two steering hand levers 6. Chassis 4 supports two pivotal lift booms or arms 10, which are raised and lowered by a pair of hydraulic lift cylinders 11. Lift arms 10 are pivoted about a horizontal axis between a raised position (FIG. 4) and a lowered position (FIG. 5). A cross brace 12 connects arms 10 in front of operator compartment 5. A pivot assembly 14 is pivotally mounted to the front end of lift arms 10. Pivot assembly 14 includes a pivoting mounting plate 16, which carries an attachment connecting mechanism (not shown). A pivot cylinder 17 has its extensible rod 18 connected between mounting plate 16 and cross member 12 as by clevis 19. Pivot cylinder 17 shifts mounting plate 16 about a second horizontal axis between an up position (FIG. 6) and a down position (FIG. 7). As shown in FIG. 6, mounting plate 16 is substantially vertical when the lift arms 10 are in the lowered position and rod 18 is retracted. Mounting plate 16 is angled with respect to the horizontal when lift arms 10 are in the lowered position and rod 18 is extended out from cylinder 17. The lift and pivot cylinders are operated by two foot pedals (not shown) located within the operator compartment.
As commonly known but not shown in the figures, mounting plate 16 carries a locking mechanism, which locks the various attachments to the mounting plate. The locking mechanism is not shown or described in detail and any conventional mounting mechanism can be used to secure the rake attachment of this invention to mounting plate 16.
As common in conventional skid steers, skid steer 2 can be operated in a float mode, wherein lift cylinders 11 are disabled to allow lift arms 10 to rest in a lowered position under their own weight and supported by chassis 4. Consequently, no additional downward force is introduced by lift cylinders 11. In the float mode, only the pivot cylinder 17 is operative, thereby reducing the number of operation controls to occupy the operator's attention. Rake attachment 20 is designed to take full advantage of this feature during .finishing operations as detailed later in this specification.
As shown in FIGS. 2 and 3, rake attachment 20 includes a forward support member 22 connect to a mounting saddle 40 by a pair of spaced side support members 30. Forward support member 22 is preferably an elongated L-shaped angle bar with a lower forward side 26 and a raised back 24. Forward support back 24 is preferably of sufficient height to prevent loosened soil from kicking over the upper edge 25 of forward support member 22, while not substantially impairing the operator's line of sight to the rake blade 50.
Mounting saddle 40 is of conventional design and can adapted for connection to any type of mounting plate 16. Mounting saddles 40 are standardized for various models of skid steers 2 to accommodate various attachments. Mounting saddle 40 includes a pair of connection plates 44 connected by a cross member 42. Cross member 42 forms a down turned upper lip 43. Each connection plate 44 has a plurality of mounting holes 45. Each connection plate 44 also includes a rearwardly extending peripheral ridge 46 along the outer lower edges, which conforms to the contour of mounting plate 16. During the mounting process of rake attachment 20 to skid steer 2, ridge 46 serves to align mounting saddle 40 with mounting plate 16. As shown best in FIG. 1, the upper lip 43 engages the upper edge of mounting plate 16. The back surface of mounting saddle 40 rests flat against the front surface of mounting plate 16. Mounting saddle 40 is then locked into place against mounting plate 16 by the skid steer's locking mechanism (not shown) carried on mounting plate 16.
As shown in FIGS. 1-3, side support members 30 are spaced apart to define a central opening 31. Each side support member 30 includes a upper extension part 32 and a lower side gussets 34 centrally connected to its upper extension part. Upper extension parts 32 are connected between the upper edge 25 of forward support back 24 and the upper edges of each connection plate 44. Each side gusset 34 has four side edges 36-39, which define a substantially triangular configuration with a truncated forward fourth side. Each truncated forward edge 36 is connected as by welds to the rear face of forward support back 31. The opposite rear edges 37 are connected as by welding to the front face of each connection plate 44. The upper edges 38 are connected as by welding to the bottom of each upper extension members 34. The lower edged 39 extend diagonally between the lower edge of the support back 31 and the lower edges of each connection plate 44.
As shown in FIGS. 2 and 3, rake attachment 20 includes an elongated tined or toothed rake blade 50 connected to a frame 30 as by fasteners 58, 59. Rake blade 50 is mounted to the bottom face of forward support member 22. Rake blade 50 is defined by interconnected rectangular panel sections 52. Each panel section 52 is bolted to rake support member 22 by bolts 58, which extend through aligned bores in panel sections 52 and lower forward side 26, and nut fasteners 59, which are affixed to bolts 58. Rake sections 52 are connected to forward support member 30 in this fashion to allow ready replacement of individual panel sections. Each panel section 52 is of flat rectangular shape with a serrated forward edge, which forms a plurality of elongated tines or teeth 56. Panel sections 52 are cut or cast from any durable and rigid metal, such as iron or steel. Panel sections 52 are preferably hardened to provide additional tensile strength. Teeth 56 are straight and rigid to allow the teeth to bite into hard soil without bending or breaking and withstand the drag force exerted by the motion of the skid steer and the weight of lift arms 10. The contour and spacing of teeth 56 prevent rocks, foliage and other debit material from collecting between the teeth, which is common in drags and other attachments with coiled tines.
As seen in the figures, rake attachment 20 has a relatively small and compact design, which allows skid steer 2 to manipulate in tight areas. Rake attachment 20 uses no moving parts to effect all operational aspects, which enhances its valve in field operations. Furthermore, the design rake attachment 20 is easy to store or transport when detached from the skid steer 2.
Rake attachment 20 is designed to take advantage of the float mode operation of skid steer 2. Rake attachment 20 is fully operational without the assistance of the lift cylinders 11. Operation of the skid steer 2 in the float mode allows the operator to manipulate rake attachment 20 through all of its operational positions using only the pivot control foot pedal. Consequently, the operation of the rake attachment and skid steer is simplified. Using only the pivot control pedal to perform the ground work simplifies the task of the operator and avoids confusion between the lift and pivot control pedals. Since rake attachment 20 can operate solely with pivot cylinder 17, its operation is less taxing on the skid steer's hydraulic systems, which translates into increased performance and life span of skid steer 2.
FIG. 6 shows skid steer 2 with rake attachment 20 in the elevated position. In the elevated position, pivot cylinder 17 draws mounting plate 16 back towards skid steer 2, so that mounting plate 16 is substantially vertical and perpendicular to the ground. In the elevated position, rake blade 50 is spaced two to three feet above the ground and approximately three feet from the bottom edge of mounting plate 16. The lower diagonal edges 39 of side gussets 34 are slanted upward at approximately a 55 degree angle to the ground. The upward slant of lower diagonal edges 39 provides front end clearance, so that skid steer 2 can be positioned adjacent to small piles of earth with teeth 56 extend over the top of a pile of soil 70, as shown in FIG. 4. In the elevated position, the operator has a clear view of the worked ground and soil 70 around side support members 30 and though central opening 31.
FIG. 7 shows skid steer 2 with rake attachment 20 in the lowered or scarifying position. In the scarifying position, pivot cylinder 17 fully extends mounting plate 16 so that mounting plate 16 is pivoted beyond horizontal and rake blade 50 engages the ground perpendicularly. The rotation of mounting plate 16 and the connected rake attachment 20 to the scarifying position forces lift arms 10 to be raised slightly from their lowered position. The weight of lift arms 10 and the vertical position of rake blade 50, provides an ideal position for scarifying soil. Under the influence of gravity, the weight of lift arms 10 is transferred directly through rake blade 50. The combined weight of lift arms 10 and rake attachment 20 embeds teeth 56 into the soil and scars the soil as the skid steer moves backward. In scarifying position, lift arms 10 and mounting plate 16 are substantial horizontal and provide a clear unobstructed view of the entire rake blade 50. Consequently, the operator can directly monitor the depth and effectiveness of each skid steer pass.
FIGS. 4 and 5 show the skid steer 2 with rake attachment in an intermediate or push/pull position. Again as seen in FIGS. 6 and 7, the design of rake attachment 20 provides the operator with a clear view of the approximate area of ground being worked. The soil can be viewed over the top of rake attachment 20, around side support members 30, or through central opening 31. In the push/pull position, mounting plate 16 is pivoted between its up and down positions, wherein lower diagonal edges 39 of side gussets 34 are approximately horizontal and parallel with the ground. In the push/pull position, rake blade 50 engages the ground at an acute angle, approximately at a 30 degree angle. The angle at which the rake blade engages the ground can be adjusted by further lowering mounting plate 16. As pivot plate 16 rotates past the rake blade's contact point with the ground, lift arms 10 are slightly raised from their lowered position to place the weight of the arms on teeth 56.
In the push/pull position, rake attachment 20 can be used to grade soil by pushing rake blade 50 forward or to drag soil by pulling soil backward. As shown in FIG. 4, forward movement of skid steer 2 pushes teeth 56 across the top layer of soil, which turns up a volume of soil along the way. The loosened soil gathers above rake blade 50 and in front of forward support member 22 as skid steer 2 moves forward. Forward support back 31 prevents the soil from moving over the top of the rake support, and does not obstruct the operators view of the ground being worked or rake blade 50. Rocks embedded in the soil are drawn up and accumulate on the top of forward support member 22. The contour, spacing and rigidity of teeth 56 allow rocks to be dislodged from the soil, but not lodged between teeth 56. Conventional rakes use coils chisels or tines, which flex under the friction of the skid steer movement, allowing rocks to lodge in between the chisels and tines. Adjusting the angle at which rake blade 50 engages the ground varies the amount of soil graded with each pass.
FIG. 5 shows soil dragged behind rake attachment 20 as skid steer 2 moves backward. As skid steer 2 moves backward, a small volume of soil is pulled backward by the under side of rake blade 50 and forward support member 22. The spacing between teeth 56 allows small amounts of loose soil to pass through, which gives a raked soil appearance. Increasing or decreasing the angle of pivot plate 16 increases or decreases the attitude of rake attachment 20 to vary the amount of soil dragged.
It is understood that the above description does not limit the invention to the details given, but may be modified within the scope of the following claims.
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A rake attachment for use on a skid steer, which can be used for multiple lawn and grounds preparation activities, such as grading, filling, leveling and scarifying. The rake attachment of this invention combines several useful attachment functions into a single compact design. The rake attachment includes a support frame that has spaced side support members to define an opening through which a skid steer operator may view the soil being worked.
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BACKGROUND OF THE INVENTION
1. FIELD OF THE INVENTION
The present invention relates to a light weight, collapsible, compact portable deer stand and more particularly, a deer stand being of unitary construction which may be carried in the form of a back pack and may be used to as a carrier to transport game.
2. DESCRIPTION OF THE PRIOR ART
The use of an elevation platform is commonplace when hunting game and especially, when hunting deer. A permanently installed hunting stand or deer stand would be convenient. But on public and federal property, a permanent deer stand cannot be erected. Since many participants are not fortunate to own or rent prime hunting ground, the only option available is to utilize a portable deer stand.
Most deer stands currently available in a portable version must be carried to a hunting site and assembled prior to being erected against a tree or like object. The carrying of a disassembled stand can be quite cumbersome and can provide a great amount of discomfort to the user. Further, the assembly of some existing stands can prove to be difficult under well lit conditions and can become much more complicated when being erecting at dawn or when being dismantled at dusk when the lighting is insufficient, which is often the case. Existing stands even in their simplest form frequently produce noise during assembly with the rattle and clatter of the myriad of parts interacting with one another. This noise could possibly frighten away any game in the immediate vicinity, making your effort null and void.
Some versions require little in the way of assembly, but these stands are usually bulky and troublesome to transport. Few stands offer a provision for removing game. Hence, if one is fortunate to have killed some form of game, a decision must be drawn as to remove the carcass, leaving the stand behind to be later retrieved or to remove the stand and return later to retrieve the carcass. In either case, one assumes the risk of someone pilfering whatever you choose to leave behind. There are stands which require little by way of assembly. Some stands are compact and relatively simple to transport and some assist in the removal of the game. However, none of the existing deer stands are of a light weight unitary construction, being collapsible into a compact form, being easy to transport, being convertible into a game carrier, as well as being simple to erect and take down while at the same time producing a nominal amount of clamor throughout the process, even under poorly illuminated environmental conditions.
U.S. Pat. No. 3,336,999 issued Aug. 22, 1967 to Thad M. McSwain discloses a hunting stand which includes a ladder supporting a platform at its upper end. The platform is releasably fastened to the periphery of a tree by a toggle-type clamp. The ladder is foldable in an accordion fashion to produce a compact portable structure. The hunting stand may also be converted into a skid having a rotatably attached wheel thereon to facilitate in the removal of game.
U.S. Pat. No. 4,045,040 issued Aug. 30, 1977 to Hershell W. Fails describes a deer stand and game carrier. The deer stand includes a collapsible ladder assembly which is set up in the form of a tripod to support an elevated observation seat. In its collapsed form, the top end of the deer stand is releasably anchored to the user's back while the bottom end of the deer stand is provided with a plurality of wheels. This enables the deer stand to be pulled behind the user while leaving the user's hands free to perform other functions. The deer stand serves as a carrier to assist in the removal of a carcass.
U.S. Pat. No. 5,016,732 issued May 21, 1991 to Stewart A. Dunn discloses a portable observation and hunting stand having an upper and lower ladder section and a combined seat and standing platform section. The three sections are telescopically joined together and the combined seat and standing platform section is engageable with a tree or like object to form the observation and hunting stand in its erected form. The stand is collapsible in the form of a back pack and is also provided with a skid to aid in the removal of game.
None of the above inventions and patents, taken either singly or in combination, is seen to describe the instant invention as claimed.
SUMMARY OF THE INVENTION
The present invention relates to a hunting stand or a deer stand. The stand is of unitary construction and is preferably fabricated from a light weight material, such as aluminum or fiberglass. The stand includes a folding ladder assembly having three sections successively joined together by hinge elements. The stand is provided with a pair of elevated observation platforms, one where a user may stand and one where the user may be seated. The platform where the user may be seated is pivotally mounted to an uppermost end of the folding ladder assembly and includes a V-shaped abutment edge which is engageable with the outer periphery of the tree. The standing platform is pivotally attached to the folding ladder assembly a predetermined distance from the uppermost end thereof. The pivotal displacement of both platforms is limited to ensure that both of the same will provide rigid support for the user. The stand may also be selectively folded in the form of a back pack or to produce a carrier for the removal of game. The stand is equipped with a pair of adjustable shoulder straps which enable the stand in its back pack form to be snugly mounted on the user's back. A roller assembly is rotatably attached to the stand to enable the carrier and the carcass thereon to be transported with relative ease.
Accordingly, it is a principal object of the invention to provide a light weight, collapsible, compact, portable deer stand being of unitary construction and being easily transported by the user.
It is another object of the invention to provide a deer stand which is easily erected, producing little commotion and requiring a negligible amount of lighting, and is easily folded up in the form of either a compact back pack or in the form of a game carrier to assist in the removal of game.
It is an object of the invention to provide improved elements and arrangements thereof in an apparatus for the purposes described which is inexpensive, dependable and fully effective in accomplishing its intended purposes.
These and other objects of the present invention will become readily apparent upon further review of the following specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an environmental perspective view of the present invention being employed as an observation platform.
FIG. 2 is an environmental perspective view of the present invention being carried in the form of a back pack.
FIG. 3 is a perspective view of the present invention completely folded in the form of a back pack.
FIG. 4 is a perspective view of the present invention shown in a partially extended posture.
FIG. 5 is a detail view of the lower hinge in a partially extended posture.
FIG. 6 is a detail view of the lower hinge in a completely extended posture.
FIG. 7 is a detail view of the uppermost hinge in a partially extended posture.
FIG. 8 is a detail view of the uppermost hinge in a completely extended posture.
FIG. 9 is an broken environmental perspective view of the observation platform embracing a tree.
FIG. 10 a partial side elevational view of the present invention showing both the observation platform and the standing platform.
FIG. 11 is a detail view of the roller assembly.
FIG. 12 is an environmental perspective view of the present invention in the form of a cart to facilitate in the removal of a carcass.
Similar reference characters denote corresponding features consistently throughout the attached drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Now referring to the drawings, FIG. 1 shows the folding deer stand or hunting stand 10 in a completely extended posture. The stand 10 embraces a tree 12 to provide an observation platform 14 in which the user 58 (not shown) may be seated and a standing platform 16 (also shown in FIG. 10) in which the user 58 may stand. The deer stand 10 is comprised of a folding ladder assembly which includes an uppermost section 18, an intermediate section 20 and a lower section 22. Each section 18,20,22 includes both a left and right spaced apart outer rail component 24,26 separated by a plurality of rungs 28 having opposing ends which are transversely connected to the left and right outer rails, respectively. Each of the rungs 28 are spaced equidistantly apart. Left and right uppermost hinges 30,32 pivotally join the uppermost section 18 to the intermediate section 20. Left and right lower hinges 34,36 pivotally join the intermediate section 20 to the lower section 22. The observation platform 14 is pivotally mounted to an uppermost end of the uppermost section 18 and has a V-shaped abutment edge which engages with the outer periphery of the tree 12. The observation platform 14 is pivotally rotatable about an axis 40 which is parallel spaced from the abutment edge 38. This rotation offers relatively limited displacement in the direction A from a position parallel to and juxtaposed to the upper section 18. This limited displacement ensures that the observation platform 14 will provide rigid support for the user 58 (not shown) to be seated. The standing platform 16 (also shown in FIG. 10) is pivotally attached the uppermost section 18 a predetermined distance from the uppermost end thereof. The standing platform 16 includes left and right foldable member 42,44 which limit the rotation of the standing platform in the direction B. A roller assembly 46 (also shown in FIG. 11) is rotatably attached between the left and right outer rails 24,26 of the uppermost section 18 adjacent the left and right uppermost hinges 30,32.
FIGS. 2 and 3 show the deer stand 10 in a completely folded posture. The uppermost left and right hinges 30,32 and the lower left and right hinges 34,36 are configured to permit the lower section 22 to be folded in between the uppermost section 18 and the intermediate section 20 to form the back pack shown. When folded in this manner, the observation platform 14 is retained between the lower section 22 and the uppermost section 18. The deer stand 10 includes both left and right shoulder straps 48,50, each having a first end releasably attachable to the left and right uppermost hinges 30,32, respectively, and each having a second end releasably attached to a central point of an uppermost rung 28 such that the two second ends converge. Each end of each shoulder strap 48,50 has attached thereon a snap-hook fastener 52 which is engageable with a respective eye-hook 54. Each shoulder strap 48,50 is also provided with an adjustment device 56 attached thereon to allow the user 58 to bias each shoulder strap 48,50 independently to snugly secure said deer stand 10 (in its back pack configuration) to the user's 58 back.
FIG. 4 shows the deer stand 10 partially extended. By folding the lower section 22 in the direction C, folding the observation platform 14 in the direction D and folding the uppermost section 18 in the direction E in succession, the deer stand 10 is formed in the shape of the back pack shown in FIGS. 2 and 3. By unfolding the deer stand 10 in reverse of the aforementioned order, the combined ladder assembly and observation platform 14 are produced. By folding the observation platform 14 in the direction D and the uppermost section 18 in the direction E in succession, the carrier shown in FIG. 12 is produced.
FIGS. 5 and 6 show the right lower hinge 36, the left lower hinge 34 (not shown) being a mirror thereof. The lower hinge 36 is comprised of an L-shaped planar member 60 and a Z-shaped planar member 62 pivotally together joined by a fastener 64. The L-shaped member 60 is secured to a lower end of the intermediate section 20 and the Z-shaped member 62 is secured to an uppermost end of the lower section 22 such that the two sections 20,22 are folded substantially parallel and juxtaposed one to the other. The L-shape member 60 and the Z-shaped member 62 are each provided with a piece of angle stock 66. When the deer stand 10 is fully extended and erected against the tree 12, the two pieces of angle stock 66 provide a contact surface for one another and the gravitational force F as well as the weight of the user 58 each prevent the two pieces 66 from disengaging and thus, prevent the deer stand 10 from collapsing.
The right uppermost hinge 32 of FIGS. 7 and 8 is similar to that of the right lower hinge 36 shown in FIGS. 5 and 6, the left uppermost hinge 30 (not shown) being a mirror thereof. The uppermost hinge 32 is also comprised of an L-shaped planar member 68 and a Z-shaped planar member 70 pivotally joined together by a fastener 64. The L-shaped member 68 is secured to a lower end of the uppermost section 18 and the Z-shaped member 70 is secured to an uppermost end of the intermediate section 20 such that the two sections 18,20 are folded to provide a gap for the lower section 22 (not shown) to be folded therebetween. As with the lower hinges 34,36, the L-shape member 68 and the Z-shaped member 70 of the uppermost hinges 30,32 are each provided with a piece of angle stock 66. Again, when the deer stand 10 is fully extended and erected against the tree 12, the two pieces of angle stock 66 provide a contact surface for one another and the gravitational force F as well as the weight of the user 58 each prevent the two pieces 66 from disengaging and thus, prevent the deer stand 10 from collapsing.
FIG. 9 shows the observation platform 14 secured to the outer periphery of the tree 12. A restraint strap 72 is fastened to each side of the observation platform 14 and embraces the tree 12. The restraint strap 72 has two ends, each of which is provided with a snap-hook fastener 52. The snap-hook fasteners 52 are fastened to respective eye-hooks 54 which are located on each side of the observation platform 14 adjacent an abutment edge 38 thereof which engages with the outer periphery of the tree 12. The restraint strap 72 is further provided with a toggle clamp 76 which enables the user 58 to tighten the restraint strap 72 around the tree 12. The toggle clamp 76 is of the conventional type having a set of teeth which engage with the restraint strap 72 to hold the restraint strap 72 taut against the tree 12. The restraint strap 72 also maintains the deer stand 10 in a selectively folded posture, either in the form of the back pack shown in FIGS. 2 and 3 or in form of the carrier shown in FIG. 12.
FIG. 12 shows the deer stand 10 being used as a carrier to facilitate in the transportation of a carcass 78. The carrier is produced by selectivity folding the deer stand 10 such that the intermediate section 20 and the lower section 22 are fully extended and the upper section 18 is folded and strapped against a back side of the intermediated section 20 via the restraint strap 72. The weight of the carcass 78 and the configuration of each lower hinges 34,36 keep the left and right outer rails 24,26 of the intermediate and lower sections 20,22 axially aligned.
It is to be understood that the present invention is not limited to the sole embodiment described above, but encompasses any and all embodiments within the scope of the following claims.
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A hunting stand for use as an elevated observation platform and a game carrier. The stand is easily foldable in the form of a back pack and is convertible into a carrier to facilitate in the removal of game. The stand is comprised of a folding ladder having three successive sections joined together such that the three sections are selectively folded to form a back pack, to produce the carrier or to produce a fully extended ladder with adjoining observation platform. The stand is of lightweight unitary construction and has a unique hinge configuration that enables it to be selectively folded into a plurality of configurations with relative ease and provides a hunting stand which is easy to transport and store.
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[0001] CROSS REFERENCE TO RELATED APPLICATION
[0002] This application claims the priority of German Application Nos. 100 03 994.4 filed Jan. 29, 2000 and 100 51 998.9 filed Oct. 20, 2000, which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0003] This invention relates to an apparatus integrated in a carding machine or a roller card unit for forming a sliver from a fiber web. The apparatus has a roll assembly, formed of a doffer, a stripping roll and a crushing roll pair. The apparatus further has a web gathering and advancing unit as well as a sliver trumpet followed by a calender (pull-off) roll pair. The sliver trumpet densifies the web and discharges a sliver. The sliver exiting the trumpet is introduced into the calender roll pair.
[0004] In practice, in the fiber batt processing industry, roller card units and carding machines are used which, for forming a fiber web, have a transitional guide plate (open web triangle), a standing roll pair and a downstream-arranged calender unit. It is a disadvantage of these known arrangements that the cross section of the produced sliver significantly deviates from a rectangular shape. It is also a drawback that the fiber material is not uniformly distributed over the sliver cross section. The thus-produced intermediate product (sliver) leads to irregularities during further processing to obtain the final product, such as a hygiene item.
[0005] German patent document 22 50 834 describes a transverse web gathering device which has a conveyor belt and a conveyor roll, followed by a sliver trumpet to form a sliver from a fiber web. The fiber web, after being densified in a closed zone, leaves the transverse gathering device and runs through a sliver trumpet and calender rolls and is thereafter deposited into a sliver can. The roll nip in the transverse gathering device is narrow and the inlet of the trumpet is at a substantial distance from the outlet of the transverse gathering device. The outlet of the trumpet has a circular cross section, and thus the exiting sliver assumes a circular cross section as well. The trumpet outlet is situated at a distance upstream of the bight defined by the calender roll pair. Such an apparatus is not adapted to form a sliver having a rectangular—particularly sharp-edged—cross section. It is a further disadvantage of the known arrangement that because of the distances of the trumpet inlet from the transverse web gathering device, on the one hand, and the trumpet outlet from the calender nip, on the other hand, the processing of the fiber material having a significant amount of short fibers is not possible. Also, the above-noted relatively large distances do not allow a high delivery speed.
SUMMARY OF THE INVENTION
[0006] It is an object of the invention to provide an improved apparatus of the above-outlined type from which the discussed disadvantages are eliminated and which, in particular, produces an improved sliver having a rectangular cross section and which further permits a production rate higher than heretofore.
[0007] This object and others to become apparent as the specification progresses, are accomplished by the invention, according to which, briefly stated, the fiber sliver producing apparatus includes an arrangement for making a running fiber web; a transverse web gathering device gathering the fiber web; and a sliver trumpet through which the gathered fiber web passes for being densified and discharged thereby as a running sliver. The sliver trumpet has a cross-sectionally rectangular outlet opening which has a width that is at least 10 times greater than its height. The apparatus further has a calender roll pair formed of two calender rolls through which the sliver passes after being discharged by the sliver trumpet. The calender roll pair defines a bight in which the outlet opening of the sliver trumpet is disposed.
[0008] By virtue of the measures according to the invention a sliver having a rectangular cross section may be produced which has a more uniform fiber distribution and a significantly increased output speed (at least 100 m/min) compared to prior art arrangements. In particular, the processing of the fiber material with a higher short-fiber proportion is advantageously feasible.
BRIEF DESCRIPTION OF THE DRAWING
[0009] [0009]FIG. 1 is a schematic side elevational view of a carding machine incorporating the invention.
[0010] [0010]FIG. 2 is an enlarged schematic side elevational view of one part of the structure shown in FIG. 1.
[0011] [0011]FIG. 3 is a perspective view of a preferred embodiment of the sliver trumpet according to the invention.
[0012] [0012]FIG. 3 a is a front elevation of the sliver trumpet, showing an adjustable wall element in the outlet region.
[0013] [0013]FIG. 3 b is a cross-sectional view of the sliver exiting the sliver trumpet.
[0014] [0014]FIG. 4 a is a schematic front elevational view of a preferred embodiment of the invention in which a crushing roll pair (only one roll is visible), a transverse gathering device, a sliver trumpet and a calender roll pair (only one roll is visible) are in a vertical arrangement.
[0015] [0015]FIG. 4 b is a side elevational view of the construction illustrated in FIG. 4 a.
[0016] [0016]FIG. 5 is a schematic front elevational view of another preferred embodiment of the invention, including a conveyor belt and a conveyor roll, calender rolls arranged parallel to the conveyor roll and a deflecting roll.
[0017] [0017]FIG. 6 is a schematic front elevational view of a further preferred embodiment of the invention having calender rolls oriented perpendicularly to the conveyor roll.
[0018] [0018]FIG. 7 a is a schematic front elevational view of the gap region between the web conveyor belts which have an after-connected web spreading element.
[0019] [0019]FIG. 7 b is a sectional view taken along line VIIb-VIIb of FIG. 7 a.
[0020] [0020]FIG. 7 c is a schematic side elevational view of the structure shown in FIG. 7 a including an after-connected sliver trumpet and calender rolls.
[0021] [0021]FIG. 8 is a schematic front elevational view of a variant of the structure illustrated in FIG. 4 a.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] [0022]FIG. 1 illustrates a carding machine CM which may be, for example, a high-performance DK 903 carding machine manufactured by Trutzschler GmbH & Co. KG, Monchengladbach, Germany. The carding machine CM has a feed roll 1 , a feed table 2 cooperating therewith, licker-ins 3 a, 3 b, 3 c, a main carding cylinder 4 , a doffer 5 , stripping rolls 6 , cooperating crushing rolls 7 , 8 , a web guiding element (transverse web gathering device) 9 , a sliver trumpet 10 , calender rolls 11 , 12 and a travelling flats assembly 13 having slowly circulating flat bars 14 . The rotary direction of the carding machine rolls is indicated by curved arrows drawn thereinto. At the output of the carding machine a coiler device 16 is provided which deposits the sliver into a coiler can 15 . The working direction, that is, the advancing direction of the fiber material in the carding machine is designated with the arrow A.
[0023] Turning to FIGS. 2 and 3, the transverse web gathering element 9 , the sliver trumpet 10 and the calender rolls 11 and 12 rotating in the direction indicated by the arrows 11 a and 12 a, are arranged downstream of the crushing rolls 7 and 8 which rotate in the direction indicated by the arrows 7 a and 7 b, respectively. The sliver trumpet 10 and the calender rolls 11 , 12 are mounted on a holding device 17 which may turn in the direction of the arrows B and C about a fixed shaft 18 . The inner passage of the sliver trumpet 10 converges in the working direction A. The height c of the inlet opening 10 b is greater than the height b of the outlet opening 10 a. The height b of the outlet opening 10 a of the sliver trumpet 10 is approximately 2-3 mm. The width a of the outlet opening 10 a of the sliver trumpet 10 is between approximately 20-100 mm, preferably 60-90 mm. The width a may be changed— as shown in FIG. 3 a —by a wall element 10 c in the region of the outlet opening 10 a by shifting it in the direction of the arrow D or E. The outlet opening 10 a is rectangular and is bounded by sharp edges. As a result of this construction the flat sliver 19 exiting the sliver trumpet 10 has, as shown in FIG. 3 b, a sharp-edged rectangular cross-sectional shape. As shown in FIG. 2, the outlet opening 10 a of the sliver trumpet 10 is situated in the intake bight 11 ′ defined between the calender rolls 11 and 12 . The inlet opening 10 b of the sliver trumpet 10 is chamfered and has an elongate shape. The inner trumpet walls 10 d and 10 e extending in the region of the trumpet outlet opening 10 a along the width thereof, are parallel to one another.
[0024] As shown in FIGS. 4 a and 4 b, the axially parallel crushing rolls 7 and 8 are horizontally arranged and are followed perpendicularly downward by the transverse web gathering element 9 , the sliver trumpet 10 and the calender rolls 11 and 12 .
[0025] The transverse web gathering element 9 has two endless flexible conveyor belts 9 a, 9 b supported by end rolls 9 1 , 9 2 and, respectively, 9 3 , 9 4 . In each instance, one end roll for each belt, for example, the end rolls 9 1 and 9 3 are driven by a respective shaft 9 * (shown in FIG. 2) by a non-illustrated, preferably common driving device. The belt flights of the conveyor belts 9 a, 9 b move in directions illustrated by the arrows F, G and H, I.
[0026] The calender roll 12 is biased by a compression spring 20 and is radially movably supported relative to the radially stationary calender roll 11 , whereby the width d of the nip between the calender rolls 11 and 12 as well as the pressure on the sliver may be adjusted. The force of the spring may be adjusted, for example, by inserting washers 20 a, 20 b of suitable thickness between a spring end and a spring support. If a subsequent doubling of the fiber web is effected prior to further processing, an excessive pressing of the calender rolls 11 , 12 may cause damage whereas if an immediate further processing is carried out, then a greater compression force is desirable.
[0027] Turning to FIG. 5, the transverse web gathering element 9 is composed of a conveyor belt 9 a and a conveyor roll 9 c defining together a nip (exit gap) having a width e which has a clearance of preferably approximately 10 mm. The axes of the end rolls 9 1 , 9 2 (supporting the belt 9 a ), the conveying roll 9 c and the calender rolls 11 , 12 are arranged in a parallel orientation. By virtue of the parallel arrangement of the calender rolls 11 , 12 , the web material lying on the belt 9 a is packed in an even more pronounced manner into the rectangular cross-sectional shape of the web by the transverse web gathering element 9 . Downstream of the calender rolls 11 , 12 a sliver deflecting roll 23 is arranged.
[0028] According to FIG. 6, in contrast to FIG. 5, the width of the sliver trumpet 10 and the axes of the calender rolls 11 , 12 are perpendicular to the axes of the end rolls 9 1 , 9 2 and the conveying roll 9 c. The advantageous arrangement of the sliver trumpet 10 with respect to the transverse web gathering element 9 also depends from the width a of the outlet opening 10 a and from the processed fiber material.
[0029] To obtain an optimal web structure for the consecutive material distribution in the rectangular trumpet 10 , the width e of the outlet nip according to FIGS. 4 a, 5 and 6 between the end roll 9 2 on the one hand and the end roll 9 4 or the conveying roll 9 c on the other hand, has to have a minimum dimension, for example, at least 10 mm to avoid a premature compression of the web at that location.
[0030] Turning to FIGS. 7 a, 7 b and 7 c, subsequent to leaving the web gathering device 9 , a web widening prior to its entering the rectangular sliver trumpet 10 may be advantageous for a desired width a of the exiting sliver 19 (final sliver width). For this purpose an arcuate web spreading element 21 is provided which is arranged between the transverse web gathering element 9 and the inlet 10 b of the sliver trumpet 10 . The web spreading element 21 is a bent bar having an approximately semicircular cross section as shown in FIG. 7 b. The sliver 22 exiting the outlet nip of the web gathering device 9 runs over the upper, convexely bent region of the web spreading element 21 and is thus laterally spread thereby. The gathered web 22 subsequently passes through the sliver trumpet 10 and is pulled off the outlet opening 10 a by the calender rolls 11 , 12 as a flat sliver 19 having a rectangular, uniform cross section.
[0031] In a variant shown in FIG. 8, the conveyor belts 9 a and 9 b of the web gathering device 9 ′ are arranged at an angle α 1 =47° and α 2 =47° with respect to the axis of the crushing rolls 7 and 8 (only the crushing roll 7 is visible).
[0032] It will be understood that the above description of the present invention is susceptible to various modifications, changes and adaptations, and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims.
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A fiber sliver producing apparatus includes an arrangement for making a running fiber web; a transverse web gathering device gathering the fiber web; and a sliver trumpet through which the gathered fiber web passes for being densified and discharged thereby as a running sliver. The sliver trumpet has a cross-sectionally rectangular outlet opening which has a width that is at least 10 times greater than its height. The apparatus further has a calender roll pair formed of two calender rolls through which the sliver passes after being discharged by the sliver trumpet. The calender roll pair defines a bight in which the outlet opening of the sliver trumpet is disposed.
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CROSS-REFERENCE TO A RELATED APPLICATION
[0001] The invention described and claimed hereinbelow is also described in German Patent Application DE 10 2012 002992.6, filed on Feb. 15, 2012. This German Patent Application, subject matter of which is incorporated herein by reference, provides the basis for a claim of priority of invention under 35 U.S.C. 119(a)-(d).
BACKGROUND OF THE INVENTION
[0002] The invention broadly relates to an agricultural working vehicle such as a forage harvester or a combine harvester.
[0003] The working tools of conventional agricultural working vehicles such as forage or combine harvesters are generally removable, whether to replace the working tool in order to adapt to work to be performed or because the dimensions of the working tool are so great that the working vehicle, with the working tool mounted thereon, is prohibited from traveling on public roads. In that case, the working tool must be delivered separately, e.g., on a trailer drawn by the working vehicle, to the site of use, where it must be lifted.
[0004] The raising and lowering of a working tool requires a great deal of caution and practice on the part of a user. Mistakes can result in damage to the working tool, which are costly to repair.
[0005] In order to control a drive assembly for raising or lowering the working tool, a conventional working tool comprises a toggle switch that is movable in two degrees of freedom. By swiveling the toggle switch in a first degree of freedom, the driver can select whether to raise or lower the working tool. By swiveling the toggle switch in the second degree of freedom, the driver sets the speed of the motion. In order to lift a working tool, a driver will generally drive the working vehicle toward the working tool with a greatly lowered, vehicle-side coupling and then raise the coupling at the slow speed for engagement thereof with a tool-side coupling. The further the vehicle-side coupling is lowered and the more slowly it is raised, the more certain it is that damage to the working tool will be prevented; however, it takes that much longer to raise the tool.
[0006] An agricultural working tool comprising a such multifunctional handle, the diverse control elements of which facilitate such control of a working tool, is known from DE 10 2009 034 154 A1.
SUMMARY OF THE INVENTION
[0007] The present invention overcomes the shortcomings of known arts, such as those mentioned above.
[0008] In an embodiment, the invention provides an agricultural working tool that permits working tools to be handled rapidly as well as safely.
[0009] In an embodiment, the invention provides a working tool, a drive assembly for raising and lowering the working tool and a control element that can be deflected from a neutral position in different directions in order to control the drive assembly. The speed at which the drive assembly moves the working tool is a continuous function of the deflection of the control element. This feature makes it possible for the user to flexibly adapt the speed of the drive assembly to the extent of the danger and, when setting down the working tool (e.g., to thereby lower the working tool rapidly at first), provided it is not close to a surface underneath and to reduce the speed upon approaching the surface underneath, in order to ultimately place the tool onto the surface underneath gently and safely.
[0010] The speed is preferably controlled by deflecting the control element via rotation about an axis.
[0011] To ensure safe handling, it is advantageous for the control element to have a corrugated circumferential surface.
[0012] The axis about which the control element can be rotated is preferably oriented transversely to the direction of travel of the working tool so that, upon deflection, the circumferential surface of the control element is moved vertically or in the direction of travel, but not in the direction transverse to the vehicle. This makes it possible, even for an untrained user, to establish a logical connection between the direction of the deflection and the direction of the tool motion and to prevent the tool from inadvertently moving in the wrong, undesired direction.
[0013] If only a portion of the surface of the control element is exposed and the rest is inaccessible, e.g., in a housing, then the exposed surface is preferably oriented such that deflection of the surface upwardly and/or in the direction of travel permits the working tool to be raised. Deflection thereof opposite the direction of travel and/or downward permits the working tool to be lowered. Thus, easy accessibility and convenient operability of the surface can be combined with a correlation, which is clearly intuitive to the user, between the direction of the deflection and the direction of the resultant tool motion.
[0014] The control element is preferably disposed on a multifunctional handle along with control elements for other functions of the working vehicle.
[0015] Such a multifunctional triol can have a gripping surface that is oriented to support at least a portion of the palm of a user's hand lying in an operating position and thereby permit operation for a long period of time without the operator becoming tired. The control element is placed on the multifunctional handle in order to reach the control element by a finger on the hand lying in the operating position.
[0016] A surface of the multifunctional handle adjoins the exposed surface of the control element in a flush manner, preferably transversely to the deflection direction. Such a surface shape help prevents inadvertent deflection of the control element.
[0017] To ensure that inadvertent, light contact with the control element does not result in unwanted movement of the tool, the control element is configured to be fixed in the neutral position by way of locking means.
[0018] The position of the working tool being influenced by accidental, small deflections of the control element also can be prevented in that an interval of the deflection, in which the speed of the working tool is zero, extends on either side of the neutral position. The tool, therefore, does not begin to move until the control element is deflected out of said interval.
[0019] Further features and advantages of the invention will become apparent from the description of embodiments that follows, with reference to the attached figures, wherein
[0020] FIG. 1 shows a schematic view of a forage harvester as an example of an agricultural vehicle according to the invention;
[0021] FIG. 2 shows a view of the head of a multifunctional handle used in the forage harvester depicted in FIG. 1 ;
[0022] FIG. 3 shows the head with a driver's hand resting thereon;
[0023] FIG. 4 shows a control element of the multifunctional handle;
[0024] FIG. 5 shows a graph that illustrates the correlation between the deflection of the control element and the raising and lowering speed of the tool of the forage harvester;
[0025] FIG. 6 shows a variant of the control element; and
[0026] FIG. 7 shows a perspective view of the head of a multifunctional handle according to a second embodiment;
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] The following is a detailed description of example embodiments of the invention depicted in the accompanying drawing. The example embodiments are presented in such detail as to clearly communicate the invention and are designed to make such embodiments obvious to a person of ordinary skill in the art. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present invention, as defined by the appended claims.
[0028] A person skilled in the art is familiar with the basic features of the forage harvester, such as the forest harvester depicted in FIG. 1 . Hence, this disclosure does not describe in detail known assemblies used in conventional harvesting machines, such as front harvesting attachment 1 , intake assembly 2 , chopping mechanism, and transfer bend 3 . What is important for an understanding of the present invention is that the front harvesting attachment 1 is removable for transport on a trailer on a public road, and permits selection and installation of the appropriate front harvesting attachment for the particular crop to be harvested. In order to remove the front harvesting attachment 1 from a non-illustrated trailer, for example, or to lower said front harvesting attachment onto said trailer after use, the height of the intake assembly 2 is adjusted with the aid of hydraulic cylinders that are driveable by a diesel engine of the forage harvester via a pump having a variable throughput rate.
[0029] Control elements for controlling various functions, in particular for adjusting the height of the intake assembly 2 , are disposed in an instrument panel 4 of a driver's cab 5 and are situated there on a multifunctional handle 6 . The multifunctional handle 6 is displaceable relative to the instrument panel 4 to control the progressive motion of the forage harvester. The multifunctional handle can have a single degree of freedom for displacement, for controlling forward and reverse motions of the forage harvester, e.g., in the form of a gate guide of the type described in U.S. Pat. No. 6,715,269 B2. Preferably, however, the multifunctional handle 6 has two degrees of freedom for displacement, one in the direction of travel for controlling the forward and reverse motion and ground speed, and one in the direction transverse to the vehicle for controlling the direction of travel.
[0030] The use of the multifunctional handle 6 , described in greater detail in the following, is not limited to a forage harvester, however, and may be used for any other type of agricultural vehicle such as a tractor or a combine harvester.
[0031] FIG. 2 shows a perspective view of the head of the multifunctional handle, as viewed by the driver. A hollow neck 8 is integrally formed on the underside of the grip head 7 , and accommodates a shaft of the handle (which is not shown in FIG. 2 ) and connects the head 7 to a joint in the instrument panel 4 . The grip head 7 is irregularly shaped. Consequently, sides of the grip head are not sharply delineated from each other and instead transition continuously into each other at edges that are rounded off to a greater or lesser extent. Yet, a continuous surface is identifiable that is curved relatively slightly, is disposed on a top side that is approximately diametrically opposed to the neck 8 and that includes a gripping surface 9 in the region thereof facing the driver that is adapted to the shape and size of a driver's palm. And, adjacent thereto in the direction of travel, the continuous surface includes a control field 10 . As shown in FIG. 2 , the gripping surface 9 has small recesses distributed thereon.
[0032] While the gripping surface 9 is sized to support the metacarpal bones of the second to fifth fingers along the entire length thereof, the width of the control field 10 is designed only for the index and middle fingers. Therefore, the remaining fingers can grip a steeply slanted flank 11 on a side of the grip head 7 that faces away from the driver and not shown in FIG. 2 . And, the driver can pull the grip head 7 toward himself using the fingers, even if the index and middle fingers are substantially extended on the control field 10 and are unable to pull.
[0033] In the FIG. 2 embodiment, the control field 10 comprises three control elements 12 , 13 , 14 . The control element 12 adjusts the height of the intake assembly 2 and the front harvesting attachment 1 ; but the control elements 13 , 14 can be dedicated to other functions of the front harvesting attachment 1 . The two control elements, 13 and 14 , are placed on the front end of the control field 10 such that, when the driver's hand rests on the gripping surface 9 ( FIG. 3 ) and the index finger is extended, the tip thereof can touch one of the two control elements 13 , 14 (which are designed as buttons), and depress them. The control element 12 is located closer on the gripping surface 9 , and therefore, the user must curve the index finger in order to touch and deflect said control element using the fingertip.
[0034] The control element 12 comprises a knurled wheel 15 having a flat, cylindrical shape. The wheel can be rotated about an axis 16 extending substantially through the grip head 7 transversely to the direction of travel of the forage harvester. The greatest portion of the knurled wheel 15 is housed in the grip head 7 . An exposed part of the circumferential surface 17 thereof is elongated on both sides in the direction of the axis 16 via arched housing segments 18 of the grip head 7 . The housing segments 18 , therefore, together with the exposed circumferential surface 17 , form a substantially flat, lenticular projection on the control field 10 .
[0035] FIG. 4 shows the knurled wheel 15 in a schematic side view in the direction of the axis 16 . The control field 10 , into which the knurled wheel 15 extends, rises slightly in the direction of travel, i.e. toward the left in FIG. 4 . In order to turn the knurled wheel 15 , therefore, the user's finger (which is in contact with the exposed circumferential surface 17 ), must make a motion in the direction of a double arrow labeled with reference numeral 19 in the figure. That is, the point on the circumferential surface 17 contacted by the driver's fingertip is deflected substantially in the direction of travel and, simultaneously, slightly upward, or is deflected opposite the direction of travel and slightly downward. It is understood to be clearly intuitive to the driver that deflection in the direction of travel triggers an upward motion of the intake assembly 2 , and motion opposite the direction of travel triggers a downward motion.
[0036] To ensure that accidental contact of the circumferential surface 17 does not result in deflection and, therefore, a change in height of the intake assembly 2 , the knurled wheel 15 is locked in the neutral position thereof. Such locking can be accomplished with the aid of a leaf spring 20 . In this case, the ends of said leaf spring are fixed in the grip head 7 , the leaf spring comprising an elastically deflectable projection 21 , which engages in a notch 22 of the knurled wheel 15 when in the neutral position.
[0037] In order to convert the position of the knurled wheel 15 into a signal that can be used to control the speed of the intake assembly 2 , a potentiometer is coupled to the knurled wheel 15 . By way of the design thereof, such a potentiometer generally limits the freedom of rotational motion of the knurled wheel 15 to approximately half of one revolution. By way thereof, a linear correlation between the deflection of the control element 13 and the displacement speed of the intake assembly 2 can be easily achieved.
[0038] The invention further contemplates use a digital angle-of-rotation sensor that converts rotation of the knurled wheel 15 into a pulse train comprising a number of pulses that is proportional to the angle of rotation that was passed through. Such an angle-of-rotation sensor is particularly suitable for attaining any type of interrelationship between the deflection α of the control element 13 and the displacement speed v of the intake assembly. That approximate interrelationship is shown as a solid curve in FIG. 5 , in which small deflections about the neutral position 0 do not result in motion and only those deflections that exceed a threshold +ε or −ε result in a displacement speed v that increases linearly depending on the deflection α.
[0039] Alternatively, a displacement speed that increases faster than linearly depending on the deflection can be implemented. Doing so makes it possible to precisely regulate a slow displacement speed and achieve rapid displacement via moderate deflection.
[0040] Such a digital angle-of-rotation sensor does not necessarily limit the freedom of rotational motion of the knurled wheel 15 , and so it is basically possible to rotate the knurled wheel 15 to any extent, even by more than one revolution, toward the neutral position. In order to ensure that the driver can quickly return to the neutral position at any time, it is advantageous to limit the freedom of rotational motion of the knurled wheel 15 . A projection 23 of the knurled wheel 15 can be used for this purpose. For example (as shown in FIG. 6 ), the projection is located in the neutral position centrally in the window 24 of the control field 10 filled by the knurled wheel 15 and is deflectable from there in the direction of travel or opposite the direction of travel until said projection impacts a front or rear edge 25 of the window 24 .
[0041] As long as the user's fingertip is touching the projection 23 , the user can gauge the intensity and direction of the deflection without having to look at the control field 10 . The operator therefore always knows how he/she must move the control element 15 in order to stop the intake assembly 2 . In this embodiment, the knurled wheel 15 need not be circular; it is sufficient to provide a segment of a circle having a circumferential surface that is long enough to fill the window 24 in any reachable position.
[0042] To enable the drive assembly to be stopped rapidly in an emergency, a return spring is dedicated to the knurled wheel 15 ( FIG. 6 ). The return spring is in the form of a hairpin spring 26 in this case. The two legs of the spring are immobilized in the head 7 at the interconnected ends thereof, and the free ends of which rest on either side of a peg 27 protruding eccentrically from the knurled wheel 15 . Any deflection of the knurled wheel 15 out of the neutral position results in deflection of a leg of the hairpin spring 26 . Hence, when the user releases the knurled wheel 15 , the knurled wheel is immediately forced back into the neutral position and the motion of the intake assembly comes to a standstill.
[0043] FIG. 7 shows a perspective view (analogous to that of FIG. 2 ), of a grip head according to another embodiment of the invention. The control element 12 (embodied as a knurled wheel 15 in this case), is disposed on a control field 28 . Control field 12 fills a lateral flank of the grip head 7 and is operated using the thumb. In accordance with the movability of the thumb, the knurled wheel 15 is rotated about an axis 16 . Axis 16 extends substantially parallel to the index finger resting on the control field 10 and extends approximately in the direction of travel of the forage harvester. The exposed circumferential surface 17 of the knurled wheel is therefore be moved up and down. An upward deflection of the circumferential surface results in an upward motion of the intake assembly 2 , and that a downward deflection of the circumferential surface 17 results in a downward motion of the intake assembly 2 conforms to the driver's intuition.
[0044] The following list of reference signs of various elements mentioned above is included (as follows), for ease of explanation:
LIST OF REFERENCE CHARACTERS
[0000]
1 front harvesting attachment
2 intake assembly
3 transfer bend
4 instrument panel
5 driver's cab
6 multifunctional handle
7 grip head
8 neck
9 gripping surface
10 control field
11 flank
12 control element
13 control element
14 control element
15 knurled wheel
16 axis
17 circumferential surface
18 housing segment
19 double arrow
20 leaf spring
21 projection
22 notch
23 projection
24 window
25 edge
26 hairpin spring
27 peg
[0072] As will be evident to persons skilled in the art, the foregoing detailed description and figures are presented as examples of the invention, and that variations are contemplated that do not depart from the fair scope of the teachings and descriptions set forth in this disclosure. The foregoing is not intended to limit what has been invented, except to the extent that the following claims so limit that.
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An agricultural working vehicle includes a working tool, a drive assembly for raising and lowering the working tool and a control element that is deflected from a neutral position in different directions. A speed (v) at which the drive assembly moves the working tool is a continuous function of a deflection (a) of the control element.
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BACKGROUND OF THE INVENTION
This invention relates to tire monitoring apparatus and the like.
A tire pressure monitoring device is disclosed in U.S. Pat. No. 4,137,520. The device comprises a wire strain gauge employed as a pressure transducer which is connected to a telemetering circuit disposed on an integrated circuit chip. Also disclosed is circuitry for encoding the telemetering signals to discriminate one tire from another.
U.S. Pat. No. 4,237,728 discloses a tire pressure transducer/telemetering system where the transducer is mechanically activated and may include a piezoelectric crystal or the like to detect either under or over inflated tire conditions. Each time an abnormal condition is sensed, a pulse is generated. After a predetermined number has been sensed in a given period of time, an alarm signal is sent.
U.S. Pat. No. 4,160,234 discloses a tire pressure monitoring apparatus including a charge storage release circuit which produces a pulsed abnormal condition signal. The charge portion of the circuit stores the transducer signal until a predetermined signal level is reached, at which time it is transmitted.
An article in "Electronics" magazine, Aug. 11, 1983, entitled "Chip Senses Heat, Pressure" describes a pressure-temperature transducer with associated signal processing circuitry disposed on an integrated circuit chip.
Other patents of interest are U.S. Pat. Nos. 4,048,614; 4,072,927; 4,263,579; 4,300,119; 4,300,120 and 4,311,984.
All of the above prior art references are submitted herewith and it is requested they be made of record.
SUMMARY OF THE INVENTION
A primary object of the present invention is to provide an improved tire monitoring apparatus.
A further object of the invention is to provide apparatus of the above type where pressure and/or temperature transducing circuitry together with telemetering circuitry is incorporated on the same integrated circuit chip.
A further object of the present invention is to provide an apparatus of the above type which may be connected to or be made part of a tire stem without consideration of tire balance due to its small size.
A further object of the present invention is to provide apparatus of the above type for monitoring the pressure of tires in automobiles, trucks, trailers, airplanes and other vehicles supported and running on pneumatic tires, and to give warning and to indicate a variation and lessening of a tire's pressure. The apparatus is particularly applicable to trucks and trailers having a multiplicity of running wheels supported by pneumatic tires.
Other objects and advantages of this invention will be apparent from a reading of the following specification and claims taken with the drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a block diagram of an illustrative overall system in accordance with the invention.
FIG. 2 is a block diagram of an illustrative integrated pressure/temperature sensing/telemetering circuit as used in FIG. 1.
FIG. 3 is an illustrative integrated circuit chip showing the location of various elements of the circuit of FIG. 2 on the chip.
FIG. 4 is a modified perspective drawing showing the location of the integrated circuit of FIG. 2 in or on a tire valve stem.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference should be made to the drawing where the like reference numerals refer to like parts.
Referring to FIG. 1, there is shown an illustrative block diagram of an overall system in accordance with the invention, which includes an integrated pressure/temperature sensing/telemetering circuit 10, which is shown in greater detail in FIGS. 2 and 3 and which, in general, senses a pressure and/or temperature to be measured and transmits an encoded signal. The transmitted signal is encoded with the measured temperature and/or pressure data together with a location code which indicates the location of circuit 10 on a vehicle or the like.
The encoded signal is transmitted to a data receiver/decoder 12, which may be, for example, a Linear Model D-8C digital receiver, where the encoded data is extracted from the transmitted signal. The encoded data is employed to activate a display 14, which may be light emitting diodes, located, for example, at the instrumental panel of the vehicle where the displayed data may include an indication of an underinflated condition of a particular tire.
Referring now to FIG. 2 an illustrative block diagram of the integrated pressure/temperature sensing/telemetering circuit 10 of FIG. 1, there are shown pressure and temperature sensors 16 and 18 (usually located in or on a tire or the like) and a temperature sensor 20 located at the brakes, for example. As indicated in FIG. 2, other sensors may also be employed. All of the sensors included on the chip may correspond to the type manufactured by Transensory Devices, Inc., their integrated circuit pressure/temperature sensor being discussed hereinbefore with respect to the article occurring in the Aug. 11, 1983 issue of "Electronics" magazine. It should be understood that although sensors 16-20 have been shown associated with one another in the same circuit, for ease of illustration, sensors 16 and 18 are actually at one location (a tire) while sensor 20 is at another (a brake). Hence, sensors 16 and 18 are, in fact, located at one integrated circuit 10 while sensor 20 is located at another circuit 10. In general, a circuit 10 will be disposed at each location where a parameter such as temperature or pressure is to be measured. Of course, at a given location a number of different parameters can be sensed.
The outputs of sensors 16-20 are applied to comparators 22-26, respectively. Also applied to the comparators in a known manner are reference, threshold voltages from variable resistors 29-33. The outputs of the comparators are applied to an encoder/output module 28 indicated by the phantom line. Encoder/output module 28 is well known and may correspond to the National Semiconductor LM 1871, General Instrument AY-3-8470 or other devices used for remote transmission purposes. The encoder/output module 28, in general, encodes the sensed data into a multibit word and outputs the word to a transmitter 30 with the correct format and timing. The module 28 includes an input detection circuit 32 responsive to the outputs of comparators 22-26. These outputs are applied to and held by latches 34 for application to encoder 26, which may be of the recirculating shift register type. Also applied to encoder 36 is the location of integrated circuit 10 from a programmable location information source 38. A clock/generator 40 is also applied to the encoder. As stated above, the encoded signal is a multibit word which is applied to output logic 42 and then transmitter 30 for transmission to data receiver/decoder 12.
Standby power circuitry generally indicated at 44 is also employed, its purpose being to remove power from most of the circuitry for predetermined periods of time to reduce power consumption. This circuitry includes a long period oscillator 46, which may be of a type corresponding to National Semiconductor LM3909, and which times the power on cycle, its output being applied to a standby power circuit 48. Also applied to circuit 48 is the output of a single shot 50, the single shot being actuated by an output from input detection circuit 32. The output of the single shot is also applied to a timing logic circuit 52, the output of which is, in turn, applied to encoder 36.
In operation, during the power on cycle, as determined by oscillator 46, the sensors 16-20 receive power from circuit 48 for a short time. The sensed signals are applied to the comparators where out-of-range signals are tested for in accordance with the thresholds set at variable resistors 29-33. If an out-of-range condition exists, the multibit word generated by encoder 36 would include a code for that particular condition. Moreover, it would include a code, as determined by source 38, identifying the location of the sensor in the vehicle. The remaining circuitry insures the word transmitted by transmitter 30 has the correct format and timing.
Reference should now be made to FIG. 3 which illustrates how certain ones of the elements of FIG. 2 may be physically located on an integrated circuit chip. The other elements may also be incorporated in a known manner.
Referring to FIG. 4, there are illustrated various methods of mounting integrated circuit 10 with respect to a tire stem 54, which may be an already existing stem or a specially constructed stem. In one arrangement, an existing stem may be employed, which stem normally extends through a valve stem mounting hole 56 disposed in a partially illustrated wheel 58. Prior to insertion of the stem through mounting hole 56, integrated circuit 10 may be mounted on the stem via a ring 60, the circuit being attached to the ring where the ring and/or stem may serve as an antenna. Once the stem is secured in place through hole 56, the integrated circuit will be securely mounted with respect to the stem to monitor tire temperature and/or pressure. Other possible locations of circuit 10 within stem 54, particularly where the stem is specially constructed to incorporate the circuit are indicated by dotted lines within the stem in FIG. 4.
In one preferred version of the device there is a fail-safe light, in addition to the numbered tire pressure fault indicating lights, which remains illuminated only while the system is fully operational.
It is to be understood that the above detailed description of the various embodiments of the invention is provided by way of example only. Various details of design and construction may be modified without departing from the true spirit and scope of the invention as set forth in the appended claims.
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A monitor for telemetering data such as temperature or pressure from a vehicle tire or the like including a transducer responsive to the data; a processor responsive to the transducer; and a transmitter responsive to the processor for transmitting the processed electrical signal to a remote location where the transducer, processor and transmitter are disposed on a single integrated circuit. Various techniques for mounting the transducer and for encoding the telemetered signal are also disclosed.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This is a Continuation Application of U.S. application Ser. No. 10/713,057 filed Nov. 17, 2003, which is a continuation of U.S. application Ser. No 09/944,399, filed Sep. 4,2001, now issued as U.S. Pat. No. 6,652,078, which is a Continuation-in-Part of U.S. application Ser. No 09/575,115 filed May 23, 2000, now issued as U.S. Pat. No. 6,409,323.
CO-PENDING APPLICATIONS/GRANTED PATENTS
[0002] Various methods, systems and apparatus relating to the present invention are disclosed in the following applications/granted patents filed by the applicant or assignee of the present invention.
09/575,197 09/575,195 09/575,159 09/575,132, 09/575,123 09/575,148 09/575,130 09/575,165 6,813,039 09/575,118 09/575,131 09/575,116 6,816,274 09/575,139 09/575,186 6,681,045 6,728,000 09/575,145 09/575,192 09/575,181 09/575,193 09/575,156 (lapsed) 09/575,183 6,789,194 09/575,150 6,789,191 6,644,642 6,502,614 6,622,999 6,669,385 6,549,935 6,591,884 6,439,706 09/575,187 6,727,996 6,760,119 09/575,198 6,290,349 6,428,155 6,785,016 09/575,174 09/575,163 6,737,591 09/575,154 09/575,129 09/575,124 09/575,188 09/575,189 09/575,162 (Abandoned) 09/575,172 (Abandoned) 09/575,170 09/575,171 09/575,161 6,428,133 6,526,658 6,315,399 6,338,548 6,540,319 6,328,431 6,328,425 09/575,127 6,383,833 6,464,332 6,390,591 09/575,152 6,328,417 6,322,194 09/575,177 6,629,745 6,409,323 6,281,912 6,604,810 6,318,920 6,488,422 09/575,108 09/575,109 09/575,110 6,290,349 6,712,452 6,416,160 6,238,043 09/575,119 6,812,972 09/575,157 6,554,459 09/575,134 09/575,121 09/575,137 6,804,026 09/575,120 09/575,122
[0003] The disclosures of these applications/granted patents are incorporated herein by reference.
FIELD OF THE INVENTION
[0004] The present invention relates to an inkjet printhead assembly. More particularly, this invention relates to an inkjet printing assembly having a rotary platen assembly.
[0005] More particularly, though not exclusively, the invention relates to a printhead assembly for a printer with an ink supply arrangement for an A4 pagewidth drop on demand printhead capable of printing up to 1600 dpi photographic quality at up to 160 pages per minute.
BACKGROUND OF THE INVENTION
[0006] The overall design of the printer in which the arrangement can be utilized revolves around the use of replaceable printhead modules in an array approximately 8 inches (20 cm) long. An advantage of such a system is the ability to easily remove and replace any defective modules in a printhead array. This would eliminate having to scrap an entire printhead if only one chip is defective.
[0007] A printhead module in such a printer can be comprised of a “Memjet” chip, being a chip having mounted thereon a vast number of thermo-actuators in micro-mechanics and micro-electromechanical systems (MEMS). Such actuators might be those as disclosed in U.S. Pat. No. 6,044,646 to the present applicant, however, there might be other MEMS print chips.
[0008] The printhead, being the environment within which the ink supply arrangement of the present invention is to be situated, might typically have six ink chambers and be capable of printing a four-color process (CMYK) as well as infrared ink and fixative.
[0009] Each printhead module receives ink via a distribution molding that transfers the ink. Typically, ten modules butt together to form a complete eight inch printhead assembly suitable for printing A4 paper without the need for scanning movement of the printhead across the paper width.
[0010] The printheads themselves are modular, so complete eight-inch printhead arrays can be configured to form printheads of arbitrary width.
[0011] Additionally, a second printhead assembly can be mounted on the opposite side of a paper feed path to enable double-sided high-speed printing.
[0012] An elongate pagewidth printhead assembly might be efficiently packaged into a printer housing if its ink supply hoses did not project longitudinally beyond the pagewidth extent of the assembly.
SUMMARY OF THE INVENTION
[0013] According to a first aspect of the invention, there is provided an inkjet printhead assembly which comprises
a carrier; an ink supply assembly that is mounted on the carrier and defines a plurality of printhead chip receiving formations that are each dimensioned to engage a printhead chip and a plurality of ink supply conduits that terminate at the formations to supply ink to printhead chips engaged with the formations; a plurality of inkjet printhead chips that are engaged with respective said formations to receive the ink via passages defmed by the printhead chips in fluid communication with respective ink supply conduits; and a rotary platen assembly that is mounted on the carrier, the rotary platen assembly comprising
a shaft that is rotatably mounted on the carrier to be driven rotatably with respect to the carrier; a platen body that is mounted on the shaft, the platen body defining a platen surface for supporting sheets of a print medium as the printhead chips carry out a printing operation on the sheets, the shaft being rotatable to bring the platen surface into and out of alignment with the printhead chips; and a displacement mechanism that is arranged on the shaft and the carrier, the displacement mechanism being configured to permit the shaft and thus the platen surface to be laterally displaced into and out of an operative position with respect to the printhead chips.
[0021] A capping assembly may be positioned on the platen body. The shaft may be rotatable to bring the capping assembly into and out of alignment with the printhead chips. The displacement mechanism may be operable to displace the shaft laterally and reversibly so that the capping assembly can engage the printhead chips to cap the printhead chips.
[0022] Blotting material may be positioned on a portion of the platen body. The shaft may be rotatable to bring the blotting material into alignment with the printhead chips and the displacement mechanism may be operable to displace the shaft laterally and reversibly so that the blotting material can be positioned operatively with respect to the printhead chips to absorb ink ejected from the chips when the chips are primed.
[0023] The platen body may be hollow and may be filled with the blotting material, the body defining an opening from which the blotting material can define a blotting surface on said portion of the platen body.
[0024] The ink supply assembly may further define a gas flow path that terminates at each printhead chip receiving formation. The ink supply assembly may be connectable to a pressurized gas supply so that gas can be directed over each printhead chip to inhibit the build-up of dust and debris on the printhead chips. A valve closure may be mounted on the ink supply assembly in the gas flow path to be displaceable with respect to the ink supply assembly between an open position in which gas is permitted to flow through the gas flow path and a closed position in which the gas is shut off. The valve closure may be connected to the shaft such that, when the platen surface is displaced into its operative position, the valve closure is displaced into its open position and when the capping assembly is displaced into engagement with the printhead chips, the valve closure is displaced into its closed position.
[0025] According to a second aspect of the invention, there is provided a printhead assembly comprising:
an elongate pagewidth ink distribution housing having a longitudinal extent in a pagewidth direction and conveying ink to a plurality of ink ejection nozzles substantially spanning said pagewidth, the housing including an inlet port configured to receive an ink hose via which ink is received by the housing, wherein the hose extends from the port in a direction that is substantially normal to said pagewidth direction.
[0027] Preferably the inlet port is positioned substantially midway between respective opposed ends of the housing.
[0028] Preferably the printhead assembly includes a pagewidth array of print modules each having said ink ejection nozzles thereon.
[0029] Preferably, the printhead assembly is configured to print color images and wherein there is provided a number of said inlet ports corresponding to the number of colors to be printed.
[0030] Preferably there is provided a number of ink hoses corresponding to the number of ports and all of the ink hoses extend from the ports in a direction that is substantially normal to said pagewidth direction.
[0031] Preferably the printhead assembly is mounted within a printer and including a stepper motor for driving ancillary equipment of the printer, the stepper motor being located not beyond the longitudinal extent of the ink distribution housing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] A preferred form of the present invention will now be described by way of example with reference to the accompanying drawings wherein:
[0033] FIG. 1 is a front perspective view of a print engine assembly
[0034] FIG. 2 is a rear perspective view of the print engine assembly of FIG. 1
[0035] FIG. 3 is an exploded perspective view of the print engine assembly of FIG. 1 .
[0036] FIG. 4 is a schematic front perspective view of a printhead assembly.
[0037] FIG. 5 is a rear schematic perspective view of the printhead assembly of FIG. 4 .
[0038] FIG. 6 is an exploded perspective illustration of the printhead assembly.
[0039] FIG. 7 is a cross-sectional end elevational view of the printhead assembly of FIGS. 4 to 6 with the section taken through the centre of the printhead.
[0040] FIG. 8 is a schematic cross-sectional end elevational view of the printhead assembly of FIGS. 4 to 6 taken near the left end of FIG. 4 .
[0041] FIG. 9A is a schematic end elevational view of mounting of the print chip and nozzle guard in the laminated stack structure of the printhead
[0042] FIG. 9B is an enlarged end elevational cross section of FIG. 9A
[0043] FIG. 10 is an exploded perspective illustration of a printhead cover assembly.
[0044] FIG. 11 is a schematic perspective illustration of an ink distribution molding.
[0045] FIG. 12 is an exploded perspective illustration showing the layers forming part of a laminated ink distribution structure according to the present invention.
[0046] FIG. 13 is a stepped sectional view from above of the structure depicted in FIGS. 9A and 9B ,
[0047] FIG. 14 is a stepped sectional view from below of the structure depicted in FIG. 13 .
[0048] FIG. 15 is a schematic perspective illustration of a first laminate layer.
[0049] FIG. 16 is a schematic perspective illustration of a second laminate layer.
[0050] FIG. 17 is a schematic perspective illustration of a third laminate layer.
[0051] FIG. 18 is a schematic perspective illustration of a fourth laminate layer.
[0052] FIG. 19 is a schematic perspective illustration of a fifth laminate layer.
[0053] FIG. 20 is a perspective view of the air valve molding
[0054] FIG. 21 is a rear perspective view of the right hand end of the platen
[0055] FIG. 22 is a rear perspective view of the left-hand end of the platen
[0056] FIG. 23 is an exploded view of the platen
[0057] FIG. 24 is a transverse cross-sectional view of the platen
[0058] FIG. 25 is a front perspective view of the optical paper sensor arrangement
[0059] FIG. 26 is a schematic perspective illustration of a printhead assembly and ink lines attached to an ink reservoir cassette.
[0060] FIG. 27 is a partly exploded view of FIG. 26 .
DETAILED DESCRIPTION OF THE INVENTION
[0061] In FIGS. 1 to 3 of the accompanying drawings there is schematically depicted the core components of a print engine assembly, showing the general environment in which the laminated ink distribution structure of the present invention can be located. The print engine assembly includes a chassis 10 fabricated from pressed steel, aluminum, plastics or other rigid material. Chassis 10 is intended to be mounted within the body of a printer and serves to mount a printhead assembly 11 , a paper feed mechanism and other related components within the external plastics casing of a printer.
[0062] In general terms, the chassis 10 supports the printhead assembly 11 such that ink is ejected therefrom and onto a sheet of paper or other print medium being transported below the printhead then through exit slot 19 by the feed mechanism. The paper feed mechanism includes a feed roller 12 , feed idler rollers 13 , a platen generally designated as 14 , exit rollers 15 and a pin wheel assembly 16 , all driven by a stepper motor 17 . These paper feed components are mounted between a pair of bearing moldings 18 , which are in turn mounted to the chassis 10 at each respective end thereof.
[0063] A printhead assembly 11 is mounted to the chassis 10 by means of respective printhead spacers 20 mounted to the chassis 10 . The spacer moldings 20 increase the printhead assembly length to 220 mm allowing clearance on either side of 210 mm wide paper.
[0064] The printhead construction is shown generally in FIGS. 4 to 8 .
[0065] The printhead assembly 11 includes a printed circuit board (PCB) 21 having mounted thereon various electronic components including a 64 MB DRAM 22 , a PEC chip 23 , a QA chip connector 24 , a microcontroller 25 , and a dual motor driver chip 26 . The printhead is typically 203 mm long and has ten print chips 27 ( FIG. 13 ), each typically 21 mm long. These print chips 27 are each disposed at a slight angle to the longitudinal axis of the printhead (see FIG. 12 ), with a slight overlap between each print chip which enables continuous transmission of ink over the entire length of the array. Each print chip 27 is electronically connected to an end of one of the tape automated bond (TAB) films 28 , the other end of which is maintained in electrical contact with the undersurface of the printed circuit board 21 by means of a TAB film backing pad 29 .
[0066] The preferred print chip construction is as described in U.S. Pat. No 6,044,646 by the present applicant. Each such print chip 27 is approximately 21 mm long, less than 1 mm wide and about 0.3 mm high, and has on its lower surface thousands of MEMS inkjet nozzles 30 , shown schematically in FIGS. 9A and 9B , arranged generally in six lines—one for each ink type to be applied. Each line of nozzles may follow a staggered pattern to allow closer dot spacing. Six corresponding lines of ink passages 31 extend through from the rear of the print chip to transport ink to the rear of each nozzle. To protect the delicate nozzles on the surface of the print chip each print chip has a nozzle guard 43 , best seen in FIG. 9A , with microapertures 44 aligned with the nozzles 30 , so that the ink drops ejected at high speed from the nozzles pass through these microapertures to be deposited on the paper passing over the platen 14 .
[0067] Ink is delivered to the print chips via a distribution molding 35 and laminated stack 36 arrangement forming part of the printhead 11 . Ink from an ink cassette 93 ( FIGS. 26 and 27 ) is relayed via individual ink hoses 94 to individual ink inlet ports 34 integrally molded with a plastics duct cover 39 which forms a lid over the plastics distribution molding 35 . As can be seen in FIGS. 4 and 6 , the ink inlet ports 34 are positioned so as to enable the ink hoses 94 to project laterally from the ink distribution molding 35 . In the preferred embodiment, the ink inlet ports 34 are positioned at a midpoint between respective opposed ends of the distribution molding 35 . By having the inlet ports 34 so positioned, a housing within which the printhead is situated need not be significantly wider than the overall length of the printhead. In previously known printheads, ink enters the printhead from one of its ends. Such arrangements are not space-efficient in the length-wise direction of the head due to the need to fit the hoses between the end of the printhead and the inside surface of the printer casing. In the depicted embodiment of the present invention, there is shown a stepper motor 17 situated at one end of the printhead. This configuration is not essential to the invention as stepper motor 17 , instead of taking up space at the end of the printhead, can be situated alongside the printhead, above it or beneath it and torque from this motor can be relayed to the feed roller 12 , feed idler rollers 13 , platen 14 , exit rollers 15 and pinwheel assembly 16 via a space-efficient transmission which might comprise intermeshing gears or a drive belt. Further advantage of this length-wise printer-into-housing space efficiency can be had by positioning the ink inlet ports 34 so as to extend laterally from the ink distribution molding as depicted so that the ink delivery hoses do not encroach on lengthwise space at the end of the molding.
[0068] The distribution molding 35 includes six individual longitudinal ink ducts 40 and an air duct 41 which extend throughout the length of the array. Ink is transferred from the inlet ports 34 to respective ink ducts 40 via individual cross-flow ink channels 42 , as best seen with reference to FIG. 7 . It should be noted in this regard that although there are six ducts depicted, a different number of ducts might be provided. Six ducts are suitable for a printer capable of printing four color process (CMYK) as well as infrared ink and fixative.
[0069] Air is delivered to the air duct 41 via an air inlet port 61 , to supply air to each print chip 27 , as described later with reference to FIGS. 6 to 8 , 20 and 21 .
[0070] Situated within a longitudinally extending stack recess 45 formed in the underside of distribution molding 35 are a number of laminated layers forming a laminated ink distribution stack 36 . The layers of the laminate are typically formed of micro-molded plastics material. The TAB film 28 extends from the undersurface of the printhead PCB 21 , around the rear of the distribution molding 35 to be received within a respective TAB film recess 46 ( FIG. 21 ), a number of which are situated along a chip housing layer 47 of the laminated stack 36 . The TAB film relays electrical signals from the printed circuit board 21 to individual print chips 27 supported by the laminated structure.
[0071] The distribution molding, laminated stack 36 and associated components are best described with reference to FIGS. 7 to 19 .
[0072] FIG. 10 depicts the distribution molding cover 39 formed as a plastics molding and including a number of positioning spigots 48 which serve to locate the upper printhead cover 49 thereon.
[0073] As shown in FIG. 7 , an ink transfer port 50 connects one of the ink ducts 40 (the fourth duct from the left) down to one of six lower ink ducts or transitional ducts 51 in the underside of the distribution molding. All of the ink ducts 40 have corresponding transfer ports 50 communicating with respective ones of the transitional ducts 51 . The transitional ducts 51 are parallel with each other but angled acutely with respect to the ink ducts 40 so as to line up with the rows of ink holes of the first layer 52 of the laminated stack 36 to be described below.
[0074] The first layer 52 incorporates twenty-four individual ink holes 53 for each of ten print chips 27 . That is, where ten such print chips are provided, the first layer 52 includes two hundred and forty ink holes 53 . The first layer 52 also includes a row of air holes 54 alongside one longitudinal edge thereof.
[0075] The individual groups of twenty-four ink holes 53 are formed generally in a rectangular array with aligned rows of ink holes. Each row of four ink holes is aligned with a transitional duct 51 and is parallel to a respective print chip.
[0076] The undersurface of the first layer 52 includes underside recesses 55 . Each recess 55 communicates with one of the ink holes of the two centre-most rows of four holes 53 (considered in the direction transversely across the layer 52 ). That is, holes 53 a ( FIG. 13 ) deliver ink to the right hand recess 55 a shown in FIG. 14 , whereas the holes 53 b deliver ink to the left most underside recesses 55 b shown in FIG. 14 .
[0077] The second layer 56 includes a pair of slots 57 , each receiving ink from one of the underside recesses 55 of the first layer.
[0078] The second layer 56 also includes ink holes 53 , which are aligned with the outer two sets of ink holes 53 of the first layer 52 . That is, ink passing through the outer sixteen ink holes 53 of the first layer 52 for each print chip pass directly through corresponding holes 53 passing through the second layer 56 .
[0079] The underside of the second layer 56 has formed therein a number of transversely extending channels 58 to relay ink passing through ink holes 53 c and 53 d toward the centre. These channels extend to align with a pair of slots 59 formed through a third layer 60 of the laminate. It should be noted in this regard that the third layer 60 of the laminate includes four slots 59 corresponding with each print chip, with two inner slots being aligned with the pair of slots formed in the second layer 56 and outer slots between which the inner slots reside.
[0080] The third layer 60 also includes an array of air holes 54 aligned with the corresponding air hole arrays 54 provided in the first and second layers 52 and 56 .
[0081] The third layer 60 has only eight remaining ink holes 53 corresponding with each print chip. These outermost holes 53 are aligned with the outermost holes 53 provided in the first and second laminate layers. As shown in FIGS. 9A and 9B , the third layer 60 includes in its underside surface a transversely extending channel 61 corresponding to each hole 53 . These channels 61 deliver ink from the corresponding hole 53 to a position just outside the alignment of slots 59 therethrough.
[0082] As best seen in FIGS. 9A and 9B , the top three layers of the laminated stack 36 thus serve to direct the ink (shown by broken hatched lines in FIG. 9B ) from the more widely spaced ink ducts 40 of the distribution molding to slots aligned with the ink passages 31 through the upper surface of each print chip 27 .
[0083] As shown in FIG. 13 , which is a view from above the laminated stack, the slots 57 and 59 can in fact be comprised of discrete co-linear spaced slot segments.
[0084] The fourth layer 62 of the laminated stack 36 includes an array of ten chip-slots 65 each receiving the upper portion of a respective print chip 27 .
[0085] The fifth and final layer 64 also includes an array of chip-slots 65 which receive the chip and nozzle guard assembly 43 .
[0086] The TAB film 28 is sandwiched between the fourth and fifth layers 62 and 64 , one or both of which can be provided with recesses to accommodate the thickness of the TAB film. The laminated stack is formed as a precision micro-molding, injection molded in an Acetal type material. It accommodates the array of print chips 27 with the TAB film already attached and mates with the cover molding 39 described earlier.
[0087] Rib details in the underside of the micro-molding provides support for the TAB film when they are bonded together. The TAB film forms the underside wall of the printhead module, as there is sufficient structural integrity between the pitch of the ribs to support a flexible film. The edges of the TAB film seal on the underside wall of the cover molding 39 . The chip is bonded onto one hundred-micron wide ribs that run the length of the micro-molding, providing a final ink feed to the print nozzles.
[0088] The design of the micro-molding allows for a physical overlap of the print chips when they are butted in a line. Because the printhead chips now form a continuous strip with a generous tolerance, they can be adjusted digitally to produce a near perfect print pattern rather than relying on very close toleranced moldings and exotic materials to perform the same finction. The pitch of the modules is typically 20.33 mm.
[0089] The individual layers of the laminated stack as well as the cover molding 39 and distribution molding can be glued or otherwise bonded together to provide a sealed unit. The ink paths can be sealed by a bonded transparent plastic film serving to indicate when inks are in the ink paths, so they can be fully capped off when the upper part of the adhesive film is folded over. Ink charging is then complete.
[0090] The four upper layers 52 , 56 , 60 , 62 of the laminated stack 36 have aligned air holes 54 which communicate with air passages 63 formed as channels formed in the bottom surface of the fourth layer 62 , as shown in FIGS. 9 b and 13 . These passages provide pressurised air to the space between the print chip surface and the nozzle guard 43 whilst the printer is in operation. Air from this pressurised zone passes through the micro-apertures 44 in the nozzle guard, thus preventing the build-up of any dust or unwanted contaminants at those apertures. This supply of pressurised air can be turned off to prevent ink drying on the nozzle surfaces during periods of non-use of the printer, control of this air supply being by means of the air valve assembly shown in FIGS. 6 to 8 , 20 and 21 .
[0091] With reference to FIGS. 6 to 8 , within the air duct 41 of the printhead there is located an air valve molding 66 formed as a channel with a series of apertures 67 in its base. The spacing of these apertures corresponds to air passages 68 formed in the base of the air duct 41 (see FIG. 6 ), the air valve molding being movable longitudinally within the air duct so that the apertures 67 can be brought into alignment with passages 68 to allow supply the pressurized air through the laminated stack to the cavity between the print chip and the nozzle guard, or moved out of alignment to close off the air supply. Compression springs 69 maintain a sealing inter-engagement of the bottom of the air valve molding 66 with the base of the air duct 41 to prevent leakage when the valve is closed.
[0092] The air valve molding 66 has a cam follower 70 extending from one end thereof, which engages an air valve cam surface 71 on an end cap 74 of the platen 14 so as to selectively move the air valve molding longitudinally within the air duct 41 according to the rotational positional of the multi-function platen 14 , which may be rotated between printing, capping and blotting positions depending on the operational status of the printer, as will be described below in more detail with reference to FIGS. 21 to 24 . When the platen 14 is in its rotational position for printing, the cam holds the air valve in its open position to supply air to the print chip surface, whereas when the platen is rotated to the non-printing position in which it caps off the micro-apertures of the nozzle guard, the cam moves the air valve molding to the valve closed position.
[0093] With reference to FIGS. 21 to 24 , the platen member 14 extends parallel to the printhead, supported by a rotary shaft 73 mounted in bearing molding 18 and rotatable by means of gear 79 (see FIG. 3 ). The shaft is provided with a right hand end cap 74 and left hand end cap 75 at respective ends, having cams 76 , 77 .
[0094] The platen member 14 has a platen surface 78 , a capping portion 80 and an exposed blotting portion 81 extending along its length, each separated by 120°. During printing, the platen member is rotated so that the platen surface 78 is positioned opposite the printhead so that the platen surface acts as a support for that portion of the paper being printed at the time. When the printer is not in use, the platen member is rotated so that the capping portion 80 contacts the bottom of the printhead, sealing in a locus surrounding the microapertures 44 . This, in combination with the closure of the air valve by means of the air valve arrangement when the platen 14 is in its capping position, maintains a closed atmosphere at the print nozzle surface. This serves to reduce evaporation of the ink solvent (usually water) and thus reduce drying of ink on the print nozzles while the printer is not in use.
[0095] The third function of the rotary platen member is as an ink blotter to receive ink from priming of the print nozzles at printer start up or maintenance operations of the printer. During this printer mode, the platen member 14 is rotated so that the exposed blotting portion 81 is located in the ink ejection path opposite the nozzle guard 43 . The exposed blotting portion 81 is an exposed part of a body of blotting material 82 inside the platen member 14 , so that the ink received on the exposed portion 81 is drawn into the body of the platen member.
[0096] Further details of the platen member construction may be seen from FIGS. 23 and 24 . The platen member consists generally of an extruded or molded hollow platen body 83 which forms the platen surface 78 and receives the shaped body of blotting material 82 of which a part projects through a longitudinal slot in the platen body to form the exposed blotting surface 81 . A flat portion 84 of the platen body 83 serves as a base for attachment of the capping member 80 , which consists of a capper housing 85 , a capper seal member 86 and a foam member 87 for contacting the nozzle guard 43 .
[0097] With reference again to FIG. 1 , each bearing molding 18 rides on a pair of vertical rails 101 . That is, the capping assembly is mounted to four vertical rails 101 enabling the assembly to move vertically. A spring 102 under either end of the capping assembly biases the assembly into a raised position, maintaining cams 76 , 77 in contact with the spacer projections 100 .
[0098] The full-width capping member 80 using the elastomeric (or similar) seal 86 caps the printhead 11 . In order to rotate the platen assembly 14 , the main roller drive motor is reversed. This brings a reversing gear into contact with the gear 79 on the end of the platen assembly and rotates it into one of its three finctional positions, each separated by 120°. The cams 76 , 77 on the platen end caps 74 , 75 co-operate with projections 100 on the respective printhead spacers 20 to control the spacing between the platen member and the printhead depending on the rotary position of the platen member. In this manner, the platen is moved away from the printhead during the transition between platen positions to provide sufficient clearance from the printhead and moved back to the appropriate distances for its respective paper support, capping and blotting functions.
[0099] In addition, the cam arrangement for the rotary platen provides a mechanism for fine adjustment of the distance between the platen surface and the printer nozzles by slight rotation of the platen 14 . This allows compensation of the nozzle-platen distance in response to the thickness of the paper or other material being printed, as detected by the optical paper thickness sensor arrangement illustrated in FIG. 25 .
[0100] The optical paper sensor includes an optical sensor 88 mounted on the lower surface of the PCB 21 and a sensor flag arrangement mounted on the arms 89 protruding from the distribution molding. The flag arrangement comprises a sensor flag member 90 mounted on a shaft 91 which is biased by torsion spring 92 . As paper enters the feed rollers, the lowermost portion of the flag member contacts the paper and rotates against the bias of the spring 92 by an amount dependent on the paper thickness. The optical sensor detects this movement of the flag member and the PCB responds to the detected paper thickness by causing compensatory rotation of the platen 14 to optimize the distance between the paper surface and the nozzles.
[0101] FIGS. 26 and 27 show attachment of the illustrated printhead assembly to a replaceable ink cassette 93 . Six different inks are supplied to the printhead through hoses 94 leading from an array of female ink valves 95 located inside the printer body. The replaceable cassette 93 containing a six-compartment ink bladder and corresponding male valve array is inserted into the printer and mated to the valves 95 . The cassette also contains an air inlet 96 and air filter (not shown), and mates to the air intake connector 97 situated beside the ink valves, leading to the air pump 98 supplying filtered air to the printhead. A QA chip is included in the cassette. The QA chip meets with a contact 99 located between the ink valves 95 and air intake connector 96 in the printer as the cassette is inserted to provide communication to the QA chip connector 24 on the PCB.
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A printer has an inkjet printhead assembly including a carrier. An ink supply assembly is mounted on the carrier and defines a plurality of printhead chip receiving formations that are each dimensioned to engage a printhead chip and a plurality of ink supply conduits that terminate at the formations to supply ink to printhead chips engaged with the formations. A plurality of inkjet printhead chips is engaged with respective said formations to receive the ink via passages defined by the printhead chips in fluid communication with respective ink supply conduits. A rotary platen assembly is mounted on the carrier. The rotary platen assembly includes a platen body that is mounted on a shaft and defines a platen surface for supporting sheets of a print medium as the printhead chips carry out a printing operation on the sheets. The shaft is rotatable to bring the platen surface into and out of alignment with the printhead chips. A displacement mechanism is arranged on the shaft and the carrier to permit the shaft and thus the platen surface to be laterally displaced into and out of an operative position with respect to the printhead chips.
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TECHNICAL FIELD
[0001] This invention relates to automobile convertible tops and, more particularly, to a hydraulic operator for a convertible top having a movable rear bow.
BACKGROUND OF THE INVENTION
[0002] Many convertible tops designed for high-end sports or other two-seat vehicles employ a movable rear or 5-bow. With the top lowered, the tonneau is opened to enable raising the top. The rear bow is then raised to enable closing of the tonneau. The rear bow is then lowered and secured to the tonneau to close the passenger compartment. To lower the top, the rear bow is raised to enable opening of the tonneau. The top is then lowered, after which the tonneau is closed. This system eliminates the need for a separate boot cover and presents a more aesthetically pleasing vehicle in both the top raised and lowered positions.
[0003] Power tops that utilize a movable rear bow normally provide a pair of cylinders to operate the top, and require manual operation to raise and lower the rear bow or provide an additional pair of cylinders to operate the rear bow. These top operating systems are unduly complex and require use of complex valving to accomplish the correct sequence of top and bow movements to raise and lower the top.
[0004] Developments have led to a hydraulic control system in which a single pair of cylinders can be used to sequentially operate both the top and rear bow movements operating through a mechanical linkage. Such a system is disclosed in U.S. Pat. No. 5,620,226—Sautter, the entire disclosure of which is incorporated herein by reference.
[0005] There is a need for a convertible top operating mechanism which uses a simplified hydraulic control system to sequentially operate the top and tonneau movements to raise and lower the top.
SUMMARY OF THE INVENTION
[0006] It is therefore an object of this invention to provide a for a convertible top operating mechanism which uses a simplified hydraulic control system to sequentially operate the top and bow movements to raise and lower the top.
[0007] In general, this invention comprises a hydraulic control system for operating cylinders that control movement of a hydraulic top and cylinders that control movement of a tonneau.
[0008] In one aspect this invention features a convertible top operating mechanism which includes a bi-directional hydraulic pump which is selectively connected to top-operating hydraulic cylinders and tonneau-operating hydraulic cylinders by a two-way, 2-condition control valve to selectively raise and lower the top and tonneau.
[0009] In one embodiment, a mechanical linkage connects the top-operating cylinders with the movable rear bow and is operable to sequentially move the rear bow in a manner that accommodates tonneau operation in coordination with top operation.
[0010] In a first valve position, both ends of the top cylinders are connected to both sides of the pump, while one end of the tonneau cylinders are connected to one side of the pump, and the other tonneau cylinder ends are blocked. When the pump is inoperative (condition 1), this allows the top to float, but secures the tonneau against movement.
[0011] In this first valve position, operation of the pump in one direction will extend the top cylinders only (condition 2) to raise the top; it will pressurize one side of the tonneau cylinders, but they cannot move since the exhaust side is blocked. Pump operation in the other direction will retract the top cylinders only (condition 3) to lower the top; the tonneau cylinders are connected to exhaust, but cannot move since the pressure side is blocked.
[0012] In a second valve position, both ends of the tonneau cylinders are connected to both sides of the pump, while one end of the top cylinders are connected to one side of the pump and the other top cylinder ends are blocked. If this position were used when the pump is inoperative, the tonneau would be unpressured and float, while the top would be secured against movement; however this condition is not desired and, consequently not utilized.
[0013] In this second valve position, pump operation in one direction will extend the tonneau cylinders only (condition 4) to raise the tonneau. Operation of the pump in the other direction will retract the tonneau cylinders only (condition 5) to lower the tonneau. In both conditions 4 and 5, the blockage of one end of the top cylinders prevents their movement.
[0014] These and other objects and features of this invention will become more readily apparent upon reference to the following detailed description of a preferred embodiment, as illustrated in the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] [0015]FIGS. 1 and 2 are perspective views of a convertible vehicle with its top shown in raised and lowered positions, respectively;
[0016] [0016]FIG. 3 is a side view of one form of convertible top, having a movable rear bow, and illustrating the linkages and hydraulic cylinders used to control sequential movement of the top and the movable tonneau;
[0017] [0017]FIG. 4 is a hydraulic schematic of the hydraulic cylinder control system, with the pump direction and control valve positioned to extend the top hydraulic cylinders and raise the top;
[0018] [0018]FIG. 5 is a schematic similar to FIG. 4, is a hydraulic schematic of the hydraulic cylinder control system, with the pump direction and control valve positioned to retract the top hydraulic cylinders and lower the top;
[0019] [0019]FIG. 6 is a schematic similar to FIGS. 4 and 5, but with the pump direction and control valve positioned to extend the tonneau hydraulic cylinders and raise the tonneau; and
[0020] [0020]FIG. 7 is a schematic similar to FIG. 6, but with the pump direction and control valve positioned to retract the tonneau hydraulic cylinders and lower the tonneau.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0021] This invention is directed to a top and tonneau operating system for the convertible top of a vehicle, such as the one disclosed in aforementioned U.S. Pat. No. 5,620,226. As shown in FIGS. 1 - 3 a convertible vehicle 20 includes a body 22 having a passenger compartment 24 that is enclosed by a windshield W, side windows S and a retractable top 26 that is selectively lowered into a storage compartment 28 behind passenger compartment 24 . A tonneau 30 covers storage compartment 28 when top 26 is lowered, and is selectively opened and closed, as later described, to permit raising and lowering of top 26 .
[0022] As shown in FIG. 3, top 26 comprises a flexible cover C supported by a header H and transverse bows B 2 , B 3 and B 4 . The bows are supported at their sides by symmetrical articulated linkages 32 that pivotally support a movable rear, or # 5 , bow 34 . In the illustrated raised position of FIGS. 1 and 3, rear bow 34 rests upon and seals against tonneau 30 . Top 26 is raised and lowered by a pair of hydraulic cylinders 36 , 36 ′, which have extensible output cylinder rods 38 , 38 ′ that operate linkages 32 via a mechanical linkage 40 that also raises and lowers rear bow 34 .
[0023] Tonneau 30 is opened and closed by a pair of hydraulic cylinders 42 , 42 ′ that have extensible output cylinder rods 44 , 44 ′. For the sake of simplicity, FIG. 3 illustrates only one side of the top and its operating system, since both sides are symmetrical. The top structure and operating system are more fully described in aforementioned U.S. Pat. No. 5,620,226.
[0024] Referring now to the schematics in FIGS. 4 - 7 , top-operating hydraulic cylinders 36 , 36 ′ have respective cylinder rods 38 , 38 ′ that extend and retract to operate articulated linkages 32 to raise and lower top 26 and rear bow 34 via mechanical linkage 40 . Tonneau-operating hydraulic cylinders 42 , 42 ′ each has a cylinder rod 44 , 44 ′ that extend and retract to raise and lower tonneau 30 . Cylinders 36 , 36 ′, 40 , 40 ′ are all supplied with hydraulic power fluid from a power pack 50 that includes the usual reservoir of hydraulic fluid (not shown) that supplies a bi-directional pump 52 driven by an electric motor M.
[0025] Pump 52 has one side connected to a fluid transfer line 54 which connects to a control unit 56 that includes a 2-position, 2-way valve 58 , that is operated by a solenoid 60 under direction of a controller C. Fluid in line 54 flows through a pilot-operated check valve 62 that is opened by pressure in a line 64 that connects to another fluid transfer line 66 connected to the other side of pump 52 .
[0026] The right side of valve 58 includes a transfer bore 68 that connects to fluid line 70 , and a blocked port 72 that connects to fluid line 74 when valve 58 is in the FIGS. 4 and 5 positions. Pump line 66 connects to a distribution fluid line 76 for lines 78 , 78 ′ that connect to the rod ends of top cylinders 36 , 36 ′. Lines 80 , 80 ′ connect the rod ends of tonneau cylinders 42 , 42 ′ to distribution line 76 . With this arrangement, pump line 66 is always connected to the rod ends of all of cylinders 36 , 36 ′ and 42 , 42 ′. There is a fluid connection through check valve 62 and valve 58 , via line 70 and lines 82 , 82 ′, between pump 52 and cylinder 36 , 36 ′. Fluid in the blind ends of tonneau cylinders 42 , 42 ′ through fluid lines 82 , 82 ′ is trapped by port 72 .
[0027] The left side of valve 58 includes a transfer bore 84 that connects to fluid line 74 , and a blocked port 86 that connects to fluid line 70 when valve 58 is in the FIGS. 6 and 7 positions. Line 74 connects through lines 88 and 88 ′ to the blind ends of tonneau cylinders 42 , 42 ′, while the blind ends of top cylinders 36 , 36 ′ are connected through lines 82 , 82 ′ and line 70 to blocked port 86 . Again, with this arrangement, pump line 66 is always connected to the rod ends of all of cylinders 36 , 36 ′ and 42 , 42 ′. There is a fluid connection through check valve 62 and valve 58 between pump 52 and cylinder 42 , 42 ′ blind ends via lines 74 , 88 , 88 ′, while fluid in the blind ends of cylinders 36 , 36 ′ is trapped by port 86 .
[0028] Top cylinder 36 is provided with extreme position limit switches 90 and 92 and intermediate limit switch 94 to monitor the position of the top cylinders. Tonneau cylinder 42 is provided with extreme limit switches 96 and 98 to monitor its position. These limit switches enable controller C to sequence operation of the hydraulic cylinders to open and close the tonneau and to raise and lower the top with appropriate raising and lowering of the rear bow in proper sequence. Intermediate limit switch 92 is necessitated by the use of the mechanical linkage 40 to control operation of the top cylinders to raise and lower rear bow 34 during top movement between raised and lowered positions, as more fully described in aforementioned U.S. Pat. No. 5,620,226.
[0029] [0029]FIG. 4 depicts the position of valve 58 and direction of pump 52 to raise the top from its lowered and stored position. FIG. 5 depicts the position of valve 58 and condition of pump 52 to lower the top. FIG. 6 depicts the position of valve 58 and direction of pump 52 to raise the tonneau. FIG. 7 depicts the position of valve 58 and condition of pump 52 to lower the tonneau. Operation of the hydraulic system under conditions depicted in these drawing figures will now be described.
[0030] In FIG. 4, pump 52 is in condition to supply pressure fluid to the system through line 54 and receive exhausted fluid through line 66 to raise top 26 . Of course makeup and excess fluid are transitioned through the sump or reservoir (not illustrated), as is usual. When commanded by controller C, pressure fluid is delivered through line 54 , check valve 62 , control valve 58 , bore 58 , line 70 and lines 82 , 82 ′ to extend top cylinders rods 38 , 38 ′. This forces fluid in the rod ends of cylinders 36 , 36 ′ to exhaust through lines 78 , 78 ′, 76 and 66 directly to pump 52 . Tonneau cylinder rods 44 , 44 ′ are held in position by the fluid trapped in the cylinder blind ends which are connected via lines 88 , 88 ′ and 74 to blocked port 74 . Only low exhaust pressure from top cylinders 36 , 36 ′ is sensed by the rod ends of cylinders 42 , 42 ′ via lines 80 , 80 ′. As cylinder rods 38 , 38 ′ extend, top 26 rises out of storage compartment 28 .
[0031] In FIG. 5, pump 52 is reversed to supply pressure fluid to the system through line 66 and to receive exhaust fluid through line 54 via valves 58 and 62 to lower top 26 . Controller C commands delivery of pressure fluid to line 66 . This causes pressurization of pilot line 64 to open check valve 62 . Pressure fluid flows through line 76 to the rod ends of top cylinders 36 , 36 ′ via lines 78 , 78 ′, and to the rod ends of tonneau cylinders 42 , 42 ′ via lines 80 , 80 ′. The blind ends of top cylinders 36 , 36 ′ connect back to pump 52 via lines 82 , 82 ′ and 70 , valve bore 68 and check valve 62 (held open by pilot pressure) and line 54 . Fluid is trapped in the blind ends of cylinders 42 , 42 ′ since outflow through lines 88 , 88 ′ is blocked by blocked port 72 . Thus, tonneau cylinders 42 , 42 ′ are prevented from retracting to close tonneau 30 , despite pressure in their rod ends. As cylinder rods 38 , 38 ′ retract, top 26 lowers into storage compartment 28 .
[0032] In FIG. 6, pump 52 is again reversed to pressurize line 54 , while solenoid 60 is commanded to shift valve 58 rightward to flow fluid through check valve 62 , valve bore 84 , and lines 74 , 88 and 88 ′ to the blind ends of tonneau cylinders 42 , 42 ′ to extend cylinder rods 44 , 44 ′ and raise tonneau 30 . Outflow from the tonneau cylinder rod ends is through lines 80 , 80 ′ and 66 to pump 52 . Top cylinders 36 , 36 ′ are locked against movement by blockage of any outflow of fluid from their blind ends, because lines 82 , 82 ′ connect to blocked port 86 in valve 58 , and fluid in their rod ends are subject to exhaust pressure in lines 76 , 78 and 78 ′. As cylinder rods 44 , 44 ′ extend, tonneau 30 rises to permit passage of top 26 between raised and lowered positions.
[0033] In FIG. 7, pump 52 is again reversed to pressurize line 66 , and pressurize pilot line 64 to open check valve 62 . Pressure fluid flows through lines 66 , 76 , 80 and 80 ′ to the rod ends of cylinders 42 , 42 ′ to retract cylinder rods 44 , 44 ′. Fluid outflow from the blind ends of the tonneau cylinders is through lines 88 , 88 ′ and 74 , through valve bore 84 and now-open check valve 62 and line 54 to pump 52 . Top cylinders 36 , 36 ′ are immobilized by trapped fluid in their blind ends, which connect through lines 82 , 82 ′ to blocked valve port 86 , even though the rod ends are pressurized via lines 76 , 78 and 78 ′. Retracting cylinder rods 44 , 44 ′ lower tonneau 30 to close storage compartment 28 .
[0034] Operation of the top operating hydraulic control system will now be described during the raise/lower cycle of the convertible top through sequential movement of the top and tonneau cylinders, beginning with the top in lowered position within storage compartment 28 with tonneau 30 closed (FIG. 2).
[0035] The hydraulics will initially be in the FIG. 6 position. Pump 52 is commanded to pressurize line cylinders 42 , 42 ′ through line 54 , valves 62 and 58 and lines 74 , 88 and 88 ′ to extend cylinder rods 44 , 44 ′ and raise tonneau 30 .
[0036] Next, valve 58 is shifted and the hydraulics are in the FIG. 4 position, with the blind ends of top cylinders 36 , 36 ′ pressurized via line 54 , valves 62 and 58 and lines 70 , 82 and 82 ′ to extend cylinder rods 38 , 38 ′ to initially raise top 26 and then to raise rear bow 34 , as more fully detailed in aforementioned U.S. Pat. No. 5,620,226.
[0037] The hydraulics then assume the FIG. 7 position via reversal of pump 52 , which now pressurizes the tonneau cylinder rod ends via lines 66 , 80 and 80 ′ to retract rods 44 , 44 ′ and lower tonneau 30 . The hydraulics are then shifted to the FIG. 5 position by shifting valve 58 . This pressurizes the rod ends of top cylinders 36 , 36 ′ via lines 66 , 76 , 78 and 78 ′ to partially retract cylinder rods 38 , 38 ′ to lower rear bow 30 is lowered as sensed by limit switch 94 which causes controller C to stop pump 52 .
[0038] When it is desired to lower the top, pump 52 is reversed to the FIG. 4 position to fully extend cylinder rods 38 , 38 ′ and again raise rear bow 30 . Then valve 58 is shifted to the FIG. 6 position and tonneau 30 is raised. Next, pump 52 is reversed and valve 58 is shifted to the FIG. 5 position and top 26 is lowered. Then valve 58 is shifted to the FIG. 7 position to lower tonneau 30 . Top 26 is raised by reversing the above procedure.
[0039] While only a preferred embodiment has been described and shown, obvious modifications are contemplated within the scope of this invention and the following claims.
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A convertible top operating mechanism includes a bi-directional hydraulic pump which is selectively connected to top-operating hydraulic cylinders and tonneau-operating hydraulic cylinders by a two-way, 5-condition control valve to selectively raise and lower the top and tonneau. A mechanical linkage connects the top-operating cylinders with a movable rear bow and is co-operable with a spring during operation of the top-operating cylinders when fully extending and initially retracting to move the rear bow to enable tonneau operation and to seal the top on the tonneau.
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BACKGROUND OF THE INVENTION
The present invention relates to a speech processing system and method that are specifically tailored for creating short messages in, or for, a telecommunications terminal.
The mobile radio standard GMS which is currently valid defines framework conditions for the transmission of text messages with a limited length (short messages) via the mobile radio networks, for which the designation SMS (Short Messaging Service) has become widespread, even in everyday life. SMS messages have become established in GSM networks as a communication tool for conveying short pieces of information. The present invention makes it easier to input SMS messages on mobile terminals.
Despite the wide variety of possible ways of transmitting SMS messages from the Internet or via call centers and in spite of the fact that they can be created more easily on PCs or laptops, the overwhelming majority of all SMS messages which are sent today are created directly on mobile terminals. These SMS messages have to be input in a relatively complicated way with the existing twelve-key keypad. Even commercially established methods for reducing the number of key-pressing operations, such as Tegic T 9 , only make the SMS inputting operation easier and quicker to a certain degree. In addition, the use of the T 9 mode requires a certain routine when creating the SMS message.
The above mentioned inputting operation using a PC or mobile computer is significantly easier owing to the keypad which can be operated in a significantly better way, and basically highly developed speech-processing systems are also suitable for using computers to input short messages via the PC. All these possibilities are, however, linked to the availability of an appropriate computer with complete alphanumeric keypad or the hardware and software resources for advanced speech processing. These resources are available to a very small number of SMS users in typical application situations.
The present invention is, therefore, directed toward making available an improved system and method for inputting SMS messages directly at a (in particular mobile) telecommunications terminal.
SUMMARY OF THE INVENTION
The present invention includes the fundamental idea of almost completely dispensing with the customary inputting of text in order to create short messages. It also includes the idea of replacing the inputting of text, irrespective of the very limited resources (processing and storage capacity) of a small hand-held telecommunications terminal, essentially by the voice-inputting operation which provides unparalleled ease and convenience for the user. The effect of the present invention is based on reducing the scope of the vocabulary to a size which is adequate for mobile terminals by utilizing preconfigurations and a self-learning system.
Accordingly, the present invention relates to methods or aspects of the speech-controlled inputting of SMS messages which can be used individually or in combination. It is, thus, concerned with the speech-controlled selection of predefined words/templates and the speech-controlled selection of word groups via speech instructions or metaphors and a self-learning system for configuring a speech recognizer with the SMS vocabulary used by the user.
Speech-Controlled SMS Templates
When creating SMS messages it is possible to input free texts. Completely inputting the message via speech would require a dictation system (with a vocabulary of ≧50,000 words) which operates without faults on the mobile terminal. Because of the limited resources on the terminals, it is not technically possible to input this at the moment. However, if it is considered that many of the items contained in SMS messages are similar, the actively used vocabulary is significantly reduced and it is often also possible to operate with prefabricated templates.
A speaker-independent speech recognizer is also implemented on the mobile terminal, the speech recognizer supporting only a limited number of words (for example, 1,000 words) in the active vocabulary owing to the resource restrictions. In the delivered state of the device, the speech recognition is preconfigured with the most important generally customary words in SMS messages such as, for example, “today”, “yesterday”, “tomorrow”, “meet”, “cinema”, etc.
This preassigned information can be supplemented or modified individually by the user (while complying with a maximum number of supported words). The changes can be made, for example, independently of the speaker via text inputs and subsequent automatic conversion to the phonetic script which the recognizer can understand (text/phoneme conversion) or speaker-dependently via text inputs and subsequent annunciation of the term. In this way, the vocabulary to be supported can be individually personalized without obtaining the resource dimensions of a dictation system. The changes can, in particular, be carried out directly on the device or in a multi-stage fashion via a PC and downloaded to the telecommunications terminal.
Selection of Text Via Voice Metaphors
Instead of individual words, a voice instruction also can be used to call small texts, referred to as templates; such as, for example, “regards”, “best wishes”, “I'm coming”, “are you coming”, “I wanted to”, “can you”, “see you soon”, etc. It is also possible to input metaphors for word groups; for example, “greeting” or “signing-off phrase”. After these words have been recognized, a number of possible text variants on this metaphor are presented on the display. For example, “greeting” can then be followed by an offer of. “Good morning, hello, how are you . . . ”. The user can select the desired entry via manual selection or via voice input (for example, of the respective place number). When this switch is accessed, the individual metaphors can be individually widened or adapted by the user.
Self-Learning Vocabulary Systems for Speech-Controlled Inputting of SMS
In order to adapt the standard vocabulary to the communications behavior of the user, an automatic, self-learning adaptation of the basic vocabulary can be influenced. For this purpose, depending on the settings, all transmitted and/or received messages are analyzed by the system. Words which were previously not known to the speech recognizer are converted via text-to-phoneme conversion which is present on the device into a form which the speech recognizer can understand, and included in the vocabulary. The vocabulary to be supported is restricted here to a maximum number of words which is adequate for embedded devices. If the maximum limit is reached, the active items of vocabulary can be adapted further via substitution strategies (for example, first-in-first-out (FIFO), prioritization according to the frequency of occurrence). As the items of vocabulary in the SMS messages for a specific user are generally relatively small, this process gradually gives rise to a personalized system which permits the user to input his/her SMS message almost completely by speech.
While the actual speech recognition module is preferably embedded as a hidden Markov model known per se (but configured with a resource requirement, adapted to the preconditions of a small hand-held electronic device) the text-phoneme converter module is preferably implemented on the basis of a neural network. The implementation of such converters on the basis of neural networks is known per se and, therefore, does not require any further explanation here for the person skilled in the art.
A “classic” input keypad, in particular an alpha-numeric keypad which is integrated into the device and has multiple assignment of keys, or a correspondingly embedded touchscreen is used to make the text inputs. It is also possible to make the text inputs using a plug-on supplementary keypad (which may be obtained from many manufacturers) or via a connected PC or laptop/notebook.
According to the above, a substitution control algorithm for replacing elements of the basic vocabulary by new words or templates, in particular as a function of the time and/or frequency of their occurrence at the text input interface, is implemented in the vocabulary control module. As a result, in the course of time, a vocabulary structure which is adapted as well as possible to the habits of the particular user and his/her communication partners is formed. On the other hand, it is also possible (using simpler hardware and software) to perform continuous updating of the vocabulary according to the FIFO principle; i.e., to eliminate from the vocabulary words which have not been used for a long time and, thus, continuously renew the vocabulary.
As is already clear from the above statements, not only words but also sequences of words (phrases) may be present as elements of the basic vocabulary and of the current vocabulary of the speech recognizer, and both types of element can be referred to in a summarizing fashion as “templates”. The more pronounced the short-message communication of a user follows established rituals, the more efficient is the storage of entire phrases alongside individual words.
The word sequences are expediently logically linked to a speech instruction or a metaphor, the inputting of which by speech calls the word sequences during the operation of the system. Here, various phrases can be assigned to the same metaphor or the same speech instruction and can be displayed in reaction to an appropriate input so that the user can select the word sequence which is desired in the respective situation. This also can be carried out via a speech instruction, but also can be done conventionally by scrolling the display and pressing the “OK” key at the desired position.
From the explanations above it is apparent that a vocabulary memory of the speech recognizer can be expediently divided into a number of memory areas which can be addressed and handled separately. A first memory area for the basic vocabulary which is also supplied by the manufacturer, and its supplements or substitutes which are accumulated during the operation of the system is separated here from another memory area in which templates which are intentionally input by the user are stored. This latter memory area, in turn, cannot be overwritten by new entries in the first memory area, at any rate not by current inputs of the user.
Additional features and advantages of the present invention are described in, and will be apparent from, the following Detailed Description of the Invention and the Figures.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a basic view of key components of a speech recognition system according to the present invention.
FIG. 2 is a schematic view of a speech recognition system, embodied as a component of a mobile phone, in an embodiment which is modified in comparison with FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
As is apparent from FIG. 1 , a vocabulary control stage, a template control stage, a text interface and an SMS buffer as well as the actual speech recognizer (with additional components in comparison with a conventional speech recognizer) can be considered as key components of a preferred speech recognition system according to the present invention. The system is connected via the text interface to a text input device; for example, a mobile phone keypad. Outgoing short messages which are created both via the keypad and the text interface and incoming text messages which are received via the mobile phone are fed to the SMS buffer. The text interface is connected on the output end to inputs of the template control stage; specifically, to a “text-to-phoneme” converter module and to a “string table” module. A voice alias or a text table are fed to these modules via the text interface and a phoneme sequence or a string table is generated therefrom. The latter are finally stored in a phrase memory of the speech recognizer.
The output of the SMS buffer is connected to a vocabulary comparator and a statistics conditioner within the vocabulary control stage. The latter are each connected at the output end to a further “text-to-phoneme” converter stage which itself is connected to a supplementary vocabulary memory in the speech recognizer. This statistics conditioning unit is also connected to a “statistics info” module in the speech recognizer in order to store statistical information there for the operation of the speech recognizer from the outgoing and incoming short messages.
The vocabulary comparator is connected via a further input to an output of the speech recognizer and receives therefrom the comparison basis for the evaluation of the current SMS for supplementing the vocabulary stored in the speech recognizer.
The method of operation of this speech recognizer is obtained from the general explanations above and from FIG. 1 itself so that no more wide ranging functional description is necessary here.
The speech recognizer system 3 of a mobile phone 1 according to FIG. 2 includes an HMM speech recognizer 5 with low resource requirements and a vocabulary and phrase memory 7 which includes a basic memory area 7 A, a supplementary vocabulary memory area 7 B and a phrase memory area 7 C. A basic vocabulary of the speech recognizer 5 is stored in invariant form in the basic memory area 7 A; i.e., the elements of the vocabulary of the speech recognizer which are stored there can be neither deleted nor overwritten. In this example, both words which are newly input by the user via text inputting and words which are made available by the speech recognition system in the fashion described below are additionally stored in the supplementary vocabulary memory area 7 B, the first-mentioned elements being identified as active inputs of the user via a flag, and also being non-deletable. When the mobile phone 1 is supplied, word sequences for standard situations in life, which the user can also incorporate in a short message in a fashion which is also described in more detail below, are already stored in the phrase memory area 7 C (in assignment to a speech instruction or a metaphor in each case).
In order to implement the present invention, an HMM-based speech recognizer can be used which has, for example, a performance range of 1,000 words; for example, for the German language, which is therefore small enough to be able to run on embedded devices. The speech recognizer 5 is preconfigured for the German language for supply with 1,000 generally customary words. The words for the preassignment information are acquired here from the analysis of a large number of SMS messages which have been sent by many users.
Furthermore, the text/phoneme converter 9 based on a neural network which converts text inputs into the phonetic script necessary for the speech recognizer is implemented on the mobile phone 1 . The speech recognizer enables the user to use the twelve-key keypad 11 of the mobile phone 1 to input, as text, words which he/she would like to store in the supplementary vocabulary memory area 7 B, and makes the storable representation available.
Furthermore, the text/phoneme converter 9 permits a self-learning function to be implemented, for whose execution are provided a buffer 13 for temporarily storing the vocabulary of received and/or transmitted short messages, a vocabulary comparator unit 15 , connected to the buffer 13 and to the vocabulary and phrase memory 7 , for the purpose of comparing the respectively stored items of vocabulary, a statistical evaluation unit 17 for determining statistical characteristic variables of the words which have newly occurred in the received or transmitted short messages, and a characteristic-variable comparator unit 19 for comparing these characteristic variables with stored characteristic variables of the basic vocabulary. The characteristic variable comparator unit 19 is connected at the input end on the one hand to the evaluation unit 17 and on the other hand to a characteristic-variable memory 21 of the HMM speech recognizer 5 where relevant values of the elements of the basic vocabulary are stored. In order to control the updating of the vocabulary, a vocabulary control stage 23 is provided which itself receives control information from the vocabulary comparator unit 15 and the characteristic-variable comparator unit 19 .
In order to automatically adapt/personalize the vocabulary, the user can actuate the self-learning function of the system. Here, both the analysis of incoming and outgoing SMS messages can be enabled. The activation of the analysis of incoming SMS messages is specifically interesting if the manual input functionality is highly restricted in the mobile terminal; for example, as in a clock mobile phone.
When the self-learning system is activated, all the words of each incoming and/or outgoing SMS message are compared with the existing basic vocabulary. If the SMS message contains words which are not in the basic vocabulary of the recognizer, they are added to the vocabulary according to a substitution strategy via text/phoneme conversion. For the substitution strategy, each word in the vocabulary is identified with the date of use and the frequency of use. Initial values are used for words which are preset at delivery. A word which is to be newly entered is substituted here for the word with the lowest frequency of use and the oldest date of use. This produces an individually personalized system on an incremental basis.
In addition, the user is provided with the possibility of creating his/her own individual templates via a template menu prompting system 25 and linking these templates to a voice instruction (voice alias). A template can be composed here of one or more words. For this purpose, the template text is input in table form and assigned to a voice alias (speech instruction), also input via the keypad 11 , as text.
The text/phoneme converter 9 translates the voice alias and enters in the vocabulary of the speech recognizer; the template text itself is stored in the phrase memory area 7 C and the speech instruction is stored in the supplementary vocabulary memory area 7 B. The voice alias replaces a word of the vocabulary here in accordance with the already described substitution strategy.
The voice alias is identified as such. It is not subject to the substitution strategy as it represents an explicit user entry. It can only be deleted by the user himself/herself.
A number of template texts also can be assigned as a supplementary function to a voice alias. When the voice alias is called, all the template texts are made available for selection with a preceding number via the menu control system 23 . The template selection is then carried out manually by selecting a key or by a voice input of the template number. For example, the voice alias “Greeting” could be linked to the template text “Best wishes” and “Yours sincerely”. When “greeting” is spoken, the user is then presented with the text “1 Best wishes” and “2 Yours sincerely”. The text “Yours sincerely” is then selected by subsequently speaking the template number “2”.
In order to arrive at a balanced proportion between the basic vocabulary and user-defined templates, a maximum number of template entries is preset; for example, 100 user templates. The user can define his/her own voice aliases up to this maximum value, the voice aliases respectively substituting an entry from the existing basic vocabulary. If the maximum limit is reached, the user is provided with a corresponding warning message. The user can change the maximum template value via an option. In an extreme case, he/she can select the maximum value of 1,000 for the templates, which, when the maximum value is used, signifies eliminating the basic vocabulary and the analysis function.
Although the present invention has been described with reference to specific embodiments, those of skill in the art will recognize that changes may be made thereto without departing from the spirit and scope of the present invention as set forth in the hereafter appended claims.
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A speech recognition system and method are provided for the speech-controlled inputting of short messages into a telecommunications terminal, in particular a mobile phone or cordless phone, having a speech recognizer module which operates independently of the speaker, a text/phoneme converter module and/or an auxiliary speech recognition module which operates in a speaker-dependent fashion and has the purpose of converting the text inputs or text transfers into a phonetic script which is adapted to the speech recognition module, and a vocabulary control module for supplementing the vocabulary or for replacing elements of the vocabulary by words or phrases which have been input or transferred.
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FIELD OF THE INVENTION
The invention relates to the field of vehicle control, and, more particularly, to vehicle remote control.
BACKGROUND OF THE INVENTION
A remote vehicle control system may be used to permit a user control of one or more vehicle devices from a distance. A typical remote vehicle control system, for example, in a more modern vehicle may include a controller connected to a plurality of vehicle devices via a data communications bus, and a remote transmitter providing the controller with remote control signals. The vehicle devices, for example, may operate the engine starter, the door locks, the power windows, or the alarm system.
An example of such a system is U.S. Pat. No. 5,719,551 to Flick, which discloses a remote transmitter that can remotely control a number of vehicle devices. The controller in the Flick '551 patent is responsive to the remote transmitter and sends command codes over a data communications bus to the vehicle devices. Similarly, U.S. Pat. Nos. 6,275,147, 6,756,885, 6,756,886, and 6,812,829, to Flick also disclose a controller/transmitter used to remotely control a number of vehicle devices via command codes sent over a communications data bus.
U.S. Pat. No. 5,583,479 to Hettich et al. also discloses a vehicle controller connected to a number of vehicle devices via a data communications bus and a remote transmitter in communication with the controller. The Hettich et al. patent further discloses that if the alarm system is not deactivated correctly, then the vehicle devices will be impaired or prevented from working properly.
U.S. Pat. No. 6,232,873 to Dilz et al. discloses a vehicle security system that detects if an original control unit is no longer active. If the security system determines that the original control unit is no longer active, an alternate circuit that remains active in the vehicle activates an electronic immobilization system.
Although conventional remote vehicle control systems operating via the data communications bus have made significant advances in convenience for the user, the overall security may still be an issue. For example, a would-be thief gaining access to the data bus, such as from under the vehicle, may generate rogue commands on the data bus compromising vehicle security. The would-be thief could temporarily connect a rogue controller to the data bus and cause the windows to roll down or the doors to unlock. Once inside the vehicle, the would-be thief could again connect to the data communications bus and start the engine. Of course, if the vehicle had a vehicle security system, the would-be thief could disarm the vehicle security system via the data communications bus.
SUMMARY OF THE INVENTION
In view of the foregoing background, it is therefore an object of the invention to provide a remote vehicle control system and associated method with both convenience and security features.
This and other objects, features, and advantages in accordance with the invention are provided by a remote device control system for a vehicle including a true controller that can detect and counteract a rogue controller. The vehicle may include a data communications bus extending throughout the vehicle, and at least one vehicle device connected to the data communications bus. The vehicle remote control system may include a remote transmitter, and the true controller at the vehicle for controlling the at least one vehicle device via a true command on the data communications bus and based upon the remote transmitter. The true controller may also control the vehicle device via a respective counteracting command on the data communications bus based upon detecting a rogue controller attempt to control the vehicle device via a rogue command on the data communications bus. In some embodiments, the counteracting command may also render inoperable the at least one vehicle device for a period of time. Accordingly, the invention provides a remote vehicle device control system with advanced security features.
The true command may include a sequence of true command codes, and the rogue command may include a sequence of rogue command codes. The true controller may detect the rogue controller attempt based upon at least one difference between the sequence of true command codes and the sequence of rogue command codes. In some embodiments, the true controller may detect the rogue controller attempt based upon a difference in timing between the sequence of true command codes, and the sequence of rogue command codes. While in other embodiments, the true controller may detect the rogue controller attempt based upon a difference in content between the sequence of true command codes and the sequence of rogue command codes.
The at least one vehicle device may be associated with engine starting, and the true controller may generate an engine shutdown command as the counteracting command. In some embodiments, the vehicle may further comprise an engine speed sensor, and the true controller may cooperate with the engine speed sensor to detect the rogue controller attempt. The vehicle may further comprise an ignition switch sensor, and the true controller may cooperate with the ignition switch sensor to detect the rogue controller attempt.
The at least one vehicle device may be associated with vehicle door lock actuation, and the true controller may generate a door lock command as the counteracting command. Alternately or additionally, the at least one vehicle device may be associated with vehicle window actuation, and the true controller may generate a window roll-up command as the counteracting command.
The at least one vehicle device may be associated with vehicle security, and the true controller may generate a re-arm vehicle security command as the counteracting command. The true controller may also include a processor and a receiver connected thereto, for example.
A method aspect of the invention is for using a vehicle remote control system for a vehicle. The vehicle may include a data communications bus extending throughout the vehicle, a remote transmitter, a true controller connected to the data communications bus and responsive to signals from the remote transmitter, and at least one vehicle device connected to the data communications bus. The method may include controlling the at least one vehicle device via a true command on the data communications bus, and based upon the remote transmitter. The method may further include controlling the at least one vehicle device via a respective counteracting command on the data communications bus based upon detecting a rogue controller attempt to control the at least one vehicle device via a rogue command on the data communications bus.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of a vehicle remote control system in accordance with invention.
FIG. 2 is a comparison of command code timing and content diagrams as may be used by the vehicle remote control system shown in FIG. 1 .
FIG. 3 is a comparison of command code timing and content diagrams as may be used by the vehicle remote control system shown in FIG. 1 .
FIG. 4 is a flowchart illustrating a method according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention will now 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. In addition, like numbers are used to refer to like elements throughout the drawings.
Referring initially to FIG. 1 , a remote device control system 10 for a vehicle 12 is now described. The vehicle 12 includes, for example, a data communications bus 14 extending throughout the vehicle, and at least one vehicle device connected to the data communications bus. In the illustrated embodiment, the at least one vehicle device includes an ignition switch 22 , an engine speed sensor 24 , a vehicle security system 26 , a hood position sensor 28 , a door lock actuator 30 , a brake pressure sensor 32 , a window actuator 34 , a transmission sensor 36 , an engine starter 39 , a fuel supply shutoff 40 , and an other controller 42 connected to the data communications bus 14 .
The vehicle remote control system 10 includes a remote transmitter 16 , and a true controller 18 at the vehicle for controlling the at least one vehicle device via a true command on the data communications bus 14 and based upon signals received from the remote transmitter. The true command is generated via a true command generator 44 of the true controller 18 . The true command generator 44 may be implemented by a software module running on the processor 46 , for example, as will appreciated by those skilled in the art.
The true controller 18 also controls the at least one vehicle device via a respective counteracting command on the data communications bus 14 based upon detecting a rogue controller 20 attempt to control the at least one vehicle device via a rogue command on the data communications bus. The counteracting command is generated via a counteracting command generator 48 based upon the rogue controller detector 50 of the true controller 18 . The counteracting command may render inoperable the at least one vehicle device for a period of time. The delay may prevent the rogue controller 20 from being successful by repeatedly sending rogue commands as will be appreciated by those skilled in the art.
The rogue controller 20 is illustrated in dotted lines to indicate that it is removably attached to the data communications bus 14 . For example, the rogue controller 20 may be attached to the data communications bus 14 by an unauthorized person in an attempt to gain access or control of the vehicle 12 . The rogue controller 20 illustratively includes a rogue command generator 60 that generates rogue commands on the data communications bus 14 meant to control the at least one vehicle device.
The processor 46 is connected to the data bus interface 52 that, in turn, connects the processor to the data communications bus 14 as will be appreciated by those skilled in the art. The processor 46 is also illustratively connected to a memory 54 and a receiver 56 . The memory may be embedded with the processor 46 in other embodiments.
The receiver 56 wirelessly receives communications from the remote transmitter 16 via the communications link 58 . A two-way communications link may also be provided so that the user may receive remote alarms or status information. The remote transmitter 16 maybe a small portable device carried by the user when away from the vehicle, may be a cell tower and related infrastructure, or may be a passive transponder activated at the vehicle.
In an alternate class of embodiments, the receiver is not directly connected to the processor 46 . Instead, the receiver 56 may be connected to the logic block 62 , and a data bus interface 64 as will be appreciated by those skilled in the art. In other words, the receiver 56 can communicate with the processor 46 over data communications bus 14 .
Turning now additionally to FIGS. 2 and 3 , embodiments of operation of the true controller 18 are further described. The true command in each figure illustratively includes a respective sequence of true command codes 66 , 68 and the rogue command in each figure includes a respective sequence of rogue command codes 70 , 72 . The true controller 18 detects the rogue controller 20 attempt based upon at least one difference between the sequence of true command codes 66 , 68 and the sequence of rogue command codes 70 , 72 .
In one class of embodiments, the true controller 18 may detect the rogue controller 20 attempt based upon a difference in timing between the sequence of true command codes 66 and the sequence of rogue command codes 70 ( FIG. 2 ). For example, the detector module 50 monitors command codes on the data communications bus 14 and compares them to a copy of the true command codes 66 stored in the memory 54 . At time t 1 the rogue controller detector 50 detects a command code entered onto the data communications bus 14 and begins to compare the command code to the copy of the command codes 66 stored in memory 54 . At time t 3 the rogue controller detector 50 determines a difference between the stored copy of the true command codes 68 and the now identified rogue command codes 70 , which causes the counteracting command generator 48 to generate a counteracting command on the data communications bus 14 .
In another class of embodiments, the true controller 18 may detect the rogue controller 20 attempt based upon a difference in content between the sequence of true command codes 68 and the sequence of rogue command codes 72 ( FIG. 3 ). At times t 8 and t 10 the rogue controller detector 50 has examined the contents of the command codes 72 and has found the content, the hexadecimal values 4H and 2B, to match the stored true command codes 68 . At time t 12 the rogue controller detector 50 has determined that the rogue command codes 72 does not match the stored true command codes 68 , that is, C3 is not C4. The counteracting command generator 48 generates a counteracting command on the data communications bus 14 in response.
In yet other embodiments, the true controller 18 may use differences in both time and content between the sequence of true command codes and the sequence of rogue command codes to detect a rogue controller 20 attempt. The true controller 18 may also include at least one dummy code in the sequence of true command codes. The dummy code does not cause any vehicle function, but is used by the true controller 18 as another marker with which to identify a rogue command code sequence as will be appreciated by those skilled in the art. In its simplest version, the true controller 18 may need a command on the data bus when the true controller itself recognizes that it did not send the command.
The counteracting command is based upon what vehicle device the rogue controller 20 attempts to control. For instance, the at least one vehicle device may be associated with engine starting, and the true controller 18 generates an engine shutdown command as the counteracting command. The vehicle 12 may further comprise an engine speed sensor 24 , and the true controller 18 cooperates with the engine speed sensor to detect the rogue controller 20 attempt. The vehicle 12 may further comprise an ignition switch sensor 22 , and the true controller 18 cooperates with the ignition switch sensor to detect the rogue controller 20 attempt as will be appreciated by those skilled in the art. In other words, the rogue controller detector 50 may indirectly detect the rogue controller command if the engine is running, but the ignition is not switched on.
In yet other embodiments, the at least one vehicle device may be associated with vehicle door lock actuation, and the true controller 18 may generate a door lock command as the counteracting command. The at least one vehicle device may be associated with vehicle window actuation, and the true controller 18 may generate a window roll-up command as the counteracting command. In yet other embodiments, the at least one vehicle device may be associated with vehicle security, and the true controller 18 may generate a re-arm vehicle security command as the counteracting command.
Those skilled in the art will appreciate the applicability of this detection and the counteracting approach for the remote vehicle control functions, as well. Indeed these concepts may be used by automotive manufacturers to discourage the aftermarket installation of improper remote control systems. Of course, overall vehicle security is also greatly enhanced as will be appreciated by those skilled in the art.
A method aspect of the invention is for using a vehicle remote control system for a vehicle as now explained with additional reference to the flowchart 74 of FIG. 4 . As explained in detail above, the vehicle includes a data communications bus extending throughout the vehicle, a remote transmitter, a true controller connected to the data communications bus and responsive to signals from the remote transmitter, and at least one vehicle device connected to the data communications bus, for example. The method starts at Block 76 and includes controlling the at least one vehicle device via a true command on the data communications bus and based upon the remote transmitter (Block 78 ). The data communications bus is monitored to detect a rogue controller attempting to control a vehicle device over the data communications bus at Block 80 . If a rogue controller attempt is detected at Block 82 , then the at least one vehicle device is controlled via a respective counteracting command on the data communications bus at Block 84 . In addition, the counteracting command can delay the operation of the vehicle device for a period of time at Block 86 , before stopping at Block 88 .
Other embodiments include, for example, a vehicle control system without the remote transmitter and associated receiver as disclosed in a co-pending patent application assigned to the assignee of the present application entitled VEHICLE CONTROL SYSTEM AND ASSOCIATED METHOD FOR COUNTERACTING ROGUE COMMAND, Ser. No. 11/000,160, the entire disclosure of which is incorporated herein in its entity by reference. Many modifications and other embodiments of the invention will come to the mind of one skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is understood that the invention is not to be limited to the specific embodiments disclosed, and that other modifications and embodiments are intended to be included within the scope of the appended claims.
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A vehicle remote control system is for a vehicle including a data communications bus extending throughout the vehicle, and at least one vehicle device connected to the data communications bus. The vehicle remote control system includes a remote transmitter, and a true controller at the vehicle for controlling the vehicle device via a true command on the data communications bus, and based upon the remote transmitter. The true controller also controls the vehicle device via a respective counteracting command on the data communications bus based upon detecting a rogue controller attempt to control the at least one vehicle device via a rogue command on the data communications bus. The true controller may thus counteract a rogue controller attempt to start the engine, unlock vehicle doors, roll down windows, and/or disarm the vehicle security system, for example.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 60/314,445, filed Aug. 23, 2001.
BACKGROUND OF INVENTION 1. Field of the Invention
[0002] The present invention generally relates to tools for creating decorative designs and patterns on surfaces. 2. Description of the Related Art
[0003] Tools and equipment currently available for creating decorative designs and patterns on wood and other charrable materials include metal hand tools and laser generators that produce a burned (i.e., charred or singed) pattern in a near-surface region of the material. Hand tools are labor-intensive, especially if a large surface is to be treated. For large surfaces or when a continuous or repetitive pattern is to be accurately reproduced, a laser is generally required. However, laser equipment is not readily affordable and often impractical for the general public. In addition, laser equipment cannot be easily transported, limiting use of the equipment to a studio or other permanent location.
SUMMARY OF INVENTION
[0004] The present invention provides a method and device for burning a pattern in a surface of wood or other charrable material. The device generally comprises a ceramic body having a raised pattern defined on a surface thereof and means for locally heating the raised pattern, preferably to a temperature higher than portions of the ceramic body away from the raised pattern. The heating means is such that the raised portion is sufficiently heated to burn a pattern in a surface of wood contacted by the ceramic body. While various heating means are possible, two notable heating means are electrically-resistive wire or an electrical-conductive ceramic material embedded in the ceramic body in proximity to the raised pattern. Both of these heating means serve to locally heat the raised pattern when current from a suitable electric current source flows therethrough.
[0005] With the device described above, a method of burning a pattern in a surface of wood generally comprises passing an electrical current through the ceramic body to heat the raised pattern to a temperature sufficient to burn wood, and then contacting the surface of the wood with the ceramic body to burn the pattern in the surface of the wood. Because the heating means is in proximity to the raised portion, the temperature of the raised pattern is higher than portions of the ceramic body away from the raised pattern, such that the pattern defined by the raised pattern is accurately transferred to the wood surface.
[0006] In view of the above, it can be seen that a significant advantage of this invention is that patterns can be accurately reproduced, including continuous and repetitive patterns, in a wood surface (or surface of another charrable material) without the use of a laser. The device of this invention is more affordable and transportable than laser equipment, enabling the device to be widely used by the general public. As a result, the device and method of this invention can be practiced as a hobby, craft or business by a very large segment of the population to enhance the decorative appearance and value of a wide variety of goods.
[0007] Other objects and advantages of this invention will be better appreciated from the following detailed description.
BRIEF DESCRIPTION OF DRAWINGS
[0008] [0008]FIGS. 1 through 9 show ceramic wood-burning tools in accordance with various embodiments of this invention.
DETAILED DESCRIPTION
[0009] Ceramic wood-burning tools in accordance with this invention are represented in FIGS. 1 through 9, with each being capable of transferring a pattern on the tool to the surface of wood or other material by burning (i.e., char or singe) the near-surface region of the material. The invention is particularly directed toward creating decorative burn patterns in the surface of wood, though various other materials could be treated with the tools of this invention to obtain desirable results. Therefore, though discussed in particular reference to wood, the invention is to be understood to apply to any material in which a pattern can be transferred to its surface by intense localized heating.
[0010] Each of the tools shown in FIGS. 1 through 9 comprises a connector or holder supporting a ceramic body on whose exterior surface a raised pattern has been defined. The ceramic body is formed of any suitable ceramic material, such as porcelain and structural clays, the latter of which includes terra cotta and a material commercially available from Eberhard Faber under the name EFAPLAST, composed of clay, binder and hardening materials. Embedded in the ceramic body in close proximity to the raised pattern is a thermal member capable of sufficiently raising the temperature of the raised pattern so that contacting a wood surface with the ceramic body causes the decorative pattern defined by the raised pattern to be transferred to the wood surface. One such thermal member is an electrically-resistive wire, which includes but is not limited to nickel-chromium and nickel-chromium-iron alloys known in the art, a commercial example of which is known as Nichrome. Another such thermal member is an electrically-conductive ceramic material, such as a ceramic material in which metal particles are dispersed. Electrically-conductive ceramic materials that are commercially available include those referred to as thermal ceramics.
[0011] In each case, the thermal member is preferably placed in the ceramic body after the body has been shaped but prior to firing, i.e., while the ceramic body is still in a green state. In addition, the raised pattern can be created in the ceramic body (such as by molding, sculpting, rolling, shaving, etc.) prior to or after embedding the thermal member. Firing the ceramic body serves to harden the ceramic material in which the thermal member is embedded, without damaging the thermal member. Electrical connection to the thermal member is provided, either by exposing opposite ends of the electrically-resistive wire, or otherwise contacting the ceramic body so that electric current will pass through the electrically-conductive ceramic material. Any suitable current source may be used.
[0012] Transferring the decorative pattern defined by the raised pattern of the ceramic body to the desired wood surface will depend in part on the form of the ceramic body. The ceramic body can have various forms, some of which are represented in FIGS. 1 through 9. In each case, the thermal member preferably raises the temperature of the ceramic body locally at the raised pattern, as opposed to the bulk of the ceramic body. After contacting the wood surface in which the decorative pattern is desired, pressure is applied with the ceramic body to transfer of the pattern to the wood surface occurs over a period of time that will depend in part on the temperature of the raised pattern.
[0013] In FIG. 1, a tip tool 10 is shown in which the ceramic body comprises a tip 12 (which defines the “raised pattern” discussed above). The tip 12 is mounted in a holder 14 that preferably can withstand the firing temperatures required for the ceramic material used to form the tip 12 . For example, the ceramic material and thermal member (electrically-resistive wire or electrically-conductive ceramic) can be packed into the holder 14 and the ceramic material shaped to define the tip 12 , after which the tip 12 is fired. In this manner, the tip 12 and holder 14 can be viewed as together forming the ceramic body discussed above. Alternatively, the thermal member can define the entire tip 12 if an electrically-conductive ceramic is used, in which case the tip 12 and holder 14 may be formed and fired separately, and then assembled such as by screwing the tip 12 into the holder 14 . The holder 14 is mounted to a connector 16 , through which a cable 18 passes for delivering the required electric current to the thermal member. FIG. 2 is similar to FIG. 1, and shows a carver 20 equipped with a ceramic bit (raised pattern) 22 that can be rotated with a motor 24 housed within the connector 26 . The carver 20 is useful for creating fill-in work, such as trees, grass, etc., in a decorative pattern.
[0014] [0014]FIG. 3 shows a design end 30 having a flat surface 32 in which the raised pattern (not shown) is defined. Similar to the embodiments of FIGS. 1 and 2, the design end 30 is mounted to a connector 36 through which a cable 38 passes for delivering electric current to the thermal member (electrically-resistive wire or electrically-conductive ceramic), which may be embedded in the design end 30 near the surface 32 , or define the entire surface 32 if an electrically-conductive ceramic is used.
[0015] [0015]FIG. 4 shows a roller 40 having a cylindrical surface 42 in which a raised pattern (not shown) is defined. A suitable material for the roller 40 is a kiln brick. The roller 40 is shown as being mounted to a connector 46 with an axle 44 . Electrical connection to the thermal member (electrically-resistive wire or electrically-conductive ceramic) embedded in the roller 40 is through a conductive path that includes a cable 48 within the connector 46 and a dynamic connection (not shown), such as carbon contacts, which enable current to be delivered to the roller 40 while the roller 40 is rotating. The roller 40 is particularly suitable for creating continuous or repetitive designs desired on long surfaces, such as panels, trim, drawer fronts, doors, etc.
[0016] [0016]FIG. 5 shows a design plate 50 having a flat surface 52 that, similar to the tool of FIG. 3, has a raised pattern (not shown) defined thereon. The plate 50 differs in its purpose for larger designs, and makes use of a holder 54 with a lip 56 for supporting and gripping a recessed edge 58 of the plate 50 , such as with screws 57 . Electrical connection to the thermal member (electrically-resistive wire or electrically-conductive ceramic) embedded in the plate 50 is through complementary connections on the holder 54 and plate 50 . FIG. 6 shows a design plate 60 that makes use of a holder 64 that supports and grips the plate 60 in the same or similar manner as shown in FIG. 5. However, the holder 64 has telescoping portions 66 and a telescoping handle assembly 68 to enable the holder 64 to adjust in size to plates of different lengths or widths.
[0017] [0017]FIG. 7 shows a contoured plate 70 that differs from the design plate 70 of FIG. 5 by having a curved surface 72 in which a raised pattern (not shown) is defined for creating a decorative pattern on a curved surface or corner. The plate 70 makes use of a holder 74 that supports and grips the plate 70 in the same or similar manner as shown in FIG. 5. However, the holder 74 is hinged to adjust for plates of different contours. The holder 74 has a support assembly 76 with telescoping curved arms 78 for adjustment of the holder 74 , with one of the arms 78 shown being mounted to a handle 79 . As before, electrical connection to the thermal member (electrically-resistive wire or electrically-conductive ceramic) embedded in the plate 70 is through complementary connections on the holder 74 and plate 70 .
[0018] [0018]FIG. 8 shows a wood-burning tool adapted for a related but different use than those of the preceding embodiments, namely, burning a mortise 89 into a door or door jamb 88 for receiving a door hinge. For this purpose, the tool makes use of a ceramic body in the form of a plate 80 , and is equipped with an adjustable clamp 84 for gripping opposite surfaces of the door/jamb 88 , as well as a press 86 mounted to the clamp 84 for applying pressure through the plate 80 to the area of the door or jamb where the mortise is desired. The plate 80 is sized and shaped to duplicate that of the hinge to be mounted. The thermal member (electrically-resistive wire or electrically-conductive ceramic) is embedded in the plate 80 , and preferably is uniformly present over the entire surface 82 of the plate 80 , such that the surface 82 is effectively the raised pattern that will define the mortise 89 . Because of the increased amount of smoke and ash that will be generated, this device may be used in combination with a fan or air filtering system.
[0019] Finally, FIG. 9 represents an automated method of continuously transferring a decorative pattern to a surface. A piece of wood 96 is shown passing beneath a roller 90 mounted on an axle 94 . The roller 90 has a cylindrical surface 92 in which a raised pattern (not shown) is defined. As with the roller of FIG. 4, the thermal member (electrically-resistive wire or electrically-conductive ceramic) is embedded in the roller 90 near its cylindrical surface 92 . Depending on the size of the roller 90 , the thermal member may be limited to a layer deposited or otherwise formed on the surface of the roller 90 . Electrical connection to the thermal member is through a conductive path that includes a dynamic connection (not shown), such as carbon contacts, which enables current to be delivered from the axle 94 to the roller 90 while the roller 90 is rotating. Finally, a drive roller 98 is shown as causing the wood 96 to move beneath the roller 90 at a speed synchronized with the roller speed. In this manner, the roller 90 can be used to accurately form continuous or repetitive designs on long surfaces, such as boards, doors, drawer fronts, trim, valances, shelves, counter top edges, etc.
[0020] With each of the above embodiments, one can make designs, inlays or tips to accurately reproduce a decorative pattern, including continuous and repetitive patterns, on a wide variety of structures. The tools are all practical for use by individuals and small and home-based businesses in view of their relatively low cost and transportability.
[0021] While the invention has been described in terms of a preferred embodiment, it is apparent that other forms could be adopted by one skilled in the art. Therefore, the scope of the invention is to be limited only by the following claims.
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A method and device for burning a pattern in a surface of wood or other charrable material. The device generally comprises a ceramic body having a raised pattern defined on a surface thereof and means for locally heating the raised pattern to a temperature sufficient to burn a pattern in a surface of wood contacted by the ceramic body. While various heating means are possible, two noted heating means are an electrically-resistive wire or an electrical-conductive ceramic material embedded in the ceramic body in proximity to the raised pattern, both of which serve to locally heat the raised pattern when current from a suitable electric current source flows therethrough.
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BACKGROUND OF THE INVENTION
The present invention relates continuous mining apparatus, and particularly to a means for controlling the dust produced in a continuous mining operation.
In a continuous mining operation considerable dust is produced as the cutting head of the miner cuts coal away from the cutting face of the mine. Obviously, some means must be provided for proper dust control in the cutting areas of continuous mining apparatus. The dust level present in the air surrounding the continuous mining apparatus must be controlled from both a health standpoint and safety standpoint to prevent explosions.
In U.S. Pat. No. 4,315,658 there is shown continuous mining apparatus that includes a curtain means for guiding the airborne dust generated by the cutting head toward a passage. The passage directs the dust-laden air away from the ventilation air that is supplied to the cutting face of the equipment. Means that includes both fans and hydraulic nozzles are provided for inducing an air flow in the passage means. While the '658 patent shows means for removing the dust-laden air from the vicinity of the cutting head, it does not disclose any means for removing the dust from the air so that the air can be recirculated within the mine. Instead, the '658 patent merely shows discharging the dust-laden air to the rear of the mining apparatus.
In U.S. Pat. No. 3,904,246 there is shown a rotary cutting head for use in a continuous mining apparatus that incorporates air flow inducing devices mounted in the cutting head. In particular, the '246 patent shows air flow guide means in the cutting head with fluid nozzles used for inducing an air flow into the guide means. Again, the '246 patent does not specifically describe any means for removing the dust from the air. The '246 patent does mention the use of nozzles for dispersing a dust suppression fluid in the dust-laden air.
Another continuous miner is shown in U.S. Pat. No. 4,037,875 that incorporates fans for removing the dust-laden air from the vicinity of the cutting heads. The '875 patent discloses the use of nozzles for spraying a liquid into the confined area adjacent the face of the mine but does not specifically disclose any means for removing the dust from the air that is exhausted by the fans that are incorporated in the mining apparatus.
Three Technology News bulletins of the Bureau of Mines, United States Department of the Interior, No. 117, Nov. 1981; No. 322, Jan. 1989; and No. 337, May 1989, all describe high pressure scrubbers for use with continuous underground mining equipment. All of these scrubbers depend on the high pressure water nozzles for producing an air flow through the scrubber and removing the dust. This results in a large consumption of water in relation to the air flow produced and creates a water disposal problem. In addition, all of the systems utilize demisters for removing the water and entrained dust from the air before it is returned to the mine atmosphere. The demisters are screen-type filters that clog after a few hours of use and require frequent cleaning.
From the above description of the prior art patents, it is seen that they all recognize the need to remove the dust-laden air from the vicinity of the cutting head in a continuous mining apparatus but do not provide an efficient means for removing such dust from the air. While the patents do disclose the use of fluid nozzles either for inducing the flow in the air removal means or for suppressing the dust, they do not describe specific means for removing the dust from the air so that the air may be recirculated in the mining operation.
SUMMARY OF THE INVENTION
The present invention provides a method and apparatus for removing the dust particles from the dust-laden air that is produced in a continuous mining operation. In particular, the invention utilizes a wet scrubber that employs twin fluid nozzles for producing a liquid mist having drops ranging in size from a few microns to 50 microns. This size range of liquid drops will remove substantially all the dust particles from the air that is removed from the vicinity of the cutting head. This particular type of wet scrubber is more particularly described and claimed in a copending application by the same inventors; Ser. No. 479,775 filed Feb. 14, 1990, now U.S. Pat. No. 5,039,315 and entitled "Method and Apparatus for Separating Particulates from Gas Streams".
The efficiency of the wet scrubber employing twin fluid atomizing nozzles produces a compact unit that can be mounted directly on the pivotal boom that supports the cutting head of the miner. The mounting of the wet scrubber directly on the pivotal boom positions it in close proximity to the cutting head of the miner. This eliminates considerable duct means and fan means that are required for removing the dust-laden air from the vicinity of the cutting head. In addition, it improves the removal efficiency and eliminates the need for curtains and other means that are utilized for isolating the cutting head from the remainder of the mine atmosphere.
The fluid used in the wet scrubber is preferably water and can be discharged directly to the mine floor or, if desired, added to the coal that is being produced by the continuous miner. The twin fluid atomizers used in the wet scrubber have a high efficiency and require very little water for their operation. Thus, there is little water produced by the wet scrubber and this amount can be discharged directly to the mine without creating a disposal problem.
The water and entrained dust are passed through a parallel plate separator where the water and entrained dust are removed from the air before it is returned to the mine atmosphere. The use of a parallel plate separator eliminates the clog problems that occur when demisters are used.
The discharge from the wet scrubber, being substantially free of any entrained dust particles, can be circulated directly back to the cutting head of the continuous miner. The air may be recirculated using the normal flow of the air curtain that is utilized in continuous miners to remove methane gas that is released during the mining operation.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be more easily understood from the following detailed description when taken in conjunction with the attached drawings in which:
FIG. 1 is a plan view of a continuous miner showing the wet scrubber of this invention.
FIG. 2 is a side view of the continuous miner and wet scrubber combination shown in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the attached drawings, there is shown a continuous mining apparatus 10. The apparatus is provided with two separate rotary cutting heads 11 and 12 that are powered by suitable electric motors 13 and 14. The cutting heads 11 and 12 are mounted on a pivoted boom 16 that is supported by the track carriage 15. Suitable means such as the hydraulic cylinder 17 is used for raising and lowering the boom so that the cutting heads can traverse the coal face 22 from the floor 20 to the roof of the mine 21. The track carriage 15 is maneuvered by a suitable drive means, such as electric motors.
While the above description refers to a continuous mining apparatus that utilizes cutting heads that rotate about a horizontal axis and are mounted on a boom which is pivoted so that they can be raised and lowered, obviously, other arrangements could be used. Many different types of continuous mining equipment are available and they all produce the same problem of dust-laden air. The present invention can be applied to any of these various types of mining equipment by those skilled in the art.
The wet scrubber 30 of the present invention is mounted on top of the boom 16 of the mining apparatus. Thus, the wet scrubber will be raised and lowered as the boom is maneuvered so that the cutting heads can cut the complete face of the coal seam. The wet scrubber is provided with duct work which includes a tapered section 31 positioned adjacent the cutting head. As shown in FIGS. 1 and 2, the tapered section 31 flares outwardly in FIG. 1 so that it will remove the dust-laden air from the complete length of the two cutting heads 11 and 12. The top surface of the tapered section 31 slopes downwardly as shown in FIG. 2 so that as the boom is raised, the cutting heads can cut to the roof of the mine. In some cases, it may be desirable to include flexible panels in the tapered inlet section 31 of the wet scrubber in order that they may deform when the cutting head is raised to a position where the section 31 would contact the roof of the mine.
The wet scrubber is provided with six twin fluid atomizers 32 as shown in FIG. 1. The twin fluid atomizers are supplied with two fluids by means of two separate lines 33 and 34. It is preferable that the fluids by water and compressed air although other combinations can be used. As explained in the copending application, the twin fluid atomizers are designed to supply a liquid mist of atomized droplets having a size range of between a few microns and 50 microns. This size range of particles has been found to be most efficient for removing dust particles from dust-laden air produced in coal mining operations.
Downstream of the twin fluid atomizers is a reduced cross section of the duct work 35. The reduced cross section is used so that the twin fluid atomizers can completely cover the cross sectional area of the duct work with a liquid mist and force all the dust-laden air to pass through the mist. Downstream from the reduced cross sectional area is a separator section 36 that is shown as composed of corrugated parallel plate members. This type of separator is highly efficient in removing liquids from the air stream while requiring only a small energy input to produce the air flow across the separator. The water removed from the air stream can be drained through an opening 37 directly to the conveyor associated with the continuous mining since the quantity of water required for the wet scrubber is considerably less than that of scrubbers that rely solely upon water sprays for removing dust particles entrapped in an air flow.
The use of parallel plate members eliminates the clogging problems associated with demisters used in the prior art. In addition, they require less energy to produce a given air flow through the separator.
The separator 36 discharges into an exhaust section 40 of the wet scrubber. The exhaust section 40 is provided with a diverter element 41 that serves to divert the air flow of either side of the wet scrubber. The air flow through the scrubber is induced by means of multiple fan elements 42 as shown in the attached drawings. The fan elements are preferably high efficiency fans that have low noise level to reduce the noise produced by the wet scrubber to permissible limits. The air discharged from the scrubber can be mixed with the air flowing in the air curtain used for removing methane from the mine.
From the above description of a preferred embodiment, it is seen that the present invention has provided a highly efficient wet scrubber which can be mounted directly on the boom of the continuous mining apparatus. By mounting the scrubber directly on the boom the need for duct work for removing the dust-laden to a remote location is eliminated. Further, the air discharged from the scrubber, being substantially free of any dust particles, can be utilized in the air flow that normally is provided in a mine for maintaining safe operations. As explained in the copending application, the overall removal efficiency of the wet scrubber is above 99.5%. Thus, the air can be utilized in normal ventilation activities in the mine while the dust-laden water can be discharged directly to the mined coal. The quantity of water required to operate the scrubber is small, i.e., less than 3 gallons per minute for an air flow of 6000 cubic feet per minute, and can be supplied from tanks mounted on the miner or other sources. The quantity of compressed air required is less than 60 standard cubic feet per minute, and can be supplied from a compressor mounted on the miner.
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A method and apparatus for controlling the dust produced by continuous underground coal mining machinery. The apparatus comprises a wet scrubber mounted on the pivoted boom adjacent the cutting head and discharges the cleaned air into the air curtain flow. The wet scrubber utilizes twin fluid atomizers to reduce the quantity of water required, produce fine water mist, and permit discharge of the dust-laden air directly to the mine.
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This is a divisional of application Ser. No. 08/470,441 filed on Jun. 6, 1995 now U.S. Pat. No. 5,628,520.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a sealing material made of expanded graphite which is used in, for example, various kinds of sealing members for high-temperature use such as a packing, a gasket, a V-shaped ring, a valve seat, and a sliding material such as a bearing, or a heat insulating material for a high temperature vacuum furnace. The present invention relates also to a method of producing the sealing material, and to a gasket sheet.
2. Description of the Prior Art
Generally, rubber or a polytetrafluoroethylene resin (PTFE, the trade name is Teflon) has been used in various types of sealing members for high-temperature use. In recent years, sealing members made of expanded graphite which is superior in terms of heat resistance and the like have widely been developed and often used.
Expanded graphite is obtained by performing an expansion process on acid-treated graphite 1A having a thickness of HO and a laminate structure of flaky graphite particles la shown in FIG. 22. The expanded graphite consists as shown in FIG. 23 of a bellow-like expanded graphite structure 1 having a thickness H (about 5 to 10 mm) in which laminations of graphite particles 1a are opened in a laminate direction (a direction indicated by arrow a) so that a gap G is formed between the graphite particles 1a.
Such an expanded graphite structure 1 is used in, for example, a gasket sheet, a die-molded product of a sheet, a string-like material combined with a fiber, or a material obtained by braiding such materials.
As a gasket sheet, for example, known is a laminate processed article which is obtained in the following manner. Press molding or roll molding is performed for applying a pressure to the expanded graphite structure 1, so that the gaps G in the opened bellow-like structure 1 which has been described with reference to FIG. 23 is reduced or eliminated. Thus, the graphite particles 1a are again in contact with each other, thereby forming a sheet-like base member 201 as shown in FIG. 24 in which the graphite particles la are self-bonded to each other. Laminate members 202 and 202 made of a PTFE film are bonded to the upper and lower faces of the sheet-like base member 201 with a binder, respectively.
In addition, known materials include a sheet-like material obtained by applying a pressure to the expanded graphite structure in which a binder is mixed, by means of press molding or roll-pressurizing molding, and a material obtained by forming local embossed portions on the principal face of a sheet-like base member made of an expanded graphite structure by using an embossing roll or other tools, and then by bonding a foil or the like using a laminate process, or by coating a rubber material.
In the gasket sheet made of a conventional expanded graphite sealing material having the above-described structure, the sheet-like base member 201 is obtained by simply applying a pressure to the expanded graphite structure 1, so that the graphite particles la on the principal face side of the base member 201 are in a high orientation state with high density. As shown in FIG. 25, therefore, the crystal planes of the portion are closely in contact with each other under pressure substantially in parallel to the principal face.
Such a high orientation state exhibits a poor surface bonding property. In the case where a laminate member 202 made of a PTFE film or the like is to be bonded to the base member by a laminate process, it is difficult for the laminate member 202 of the PTFE film as shown in FIG. 24 or the binder to penetrate between the expanded graphite particles 1a1 in the high ostentation portion on the principal face side. This may easily cause the peeling of the laminate member 202 or the binder layer.
In addition, the above-described process for simply applying a pressure to the expanded graphite structure 1 cannot overcome inherent drawbacks of the expanded graphite structure 1 in that the airtight sealing property is poor (air leakage), the strength is low, and the principal face of the base member 201 is easily damaged.
If the gasket sheet is used in a sandwiched state between joint flanges, there arise further problems as follows. The laminate member 202 may be stuck to the joint flange face, or the components such as sulfur, and chlorine contained in the graphite particles 1a may attack and corrode the counterpart metal.
SUMMARY OF THE INVENTION
The present invention has been developed in view of the above-described circumstances.
It is an object of the present invention to provide an expanded graphite sealing material in which the adaptability of a contact face, and the like can be ensured, a method of producing the sealing material, and a gasket sheet.
It is another object of the present invention to provide an expanded graphite sealing material in which sticking to a flange face and the like can be prevented, from occurring, to a method of producing the sealing material, and to a gasket sheet.
It is a further object of the present invention to provide an expanded graphite sealing material in which a lining material laminated on a sheet-like base member made of an expanded graphite structure has a large peel strength, to a method of producing the sealing material, and to a gasket sheet.
It is a still further object of the present invention to provide an expanded graphite sealing material in which the corrosion of the counterpart metal can be prevented from occurring, a to method of producing the sealing material, and to a gasket sheet.
The expanded graphite sealing material according to the present invention which has been developed in order to attain the above-mentioned objects is provided with an expanded graphite base member in which expanded graphite particles are pressurized and integrated together. In the expanded graphite sealing material, raised and opened thin-leaf graphite portions are formed in at least a portion of a principal face of the expanded graphite base member. The present invention includes an expanded graphite sealing-material in which the principal face of the base member having the opened thin-leaf graphite portions is impregnated with a sealing member, provided with a coating layer, or applied with a binder. The expanded graphite sealing material according to the present invention may be in various types of forms such as a sheet, a press-molded product, a fabric, a string, and a braided article.
According to the expanded graphite sealing material of the present invention having the above-mentioned construction, opened thin-leaf graphite portions are formed by, for example, a micro blasting process, in a portion of a principal face of an expanded graphite base member in which expanded graphite particles are pressurized and integrated together. As a result, the high orientation state of expanded graphite in the principal face portion is reduced, so that the adaptability, the bonding strength, and the like of the principal face of the expanded graphite base member are ensured, and the bonding property is improved. Thus, the high orientation state of graphite in the principal face is suppressed, so that the adaptability and the bonding strength of the principal face are improved, and the sealing properties can be remarkably increased.
In the sealing material in which the principal face of the base member is impregnated with a sealing member, provided with a coating layer, or applied with a binder, the coating member or the binder enters gaps between the thin-leaf expanded graphite particles formed in the principal face by the blasting process, so that peel strength is increased due to the three-dimensional binding, and the sealing properties are significantly improved. The expended graphite particles are not exposed from the coating layer or the like, so that, in practical use, corrosion of the counterpart metal can be effectively prevented from occurring, and the releasing property is improved.
In addition, if the expanded graphite sealing material is in the form of a sheet, it can be cut into pieces having desired sizes, so that they can be used for various applications. If the expanded graphite sealing material is in the form of a press-molded product, a ring-shaped packing or bearing can easily be produced. If the expanded graphite sealing material is in the form of a string or a braided article, the size adjustment in the case where it is actually mounted as a packing or the like can easily be performed.
In the method of producing an expanded graphite sealing material according to the present invention, an expanded graphite base member is formed by pressurizing expanded graphite particles and integrating them together, and raised and opened thin-leaf graphite portions are then formed in a portion of a principal face of the base member by using at least one method selected from micro blasting, ultrasonic irradiation, laser irradiation, and plasma irradiation.
According to the production method, since the thin-leaf graphite portions are formed in a portion of the principal face of the base member by using at least one method selected from micro blasting, ultrasonic irradiation, laser irradiation, and plasma irradiation, desired thin-leaf graphite portions can be selectively and efficiently formed in the principal face of the base member.
The gasket sheet according to the invention is formed by laminating a plurality of the expanded graphite sealing materials via a binder applied to the principal faces thereof and integrating them together. In this case, reinforcing members may be interposed between the plurality of sealing materials, respectively.
According to the invention, a thick gasket sheet can easily be produced, and it is possible to obtain a gasket sheet having a large bending strength and a large strength against the tightening in a mounting process.
The means for forming the opened thin-leaf graphite portions is not limited to the micro blasting process. When the blasting process is to be employed, it is preferable to satisfy the following conditions.
Specifically, expanded graphite which is commercially produced has a size of 1 mm or less in the width direction (a direction indicated by arrow b in FIG. 23). In view of this, particles used for the blasting process preferably have a particle diameter of 1 mm or less. In consideration of the gap G between expanded graphite particles la (FIG. 23), particles having the particle diameter of 10 to 20 μm are preferably used for the blasting process. Examples of particles for the blasting process include SiC, glass beads, iron powder, walnut shell flour, and plastic beads.
As the coating member, PTFE is suitably used. In addition to PTFE, useful coating members include various synthetic resins such as epoxy, phenol, nylon, and polyethylene, or high-viscosity members such as various kinds of oils, e.g., silicon and fluorine. Such coating members are useful for improving the adaptability of the principal face.
As the sealing member with which the principal face is impregnated, a rubber solvent is useful in which various kinds of rubbers and graphite are dispersed in methyletylketone (MEK). The various kinds of rubbers include acrylonytrile-butadiene rubber (NBR) chloroprene rubber (CR), silicon rubber, ethylene-propylene-diene-methylene rubber, natural rubber, styrene rubber, and the like. These rubbers may be used also as the coating member.
Laminate minerals such as mica, talc, and flaky graphite, fibrous inorganics such as potassium titanate, sepiolite, and wollastonite, inorganic powders such as talc, calcium silicate, calcium carbonate, and kaolin, and chops of various kinds of inorganic fibers such as glass, ceramic, and carbon may be mixed into the coating member together with the binder. In such a case, sticking to a counterpart such as a flange face, and coating member creep can be more effectively prevented from occurring.
In addition, if sacrifice metals such as zinc and aluminum, greases such as petrolatum and wax, corrosion preventive oils such as amines, and passivation agents such as nitrite are mixed into the coating member, the corrosion of the counterpart metal can be more surely prevented from occurring.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic perspective view showing an expanded graphite sealing material according to Embodiment 1 of the present invention;
FIG. 2 is a perspective view in which a part of the sealing material in Embodiment 1 is shown in an enlarged cross section;
FIG. 3 is a view showing a crack caused on the surface of acid-treated graphite;
FIG. 4 is a view showing a condition in which thin-leaf graphite portions are formed on the surface of expanded graphite particles;
FIG. 5 is a perspective view in which the formation condition of the thin-leaf graphite portion is enlarged;
FIG. 6 is a perspective view schematically showing an expanded graphite sealing material according to Embodiment 2 of the present invention;
FIG. 7 is a schematic perspective view showing an expanded graphite sealing material according to Embodiment 3 of the present invention;
FIG. 8 is a schematic perspective view showing an expanded graphite sealing material according to Embodiment 4 of the present invention;
FIG. 9 is a schematic perspective view showing an expanded graphite sealing material according to Embodiment 5 of the present invention;
FIG. 10 is a schematic perspective view showing an expanded graphite sealing material according to Embodiment 6 of the present invention;
FIG. 11 is a schematic perspective view showing an expanded graphite sealing material according to Embodiment 7 of the present invention;
FIG. 12 is a schematic perspective view showing an expanded graphite sealing material according to Embodiment 8 of the present invention;
FIG. 13 is a schematic perspective view showing an expanded graphite sealing material according to Embodiment 9 of the present invention;
FIG. 14 is a schematic perspective view showing an expanded graphite sealing material according to Embodiment 10 of the present invention;
FIG. 15 is a schematic perspective view showing a gasket sheet using an expanded graphite sealing material according to Embodiment 11 of the present invention;
FIG. 16 is a schematic perspective view showing a gasket sheet using an expanded graphite sealing material according to Embodiment 12 of the present invention;
FIGS. 17A and 17B are tables showing the structures and effects of Embodiments 1 to 12 of the present invention;
FIG. 18 is a diagram showing a configuration of an apparatus for measuring the leakage amount with respect to the tightening face pressure;
FIG. 19 is a characteristic diagram showing results of measurements of leakage amounts using the sealing materials according to Embodiments 1 and 2 as samples, in a comparative manner with that of a conventional material;
FIG. 20 is a characteristic diagram showing results of measurements of leakage amounts using the sealing material according to Embodiment 3 as a sample, in a comparative manner with that of a conventional material;
FIG. 21 is a characteristic diagram showing results of measurements of leakage amounts using the sealing material according to Embodiment 9 as a sample, in a comparative manner with that of a conventional material;
FIG. 22 is an enlarged view showing the condition before expansion of acid-treated graphite particles;
FIG. 23 is an enlarged perspective view showing expanded graphite particles;
FIG. 24 is a perspective view in which a part of a gasket sheet using a conventional expanded graphite sealing material is shown in cross section; and
FIG. 25 is an enlarged perspective view showing a part of the principal face of a conventional expanded graphite base member.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, embodiments of the present invention will be described with reference to the drawings.
Embodiment 1
In FIG. 1, 10 designates a sheet-like sealing material made of expanded graphite. A base member 11 of the sealing material 10 is obtained by performing an expansion process as shown in FIG. 23 on acid-treated graphite 1A shown in FIG. 22, and by applying a pressure to graphite particles 1a to integrate them together. In FIG. 1, substantially the entire area of the principal face, e.g., the upper face 11a of the expanded graphite base member 11 is subjected to a micro blasting process by using an abrasive material such as SiC having a particle diameter of 10 to 20 μm, so that raised and opened thin-leaf graphite portions 12 are formed. That is, the high orientation state of the upper face 11a is reduced due to the opened thin-leaf graphite portions 12 as shown in FIG. 2, while the expanded graphite 1 in the lower face 11b to which the blasting process is not performed maintains the high orientation state.
On the surface of the acid-treated graphite 1A of FIG. 22, cracks 1b are produced as shown in FIG. 3. When the expansion process is performed, raised portions 12a of graphite having top ends at the cracks 1b are formed as shown in FIGS. 4 and 5. By the micro blasting process, in addition to the raised portions 12a, raised portions 12b which are relatively thick layers and in which gaps between layers are expanded (i.e., in a honeycomb shape) are formed. These portions constitute the thin-leaf graphite portions 12.
Specifically, in the sealing material of Embodiment 1, the thin-leaf graphite portions 12 are formed in the upper face 11a of the expanded graphite base member 11, so that the high orientation state can be reduced, and the adaptability of the principal face is improved. Accordingly, the sealing properties are improved, and the bonding strength is enhanced.
Embodiment 2
In FIG. 6, 20 designates a sheet-like sealing material made of expanded graphite. On the upper face 11a of a base member 11 of the expanded graphite sealing material 20, thin-leaf graphite portions 12 are formed in the same way as Embodiment 1. Thereafter, as a secondary process, the upper face 11a is impregnated or coated with a sealing member, for example, PTFE particles 21. In this case, the PTFE particles 21 enter the thin-leaf graphite portions 12 so as to establish a three-dimensional binding relationship, whereby the bonding strength is increased.
Due to the three-dimensional binding, the strength of the PTFE particles 21 is also increased, and the strength in the direction indicated by arrow a shown in FIG. 23 is remarkably increased as compared with that in the direction indicated by arrow b. Accordingly, sliding resistance is improved. An exposed area of the expanded graphite particles 1a is reduced by the PTFE particles 21, so that the probability of corrosion of the counterpart metal by the contained sulfur components can be eliminated, and the peeling property with respect to the contact face is improved. Color alteration can be easily attained by the PTFE particles 21. This is effective in the case where a marking or the like is required.
Embodiment 3
In FIG. 7, 30 designates a ring-shaped sealing material made of expanded graphite. This embodiment uses an expanded graphite base member 11 which is the same as that in Embodiment 2. The expanded graphite base member 11 is cut into narrow strips, and the strips are die-molded into a ring shape in which the inner face is a principal face 11a of the PTFE-impregnated face. Such a ring-shaped sealing material can directly be used as a bearing.
Embodiment 4
In FIG. 8, 40 designates a sheet-like sealing material made of expanded graphite. The sheet-like sealing material is obtained in the following manner. Instead of the PTFE particles, an upper face which is a principal face 11a of an expanded graphite base member 11 is impregnated with a solution 41 as the sealing member in which NBR and graphite are dispersed in a solvent such as MEK. Accordingly, the sealing member can easily enter the inside of the thin-leaf graphite portions 12.
Embodiment 5
In FIG. 9, 50 designates a ring-shaped sealing material made of expanded graphite. The ring-shaped sealing material is formed by stamping the sheet-like sealing material 20 in Embodiment 2 into a ring shape. That is, the ring-shaped sealing material of this embodiment can be treated as a press-molded product. On an end face which is a principal face 11a, opened thin-leaf graphite portions 12 are formed, and the end face is impregnated with a sealing member 21 described in Embodiment 4.
Embodiment 6
In FIG. 10, 60 designates a ring-shaped sealing material made of expanded graphite. The sealing material is obtained in the following manner. An expanded graphite base member 11 formed in the same way as Embodiment 1 is cut into tape-like pieces each having a predetermined narrow width. The tape-like pieces are die-molded into a ring shape. Thereafter, the outer face which is a principal face 11b and the inner face which is a principal face 11a of the ring-shaped base member 11 are subjected to the micro blasting process in the same manner as described above. As a result, opened thin-leaf graphite portions 12 are formed, and the blasting-processed faces are applied or impregnated with PTFE particles 21.
Embodiment 7
In FIG. 11, 70 designates a ring-shaped sealing material made of expanded graphite. The ring-shaped sealing material is obtained in the following manner. On an end face which is a principal face 11c of the ring-shaped base member 11 obtained as a result of the die-molding in Embodiment 6, thin-leaf graphite portions 12 are formed by a micro blasting process. Then, the face is impregnated with PTFE particles 21, dried, and then baked.
Embodiment 8
In FIG. 12, 80 designates a string-like sealing material made of expanded graphite. The string-like sealing material is obtained in the following manner. A binder is applied to a fiber, and then expanded graphite particles are applied to the surface thereof under pressure, so as to form a base member 81. On the surface which is a principal face 81a of the base member 81, opened thin-leaf graphite portions 12 are formed by the micro blasting process in the same way as described above. Then, the principal face 81a is impregnated with PTFE particles 21.
Embodiment 9
In FIG. 13, 90 designates a cord-like sealing material made of expanded graphite. The cord-like sealing material is obtained in the following manner. The base material produced in Embodiment 8 is braided, so as to form a base member 91. On a surface which is a principal face 91a of the base member 91, opened thin-leaf graphite portions 12 are formed by the micro blasting process in the same way as described above. Then, the principal face 91a is impregnated with PTFE particles 21.
Embodiment 10
In FIG. 14, 100 designates a cord-like sealing material made of expanded graphite. In this embodiment, a surface which is a principal face 91a of the base member 91 obtained in Embodiment 9 is coated with a silicon rubber functioning as a sealing member 101, instead of the PTFE particles 21. The coating may be performed in the same way as Embodiment 4. The sealing material in Embodiment 8 has the string-like shape, and the sealing materials in Embodiments 9 and 10 have the cord-like shape. Accordingly, these embodiments have an advantage in that, for example, when the material is to be mounted as a ring-shaped gasket, the material can be cut into any desired length, and the length can be easily adjusted.
In Embodiments 1 to 10 described above, it is possible to use ultrasonic irradiation, laser irradiation, and plasma irradiation, instead of the micro blasting process. Also in such cases, raised and opened thin-leaf graphite portions can be formed.
Embodiment 11
FIG. 15 shows a gasket sheet made of expanded graphite. This embodiment uses a sheet-like expanded graphite base member 11 which is the same as that in Embodiment 1. On the lower face 11b which is a principal face of the base member 11 and the upper face 11a which is a principal face, opened thin-leaf graphite portions 12 are formed by a micro blasting process. The blasting-processed faces are impregnated with a phenol resin functioning as a sealing member 111, so as to form a sheet-like sealing material. A plurality of such sealing materials 112 are stacked, and then subjected to a thermal pressing process. Thus, all the materials are joined and integrated into a unit.
In general, there exists only an expanded graphite sealing material having a thickness of about 0.1 to 1 mm. The bulk density {d(g/cm 3 )} of the expanded graphite particles 1a is in the range of 1/500 to 1/1000. In order to obtain a sheet having a density of about 1 g/cm 3 and having a relatively large thickness in the range of about 3 to 6 mm, it is required to perform the pressing process on a mat-like bulk of expanded graphite particles and having a thickness of about 3 to 5 m. This is impossible in practice. Accordingly, by adopting the construction of Embodiment 11, a gasket sheet having a relatively large thickness can easily be obtained.
Embodiment 12
FIG. 16 shows a gasket sheet made of expanded graphite. This embodiment uses a sheet-like expanded graphite base member 11 which is the same as that in Embodiment 1. One face which is a principal face of the base member 11 is subjected to a micro blasting process in the same way as described above, so as to form thin-leaf graphite portions, and then impregnated with a phenol resin. A plurality of such sheet-like sealing materials 112, for example two materials are prepared. The material 112 is superposed on the other material 112 in such a manner that their blasting-processed faces are opposed and a reinforcing member 121 such as a stainless steel plate is interposed therebetween. Then, the whole structure is integrated together by a thermal pressing process. According to this embodiment, the mechanical strength in a mounted state is sufficiently ensured. In the gasket sheets 110 and 120, the upper and lower faces may be coated with PTFE, or the like.
In order to facilitate understanding of the structures of the Embodiments 1 to 12 and the effects which are deemed to be attained by these structures, they are collectively listed as tables in FIGS. 17A and 17B.
FIG. 18 shows an apparatus for measuring a leakage amount of a gasket sheet made of a sealing material of Embodiment 1 or 2, or the like. A sample M of such an embodiment is stamped into a size of 110×90 in diameter. The stamped sample M is clamped by a leakage jig N, and compressed by an oil hydraulic press for attaining a predetermined tightening face pressure. Then, nitrogen gas N 2 is charged from a cylinder P into an inner side of the sample M up to a predetermined pressure. After an elapse of three minutes, the gas is recovered, and the leakage amount is measured from the amount of the recovered gas. The measurement results are shown in FIG. 19.
From the measurement results shown in FIG. 19, it is found that, in the sample according to Embodiment 1, the leakage amount can be suppressed to a level as low as that of a conventional expanded graphite sealing material. It is also found that, in the sample according to Embodiment 2 and the sealing material in which PTFE is baked, the leakage amount is greatly reduced as compared with the conventional material, and the sealing properties can be improved.
FIG. 20 is a characteristic diagram showing the results obtained by measuring the relationships between the number of sliding operations and the leakage amount in which a sample according to Embodiment 3 is used as a packing, in a comparative manner with those of conventional materials. A conventional material A is formed from an expanded graphite sealing material without having a metal mesh therein, and a conventional material B is formed by simply impregnating an expanded graphite sealing material with PTFE. For the conventional material A, the leakage amount is drastically increased from the beginning of the increase of the number of sliding operations. For the conventional material B, the leakage amount is remarkably increased after the number of sliding operations exceeds 360 (2 h). On the other hand, for the material according to Embodiment 3, it is found that, even when the number of sliding operations is increased, the leakage amount can be reduced to an extremely low level.
FIG. 21 is a characteristic diagram showing the results obtained by measuring the relationships between the number of sliding operations and the leakage amount in which a sample according to Embodiment 9 is used as a packing, in a comparative manner with those of conventional materials. A conventional material A is obtained by braiding a yarn in which expanded graphite is bonded to a cotton string with a binder. A conventional material B is impregnated with PTFE.
Also in this case, it is found that, as compared with the conventional materials A and B, the leakage amount is reduced and the sealing property can be improved for the material according to Embodiment 9.
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An expanded graphite sealing material is provided in which the adaptability of the principal face of an expanded graphite base member is improved, the bonding strength to a coating layer and the like can be increased, and the sealing properties can be enhanced. A method of producing such a sealing material, and a gasket sheet using the sealing material are also of concern. On at least a portion of a principal face of the expanded graphite base member in which expanded graphite particles are pressurized and integrated together, opened thin-leaf graphite portions are formed. The principal face of the expanded graphite base member having the thin-leaf graphite portions can be impregnated with a sealing member such as PTFE or covered with a coating layer. As the form of the sealing material, a sheet, a press-molded product, a fabric, a string, or a braided article can be adopted.
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BACKGROUND OF INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to integrated circuits, and more particularly to methods and apparatus for programmable and/or scalable terminations within integrated circuits.
[0003] 2. Background
[0004] As the speed of transmission lines included in memory interfaces and buses increases, impedance “matching” become increasingly important. The characteristic impedance of a transmission line is the ratio of voltage to current of a signal moving along the transmission line. By terminating the transmission line with a load (e.g., an impedance) equal to the characteristic impedance of the transmission line, a signal pulse applied to the transmission line is transferred to the load without reflection. The benefits of impedance matching, such as reduced signal reflection and signal loss during signal transmission, are well known to one of skill in the art and is not be described further herein.
[0005] FIG. 1 is a diagram of a conventional programmable termination circuit 100 . The programmable termination circuit 100 includes an impedance evaluation control circuit 102 coupled to a resistive element 104 . The resistive element 104 is coupled to a port 106 included in a memory system (not shown). The port 106 may correspond to a transmission line included in a bus for the memory system, or a memory interface, for example.
[0006] The resistive element 104 includes an upper portion 108 of circuitry including a plurality of p-channel metal-oxide semiconductor field-effect transistors (PFETs) P 0 -P 7 connected in parallel between a high voltage level (e.g., V DDQ ) and the port 106 . The PFET P 0 is a default device that is always on and determines (along with NFET N 0 ) the maximum impedance that may be created by the resistive element 104 . The PFETs P 1 -P 7 are arranged in size order such that PFET P 1 is the narrowest transistor and PFET P 7 is the widest transistor.
[0007] The resistive element 104 includes a lower portion 110 of circuitry including a plurality of n-channel metal-oxide semiconductor field-effect transistors (NFETs) N 0 -N 7 connected in parallel between the port 106 and ground. The NFET N 0 is a default device that is always on and determines (along with PFET P 0 ) the maximum impedance that may be created by the resistive element 104 . The NFETs N 1 -N 7 are arranged in size order such that NFET N 1 is the narrowest transistor and NFET N 7 is the widest transistor.
[0008] The upper portion 108 of circuitry is connected in series with the lower portion 110 of circuitry to create a voltage divider that provides a termination for a signal output from circuitry that employs the programmable termination circuit 100 . The terminated impedance is created by the resistive element 104 , on the port 106 . Each PFET, NFET combination (e.g., P 0 -N 0 , P 1 -N 1 , P 2 -N 2 , etc.) is referred to herein as a stacked transistor pair. However, it should be understood that each of the transistors PFETs P 1 -P 7 and NFETs N 1 -N 7 may operate independently.
[0009] The impedance evaluation control logic 102 outputs a fixed set of control or binary termination signals (e.g., binary counts) p 1 -p 7 and n 1 -n 7 to the PFETs P 1 -P 7 and NFETs N 1 -N 7 , respectively, for selectively activating or de-activating the transistors (thereby creating a resistive element 104 of a fixed impedance (e.g., once programmed via the impedance evaluation control logic 102 described below with reference to FIG. 2 ), which is used for outputting a signal on the port 106 ). In one embodiment, the most significant bit of a binary count is provided to the widest transistor, and the least significant bit is provided to the narrowest transistor. As stated, because the default devices P 0 , N 0 are always on, the default devices P 0 , N 0 sets the maximum impedance value of the resistive element 104 .
[0010] FIG. 2 is a diagram of the conventional impedance evaluation control circuit 102 of FIG. 1 . The impedance evaluation control circuit 102 may include control logic 202 coupled to a plurality 204 of PFETs 204 a - h connected in parallel between a high voltage level (e.g., V DDQ ) and a port 206 (e.g., a chip pad) included, for example, in a memory system (not shown). The PFETs 204 a - h may be arranged in size order in a manner similar to the PFETs P 1 -P 7 included in the upper portion 108 of the resistive element 104 of FIG. 1 .
[0011] The control logic 202 may be coupled to the port 206 via a feedback line 208 . A resistor 210 (e.g., an external resistor connected to a system board) is coupled between the port 206 and ground. Consequently, the impedance evaluation control circuit 102 acts as a voltage divider.
[0012] The control logic 202 outputs bits of a binary count signal (e.g., signals p 1 -p 7 ) to the plurality 204 of PFETs 204 a - h , respectively, and in response thereto receives a value indicating the voltage at the port 206 via the feedback line 208 . In one embodiment, the most significant bit of the binary count signal is provided to the widest transistor, and the least significant bit is provided to the narrowest transistor. The control logic 202 compares the voltage at the port 206 with a reference voltage (e.g., a desired value such as V DDQ /2) included in the control logic 206 and outputs a different binary count signal until the voltage at port 206 matches the reference voltage (e.g., V DDQ /2). Once the voltage at port 206 matches the reference voltage, the impedance evaluation control circuit 102 fixes and outputs the binary count (e.g., control signals p 1 -p 7 ) used for creating the voltage at port 206 to the PFETs P 1 -P 7 of FIG. 1 . Although not shown in FIG. 2 , the impedance evaluation control circuit 102 may create control signals n 1 -n 7 in a similar manner and provide the same to the NFETs N 1 -N 7 of FIG. 1 . In this manner, the impedance evaluation control circuit 102 generates control or binary termination signals p 1 -p 7 , n 1 -n 7 used for creating a resistive element 104 (e.g., terminator) of a fixed impedance (e.g., the characteristic impedance) based on the value of the external resistor 210 . Thus, the conventional impedance evaluation control circuit 102 determines a characteristic impedance of a port by generating a plurality of binary termination signals.
[0013] Different applications and different types of signals corresponding to an application, such as data, address, and/or clock signals, may require different termination values for optimal transmission. Although a different programmable termination circuit 100 may be used for creating the required termination value for each different port of an application (e.g., a memory system) such a solution requires the above circuitry for each port.
SUMMARY OF INVENTION
[0014] To overcome the disadvantages of the prior art, in one or more aspects of the present invention, methods and apparatus for scalable terminations within integrated circuits are provided. For example, in a first aspect of the invention, a first method is provided for providing multiple termination values using a plurality of binary termination signals. The first method includes the steps of (1) determining a characteristic impedance of a first port by generating a plurality of binary termination signals; and (2) modifying a characteristic impedance of a second port by manipulating one or more of the plurality of binary termination signals.
[0015] In a second aspect of the invention, a second method is provided for providing multiple termination values using a set of control signals. The second method includes the steps of (1) employing the set of control signals to provide a fixed output impedance on a first port; and (2) employing the set of control signals to provide a variable output impedance on a second port. Numerous other aspects are provided, as are systems and apparatus in accordance with these and other aspects of the invention.
[0016] Other features and aspects of the present invention will become more fully apparent from the following detailed description, the appended claims and the accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
[0017] FIG. 1 is a diagram of a conventional programmable termination circuit.
[0018] FIG. 2 is a diagram of the conventional impedance evaluation control circuit of FIG. 1 .
[0019] FIG. 3 is a block diagram of a first exemplary scalable termination circuit provided in accordance with the present invention.
[0020] FIG. 4 is a block diagram of a second scalable termination circuit for providing a fixed termination value on a first port and a variable termination value on a second port using a single set of control signals in accordance with an embodiment of the present invention.
[0021] FIG. 5 is a block diagram of a third scalable termination circuit for providing a variable impedance on a port of a memory system in accordance with the present invention.
[0022] FIGS. 6A and 6B are a block diagram of a fourth exemplary scalable termination circuit for providing a fixed termination value on a first port and a variable termination value on a second port using a single set of control signals in accordance with an embodiment of the present invention.
[0023] FIG. 7 is a block diagram of a fifth exemplary scalable termination circuit for providing a fixed termination value on a first port and a variable termination value on a second port using a single set of control signals in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION
[0024] FIG. 3 is a block diagram of a first exemplary scalable termination circuit 301 provided in accordance with the present invention. The scalable termination circuit 301 provides a variable termination on a transmission line coupled to a port 302 . The scalable termination circuit 301 includes scalable termination logic 300 having a resistive element 304 coupled to the port 302 of a memory system, transistor enable logic 306 and the conventional impedance evaluation control circuit 102 . The resistive element 304 and the transistor enable logic 306 may be coupled to and receive control signals p 1 -p 7 , n 1 -n 7 from the conventional impedance evaluation control circuit 102 . When a logic enable signal, ENABLE, is not asserted via an input 308 of the transistor enable logic 306 , the scalable termination logic 300 provides a first termination value on the port 302 . Alternatively, when the logic enable signal, ENABLE, is asserted, the scalable termination logic 300 provides or outputs a second termination value on the port 302 .
[0025] In one embodiment, the resistive element 304 may include a plurality of transistors similar to the transistors (e.g., P 1 , P 2 , N 1 , N 2 , etc.) of resistive element 104 shown in FIG. 1 . However, for each transistor (e.g., P 1 ) included in the resistive element 104 , the resistive element 304 includes a group of transistors (e.g., P 1 A-P 1 B-P 1 C-P 1 D), referred to as a fingered transistor set, connected in parallel. The width of each transistor included in the fingered transistor set is the width of the transistor (e.g., P 1 ) shown in FIG. 1 to which the fingered transistor set (e.g., P 1 A-P 1 B-P 1 C-P 1 D) corresponds reduced by a factor based on the number of transistors in the fingered transistor set. For example, the group of PFETs P 1 A-P 1 B-P 1 C-P 1 D shown in FIG. 3 corresponds to the transistor P 1 shown in FIG. 1 . Each of the PFETs P 1 A-P 1 D is ¼ the width of transistor P 1 . Likewise, the group of NFETs N 1 A-N 1 B-N 1 C-N 1 D shown in FIG. 3 corresponds to the transistor N 1 shown in FIG. 1 ; and each of the NFETs N 1 A-N 1 D is ¼ the width of transistor N 1 .
[0026] The group of PFETs P 1 A-P 1 D may be connected in series with the group of NFETs N 1 A-N 1 D as shown. Consequently, the programmable termination circuit 300 includes a stacked fingered transistor pair P 1 A-P 1 D/N 1 A-N 1 D, which include a plurality of stacked transistor pairs (e.g., P 1 A-N 1 A, P 1 B-N 1 B, P 1 C-N 1 C, P 1 D-N 1 D), corresponding to the stacked transistor pair P 1 -N 1 shown in FIG. 1 .
[0027] Although the resistive element 304 only illustrates one stacked fingered transistor pair P 1 A-P 1 D/N 1 A-N 1 D that corresponds to the stacked transistor pair P 1 -N 1 included in the resistive element 104 of FIG. 1 , it should be understood that in practice the resistive element 304 includes a stacked fingered transistor pair that corresponds to each of the remaining stacked transistor pairs (e.g., P 2 -N 2 , P 3 -N 3 , P 4 -N 4 , P 5 -N 5 , P 6 -N 6 , and P 7 -N 7 ) shown in FIG. 1 . Although not illustrated, the resistive element 304 may include a stacked fingered transistor pair that corresponds to the default stacked transistor pair (e.g., P 0 -N 0 ) shown in FIG. 1 .
[0028] The signals (e.g., modified or manipulated control signals) output by the transistor enable logic 306 may be coupled to and selectively activate or de-activate one or more stacked transistor pairs (e.g., P 1 D-N 1 D) in each stacked fingered transistor pair (e.g., P 1 A-P 1 D/N 1 A-N 1 D). For example, if the logic enable signal, ENABLE, is not asserted, the scalable termination logic 300 outputs a first termination value (e.g., the characteristic impedance of the transmission line coupled to the port 302 with transistors P 1 D-N 1 D on). Alternatively, if the transistor enable logic, enable signal, ENABLE, is asserted, the scalable termination logic 300 outputs a second termination value that is a scaled value of the first termination value (as the stacked transistor pair P 1 D-N 1 D are off).
[0029] The numerator of the scaling factor provided by the scalable termination logic 300 is the number of stacked transistor pairs included in each stacked fingered transistor pair when the enable signal is of a first logic state. The denominator of the scaling factor is the number of stacked transistor pairs that are activated in each stacked fingered transistor pair, which includes stacked transistor pairs that are activated by the control signals provided by the impedance evaluation control circuit 102 when the enable signal is of a second logic state. Therefore, the exemplary scalable termination logic 300 shown in FIG. 3 may scale or adjust the first termination value by 4/3 when the logic 306 enable signal, ENABLE, is asserted. Through use of the scalable termination logic 300 shown in FIG. 3 , a variable termination value may be provided on a port 302 using control signals provided by transistor enable logic 306 and the impedance evaluation control circuit 102 .
[0030] FIG. 4 is a block diagram of a second scalable termination circuit 401 for providing a fixed termination value on a first port and a variable termination value on a second port using a single set of control signals in accordance with an embodiment of the present methods and apparatus. The second scalable termination circuit 401 includes scalable termination logic 400 having a first resistive element 402 coupled to a first port 404 of a memory system (not shown) and the conventional impedance evaluation control circuit 102 . The scalable termination logic 400 includes the scalable termination logic 300 shown in FIG. 3 coupled to a second port 406 of the memory system. The conventional impedance evaluation control circuit 102 may be coupled to and provide signals to the first resistive element 402 and the resistive element 304 of the scalable termination logic 300 , which serves as a second resistive element in the scalable termination logic 400 .
[0031] The structure of the first resistive element 402 may be similar to the structure of the resistive element 104 shown in FIG. 1 . However, the first resistive element 402 includes a fingered transistor set (e.g., a group of transistors connected in parallel) for each transistor included in the resistive element 104 shown in FIG. 1 . Therefore, the scalable termination logic 400 includes a stacked fingered transistor pair P 1 A-P 1 D/N 1 A-N 1 D corresponding to the stacked transistor pair P 1 -N 1 of FIG. 1 . Although the first resistive element 402 shown in FIG. 4 illustrates only one stacked fingered transistor pair P 1 A-P 1 D/N 1 A-N 1 D, it should be understood that the first resistive element 402 includes a stacked fingered transistor pair for each of the remaining stacked transistor pairs included in the resistive element 104 shown in FIG. 1 . Although not illustrated, the first resistive element 402 may include a stacked fingered transistor pair that corresponds to the default stacked transistor pair (e.g., P 0 -N 0 ) shown in FIG. 1 . Because the structure of the scalable termination logic 300 was described in detail above, it is not described again herein.
[0032] In operation, the scalable termination circuit 401 employs a set of control signals for providing a fixed output impedance on a first port. More specifically, the first resistive element 402 of the scalable termination logic 400 may receive control signals (e.g., binary counts) p 1 -p 7 , n 1 -n 7 from the conventional impedance evaluation control circuit 102 that serve to selectively activate or deactivate one or more stacked transistor pairs (e.g., P 1 D-N 1 D in each stacked fingered transistor pair (e.g., P 1 A-P 1 D/N 1 A-N 1 D) to create a resistive element of a fixed impedance. Because the resistive element 402 is coupled to the first port 404 , an output impedance (e.g., the characteristic impedance) is provided on the first port 404 based on the set of control signals. The output impedance terminates a transmission line coupled to the first port 404 .
[0033] A set of control signals may be employed to provide a variable output impedance on a second port. The conventional impedance evaluation circuit 102 may provide the same set of control signals p 1 -p 7 , n 1 -n 7 provided to the first resistive element 402 to the scalable termination logic 300 . As stated above while describing FIG. 3 , the control signals p 1 -p 7 , n 1 -n 7 along with secondary control signals output by the transistor enable logic 306 may serve to selectively activate or de-activate one or more stacked transistor pairs included in one or more stacked fingered transistor pairs (e.g., P 1 A-P 1 D/N 1 A-N 1 D of the second resistive element 304 to create a resistive element 304 of a first impedance. However, it should be understood that these transistors operate (e.g., may be activated) independently. If a logic 306 enable signal, ENABLE, is asserted, the transistor enable logic 306 may modify or manipulate one or more portions of the control signals p 1 -p 7 , n 1 -n 7 and output modified secondary control signals to the resistive element 304 . The control signals p 1 -p 7 , n 1 -n 7 along with the modified secondary control signals serve to selectively activate or de-activate one or more stacked transistor pairs (e.g., P 1 D-N 1 D) included in one or more stacked fingered transistor pairs of the second resistive element 304 . In this manner, the resistive element 304 may be modified to create another (e.g., a second) impedance. Because the resistive element 304 may be modified and is coupled to the second port 406 , an impedance that may be adjusted (e.g., a variable impedance) is provided or output on the second port 406 based in part on the control signals p 1 -p 7 , n 1 -n 7 .
[0034] The scalable termination circuit 401 uses resistive elements that include stacked fingered transistor pairs to provide a fixed termination value on a first port and a variable termination value on a second port using a single set of control signals. Because only a single set of control signals are provided to the scalable termination logic 400 , only a single impedance evaluation circuit 102 is required.
[0035] Although using a stacked fingered transistor pair, which corresponds to a stacked transistor pair included in the resistive element 104 , in the resistive elements 304 , 402 , may allow impedance to be varied simply, it may be difficult to replace the narrow transistors included in the resistive element 104 with fingered transistors, because dividing a narrow transistor into four transistors, each of which are ¼ the width, for example, may require the width of each transistor included in the fingered transistor to be below a design rule minimum required for optimal model accuracy and therefore, may be impractical.
[0036] FIG. 5 is a block diagram of a third scalable termination circuit 501 for providing variable impedance on a port of a memory system in accordance with the present invention. The third scalable termination circuit 501 , includes scalable termination logic 500 , which is coupled to the impedance evaluation control circuit 102 , having the resistive element 104 , which includes the upper portion 108 of circuitry and the lower portion 110 of circuitry, coupled to a port 502 of a memory system. The resistive element 104 was described above and is not described again in detail herein. The upper portion 108 of circuitry may be coupled to math logic 504 , and the lower portion 110 of circuitry may be coupled to math logic 506 . The math logic 504 , 506 is coupled to and receives control signals p 1 -p 7 , n 1 -n 7 , respectively, from the conventional impedance evaluation circuit 102 . The math logic 504 , 506 may receive an input from a line 508 coupled to a fuse (not shown) or a register (not shown), such as a programmable register, indicating a mathematical operation to be performed on the control signals p 1 -p 7 , n 1 -n 7 . The math logic 504 , 506 may include combinational and/or sequential logic or may be implemented using an application specific integrated circuit (ASIC).
[0037] The scalable termination circuit 501 receives control signals p 1 -p 7 , n 1 -n 7 from the impedance evaluation circuit 102 that when applied directly to the resistive element 104 create an original impedance (e.g., a characteristic impedance) on a port 502 to which the resistive element 104 is connected. The scalable termination logic 500 modifies or manipulates one or more of the control signals p 1 -p 7 , n 1 -n 7 using math logic 504 , 506 , and adjusts the value of the impedance on the port 502 using the modified control signals. More specifically, the math logic 504 may receive a portion of the control signals p 1 -p 7 (e.g., a binary count) output by the impedance evaluation circuit 102 and receive a scaling factor (e.g., a factor by which to modify the control signals) from a fuse (not shown) or register (not shown) via line 508 . The math logic 504 may perform a multiplication and/or division operation on the binary count p 1 -p 7 to modify the control signals p 1 -p 7 appropriately such that they (along with modified control signals n 1 -n 7 ) may be used to modify the impedance on the port 502 as required by the scaling factor. Because the impedance varies in proportion to the inverse of the binary count, a 4/3 increase in impedance may be achieved by reducing the binary count by 34 , for example. The math logic 506 modifies the control signals n 1 -n 7 in a similar manner. Although FIG. 5 illustrates a first math logic 504 that modifies the control signals p 1 -p 7 and a second math logic 506 that modifies the control signals n 1 -n 7 , it should be understood that a single math logic may be used for modifying the control signals p 1 -p 7 , n 1 -n 7 .
[0038] The math logic 504 , 506 outputs the modified control signals to the resistive element 104 . The modified signals may serve to selectively activate or de-activate one or more stacked transistor pairs (e.g., P 1 -N 1 and P 2 -N 2 ) included in the resistive element 104 , which modifies the structure and therefore the impedance of the resistive element 104 . Because the resistive element 104 is coupled to the port 502 , a second impedance, which may be scaled or adjusted version of the original impedance, is provided or output on the port 502 based on the modified control signals. Although using math logic 504 , 506 to modify control signals p 1 -p 7 , n 1 -n 7 , which are used for creating an original impedance on a port, may provide a method of scaling the impedance on the port, because the default transistors P 0 , N 0 included in the resistive element 104 do not receive modified control signals, they are unaffected by the changes made by the math logic 504 , 506 . Therefore, every transistor included in the resistive element 104 does not receive an adjustment based on the scaling factor. Consequently, the modified impedance output on the port 502 does not accurately reflect the original impedance (e.g., characteristic impedance) modified (e.g., multiplied or divided) by the scaling factor.
[0039] FIGS. 6A and 6B are a block diagram of a fourth exemplary scalable termination circuit 601 for providing a fixed termination value on a first port and a variable termination value on a second port using a single set of control signals in accordance with an embodiment of the present invention. Therefore, the scalable termination logic 600 only requires a single impedance evaluation circuit. The fourth scalable termination circuit 601 includes scalable termination logic 600 , which is coupled to the conventional impedance evaluation control circuit 102 , having a first resistive element 104 (e.g., the programmable termination circuit 104 shown in FIG. 1 ) coupled to a first port 602 . The scalable termination logic 600 may include a second resistive element 104 (e.g., the resistive element 104 , included in the scalable termination logic 500 shown in FIG. 5 ) coupled to a second port 604 . Because both the programmable termination circuit 104 and the scalable termination logic 500 were described above, they are not described again in detail herein. The scalable termination circuit 104 and the scalable termination logic 500 may be coupled to and receive control signals p 1 -p 7 , n 1 -n 7 from the impedance evaluation circuit 102 .
[0040] In operation, the scalable termination circuit 601 employs a set of control signals for providing a fixed output impedance on a first port 602 . More specifically, the first resistive element 104 of the scalable termination circuit 601 may receive control signals (e.g., a binary count) p 1 -p 7 , n 1 -n 7 from the impedance evaluation control circuit 102 that serve to selectively activate or de-activate one or more stacked transistor pairs (e.g., P 1 -N 1 , P 2 -N 2 , and P 3 -N 3 ) for creating a resistive element 104 of a fixed impedance. Because the resistive element 104 is coupled to the first port 602 , an output impedance (e.g., the characteristic impedance) is provided on the first port 602 based on the control signals p 1 -p 7 , n 1 -n 7 .
[0041] The same set of control signals may be employed to provide a variable output impedance on the second port 604 . More specifically, the impedance evaluation circuit 102 may provide control signals p 1 -p 7 , n 1 -n 7 to the scalable termination logic 500 . As stated above while discussing the scalable termination circuit 500 , math logic 504 , 506 may receive and modify or manipulate the control signals p 1 -p 7 , n 1 -n 7 , respectively, and output the modified control signals to the second resistive element (e.g., the resistive element 104 included in the programmable termination circuit). As stated above, the math logic 504 , 506 modifies the control signals p 1 -p 7 , n 1 -n 7 based on adjustable scaling factors, which may be provided by a fuse (not shown) or a register (not shown), such as a programmable register, via an input 508 . The modified control signals may serve to selectively activate or de-activate one or more stacked transistor pairs (e.g., P 1 -N 1 , P 2 -N 2 ) included in the second resistive element to create a resistive element having an impedance that is a scaled version of the impedance created on the first port 602 .
[0042] By modifying the scaling factor provided to the math logic 504 , 506 , the math logic 504 , 506 may output a different set of modified control signals. The different set of modified control signals may be used for creating a resistive element (e.g., the resistive element 104 included in the programmable termination circuit) having a different impedance, which is a scaled or adjusted version of the impedance created on the first port 602 . Because the resistive element 104 included in the scalable termination logic 500 is coupled to the second port 604 and the impedance created by the resistive element included in the scalable termination logic 500 may be varied, a variable impedance is provided or output on the second port 604 based on the control signals p 1 -p 7 , n 1 -n 1 .
[0043] The scalable termination logic 600 uses resistive elements coupled to math logic for providing a fixed termination value on a first port and a variable termination value on a second port using a single set of control signals. Because only a single set of control signals are provided to the scalable termination logic 600 , only a single impedance evaluation circuit is required.
[0044] Although using math logic 504 , 506 for modifying control signals, which are used to create an impedance on a port, may provide a method of scaling an impedance on the same or another port, because the default transistors P 0 , N 0 included in the resistive element 104 and the resistive element included in the scalable termination circuit 500 do not receive modified control signals they are unaffected by the changes made by the math logic 504 , 506 . Therefore, every transistor included in the resistive elements does not receive an adjustment based on the scaling factor. Consequently, the modified impedance output on the port 602 , 604 does not accurately reflect the characteristic impedance modified (e.g., multiplied or divided) by the scaling factor.
[0045] FIG. 7 is a block diagram of a fifth exemplary scalable termination circuit for providing a fixed termination value on a first port and a variable termination value on a second port using a single set of control signals in accordance with an embodiment of the present invention. The scalable termination circuit 701 includes scalable termination logic 700 , which is coupled to the impedance evaluation control circuit 102 , having a first resistive element 702 coupled to a first port 704 and a second resistive element 706 coupled to a second port 708 . The first resistive element 702 is coupled to and receives control signals from impedance evaluation control logic 102 . The second resistive element 706 is coupled to and receive control signals from math logic 714 , which is coupled to and receives control signals from the impedance evaluation control logic 102 . The second resistive element 706 may be coupled to and receive control signals (e.g., secondary control signals) from transistor enable logic 707 . The transistor enable logic 707 and the math logic 714 may be coupled to a logic enable signal, ENABLE, via an input 308 , that serves to activate the transistor enable logic 707 and math logic 714 . The math logic 714 may be coupled to a fuse (not shown) or a register (not shown), such as a programmable register, via an input 508 , that indicates a scaling factor (e.g., a factor by which to modify the control signals).
[0046] The structure of the first resistive element 702 is similar to the structure resistive element 104 included in the programmable termination circuit 100 of FIG. 1 . In contrast to the resistive element 104 , each default transistor of the first resistive element 702 is a fingered transistor set. For example, the default PFET includes transistors P 0 A, P 0 B, P 0 C, and P 0 D connected in parallel to form a fingered transistor set. Each of the transistors P 0 A, P 0 B, P 0 C, P 0 D included in the default PFET are connected to ground such that the default fingered PFET set is always on. Similarly, the default NFET includes transistors N 0 A, N 0 B, N 0 C, and N 0 D connected in parallel to form a fingered transistor set. Each of the transistors N 0 A, N 0 B, N 0 C, N 0 D included in the default NFET are connected to a high voltage level (e.g., a logic “1”) such that the default fingered NFET is always on. A PFET from the default fingered transistor set P 0 A-P 0 D may be coupled to a corresponding NFET from the default fingered transistor set N 0 A-N 0 D to create a plurality of stacked transistor pairs (e.g., P 0 A-N 0 A, P 0 B-N 0 B) and thereby creating a stacked fingered transistor pair (e.g., P 0 A-P 0 D/N 0 A-N 0 D) 710 .
[0047] The structure of the second resistive element 706 is similar to the first resistive element 702 . In contrast to the first resistive element 702 , one or more stacked transistor pairs (e.g., P 0 D-N 0 D) included in the default stacked fingered transistor pair 712 (e.g., P 0 A-P 0 D/N 0 A-N 0 D), may be coupled to the logic enable signal, ENABLE, and an output of transistor enable logic 707 , respectively. Remaining transistors 718 (e.g., P 1 -P 7 , N 1 -N 7 ) included in the second resistive element 706 may be coupled to an output of the math logic 714 . A PFET from the remaining transistors 718 may be coupled to a corresponding NFET in the remaining transistors 718 to create a plurality of stacked transistor pairs (e.g., P 1 -N 1 , P 2 -N 2 , etc.).
[0048] In operation, the scalable termination circuit 701 employs a set of control signals p 1 -p 7 , n 1 -n 7 for providing a fixed output impedance on a first port 704 . More specifically, the default stacked fingered transistor pair 710 is always on and is connected in parallel to the remaining transistors 716 (e.g., stacked transistor pairs P 1 -N 1 to P 7 -N 7 ) included in the first resistive element 702 . The remaining transistors 716 included in the first resistive element 702 of the scalable termination circuit 700 may receive control signals (e.g., binary counts) p 1 -p 7 , n 1 -n 7 from the impedance evaluation control circuit 102 that serve to selectively activate or de-activate one or more of the stacked transistors (e.g., P 1 -N 1 to P 7 -N 7 ) to create a resistive element 702 of a fixed impedance. Because the resistive element 702 is coupled to the first port 704 , an output impedance (e.g., the characteristic impedance) is provided on the first port 704 based on the control signals p 1 -p 7 , n 1 -n 7 .
[0049] The same set of control signals may be employed for providing a variable impedance on the second port 708 . More specifically, the impedance evaluation control circuit 102 may provide the same control signals p 1 -p 7 , n 1 -n 7 provided to the first resistive element 702 to the math logic 714 . When the logic 707 enable signal, ENABLE, coupled to the math logic 714 is asserted, the math logic 714 modifies or manipulates the control signals p 1 -p 7 , n 1 -n 7 output by the impedance evaluation control circuit 102 as indicated by an adjustable scaling factor provided to the math logic 714 (e.g., via the input 508 ). In one embodiment, the math logic 714 may perform a multiplication and/or division operation on the control signals p 1 -p 7 , n 1 -n 7 (e.g., the binary counts) as required by the scaling factor. The math logic 714 outputs modified control signals, which may be used to selectively activate or deactivate one or more stacked transistor pairs (e.g., P 1 -N 1 , P 2 -N 2 ) included in the remaining transistors 718 of the second resistive element 706 , to create a resistive element using the remaining transistor 718 having an impedance that is a scaled version of the impedance created by the remaining transistors 716 of the first resistive element 702 .
[0050] By modifying the scaling factor provided to the math logic 714 , the math logic 714 may output a different set of modified control signals to the remaining transistors 718 included in the second resistive element 706 . The different set of modified control signals may be used to create a resistive element (using the remaining transistors 718 ) having a different impedance, which is the impedance created by the remaining transistors 716 of the first resistive element 702 modified (e.g., multiplied or divided) by the scaling factor.
[0051] When the logic enable signal, ENABLE, coupled to the math logic 714 is not asserted the remaining transistors 718 included in the second resistive element 706 may receive an unmodified version the control signals p 1 -p 7 , n 1 -n 7 from the math logic 714 that serve to selectively activate or de-activate one or more of the stacked transistor pairs in the remaining transistors 718 to create a resistive element using the remaining transistors 718 having the same impedance created by the remaining transistors 716 of the first resistive element 702 .
[0052] The transistor enable logic 707 may receive a secondary control signal (e.g., ENABLE). When the enable logic 707 receives the enable signal, ENABLE, the logic 707 may modify the secondary control signal, and output control signals (e.g., modified secondary control signals) to one or more stacked transistor pairs (e.g., P 0 D-N 0 D) included in the default stacked fingered transistor pair 712 . For example, the enable logic 707 may receive a secondary control signal ENABLE as an input and output modified secondary control signals ENABLE and not ENABLE to the transistors included in the stacked transistor pair P 0 D-N 0 D, respectively. The modified secondary control signals may serve to selectively activate or de-activate one or more stacked transistors (e.g., P 0 D-N 0 D) included in the default stacked fingered transistor pair 712 . The structure of the default stacked fingered transistor pair 712 is changed from that of the default stacked fingered transistor pair 710 , and therefore the impedance of the default stacked fingered transistor pair 712 may be the impedance of the default stacked fingered transistor pair 710 modified by a scaling factor.
[0053] In one embodiment, the numerator of the scaling factor provided by the enable logic 707 may be the number of stacked transistor pairs (e.g., P 0 A-N 0 A) included in the default stacked fingered transistor pair 712 when the ENABLE signal is low and the denominator of the scaling factor provided by the enable logic 707 may be the number of stacked transistor pairs (e.g., P 0 A-N 0 A) that are activated in the default stacked fingered transistor pair 712 when the ENABLE signal is high. In the exemplary scalable termination logic 700 , the enable logic 707 may deactivate the stacked transistor pair P 0 D-N 0 D and therefore, scale the impedance of the default stacked fingered transistor pair 712 by 4/3 when ENABLE is asserted.
[0054] When the enable logic 707 is not enabled by the logic enable signal, ENABLE, the default stacked fingered transistor pair 712 may receive a second version of the modified secondary control signals from the enable logic 707 that serves to selectively activate or de-activate one or more of the stacked transistor pairs (e.g., stacked P 0 D-N 0 D to create a default stacked fingered transistor pair 712 having the same impedance as the default stacked fingered transistor pair 710 included in the first resistive element 702 .
[0055] The math logic 714 and the enable logic 707 are activated by the same enable signal, ENABLE. Therefore, the math logic 714 may modify or adjust the impedance of the remaining transistors (e.g., stacked transistor pairs P 1 -N 1 to P 7 -N 7 ) 718 included in the second resistive element 706 while the transistor enable logic 707 modifies or adjusts the impedance of the default stacked fingered transistor pair 712 included in the second resistive element 706 . Because the default stacked fingered transistor pair 712 is connected in parallel to the remaining transistors 718 , the value of the scaled impedance provided or output on the second port 708 by the second resistive element 706 may be easily determined by one of skill in the art. In one embodiment, the math logic 714 modifies the impedance of the remaining transistors 718 by the same scaling factor that the enable logic 707 modifies the impedance of the default stacked fingered transistor pair 712 . Therefore, the impedance created on the second port 708 is the impedance created on the first port 704 modified (e.g., multiplied or divided) by the scaling factor.
[0056] The scalable termination logic 700 may use the first resistive element 702 to provide a fixed termination value on a first port 704 , and a resistive element (e.g., the remaining transistors 718 ) coupled to math logic 714 and resistive element (e.g., the default stacked fingered transistor pair 712 ) coupled to enable logic 707 to provide a variable termination value on a second port 708 using a single set of control signals p 1 -p 7 , n 1 -n 7 . The default stacked fingered transistor pair 712 may be used for providing a scalable maximum termination value on the second port 708 . The remaining transistors 718 may be used for providing a scaled impedance which, when combined with the maximum impedance, serves to reduce the maximum impedance by a certain amount. Because only a single set of control signals p 1 -p 7 , n 1 -n 7 are provided to the scalable termination circuit 701 , only a single impedance evaluation control circuit 102 is required.
[0057] As stated, the scalable termination circuit 701 may scale the impedance provided by the default stacked fingered transistor pair 712 included in the second resistive element 706 and may scale the impedance provided by the remaining transistors (e.g., stacked transistor pairs P 1 -N 1 to P 7 -N 7 ) 718 included in the second resistive element 706 using a same scaling factor. Therefore, the scalable termination circuit 700 may provide a characteristic impedance on a second port 708 that accurately reflects the characteristic impedance on a first port 704 modified (e.g., multiplied or divided) by the scaling factor.
[0058] As stated above, the first and second resistive elements 702 , 706 include default fingered transistors (e.g., P 0 A-P 0 D, N 0 A-N 0 D), respectively, that each correspond to the default transistors P 0 , N 0 included in the resistive element 104 of the programmable termination circuit 100 . Because the default transistors included in the programmable termination circuit 100 are large (e.g., wide), the default transistors P 0 , N 0 may be divided into a plurality separate transistors, each of which is 1/N the width of the default transistors P 0 , N 0 , where N is the number of transistors included in the plurality, and included in the scalable termination circuit 700 without approaching the design rule minimum required for optimal model accuracy.
[0059] The foregoing description discloses only the exemplary embodiments of the invention. Modifications of the above-disclosed embodiments of the present invention which fall within the scope of the invention will be readily apparent to those of ordinary skill in the art. For instance, while the present methods and apparatus disclose the use of fingered transistors that include a group of four transistors (e.g., P 0 A-P 0 D, N 0 A-N 0 D), in other embodiments the fingered transistors may include a larger or smaller group of transistors. Further, while the present methods and apparatus disclose providing control signals to seven PFET transistors P 1 -P 7 and seven NFET transistors N 1 -N 7 , in other embodiments, control signals may be provided to a larger or smaller number of transistors included in the first and second resistive elements 702 , 706 . Further, while in the above embodiments, a single math logic 714 provides modified control signals to the transistors P 1 -P 7 and N 1 -N 7 included in the second resistive element 706 , separate math logic may be employed to provide portions of the modified control signals to the transistors P 1 -P 7 , N 1 -N 7 , respectively. Although a first termination logic (e.g., the math logic 504 , 506 ) in the above embodiments was always enabled, in other embodiments the math logic 504 , 506 may be operatively coupled to and receive an enable signal that serves to activate the math logic 504 , 506 . Further, the above methods and apparatus may be implemented in a memory system. Although in the above embodiments, control signals, modified control signals, and modified secondary control signals are used to selectively activate or de-activate one or more stacked transistor pairs included in a resistive element, in other embodiments, such signals may be used to selectively activate or de-activate one or more individual transistors included in the resistive element.
[0060] Accordingly, while the present invention has been disclosed in connection with exemplary embodiments thereof, it should be understood that other embodiments may fall within the spirit and scope of the invention as defined by the following claims.
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In a first aspect, a first method is provided for providing multiple termination values using a plurality of binary termination signals. The first method includes the steps of (1) determining a characteristic impedance of a first port by generating a plurality of binary termination signals; and (2) modifying a characteristic impedance of a second port by manipulating one or more of the plurality of binary termination signals. Numerous other aspects are provided.
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This application is a Continuation In Part of application Ser. No. 07/730,089 filed Jul. 15, 1991.
BACKGROUND OF THE INVENTION
This invention relates generally to the separation of fluids of differing specific gravity with or without contaminates of solid particulate from fluid solutions. More particularly, this invention relates to removal of oil and particulate intermixed with water contained in a storage tank continually receiving water intermixed with oil and particulate of approximately minus 200 mesh with some minus 60 mesh coming from a ground pollution washplant operation. This required continual removal of pollution products from the water in the storage tank. A search for a device suitable to treat the polluted water reveled only costly, intricate apparatus prone to mechanical problems, maintenance problems, expensive filters to replace, etc. It appeared that the answer to the problem would be two separators, a centrifugal separator and a flotation separator. This was unacceptable. U.S. Pat. Nos. 4,175,040 and 4,534,860 describe centrifugal oil separators, one being complex and the other relatively simple. U.S. Pat. No. 4,534,862 describe apparatus for flotation and the mechanics of bubble and particle attachment. It is possible to separate oil and fine particulate from fluid solutions by flotation but typical apparatus is slow, large and cumbersome. Nothing suitable was found for the specific requirements necessary.
The invention uses no rotating apparatus or bearings within the cell, eliminating mechanical malfunction, is low cost, easily built, with no complex adjustments. A pump, preferably with a variable speed drive provides the power to operate the separator. The invention is not limited to any specific separation process. It is usable as a centrifugal separator alone or flotation separator using gas. Due to the simple design and capacity it is intended for use as a primary or head end separator. Others skilled in the art would find the invention useful in different applications in other fields of industry.
SUMMARY OF THE INVENTION
The subject of this invention is therefore an apparatus for separation of fluids and particulate from fluid solutions using centrifugal force with or without gas flotation. The object of the invention is to provide a separator with a minimal amount of moving parts minimizing mechanical malfunctions. Another object is to provide a separator with optional separation means having a minimal amount of adjustments and retain flexibility under different separating requirements and conditions.
DESCRIPTION OF THE DRAWINGS
Reference to FIGS. 1 and 2 will make the description of the invention more fully understood.
FIG. 1 is a cross sectional view,
FIG. 2 is a top view.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The use of the word "fluid" and "fluids" in the specification and claims is intended to have the same meaning as "liquid" or "liquid solutions" for descriptive and functional purposes.
The invention in drawings 1 and 2 is comprised of vertical elongated vessel 5 defining a cylinder, pump means to supply fluids into at least one input tube 14 attached adjacent the lower periphery of the vessel 5, entering horizontally at a tangent. The input tube diameter is reduced at the entrance to the vessel to gain vortical fluid velocity. More than one input tube can be used to obtain fluid velocity more efficiently, reducing the danger of forming emulsions. A nozzle with a sealing cap 21 is attached to input tube 14 for injection of gas or chemicals. The circular bottom plate 6 has an aperture in the center, an aperture adjacent the center aperture and an aperture adjacent the outer periphery. A launder 16 circumscribes the upper outer periphery of the elongated vessel 5 for collection of discharged high specific gravity fluids and high density particulate. Tangential outlet tubes could be used in place of a launder but they cause a turbulence at the tube around outer periphery, degrading performance of the separation. At least one conduit means 7, such as a flexible hose is attached to the launder 16 for transportation of the fluids and particulate to a desired place. A contaminate trap 17 with a drain plug is attached to the outer aperture in bottom plate 6. A vertically oriented annular discharge assembly is comprised of annular frame member 11, defining a annular cylinder, a vertically oriented guide rod 10 is attached in the center of the vertical axis of cylinder 11, the lower portion formed with an offset and fixedly attached onto the inner wall of frame member 11. Buoyant annular upper member 9 comprises two elongate cylinders, the inner cylinder being less in diameter than the outer cylinder, leaving a substantial annular space between the walls, the annular space is closed at the top bottom with flat plates cut to fit the annular space between the walls and fixedly attached airtight. Holes are drilled and tapped for pipe plugs 23 in the top and bottom flat plates between the inner and outer walls for adding or removing fluid from the annular space, forming an airtight annular space within the inner and outer walls of buoyant cylinder 9. This arrangement enables buoyant cylinder 9 to float in fluid mixtures and allows the specific gravity of buoyant cylinder 9 to be changed. The inner wall of cylinder 9 is made longer than the outer wall, leaving the inner wall projecting out past the outer wall some on one end, defining a buoyant annular double wall cylinder having a sealed annular space between the walls with an inner wall projection on one end. The inner wall of 9 has a plurality of short members 24 attached midway between the top and bottom to allow a loose fit with rod 10, restricting horizontal movement of 9, yet allowing 9 to have some tilt off the vertical axis should the separator move of vertical plumb, such as would occur if the separator were installed on a sea going vessel. The loose fit between 9 and 10 allows the separator to operate reliably during vertical angle changes of the vessel. Member 8 is an annular collapsible member, collapsible in the vertical axis, defining a circular bellows, and is attached to the upper outer periphery of annular cylinder 11 and the remaining end of annular collapsible member 8 is attached to the outer periphery of the projecting inner wall of buoyant annular cylinder 9. Annular cylinder 11 penetrates and is attached vertically to the center aperture of bottom plate 6 in the center of vertical axis of vessel 5, the vertical guide rod 10 restricts horizontal movement of the annular collapsible member 8 and buoyant annular cylinder 9. The discharge assembly is watertight around the outer periphery and annular the full length, the arrangement allows a vertical movement of cylinder 9 at least one third the height of vessel 5. Due to the buoyancy provided by the closed annular space within the inner and outer walls in cylinder 9, a vertical annular discharge assembly that is self adjusting in vertical height in accordance with the fluid level surrounding cylinder 9 is provided. There is a slight resistance to vertical movement of cylinder 9 presented by the bellows and cylinder 9 is made with more buoyancy than would be necessary and than weighted to the operating specific gravity, isolating it somewhat from the bellows resistance to movement. Vertical movement stability of 9 is aided by the weighting. The discharge assembly components are arranged and assembled to allow the upper end of cylinder 9 to reach slightly above the upper edge of vessel 5. A deep vortex can be formed during operation and the lower limit of travel of cylinder 9 is taken into consideration also. The minimum usable vertical travel of cylinder 9 should be at least one third the height of the vessel. In the event of operation stoppage or malfunction no liquid flow down the discharge assembly is possible. Some vortex is normally present during operation and in the event of stoppage or malfunction the fluid drops as the vortex subsides and no fluid flow is possible at the outer discharge launder 16.
The discharge assembly is somewhat synergistic in the fact that it is self leveling in fluids and can also self discharge low specific gravity fluids being separated from high specific gravity fluids because the specific gravity of cylinder 9 can be adjusted to approximately the point of equilibrium between the high and low specific gravity fluids wherein the top of cylinder 9 will float above the high specific gravity fluid and the top will sink below the surface of the low specific gravity fluid. For example; in the separation of oil from water the buoyant cylinder 9 would be adjusted by weighting with fluid thru plug 23 hole for the top to float an inch or two of its height above the water, the fluid velocity is adjusted to have a vortex form, as oil starts to build up in the vortex the oil does not displace any significant amount of area of cylinder 9 and due to the lower specific gravity the oil will not float cylinder 9 upwards at the same rate as the water would and cylinder 9 does not float any significant amount higher, consequently after a certain amount of oil buildup in the vortex surrounding annular cylinder 9 the oil reaches the top of cylinder 9 and flows over the top and into the annular discharge assembly and out of the vessel. No gas charging of the fluids or foam flotation is necessary, the oil will self discharge out of separator thru the central discharge assembly. The only requirement is that some vortex be used, there will always be some oil remaining in the vortex. This particular advantage of the discharge assembly being able to self discharge lighter fluids allows the separator to be used as a stand alone centrifugal separator for fluids of differing specific gravity without the use of flotation. Separation at high oil to water ratios, high volume with respect to vessel size can be accomplished, such as needed in oil spill cleanup. For flotation use of the separator an air or gas eductor arrangement (not shown in the drawings) can be used with the tangential inlet tube for charging the fluids with gas, an old method well known those skilled in the art and requiring no further explanation. A conduit 12 is attached to the lower end of frame member 11 for transportation of separated foam and fluids coming down the discharge assembly from within the elongate vessel, the other end of conduit 12 is connected to the intake of a centrifugal air blower 19. The outlet of blower 19 has a filter holder for plastic or stainless steel strand filter or cellular filter attached to the air outlet. The blower 19 is the removal means for the foam from within the vessel and the filter helps to break down and dehydrate the foam. If a centrifugal pump is used for pump 1 it can be modified for air or gas sparging by removal of the bowl surrounding the impellers and all the impeller drilled with holes thru the flat portion near the outer end uniformly to retain balance. This is not shown in the drawings, those skilled in the art know the construction of pumps, the size and amount of the holes are optional, but in a five horsepower closed impeller water pump about five one sixteenth inch holes per blade thru the flat part is all that is required, pumps differ in rpm, number of impellers, diameter, head design, ect., and one must use their own judgment on the holes. The holes cause increased slip when air is admitted into into the pump and consequently decreases efficiency of the pump 1 somewhat and also causes some internal turbulence that decreases the efficiency somewhat more. The loss of efficiency is offset by gaining an efficient small bubble-fluid dispersion apparatus necessary in flotation separation. There is little noticeable internal turbulence or loss in efficiency when no air is used. The capacity of the pump 1 is taken into consideration due to the foregoing factors. The modified pump would be useful for particle separation and some immiscible liquid solutions. A low turbulence pump must be used for fluid separations if a danger of mixing or forming an emulsion exist. The pump 1 is powered with a variable speed drive 18 to adjust operating conditions. The pressure outlet port of pump 1 is attached to input tube 14. An adjustable intake flow control valve is attached to pump 1 intake port. The pump 1 intake port also has plurality of spring loaded, self closing, self aspiration valves 3 attached, the valves provided with sealing caps, providing a means for admittance of air or gas when needed or all valves 3 capped off when no air or gas is needed. An intake tube 13 is attached to intake flow control valve 15. A nozzle 22 with a sealing cap is attached to intake tube 13, providing a point for admittance of gas or chemicals. Valve 15 controls fluid supply to pump 1 intake port, and controls suction at pump 1 intake port, thereby effecting operation of valves 3 when they are in use. A recirculation tube 2 is attached and penetrates the remaining aperture in the bottom plate 6, extending vertically into the elongate cylinder 5 a short distance from the bottom adjacent to the cylinder frame member 11. The other end of recirculation tube 2 is attached to adjustable valve 4. Valve 4 is also attached to pump 1 intake port. Various plumbing fittings are required. Recirculation of the solution is normally necessary or there would be an excessive amount of solution flow thru the separator and little time for adequate separation to occur. Valve 4 controls the amount of recirculation flow of fluid solution and also effects the centrifugal force developed, the depth of the vortex and the amount of solution processed in a given time. Adjustment of valve 15 and variable drive 18 cooperates with valve 4 to achieve the desired operating conditions. At start up of operation the weight of buoyant cylinder 9 is adjusted until about one or two inches of the top of 9 floats above the highest specific gravity fluid in the vessel, valves 3 should be capped off, variable drive 18 at low speed, valve 4 open more than valve 15 to let the solution build up gradually, adjusting variable drive 18, valves 4 and 15 until a vortex forms, continuing adjustments until desired results are obtained. During flotation separation normally only a small amount of foam is necessary for satisfactory separation. Many contaminants in solutions will foam without gas, if not gas is admitted thru valves 3. Nozzles 21 and 22 normally capped off can be used for admittance of gas or chemicals such as flotation foaming agents, foam suppressing agents or flocking agents.
The foregoing description of the preferred embodiment of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Other modifications and variations are possible in light of the above teaching. Some other embodiments will be suggested that have merit and should be considered.
An optional foam skimmer blade can be made for flotation. The blade is flat, light weight material, easy to form and has a long slot on one end, attached to a bracket that also has a slot, and a pin engages the two slots, together forming a sliding pivot hinged arrangement. The other end of blade is curved on the bottom edge to conform as well as possible with the annular opening of buoyant cylinder and be able to follow the vertical movement of the buoyant cylinder, the bracket attaches to the top of launder. The rotation of the fluid causes the foam to rotate also and the blade deflects the foam into the cylinder.
A top cover for the vessel could be made from a round flat plate slightly larger in diameter than the vessel, attached with brackets to the side wall, leaving about a one half inch gap between the cover and the top outer periphery of the vessel. The cover would be particularly usefull for a seagoing vessel installation.
An adapter with a plurality of spiral grooves circumscribing the upper outer periphery and extending over the top to the inner wall could be made that fits over the top of buoyant cylinder 9 of the discharge assembly, the groves being in the direction and angle that would enable rotating fluids to climb up and over the top and flow down the inside of buoyant cylinder 9. The adapter would enable separation of substantially all the low specific gravity fluids remaining in the vortex without the use of foam or flotation and could be made for fast installation and removal.
An anulus made of flat plate circumscribing the upper inner periphery of elongate cylinder 5 reducing the inner diameter of the elongate cylinder 5 would enable increasing fluid velocity, thus increasing centrifugal force of the fluid, possibly obtaining more complete separation, however the lip would be a barrier for heavier solids rotating around the inner wall, unable to exit the separator and a buildup of solids would occur, therefore no solutions containing solids could be processed. If the anulus angled upwards toward the inner diameter the solids could exit.
Another embodiment is a conical shape elongate cylinder 5 that would enable solutions containing a high volume of heavy solids to flow over the outer edge due to centrifugal force. An anulus reducing the inner diameter with a steep upward angle toward the inner diameter could be useful in restricting the solids somewhat slowing their exit and allowing more separating time should they be contaminated with oil or other contaminates.
Using a frusto-conical shape elongate cylinder 5 allows lower fluid inlet velocity and retains the ability to form a deep vortex due to the increasing fluid velocity as the fluid moves upward into a decreasing diameter cylinder. This shape would allow fluids prone to emulsion or mixing to be pumped at a lower velocity and may be the best shape vessel for separating oil and water or other combinations of fluids. Recirculation of part of the separated discharged fluid from the launder 16 could be arranged by adding a conduit and valve between the the recirculation tube and the receiving point of the fluids that have been discharged into the launder allowing selection of fluid in the recirculation circuit. This would benefit the separation percentages of fluids and be of particular value if used with a frusto-conical shape vessel. Reducing the recirculation fluid flow from within the vessel correspondingly reduces the depth of vortex formed in a cylindrical vessel so recirculation of discharged fluid would work well with a frusto-conical shape vessel that forms a vortex easily.
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A highly versatile fluids and particulate separator that can be used in a centrifugal mode or centrifugal with gas flotation mode without the use of rotating apparatus within the cell. A pump and recirculation system provide the means for centrifugal force and gas flotation. A buoyant self adjusting discharge assembly with a vortex of fluids surrounding it provide the exit path for separated light fluids and light particles. In oil and water separation the buoyant assembly allows self discharge of the oil and can be used with high oil to water ratios at high volume. Oil spill cleanup is possible. Conversely gas flotation may be used for low volume separating applications.
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This is a continuation-in-part of application Ser. No. 788,246, filed Oct. 17, 1985, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to methods for producing health drinks from clay, and more particularly, to methods for producing highly alkaline drinks for improving and keeping health, wherein the material is obtained from clay.
2. Description of Prior Art
Generally various kinds of health foods and drink are becoming popular, and available in the market. In the case of an alkaline drink it is obtained from springs or wells as a natural water. Sometimes it is condensed at the producer's factory. However, the obtained alkaline drink has a low alkalinity. Unless people take it for a long time, it will not be effective to serve the purposes, such as health-keeping and beauty-keeping.
The inventor has been engaged in ceramic art for a long time, and familiarized himself with clay and ceramic. He has a vast knowledge of clay. Accidentally he has invented a method of producing a drinking water containing a high percentage of alkali with the use of clay, which is routine and common to him.
SUMMARY OF THE INVENTION
An object of the present invention is to provide methods for producing highly alkaline drinks at reduced costs, and with a simple facility.
Other objects and advantages of the present invention will become more apparent from the following description.
According to one aspect of the present invention, there is provided a method for producing a highly alkaline drink, the method comprising:
forming a heat-proof clay mass;
applying a mud to the mass;
allowing the mud-covering mass to dry;
heating the muddy mass at a temperature of not lower than 750° C.;
placing the heating mass into contact with charcoal or wood so that at least part of it is incinerated;
submerging the heated mass in water before it cools below 500° C.; and
removing the mass and floating pieces from the water.
According to another aspect of the present invention, there is provided a method for producing highly alkaline drink, the method comprising:
heating clay placed in contact with charcoal ar wood at a temperature of not lower than 750° C. so that at least part of the charcoal or wood is incinerated;
submerging the heated clay in water before it cools below 500° C.; and
removing solid pieces from the water.
DETAILED DESCRIPTION OF THE INVENTION
For the clay usable for the present invention, the clay for making pottery can be effectively used. In general the clay for this use is divided into two types: a primary clay and a secondary clay. The primary clay is obtained near the country rock, and the secondary clay is obtained from deposits occurring naturally as a result of flowing primary clay, away from the country rock. The secondary clay often contains organic matter, such as carbonized plants, and ferric oxide, because of the latter content the clay looking red. This accounts for its name of red clay. There is another type of clay, commonly called gairome clay, which is an intermediate between the primary clay and the secondary clay. The above-mentioned three kinds of clay can be selectively used for the present invention. Table (1) shows the chemical compositions of clay in general use for pottery.
In this specification the clay includes a primary clay, such as kaolin, a secondary clay, such as red clay, and intermediates therebetween. It has been found out that red clay is more effective than any other.
Clay can be obtained from place to place in the country, but the qualitative analysis has ascertained that red clay contains not only iron oxides but also mica, montomorillonite, and other similar adsorptive minerals. In particular, the primary and secondary clays utilized in the present invention may be one of the various clays found in and around Kyoto, Japan; however, any clay from any location may be utilized from any source so long as it meets the criteria described above and is not contaminated with toxic substances such as herbicides, insecticides, radioactive material, cyan, mercury, lead, arsenic, etc.
The heat-proof clay mass mentioned above is obtained by molding kibushi clay (containing clay containing carbonized plant), porcelian or ceramic in such shapes as to allow heat to pass therethrough when the masses are piled in a stack in the furnace, and to have a vast surfacial area and stability when they are overlaid.
The clay mass is heated at a temperature of not lower than 750° C. This is because if it is heated below 750° C., the resulting ash content will fail to be attached to the surface of clay. A preferred range is 800° C. to 1000° C. As a result of the repeated experiments this range has been selected, because when the mass is heated at 800° C. or more, the ash content is well attached to the clay in a short time. However, it is impractical to heat it at more than 1000° C. when the furnace is a small, handy type. The fuel efficiency will be reduced.
In addition, charcoal and wooden pieces are often referred to in this specification. The charcoal and the wooden piece are obtained from an oak tree, a cherry tree, a cypress tree, kunugi (a kind of oak) or any other kinds of deciduous trees suitable for producing charcoal. However, the source of the charcoal and wooden pieces is not limited thereto. The ashes mentioned in this specification are obtained by burning trees, and they exclude the ashes obtained by burning grasses or straws.
The invention will be more particularly described by way of example.
EXAMPLE (1)
Clay used for pottery was molded in a cylinder having an outside diameter of 110 cm, an inside diameter of 80 cm and a height of 50 cm, and allowed to dry for 2 days. Commercial red clay was made muddy by adding water at the ratio of 1.9 kg of water to 1.0 kg of clay. The cylindrical clay mass was wholly covered with the muddy red clay by means of a brush. The mud film had a thickness of about 1 mm. The mud-covered clay mass was allowed to dry in the room for 24 hours. In this way 100 pieces of masses were produced. The mud-covered clay masses were piled in a stack in an electric furnace, and heated for about 5 hours. When their surfacial temperatures reached about 850° C., 5 kg of pine charcoal was placed on contact with the individual clay masses. After about 10 minutes when the charcoal became red, 50 pieces were taken out one after another, and put into water in a vessel. The water had had a room temperature, and its amount was 15 liters. When all of them were put, the temperature of the water reached 100° C., that is, the boiling point. The other 50 pieces were put in another vessel, and left for about an hour as they were. When the temperature of the water lowered to 40° C. to 50° C., the clay masses were picked up from the vessel. The water in the vessel contained grey floating matter, and looked milky-white. The water was roughly filtered by means of cotton cloth, and then filtered by means of cotton cloth, and then filtered by means of a nylon mat. The filters were highly alkaline.
The filtrate was clearly transparent with no color or visible floating matter through a transparent container.
EXAMPLE (2)
Instead of the red clay in Example (1) white clay was used, which had the chemical composition shown in Table (5). The other conditions were the same as those in Example (1).
The filtrate had no visible floating matter, and the taste was not different from that of the water of Example (1).
EXAMPLE (3)
Instead of the pine charcoal in Example (1), 5 kg of a pine piece was used, and the heating temperature was raised to about 900° C. Ten minutes after the wood pieces are burnt to ashes, the clay masses were taken out of the furnace. The other conditions were the same as those for Example (1).
The obtained water was clear enough to observe no floating matter therein, and tasted as pure water does.
EXAMPLE (4)
Charcoal was pulverized to grain-sizes ranging from 3 mm to 5 mm, and the same red clay as the one used in Example 1 was combined with the pulverized charcoal at the ratio of 10 (clay) to 2 (charcoal) by weight. The mixture was heated at about 800° C. The other conditions were the same as those for Example (1).
The obtained water was clear enough to observe no visible floating matter therein, such as ashes, and tasted as pure water does.
Table (3) shows the pH value, ash content, and iodide ions of the water obtained from each of the Examples (1) to (4). The analysis of the ash content was conducted by vaporizing the specimen on a tray so as to solidify thereon, heating it at 600° C. in an electric furnace for three hours, and measuring the weight of the residue. The quantity of the ash content after filtration was analyzed through the measurement of the ash content remaining on a filter paper with pore diameter of 7 microns.
Table (4) shows the results of qualitative analysis with respect to the metal contents for the water obtained from each example. The metal content has been identified by luminous analyses.
The water obtained under the present invention has no color (transparent), odor or taste. As shown in Tables (3), (4) and (5), the water exhibits a high alkalinity with high pH values, and contains an ash content in addition to small portions of Na, Si and Mg. It has been also ascertained that very small portions of Fe and Al are respectively contained.
Table (5) shows the results of quantitative analysis of Na, Cl, Si and Mg contained in the water produced under the present invention.
Table (1) shows the chemical composition of clay generally known as "clay for pottery", which data was obtained by analyzed four specimens.
In contrast to Table (1), Table (2) shows the chemical composition of the clay used for carrying out the present invention, which data was obtained by analyzing two specimens.
TABLE (1)______________________________________ Spc. (1) Spc. (2) Spc. (3) Spc. (4)Chemical Composition % % % %______________________________________Silica (SiO.sub.2) 47.8 49.5 48.1 50.0Alumina (Al.sub.2 O.sub.3) 36.1 34.4 34.8 33.9Ferric Oxide 0.4 1.3 1.0 1.3(Fe.sub.2 O.sub.3)Calcium Oxide 1.8 0.5 0.5 0.5(CaO)Magnesia (MgO) 1.0 0.3 0.4 0.1Potassium Oxide 0.5 0.6 0.9 0.8(K.sub.2 O)Sodium Oxide 0.2 0.6 0.2 0.2(Na.sub.2 O)Weight Loss 12.4 12.9 14.3 16.1(1 g loss)______________________________________ [Note]- `Spc.` stands for speciman. Spc. (1) was obtained from a primary clay (kaolin). Spc.(2) was obtained from an intermediate (commonly called gairome clay). Spc. (3) and Spc. (4) were obtained from a secondary clay (kibushi clay).
TABLE (2)______________________________________ Spc. (1) Spc. (2)Chemical Composition % %______________________________________Silica (SiO.sub.2) 60.37 77.53Alumina (Al.sub.2 O.sub.3) 18.76 13.82Titan (TiO.sub.2) 0.90 0.34Ferric Oxide (Fe.sub.2 O.sub.3) 9.60 0.60Calcium Oxide (CaO) 0.34 0.23Magnesia (MgO) 0.73 0.32Potassium Oxide (K.sub.2 O) 1.75 2.33Sodium Oxide (Na.sub.2 O) 0.16 0.20Weight Loss (1 g loss) 7.34 4.36______________________________________ [(Note]- `Spc.` stands for speciman, and Spc.(1) is the red clay which was used in Examples (1), (3) and (4). Spc. (2) is white clay which was used in Example (2).
TABLE (3)______________________________________ Ash Content Ash ContentItems (unfiltered) (filtered) Iodide IonsSpecimens pH (mg/l) (mg/l) (mg/l)______________________________________Spc. 1 10.6 81 78 0.5 or belowSpc. 2 8.2 75 70 0.5 or belowSpc. 3 10.1 81 75 0.5 or belowSpc. 4 9.5 76 68 0.5 or below______________________________________ [Note]- The Spc. stands for a specimen, and the Spcs. (1) to (4) were obtained from Examples (1) to (4), respectively.
TABLE (4)______________________________________Fe Al Ca Cu Na K Ba Si Mg B______________________________________Spc. 1 tr ++ +++ - + - - + + -Spc. 2 tr tr +++ - + - - + + -Spc. 3 tr tr +++ - ++ - - ++ + -Spc. 4 tr + +++ - + - - + + -______________________________________ [Note]- The Spc. stands for a specimen, and the Spcs. (1) to (4) were obtained from Examples (1) to (4), respectively. The sign - shows that no element was identified, the sign tr shows that a trace of presence was observed, and the sign + shows that a small amount was detected. The sign ++ shows that the detected amount was more than that of the sign +. Likewise, the sign +++ shows that the detected amount was more than that of the sign ++. The absolute amount of each sign +, ++ and +++ is different with each element.
TABLE (5)______________________________________Contents Spc. (1) Spc. (2) Spc. (3) Spc. (4)______________________________________Na (mg/l) 5.9 5.9 5.4 5.8Ca (mg/l) 16 11 14 11Si (mg/l) 7.2 5.9 6.8 6.6Mg (mg/l) 95 79 83 59______________________________________ [Note]- Spc. stands for a specimen. and Spcs. (1) to (4) were obtained from Examples (1) to (4), respectively.
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A method for producing a highly alkaline drink, comprising the steps of forming a heat-proof clay mass, applying a muddy clay to the clay mass, allowing the mud-covered clay mass to dry, heating the muddy clay mass at a temperature of not lower than 750° C., placing charcoal or wood into contact with the heating clay mass so that at least part of the charcoal or wood is incinerated, submerging the heated clay mass in the water in a vessel before the heated clay mass cools down below 500° C., and removing the clay mass and floating matter from the water.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of patent application Ser. No. 09/226,284, entitled “Soffit Installation Apparatus”, filed on Jan. 7, 1999, and the specification thereof is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention is an apparatus to aid with the installation of soffit beneath the eaves of buildings.
[0003] Buildings, particularly residential homes, often have eaves or a projecting edge. The outermost edge of the eave typically has a brief vertical section that is referred to as fascia. The under portion of the eave occasionally remains open, exposing the joist and rails of the trusses. More commonly, these areas are covered with a planar material such as plywood. This material is generally attached to a horizontal or nearly horizontal member of the support structure on the underside of the eave. If the described area is covered then the covering is usually referred to as “soffit.”
[0004] Due to the location of the work to be done to install a soffit, and the time of the installation, this work is labor intensive (commonly requiring 2-3 workers), and can be hazardous for the worker(s).
[0005] U.S. Pat. No. 5,459,967 to Bodthker shows an adjustable support structure used to support various types of roofs.
[0006] U.S. Pat. No. 4,309,857 to Lovering discloses a soffit support structure used to support structure incorporating parallel spaced vertical props connected by a horizontal member, with the props having heads thereon for supporting a short beam for supporting the soffit.
[0007] The patents to Bodthker and Lovering reveal that a need still remains for a tool that reduces the labor, improves the efficiency, and economy of soffit installation. The invention presented here meets that need.
BRIEF SUMMARY OF THE INVENTION
[0008] An object of the present invention is to provide a soffit installation apparatus that improves the efficiency, economy, and safety of soffit installation beneath eaves.
[0009] The present invention is temporarily secured to the roof and or fascia of the eave and includes elements which permit a segment of soffit material to be swung into position horizontally immediately beneath the eave, and held in position while permanent attachment of the soffit is performed.
[0010] Advantages of this invention include simplicity and ease in use, operation by a single user, adaptability to related functions in the art of soffit installation, and economy of manufacture. The invention is easy to use by those skilled in the art of installing soffit and can be easily learned by those new to the art of soffit installation.
[0011] Other objects, advantages and novel features, and further scope of applicability of the present invention will be set forth in part in the detailed description to follow, taken in conjunction with the accompanying drawings, and in part will become apparent to those skilled in the art upon examination of the following, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The accompanying drawings, which are incorporated into and form a part of the specification, illustrate several embodiments of the present invention and, together with the description, serve to explain the principles of the invention. The drawings are only for the purpose of illustrating a preferred embodiment of the invention and are not to be construed as limiting the invention. In the drawings:
[0013] [0013]FIG. 1 is an exploded side view of a preferred embodiment of the apparatus of the invention.
[0014] [0014]FIG. 2 is a right side view of the apparatus depicted in FIG. 1, showing the apparatus assembled for use.
[0015] [0015]FIG. 3 is an elevation view of an alternative embodiment of the apparatus of the invention, shown in use position upon the eave of a building.
[0016] [0016]FIG. 4 is an elevation view of the preferred embodiment seen in FIG. 2, in preliminary position partially disposed upon an eave of a building.
[0017] [0017]FIG. 5 is an elevation view of the embodiment seen in FIG. 4, depicting the apparatus fully attached to the building eave, and showing a portion of a soffit material in place upon the apparatus.
[0018] [0018]FIG. 6 is an elevation view of the apparatus seen in FIG. 5, shown later in time with the swing arm bearing the soffit material pivoted into position below the eave.
[0019] [0019]FIG. 7 is an elevation view of the apparatus seen in FIG. 6, shown later in time with the swing arm bearing the soffit material pivoted into position below the eave, and illustrating how the soffit material may be lifted off the swing arm for positioning to be attached to the eave.
[0020] [0020]FIG. 8 is an elevation view of the apparatus seen in FIG. 7, shown later in time with the swing arm bearing the soffit material pivoted into position below the eave, and illustrating the soffit attached to the eave.
[0021] [0021]FIGS. 2 and 4- 8 show the components used to attach the optional clamp arm. To use the invention without the clamp arm, certain of the illustrated components are removed and a single screw is used as seen in FIG. 3.
DETAILED DESCRIPTION OF THE INVENTION
[0022] The apparatus of the invention may take several forms and embodiments, and this disclosure includes descriptions of two of those embodiments. The function is generally the same for all alternative embodiments and can be assumed to be the same except as to the differences particularly noted.
[0023] A broad description of the apparatus is made with reference to FIGS. 1 - 3 : The apparatus is made of four main elements with a fifth element that is optional. The first element is the standoff 40 which is used in either of the embodiments described herein to temporarily fasten the apparatus. The second element is the main body 10 which aligns nearly parallel to the sub-fascia 21 . The third main element is a swing arm 12 which allows the soffit material 23 to be placed for lifting into position for final installation. The fourth main element is a lock arm 14 that temporarily locks the swing arm into position while the soffit material 23 is affixed to the structure, as suggested in FIG. 3. A fifth element, a clamp arm 16 , may be used (if preferred). Clamp arm 16 aligns to the roofline 25 and hooks to a batten 27 previously temporarily installed by the roofer.
[0024] Standoff Assembly Detail:
[0025] A. Movably attached to the main body 10 is a standoff 40 . Standoff 40 allows the main body 10 to remain nearly parallel to the sub-fascia 21 with no interference from the roof decking material 25 or other parts that may protrude outward beyond the sub-fascia 21 , thereby preventing the desired alignment of the main body 10 .
[0026] B. The upper part of the standoff 40 has a hole 42 therein for attaching the clamp arm 16 to the standoff. A pin 43 on standoff 40 mounts through a corresponding hole the main body 10 .
[0027] C. A boss 46 , integral to the standoff 40 , defines a coaxial hole 47 passing there through.
[0028] D. Other components of the standoff assembly are a release cam 36 , a spring 38 , and a spring retainer 50 . The standoff assembly has two alternative embodiments: the first is for use with the optional clamp arm 16 ; the other is for use when the clamp arm 16 is not employed.
[0029] E. If the clamp arm 16 is not used, a lag screw 80 (see FIG. 3) passes through the hole 47 to attach the main body 10 to the sub-fascia 21 . If the clamp arm 16 is used, then a spring 38 is placed over the boss 46 , and the spring retainer 50 is passed through the spring 38 and the hole 47 , and is pivotally anchored to a cam lever 36 on the far side of the main body 10 .
[0030] F. The purpose of the spring 38 is to maintain tension or force against the standoff 40 and the spring retainer 50 , in turn applying pressure to the sub-fascia 21 and the hook 60 on the clamp arm 16 . When the cam lever 36 is activated, the spring 38 is compressed and the forces against the sub-fascia 21 and the hook 60 on the clamp arm 16 are removed, allowing the operator to easily release the hook 60 from the batten 27 .
[0031] Main Body Detail:
[0032] The main body 10 may be comprised of a “U” or “L” shaped material so long as there are at least two surfaces that are perpendicular to one another and form an outside corner or corners.
[0033] The main body holes 54 are positioned such that the pin 43 on the standoff 40 goes into an upper one of the holes 54 and a lag screw or the spring retainer is passed through a second lower one of the holes 54 . Holes 54 are provided at uniformly spaced intervals along the main body 10 to allow adjustment for varying sub-fascia depths for proper operation and positioning of the swing arm 12 . Below the bottom one of the adjusting holes 54 in the main body 10 , a pin 56 is on the main body 10 for the mounting of the swing arm 12 . Below the swing arm pin 56 another pin 58 is on the main body 10 for the attachment of the locking arm 14 .
[0034] The main body 10 and the standoff 40 may be connected directly to the sub-fascia 21 via a lag or similar type screw or bolt 80 (FIG. 3). The use of a lag screw to attach the main body 10 to the subfascia 21 eliminates the need for the optional clamp arm 16 , the spring 38 , the retainer 50 and the cam lever 36 . The main body 10 is an elongated shaft or strut to allow for the various depths of sub-fascia 21 that may be encountered.
[0035] Swing Arm Detail:
[0036] The swing arm 12 is sufficiently long to allow for soffit material that is up to 24 inches in width. On one end of the arm 12 there is a stop 62 upon which the soffit material 23 rests. For the swing arm 12 to be adjustable, a plurality of adjusting holes 64 are provided at uniform intervals along the swing arm, as seen in FIG. 1. The holes 64 are for the pivotal attachment of the swing arm 12 to the main body 10 and to the lock arm 14 . Depending upon the width of the soffit material 23 being installed, the appropriate holes 64 are selected for assembly from job to job. The holes 64 start from the end of the swing arm having the stop 62 and are spaced toward the end away from the stop, and there are, for example, 25 adjusting holes 64 . The adjustable connections between the main body 10 , the locking arm 14 and the swing arm 12 allows adjustment for soffit material widths from 12 to 24 inches.
[0037] Locking Arm Detail:
[0038] The locking arm 14 has a pivot pin 66 at one end. Proximate to the opposite end of the locking arm 14 is a sideways “J” slot 68 having a short leg nearly perpendicular to the long axis of the locking arm.
[0039] Clamp Arm Detail:
[0040] The clamp arm 16 is an optional element, and is described here as an element of a preferred embodiment of the invention. On the distal end is provided an adjusting screw 70 with a hook 60 attached. The hook 60 adjusts as it follows the threads of the adjusting screw as the adjusting screw is manually turned at the knob 71 . This allows for the adjustment of the position of the hook 60 along the clamp arm 16 to accommodate the varying positions of batten 27 . On the other end of the clamp arm 16 there is provided a threaded pin 72 and lock nut for pivotal mounting to the top of the standoff 40 , to accommodate varying roof slopes.
[0041] Assembly:
[0042] The swing arm 12 and the locking arm 14 are pivotally connected via a hole 64 , a pin 66 and a retainer pin. The swing arm 12 is pivotally attached to the lower portion of the main body 10 via a hole 64 , a projecting pin 56 and a retainer pin (such as a cotter pin, inserted laterally through the pin 56 ). Swing arm 12 is mounted via holes 64 so as to support varying widths of the soffit material 23 . The locking arm 14 is pivotally attached to the main body 10 via the J-slot 68 , a pin 58 and a retainer pin.
[0043] The pin 43 on the standoff 40 is aligned to the desired one of the holes 54 in the main body 10 for the depth of the sub-fascia to be worked with, and the standoff 40 is attached to the main body 10 with a retainer pin (e.g., a cotter pin).
[0044] If the clamp arm 16 is to be used, it is pivotally attached at the hole 42 in the standoff 40 using threaded pin 72 and a lock nut, so that while the apparatus is in use, the main body 10 maintains a position parallel to the sub-fascia. When the clamp arm 16 is used, the spring 38 is placed over the boss 46 and the spring retainer 50 is passed through the spring 38 and the hole 47 in the boss 46 and through one of the holes 54 of the main body 10 ; the cam lever 36 is then pivotally anchored to the spring retainer 50 with a retainer pin such as a cotter pin.
[0045] Using The Apparatus:
[0046] Once the assembly has been completed for the desired soffit material width, and the depth of the sub-fascia, the apparatus is attached to the sub-fascia. Positioning of the apparatus is such that it is about the center of where the soffit material will be installed. If the clamping arm 16 is used, the hook 60 is placed over the temporary batten 27 , and the apparatus is allowed to hang free. The cam lever 36 is rotated to release the spring 38 and the spring retainer 50 engages the sub-fascia 21 . The hook 60 sinks into the batten 27 and the apparatus is ready to be loaded.
[0047] Initially, the locking arm 14 should not be in the locked position, and the swing arm 12 should be hanging down from the eave (FIG. 4). The soffit material 23 is loaded such that the length of the material 23 is about centered on the stop 62 on the swing arm 12 . The soffit material 23 is rotated toward the eave until the short leg of the J-slot 68 drops over pin 58 of the main body 10 . The soffit material 23 thus is swung in position for final attachment to the structure, as seen in FIGS. 5 - 8 . Once the soffit material 23 has been installed the apparatus can be moved to the next location.
[0048] The practice of the invention may now be described. Broadly summarized, the use of the apparatus begins by pivoting the swing arm 12 into an open position (FIGS. 3, 4). The apparatus is temporarily attached to the subfascia 21 , and the segment of soffit 23 is placed in a balanced position upon the swing arm 12 (as suggested in FIG. 5). With a single smooth motion (as the J-slot 68 in the lock arm 14 slides along the main body 10 on pivot pin 58 ), the outside or proximate end of the swing arm 12 is pulled down, levering the distal end of the swing arm upward as the swing arm pivots about its connection with the main body 10 . When the J-slot 68 slides on pin 58 to the short leg of the slot, it drops into place to lock the lock arm 14 against further movement. The lock arm 14 , swing arm 12 and main body 10 thus are locked into a triangular configuration, with the swing arm 12 bearing the soffit material 23 having achieved a generally horizontal position (as suggested in FIG. 6). The soffit material 23 is within about ½ inch from the nail rail on the framed wall of the structure. The apparatus holds the soffit 23 in a generally horizontal position while the user manipulates the soffit into final position and nails both ends in place (FIGS. 7 and 8), and then proceeds to nail the entire soffit along its length into place. The apparatus maintains position until the user moves it to initiate installation of the next segment of soffit.
[0049] Further operational detail for the embodiment utilizing the spring-biasing function of the standoff assembly is provided by making combined reference to the drawing figures. There are four basic stages in using this embodiment of the apparatus. In the first stage, the apparatus is fastened to the subfascia 21 . In the second stage, the soffit 23 is placed on the swing arm 12 . Thirdly, the swing arm 12 is pivoted to raise the soffit 23 into place. In the final stage, the apparatus holds the soffit 23 steadily in place until the soffit is fastened to the framing.
[0050] Reference is made to FIG. 4. The first step is to place the clamp arm 16 along the roof 25 so that the hook 60 engages the batten 27 . The cam lever 36 is rotated and releases the spring 38 to apply pressure to the spring retainer 50 and in turn to the subfascia 21 . The bias of the spring 38 pushes the standoff 40 away from the subfascia 21 , thereby drawing the clamp arm 16 downward parallel with the roof 25 to hold the hook 60 securely against the batten 27 . The apparatus thus is clamped against the subfascia 21 and the batten 27 by the spring action transmitted by the clamp arm 16 , as suggested in FIG. 5. Continuing reference to FIG. 5, the soffit 23 is then placed in a reasonably balanced position upon the lower section of the swing arm 12 . The soffit material 23 can balance on the swing arm 12 , and be steadied by the user while the apparatus is actuated.
[0051] The top section of the swing arm 12 is then pulled downward. This causes the swing arm 12 to pivot about its fixed pivot pinned connection with the main body 10 , resulting in the raising of the lower section of the swing arm 12 which bears the soffit 23 . Referring to FIGS. 5 and 6, the raising of the lower section of the swing arm 12 thus swings the soffit 23 into a generally horizontal position for installation. The J-slot 68 in the lock arm 14 slides along the pivot pin connecting the lock arm 14 to the body, allowing the lock arm to translate as well as pivot with respect to the main body 10 while the swing arm 12 is rotating. Lock arm 14 and swing arm 12 also pivot about their mutually connecting pivot pin. When the short angled leg of the J-slot 68 reaches the end of its translational movement, it drops onto the main body pin 58 , which effectively locks the lock arm 14 in position with respect to the main body 10 and the swing arm 12 . Thus locked in place, the stable triangular configuration of the lock arm, swing arm and main body holds the swing arm and thus the soffit material 23 in horizontal installation position as seen in FIGS. 6 and 7. The soffit 23 rests upon the swing arm 12 , but may still need to be slidably positioned for nailed installation.
[0052] Combined reference is made to FIGS. 7 and 8. The user then lifts the soffit 23 the short distance up off the swing arm 12 and slides the soffit toward the wall. The soffit 23 can then be fastened to the nail rail and the subfascia 21 (or other framing elements) generally according to known methods. The apparatus may be removed from its temporary position upon the structure by rotating the cam lever 36 , thus compressing the spring 38 and allowing the hook 60 to be lifted and disengaged from the batten 27 . The apparatus may then be moved to a new location to begin a new installation cycle.
[0053] An alternative embodiment employs a standoff 40 that is temporarily screwed to the subfascia 21 to support the apparatus in place. The four basic stages of operation, as described herein above, are the same for this alternative embodiment, except that stage 1 is accomplished in a different manner to provide for more universal application. The overall general function and operation of the alternative embodiment thus is substantially similar to the previously described embodiment, and similar parts are utilized, except where hereafter noted.
[0054] Referring to FIG. 3, it is seen that in this alternative embodiment the apparatus is placed in the open position, with the lower section of the swing arm 12 hanging downward. The standoff 40 is pressed against the vertical face of the subfascia 21 . A power tool is employed to drive a screw 80 into the subfascia 21 , thereby temporarily securing the standoff 40 to the subfascia to maintain the apparatus in position for use. Once the soffit 23 is nailed or screwed into proper place, the swing arm 12 can be released by the user's unlocking the locking arm 14 . The swing arm 12 can then be rotated to lower its distal end. The power tool is then used to back the screw out of the subfascia 21 , and the apparatus is moved to a new location where the process is repeated.
[0055] A person of ordinary skill will note that by providing a series of holes 64 along a major portion of the length of the swing arm 12 and pins on locking arm 14 and main body 10 , and by utilizing removable pins to connect the arms and main body together, the apparatus can be adapted to meet various size needs by planned placement of the keeper pins in appropriate holes to assemble the apparatus.
[0056] The apparatus offers a safer means for hanging soffit. The apparatus requires only one individual to operate, thus eliminating the need for two people to be on a scaffolding or ladders at the same time. One person using the apparatus can thus perform the work previously performed by two persons. Moreover, the apparatus allows the job to be performed faster, because only one person has to position himself, and because the soffit is held steadily in place until the task of nailing is finished—thus eliminating the human errors that may occur when one person holds while another person nails.
[0057] The entire disclosures of all patents, and publications cited above are hereby incorporated by reference.
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An apparatus for installing soffit segments below the eaves of a building. A main body with a standoff is temporarily fastened to the sub-fascia. A swing arm and a locking arm are pivotally connected to each other and also to the main body, except that a J-shaped slot in the locking arm permits the locking arm to translate, as well as pivot, with respect to the main body. A segment of soffit material is placed upon the swing arm, and the swing arm is rotated about the pivot joint on the main body creating a lever action to lift the soffit material into a horizontal position immediately below the eave. The locking arm slot is notched to lock the locking arm and swing arm, into a fixed position. The apparatus thereby steadily maintains the soffit segment in position pending its permanent attachment to the underside of the eave. The apparatus is temporarily attached to the structure via a clamp arm or via screw into the sub-fascia.
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FIELD OF THE INVENTION
The present invention relates to a semiconductor fabrication technology; and, more particularly, to a semiconductor device having a heat release structure that uses a silicon-on-insulator (SOI) substrate, and a method for fabricating the semiconductor device.
DESCRIPTION OF RELATED ART
The operation of a semiconductor device inevitably generates heat. Semiconductor devices that consume much electric power, such as power devices and high-frequency devices, generate a lot of heat when they are operated. The heat not only degrades the performance of the semiconductor devices, but also has a negative effect on the other neighboring circuits.
The heat is originated from the resistance component inside the semiconductor devices. To reduce the heat generation, the wires and contacts should be formed of low-resistant materials. However, this idea has a limit in suppressing the heat generation due to the limit in designing and processing.
Conventionally, a heat-releasing plate is attached to the rear surface of a substrate in the lower part of an integrated circuit (IC), when a semiconductor device is packaged.
FIG. 1 is a cross-sectional view showing a conventional semiconductor device having a heat release structure. Referring to FIG. 1, the conventional semiconductor device having a heat-releasing structure includes: a silicon-on-insulator (SOI) substrate 10 formed of a bottom silicon substrate 11 , a buried oxide 12 and a top silicon layer 13 ; an IC 14 formed on the top silicon layer 13 of the SOI substrate 10 ; and a gold-plated material layer 15 on the rear surface of the bottom silicon substrate 11 .
Here, if the thickness of the bottom silicon substrate 11 is maintained by the thickness of a wafer, the heat-releasing effect is deteriorated. So, the rear surface of the bottom silicon substrate 11 is polished to be thin and gold-plated.
Meanwhile, although FIG. 1 shows an example where the IC 14 is formed on the SOI substrate 10 , the processes of polishing the rear surface and gold plating can be applied to a case where the IC is formed on a bulk silicon substrate, too.
However, No matter what silicon substrate is used, i.e., bulk silicon substrates and SOI substrates alike, the conventional method deteriorates the heat-releasing efficiency, because the substrate itself releases the heat. Particularly, when the SOI substrate 10 is used, the heat-releasing efficiency drops more due to the low heat conductivity of a buried oxide 12 , compared to when the bulk silicon substrate is used.
SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to provide a semiconductor device having a heat-releasing structure with high heat-releasing efficiency, and a method for fabricating the semiconductor device.
In accordance with an aspect of the present invention, there is provided a semiconductor device, comprising: a silicon-on-insulator (SOI) substrate including a bottom silicon substrate, a buried insulation layer, and a top silicon layer; an integrated circuit formed on the top silicon layer of the SOI substrate; and a tunneling region formed between the bottom silicon substrate and the top silicon layer, which are under the integrated circuit.
In accordance with another aspect of the present invention, there is provided a method for fabricating a semiconductor device, comprising the steps of: preparing an SOI substrate including a bottom silicon substrate, a buried insulation layer and a top silicon layer; forming an integrated circuit on the top silicon layer of the SOI substrate; and forming a tunneling region between the bottom silicon substrate and the top silicon layer, which are under the integrated circuit.
The semiconductor device fabrication method of the present invention forms an integrated circuit (IC) on a silicon-on-insulator (SOI) substrate, and forms a tunneling region by removing the buried insulation layer in the lower part of the IC to thereby release the heat and high-frequency noise generated in the IC to the outside of the substrate quickly through the tunneling region. In the mean time, the heat-releasing efficiency can be improved more by flowing air or gases having high heat conductivity to the tunneling region, or by forming unevenness on the surface of the upper and lower part of the tunneling region.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects and features of the present invention will become apparent from the following description of the preferred embodiments given in conjunction with the accompanying drawings, in which:
FIG. 1 is a cross-sectional view showing a conventional semiconductor device having a heat release structure;
FIG. 2 is a layout describing a semiconductor device having a heat release structure in accordance with an embodiment of the present invention;
FIG. 3 is a cross-sectional view showing the semiconductor device of FIG. 2 severed along the line A-A′; and
FIGS. 4A to 4 K are cross-sectional views illustrating the fabrication method of the semiconductor device shown in FIG. 2 .
DETAILED DESCRIPTION OF THE INVENTION
Other objects and aspects of the invention will become apparent from the following description of the embodiments with reference to the accompanying drawings, which is set forth hereinafter.
FIG. 2 is a layout describing a semiconductor device having a heat release structure in accordance with an embodiment of the present invention, and FIG. 3 is a cross-sectional view showing the semiconductor device of FIG. 2 severed along the line A-A′.
Referring to FIGS. 2 and 3, the semiconductor device having a heat-releasing structure in accordance with an embodiment of the present invention includes: a silicon-on-insulator (SOI) substrate 20 having a bottom silicon substrate 21 , a buried oxide 22 and a top silicon layer 23 ; an integrated circuit (IC) 24 formed on the top silicon layer 23 of the SOI substrate 20 ; a polysilicon layer 27 inserted in the buried oxide 22 and top silicon layer 23 around the IC 24 at a predetermined interval; a silicon oxide layers 25 and 29 formed on the top of the SOI substrate 20 ; a tunneling region T 2 formed in the lower part of the IC 24 inside the region defined by the polysilicon layer 27 ; and one or more trench regions T 1 that penetrates the top silicon layer 23 and silicon oxide layers 25 and 29 between the polysilicon layer 27 and the IC 24 to expose the tunneling region T 2 .
Here, the air or other gases having high heat conductivity may be flown into the trench regions T 1 and the tunneling region T 2 . The trench regions T 1 may be expected to work as a heat-releasing exit. However, it may be regarded as nothing more than a by-product generated in the process of removing the buried oxide 22 to form the tunneling region T 2 . The polysilicon layer 27 works as a barrier layer (i.e., etching barrier layer) in the process of removing the buried oxide 22 to form the tunneling region T 2 , rather than works as a conductor layer.
The semiconductor device of the present invention releases out the heat generated not only in the silicon substrate 21 but also in the IC 24 through the tunneling region T 2 end the trench regions T 1 more quickly. In the conventional technology, a semiconductor device has the buried oxide 22 in the lower part of the IC 24 . Since the buried oxide 22 has low heat conductivity, the efficiency of releasing heat to the lower part of the substrate is low. However, since the embodiment of the present invention does not have the buried oxide 22 in the lower part of the IC 24 , the heat release efficiency towards the lower part of the substrate can be improved.
Meanwhile, unevenness can be formed on the upper and lower surfaces of the tunneling region T 2 , as illustrated in the drawing. If the upper and lower surfaces of the tunneling region T 2 are formed uneven, the surface area that can release heat becomes wider, and thus the heat release efficiency is increased. One other method that can increase the heat release efficiency is to perform metal coating on the trench region T 1 and the tunneling region T 2 .
FIGS. 2 and 3 show an example where the entrance of the trench region T 1 is open. However, depending on cases, the entrance of the trench region T 1 may be closed. If the entrance is closed, the air or gases having excellent heat conductivity can be filled in the trench region T 1 and the tunneling region T 2 . When the entrance is closed, the heat release efficiency may drop, compared to a case where the entrance of the trench region T 1 is open. However, since the buried oxide 22 does not exist in the lower part of the IC 24 , the heat-release efficiency towards the lower part of the substrate is more excellent than the conventional technology. Therefore, the ICs releasing a lot of heat use the structure of opening the entrance of the trench region T 1 , and the ICs releasing rather a small amount of heat use the structure of closing the entrance of the trench region T 1 .
FIGS. 4A to 4 K are cross-sectional views illustrating the fabrication method of the semiconductor device shown in FIG. 2 . Referring to FIG. 4A, the semiconductor device fabrication method of the present invention forms the IC 24 on the SOI substrate 20 . The SOI substrate 20 includes a bottom silicon substrate 21 , a buried oxide 22 and a top silicon layer 23 piled in order. To form the IC 24 , such as power device or high-frequency device, a well and a plurality of transistors are formed on the top silicon layer 23 .
Referring to FIG. 4B, a silicon oxide layer 25 is deposited as a protection layer on the top of the entire structure, and then a photoresist pattern 26 is formed thereon through a lithography process. Here, the silicon oxide layer 25 can be replaced by another insulation layer, such as a silicon nitride, polymer and polyimide. The photoresist pattern 26 is formed to expose the silicon oxide layer 25 neighboring the IC 24 in a predetermined width (see FIG. 2 ).
Referring to FIG. 4C, the exposed silicon oxide layer 25 is etched sing the photoresist pattern 26 as an etching mask. Then, the remaining photoresist pattern 26 is removed.
Referring to FIG. 4D, the top silicon layer 23 and the buried oxide 22 are etched using the patterned silicon oxide layer 25 as an etching mask. Here, the bottom silicon substrate 21 is exposed in the bottom of the trench, which is formed by etching.
Referring to FIG. 4E, the inside of the trench is filled up by depositing a polysilicon layer 27 . The polysilicon layer 27 can be applied to both doped state and un-doped state, and it can be substituted by other metallic material or insulation material.
Referring to FIG. 4F, the polysilicon layer 27 on the top of the silicon oxide layer 25 is removed by performing a chemical mechanical polishing (CMP) or etch-back process. Then, a photoresist pattern 28 is formed through a lithography process. The photoresist pattern 28 has one or more openings (see FIG. 2) having an isolated pattern between the trench region where the polysilicon layer 27 is filled and the IC 24 . The shape of the photoresist pattern 28 is not significant.
Referring to FIG. 4G, the silicon oxide layer 25 is etched using the photoresist pattern 28 as an etching mask.
Referring to FIG. 4H, the photoresist pattern 28 is removed, and the top silicon layer 23 is etched to form the trench region T 1 , using the patterned silicon oxide layer 25 as an etching mask.
Referring to FIG. 4I, the buried oxide 22 inside a region defined by the polysilicon layer 27 is removed to form the tunneling region T 2 . Here, when the buried oxide 22 is removed, a gas phase etching method using such gases as HF and BHF may be used. Since the polysilicon layer 27 performs the role of an etching barrier layer, only the buried oxide 22 inside the region defined by the polysilicon layer 27 can be removed. Meanwhile, when part of the buried oxide 22 inside the region defined by the polysilicon layer 27 remains, the remaining buried oxide 22 can work as a pillar that supports the top silicon layer 23 , where the IC 24 is formed.
Referring to FIG. 4J, unevenness is formed on the upper and lower part of the tunneling region T 1 by performing a gas phase etching using a silicon etching source, or a dry etching. Here, for the silicon-etching source, at least one selected from a group consisting of HBr, He, O 2 , N 2 , SF 6 , CF 4 , SiF 4 , BCl 3 , Cl 2 , NF 3 , CHF 3 , C 2 F 6 , and C 2 ClF 5 gases.
Referring to FIG. 4K, a silicon oxide 29 is deposited on the top of the entire surface to close the entrance of the trench region T 1 . Here, if the entrance of the trench region T 1 is not formed overly big, the entrance of the trench region T 1 is closed in the process of depositing the silicon oxide layer 29 , so it becomes very easy to close the entrance. If the air or other gases are used as an ambient gas of a reactor for depositing the silicon oxide layer 29 , the trench region T 1 and the tunneling region T 2 can be filled up with the air or other gases having a high heat conductivity. The heat conductivity can be increased by performing metallic coating on the surface of the trench region T 1 and the tunneling region T 2 . Desirably, the metallic coating is performed by putting a metallic source material in the trench region T 1 and the tunneling region T 2 and performing a thermal treatment at an appropriate temperature. The silicon oxide layer 29 can be substituted by an insulation material, such as a silicon nitride, polymer and polyimide.
Subsequently, when the silicon oxide layer 29 in the trench region T 1 is removed optionally, the cross-section of FIG. 3 can be obtained.
As described above, the semiconductor device and the fabrication method of the present invention can release the heat generated in the semiconductor device to the outside so quickly that no separate fan or a heat release plate is required. Therefore, the semiconductor device and the fabrication method of the present invention can be applied to a semiconductor parts that generates a lot of heat when the devices are operated.
While the present invention has been described with respect to certain preferred embodiments, it will be apparent to those skilled in the art that various changes and modifications may be made without departing from the scope of the invention as defined in the following claims. For example, in the embodiment of the present invention shows that an oxide layer is used as the buried insulation layer of the SOI substrate, but the device and method of the present invention can be applied to cases where other type of insulation layer is used as the buried insulation layer.
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Provided is a semiconductor fabrication technology; and, more particularly, to a semiconductor device having a heat release structure that uses a silicon-on-insulator (SOI) substrate, and a method for fabricating the semiconductor device. The device and method of the present research provides a semiconductor device having a high heat-release structure and high heat-release structure, and a fabrication method thereof. In the research, the heat and high-frequency noises that are generated in the integrated circuit are released outside of the substrate through the tunneling region quickly by forming an integrated circuit on a silicon-on-insulator (SOI) substrate, aiid removing a buried insulation layer under the integrated circuit to form a tunneling region. The heat-release efficiency can be enhanced much more, when unevenness is formed on the surfaces of the upper and lower parts of the tunneling region, or when the air or other gases having excellent heat conductivity is flown into the tunneling region.
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This application claims the benefit of U.S. Application No. 60/564,541 file Apr. 22, 2004 and the same is hereby incorporated by reference.
BACKGROUND
The present invention relates generally to devices, methods and systems for vascular treatment. One embodiment of the present invention relates to a device including an ECM material section and an associated retention member. The ECM material may be placed in a vascular lumen with at least one portion anchored to a vessel. The apparatus can shield a portion of the vessel and also permit further treatment to that or other area(s). While the invention is described with respect to vascular applications, it may also apply to treatment of the hepatic, urinary, respiratory, digestive or reproductive systems, and other anatomical lumen(s), for example.
Vascular diseases and disorders are widespread health problems affecting many people. There are many chronic and acute diseases and disorders relating to the vascular system including, for example, thrombosis, embolism, aneurysm, atherosclerosis, arterioschlerosis, infarction and still others. Heart attacks and strokes are leading health concerns. Obstruction of blood flow and/or vessel rupture may cause inadequate blood supply the heart, brain and other parts or all of the body. Occlusive diseases involving constriction, narrowing or obstruction of a blood vessel often present serious possibly life-threatening risks. Additionally, complications in vascular treatment(s) may themselves necessitate further treatment. Some such risks include formation of emboli, vessel damage, thrombogenesis, blood loss, hemorrhage, and others. Furthermore, trauma and other injuries may damage the vascular system and often require repair or replacement.
At present, treatment of vascular disease, damage and disorders suffers from limitations, drawbacks and risks. The invention provides unique treatments and solutions to treatment of the foregoing and other problems.
SUMMARY
According to one embodiment of the present invention there is contemplated a method including introducing a device into an organ, the organ having an interior surface and containing a fluid, shielding at least a portion of the interior surface from the fluid and administering additional treatment to at least the shielded portion.
A further embodiment according to the present invention relates to an implantable prosthesis including an ECM material and an anchoring member, wherein the implant is introduceable into a blood vessel in a first state and the anchoring member maintains a portion of the implant in a substantially fixed relationship with the blood vessel in a second state.
Yet another embodiment according to the present invention relates to a device including a buffer member adapted to be introduced into a blood vessel to buffer at least a portion of the blood vessel from blood therein, and a retaining member conformable to maintain at least a portion of the buffer member in contact with a portion of the blood vessel.
Still a further embodiment according to the present invention includes a treatment system including an intraluminal prosthesis including at least a first portion which is secured relative to a flow in the lumen, a second portion which is capable of movement relative to the first portion in a first state and a treatment device inserted into the lumen and positionable to a location adjacent the prosthesis, the device delivering treatment at about the adjacent location, wherein blood flow is substantially unobstructed by the prosthesis.
Yet another embodiment according to the present invention relates to a medical device including a lumen shield of ECM material and an anchor member which is conformable to a retaining position effective to maintain at least a part of the shield in a fixed position with respect to a lumen into which the device has been introduced.
Still a further embodiment according to the present invention relates to an apparatus including a tubular piece formed at least in part of an ECM and a stent at least a part of which is affixed to at least a part of the tubular piece wherein the apparatus is sized to permit introduction into a blood vessel in a first state and is conformable to a second state in which it is effective to shield an interior surface of the blood vessel from the blood flowing therethrough.
Yet a further embodiment according to the present invention relates to a method of treating disease or damage of a blood vessel including sheltering a portion of a luminal surface of the blood vessel from the blood flow therethrough, administering treatment to the blood vessel, and inducing repair or restoration of the blood vessel with an ECM material.
Various embodiments of the present invention provide unique apparatus and methods of treating the vascular system. Still other embodiments, examples and features according to the present invention will be apparent from the following description and claims.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 illustrates a cross section of a stenotic blood vessel.
FIG. 2 illustrates FIGS. 2 and 2A illustrate a cross section of an apparatus according to embodiments of the present invention in a blood vessel.
FIG. 3 illustrates a cross section of the apparatus of FIG. 2 in another state.
FIG. 4 illustrates a cross section of treatment of stenosis according to one embodiment of the present invention.
FIG. 5 illustrates a cross section of treatment of stenosis according to one embodiment of the present invention.
FIG. 6 illustrates a cross section of an apparatus according to one embodiment of the present invention.
FIGS. 7-10 illustrate cross sections of the apparatus of FIG. 6 in other states.
DETAILED DESCRIPTION
For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. Nevertheless, no limitation of the scope of the invention is intended. Such alterations and further modifications in the illustrated and described embodiments, and such further applications of the principles of the invention as illustrated therein as would occur to one skilled in the art to which the invention relates are contemplated.
With reference to FIG. 1 there is shown an illustrative view of a blood vessel 110 which includes interior surface 111 and lumen 150 . Blood flow through vessel 110 is generally in the direction indicated by arrow F and may vary according to physiological conditions. Stenosis 113 is a narrowing or constriction of lumen 150 of vessel 110 in the region generally indicated at 112 . The narrowing or constriction of lumen 150 results in reduced blood flow through vessel 110 and increased risk of thrombosis, embolism, and other complications. While stenosis 113 is illustrated, other diseases, damage, or disorders could be present in region 112 or other in other regions. For example, thrombosis, aneurysm, lodged embolism, necrotic tissue, cut or damaged vessel tissue, perforation, and other lesions, disease, disorders or damage including those described above (hereinafter “disease(s)”) may all be treated by the present invention. For the sake of brevity, treatment of stenosis is illustrated and described with the understanding that treatment of the aforementioned diseases and others is also contemplated and protected. Furthermore, it should be understood that the term “vascular” includes, without limitation, the vascular, cardiovascular and/or circulatory systems or portions thereof. Further still, it will be understood that present invention may be applied to still other tubular organs, such as the gall bladder, esophagus, kidney, as well as to organs of the renal, urinary, digestive, alimentary, hepatic, reproductive, respiratory, endocrine and other physiological systems.
With reference to FIG. 2 there is shown an illustrative view of a device 119 according to one embodiment of the present invention which has been placed in lumen 150 of blood vessel 110 . Device 119 includes member 120 and expandable member 130 . Device 119 includes member 120 which extends from distal end 122 to proximal end 123 . Member 120 includes interior surface 121 and lumen 151 .
As illustrated in FIG. 2 , member 120 is tubular, however, in other embodiments member 120 could be partially tubular, a split tube, a coil, a roll, an overlapping tube, a strip, overlapping strips, a ribbon, or a patch to name a few examples. Still other embodiments of the present invention contemplate combinations of these and other structures.
Member 120 may include ECM material(s). As used herein, ECM material(s) or extracellular matrix materials refer(s) to a class of biomaterials including, but not limited to, submucosa, mucosa, serosa, pericardium, dermis, fascia, basement membrane, and/or combinations thereof. ECM materials may be derived from various tissue sources including the alimentary, hepatic, respiratory, intestinal, integument, urinary, or genital tracts. ECM materials can be harvested from animals, including, for example, pigs, cattle, sheep, porcine, bovine, ovine or other warm-blooded vertebrates to produce heterologous implants or grafts. Products comprising submucosa tissue derived from porcine small intestine are commercially available ECM materials produced by COOK BIOTECH INCORPORATED of West Lafayette, Ind.
Member 120 can comprise any of the aforementioned ECM materials or other ECM materials. Member 120 can also include 1, 2, 3, 4, 5, 6, 7, 8 or more ECM layers. Further, in some embodiments, member 140 can comprise any devitalized or substantially acellular collagenous matrix, naturally-derived or synthetic, and desirably remodelable. The remainder of the text will refer to ECM material unless specifically stated to the contrary. This will not, however, be limiting of the broader aspects of the invention.
It is also contemplated that member 120 could also include synthetic polymeric material instead of or in addition to ECM material(s). Such synthetic polymeric materials include, but not limited to polytetrafluoroethylene (“PTFE”) (including expanded PTFE) and/or polyethylene terephthalate (“PET). Further, the synthetic polymer materials can be either a biostable or a bioabsorbable polymer. Bioabsorbable polymers that could be used include, but are not limited to, poly(L-lactic acid), polycaprolactone, poly(lactide-co-glycolide), poly(hydroxybutyrate), poly(hydroxybutyrate-co-valerate), polydioxanone, polyorthoester, polyanhydride, poly(glycolic acid), poly(D,L-lactic acid), poly(glycolic acid-co-trimethylene carbonate), polyhydroxyalkanaates, polyphosphoester, polyphosphoester urethane, poly(amino acids), cyanoacrylates, poly(trimethylene carbonate), poly(iminocarbonate), copoly(ether-esters) (e.g., PEO/PLA), polyalkylene oxalates, and polyphosphazenes. Biostable polymers that could be used include, but are not limited to, polyurethanes, silicones, and polyesters and other polymers such as, but not limited to, polyolefins, polyisobutylene and ethylene-alphaolefin copolymers; acrylic polymers and copolymers, vinyl halide polymers and copolymers, such as polyvinyl chloride; polyvinyl ethers, such as polyvinyl methyl ether; polyvinylidene halides, such as polyvinylidene fluoride and polyvinylidene chloride; polyacrylonitrile, polyvinyl ketones; polyvinyl aromatics, such as polystyrene, polyvinyl esters, such as polyvinyl acetate; copolymers of vinyl monomers with each other and olefins, such as ethylene-methyl methacrylate copolymers, acrylonitrile-styrene copolymers, ABS resins, and ethylene-vinyl acetate copolymers; polyamides, such as Nylon 66 and polycaprolactam; alkyd resins, polycarbonates; polyoxymethylenes; polyimides; polyethers; epoxy resins, polyurethanes; rayon; and rayon-triacetate. The material may be in the form of yarns, fibers, and/or resins, monofilament yarns, high tenacity polyester and others. Further, the present application contemplates other plastic, resin, polymer, woven, and fabric surgical materials, other conventional synthetic surgical materials, and/or combinations of such materials.
It will be appreciated that the length, shape, thickness, layers, composition, orientation, other dimensions and attributes of member 120 may be dictated by the desired treatment. Examples of particularized treatment considerations include: a lesion spanning part of or the entire circumference of a vessel calling for a tubular structure, overlapping tube(s), split tube(s), overlapping strips or other circumference spanning configurations. Varying vessel dimensions may also influence attributes of member 120 . For example, an aneurysm may require one or more layers of certain materials to provide adequate strength. The location and nature of vascular disease(s) may also be a factor. Desire for tissue remodeling may suggest use of ECM materials, desire for other characteristics, for example, durability or strength may indicate one or more synthetic materials, and desire for combinations of characteristics may call for hybrid structures. It is also contemplated that member 120 could be one piece, or could include two or more pieces, parts, or units.
With continuing reference to FIG. 2 , retention member 130 contacts the interior of member 120 and extends from outside proximal end 123 of member 120 into member 120 . Member 130 could also extend from farther outside end 123 , from end 123 , or from inside end 123 . In certain embodiments member 130 could extend substantially the length, the entire length, or more than the entire length of member 120 .
Member 130 is shown in an expanded configuration in which it can exert bias toward surface 121 of member 120 and maintain a portion of member 120 against interior surface 111 of blood vessel 110 . It is also contemplated that member 130 could contact the interior surface of member 120 , be between two layers of a multi-layer member 120 , embedded within member 120 , attached to the outer surface of member 120 , pierce through member 120 , be coupled to member 120 by intermediate structure, attached to member 120 using additional fasteners, connectors, glue, adhesive, tape, suture, staples, or other structures.
Retention member 130 is illustrated as a self-expanding vascular stent but could also be a balloon expandable vascular stent, or any other structure that is not classified as a stent but capable of being introduced into a blood vessel and maintaining at least a portion of member 120 in a desired position or location. Member 130 could be compressible, flexible, bendable, collapsible, rolled, coiled, or twistable, hinged, jointed or otherwise conformable to permit retention of member 120 . Member 120 could also include or consist of barbs or other structures (e.g. FIG. 2A ) which perforate part or all of member 120 and/or a vascular structure.
Member 130 is shown as having a particular braided structure, however, it is contemplated that a wide variety of structures could be used. For example, coil structure(s), spiral structure(s), helical structure(s), woven structure(s), other braided structure(s), ring(s), sinusoidal structure(s), Z-shaped structure(s), zig-zag structure(s), closed cell structure(s), open cell structure(s), and other types of vascular stents are contemplated. Furthermore, the material or materials of member 130 could include stainless steel, tantalum, nitinol, platinum, iridium, polymers, niobium, cobalt, molybdenum, drug eluting coating(s), ECM coating(s) and other materials, alloys, or combinations of the foregoing non-limiting examples. Additionally, it is contemplated that one or more other members could be used at various locations in connection with member 120 , and could be the same, similar to or different from member 130 including, for example, the variations described above.
As shown in FIG. 2 , a portion of member 120 extends beyond member 130 to end 122 . This portion of member 120 is maintained against interior surface 111 by hemostatic pressure. As illustrated, member 120 can conform to the shape of interior 111 as well as to the irregularities presented by stenosis 112 . Hemostatic pressure may be present within member 120 due to the blood flow therethrough, but in the case of trauma or patient and treatment conditions, for example, wide variation in pressure may exist. Blood flow enters member 120 at end 123 and is routed through lumen 151 of member 120 and out of end 122 in the direction generally indicated by arrow F 1 . Thus, blood flow is isolated from stenosis 113 and from portions of interior surface 111 .
With reference to FIG. 3 there is shown an illustrative view of the apparatus and blood vessel described above under different environmental conditions. There are shown various attributes described above in connection with FIGS. 1 and 2 indicated with identical reference numerals. In FIG. 3 the fluid or hemostatic pressure of blood in vessel 110 is less than in FIG. 2 and could be neutral or negative as well. Accordingly, there may be less tendency for member 120 to be maintained against interior surface 111 by hemostatic pressure and a portion of member 120 may move to the position illustrated in FIG. 3 or to other positions, or might move minimally or substantially not at all. In other embodiments, member 130 could be differently positioned or proportioned to maintain more or less of member 120 against interior surface 111 . In still further embodiments part or all of member 120 need not directly contact the vessel wall, and could be maintained in position by an intermediate structure or structures. Furthermore, in some situations hemostatic pressure and/or properties of member may increase the tendency of member 120 to remain against or adjacent to interior surface 111 .
FIGS. 4 and 5 illustrate treatments of stenosis 113 . In FIG. 4 a dilation balloon 410 has been introduced into blood vessel 110 and advanced to region 112 where it has been expanded as indicated by arrow E. This expansion exerts force on stenosis 113 which causes it to break down. This treatment and others can produce emboli 420 which are fragments of stenosis 113 . Member 120 protects emboli 420 from blood flow and prevents them from entering the bloodstream.
As illustrated in FIG. 5 , vascular stent 510 may be used to reduce stenosis instead of or in addition to dilation balloon 410 . Stent 510 may be any vascular stent or other structure including the examples discussed above. Treatment(s) including multiple stents, interconnected stent, stents which do not touch, stents kept apart by intermediate structures, stent segments, supplemental stents and other structures is also contemplated. FIG. 5 also shows emboli 520 which are isolated by member 120 from blood flow.
Still further treatments are contemplated, for example, administration of drugs, hormones, testing compounds, and other medicaments. Introduction of devices, suturing, anastomosis, cutting, fusing, testing, biopsy, and other operations are also contemplated. Furthermore, laser treatment, heat application, assisted viewing and probing may occur. As used herein “treating” and “treatment(s)” includes, without limitation, the foregoing examples, unless specifically indicated to the contrary.
With reference to FIGS. 6-10 there is illustrated one delivery method and apparatus according to the present invention. Attributes which are the same or similar to those discussed above are indicated with reference numerals which are increased from the 100's to the 600's (e.g. 120 becomes 620). It should be understood that delivery of various other embodiments, including those mentioned above, is also contemplated. It should further be understood that the following procedures could be performed in the order listed or in a variety of other orders, for example, deploying an opposite end first, staggered deployment, fluoroscopically aided deployment, and in still other manners. FIG. 6 shows guidewire 610 which may be any guidewire appropriate for endovascular surgery and may vary according to various treatment indications, including those mentioned above.
With continuing reference to FIG. 6 , tubular member 620 and expandable member 630 are shown compressed about guidewire 610 . Tip 605 may cover a terminal portion of guidewire 610 and an end portion of member 620 . Tip 605 could be a flexible tip, a guiding tip, a cannula or any other tip or tips of differing size, shape and structure. Member 630 and a portion of member 620 are housed within sheath or catheter 640 . Sheath or catheter 640 maintains member 630 in a compressed state in the case of a self-expanding stent, for example. Sheath or catheter 640 could also extend to house more of member 620 and guidewire 610 and could extend even further to house some or all of tip 605 . As a further option, sheath or catheter 640 could have a tip of its own, for example, a nose cone. In still other embodiments tip 605 may not be present and member 620 could be maintained in place by a dissolvable adhesive, by a low profile removable wrap or other structure, or could be compressed about guidewire 610 where exposure to liquid, e.g. blood, was limited or eliminated until deployment was desired.
With reference to FIGS. 7 and 8 there is illustrated an example of deployment of member 630 and one end of member 620 . In FIG. 7 catheter or sheath 640 has been moved relative members 620 and 630 . This can be accomplished by advancing guidewire 610 in the direction indicated by arrow G effective to move members 620 and 630 in the same direction, by retracting catheter or sheath 640 in the direction indicted by arrow C, or by a combination of both movements. Other deployment techniques and devices are also contemplated. For example, one or more additional wires, sheaths, catheters, snares, pushers, dilation balloons, or other structures which could move members 620 and 630 and/or catheter or sheath 640 are contemplated.
Regardless of which deployment mode is used, member 630 can expand as it exits catheter or sheath 640 . This expansion also causes member 620 to expand with member 630 . FIG. 8 illustrates member 630 after it has completely exited catheter or sheath 640 and is fully expanded. In vivo, member 630 can maintain member 620 against the interior surface of a blood vessel as was described above or in another desired position or location.
With reference to FIGS. 9 and 10 there is illustrated deployment of the opposite end of member 620 . In FIG. 9 , guidewire 610 has been advanced in the direction indicated by arrow T which is effective to move tip 605 in the same direction. During this movement, members 620 and 630 can be maintained in place by force exerted by member 630 against the interior wall of a blood vessel. The result of this movement is shown in FIG. 10 where tip 605 has been advanced completely off of end 622 of member 620 allowing expansion of end 622 . Once members 620 and 630 are in the configuration shown in FIG. 10 , blood flow can be routed through member 620 to expand member 620 as described above and illustrated in connection with FIGS. 2 and 3 . Additional deployment modes for the opposite end of member 620 are also contemplated including, for example, those discussed above.
While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiment has been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected. It should be understood that while features described above may be desirable, they nonetheless may not be necessary and embodiments lacking the same may be contemplated as within the scope of the invention, that scope being defined by the claims that follow. In reading the claims it is intended that when words such as “a,” “an,” “at least one,” “a portion,” “at least a portion” are used there is no intention to limit the claim to only one item unless specifically stated to the contrary in the claim. Further, when the language “at least a portion” and/or “a portion” is used the item may include a portion and/or the entire item unless specifically stated to the contrary.
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According to one embodiment there is disclosed a device including a shield member including an ECM material and a retaining member conformable to maintain at least a portion of the shield member in a desired relationship with respect to an area of a blood vessel to be treated or repaired.
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TECHNICAL FIELD
[0001] This disclosure relates generally to pet carriers. More particularly, the disclosure relates to a deployable pet carrier for a motor vehicle, the carrier being conveniently disposed within the vehicle for easy access and use.
BACKGROUND
[0002] Persons often must travel in their motor vehicles with their pets, for example for veterinary appointments, when moving, or even simply for companionship. However, an unrestrained animal in a vehicle presents a driver distraction and so potentially a hazard. Additionally, in the event of even a minor collision, an unrestrained animal is subject to severe injury. Still more, even a small unrestrained pet subjected to deceleration forces in a collision becomes a dangerous projectile that can injure the vehicle occupants.
[0003] For these and other reasons, various means of restraining animals in a vehicle have been developed. It is known, for example, to restrain animals by attaching a leash or other tether at one end to a collar or harness worn by the animal and at the other end to a portion of the vehicle such as a seatbelt harness, door handle, etc. This type of restraint likewise risks injury to the animal during a collision, since the animal will travel at least a short distance before reaching the end of the leash, exacerbating the deceleration force of the collision. Also, a leashed pet may be less likely to exercise restraint in relieving itself in the vehicle at need.
[0004] It is likewise known to use pet carriers to transport an animal in a vehicle. These are typically simply conventional carriers or crates as would be used in a home, placed loose in the vehicle and into which the animal is placed prior to operating the vehicle. However, such loose crates likewise become projectiles during a collision, risking injury to vehicle occupants. Conventional crates or pet carriers, while effective in restraining an animal, are also inconvenient in that they occupy significant space in a vehicle even if no pet is present.
[0005] To solve this and other problems, the present disclosure relates at a high level to a deployable pet carrier. Advantageously, the described deployable pet carrier is configured for securing to a motor vehicle seat back, includes collapsible side walls for pet security, and further includes a convenient deploying mechanism.
SUMMARY
[0006] In accordance with the purposes and benefits described herein, in one aspect a deployable pet carrier assembly for a vehicle is described. The carrier assembly includes a sliding rail guide system configured to attach the pet carrier to a vehicle seat back and collapsible front, rear, and side walls defining a carrier structure when deployed. The sliding guide rail system includes front and rear guide rails configured to slidingly hold the pet carrier front wall and rear wall. An actuator is provided, configured to retain or release the pet carrier walls for transitioning the pet carrier between a collapsed configuration and a deployed configuration.
[0007] In embodiments, each of the pet carrier front wall and rear wall is defined by a plurality of intersecting rails configured to provide a collapsible grid. Likewise, in embodiments each of the pet carrier side walls is defined by a plurality of interconnected panels configured to provide a collapsible panel. A tray is provided to define a floor for the carrier.
[0008] In the following description, there are shown and described embodiments of the disclosed deployable pet carrier. As it should be realized, the carrier is capable of other, different embodiments and its several details are capable of modification in various, obvious aspects all without departing from the devices and methods as set forth and described in the following claims. Accordingly, the drawings and descriptions should be regarded as illustrative in nature and not as restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The accompanying drawing figures incorporated herein and forming a part of the specification, illustrate several aspects of the disclosed deployable pet carrier, and together with the description serve to explain certain principles thereof. In the drawing:
[0010] FIG. 1 depicts a deployable pet carrier according to the present disclosure;
[0011] FIG. 2 depicts deployed front and rear walls of the carrier of FIG. 1 ;
[0012] FIG. 3 depicts a deployed folding wall of the carrier of FIG. 1 ;
[0013] FIG. 4A depicts the carrier of FIG. 1 in the stored configuration, including an actuator embodiment for deploying the carrier;
[0014] FIG. 4B shows the actuator embodiment of FIG. 4A in isolation;
[0015] FIG. 5 depicts the carrier of FIG. 1 in the stored configuration, attached to an upright seat back of a second row seat of a motor vehicle;
[0016] FIG. 6 shows the carrier of FIG. 5 with the second row seat back folded forward; and
[0017] FIG. 7 depicts the carrier of FIG. 6 in the deployed configuration.
[0018] Reference will now be made in detail to embodiments of the disclosed deployable pet carrier, examples of which are illustrated in the accompanying drawing figures.
DETAILED DESCRIPTION
[0019] Turning to FIG. 1 , a collapsible pet carrier assembly 10 is depicted, configured for attaching to a vehicle seat back 12 . Broadly, the pet carrier assembly 10 includes collapsible front and rear walls 14 , 14 ′ and collapsible side walls 16 , 16 ′. Front and rear (not visible in this view) guide rails 18 , 18 ′ slidingly hold at least the front and rear walls 14 , 14 ′ and secure the pet carrier assembly 10 to the vehicle seat back 12 . In one embodiment, at least one edge of front and rear walls 14 , 14 ′ is pivotally attached to a corresponding end of guide rails 18 , 18 ′ (see arrow).
[0020] A tray 20 is provided which serves as a floor for the pet carrier 10 , optionally including a separate or integral perforated mat 22 . As will be appreciated, the mat 22 provides a surface for a pet (not shown) having greater grip, and further allows drainage of liquid onto tray 20 in the event the pet relieves itself. Conveniently, tray 20 and mat 22 are removable for ease of cleaning and replacement at need. Molded studs or other fasteners (not visible in this view) prevent inadvertent dislodgment of the tray 20 /mat 22 when the pet carrier assembly 10 is held in a stored configuration as discussed below.
[0021] In an embodiment (see FIG. 2 ), the front and rear walls 14 , 14 ′ are defined by a plurality of intersecting rails 24 , pivotally interconnected one to another to define a collapsible grid structure. A plurality of first rods 26 pivotally connect the edges of front wall 14 to the corresponding edges of rear wall 14 ′, similar in design to a collapsible laundry rack as is known in the art. Intersecting rails 24 may be pivotally interconnected by any suitable structure, such as by pins 28 as shown. As will be appreciated, this feature of a plurality of intersecting rails 24 pivotally interconnected one to another to define collapsible front and rear walls 14 , 14 ′ allows altering a width dimension of front and rear walls 14 , 14 ′ during deployment and collapsing of the pet carrier assembly 10 as will be discussed.
[0022] An embodiment of side walls 16 , 16 ′ is shown in FIG. 3 . As shown therein, each of side walls 16 , 16 ′ is defined by a plurality of interconnected panels 30 . Each panel 30 is configured to pivotally accept a first rod 26 through a first edge thereof. In turn, each panel 30 is likewise configured to pivotally accept a second rod 32 through a second, opposed edge thereof, thus interconnecting the plurality of panels 30 to define a collapsible panel side wall that is substantially solid when the pet carrier 10 is in the deployed configuration. In the depicted embodiment, hinge structures 34 are defined in the first and second edges of the panels 30 to allow interconnection thereof as described. As will be appreciated, this feature of interconnected panels 30 to define collapsible side walls 16 , 16 ′ preserves a width dimension of side walls 16 , 16 ′ during deployment and collapsing of the pet carrier assembly 10 as will be discussed.
[0023] With reference to FIGS. 4A and 4B , the pet carrier assembly 10 further includes an actuator 36 for retaining the carrier in either the collapsed or the deployed configuration. In one embodiment, the actuator 36 is simply a pushbutton release 38 , including a spring 40 for biasing pushbutton 38 outwardly through a first bore 42 defined in front rail 18 . In this configuration, the pet carrier 10 is in the collapsed configuration shown in FIG. 4A . To deploy the carrier, a user need only urge the pushbutton 38 rearwardly against spring 40 (see arrow A) to clear bore 42 , and may then raise front/rear walls 14 , 14 ′ and side walls 16 , 16 ′ upwardly to a deployed configuration.
[0024] As the carrier is deployed, the “footprint” defined by front/rear walls 14 , 14 ′ and side walls 16 , 16 ′ decreases slightly, and pushbutton 38 translates laterally (see arrow B). As the carrier reaches the fully deployed configuration (see FIG. 7 ), pushbutton 38 reaches and engages a second bore 44 , thus maintaining deployed configuration until a user wishes to collapse the structure. Of course, the process of collapsing the carrier is simply the inverse of the process of deploying as described above.
[0025] Turning now to FIGS. 5-7 , conveniently the pet carrier assembly 10 is secured in the collapsed configuration to an upright vehicle V seatback 12 by guide rails 18 , 18 ′ (see FIG. 5 ). As shown, front wall 14 is disposed above rear wall 14 ′. In this configuration, actuator 36 is conveniently accessible to a user by way of passenger door D (not shown in this view, but see FIG. 6 ) when seatback 12 is folded forward. However, although the inverse relationship is also contemplated (rear wall 14 ′ disposed above front wall 14 ). Thus, the pet carrier assembly 10 is conveniently available for use at a moment's notice, but does not occupy a significant portion of the available storage space of, for example, the vehicle cargo area C.
[0026] To use the pet carrier assembly 10 , at least the portion of vehicle seat back 12 to which the carrier is secured is folded forward (see FIG. 6 ). Next, the pet carrier is deployed as described above, by operation of actuator 36 , and the carrier is translated to the deployed configuration ( FIG. 7 ). During this translation, as the front/rear walls 14 , 14 ′ and side walls 16 , 16 ′ are raised, the carrier footprint decreases slightly as described above, i.e. front/rear walls 14 , 14 ′ lessen in width and side wall 16 ′ translates towards side wall 16 without altering a width dimension thereof (note the greater portion of guide rails 18 , 18 ′ visible in the deployed configuration compared to the collapsed configuration of FIG. 6 ). Then, actuator 36 engages second bore 44 (not visible in this view) to retain the carrier in the deployed configuration.
[0027] Typically, a pet is placed on tray 20 /mat 22 before deploying the pet carrier assembly 10 as described above. This is because after deployment the vehicle roof/headliner is typically sufficiently near a top edge of front/rear walls 14 , 14 ′ and side walls 16 , 16 ′ that the vehicle roof/headliner serves as a de facto lid or top for the pet carrier assembly 10 . However, it will be appreciated that alternative configurations are possible, for example providing a separate lid or top (not shown) for a pet carrier assembly 10 having shorter walls or when using the pet carrier assembly in a vehicle having a higher roof/headliner to prevent the pet from inadvertently exiting the carrier.
[0028] Thus, it will be appreciated that a simple, effective vehicle-mounted pet carrier is provided, which is stored in a vehicle without significant negative impact on available storage space in the vehicle. The carrier is easily deployed for use as needed, and equally easily collapsed for storage when not needed. Obvious modifications and variations are possible in light of the above teachings. All such modifications and variations are within the scope of the appended claims when interpreted in accordance with the breadth to which they are fairly, legally and equitably entitled.
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A deployable pet carrier assembly for a vehicle includes a sliding rail guide system configured to attach the pet carrier to a vehicle seat back and collapsible front, rear, and side walls defining a box structure when deployed. An actuator is provided, configured to retain or release the pet carrier walls for transitioning the pet carrier between a collapsed configuration and a deployed configuration. The sliding guide rail system includes front and rear guide rails configured to slidingly hold the pet carrier front wall and rear wall. A tray may be included to define a floor of the pet carrier.
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This invention was made in part with government support under the following grants: DK50184 and NS35368, awarded by the National Institutes of Health. The government has certain rights in the invention.
BACKGROUND OF THE INVENTION
1. Field of Invention
The present invention generally relates to an apparatus and method for reconstructing images in computed tomographic fluoroscopy, and particularly to an iterative process for performing this functionality in real-time applications utilizing a row-action or modified ordered-subset expectation maximization algorithm or other ordered-subset based algorithms in fan-beam or cone-beam geometry.
2. Description of Prior Art
X-ray computed tomographic fluoroscopy (CTF) has been applied in a variety of real-time application domains, particularly, image guided medical intervention. Specific example applications include evacuation of intracranial blood clots, radiodense rod and seed placement for brachytherapy, synchronization of scanning with contrast bolus arrival for dynamic scanning, and motion analysis. Typical CTF systems incorporate an x-ray source projecting a fan-shaped beam within a single X-Y plane referred to as the imaging plane. The beam passes through the subject, such as a patient in a medical procedure, thereby attenuating the beam which ultimately strikes an array of x-ray detectors. The individual detectors generate electrical signals corresponding to the beam attenuation at the particular detector location.
Known third generation CTF systems include a gantry which allows rotation of the x-ray source and detector array around the subject in the imaging plane. The projection data collected at a particular gantry angle is referred to as a view, and a typical scan of the subject consists of the projection data associated with a set of views collected during a complete rotation of the gantry. A partial scan consists of a subset of projection data associated with views comprising less than a complete rotation of the gantry. The projection data associated with a scan may be used to generate a two-dimensional image using a process referred to as filtered backprojection (FB). This image reconstruction technique requires computationally expensive filtration followed by backprojection.
Currently, filtered backprojection is the method for CTF image reconstruction. However, this method of image reconstruction suffers from metal artifacts resulting from metallic implants, surgical probes or other metallic instruments. Further, utilization of low tube currents in medical applications may lead to increased image noise; FB reconstruction does not provide compensation for this increased image noise.
A maximum likelihood (ML) expectation maximization (EM) approach provides an alternative for image reconstruction that reduces both metallic artifacts and image noise resulting from low current. The problem with this technique, however, is the computational expense due to the simultaneous iterative nature of the algorithm. This computational expense renders this approach not viable in the field of CTF real-time applications where image reconstruction must occur rapidly.
A row-action alternative to the EM formula was developed for maximum likelihood reconstruction in emission CT. This alternative greatly reduces the computational expense of the traditional EM approach. In simulated tests, iterations 1, 2, 3 and 4 of the row-action alternative provided results at least as good as iterations 45, 60, 70 and 80, respectively, of the traditional EM approach (Browne J, De Pierro A R: A row-action alternative to the EM algorithm for maximizing likelihoods in emission tomography. IEEE Trans. Med. Imag. 15:687-699, 1996).
The current invention utilizes an ordered-subset based algorithm, such as row-action EM, in fan-beam or cone-beam geometry to reduce metal artifacts and image noise while attaining image reconstruction speeds faster than FB in the CTF context.
SUMMARY OF THE INVENTION
In the present invention, an iterative process is provided for computed tomographic fluoroscopy (CTF) based upon an ordered-subset based algorithm or an adaptation of the row-action expectation maximization (RAEM) formula. This process is applied to reduce metal artifacts in CTF imaging, reduce image noise and provide rapid-image updating suitable for real-time applications. In one embodiment, generation of a projection mask and computation of a relaxation matrix are used to compensate for beam divergence and data incompleteness, and a priori knowledge such as a known image support is used to reduce image reconstruction errors.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 provides a schematic diagram of a device that may incorporate the present invention.
FIG. 2 is a block diagram of the components that may be used to implement the present invention.
FIG. 3 is a flowchart of the process of RAEM tomographic image reconstruction according to the present invention.
FIG. 4 illustrates the discretized reprojection process.
FIG. 5 illustrates the discretized backprojection process.
FIG. 6 illustrates the computation of bi-linear interpolation of the four nearest neighbors of an arbitrary point in an image.
FIG. 7 displays the convergence behavior of the RAEM algorithm.
FIG. 8A depicts an idealized, simulated CTF image at time zero of an intervention with a metallic probe.
FIG. 8B depicts an idealized, simulated CTF image at ten seconds into an intervention with a metallic probe.
FIG. 8C depicts a simulated CTF image at ten seconds into an intervention with a metallic probe reconstructed using FB.
FIG. 8D depicts a simulated CTF image at ten seconds into an intervention with a metallic probe reconstructed using RAEM.
FIG. 9A depicts an idealized, simulated CTF image at time zero of an intervention.
FIG. 9B depicts an idealized, simulated CTF image at eight seconds into an intervention.
FIG. 9C depicts a simulated CTF image with low contrast at eight seconds into an intervention reconstructed using FB.
FIG. 9D depicts a simulated CTF image with low contrast at eight seconds into an intervention reconstructed using RAEM.
DETAILED DESCRIPTION OF THE INVENTION
In an embodiment, the present invention may be implemented in conjunction with a fan-beam x-ray tomographic system, such as depicted schematically in FIG. 1.
As shown in FIG. 1, the x-ray tomographic system 100 that may be used in the present invention uses a gantry 110. The gantry 110 contains an x-ray point source 105 that projects a beam 120 at a detector array 115 on the opposite side of the gantry 110. The beam 120 passes through the subject 125, and the individual detectors 130 within the detector array 115 sense the attenuation of the beam 120 passing through the subject 125. The detectors 130 generate electrical signals corresponding to the attenuation, and the x-ray source and detector assembly rotates about the subject 120 to generate projection data.
The detectors 130 transmit the projection data to the computer system 135, which reconstructs an image from the projection data. The computer 135 transmits this image to a sub-system for display, and possible archiving, which in one embodiment might be the computer's display 135D. In an embodiment, the computer 135 may comprise a Silicon Graphics O 2 computing platform (Silicon Graphics, Inc.; Mountain View, Calif., USA), or any other suitable single or multiprocessor computing system.
In a real-time usage of this system, an initial preoperative scan may be performed to generate a base image. The projection data for this scan is transmitted to the workstation 135, which creates an initial image and further applies a translation to the image to guarantee nonnegativity as required by the iterative RAEM approach. Subsequent images are generated utilizing an iterative RAEM approach from the current image and subsequent projection data.
In a two-dimensional CT problem, the cross-section of the subject is divided into n abutting square pixels with constant x-ray linear attenuation coefficients x j , j=1, . . . , n; x represents the corresponding n-dimensional vector. Suppose that projection data b i are measured along m lines, i=1, . . . , n; b represents the corresponding m-dimensional vector. Let A=(a ij ) describe the contribution of x j to b i , i=1, . . . , n, j=1, . . . , n resulting in the following linear system:
Ax=b
The EM formula for inverting this system is ##EQU1## where k represents the iteration number.
The RAEM formula can be expressed as ##EQU2## where ##EQU3## and k represents the iteration number.
A CTF algorithm based upon the RAEM formula results by setting ##EQU4## and obtaining ##EQU5## where k represents the iteration number.
The CTF problem can be characterized as real-time tomographic reconstruction of an image that continuously undergoes localized changes. Because of the real-time nature of CTF, projection data must be continuously collected, and images must be reconstructed and updated from consecutive partial scans S i , i=1, 2, . . . , p, which consists of q consecutive projections, where q is a constant optimized for the particular real-time application.
The following analysis examines the convergence behavior of the row-action EM formula in the early stage. By "the early stage", we mean that projection data involved for image reconstruction are less than that from a half-scan.
First, we consider a homogeneous disk with a CT value b 0 that is centered at the origin of the reconstruction system, as shown in FIG. 7. Let us model a localized image variation as an incremental change d 0 at the origin, and consider those X-rays that pass through the origin. Due to the incremental change, the true ray-sum becomes p+b 0 +d 0 , where p denotes the ray-sum along the same path excluding the contribution from the origin. Applying the row-action EM reconstruction formula with projections in S 1 , we have ##EQU6## Generally, after applying the row-action EM reconstruction formula with projections in S k+1 , we have ##EQU7## Hence, ##EQU8## That is, d k vanishes monotonically and exponentially.
Several comments are in order. First, in practice the time-varying pixel may not be at the origin. For an arbitrary pixel location, projection values associated with the rays through the pixel are generally not the same. In this case, the error bounds for d k can be easily obtained by replacing p with p max because p/(p+c) is an increasing function of p for p, c>0. As a result, the exponential convergence of the row-action EM formula still holds. Second, the disk may be inhomogeneous. Consequently, various projection values through a specific pixel can be different. Similarly, we can replace p with p max and still enjoy the exponential convergence. Third, if we consider not only the rays through the origin but also all other rays, interactions among over- and under-corrected values of all the pixels in the field of view will affect the correction at a given point. However, it can be shown that discrepancy at a pixel on a radial line through the point is ##EQU9## , which is very small in practice. For those pixels that are not on such a radial line, the discrepancies are even smaller, which are in O(α 2 ). Hence, these perturbations would not alter our conclusion on the convergence behavior of the row-action EM.
FIG. 2 provides a block diagram for an apparatus 200 implementing the iterative RAEM image reconstruction according to the present invention. In one embodiment, this apparatus could be integrated into the computer 135 of FIG. 1 as a specialized hardware element. The apparatus of FIG. 2 is described in further detail as follows.
First, a positive image of the subject is loaded into the current image memory 205. Either a positive constant image or an image generated from a preoperative scan and translated to guarantee non-negativity are examples of suitable images. A projection mask is created by the projection mask logic 215 from the most recent partial projection data of a pre-specified size stored in the projection data memory 210. The projection mask is stored in the projection mask memory 220. A relaxation matrix is generated from the projection mask utilizing the backprojector 225 and is stored in the relaxation matrix memory 230.
A reprojector 235 is used to generate estimated projection data based upon the image stored in the current image memory 205. The generated estimated projection data is stored in the estimated projection memory 240. Discrepancy data is created and stored in the discrepancy data memory 245 using a divider 250, the projection data in the projection data memory 210 and the estimated projection data in the estimated projection data memory 240.
The discrepancy data in the discrepancy data memory 245 is backprojected by the backprojector 220 over the image reconstruction grid to produce a backprojected image. The backprojected image is pixel-wise divided using a divider 255 by the relaxation factor stored in the relaxation matrix memory 230 and then pixel-wise multiplied using a multiplier 260 by the image stored in the current image memory 205. A priori knowledge, such as known image support, can be enforced upon the updated image utilizing the constraint logic 265 which ultimately passes an updated image to the current image memory 205. The reconstruction errors may be estimated in either the image or projection domains.
It is emphasized that the CTF method of the present invention can also be implemented using other ordered-subset based algorithms. An example is given below. Let us repeat the EM formula for emission CT as follows: ##EQU10## This EM formula has a geometrical explanation. Ratios between measured and predicted data are used to correct a guess to the underlying function. If difference, instead of ratio, is used to quantify discrepancy between measured and predicted data, the following additive iterative deblurring equation can be obtained: ##EQU11## An ordered-subset algorithm can be similarly developed for this additive iterative deblurring formula.
FIG. 3 displays a flowchart of the iterative RAEM reconstruction process of the present invention. Again, this process may be performed by the computer 135 of FIG. 1, which in an embodiment may be a Silicon Graphics O 2 computing platform, as previously described. The process depicted in FIG. 3 is described in further detail as follows.
First, in step 305 all the parameters of the scanner geometry and the imaging techniques are input. The parameters of the scanner geometry include the source-to-isocenter distance, the detector-to-isocenter distance, the fan-beam angle, the number and positions of the detectors, and so on. The parameters of the imaging techniques include the tube voltage and current, the dimensions of the field of view, the pixel size, and the dynamic range of reconstruction. Next, in step 310 the current image of the field of view is initialized. Either a pre-operative CT image of the same patient or a positive constant image can be used. If a pre-operative CT image is used, an appropriate translation is needed to make sure the image is nonnegative, which is required by the RAEM formula, and also is consistent to the underlying physics. The parameters specific to the CTF reconstruction such as the size of each subset and the threshold for determining if photo readings are significant are entered in step 315.
Because of the real-time nature of CTF, projection data must be continuously collected, and images be reconstructed and updated from consecutive partial scans. Therefore, we require that a partial scan consist of q consecutive projections, where q is a constant, and should be optimized according to applications. When x-ray dense objects, such as metal parts, exist in the region scanned by the fan-beam, x-ray photos can be blocked so they cannot reach detectors, and a threshold is needed to decide whether or not detectors are completely shadowed.
In step 320, a scanner is turned on to collect raw data continuously while a medical intervention is being performed. In reference to the subset size, the data acquisition process is monitored to wait for the most recent subset of data collected in step 325.
When a subset of data has accumulated in step 325, the process continues with step 330, where based on the recently collected subset of data and the pre-specified threshold, a projection mask is formed for each projection in the subset. Each element of this characteristic projection mask denotes whether or not significant measurement is made from the source to a detector. A projection mask is associated with an x-ray opaque object. Available x-rays are those not blocked by the metal. To take inhomogeneousness of cone-beam data into account, a relaxation function ##EQU12## is generated from the projection mask, the imaging geometry and the scanning locus. A relaxation matrix is formed in a backprojection manner in step 335. This matrix allows compensation for both beam divergence and data incompleteness.
In step 340, based on the current image, projection data are estimated via reprojection using the ray-tracing method. Next in step 345, real data and estimated data are point-wise divided to produce discrepancies of measured and estimated projection data. The process proceeds with step 350 where the discrepancies are backprojected over the image reconstruction grid to produce a backprojected image, and the backprojected image is then pixel-wise divided by the relaxation factor, which is then multiplied by the current image pixel-wise to update the current image. In step 355, a priori knowledge, such as a known image support, can be enforced upon the updated image, and reconstruction errors may be estimated in image and/or projection domains. In a further embodiment, steps 330 through 355 inclusive may be implemented in special hardware such as parallel processors, or stored as executable instructions in a computer-readable, digital storage device such as memory (RAM, ROM, etc.), a hard disk drive or other media (CD-ROM, floppy disk, magnetic tape, punched card, etc.).
Finally in step 360, the current image is displayed to provide immediate feedback during the real-time application. In step 365, a determination is made as to whether the real-time application is complete. If so, the image reconstruction process ends. If not, steps 320 through 360 are repeated until the real-time application is complete.
Additional details of the reprojection and the backprojection steps discussed above are provided as follows. In either reprojection or backprojection, each of the x-rays may be evenly divided at a specified step length, such as the pixel side length, being consistent to the discrete imaging model. In reprojection, the pixel values of four nearest neighbors of each dividing point contribute to the projection value via bi-linear interpolation. In backprojection, a projection value is additively re-distributed to the four nearest neighbors of each dividing point after weighting with corresponding bi-linear interpolation coefficients.
Image reconstruction according to the present invention requires both reprojection and backprojection. FIGS. 4 and 5 illustrate reprojection and backprojection processes respectively that may be used in the present invention. Both processes utilize a bi-linear interpolation as depicted in FIG. 6. Interpolation needed in reprojection and backprojection can also be performed in other ways.
In the reprojection process of FIG. 4, each of the x-rays may be evenly divided at a predetermined length, such as the pixel side length. The pixel values of the four nearest neighbors of each dividing point contribute to the projection value via bi-linear interpolation.
In the backprojection process of FIG. 5, each of the x-rays may be also evenly divided at a predetermined length, such as the pixel side length. A projection value is additively re-distributed to the four nearest neighbors of each dividing point after weighting with corresponding bi-linear interpolation coefficients.
We emphasize that our description in the fan-beam geometry can be directly extended into the cone-beam geometry. In the cone-beam case, tri-linear interpolation should be used in the place of bi-linear interpolation.
Numerical simulations were performed on clinical CTF images to demonstrate the effectiveness of the RAEM approach of the present invention. In this simulation, 512 by 512 pixel CTF images were down-sampled to 128 by 128 arrays.
Both the FB and RAEM algorithms were programmed in the IDL programming language (Research Systems; Boulder, Col., USA). The primary operations in both algorithms are reprojection and backprojection; these operations are discussed individually above. In both algorithms the backprojection was implemented via a Riemann function in IDL, which was optimized for speed. Since image values and projection data are available only on grid points, interpolation is needed to compute reprojection values along x-rays as well as backprojection contribution from various orientations. Linear interpolation was used in both processes as discussed above. Other types of interpolation are possible; however, they were not tested in these numerical simulations.
The initial guess was arbitrarily selected to be a positive constant image. Reconstruction was performed using 180 projections, 190 detectors per projection and half-scan data. A point source and point detectors were assumed.
The log conversion in data preprocessing may greatly amplify noise, especially when metal is present. In the case of very poor projection data, the measurement was considered invalid. In the row-action EM-like CTF algorithm, this knowledge was summarized in a projection mask. A matrix of spatially varying relaxation coefficients was synthesized based on the projection mask, and then used to iteratively minimize the I-divergence between the valid projection measures and the predicted counterparts.
Because the Poisson noise model is not valid for x-ray projection data, the noise added in the projection domain was uniform, whose interval was scaled to generate a realistic noisy appearance in CT images via filtered backprojection. The noise removal capability of the RAEM CTF algorithm was tested with not only uniform noise but also Gaussian and Poisson data, and similar results obtained. The tests indicated that the new CTF algorithm is much less sensitive than filtered backprojection. Additionally, the tests demonstrated that the image noise would not be amplified when the scan time was increased, because the image quality is basically determined by the signal-to-noise ratio, which would not be changed by extending the scan time.
FIGS. 8A-8D depict representative results for suppression of metal artifacts. FIG. 8A shows an actual image with a superimposed metal block at the beginning of a real-time medical intervention. FIG. 8B shows the image of FIG. 8A with an idealized metal needle inserted ten seconds into a simulated, real-time medical intervention. FIG. 8C shows the image of FIG. 8B reconstructed using the FB approach. This image suffers from prominent streaking resulting from metallic artifacts FIG. 8D shows the image of FIG. 8B using the RAEM approach. The metallic artifact streaking in this image is significantly less than the FB produced reconstruction.
Further, FIGS. 9A-9D depict representative results for noise reduction resulting from decreased tube current during CTF. FIG. 9A shows an actual image at the beginning of a real-time medial intervention. FIG. 9B shows the image of FIG. 9A with an idealized metal needle inserted eight seconds into a simulated, real-time medical intervention. FIG. 9C shows the image of FIG. 9B reconstructed via the FB approach. The image suffers from significant noise. FIG. 9D shows the image of FIG. 9B reconstructed via the RAEM approach. The image reconstructed via the RAEM approach displays better clarity than the image reconstructed via the FB approach.
In conclusion, the present invention makes use of a row-action or ordered-subset based algorithm in fan-beam or cone-beam geometry for reconstruction of x-ray CTF images suitable for real-time applications. The simulation results demonstrate the present invention's metal artifact and noise reduction capabilities.
Although the present invention has been described with reference to certain preferred embodiments thereof, variations and modification of the present invention can be effected within the spirit and scope of the following claims.
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In the present invention, an iterative process is provided for computed tomographic fluoroscopy (CTF) based upon an ordered-subset based algorithm or an adaptation of the row-action expectation maximization (RAEM) formula. This process is applied to reduce metal artifacts in CTF imaging, reduce image noise and provide rapid-image updating suitable for real-time applications. In one embodiment, generation of a projection mask and computation of a relaxation matrix are used to compensate for beam divergence and data incompleteness, and a priori knowledge such as a known image support is used to reduce image reconstruction errors.
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CLAIM OF PRIORITY
This application claims the benefit of U.S. Provisional Patent Application 61/357,080, entitled “METHODS AND SYSTEMS FOR A PORTAL FRAMEWORK IN AN ONLINE DEMAND SERVICE ENVIRONMENT,” by McFarlane et al., filed Jun. 21, 2010, the entire contents of which are incorporated herein by reference.
COPYRIGHT NOTICE
A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever.
FIELD OF THE INVENTION
One or more implementations relate generally to data presentation, and more particularly to manipulation of presented data.
BACKGROUND
The subject matter discussed in the background section should not be assumed to be prior art merely as a result of its mention in the background section. Similarly, a problem mentioned in the background section or associated with the subject matter of the background section should not be assumed to have been previously recognized in the prior art. The subject matter in the background section merely represents different approaches, which in and of themselves may also be inventions.
Conventional systems may desire to present data associated with the system to a user. For example, systems may retrieve system data from a database and present it to a user utilizing a display. Unfortunately, data presentation techniques have been associated with various limitations.
Just by way of example, traditional methods of presenting system data to a user may involve a static layout and static display of one or more data elements that may not be in a format preferred by the user, and may not convey information desired by the user. Additionally, the display may be slow to load due at least in part to one or more data requests associated with the display. Accordingly, it is desirable to allow a user to manipulate a display of presented system data and to optimize the presentation of such system data.
BRIEF SUMMARY
In accordance with embodiments, there are provided mechanisms and methods for performing actions associated with a portal. These mechanisms and methods for performing actions associated with a portal can enable an improved user experience, increased efficiency, optimized productivity, etc.
In an embodiment and by way of example, a method for performing actions associated with a portal is provided. In one embodiment, a request is received from a user to view a portal. Additionally, the portal is displayed to the user. Further, one or more actions associated with the portal are performed, based on user input.
While one or more implementations and techniques are described with reference to an embodiment in which performing actions associated with a portal is implemented in a system having an application server providing a front end for an on-demand database system capable of supporting multiple tenants, the one or more implementations and techniques are not limited to multi-tenant databases nor deployment on application servers. Embodiments may be practiced using other database architectures, i.e., ORACLE®, DB2® by IBM and the like without departing from the scope of the embodiments claimed.
Any of the above embodiments may be used alone or together with one another in any combination. The one or more implementations encompassed within this specification may also include embodiments that are only partially mentioned or alluded to or are not mentioned or alluded to at all in this brief summary or in the abstract. Although various embodiments may have been motivated by various deficiencies with the prior art, which may be discussed or alluded to in one or more places in the specification, the embodiments do not necessarily address any of these deficiencies. In other words, different embodiments may address different deficiencies that may be discussed in the specification. Some embodiments may only partially address some deficiencies or just one deficiency that may be discussed in the specification, and some embodiments may not address any of these deficiencies.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following drawings like reference numbers are used to refer to like elements. Although the following figures depict various examples, the one or more implementations are not limited to the examples depicted in the figures.
FIG. 1 illustrates a method for performing actions associated with a portal, in accordance with one embodiment;
FIG. 2 illustrates a method for accessing and interacting with a portal, in accordance with another embodiment;
FIG. 3 illustrates an exemplary portal, in accordance with another embodiment;
FIG. 4 illustrates another exemplary portal, in accordance with another embodiment;
FIG. 5 illustrates another exemplary portal that is manipulated by a user, in accordance with another embodiment;
FIG. 6 illustrates another exemplary portal in which a help search is performed, in accordance with another embodiment;
FIG. 7 illustrates a block diagram of an example of an environment wherein an on-demand database system might be used; and
FIG. 8 illustrates a block diagram of an embodiment of elements of FIG. 7 and various possible interconnections between these elements.
DETAILED DESCRIPTION
General Overview
Systems and methods are provided for performing actions associated with a portal.
As used herein, the term multi-tenant database system refers to those systems in which various elements of hardware and software of the database system may be shared by one or more customers. For example, a given application server may simultaneously process requests for a great number of customers, and a given database table may store rows for a potentially much greater number of customers.
Next, mechanisms and methods for performing actions associated with a portal will be described with reference to example embodiments.
FIG. 1 illustrates a method 100 for performing actions associated with a portal, in accordance with one embodiment. As shown in operation 102 , a request is received from a user to view a portal. In one embodiment, the portal may include data retrieved from one or more sources. For example, the portal may include data from one or more databases, data from a multi-tenant on-demand database system, data from one or more web sites, etc.
Additionally, in one embodiment, the portal may include one or more web pages (e.g., one or more hypertext markup language (HTML) pages, etc.). In another embodiment, the request to view the portal may include login data associated with the user. For example, the request to view the portal may include a user name and password associated with a user account within a system that provides the portal that is input by the user utilizing a graphical user interface (GUI).
Further, in another embodiment, the request to view the portal may include an address of a location of the portal. For example, the request to view the portal may include a uniform resource locator (URL) that is input by the user into a web browser. In yet another embodiment, the request to view the portal may include a selection of a link to the portal. For example, the request to view the portal may include the selection of a link that is provided to the user by a search engine (e.g., an Internet-based search engine, etc.) as a result of a query input by the user into the search engine. In another example, the request to view the portal may include the selection of a link (e.g., a help link, etc.) within a web page of the provider of the portal.
Further still, in one embodiment, the portal may be associated with a multi-tenant on-demand database system. For example, the user may include a customer of the multi-tenant on-demand database system (e.g., an organization of the system, etc.), an employee of a customer of the multi-tenant on-demand database system, an administrator of a customer of a multi-tenant on-demand database system, etc., and the portal may provide information associated with such system to the user. In another embodiment, the portal may be provided by the multi-tenant on-demand database system.
Also, it should be noted that, as described above, such multi-tenant on-demand database system may include any service that relies on a database system that is accessible over a network, in which various elements of hardware and software of the database system may be shared by one or more customers (e.g. tenants). For instance, a given application server may simultaneously process requests for a great number of customers, and a given database table may store rows for a potentially much greater number of customers. Various examples of such a multi-tenant on-demand database system will be set forth in the context of different embodiments that will be described during reference to subsequent figures.
Additionally, as shown in operation 104 , the portal is displayed to the user. In one embodiment, displaying the portal to the user may include requesting and retrieving data from one or more sources, which may then be presented to the user by the portal. For example, one or more applications, databases, etc. may be queried for data, and such data may be retrieved and presented to the user through the portal. In another embodiment, the retrieved data may be associated with the user. For example, the retrieved data may include user data retrieved from a database associated with a user's account, etc.
In another embodiment, the portal may provide one or more services to the user. For example, the portal may provide messaging services (e.g., electronic mail messaging, instant messaging, etc.) to the user. In another example, the portal may provide one or more search services (e.g., portal search, Internet search, etc.) to the user. In yet another embodiment, the portal may be displayed utilizing a web browser. For example, the portal may be displayed as one or more web pages within the web browser.
Further, in one embodiment, the portal may include one or more widgets (e.g., one or more portlets, gadgets, etc.) that are displayed through the portal. For example, the portal may include one or more applications that are executed within the portal. In another embodiment, each of the widgets displayed within the portal may be associated with particular data. For example, each widget may retrieve data from a specific source. In another example, each widget may display a certain type of data to the user. In yet another embodiment, the portal may include a plurality of columns, where each widget may be located within one of the plurality of columns.
Further still, in one embodiment, one of the widgets displayed through the portal may display data retrieved from a social media source. In another embodiment, one of the widgets displayed through the portal may display data associated with a knowledge base (e.g., a knowledge base of a multi-tenant on-demand database system, etc.). In yet another embodiment, one of the widgets displayed through the portal may display frequently asked questions (FAQs) associated with a system (e.g., FAQs associated with a multi-tenant on-demand database system, etc.). For example, the widget may display most popular FAQs, highest rated FAQs, etc. In still another embodiment, the widget may display training and/or certification information. For example, the widget may include a jumpstart widget that links to a training area associated with an organization of the user.
In another embodiment, the widget may include case information associated with the user. For example, the widget may display open tickets associated with the user, open cases associated with the user, terms associated with a contract, etc. In yet another embodiment, the widget may display information associated with a status of a system (e.g., a status of the user's local computer, a status of one or more servers, a status of a multi-tenant on-demand database system, etc.).
Also, in one embodiment, the widgets may be displayed to the user through the portal based on one or more privileges associated with the user. For example, the user may have an associated level of access (e.g., an access score, an associated role within an organization, etc.), and only widgets that correspond to the user's access score (e.g., widgets that have a score less than or equal to the user's access score, etc.) may be displayed to the user through the portal.
Additionally, in one embodiment, the widgets may be loaded in parallel with the portal. For example, a web page associated with the portal may load immediately in response to the request, and one or more widgets may load within the portal in parallel (e.g., via asynchronous data requests, etc.). In another embodiment, the widgets may be loaded within the portal after the portal is loaded. In yet another embodiment, the one or more widgets may be loaded within the portal according to one or more settings associated with the user. For example, one or more portal preferences associated with the user may be saved that describe which widgets are to be displayed to the user through the portal.
Further, as shown in operation 106 , one or more actions associated with the portal are performed, based on user input. In one embodiment, the user input may include a user request to manipulate one or more elements associated with one or more widgets of the portal. For example, the user input may include one or more of the user selecting one or more widgets within the portal utilizing an icon of a GUI, dragging and dropping one or more widgets within the portal, selecting one or more icons within one or more widgets, etc.
Further still, in one embodiment, the one or more actions may include manipulating one or more widgets of the portal. For example, the one or more actions may include changing a location of a widget within the portal based on the user clicking and dragging the widget to a different location (e.g., a different columns, etc.) within the portal. In another example, the location of one or more widgets may be arranged within the portal by the user. In another embodiment, the location of a widget may be calibrated when the widget is moved. In yet another embodiment, the one or more actions may include adding and/or removing one or more widgets from the portal. For example, a widget may be added to the portal in response to the user selecting and dragging an icon associated with the widget from a toolbar of the portal to another location within the portal (e.g., a display area within the portal, etc.). In another example, a widget may be removed from the portal in response to a user selecting an icon within the widget (e.g., a removal icon, etc.).
Also, in one embodiment, the one or more actions may include displaying additional information within a widget of the portal. For example, an additional layer of a hierarchical widget may be displayed in response to the user selecting an icon next to a representation of the widget within the portal. In another example, additional information may be displayed within a widget in response to the user selecting a tab within the widget. In another embodiment, the one or more actions may include minimizing a widget that is shown within the portal. For example, the widget may be minimized within the portal in response to the user selecting an icon of the widget. In another embodiment, the one or more actions may include maximizing a minimized widget that is shown within the portal.
In addition, in one embodiment, one or more widgets of the portal may be categorized based on a common theme, pattern, etc. Additionally, one or more actions may be performed on all widgets of a certain categorization, based on user input. For example, only a top number of items may be shown in all widgets that include lists of items. In another example, only a certain number of columns may be shown for all widgets that include tables. In yet another example, all widgets of a certain categorization may be removed, maximized, etc. based on the user input.
In another embodiment, the one or more actions may include manipulating one or more elements of the portal layout. For example, one or more columns of the portal may be added, removed, or adjusted in response to the user input. In another embodiment, one or more preferences associated with the user input may be saved. For example, after performing the one or more actions, the state of the portal may be saved to memory. Additionally, the saved state may be later used to recreate the preferences of the user within the portal when the user logs on at a later time.
FIG. 2 illustrates a method 200 for accessing and interacting with a portal, in accordance with another embodiment. As an option, the method 200 may be carried out in the context of the functionality of FIG. 1 . Of course, however, the method 200 may be carried out in any desired environment. The aforementioned definitions may apply during the present description.
As shown in operation 202 , a user performs an internet search utilizing a search engine. In one embodiment, the user may perform the search by inputting a search query into a field of the search engine interface. Additionally, as shown in operation 204 , the user selects a link to a portal from the search engine results. For example, the search engine may return multiple hyperlinks in response to the internet search, and the user may select one of the hyperlinks, where the selected hyperlink may direct the user to the portal.
Further, as shown in operation 206 , the portal presents one or more widgets to the user, based on one or more settings associated with the user. In one embodiment, the settings may include data stored by the user's web browser (e.g., one or more cookies, etc.). In another embodiment, the settings may identify the user to the portal. In yet another embodiment, the portal may compare the identification of the user to one or more user portal profiles stored by the provider of the portal. Additionally, if the identification of the user matches an existing profile stored by the provider, the matching profile may be retrieved. If the identification of the user does not match an existing stored profile, then a default profile may be retrieved.
Further still, in one embodiment, the retrieved profile may be used to determine which widgets are displayed to the user within the portal. For example, a list of available widgets may be stored in a master table in association with the portal, and the retrieved profile may dictate which widgets from the list are to be displayed to the user within the portal. Additionally, one or more row and column coordinates may be stored within the retrieved portal for each widget displayed within the portal, such that each widget may be displayed to the user in the same manner that the user last viewed them. In another embodiment, the number of widgets presented to the user through the portal may be based on an authorization level of the user.
Also, in one embodiment, each of the widgets displayed to the user may retrieve information from one or more sources. For example, each widget may retrieve information from a database of the portal provider, from a web application call, from a knowledge base application, etc. In another embodiment, each of the widgets may retrieve information from the one or more sources after the portal has loaded. For example, each widget may display a “loading” indicator after the portal has loaded while the widget retrieves the information. In this way, the portal may be quickly loaded and presented to the user. In another example, a widget may cache the retrieved information. In yet another embodiment, each of the widgets may be displayed using a scripting language (e.g. Javascript®, etc.), and may retrieve information utilizing a platform (e.g., a Force.com® platform utilizing Apex® code, etc.).
Additionally, as shown in operation 208 , the user attempts to manipulate one or more elements of the portal. In one embodiment, the user may attempt to manipulate the structure of the portal. For example, the user may click and drag one or more columns of the portal. In another example, the user may rearrange the order of one or more widgets displayed within the portal. In another embodiment, the user may attempt to add one or more widgets to the display area of the portal. For example, the portal may include a toolbar where the user may select one or more unused and/or new widgets to be displayed by the portal.
Further, in one embodiment, the user may attempt to remove one or more widgets displayed within the portal, minimize one or more widgets displayed within the portal, maximize one or more widgets displayed within the portal, etc. In another embodiment, the user may attempt to set a particular format for one or more categories of widgets. For example, one or more widgets may be grouped into a category based on common themes and/or patterns (e.g., list view, single view/edit, graph, etc.), and the user may attempt to set a format (e.g., a number of items listed, rows displayed, etc.) for the category.
Further still, in one embodiment, the user may attempt to view a different portion of a widget (e.g., by selecting a tab associated additional information provided by the widget, etc.). In another embodiment, the user may attempt to view an additional hierarchy associated with the widget (e.g., by clicking on an icon associated with the widget such that the widget expands to show hierarchical information, etc.).
Also, as shown in decision 210 , it is determined whether the user has sufficient authorization to perform the attempted manipulation. In one embodiment, an authorization level may be associated with the user and may be stored within the user's local computer (e.g., as a cookie, etc.) and/or a server database associated with the provider of the portal (e.g., as a portal state custom object, etc). In another embodiment, this authorization level may be compared to the user's attempted manipulation. For example, this authorization level may be compared to the authorization level needed to add, remove, view, or otherwise manipulate data associated with one or more widgets (e.g., a widget's authorization level, etc.), the authorization level needed to perform one or more modifications to the portal, etc.
If it is determined in decision 210 that the user has sufficient authorization to perform the attempted manipulation, then in operation 212 the attempted manipulation is performed. In one embodiment, the portal may dynamically adjust in response to the performed manipulation. For example, the portal may automatically line up an added widget with other displayed widgets, and may automatically pull information needed by the widget from the data source after the attempt is authorized. In another example, the portal may push down existing information in order to display additional hierarchical information associated with a widget. In another embodiment, queries associated with the portal manipulation may be performed in bulk in order to minimize a consumption of system resources.
Additionally, as shown in operation 214 , the portal settings associated with the portal manipulation are saved. In one embodiment, the settings may be saved to the user's local computer (e.g., as one or more cookies, etc.), to a server database, etc. In another embodiment, the settings may include toolbar settings, widget settings, portal arrangement settings, etc. In yet another embodiment, one or more actions of the user (e.g., a number of times the user opens a page of the portal, minimizes a widget of the portal, etc.) may be tracked and stored by the portal.
If it is determined in decision 210 that the user does not have sufficient authorization to perform the attempted manipulation, then in operation 216 the user is prompted with a message requiring the user to log in to or register with the provider of the portal. In this way, the user may be further authorized in order to determine whether the attempted manipulation may be carried out.
Further, in another embodiment, a purpose of the widget framework may be to allow the user to arrange a custom desktop with useful and relevant information for their needs. It may serve up dynamic content and reduce the need for a user to click to get value from the portal page. In yet another embodiment, the portal may include a user dashboard. In this way, value may be provided to different types of users through the availability of a wide variety of widgets.
FIG. 3 illustrates an exemplary portal 300 , in accordance with another embodiment. As an option, the portal 300 may be implemented in the context of the functionality of FIGS. 1-2 . Of course, however, the portal 300 may be carried out in any desired environment. The aforementioned definitions may apply during the present description.
As shown, the portal 300 includes a plurality of widgets 304 a - g displayed within three columns of the body of the portal 300 . Additionally, the portal 300 includes a help window 302 . In one embodiment, a user of the portal 300 may input one or more keywords into the help window 302 , and such keywords may be compared against a help database of the portal 300 . Further, the portal 300 includes a site search window 306 , where a user may input one or more keywords that are to be searched within the site of the provider of the portal 300 .
FIG. 4 illustrates another exemplary portal 300 , in accordance with another embodiment. As an option, the portal 400 may be implemented in the context of the functionality of FIGS. 1-3 . Of course, however, the portal 400 may be carried out in any desired environment. The aforementioned definitions may apply during the present description.
As shown, the portal 400 includes a social media widget 402 . In one embodiment, the social media widget 402 of the portal 400 may retrieve data from an external social media web site, and may display such retrieved data within the social media widget 402 . In this way, a user may not have to leave the portal 400 in order to view data associated with a social media web site.
FIG. 5 illustrates another exemplary portal 500 that is manipulated by a user, in accordance with another embodiment. As an option, the portal 500 may be implemented in the context of the functionality of FIGS. 1-4 . Of course, however, the portal 500 may be carried out in any desired environment. The aforementioned definitions may apply during the present description.
As shown, a social media widget 502 of the portal 500 has been minimized. In one embodiment, this minimization of the social media widget 502 may be performed by a user selecting an icon 504 within the social media widget 502 . In this way, the user may manipulate the display of the widgets within the portal 500 .
FIG. 6 illustrates another exemplary portal 600 in which a help search is performed, in accordance with another embodiment. As an option, the portal 600 may be implemented in the context of the functionality of FIGS. 1-5 . Of course, however, the portal 600 may be carried out in any desired environment. The aforementioned definitions may apply during the present description.
As shown, a search term 604 is entered into the help window 602 of the portal 600 . As the search term 604 is entered into the help window 602 , help search results 606 related to the input search term 604 are displayed within the portal 600 . In this way, a user of the portal 600 may receive system assistance, widget help, keyword searching, etc. while using the portal 600 .
System Overview
FIG. 7 illustrates a block diagram of an environment 710 wherein an on-demand database system might be used. Environment 710 may include user systems 712 , network 714 , system 716 , processor system 717 , application platform 718 , network interface 720 , tenant data storage 722 , system data storage 724 , program code 726 , and process space 728 . In other embodiments, environment 710 may not have all of the components listed and/or may have other elements instead of, or in addition to, those listed above.
Environment 710 is an environment in which an on-demand database system exists. User system 712 may be any machine or system that is used by a user to access a database user system. For example, any of user systems 712 can be a handheld computing device, a mobile phone, a laptop computer, a work station, and/or a network of computing devices. As illustrated in FIG. 7 (and in more detail in FIG. 8 ) user systems 712 might interact via a network 714 with an on-demand database system, which is system 716 .
An on-demand database system, such as system 716 , is a database system that is made available to outside users that do not need to necessarily be concerned with building and/or maintaining the database system, but instead may be available for their use when the users need the database system (e.g., on the demand of the users). Some on-demand database systems may store information from one or more tenants stored into tables of a common database image to form a multi-tenant database system (MTS). Accordingly, “on-demand database system 716 ” and “system 716 ” will be used interchangeably herein. A database image may include one or more database objects. A relational database management system (RDMS) or the equivalent may execute storage and retrieval of information against the database object(s). Application platform 718 may be a framework that allows the applications of system 716 to run, such as the hardware and/or software, e.g., the operating system. In an embodiment, on-demand database system 716 may include an application platform 718 that enables creation, managing and executing one or more applications developed by the provider of the on-demand database system, users accessing the on-demand database system via user systems 712 , or third party application developers accessing the on-demand database system via user systems 712 .
The users of user systems 712 may differ in their respective capacities, and the capacity of a particular user system 712 might be entirely determined by permissions (permission levels) for the current user. For example, where a salesperson is using a particular user system 712 to interact with system 716 , that user system has the capacities allotted to that salesperson. However, while an administrator is using that user system to interact with system 716 , that user system has the capacities allotted to that administrator. In systems with a hierarchical role model, users at one permission level may have access to applications, data, and database information accessible by a lower permission level user, hut may not have access to certain applications, database information, and data accessible by a user at a higher permission level. Thus, different users will have different capabilities with regard to accessing and modifying application and database information, depending on a user's security or permission level.
Network 714 is any network or combination of networks of devices that communicate with one another. For example, network 714 can be any one or any combination of a LAN (local area network), WAN (wide area network), telephone network, wireless network, point-to-point network, star network, token ring network, hub network, or other appropriate configuration. As the most common type of computer network in current use is a TCP/IP (Transfer Control Protocol and Internet Protocol) network, such as the global internetwork of networks often referred to as the “Internet” with a capital “I,” that network will be used in many of the examples herein. However, it should be understood that the networks that the one or more implementations might use are not so limited, although TCP/IP is a frequently implemented protocol.
User systems 712 might communicate with system 716 using TCP/IP and, at a higher network level, use other common Internet protocols to communicate, such as HTTP, FTP, AFS, WAP, etc. In an example where HTTP is used, user system 712 might include an HTTP client commonly referred to as a “browser” for sending and receiving HTTP messages to and from an HTTP server at system 716 . Such an HTTP server might be implemented as the sole network interface between system 716 and network 714 , but other techniques might be used as well or instead. In some implementations, the interface between system 716 and network 714 includes load sharing functionality, such as round-robin HTTP request distributors to balance loads and distribute incoming HTTP requests evenly over a plurality of servers. At least as for the users that are accessing that server, each of the plurality of servers has access to the MTS' data; however, other alternative configurations may be used instead.
In one embodiment, system 716 , shown in FIG. 7 , implements a web-based customer relationship management (CRM) system. For example, in one embodiment, system 716 includes application servers configured to implement and execute CRM software applications as well as provide related data, code, forms, webpages and other information to and from user systems 712 and to store to, and retrieve from, a database system related data, objects, and Webpage content. With a multi-tenant system, data for multiple tenants may be stored in the same physical database object, however, tenant data typically is arranged so that data of one tenant is kept logically separate from that of other tenants so that one tenant does not have access to another tenant's data, unless such data is expressly shared. In certain embodiments, system 716 implements applications other than, or in addition to, a CRM application. For example, system 716 may provide tenant access to multiple hosted (standard and custom) applications, including a CRM application. User (or third party developer) applications, which may or may not include CRM, may be supported by the application platform 718 , which manages creation, storage of the applications into one or more database objects and executing of the applications in a virtual machine in the process space of the system 716 .
One arrangement for elements of system 716 is shown in FIG. 7 , including a network interface 720 , application platform 718 , tenant data storage 722 for tenant data 723 , system data storage 724 for system data 725 accessible to system 716 and possibly multiple tenants, program code 726 for implementing various functions of system 716 , and a process space 728 for executing MTS system processes and tenant-specific processes, such as running applications as part of an application hosting service. Additional processes that may execute on system 716 include database indexing processes.
Several elements in the system shown in FIG. 7 include conventional, well-known elements that are explained only briefly here. For example, each user system 712 could include a desktop personal computer, workstation, laptop, PDA, cell phone, or any wireless access protocol (WAP) enabled device or any other computing device capable of interfacing directly or indirectly to the Internet or other network connection. User system 712 typically runs an HTTP client, e.g., a browsing program, such as Microsoft's Internet Explorer browser, Netscape's Navigator browser, Opera's browser, or a WAP-enabled browser in the case of a cell phone, PDA or other wireless device, or the like, allowing a user (e.g., subscriber of the multi-tenant database system) of user system 712 to access, process and view information, pages and applications available to it from system 716 over network 714 . Each user system 712 also typically includes one or more user interface devices, such as a keyboard, a mouse, trackball, touch pad, touch screen, pen or the like, for interacting with a graphical user interface (GUI) provided by the browser on a display (e.g., a monitor screen, LCD display, etc.) in conjunction with pages, forms, applications and other information provided by system 716 or other systems or servers. For example, the user interface device can be used to access data and applications hosted by system 716 , and to perform searches on stored data, and otherwise allow a user to interact with various GUI pages that may be presented to a user. As discussed above, embodiments are suitable for use with the Internet, which refers to a specific global internet work of networks. However, it should be understood that other networks can be used instead of the Internet, such as an intranet, an extranet, a virtual private network (VPN), a non-TCP/IP based network, any LAN or WAN or the like.
According to one embodiment, each user system 712 and all of its components are operator configurable using applications, such as a browser, including computer code run using a central processing unit such as an Intel Pentium® processor or the like. Similarly, system 716 (and additional instances of an MTS, where more than one is present) and all of their components might be operator configurable using application(s) including computer code to run using a central processing unit such as processor system 717 , which may include an Intel Pentium® processor or the like, and/or multiple processor units. A computer program product embodiment includes a machine-readable storage medium (media) having instructions stored thereon/in which can be used to program a computer to perform any of the processes of the embodiments described herein. Computer code for operating and configuring system 716 to intercommunicate and to process webpages, applications and other data and media content as described herein are preferably downloaded and stored on a hard disk, but the entire program code, or portions thereof, may also be stored in any other volatile or non-volatile memory medium or device as is well known, such as a ROM or RAM, or provided on any media capable of storing program code, such as any type of rotating media including floppy disks, optical discs, digital versatile disk (DVD), compact disk (CD), microdrive, and magneto-optical disks, and magnetic or optical cards, nanosystems (including molecular memory ICs), or any type of media or device suitable for storing instructions and/or data. Additionally, the entire program code, or portions thereof, may be transmitted and downloaded from a software source over a transmission medium, e.g., over the Internet, or from another server, as is well known, or transmitted over any other conventional network connection as is well known (e.g., extranet, VPN, LAN, etc.) using any communication medium and protocols (e.g., TCP/IP, HTTP, HTTPS, Ethernet, etc.) as are well known. It will also be appreciated that computer code for implementing embodiments can be implemented in any programming language that can be executed on a client system and/or server or server system such as, for example, C, C++, HTML, any other markup language, Java™, JavaScript, ActiveX, any other scripting language, such as VBScript, and many other programming languages as are well known may be used. (Java™ is a trademark of Sun Microsystems, Inc.).
According to one embodiment, each system 716 is configured to provide webpages, forms, applications, data and media content to user (client) systems 712 to support the access by user systems 712 as tenants of system 716 . As such, system 716 provides security mechanisms to keep each tenant's data separate unless the data is shared. If more than one MTS is used, they may be located in close proximity to one another (e.g., in a server farm located in a single building or campus), or they may be distributed at locations remote from one another (e.g., one or more servers located in city A and one or more servers located in city B). As used herein, each MTS could include one or more logically and/or physically connected servers distributed locally or across one or more geographic locations. Additionally, the term “server” is meant to include a computer system, including processing hardware and process space(s), and an associated storage system and database application (e.g., OODBMS or RDBMS) as is well known in the art. It should also be understood that “server system” and “server” are often used interchangeably herein. Similarly, the database object described herein can be implemented as single databases, a distributed database, a collection of distributed databases, a database with redundant online or offline backups or other redundancies, etc., and might include a distributed database or storage network and associated processing intelligence.
FIG. 8 also illustrates environment 710 . However, in FIG. 8 elements of system 716 and various interconnections in an embodiment are further illustrated. FIG. 8 shows that user system 712 may include processor system 712 A, memory system 712 B, input system 712 C, and output system 712 D. FIG. 8 shows network 714 and system 716 . FIG. 8 also shows that system 716 may include tenant data storage 722 , tenant data 723 , system data storage 724 , system data 725 , User Interface (UI) 830 , Application Program Interface (API) 832 , PL/SOQL 834 , save routines 836 , application setup mechanism 838 , applications servers 800 1 - 800 N , system process space 802 , tenant process spaces 804 , tenant management process space 810 , tenant storage area 812 , user storage 814 , and application metadata 816 . In other embodiments, environment 710 may not have the same elements as those listed above and/or may have other elements instead of, or in addition to, those listed above.
User system 712 , network 714 , system 716 , tenant data storage 722 , and system data storage 724 were discussed above in FIG. 7 . Regarding user system 712 , processor system 712 A may be any combination of one or more processors. Memory system 712 B may be any combination of one or more memory devices, short term, and/or long term memory. Input system 712 C may be any combination of input devices, such as one or more keyboards, mice, trackballs, scanners, cameras, and/or interfaces to networks. Output system 712 D may be any combination of output devices, such as one or more monitors, printers, and/or interfaces to networks. As shown by FIG. 8 , system 716 may include a network interface 720 (of FIG. 7 ) implemented as a set of HTTP application servers 800 , an application platform 718 , tenant data storage 722 , and system data storage 724 . Also shown is system process space 802 , including individual tenant process spaces 804 and a tenant management process space 810 . Each application server 800 may be configured to tenant data storage 722 and the tenant data 723 therein, and system data storage 724 and the system data 725 therein to serve requests of user systems 712 . The tenant data 723 might be divided into individual tenant storage areas 812 , which can be either a physical arrangement and/or a logical arrangement of data. Within each tenant storage area 812 , user storage 814 and application metadata 816 might be similarly allocated for each user. For example, a copy of a user's most recently used (MRU) items might be stored to user storage 814 . Similarly, a copy of MRU items for an entire organization that is a tenant might be stored to tenant storage area 812 . A UI 830 provides a user interface and an API 832 provides an application programmer interface to system 716 resident processes to users and/or developers at user systems 712 . The tenant data and the system data may be stored in various databases, such as one or more Oracle™ databases.
Application platform 718 includes an application setup mechanism 838 that supports application developers' creation and management of applications, which may be saved as metadata into tenant data storage 722 by save routines 836 for execution by subscribers as one or more tenant process spaces 804 managed by tenant management process 810 for example. Invocations to such applications may be coded using PL/SOQL 834 that provides a programming language style interface extension to API 832 . A detailed description of some PL/SOQL language embodiments is discussed in commonly owned U.S. Pat. No. 7,730,478 entitled, METHOD AND SYSTEM FOR ALLOWING ACCESS TO DEVELOPED APPLICATIONS VIA A MULTI-TENANT ON-DEMAND DATABASE SERVICE, by Craig Weissman, filed Sep. 21, 2007, which is incorporated in its entirety herein for all purposes. Invocations to applications may be detected by one or more system processes, which manages retrieving application metadata 816 for the subscriber making the invocation and executing the metadata as an application in a virtual machine.
Each application server 800 may be communicably coupled to database systems, e.g., having access to system data 725 and tenant data 723 , via a different network connection. For example, one application server 800 1 might be coupled via the network 714 (e.g., the Internet), another application server 800 N-1 might be coupled via a direct network link, and another application server 800 N might be coupled by yet a different network connection. Transfer Control Protocol and Internet Protocol (TCP/IP) are typical protocols for communicating between application servers 800 and the database system. However, it will be apparent to one skilled in the art that other transport protocols may be used to optimize the system depending on the network interconnect used.
In certain embodiments, each application server 800 is configured to handle requests for any user associated with any organization that is a tenant. Because it is desirable to be able to add and remove application servers from the server pool at any time for any reason, there is preferably no server affinity for a user and/or organization to a specific application server 800 . In one embodiment, therefore, an interface system implementing a load balancing function (e.g., an F5 Big-IP load balancer) is communicably coupled between the application servers 800 and the user systems 712 to distribute requests to the application servers 800 . In one embodiment, the load balancer uses a least connections algorithm to route user requests to the application servers 800 . Other examples of load balancing algorithms, such as round robin and observed response time, also can be used. For example, in certain embodiments, three consecutive requests from the same user could hit three different application servers 800 , and three requests from different users could hit the same application server 800 . In this manner, system 716 is multi-tenant, wherein system 716 handles storage of, and access to, different objects, data and applications across disparate users and organizations.
As an example of storage, one tenant might be a company that employs a sales force where each salesperson uses system 716 to manage their sales process. Thus, a user might maintain contact data, leads data, customer follow-up data, performance data, goals and progress data, etc., all applicable to that user's personal sales process (e.g., in tenant data storage 722 ). In an example of a MTS arrangement, since all of the data and the applications to access, view, modify, report, transmit, calculate, etc., can be maintained and accessed by a user system having nothing more than network access, the user can manage his or her sales efforts and cycles from any of many different user systems. For example, if a salesperson is visiting a customer and the customer has Internet access in their lobby, the salesperson can obtain critical updates as to that customer while waiting for the customer to arrive in the lobby.
While each user's data might be separate from other users' data regardless of the employers of each user, some data might be organization-wide data shared or accessible by a plurality of users or all of the users for a given organization that is a tenant. Thus, there might be some data structures managed by system 716 that are allocated at the tenant level while other data structures might be managed at the user level. Because an MTS might support multiple tenants including possible competitors, the MTS should have security protocols that keep data, applications, and application use separate. Also, because many tenants may opt for access to an MTS rather than maintain their own system, redundancy, up-time, and backup are additional functions that may be implemented in the MTS. In addition to user-specific data and tenant specific data, system 716 might also maintain system level data usable by multiple tenants or other data. Such system level data might include industry reports, news, postings, and the like that are sharable among tenants.
In certain embodiments, user systems 712 (which may be client systems) communicate with application servers 800 to request and update system-level and tenant-level data from system 716 that may require sending one or more queries to tenant data storage 722 and/or system data storage 724 . System 716 (e.g., an application server 800 in system 716 ) automatically generates one or more SQL statements (e.g., one or more SQL queries) that are designed to access the desired information. System data storage 724 may generate query plans to access the requested data from the database.
Each database can generally be viewed as a collection of objects, such as a set of logical tables, containing data fitted into predefined categories. A “table” is one representation of a data object, and may be used herein to simplify the conceptual description of objects and custom objects. It should be understood that “table” and “object” may be used interchangeably herein. Each table generally contains one or more data categories logically arranged as columns or fields in a viewable schema. Each row or record of a table contains an instance of data for each category defined by the fields. For example, a CRM database may include a table that describes a customer with fields for basic contact information such as name, address, phone number, fax number, etc. Another table might describe a purchase order, including fields for information such as customer, product, sale price, date, etc. In some multi-tenant database systems, standard entity tables might be provided for use by all tenants. For CRM database applications, such standard entities might include tables for Account, Contact, Lead, and Opportunity data, each containing pre-defined fields. It should be understood that the word “entity” may also be used interchangeably herein with “object” and “table”.
In some multi-tenant database systems, tenants may be allowed to create and store custom objects, or they may be allowed to customize standard entities or objects, for example by creating custom fields for standard objects, including custom index fields. U.S. patent application Ser. No. 10/817,161, filed Apr. 2, 2004, entitled “Custom Entities and Fields in a Multi-Tenant Database System”, and which is hereby incorporated herein by reference, teaches systems and methods for creating custom objects as well as customizing standard objects in a multi-tenant database system. In certain embodiments, for example, all custom entity data rows are stored in a single multi-tenant physical table, which may contain multiple logical tables per organization. It is transparent to customers that their multiple “tables” are in fact stored in one large table or that their data may be stored in the same table as the data of other customers.
While one or more implementations have been described by way of example and in terms of the specific embodiments, it is to be understood that one or more implementations are not limited to the disclosed embodiments. To the contrary, it is intended to cover various modifications and similar arrangements as would be apparent to those skilled in the art. Therefore, the scope of the appended claims should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements.
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Provided are mechanisms and methods for performing actions associated with a portion of portal content provided to a user. These mechanisms and methods for performing the actions associated with the portion of the portal content can enable an improved user experience, increased efficiency, optimized productivity, etc. Further, the actions associated with the portion of the portal content can include manipulations requested by the user, such as an addition to, a removal of, and a rearrangement of the portion of the portal content.
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BACKGROUND OF THE INVENTION
The present invention relates to a pattern plate carrier for air-pressurized compaction processes and, more particularly, a carrier for supporting a pattern plate in a sand mold making process wherein the carrier is equipped with air venting structure running along the inner contour of the molding box of the sand molding apparatus.
In modern sand molding processes used to produce sand molds for casting molten metal, compressed air is made to flow vertically from the top of the sand located in the sand mold to the bottom. In order to obtain better compaction of the sand on the pattern in the molding apparatus, particularly in the marginal zones along the interior wall of the molding box, the compressed air flowing in on the upper side of the molding box and vertically down through the molding sand must be able to escape on the pattern side of the molding box. Heretofore, this has been accomplished by providing orifices in the pattern plate in the form of round nozzles in the area of the pattern plate between the pattern and the molding box, see for example German Patentschrift 26 08 740. As a result of the foregoing, the area of the pattern plate which can be utilized is greatly reduced.
Naturally, it would be highly desirable to provide a sand molding apparatus which would allow for the air flowing through the sand material to escape on the pattern side of the mold while at the same time allowing for high utilization of the area of the pattern plate thereby resulting in higher casting yield per mold box.
Accordingly, it is the principal object of the present invention to provide an apparatus as aforesaid which allows for an enlarging of the pattern plate area utilized in a molding box thereby resulting in higher casting yield per molding box.
It is a further object of the present invention to provide a pattern plate carrier with venting structure for allowing air to escape the molding space on the pattern side of the molding box.
It is a particular object of the present invention to provide a pattern plate carrier as aforesaid which includes elongated slotted bars around the periphery of the pattern plate for venting air.
It is a still further object of the present invention to provide a pattern plate carrier which is simple in structure and efficient in operation.
Further objects and advantages of the present invention will appear hereinbelow.
SUMMARY OF THE INVENTION
In accordance with the present invention the foregoing objects and advantages are readily obtained.
The present invention relates to an apparatus for compacting molding sand with compressed air. The apparatus includes a pattern plate having a molding box positioned thereon for defining therewith a molding space. In one embodiment of the present invention vents are provided on the pattern plate for allowing the compressed air to escape the molding space on the pattern side of the molding box, the vents being in the form of a plurality of elongated slotted bars each having a longitudinal axis and a plurality of slots extending substantially transversely to the longitudinal axis of the bars. By providing slotted bars as aforesaid, the space requirement for the venting structure is considerably reduced when compared to the nozzle structure of the prior art. Consequently, the utilization of the pattern plate can be increased over the prior art molding structures. The enlarged utilization area of the pattern plate permits better coverage with the patterns which, consequently, results in a higher casting yield per mold box.
In accordance with the preferred embodiment of the present invention a pattern plate carrier for supporting a pattern plate in a sand mold making process is equipped with an air venting structure running along the inner contour of the molding box of the sand molding apparatus. The pattern plate carrier comprises a carrier surface for supporting a pattern plate thereon. A molding box surrounds the pattern plate and is spaced therefrom so as to define between the molding box and the pattern plate a peripheral area on the surface of the carrier. In accordance with a particular feature of the present invention, the peripheral area on the surface of the carrier is provided with an air venting structure extending around the pattern plate. In the preferred embodiment the air venting structure comprises a plurality of elongated slotted bars each of which has a longitudinal axis and a plurality of slots in the elongated bars extending substantially transversely to the longitudinal axis of the bars. By providing slotted bars as aforesaid, the amount of machining required in the pattern plate carrier to effect air evacuation is reduced when compared to a nozzle structure which requires a plurality of precisely located bores. As a result, the structure of the present invention is efficient and economical.
In accordance with a further feature of the present invention, the peripheral area surface on the carrier is provided with a recessed groove for receiving the elongated slotted bars. The slotted bars form with the bottom surface of the groove a venting channel for the compressed air which allows the air to flow on the pattern side out of the molding box.
A further feature of the present invention provides the slotted bars with slots having a width of, preferably, less than or equal to 0.30 mm with the width of the slot increasing with the slot depth where the maximum slot width is, as stated above, less than or equal to 0.30 mm.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is explained in greater detail hereinbelow with reference to the following drawings wherein:
FIGS. 1A and 1B are top views of carrier plates used in the making of sand molds wherein FIG. 1A represents a carrier plate known in the prior art and FIG. 1B illustrates a carrier plate in accordance with the present invention.
FIGS. 2A and 2B are cross-sectional views of the carrier plates of FIGS. 1A and 1B respectively in combination with a molding box for defining a sand mold cavity.
DETAILED DESCRIPTION
For purposes of illustration only FIG. 1 shows schematically a pattern plate carrier divided in half by line 1--1 wherein the pattern plate carrier structure with nozzles is illustrated on the right hand side of line 1--1 and the pattern plate carrier structure of the preferred embodiment of present invention having slotted bars is illustrated on the left side of line 1--1. FIG. 2 is a cross section of FIG. 1 taken along line 2--2 showing on the right side of section line 1--1 the nozzle venting design for a pattern plate carrier and on the left side of section line 1--1 the preferred slotted bar venting structure of the pattern plate carrier in accordance with the present invention.
With reference to the figures, a partial section of sand molding apparatus 10 is illustrated and comprises a pattern plate carrier 12 for supporting a pattern plate 14 thereon. A mold box 16 is supported on the top surface 18 of the pattern plate carrier and defines therewith a molding space 20. A pattern 22 is located on the pattern plate 14 within the molding space 20. Molding sand 24 is fed to the molding space 20 in any known manner and thereafter the sand on the top surface is subjected to a burst of compressed air for compacting the sand 24 within the molding space 20 about the patterns 22 on the pattern plate 14.
With reference to the right hand sides of FIGS. 1 and 2 the venting structure of the present invention employing slotted nozzles will be described. In order for the air flowing through the molding sand 24 to escape from the molding space 20 the surface 18 of the pattern plate carrier 12 is provided with a plurality of round orifices 26 which communicate with through bores 28 and space 30 defined within the carrier body. Round slotted nozzles 32 are positioned within each of the plurality of round orifices 26 for allowing the air flowing through the molding sand 24 to pass through bore 28, space 30 to atmosphere via openings 34. Each of the round slotted nozzles 32 are provided with slots which are about less than or equal to 0.30 mm wide. The width (w) of the slots increased from top to bottom, that is, as the air passed from the molding space 20 through the slotted nozzles into through bores 28. The slots are so sized so as to allow air to escape through the slots while at the same time prohibiting sand grains from passing therethrough. The free space of the slots which allow for air to pass therethrough, as a result of design considerations, amounted to between 15-20% of the overall surface area of the slotted nozzles 32. Thus, it is necessary, in order to obtain sufficient flow area for the air, to arrange as many slotted nozzles as possible around the periphery of the pattern plate. The diameter of the nozzles and a certain minimum material thickness of the carrier plate surface for supporting the nozzles determine the overall space requirements for the venting structure on the carrier and consequently the size of the pattern plate which can be used for a given mold box size.
In accordance with the preferred embodiment of the present invention, as can be seen from the structure illustrated on the left hand side of FIGS. 1 and 2, it has been found that if the round slotted nozzles 32 are replaced by elongated slotted bars 40 having slots of width (w) not greater than 0.40 mm, preferably 0.30 mm, the space requirement for the venting structure for passing an equal amount of air as the nozzle structure is greatly reduced. In addition, the pattern plate carrier 12 need only be provided with an L-shaped groove 42 on the surface 18 of the carrier for receiving the longitudinal bars 40 and the pattern plate may sit in a recess 44 formed in the carrier 12 with the peripheral edge of the pattern plate 14 abutting the sidewall of the recess 44 and the sidewall of elongated bar 40. As can be seen from the figures, a bar having a width b and slot widths of 0.30 mm can allow for a surface area cross section for the passage of air which is equal to a plurality of round nozzles which would occupy a width on the carrier of about 2.2 b. As can clearly be seen from FIG. 1, the consequences of this is that the pattern plate employed in the molding box having a vent structure in accordance with the preferred embodiment of the present invention may have an area which is up to 25% greater than that which can be achieved in the structure by employing round nozzles. By being able to enlarge the size of the pattern plate, the yield of the molding box can be increased considerably.
In accordance with the preferred embodiment of the present invention the elongated slotted bar employed in the apparatus of the present invention is preferably formed of a U-shaped profile. The U-shaped profile defines with the bottom surface of the L-shaped groove 42 a collecting channel 46 for the air passing through the slots of the U-profile slotted bar. A plurality of vent bores 28 can then be located about the groove 42 for receiving the air from the channel 46. Only a few bores 28 are required to vent the air from the channel to the space 30. To the contrary, when employing the round nozzles, each of the round nozzles requires a precisely located bore 28 for communicating the round nozzle with the space 30. As a result, the slotted bars of the present invention are simpler to manufacture and more economical for the pattern plate carrier of the present invention.
In accordance with the present invention the width of the slots W are less than or equal to 0.40 mm and preferably less than or equal to 0.30 mm. In addition, it is preferred that the slots increase in width from the top of the bar toward the bottom of the bar.
It is to be understood that the invention is not limited to the illustrations described and shown herein, which are deemed to be merely illustrative of the best modes of carrying out the invention, and which are susceptible of modification of form, size, arrangement of parts and details of operation. The invention rather is intended to encompass all such modifications which are within its spirit and scope as defined by the claims.
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The molding apparatus includes a pattern plate carrier for air-pressurized compaction processes. The carrier is equipped with air venting structure running along the inner contour of the mold box of the sand molding apparatus in the form of elongated slotted bars.
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FIELD OF THE INVENTION
[0001] Suspendible device for holding items, particularly for suspension on a ladder.
BACKGROUND OF THE INVENTION
[0002] Suspendible containers are often helpful to users of ladders, scaffolding, ledges and the like. These users often require the containers to hold their tools and other work items. Examples of such tools and items include paintbrushes, cans of paint, and tools used by window washers and builders. The number of possible uses for ladders and elevating apparatus, and the tools required for such uses, is unlimited. The prior art teaches a number of suspendible containers that can be elevated from building surfaces such as ladders, scaffolding and ledges. However, the prior art primarily is limited to containers that clamp to the edges of the top caps or rungs of a ladder or other elevating building surfaces. One such device is described in U.S. Pat. No. 4,480,810 (the “′patent”) entitled “Tool and Parts Tray”. The ′810 patent discloses a suspendible ladder pan that is attachable to the top cap or rungs of a ladder through the use of an adjustable clamping member.
[0003] Many ladders today are manufactured with holes in their top caps. However, none of the prior art teaches a removable suspendible device that can be suspended exclusively from these holes on the top caps of ladders.
SUMMARY OF THE INVENTION
[0004] The present invention relates to a suspendible container for holding items, such as tools and paint cans, that is capable of being attached to a horizontal surface containing holes. At least one prong is attached to a container at one end, and at the other end is removably insertable into the hole on the horizontal surface. Preferably, the container has two prongs, which are adjustable along three dimensions, thereby enabling the container to be attached to a horizontal surface having holes of numerous configurations.
[0005] The present invention is particularly adaptable to be suspended from the top cap of a ladder. Top caps of ladders, typically are constructed with holes of various configurations. The adjustable nature of the prongs of the invention enable the container to be suspended from a variety of ladders containing a variety of configurations of holes. In addition, the adjustability of the prongs enables the bottom surface of the container to lay flat even as the ladder is positioned at various levels of inclination. In a preferred embodiment, the dimensions of the container are sufficient for holding tools, paint cans, and other items often needed by the users of ladders. The suspension of the container from the top cap of a ladder enables the user to have access to items inside the container while standing on the ladder.
[0006] Because the prongs of the device are removably insertable into a number of ladders, the device is both easy to use, efficient, and economical. The device, however, is not limited to use only with ladders, it may be used on scaffolding or other ledges that contain horizontal surfaces containing holes. In addition, the container could include a removable and/or rotatable lid for protecting items in the container.
[0007] In the preferred embodiment, the adjustable prongs are comprised of a horizontal member that is perpendicularly attached to a vertical member. The horizontal member is attached to a flange which is perpendicularly attached to the top edge of one of the sidewalls of the container. The horizontal member is adjustably attached to the flange and the vertical is adjustably attached to the horizontal member.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The accompanying drawings, which are incorporated in and form a part of the specification, illustrate the embodiments of the present invention and, together with the description serve to explain the principles of the invention.
[0009] In the drawings:
[0010] [0010]FIG. 1 is a perspective view of the device according to the invention, showing the device attached to a ladder.
[0011] [0011]FIG. 2 is a perspective view of a preferred embodiment of the device according to the invention;
[0012] [0012]FIG. 3 is a front elevation view of the container of the device;
[0013] [0013]FIG. 4 is a top view of a preferred embodiment of the device;
[0014] [0014]FIG. 5 is a side elevation view of a preferred embodiment of the device;
[0015] [0015]FIG. 6 is a fragmentary perspective view of the device illustrating the adjustable features of the prongs;
[0016] [0016]FIG. 7 is a cross-sectional view of fragmentary perspective view 6 ;
[0017] [0017]FIG. 8 is a fragmentary perspective view of the device illustrating the adjustable features of the prongs;
[0018] [0018]FIG. 9 is a view of a version of the flange;
[0019] [0019]FIG. 10 is a perspective view of an embodiment of the device according to the invention;
[0020] [0020]FIG. 11 is a perspective view of the device according to the invention, with a removable lid shown;
[0021] [0021]FIG. 12 is a perspective view of the device, according to one embodiment;
[0022] [0022]FIG. 13 is a side view of an inner piece of FIG. 12, according to one embodiment; and
[0023] [0023]FIG. 14 is a side view of an outer piece of FIG. 12, according to one embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] In describing a preferred embodiment of the invention illustrated in the drawings, specific terminology will be used for the sake of clarity. However, the invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalence which operate in a similar manner to accomplish a similar purpose.
[0025] With reference to the drawings, in general, and FIGS. 1 - 14 in particular, the device of the present invention is disclosed.
[0026] [0026]FIG. 1 shows a suspendible device 10 suspended by at least one prong 44 inserted in at least one hole 14 of a horizontal surface 12 . In this preferred embodiment, the device 10 is suspended by two prongs 44 inserted in two holes 14 in the horizontal surface 12 , which is the top cap of a ladder. However, the device 10 may be suspended from any horizontal surface containing at least one hole.
[0027] [0027]FIG. 1, along with FIGS. 2 - 5 , show a preferred embodiment of the device 10 . As illustrated in these FIGS. , the device 10 includes a container 16 . The container 16 is made of a plurality of side walls 18 and a bottom wall 20 which are connected to one another thereby defining a cavity 22 into which items may be placed. In this embodiment, the prongs 44 are made of a horizontal member 24 and a vertical member 26 , which is generally perpendicularity attached to the horizontal member 24 . The horizontal member 24 has a container end and a suspension end. The container end is the end that is closest to the container 16 and the suspension end is the end that is furthest from the container 16 . The vertical member 26 is removably insertable into the hole 14 of the horizontal surface 12 .
[0028] Each sidewall 18 has a top edge and a bottom edge. One sidewall 18 has a flange 52 projecting from the top edge of the sidewall 18 . In this preferred embodiment, the flange 52 is molded from the same material as the container 16 is made. In a preferred embodiment, the container 16 and flange 52 are molded from plastic, and the horizontal member 24 and vertical member 26 are made of metal. It is to be understood that the type of metal from which the horizontal member 24 and vertical member 26 are made is discretionary. However, metals that can be used include, but are not limited to, sheet metal, tin, aluminum and copper. The type of metal from which the container 16 and flange 52 can be formed also is discretionary, however a preferred metal is sheet metal. Other metals that can be used include, but are not limited to, tin, aluminum and copper. Alternatively, the container 16 and flange 52 can be molded from any of the plastics currently known in the art or later developed.
[0029] [0029]FIGS. 4 and 5 show a preferred embodiment in which container 16 has a front sidewall 36 , a back sidewall 38 , and two end sidewalls 40 . One end sidewall 40 is located between each front sidewall 36 and back sidewall 38 . Preferably, the front sidewall 36 has dimensions of approximately 14.5 inches long and 4.75 inches wide; each end sidewall 40 has dimensions of about 3.25 inches high, 3.75 inches wide along the bottom edge, and 4.75 inches wide along the top edge; and the flange has dimensions of approximately one inch wide and {fraction (1/16)} th of an inch thick. It is also preferred that the horizontal member 24 be about ¾inches wide, 4½inches long and ⅛ th of an inch thick.
[0030] As one skilled in the art would recognize, different dimensions for each of the above-named parts may be used depending on the particular use intended for the device. For example, a worker on scaffolding may require a container longer or shorter than 14.5 inches.
[0031] FIGS. 1 - 5 , along with FIGS. 6 - 8 , particularly illustrate the adjustable embodiments of the horizontal member 24 and the vertical member 26 . As seen in these embodiments, the flange 52 has at least one elongated slot 46 to which the horizontal member 24 is attached. The horizontal member 24 may be attached anywhere along the elongated slot 46 . In addition, as seen in these embodiments, the horizontal member 24 may be attached to flange 52 at a 90 degree angle, thereby creating a perpendicular orientation between the horizontal member 24 and the flange 52 , as seen in FIG. 6. Alternatively, the horizontal member 24 may be attached to flange 52 at an angle that is greater than or less than 90 degrees, thereby creating a diagonal orientation between the horizontal member 24 and the flange 52 , as illustrated in FIG. 8. The horizontal member 24 can be attached to the elongated slot 46 by any adjustable fastener 48 currently known in the art or later developed. Adjustable fasteners that could be used include, pins, screws, bolts, rivets and the like.
[0032] FIGS. 6 - 8 also particularly show the adjustable nature of the vertical member 26 in relation to the horizontal member 24 . In this preferred embodiment, the vertical member 26 is shown in the form of a stove bolt 32 . Each horizontal member 24 contains a channel 50 through which the stove bolt 32 may be inserted.
[0033] The stove bolt 32 contains a head 54 which is wider than the channel 50 . Accordingly, as the stove bolt 32 is inserted through the channel 50 , the head 54 cannot pass through the channel 50 . A hex-nut 34 is then threadable onto the bottom of the stove bolt 32 to rest against the underside of the horizontal member 24 , thereby holding the stove bolt 32 in place along the channel 50 . As illustrated in FIGS. 6 - 8 , the stove bolt 32 can be attached to the horizontal member 24 at any point along the channel 50 , thereby creating a range of adjustability for the stove bolt anywhere along the length of the horizontal member 24 . As a result of the adjustability of both the horizontal member 24 and the vertical member 26 , which in this preferred embodiment is a stove bolt 32 , the device 10 can be suspended from any member of configurations of holes 14 in a horizontal surface 12 .
[0034] As discussed above, the flange 52 and the container 16 can be one piece made of the same material. For example, the flange 52 and container 16 can be molded together or can be made from one piece of sheet metal. In another embodiment, the flange 52 and container 16 are separate pieces that are attached to each other.
[0035] [0035]FIG. 9 illustrates a preferred embodiment of the flange 52 where the flange 52 is comprised of a projecting arm 28 and an attachment arm 30 . Device 56 is shown in FIG. 10. In this embodiment, the flange 52 is attached to the container 16 . Preferably, the attachment arm 30 of the flange 52 is attached to the container 16 by welding. However, the manner by which the flange 52 is attached to the container 16 is discretionary. As a result, the flange 52 could be attached to the container 16 by an adhesive, rivets, and the like. In this embodiment, the attachment arm 30 is generally perpendicularly oriented to the projecting arm 28 . Preferably, the projecting arm 28 has a length that is shorter than the attachment arm, and the projecting arm 28 is centrally located along the attachment arm 30 . The horizontal member 24 is attached to the projecting arm 28 , in the manners previously described in relation to FIGS. 1 - 8 .
[0036] Reference is now made to FIG. 11 which is another embodiment of the device 58 . In this embodiment, the horizontal member 24 is attached to the top edge of one of the sidewalls 18 directly. In this embodiment, the horizontal member may be adjustably attached to the sidewall 18 by any number of adjustable fasteners currently known in the art or later developed. Alternatively, the horizontal member 24 could be fixedly attached to sidewall 18 . This embodiment also shows an optional lid 42 which may be removably attached to one of the sidewalls 18 .
[0037] In an alternative embodiment, the container 16 could be made of two pieces so as to be adjustable in size. As illustrated in FIGS. 12 - 14 , this is accomplished by allowing an inner piece 100 to fit inside an outer piece 102 . A folded or formed channel 104 is located on a top edge 106 of the outer piece 102 to hold a top edge 108 of the inner piece 100 allowing them to slide together. Holes 100 are formed through the top edges of both pieces to permit the pieces to be locked together, with a clip 112 , at the desired size. Instead of one flange 52 on the side of the container 16 , there are two shorter brackets 114 , one on the inner piece 100 and one on the outer piece 102 . Each bracket 114 would be designed to allow the same adjustability as the flange 52 . The clip 112 is made to insert through two of the holes 110 on the top edge. The clip 112 has a groove 116 cut in a pin part 118 to allow an “E” ring 120 to snap onto it, thus securing the pin 118 in place. The pins 118 could also be made with a knob 122 on the end causing it to snap in place. Each half of the container 16 would be similar in shape to the original design, but would be 10 ¼″ long, allowing adjust from approximate 14″ to 19″ in length.
[0038] Although this invention has been illustrated by reference to specific embodiments, it will be apparent to those skilled in the art that various changes and modifications may be made which clearly fall within the scope of the invention. The invention is intended to be protected broadly within the spirit and scope of the appended claims.
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A suspendible container for holding items that is capable of being attached to holes on a horizontal surface. The container is particularly adaptable to being attached to the top cap of a ladder. The container includes at least one prong which attaches to the container and is removably insertable into a hole in the horizontal surface. The container is particularly suited for holding items such as tools and paint cans that would be needed by the user of a ladder.
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RELATED APPLICATION
[0001] This patent application claims the priority benefit of U.S. Provisional Patent Application Ser. No. 60/904,673 filed Mar. 2, 2007 and entitled “PMMA CEMENT WITH ADAPTED MECHANICAL PROPERTIES” and to U.S. Provisional Patent Application Ser. No. 60/967,052 filed Aug. 31, 2007 and entitled “PMMA CEMENT WITH ADAPTED MECHANICAL PROPERTIES”, which applications are incorporated herein by reference.
BACKGROUND
[0002] Vertebral compression factures in osteoporotic patients are typically treated by a surgical procedure known as vertebroplasty. In this procedure the fractured vertebral body is augmented with a bone cement. The bone cement polymerizes and hardens upon injection into the vertebral body and stabilizes the fracture. Pain relief for the patient is usually immediate and vertebroplasty procedures are characterized by a high rate of success.
[0003] Typically, bone cement is prepared directly prior to injection by mixing bone-cement powder (e.g., poly-methyl-methacrylate (PMMA)), a liquid monomer (e.g., methyl-methacrylate monomer (MMA)), an x-ray contrast agent (e.g., barium sulfate), and an activator of the polymerization reaction (e.g., N, N-dimethyl-p-toluidine) to form a fluid mixture. Other additives including but not limited to stabilizers, drugs, fillers, dyes and fibers may also be included in the bone cement. Since the components react upon mixing, immediately leading to the polymerization, the components of bone cement must be kept separate from each other until the user is ready to form the desired bone cement. Once mixed, the user must work very quickly because the bone cement sets and hardens rapidly.
[0004] Other examples of bone cement compositions and/or their uses are discussed in U.S. Pat. No. 7,138,442; U.S. Pat. No. 7,160,932; U.S. Pat. No. 7,014,633; U.S. Pat. No. 6,752,863; U.S. Pat. No. 6,020,396; U.S. Pat. No. 5,902,839; U.S. Pat. No. 4,910,259; U.S. Pat. No. 5,276,070; U.S. Pat. No. 5,795,922; U.S. Pat. No. 5,650,108; U.S. Pat. No. 6,984,063; U.S. Pat. No. 4,588,583; U.S. Pat. No. 4,902,728; U.S. Pat. No. 5,797,873; U.S. Pat. No. 6,160,033; and EP 0 701 824, the disclosures of which are herein incorporated by reference.
[0005] The elastic moduli of typical PMMA bone cements lie around 2-4 GPa, while the elastic modulus of osteoporotic cancellous bone lies in the range of 0.1-0.5 GPa. This mismatch in stiffness is generally perceived as favoring the subsequent fracturing of the vertebral bodies that are adjacent to the augmented vertebral body.
[0006] It is therefore an object of the invention to obtain a bone cement with a reduced stiffness that is adapted to the stiffness of the surrounding bone. This is thought to be an efficient way to reduce the risk of adjacent vertebral body fractures after the augmentation of vertebral bodies.
[0007] Reduction of the stiffness by introducing non-miscible phases, such as aqueous
[0000] components, into the PMMA upon polymerization is well known and has been described before. This leads to a macroporous structure with reduced stiffness.
SUMMARY OF THE INVENTION
[0008] The invention relates to a bone cement including a monomer and a substance that is substantially miscible with the monomer and substantially does not contribute to a polymerization reaction. In one embodiment of the invention, the substance is N-methyl-pyrrolidone. In another embodiment, the substance is dimethyl-sulfoxide (DMSO). In another embodiment, the substance is polyethylene glycolide (PEG). In another embodiment, the substance is cellulose and cellulose derivates. In another embodiment, the substance is a mixture or blend of the mentioned substances or other, comparable substances. In another embodiment, the substance reduces a crosslink density of the bone cement. In another embodiment, the substance creates a microporous structure in the bone cement. In another embodiment, the bone cement further includes polymerization of the monomer. In another embodiment, a portion of the monomer in substituted by the substance during polymerization. In another embodiment, substitution of the monomer by the substance yields a decrease in the stiffness of the bone cement.
[0009] The invention also relates to a bone cement including methyl-methacrylate and N-methyl-pyrrolidone. In one embodiment of the invention the volume percentage of the methyl-methacrylate which is substituted by NMP, DMSO, PEG or other analogous substances lies in the range of 20%-60%. One specific example includes a volume percentage substitution of 25%. The volume of MMA can be substituted by either one of the pure substances mentioned above or by a mixture of these substances. In another embodiment of the invention, a stiffness of the bone cement is between about 100 MPa to about 2000 MPa. In another embodiment of the invention, a stiffness of the bone cement is between about 100 MPa to about 1500 MPa. In another embodiment of the invention, a stiffness of the bone cement is between about 500 MPa to about 1200 MPa. In another embodiment of the invention, a yield strength of the bone cement is from about 30 MPa to about 100 MPa. In another embodiment of the invention, a yield strength of the bone cement is from about 30 MPa to about 80 MPa.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a graph showing the stiffness and yield strength of bone cements according to an embodiment of the present invention;
[0011] FIG. 2 is a graph showing the hardening behavior of bone cements in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION
[0012] The present invention relates to a polymer bone cement or a derivative thereof having improved mechanical properties that is adapted to bone or osteoporotic bone. In one embodiment of the invention, the polymer bone cement is PMMA. The improved mechanical properties are achieved by adding a fully miscible solvent that does not react with the PMMA to the reactive MMA monomer. By doing so, the crosslink density of the material and the stiffness can be reduced.
[0013] The present invention is based on using a substance that is fully miscible with the monomer and is, therefore, molecularly dissolved in the PMMA after polymerization. However, due to its non-reactivity, this leads to a reduction in the final crosslink density and/or to a material with a microporous structure and, therefore, the stiffness of the material is reduced. After implantation and full polymerization of the material, the crosslink-lowering substance may be gradually substituted by body fluids.
[0014] This concept was tested by substituting different amounts of the reactive monomer with N-methyl-pyrrolidone (NMP), which does not contribute to the polymerization reaction. Subsequent mechanical testing of PMMA samples produced in this way showed a reduction in stiffness greater than about 50% in some embodiments.
[0015] The described effect of lowering the stiffness of the material can be obtained with any solvent that is miscible with the monomer of PMMA but does not contribute to the polymerization reaction. Another example of such of a solvent is Dimethyl-sulfoxide (DMSO). In other embodiments, a range of other solvents can also be envisioned. In another embodiment, substances such as PEG, cellulose, cellulose derivates or mixtures thereof can be added.
[0016] Furthermore, the present concept is not limited to PMMA cements, it can be applied to a wide variety of derivatives of PMMA, e.g. modifications in which Styrene groups are built into the polymer backbone. The same concept also applies to cements that are not based on the acrylate chemistry.
[0017] A material as described above, with mechanical properties adapted to those of e.g. osteoporotic bone can be used in any indication, where bone needs to be augmented, e.g. the proximal femur, the proximal humerus, long bones, vertebral bodies or the like.
[0018] As shown by the data in Table 1, the bone cements according to embodiments of the present invention that include NMP exhibit a decrease in stiffness when compared to the bone cement without NMP. The decrease in stiffness occurs as a result of the substitution of some of MMA monomer by NMP. According to some embodiments, by substituting a part of the reactive liquid MMA monomer with non-reactive organic solvent NMP during polymerization, the crosslink density in the final material was lowered and therefore the stiffness of the material was reduced. In other embodiments, the NMP can act as a pore forming phase, resulting in bone cement having a microporous structure. As discussed above, a decrease in stiffness is an efficient way to reduce the risk of adjacent vertebral body fractures in vertebroplasty procedures.
[0019] In some embodiments, the bone cements including NMP demonstrate an increase in hardening time. That is, the time for the bone cement to set and harden is longer for the cements having an NMP component. In some embodiments, an increase in handling time allows for greater working time for the user, which can increase the safety of surgical procedures.
[0020] In addition to the reduced stiffness, another property which is influenced by the mentioned modification is the maximum polymerization temperature of the exothermic polymerization of PMMA. Typically, polymerization of the PMMA can generate enough heat and increase the temperature of the bone cement to such a degree as to cause tissue necrosis. Because the bone cements of the present invention includes a lower content of monomer (MMA), which is the component that generates the heat during the polymerization reaction, the maximum polymerization temperature can be lowered. This is particularly advantageous because tissue necrosis may be reduced or avoided when the bone cement of the present invention is used, which allows for the use of the bone cement in areas of the body which are particularly sensitive to heat. For example, bone necrosis or other tissue necrosis can be a substantial problem during cranial reconstruction where the bone cement may contact the dura mater, due to the delicacy of the tissues and bone structures. Use of a bone cement having reduced heat generation is therefore particularly desirable in these areas.
[0021] Another advantage of the bone cements of the present invention is the potential reduction in the toxicity of the composition. Bone cement monomers, including methyl methacrylate, give off toxic vapors which can be irritating to the eyes and respiratory system. Furthermore, acrylate monomers can irritate the skin, and contact with minute concentrations can cause sensitization. Therefore, since the bone cement of the present invention uses a lower amount of monomer, the potential for the above problems to occur while using the bone cement of the present invention may be reduced.
[0022] In some embodiments of the present invention, the bone cement can be useful for vertebroplasty. The mentioned properties of hardening behavior, mechanical and thermal properties especially increasing of the handling time (more time for the surgeon and therefore more safety), lowering the stiffness (avoiding the mechanical property mismatch of the bone to the cement) and reducing the polymerization temperature (reduce tissue necrosis) are important properties for cement used in vertebroplasty. It is possible, that all of these requirements could be achieved by substituting some of the MMA monomer with NMP.
Example
[0023] The following example was carried out using commercial PMMA cement Vertecem. Vertecem is a fast setting, radiopaque acrylic bone cement for use in percutaneous vertebroplasty. The fluid phase is composed of 97.6% methyl-methacrylate (MMA), 2.4% N, N-dimethyl-p-toluidine as activator and very small quantities (20 ppm) of hydroquinones as stabilizer. The polymer powder is composed of 64.4% PMMA, 0.6% benzoyl peroxide which initiates the polymerization, 25% barium sulfate as radiopaque agent and 10% hydroxyapatite.
[0024] The fluid MMA monomer phase was partly substituted by NMP organic solvent by different amounts. NMP is totally miscible with the MMA monomer fluid. The amounts of MMA, and NMP, and PMMA used in the different compositions are listed in Table 1.
[0000]
TABLE 1
Sample
MMA/
NMP/
PMMA
Stiffness/
Yield strength/
Name
ml
ml
powder/g
MPa Average
MPa Average
0%
10
0
21
2384
78
20%
8
2
21
1838
86
30%
7
3
21
752
52
50%
5
5
21
456
37
60%
6
4
21
320
24
[0025] The MMA monomer and NMP was premixed to form a fluid mixture. Subsequently the fluid mixture was mixed with the PMMA powder to form a paste. To prepare the samples for mechanical testing, the paste was filled into cylindrical Teflon® molds (20 mm height, 6 mm diameter). The hardened cylinders were then removed from the mold, sawed and ground to the length of 12 mm, these dimensions correspond to the requirements of standard ISO 5833. After storing the samples in water for 6 days at room temperature they were submitted for mechanical compression testing according to standard ISO 5833. The elastic modulus and yield strength were determined according to the mentioned standard and presented in FIG. 1 . Results are shown in FIG. 1 , illustrating trends versus percent of MMA that is substituted by NMP.
[0026] For the investigation of the hardening behavior of the cement compositions, 3 ml of the mixed bone cement were placed in a rotational rheometer with a custom designed double gap measurement system and rheological data were recorded directly to a computer for 24 portions of cement. The real (fluid-like) part of complex viscosity vs. time data are presented in FIG. 2 .
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A bone cement is shown that includes a monomer, and a non-reactive substance that is fully miscible with the monomer. A resulting cured bone cement exhibits desirable properties such as modification in a stiffness of the material. Modified properties such a stiffness can be tailored to match bone properties and reduce an occurrence of fractures adjacent to a region repaired with bone cement. One example includes adjacent vertebral body fractures in vertebroplasty procedures.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation application of and claims the benefit of priority under 35 U.S.C. §120 from U.S. Ser. No. 10/581,360, filed Jun. 2, 2006, which is a National Stage application of PCT/EP04/13743, filed Dec. 2, 2004 and claims benefit of priority under 35 U.S.C. §119 from French Application No. 0314527, filed Dec. 11, 2003, the entire contents of each of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The invention relates to a method for improving the fatigue resistance of a threaded tubular connection subjected to stress variations, said connection comprising a male tubular element including a tapered male threading, and a female tubular element including a tapered female threading which cooperates with the male threading by screwing to produce a rigid mutual connection of said tubular elements with radial interference between radial load transfer zones of said threadings.
[0003] That type of threaded connection is primarily intended for the production pipe strings for hydrocarbon or the like wells.
[0004] Said radial interference is primarily intended to prevent breakout of the threaded connections in service—which would be catastrophic—, and it also renders the threaded connection far more monolithic.
DISCUSSION OF THE BACKGROUND
[0005] Threaded connections of that type are known in which radial interference is obtained by contact between thread crest and corresponding thread root, in particular between the crest of the female thread and the root of the male thread.
[0006] Such contact zones between corresponding thread crests and roots then constitute radial load transfer zones for the threadings.
[0007] It has been established that, when such a threaded connection is subjected to stress variations, in addition to cracking by fatigue in stress concentration zones, for example at the foot of the load flank, micro-cracks appear in contact zones at the thread root, which tend to develop if high and variable tensile stresses exist in that zone, compromising the fatigue resistance of the connection.
[0008] Such phenomena primarily occur in rotary drillpipe strings and have required for such products threadings cut in very thick attached elements termed “tool joints” comprising triangular threads of great depth with rounded crests and roots. There is no contact between those thread roots and crests, nor in general any radial interference. Even if such interference were implemented, the radial loads would be transferred to the thread flanks where the tensile stresses are much lower than at the thread root. The load flanks which, it will be recalled, are the flanks directed towards the side opposite to the free end of the tubular element under consideration, make an angle of 60° with respect to the axis of the threaded connection. The stabbing flanks are disposed symmetrically, making the same angle with the axis.
[0009] These phenomena also occur in pipe strings connecting an offshore platform with the sea bed, under the action of waves, wind, tides and sea currents, which induce variable tensile or bending loads on the string.
SUMMARY OF THE INVENTION
[0010] However, with that type of connection, it is not always possible to produce threads with a large thread depth and triangular threads run the risk of disengaging or jumping out from the tubular elements in service in the well.
[0011] The invention aims to overcome these disadvantages.
[0012] The invention aims in particular at a method of the type defined in the introduction and provides that the threadings each have a load flank extending substantially perpendicular to the axis of the threadings, and provides that said radial load transfer zones are at a radial distance from the envelopes of the thread roots of the male and female threadings and form an angle of less than 40° with the axis of the threadings.
[0013] The term “envelope of the thread root” means the tapered surface which envelops the thread roots which is furthest from the thread crests.
[0014] Due to the radial separation of the radial load transfer zones with respect to the envelopes of the thread roots, the micro-cracks which can form therein are not affected by the tensile stresses existing in the material beyond the thread root envelope and thus do not deleteriously affect the fatigue resistance of the connection.
[0015] Optional characteristics of the invention, which may be complementary or substitutional, will be given below:
said radial load transfer zones are constituted by i) the crest of at least one helical protuberance formed on the thread root of at least one threading with respect to the envelope of the thread root and ii) the facing zone located on the thread crest of the corresponding threading; the protuberance or protuberances is/are disposed on the male thread root; the crest of the protuberances is convexly domed; the protuberances are connected to the thread root via one or more concave rounded portions; said protuberances are each constituted by the crest of a helical rib formed on the thread root of the threading under consideration; said radial load transfer zones comprise the crests of at least two helical ribs which are in axial succession along the thread root of the male threading; said radial load transfer zones comprise the crest of a boss extending from the foot of the load flank to the foot of the stabbing flank on the thread root of the threading under consideration; said radial load transfer zones comprise the crest of a boss bearing on one of the flanks of the threading under consideration; said facing zones located on the thread crest of the corresponding threading each have a recessed helix partially enveloping each protuberance; said radial load transfer zones are constituted by respective intermediate regions of the stabbing flanks of the male and female threadings, said intermediate regions forming a smaller angle with the axis of the threadings than the neighbouring regions of said flanks; the angle between said intermediate regions and the axis of the threadings is substantially zero; said radial load transfer zones are ramps constituting the stabbing flanks of the male and female threadings over the major portion of the radial height thereof; the angle between said ramps and the axis of the threadings is in the range 20° to 40°; the angle between said ramps and the axis of the threadings is about 27°; the invention is implemented in a zone of full height threads termed perfect threads; the invention is implemented both in a zone of perfect threads and in a zone of imperfect threads, in particular in a zone of run-out threads; the profile of the male threading comprises a first concave rounded portion defining the thread root and tangential to said ramp; the profile of the male threading comprises a second concave rounded portion with a smaller radius of curvature than the first rounded portion and tangential thereto and to the load flank; a groove defining the female thread root extends axially from a first wall constituted by the load flank to a second wall which is connected to the ramp of the female threading; the profile of said groove comprises a central concave rounded portion framed by first and second rounded concave portions respectively tangential to said first and second walls and with a smaller radius of curvature than the central rounded portion; the profile of the female threading comprises a convex rounded portion tangential to a second rounded portion and to said ramp, the zone of inflexion between the convex rounded portion and the second rounded portion constituting the second wall.
[0037] The invention also relates to a threaded tubular connection for implementing the above-defined method, comprising a male tubular element including a tapered male threading, and a female tubular element including a tapered female threading which cooperates with the male threading by screwing to produce a rigid mutual connection of said tubular elements with radial interference between radial load transfer zones of said threadings.
[0038] The threaded connection comprises in accordance with the invention at least one of the following particularities:
said radial load transfer zones are constituted by i) the crest of at least one helical protuberance formed on the thread root of at least one threading with respect to the envelope of the thread root and ii) the facing zone located on the thread crest of the corresponding threading; said radial load transfer zones comprise the crest of a boss extending from the foot of the load flank to the foot of the stabbing flank on the thread root of the threading under consideration; said radial load transfer zones comprise the crest of a boss bearing on one of the flanks of the threading under consideration; said radial load transfer zones are constituted by respective intermediate regions of the stabbing flanks of the male and female threadings, said intermediate regions forming a smaller angle with the axis of the threadings than the neighbouring regions of said flanks; said radial load transfer zones are ramps constituting the stabbing flanks of the male and female threadings over the major portion of the radial height thereof, and the profile of the male threading comprises a first concave rounded portion defining the thread root and tangential to said ramp; said radial load transfer zones are ramps constituting the stabbing flanks of the male and female threadings over the major portion of the radial height thereof, and a groove defining the female thread root extends axially from a first wall constituted by the load flank to a second wall which is connected to the ramp of the female threading.
BRIEF DESCRIPTION OF THE DRAWINGS
[0045] The characteristics and advantages of the invention will now be described in more detail in the following description made with reference to the accompanying drawings.
[0046] FIGS. 1 to 6 are partial views in axial cross section of the threadings of different tubular connections of the invention.
[0047] FIG. 7 shows an application of the threads of FIG. 1 on a male tubular element.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0048] The threaded tubular connection shown in part in FIG. 1 comprises a male tubular element 1 and a female tubular element 2 respectively including a tapered male threading 3 and a tapered female threading 4 . The female threading 4 has a conventional trapezoidal profile, defining a load flank 5 which extends substantially perpendicular to the axis of the threadings, i.e. vertically in the figure, the axis being horizontal, a stabbing flank 6 forming a different angle which is, however, close to 90° with the axis of the threadings, a thread root 7 and a thread crest 8 substantially parallel to the axis, the root 7 and crest 8 being connected to flanks 5 and 6 via rounded portions. The direction of the inclination of the flank 6 is such that the helical groove formed by the female threading shrinks in the direction of the root 7 .
[0049] The profile of the female threads 4 can in particular correspond to a profile designated in the American Petroleum Institute's specification API 5CT as a “buttress” profile.
[0050] The “buttress” threading has a taper of 6.25% ( 1/16), 5 threads per inch of length, a load flank angle of +3° and a stabbing flank angle of +10°.
[0051] Other threadings, in particular derived from the “buttress” threading type, can be used.
[0052] The male threading 3 has a load flank 10 , a stabbing flank 11 and a thread crest 12 located facing flanks 5 and 6 and the thread root 7 respectively and orientated in the same manner thereas, as well as a thread root 13 located facing the thread crest 8 and which extends parallel to the axis but which is interrupted by two helical ribs 14 , the height of which with respect to the thread root 13 is advantageously in the range about 0.2 to 0.4 mm. The crest 12 and root 13 are connected to flanks 10 and 11 via rounded portions. The two ribs 14 with identical profiles and the same pitch as threadings 3 and 4 are offset with respect to each other in the axial direction to leave a fraction of flat bottom 13 between them, and two other fractions either side of the ribs. The ribs 14 have a rounded crest 15 defining a helical contact line between the rib and the female thread crest 8 . They are also connected to the bottom of the male thread 13 via rounded portions.
[0053] Because of the disposition of the invention, when threadings 3 and 4 are made up one into the other so that load flanks 5 , 10 bear on each other and a radial interference fit is obtained between the elements 1 and 2 , the radial loads transferred between elements 1 and 2 are transferred via the contact lines 15 which are at a radial distance from the thread root 13 , so that microcracks which may form there because of stress variations or slight relative movements cannot develop, the tensile stresses only existing beneath the threading roots inside the envelope E of the thread root 13 (i.e. below this envelope in FIG. 1 ).
[0054] It should be noted that after makeup, a radial clearance subsists between the crest of the male thread 12 and the root of the female thread 7 . An axial clearance also subsists between the stabbing flanks 6 , 11 , which axial clearance should advantageously be minimized. The radial clearance between the male thread crest 12 and the female thread root 7 is in particular a function of the rounded portion between this thread root and the female load flank 5 . The radius of curvature of this rounded portion should be maximized to limit stress concentrations which are deleterious to the fatigue resistance. This is the same for the rounded portion between the male load flank and the male thread root 13 .
[0055] FIG. 2 shows part of a male tubular element 1 a and a female tubular element 2 a provided with respective threadings 3 a and 4 a. Reference numerals 5 , 7 , 8 , 10 and 12 designate elements that were already described above with reference to FIG. 1 and will not be described again. In contrast to FIG. 1 , the male thread root 13 a extends continuously parallel to the axis of the threadings facing the female thread crest 8 . The stabbing flank of the male threading is in three portions, namely a portion 20 having substantially the same inclination as flanks 6 and 11 of FIG. 1 and connecting via a rounded portion to root 13 a, a portion 21 with the same inclination as portion 20 , connecting via a rounded portion to the thread crest 12 , and an intermediate portion 22 extending parallel to the axis and connecting to portions 20 and 21 via rounded portions. Similarly, the stabbing flank of the female threading comprises three portions, namely portions 24 and 25 with the same inclination as portions 20 and 21 , located respectively facing them and connected via rounded portions to the thread crest 8 and to the thread root 7 respectively, and an axially extending intermediate portion 26 facing the portion 22 and connected to portions 24 and 25 via rounded portions. When the threadings 3 a and 4 a are made up one into the other to obtain radial interference, the radial loads are transferred via portions 22 and 26 of the stabbing flanks, which are radially distanced from the thread root 13 a of the male threading and the envelope E of the male thread root, thus producing the effect described with reference to FIG. 1 .
[0056] The above observations concerning the radial clearance between the male thread crest 12 and the female thread root 7 , and the rounded portions between the load flanks and the thread roots are also applicable to the connection of FIG. 2 . There is also an axial clearance between portions 21 - 25 and between portions 20 - 24 of the stabbing flanks.
[0057] FIG. 3 partially shows a male tubular element 1 b and a female tubular element 2 b provided with respective threadings 3 b, 4 b. As with the embodiments described above, the load flanks 5 , 10 of the female and male threadings extend substantially radially and their thread crests 8 , 12 extend substantially axially. Regarding the thread roots and stabbing flanks, their profiles are defined by a combination of straight lines and rounded portions which is described below, the values for the radii of curvature being indicated by way of example for a tubular connection belonging to a pipe string with an external diameter of 177.8 to 339.73 mm (7″ to 13″ ⅜).
[0058] Opposite to the male load flank 10 perpendicular to the axis of the threaded connection, the rectilinear axial profile of the male thread crest 12 connects via a convex rounded portion 30 to the stabbing flank constituted by a straight line 31 which forms an angle of 27° with the axis and which moves away from the flank 5 in the direction of the axis. At the opposite end to the crest 12 , segment 31 is tangential to a concave rounded portion 32 with a large radius of curvature, more than 1 mm, for example of the order of 1.5 mm, which defines the male thread root, a further concave rounded portion 33 with a radius of curvature of 0.3 mm being tangential to the rounded portion 32 and to the radial rectilinear profile of the load flank 10 .
[0059] The double rounded portions 32 + 33 minimize stress concentrations at the foot of the load flank 10 .
[0060] Opposite to the load flank 5 , the axial rectilinear profile of the female thread crest 8 connects via a large radius of curvature convex rounded portion 35 to the stabbing flank constituted by a straight segment 36 with the same inclination as the segment 31 . Opposite to the rounded portion 35 , the segment 36 is tangential to a convex rounded portion 37 with a low radius of curvature which is itself tangential to a concave rounded portion 38 , also with a low radius of curvature, the common tangent of the rounded portions 37 and 38 forming a zone of inflexion being inclined in the same direction as segments 31 and 36 and forming an angle of 70° with the axis. The rounded portion 38 is followed by two other concave rounded portions 39 and 40 the radii of curvature of which are more than and less than 1 mm respectively, the rounded portion 40 connecting to the load flank 5 . The common tangent to the rounded portions 38 and 39 is orientated axially and defines the female thread root.
[0061] The set of rounded portions 37 , 38 , 39 , 40 constitutes a kind of groove. The double rounded portions 39 - 40 minimize the stress concentrations at the foot of the load flank 5 .
[0062] The zone of inflexion between the rounded portions 37 , 38 constitutes one of the walls of said groove; the other wall is constituted by the load flank 5 .
[0063] When threadings 3 b and 4 b are made up into each other, in addition to axial bearing between load flanks 5 , 10 and between stabbing flanks 31 , 36 , radial interference is obtained between the stabbing flanks defined by the inclined segments 31 and 36 , which are at a radial distance from the envelope E of the male thread root, producing the advantages described with respect to FIG. 1 .
[0064] The embodiment shown in FIG. 3 has a certain number of advantages:
a) the pre-stress generated by the threads bearing both on the load flanks and on the stabbing flanks reduces the geometrical stress concentration factor at the thread root; b) bearing at the stabbing flanks 31 , 36 eases any possible axial abutment (shown in FIG. 7 ) under axial compression and bending loads. c) The angle of 27° with respect to the axis of the stabbing flanks 31 , 36 (i.e. an angle of 63° with respect to the normal to the axis) can minimize the torque generated by axial bearing of said flanks with respect to that generated by radial interference.
[0068] An angle for the stabbing flank with respect to the axis of more than 40° renders the contribution of axial bearing on the makeup torque preponderate and prejudicial. That angle is preferably kept below 30°.
[0069] Further, too great an angle requires a substantial reduction in the tolerances on the thread width, which is detrimental to production costs for the threadings. Similarly, a sufficiently small angle produces a certain flexibility in the thread crest, which distributes the load over the load flank better.
[0070] A stabbing flank angle of less than 20° with respect to the axis, in contrast, results in too much axial hindrance in the threads.
[0071] Modifications can be made to the embodiments described and shown without departing from the scope of the invention. Thus, the two ribs 14 in FIG. 1 can be replaced by a single rib or by three or more ribs. The crest of the ribs, instead of being a point in axial cross section, can have a certain extent in the axial direction, resulting in a contact surface and not in contact line with the female thread crest.
[0072] In the embodiment shown in FIG. 4 , elements 1 c, 2 c, 3 c, 4 c and 8 c correspond to elements 1 , 2 , 3 , 4 and 8 of FIG. 1 . The ribs 14 are replaced by a boss 45 which extends between the foot of the male load flank 10 and the foot of the male stabbing flank 11 and which connects with the male thread root 13 c.
[0073] In the embodiment shown in FIG. 5 , elements 1 d, 2 d, 3 d and 4 d correspond to elements 1 , 2 , 3 and 4 of FIG. 1 . A boss 55 is connected on one side to the male load flank 5 and bears against it, and on the other side to the male thread root 13 d.
[0074] In the embodiment shown in FIG. 6 , elements 3 e, 4 e and 65 correspond to elements 3 d, 4 d and 55 of FIG. 5 . A rib 14 e is pre- sent on the male thread root 13 e and the female thread crest 8 e has a recessed helix partially enveloping the rib 14 e after making up the tubular elements 1 e, 2 e such that a radial clearance exists between the remaining portions of the female thread crest and the male thread root.
[0075] In the embodiment shown in FIG. 2 , the intermediate regions 22 and 26 of the stabbing flanks are not necessarily orientated axially, but can be slightly inclined with respect to the axis.
[0076] In the embodiments shown in FIGS. 1 , 2 , and 4 to 6 , the angle of the load flank can be slightly negative as described, for example, in International patent application WO-A-84/04352 or in the VAM TOP threaded connection sold by the Applicant (catalogue no. 940, publication date July 1994).
[0077] The angle of the stabbing flank can be less than 10° or more than 10°.
[0078] FIG. 7 shows the application of the invention as shown in FIG. 1 to a threaded connection the male threading 3 of which includes a portion with perfect threads 43 of full height and similar to those shown in FIG. 1 and a portion of run-out threads 44 of truncated height which progressively reduce from the full height at the junction with the portion 43 to zero when the envelope line E of the thread roots reaches the outer surface of the tube where the male threaded element is formed.
[0079] The ribs 14 at the male thread root can advantageously be implanted both in the perfect thread zone 43 and in the run-out thread zone 44 .
[0080] The embodiment of FIG. 7 can also be applied to the threadings of FIGS. 2 to 6 .
[0081] The invention can be applied to many types of radially interfering threads, with a single threaded portion or with a plurality of axially distinct threaded portions disposed on the same tapered surface or on a plurality of radially distinct tapered surfaces.
[0082] The taper of the threadings can vary widely, for example between 5% and 20%.
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A pipe string component that connects an offshore platform with a sea bed is provided. The pipe string component includes a threaded tubular connection. The threaded tubular connection includes a male tubular element including a tapered male threading, and a female tubular element including a tapered female threading that cooperates with the male threading by makeup to produce a rigid mutual connection of the tubular elements with radial interference between radial load transfer zones of the threadings. The male and female threadings each have a load flank extending substantially perpendicularly to an axis of the male and female threadings. The radial load transfer zones are at a radial distance from envelopes of thread roots of the male and female threadings. The radial load transfer zones of the threadings comprise at least one surface substantially parallel to an axis of the connection.
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TECHNICAL FIELD
The present inventions relate to improvements in robotic technology used in the oil and gas industry to significantly reduce oil and gas operational costs, especially in deep wells. More particularly the present inventions relate to the use of programmable tools permanently located downhole in a well and which can on demand perform various downhole tasks in the wells such as, for example, resetting safety valves, adjusting flow control devices; setting and removing downhole devices; measuring well parameters at various locations and condition, and retrieving measurement and performance data.
BACKGROUND OF THE INVENTIONS
During the wellbore completion phase of wells, a rig is normally present at the wellhead. Occasionally, the large drilling rig is removed and a small work rig is erected to perform completion operations. However, many operations during the completion phase could be performed without the use of a rig if a mobile platform robotic device could be utilized to move into position in the bottom hole assembly in the wellbore, especially in the horizontal sections of the wellbores. Wells usually continue to produce hydrocarbons for many years. Various types of operations are performed during the life of producing wells. Such operations include removing, installing and replacing different types of devices including fluid flow control devices, sensors, packers or seals; performing remedial work including sealing off zones, cementing, reaming, repairing junctures, milling and cutting; diverting fluid flows, controlling production from perforated zones; activating sliding sleeves, testing wellbore production zones or portions thereof, and making periodic measurements relating to wellbore and formation parameters. During the production phase or workover or testing operations, a rig is especially erected at the well site prior to performing many of these operations. Using conventional rig operations can be time consuming and expensive. The primary function of the rig in some of such operations is to convey, position and orient tools to the desired work site. A mobile platform robotic device that can move and position tools at the desired work site can allow the desired downhole tasks to be performed without requiring a rig and bulky tools and tool handling systems.
Mobile platform robotic devices tethered to the surface by wirelines or coil tubing are used in vertical and horizontal well operations. These devices sometimes called tractors can move in the well using various forms of traction devices. In deep wells, the use of a tether requires the tractor to generate excessive force as the distance increases to pull the tether. In extended downhole distances, time is consumed in moving the devices to location. Some tethered tractors carry a self-contained battery powered tractor unit that will disconnect from the tethered tractor to extend the operation range by performing downhole operations without a tether. Typically, communication systems are used to connect the untethered tractor to the tethered tractor. Examples of these units can be found in the U.S. Pat. Nos. 5,947,213; 6,026,911 and 6,112,809 owned by Intelligent Inspection Corporation. The disclosures of these patents are incorporated herein for all purposes.
While the proposed use of a detachable untethered unit can provide tool access to otherwise unreachable well locations it does not solve the problems associated with the time and expense required in moving to these remote locations. When repeated or regular downhole operations are required in deep wells, moving the tractor units to and from the surface is unacceptable and uneconomical.
SUMMARY OF THE INVENTIONS
The present inventions relate to using an electro-mechanical tractor that docks at a downhole docking station from which it exits, moves within the well to perform tasks and then returns to the docking station. Wells to which these inventions pertain, comprise all wells having subterranean portions. Although the present inventions have particular advantages when applied to deep locations in wells, the term downhole is used to include any location spaced from the wellhead. Down and up in this regard refer to a direction along the well toward the wellhead and away from the wellhead even though the actual portion of the well may not be vertically upright. Wellhead or surface includes both land and sub sea locations and in the latter case can refer to the seabed or water surface. Preferably, conductors connect the docking station to the surface for conveying power and control information. These conductors could be either embedded in the tubing wall or separate. The described examples use a docked tractor to move out into the well to mechanically open and close a subsurface safety valve or sliding sleeve valve as needed.
The task of operating the safety valve is just one operation that can be performed at these remote downhole locations without requiring the time consuming procedure of opening the well and moving the tractor assembly from the surface to the remote downhole location. These tasks could be as varied as removing, installing and replacing different types of devices including fluid flow control devices, sensors, packers or seals; performing remedial work including sealing off zones, cementing, reaming, repairing junctures, milling and cutting; diverting fluid flows, controlling production from perforated zones; activating, resetting and adjusting valves such as safety valves and sliding sleeves, testing wellbore production zones or portions thereof, making periodic measurements relating to wellbore and formation parameters, setting plugs remotely, or retrieving pressure temperature recording devices and uplink data to the surface via electronics located either onboard the tractor or in the docking station. As used herein the term tasks is used in its broadest generic sense to include all well operations.
More particularly, the tractor tool assembly could move from a downhole docking station to a valve and engage the valve and perform the task of opening, closing or adjusting it. In the safety valve embodiment the tractor could have a tool that locks into a profile on the safety valve's flow tube and then the tractor would extend against the tubing wall and telescope, forcing the valve to the open position. When the flow tube reaches the valve open position, a mechanical or electrical powered lock or latch engages and holds the flow tube in the open position. In this embodiment, the remote controlled tool then disengages from the valve and retreats to the docking station.
The docking stations in the disclosed embodiments are in the form of a side pocket mandrel assembled in the production tubing. As used herein docking means or tractor docking station includes any location downhole in the well where the tractor can reside in the well when not in use. In tractors whose profile causes minimal flow restrictions docking in the main wellbore itself is possible, in other cases it is preferable for the tractor to be docked in a side pocket mandrels or branching bores out of the wellbore. Preferably, the docking means provides a source of power for the tractor either in the form of a conductor or receptacle for recharging batteries onboard the tractor. Various embodiments of means for supplying electrical power to the docking station are envisioned, including conductors extending to the surface, rechargeable or chemical batteries, and downhole electrical power generators. The tractor is operably associated with the docking station, in that, it receives power from the docking station allowing it to remain downhole indefinitely and perform repeated tasks without leaving the well tubing. In some embodiments, the tractor is also operably associated with the docking station by receiving its operating instructions from the docking station either by hardware or wireless means. In this invention, the remote controlled tractor and the valve assembly are all in direct, intimate contact with the wellbore fluid, and thus are inherently pressure balanced with wellbore fluid pressure. This feature makes the performance of the valve insensitive to setting depth.
The tractor could be powered by onboard batteries that are charged when the tractor is docked. In that position, the tractor could engage an electrical socket that would charge the batteries when the tractor is in the stowed position. The tractor could be signaled by a spooled control wire or could be wireless. The tractor could be programmed to travel a certain distance then seek the profile and engage it. Once full stroked, the tractor could disengage the profile and crawl back home or be flowed back into the docking station. Once in the docking station, the tractor would plug into the power socket to be charged for the next cycle. Alternatively, the tractor could drag a power and control conducting tether from the docking station to the task location. The tether could be mechanically retractable (spooled) to quickly return the tractor to its docking station.
The term tractor means or tractor assembly means is used to refer to a self propelled device that can move about the wellbore without mechanical connection to the well surface and includes but is not limited to the particular tractor and robots described herein directly and by reference. The means for moving the tractor about the wellbore can include wheels, endless tracks, articulating inchworm type devices, propellers, cable-spool assemblies and the like. The moving means can be powered by solenoids, actuators, motors and other electrically operable means or hydraulically operated via electrical control devices. Means for performing tasks on the tractor can be a manipulateable arm, rotating device or the like. Each tractor has a means for controlling the movement means and task performing means which can comprise a programmable computer on the tractor or remote from the tractor.
A variety of tools could be stored downhole in tool stations and picked up and used by the tractor means as required to perform the desired task.
As such, these tractors could be individually addressable by wire or wireless commands to perform various tasks. Means for communicating with the tractor is provided and includes both wire and wireless communication links. Wireless includes electromagnetic, optical, acoustic, and pressure transmissions.
Therefore it may be seen that an array of tractors could be located within a wellbore and associated laterals to perform a diversity of tasks.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings are incorporated into and form a part of the specification to illustrate several examples of the present inventions. These drawings together with the description serve to explain the embodiment and operations of the inventions. The drawings are only for the purpose of illustrating preferred and alternative examples of how the inventions can be made and used and are not to be construed as limiting the inventions to only the illustrated and described examples. The various advantages and features of the present inventions will be apparent from a consideration of the drawings in which:
FIG. 1 is a side elevation view partially in section illustrating an embodiment of the docking station and dockable mechanical tractor of the present inventions shown installed in a subterranean location in a cased well adjacent to a subsurface well safety valve;
FIGS. 2 and 3 are views similar to FIG. 1 showing the tractor engaging a closed safety valve and opening the valve;
FIG. 4 is a side elevation view partially in section illustrating another embodiment of the docking station and dockable mechanical tractor of the present inventions with a downhole tool storage site; and
FIG. 5 is a side elevation view partially in section illustrating a further embodiment of the docking station and dockable mechanical tractor of the present inventions with a removable docking station.
DETAILED DESCRIPTION
The present inventions are described by reference to drawings showing one or more examples of how the inventions can be made and used. In these drawings, reference characters are used throughout the several views to indicate like or corresponding parts.
In FIG. 1 a portion 10 of a subterranean well is illustrated. Although, not shown the portion 10 is located a sufficient distance below the land or sea surface to require substantial effort to mechanically operate or engage downhole tools at this depth. The illustrated configuration could, for example, be in a deepwater well or at a difficult to reach lateral location. The illustrated portion 10 is cased 12 and contains a tubing string 14 . A schematic representation of a docking station assembly 20 , tractor assembly 40 and a subsurface safety valve assembly 60 is illustrated. In FIG. 1, the safety valve assembly 60 is in the open or flow position and as is well known in the industry will move to the closed position as required. This particular safety valve design is electrically signaled and mechanically operated. As will be described the valve will close upon loss of electrical power to the valve. The tractor 40 is used to reopen the valve. The inventions are described in this embodiment as servicing a subsurface safety valve, but it is to be understood that other subsurface operations and tools could be utilized. In the FIG. 1 embodiment, the remote controlled tractor 40 moves along the tubing string 14 from the docking station 20 to the safety valve 60 . It engages the safety valve 60 to operate it. After completing the task the tractor 40 is returned to the docking station 20 where it remains until needed.
Preferably the docking station 20 is connected in the tubing string 14 a convenient distance from the safety valve 60 and any other tools (not shown) which the tractor is to service. The docking station 20 is illustrated as comprising a side pocket type mandrel with a cavity or side pocket bore 22 of sufficient size to dock the tractor 40 . When the tractor 40 is in the cavity 22 , it is out of the main bore 23 of the tubing string and provides no restrictions to full bore access to the well. Although docking configurations which provide some limitations or restrictions on the full bore size are acceptable, no bore restriction is preferable. Other possible docking station configurations would include docking in a lateral or even docking within the well bore itself.
The docking station contains a means providing a source of electrical power. In this illustrated embodiment, one or more power conductors such as cable 24 act as the power source means. Cable 24 extends to the well surface in the annulus formed between the tubing string 14 and the casing 12 . Preferably an electrical connector 26 , such as a receptacle or plug, is located in the docking station for releasable connection to the tractor assembly 40 . In FIG. 2, a suitable mating socket connector 44 can be located on the tractor 40 .
Depending on the particular configuration of the present invention one or more conductors could be present in connector 26 . The one or more electrical conductors of the cable 24 could be embedded in the wall of the tubing string 14 to transport power and data to the docking station. Examples of tubing strings with embedded conductors are described in U.S. Pat. Nos. 5,913,337 and 6,016,845. Although not illustrated in this figure, the present inventions include combinations using tubing embedded conductors and the descriptions and drawings of the above embedded conductor patents are included herein in their entirety by reference for all purposes.
In another embodiment, the docking station's power source means is an electrical storage device such as batteries located downhole near the docking or in the docking station processing unit 28 . These batteries could be recharged by down hole power generation, conductors to the surface, or movable service tools.
Docking station 20 includes means for controlling the operation of the tractor. Cable 24 can act as a means and can contain one or more data conductors extending from the docking station to the surface for providing instructions to the station and tractor. Conductors in cable 24 could be shared for both data and power transmission to the docking station. Alternatively, data could be transmitted wirelessly to a receiver in the processing unit 28 , which acts as a means for controlling the operation of the tractor. Alternatively, data and instructions could be transmitted wirelessly from the docking station to a processing unit on the tractor assembly 40 .
Docking station 20 could be provided with a processing means 28 providing one or more data storage, data processing, power storage, and information, transmission or reception. In embodiments where the tractor 40 is tethered to the station by a data and/or power conductors, a series of operating instructions can be conveyed to the tractor 40 through the conductors. Where the tractor 40 is untethered to the docking station, wireless instructions can be transmitted to and from the tractor and the well surface or the docking station 20 . If the docking station is used as the instruction transmitter then a transmitter and signal processor for the wireless signals will be present in the docking stations processing unit 28 .
Tractors suitable for use in a wellbore are the MULE brand downhole tractors are available from Sondex Ltd. of the United Kingdom; the Omega brand tractor is available from Omega Completion Technology Ltd. of the United Kingdom; and the SmarTract brand wireline tractor are available from SmarTract, Inc. of Houston, Tex. Examples of the structures of these tractors are disclosed in U.S. Pat. Nos. 5,947,213; 6,026,911 and 6,112,809 and for purposes of efficiency the descriptions contained in these patents are incorporated herein by reference in their entirety as if the entire patent had been reproduced here. The tractors 40 of this invention can be either tethered or untethered, having either conductor-supplied power or onboard power sources and can be controlled through either wired control or wireless communications. Also, the tractors 40 can include onboard movement and task control means including instruction processors, data storage and memory, sensors, cameras, batteries, receivers, transmitters, and the like, such as described in the above patents and commercially available products.
Tractors 40 have self contained means for moving about the wellbore. In the above patents one means for moving about the wellbore is an inchworm type mechanism wherein the “body” changes in axial length while “legs” selectively engage the wellbore. Other means for moving include endless belts and wheels engaging the wellbore to move. Moving means may also include using a flexible line to pull the tractor along the wellbore or even a rotating propeller move in the well fluids.
U.S. Pat. Nos. 4,862,808 to Hedgcoxe et al., 5,203,646 to Landsberger et al. and 5,392,715 to Pelrine disclose means for moving through the interior of a pipe. The Hedgcoxe et al. patent discloses a robotic pipe crawling device with two three-wheel modules pivotally connected at their centers. The Landsberger et al. patent discloses an underwater robot that is employed to clean and/or inspect the inner surfaces of high flow rate inlet pipes. The robot crawls along a cable positioned within the pipe to be inspected or cleaned. A plurality of guidance fins rely upon the flow of fluid through the pipe to position the robot as desired. Retractable legs can fix the robot at a location within the pipe for cleaning purposes. A fluid driven turbine can generate electricity for various motors, servos and other actuators contained onboard the robot. The robot also can include wheel or pulley arrangements that further assist the robot in negotiating sharp corners or other obstructions. The Pelrine patent discloses an in-pipe running robot with a vehicle body movable inside the pipe along a pipe axis.
In the embodiment illustrated in FIGS. 1 and 2, an inchworm configuration (shown schematically) is used as a means for moving to allow the tractor 40 to move back and forth along the wellbore. It is intended that any one of the means for moving the tractor described above could be used. The description of the various moving means from the above patents and products is included the corresponding structures for the moving means. One or more tools 46 can be provided on the tractor 40 for performing down hole tasks.
The tractor assembly 40 includes the mobile platform and the tool 46 and may include an imaging device and any other desired device that is required to perform the desired downhole operations. Tractor assembly 40 preferably includes a processing unit 42 which acts as a control means containing all the electronics, data gathering and processing circuits and computer programs and communication electronics, required to perform operations downhole with or without the aid of a surface control unit 80 . A suitable telemetry or acoustic system or the like may also be utilized in the surface unit 80 , docking station 20 and the processing unit 42 to communicate command signals and data between the tractor assembly 40 and the docking station 20 and/or surface control unit 80 . The tractor assembly 40 terminates at its uphole end with an electrical connector 44 matching a detachable connector 26 at docking station 20 . The tractor assembly 40 is designed so that upon command or in response to programmed instructions associated therewith, it can cause the connector 44 on tractor assembly 40 to detach itself from the connector 26 at docking station 20 and travel to the desired work site in the tubing string 14 to perform the intended operations.
To operate the tractor assembly 40 , the docking station 20 receives instructions from the surface unit controller 80 . The docking station controller 28 contains data communication links for transporting data and signals between the tractor assembly 40 and the surface control unit 80 . Upon command from the surface control unit 80 or according to programmed instructions stored in the processing unit 28 or 42 , the tractor assembly 40 detaches itself from the docking station 20 and travels downhole to the desired work site (such as the safety valve 60 ) and performs the intended operations. The illustrated safety valve assembly 60 is connected in the tubing string. Alternatively, the safety valve 60 could be a retrievable safety valve connected inside the tubing string. Tractor assembly 40 is useful for performing periodic maintenance operations such as cleaning operations, testing operations, data gathering operations with sensors deployed thereon, gathering data from sensors installed in the tubing string 14 or for operating devices such as a fluid control valve or a sliding sleeve. After the mobile tractor assembly 40 has performed the intended operations, it returns to the docking station 20 and reconnects itself via the connectors 44 and 26 . The tractor assembly includes batteries which can be recharged by power supplied from the docking station 20 .
As a fail-safe measure, the tractor could be programmed to return to the docking station if it loses its current instructions. At the docking station the tractor could be reprogrammed with instructions. The return program could be hard wired (such as in an EPROM type circuit) in the tractor's instructions.
As an alternative embodiment (not shown), a data conductor or control line can connect the tractor assembly 40 to the docking station 20 . In this tethered embodiment, instructions are provided to the tractor 40 via the conductor. In this embodiment long power and control cables extending to the surface are replaced by light control cables extending to the closely located docking station. Additionally, the control line can be spooled out as the tractor moves from the docking station to the work site and the tractor returned to the docking station by reeling in the spool of control line. The spool could be electrically powered and located on either the tractor or docking station.
In FIG. 2 the safety valve 60 is in the closed condition. The tool 46 on the tractor 40 assembly has profile 48 for engaging a profile 62 in the flow tube 64 of the safety valve 60 or some other assembly such as flow control (e.g., sliding sleeve) valve. The remote controlled tractor 40 has “crawled” along the tubing string 14 from the docking station to the safety valve 60 and has engaged the profile 62 on the flow tube. Once the tool 46 is locked into the profile 62 , tractor 40 extends against the wall of tubing string 14 and telescopes, forcing the flow tube 64 downward to the open position FIG. 3 . When the flow tube 64 reaches the valve open position, an electro-mechanical lock or latch 72 engages and holds the bore closure assembly in the open position. In the illustrated embodiment an electro-mechanical lock 72 engages the flow tube to hold it down with the spring 66 compressed and the valve closure element 68 open away from its seat 70 . Electrical power supplied from the surface through conductor 74 is required to maintain latch 72 engaged with the flow tube to hold it in the open condition illustrated in FIG. 3 . The tractor 40 disengages from the valve 60 and retracts to a stowed position in the docking station 20 , illustrated in FIG. 1 . In addition the tractor assembly 40 could be used open or to set and remove retrievable safety valves.
The embodiment illustrated in FIG. 4 includes a docking station 20 and tractor assembly 40 . The tractor assembly 40 is shown docked in the station 20 with its connector 44 engaging the connector 26 . In this embodiment, the docking station is “dumb” and includes onboard data storage and processing unit. The processing unit for controlling the operations of the tractor assembly 40 is onboard the tractor. Cable 24 can convey power and communications between the surface and the tractor 40 when it is docked in the station 20 . Alternatively, surface communication is wireless. According to a particular feature of this embodiment one or more side pocket mandrel tool storage stations 120 (only one is illustrated) for storing tools 46 that can be releasably attached to the tractor 40 . Tools for use in performing different tasks can be stored downhole and connected to the tractor when needed. Tool 46 has a connector or receptacle 48 b that releasably mates with a connector 48 a on the tractor. When needed, the tractor 40 disengages from the docking station 20 , moves to one of the tool storage station 120 , and engages and connects to the tool 46 with releasable connectors 48 a and 48 b . In this embodiment the tool 46 is for use in opening or adjusting a sliding sleeve valve 160 controlling flow from a branching bore 114 . After completing the task the tractor returns the tool 46 to the station 120 and moves into the storage position in the station 20 .
In FIG. 5, an alternative configuration of the docking station is illustrated. In this embodiment, the docking station 220 utilizes a removable data storage and processing unit 228 . Docking station 220 is configured as a side pocket mandrel with connector 226 at its upper end for engaging connector 244 on unit 228 . Unit 228 can contain batteries for storing electrical power, cable spools for tethered configurations, data storage and computing means for controlling the tractor's movements, communication equipment for sending information, data and instructions to and from docking station and the tractor and surface controller. As is well known in the art, the unit 228 can be latched in place and removed using a wire line or other setting devices in the same manner as valves are set in side pocket mandrels. This allows the unit 228 to be installed as a last step during completion (or even later) and to be replaced if it malfunctions or needs to be replaced. It is envisioned that the tractor assembly 40 could be installed and removed with the unit 228 and in the untethered version installed independently. Mating connector 226 on the unit 228 mates with docking connector 44 on tractor 40 as previously described with respect to FIGS. 1-4.
In addition tubing 112 contains embedded conductors 224 which terminate at connector 226 . As previously described conductors 224 extend to the surface and can be used to provide power and to communicate data and instructions between the docking station and the surface. Preferably, a locating profile 229 is located adjacent the docking station.
In these examples, the remote controlled tool 40 and the safety valve assembly 60 are all in direct, intimate contact with the wellbore fluid, and thus are inherently pressure balanced with wellbore fluid pressure. This feature makes the performance of the valve 60 insensitive to setting depth.
The tractor could be powered by onboard batteries that are charged when the tractor is docked in a side pocket mandrel. In that position, the tractor could engage a socket that would charge the batteries when the tractor is in the stowed position. The tractor could be signaled by a spooled control wire or could be wireless. The tractor could be programmed to travel a certain distance then seek the profile and engage it. Once fully stroked, the tractor could disengage the profile and crawl or spool back or even be flowed back to the docking station. Once in the docking station, the tractor would plug into the power socket to be charged for the next cycle.
Furthermore, this tractor could be stowed (as described above) in lateral docking stations, then deployed to perform certain tasks. As such, these tractors could be individually addressable for tasks by wire/wireless commands. An array of tractors could be located within a wellbore and associated laterals to perform a diversity of tasks. These operations could be as varied as adjusting flow control devices such as sliding sleeve valves to setting plugs remotely. Another possible task would be to retrieve pressure/temperature recording devices and uplink data to the surface via electronics located either onboard the tractor or in the docking station.
The embodiments shown and described above are only exemplary. Many details are often found in the art such as the tractor assemblies both tethered and untethered and communication and control systems. Therefore, many such details are neither shown nor described. It is not claimed that all of the detail parts, elements, or steps described and shown were invented herein. Even though numerous characteristics and advantages of the present inventions have been set forth in the foregoing description, together with details of the structure and function of the inventions, the disclosure is illustrative only, and changes may be made in the detail, especially in matters of shape, size and arrangement of the parts within the principles of the inventions to the full extent indicated by the broad general meaning of the terms used in the attached claims.
The restrictive description and drawings of the specific examples above do not point out what an infringement of this patent would be, but are to provide at least one explanation of how to make and use the inventions. The limits of the inventions and the bounds of the patent protection are measured by and defined in the following claims.
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The present invention provides an improved system and method for performing a desired operation at a remote location in a wellbore. The system is composed of a downhole docking station assembly and a detachable downhole tool assembly. The downhole tool assembly includes electrically operated means to move in the wellbore and an end work device to perform the desired work. The downhole tool can also include an imaging device to provide pictures of the downhole environment and various sensors. Data from the downhole tool is communicated to a surface computer, which controls the operation of the tool and displays pictures of the tool environment. The downhole tool detaches itself from the docking station, travels to the desired location in the wellbore and performs a predefined operation according to programmed instruction. The downhole tool returns and connects to the docking station, where it transfers data relating to the operation and can be recharged for further operation. Various attachments for the downhole tool assembly can be stored and selectively retrieved for downhole locations.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a weather strip which is assembled onto a flange of an automobile body with an adhesive, and also relates to a method for assembling the same.
2. Description of Related Art
A related weather strip has been disclosed, for example, in U.S. Pat. No. 4,617,220. In the weather strip disclosed therein, as represented by FIG. 13 of the attached drawings, a trim portion 21 has a pair of attachment pieces 22 provided with adhesive double sided tape 23. During assembly, the attachment pieces 22 are bent downwardly and inwardly towards one another as indicated by the arrows in FIG. 13, and an adhesive surface 230 of the adhesive double sided tape 23 adheres to an adhesion surface 240 of a flange 24. Flange 24 is fixed to the automobile body and serves to support the trim portion 21. A hollow sealing portion 26 is provided on the outer surface of trim portion 21 and is positioned so as to be partially compressed by another body (such as a door or the like) and provide a seal between the flange and such body.
In this weather strip, however, the lower surface 25 of the trim portion 21 between the attachment pieces 22 is flat, and, as a result, the trim portion 21 cannot be accurately positioned in the widthwise direction (left to right in FIG. 13), relative to the flange 24. Therefore, during assembly, the trim portion 21 may be improperly aligned with respect to flange 24, and sealing portion 26 may thus be unable to accomplish its proper sealing function.
Another type of a weather strip has been disclosed in U.S. Pat. No. 4,263,750. In this weather strip, as shown in FIG. 14, a trim portion 31 having a substantially oval-shaped section is integrally provided with a slit 32, forming a pair of legs 33. A flange 34 is inserted into the slit 32, and a tip end of each leg 33 is engaged with a respective partially cut and bent piece 35 extending from flange 34. The trim portion 31 is thus assembled onto the automobile body.
In this weather strip, however, since the flange 34 must be provided with the aforementioned partially cut and bent pieces 35 in order to prevent disengagement of the trim portion 31 therefrom, the cost of manufacturing this flange is relatively high.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a weather strip for an automobile which can be securely adhered to an inexpensively manufactured flange. Another object of the present invention is to provide a simple method of assembling the weather strip which ensures accurate positioning of the portion relative to the flange.
In order to achieve the above object, the present invention provides a weather strip for an automobile including a trim portion securable to a flange of an automobile body. The trim portion has a holding piece and a concave portion. The concave portion is provided at a base portion of the holding piece and is in contact with an end of the flange. The concave portion is cooperable with the end of the flange to enable the trim portion to be slidably rotatable with respect to the end of the flange when being secured to the flange. In addition, an adhesive is provided at an inner surface of the holding piece for adhering the trim portion to the flange. The configuration of the holding piece and the position of the adhesive, which is preferably double sided tape, may be varied according to the configuration of the particular flange.
The present invention applies to weather strips provided on various portions of an automobile, such as the trunk, sliding roof, drip seal, door glass, roof side, and door opening or frame.
In assembling the weather strip of the present invention, the concave portion of the trim portion bears against the tip end of the flange so as to determine the widthwise position of the trim portion with respect to the flange and to also determine the center of rotation of the trim portion with respect to the flange during assembly. During assembly, the trim portion is rotated around the flange while the concave portion maintains contact with the tip end of the flange. As a result holding piece is brought toward the flange and securely adhered thereto by the adhesive surface of the adhesive double sided tape disposed between the holding piece and an adhesion surface of the flange. Therefore, the trim portion can be easily and precisely assembled at the desired position on the flange. Furthermore, because an adhesive, such as double sided tape, is used to prevent disengagement of the trim portion from the flange, the flange does not require a cut and bent portion or the like. As a result, the weather strip can be securely fastened to an inexpensively manufactured flange.
The trim portion is preferably formed from a solid rubber (generally extruded) capable of maintaining a tight hold on the flange. The solid rubber may be, for example, EPDM (ethylene-propylene-diene copolymer) solid rubber.
The trim portion preferably has its outer surface provided with a sealing element formed of soft and elastic sponge rubber.
The trim portion may be provided with a second holding piece, which is preferably provided with a recess at the inner surface of its base. The recess ensures that the base portion of the second holding piece does not interfere with the tip end of the flange during rotation of the trim portion around the contact portion between the concave portion and the flange. Even if the tip end of the second holding piece bends to some extent, a bulge caused by this bend is located in the recess so that the concave portion is not narrowed and the trim portion can still be rotated through a large angle.
It is preferable that only the first holding piece bear the adhesive double sided tape. Since the double sided tape is provided on only one holding piece, the amount of the adhesive double sided tape can be conserved, and expenses thereby saved. Typically, the width of the adhesive double sided tape corresponds to the width of the first holding piece so as to substantially cover the inner surface of the first holding piece. The second holding piece is formed to have its tip end located substantially at the same level as an inner edge, adjacent the concave portion, of the adhesive double sided tape. Thus, it can be appreciated that the holding pieces have different lengths, which allows the concave portion to easily engage the flange.
The second holding piece is preferably thinner than the first holding piece so that the second holding piece can be easily bent during assembly.
The first holding piece may have its inner surface provided with a small projection pressing against the flange for enhancing the sealing capability of the strip. The first holding piece may further be provided, at its tip end, with a lip bearing against the flange. The lip also improves the sealing capability of the strip.
The concave portion may have a diameter larger than the thickness of the flange, in which case the trim portion can be smoothly and easily rotated while maintaining contact between the concave portion and the tip end of the flange.
Alternatively, the concave portion may have a diameter substantially equal to the thickness of the flange, which enables the trim portion to tightly grip the flange. In this case, the concave portion is forced to engage the tip end of the flange while maintaining the bent state of the holding piece in an inclined position during assembly.
The present invention also provides an assembly method including the steps of, engaging a concave portion of the weather strip with an end of a flange of an automobile such that a holding piece of the weather strip is inclined with respect to an adhesion surface of the flange, rotating the weather strip around portions of engagement between the concave portion and the flange such that the holding piece is directed toward the adhesion surface of the flange, and adhering the holding piece to the adhesive surface of the flange. This assembly method may be executed manually or by an automatic assembly machine.
The method of the present invention enables easy, precise assembly of the weather strip to the flange.
Other objects of this invention will become apparent upon an understanding of the following illustrative embodiments and claims. Advantages not referred to herein will occur to one skilled in the art upon employment of the invention in practice.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross section of a weather strip for a trunk of a first embodiment of the present invention;
FIG. 2 is a cross section illustrating an assembly method of the weather strip in FIG. 1;
FIG. 3 is a cross section of a weather strip for a sliding roof of a second embodiment of the present invention;
FIG. 4 is a cross section illustrating an assembly method of the weather strip in FIG. 3;
FIG. 5 is a cross section of a weather strip for a drip sealing of a third embodiment of the present invention;
FIG. 6 is a cross section illustrating an assembly method of the weather strip in FIG. 5;
FIG. 7 is a cross section of a door glass run illustrating another example to which the present invention applies;
FIG. 8 is a cross section of a weather strip for a roof side illustrating still another example to which the present invention applies;
FIG. 9 is a cross section of a weather strip for a door opening illustrating yet another example to which the present invention applies;
FIG. 10 is a cross section of the assembly operation of another weather strip of the first embodiment of the present invention;
FIG. 11 is a cross section after assembly of the weather strip in FIG. 10;
FIG. 12 is a cross section illustrating another example to which the weather strip in FIG. 9 applies;
FIG. 13 is a cross section of a weather strip of the prior art; and
FIG. 14 is a cross section of another weather strip of the prior art.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the first embodiment of the present invention, the weather strip is attached to a trunk of an automobile. This embodiment will be described below with reference to FIGS. 1 and 2. A weather strip W1 of the first embodiment is integrally provided with a trim portion 2 attached to a flange 1 of an automobile body. A hollow sealing element 3 is secured to trim portion and seals the gap between the body and the trunk lid (not shown). The trim portion 2 is formed of EPDM solid rubber extruded into a substantially J-shaped section. The hollow sealing element 3 is formed of EPDM sponge rubber formed by common extrusion and has a substantially O-shaped section. In order to reduce the weight of the weather strip, the trim portion 2 is made from hard solid rubber so that it does not have to be reinforced with a metal insert.
The trim portion 2 is provided with a pair of long and short holding pieces, 4 and 5 respectively, for holding flange 1. The long holding piece 4 is provided at its inner surface with an adhesive double sided tape 6 for adhering the long holding piece 4 to an adhesion surface 10 of the flange 1. The width of the adhesive double sided tape 6 (top to bottom in FIG. 1) substantially correlates to the width of the long holding piece 4 (also top to bottom in FIG. 1) so as to cover the majority of the inner surface 44 of long holding piece 4. The short holding piece 5 has its tip end 41 located substantially at the same level as an inner edge of the adhesive double sided tape 6. On an outer surface of the short holding piece 5, a cover lip 7 is formed by common extrusion. The cover lip 7 is made of EPDM sponge rubber and covers an edge portion of an interior member (not shown) of the trunk.
The holding pieces 4 and 5 are provided, at a base portion therebetween, with a concave portion 8, which comes into contact with the tip end of the flange 1. The concave portion 8 serves to determine the widthwise position of the trim portion 2 with respect to the flange 1. Concave portion 8 also defines a center of rotation of the trim portion during assembly. In order to enable the trim portion 2 to rotate smoothly while maintaining contact between the tip end of the flange 1 and the concave portion 8, the concave portion 8 is provided with a width slightly larger than a thickness of the flange 1 and includes a recess 9 at the base portion of the short holding piece 5 in this embodiment.
An assembly method of the weather strip W1 of the first embodiment thus constructed will now be described hereinbelow. In the assembly operation, as shown in FIG. 2, the concave portion 8 is first engaged with flange 1 while maintaining a position in which the trim portion 2 is inclined with respect to the adhesion surface 10 of the flange 1. The concave portion 8 easily engages flange 1 because the holding pieces 4 and 5 have different lengths. In this engaged state, the bottom surface of the concave portion 8 is in contact with the end of the flange 1, and the tip end 41 of the short holding piece 5 is in contact with the exterior surface 42 of flange 1. The widthwise position of the trim portion 2 with respect to flange 1 and the center of rotation thereof is thereby determined.
While the inclination of the trim portion 2 with respect to flange 1 is maintained, a release liner 43 of the adhesive double sided tape 6 is peeled off to expose an adhesive surface 16. Then, the trim portion 2 is rotated in a direction (indicated by an arrow) around the portion of contact between the concave portion 8 and the flange 1 so that the double sided tape 6 adheres the long holding piece 4 to the adhesion surface 10 of the flange 1. Since the concave portion 8 includes recess 9, the base portion of the short holding piece 5 does not interfere with the tip end of flange 1. Even if the tip end 41 of the short holding piece 5 bends to some extent, a bulge caused by this bend is located in the recess 9, so that concave portion 8 is not narrowed. Therefore, the trim portion 2 can be rotated through a large angle, and the long holding piece 4 can be firmly pressed and adhered to flange 1.
As a result of the foregoing process, the trim portion 2 is securely attached to flange 1, as shown in FIG. 1, and thereby, the weather strip W1 is assembled onto the automobile body. In the instance in which the release liner 43 of the adhesive double sided tape 6 is not provided or is peeled off prior to engagement of the concave portion 8 with the tip end of flange 1, this peeling step can obviously be omitted from the present method of assembly. It should also be noted that while it is preferable to use double sided tape as the adhesive, other adhesives, such as glue, may be employed.
According to the weather strip W1 and the assembly method of this embodiment, the trim portion 2 maintains its widthwise position with respect to flange 1 while being rotated about the end of flange 1. Therefore, the weather strip W1 can be easily assembled at a precise position on the flange 1. Strong adhesion of the trim portion 2 to flange 1 is achieved by the adhesive double sided tape 6 provided on the long holding piece 4 so that the flange 1 can be manufactured without a cut and bent piece or the like. This significantly reduces manufacturing costs. In addition, since only one of the two holding pieces is provided with the double sided tape 6, a relatively small amount of tape is used, which further adds to the savings in manufacturing costs.
In the second embodiment of the present invention, the weather strip is attached to a sliding roof of an automobile. This embodiment will be described below with reference to FIGS. 3 and 4, in which the corresponding portions of the first embodiment bear the same reference numerals. A weather strip W2 of the second embodiment is integrally provided with trim portion 2 attached to flange 1 of roof 11. The hollow sealing element 3 seals a gap between the sliding roof 11 and a frame or body 12. The hollow sealing element 3 is made of EPDM solid rubber, which is softer than the trim portion 2, and has fixed electrostatic hairs 13 provided at its outer surface for promoting slippage with respect to body 12 during rotation of trim portion 2. As an alternative to fixed electrostatic hairs 13, urethane may be applied to the outer surface of the hollow sealing 3 for smoothing the same.
The trim portion 2 is provided with a pair of upper and lower holding pieces, 4 and 5 respectively, for holding the trim portion 2 to the flange 1. The upper holding piece 4 has adhesive double sided tape 6 adhered to its inner surface for adhering weather strip W2 to the adhesion surface 10 of the flange 1. The upper holding piece is also provided with small projections 14 bearing against flange 1 to provide a seal therebetween. On the outer surface of the holding piece 4, there is provided a pair of ribs or protrusions 15 for preventing a deformed adhesion of the center of hollow sealing element 3 to trim portion 2. The lower holding piece 5 is thinner than the upper holding piece 4 for facilitating bending thereof during assembly. The lower holding piece 5 is also provided with an end lip 17 pressed against the exterior surface of the flange 1. The holding pieces 4 and 5 are provided with the concave portion 8 at the base thereof. The tip end of the flange 1 bears against the concave portion 8, which has a depth that permits absorption of positional deviation of the tip end of the flange 1.
In the assembly of the weather strip W2, as shown in FIG. 4, the holding piece 4 is bent outwardly so as to be inclined with respect to flange 1. The concave portion 8 is engaged with the flange 1 while maintaining this inclined position. As a result, the concave portion 8 contacts the lower surface of flange 1 so as to determine the relative position of the trim portion 2 with respect to the flange 1. In this manner, the center of rotation of trim portion 2 is also determined. Then, by rotating the trim portion 2 around the contact portion in the direction indicated by the arrow in FIG. 4, the upper holding piece eventually meets flange 1, with the adhesive double sided tape 6 therebetween. The double sided tape 6 serves to adhere holding piece 4 to adhesion surface 10 of the flange 1. Thereby, as shown in FIG. 3, the trim portion 2 is securely attached to the flange 1, and the weather strip W2 is precisely assembled onto the periphery of the sliding roof 11.
In a third embodiment of the present invention, the weather strip operates as a drip sealing of an automobile. This embodiment will be described below with reference to FIGS. 5 and 6. Weather strip W3 of the third embodiment is integrally provided with the trim portion 2 attached to flange 1 of the automobile body. A water receiving lip 18 extends from trim portion 2 and receives water at the inside of the automobile door (not shown). The trim portion 2 includes holding piece 4 of a substantially L-shaped section for securing a bent portion 1a of the flange 1. The adhesive double sided tape 6 is adhered to the inner surface of the L-shaped holding piece 4. The C-shaped holding piece 5 is provided with concave portion 8, which comes into contact with the lower portion of the bent portion 1a. The weather strip W3 may include a hollow sealing element 3, if required.
In the assembly of weather strip W3, as shown in FIG. 6, the L-shaped holding piece 4 is bent outwardly so that trim portion 2 is inclined with respect to adhesion surface 10 of flange 1. Concave portion 8 is engaged with the flange 1 while the L-shaped holding piece 4 maintains the inclined position. As a result, the concave portion 8 bears against the lower portion of the bent portion 1a so as to determine the relative vertical and horizontal positions of the trim portion 2 with respect to flange 1. In addition, the center of rotation of trim portion 2 with respect to flange 1 during assembly is also determined. Thereafter, by rotating the trim portion 2, around the contact portion in the direction indicated by the arrow in FIG. 6, the L-shaped holding piece 4 eventually meets flange 1, with the adhesive double sided tape 6 therebetween. The double sided tape 6 serves to adhere L-shaped holding piece 4 to adhesion surface 10 of the flange 1. Thus, as shown in FIG. 5, the trim portion 2 is securely attached to the flange 1, and the weather strip W3 is precisely assembled onto the body.
The present invention may also apply, for example, to a weather strip W4 for a door glass as shown in FIG. 7, a weather strip W5 for roof side as shown in FIG. 8, and a weather strip W6 for door opening or frame as shown in FIG. 9. In these examples, the weather strips W4-W6 can be easily and accurately assembled onto the flange 1 of an automobile body in a manner similar to that of the foregoing embodiments. Furthermore, as shown in FIG. 10, the weather strip W1 of the first embodiment may be provided with a supporting lip 19 of a tongue-shaped section, preferably made from EPDM sponge rubber and formed by common extrusion, at the lower end portion of long holding piece 4. Supporting lip 19 is in friction contact with a panel 20 of an automobile body, as shown in FIG. 11. The frictional resistance between the supporting lip 19 and the panel 20 serves to prevent clockwise rotation (as viewed in FIG. 11) of the weather strip W1, which may result from external forces applied after adhesion. As a result, the weather strip can be even more securely adhered to flange 1.
As shown in FIG. 12, the supporting lip 19 can also be provided with the weather strip W6 of FIG. 9.
It has been made apparent that several different embodiments of this invention are possible without departing from the spirit and scope thereof. Therefore, it is to be understood that the present invention incudes all modifications encompassed within the spirit and scope of the following claims.
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A weather strip for an automobile comprising a trim portion securable to a flange of an automobile. The trim portion has a holding piece and a concave portion. The concave portion is disposed at a base portion of the holding piece and is in contact with an end of the flange. The concave portion is cooperable with the end of the flange to enable the trim portion to be slidably rotatable with respect to the end of the flange when being secured to the flange. An adhesive is provided at an inner surface of the holding piece for adhering the trim portion to the flange.
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CROSS REFERENCE OF RELATED APPLICATION
[0001] This application claims the benefit under 35 U.S.C. §120 of the filing date of non-provisional patent application Ser. No. 14/206,867 filed Mar. 12, 2014, now U.S. Pat. No. ______, which claims the benefit under 35 U.S.C. §119(e) of the filing date of provisional patent application Ser. No. 61/798,091 filed Mar. 15, 2013, the respective disclosures of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] Aspects of the invention relate to systems, methods, and apparatus for selectively opening deformable fluid vessels. One aspect of the invention relates to generating compressive forces for compressing deformable fluid vessels to displace fluid therefrom in a low profile instrument. Other aspects of the invention relate to opening the deformable fluid vessel in a manner that reduces the amount of compressive force required to displace fluid from the vessel. Other aspects of the invention relate to an apparatus for protecting the deformable fluid vessel from inadvertent exposure to external forces and for interfacing with the vessel to permit intentional application of external compressive force without removing the vessel-protective features.
BACKGROUND OF INVENTION
[0003] The present invention relates to systems, methods, and apparatus for manipulating deformable fluid vessels. An exemplary device having such deformable fluid vessels is shown in FIGS. 1A and 1B . A liquid reagent module 10 includes a substrate 12 on which a plurality of deformable fluid vessels, or blisters, are attached. Devices such as the liquid reagent module 10 are often referred to as cartridges or cards. In an embodiment, the liquid reagent module 10 includes an input port 16 , which may comprise a one-way valve, for dispensing a sample fluid into the module 10 . A fluid channel 18 carries fluid from the input port 16 . A sample vent 14 vents excess pressure from the module 10 . A labeled panel 20 may be provided for an identifying label, such as a barcode or other human and/or machine-readable information.
[0004] Liquid reagent module 10 further includes a plurality of deformable (collapsible) vessels (blisters), including, in the illustrated embodiment, an elution reagent blister 22 , a wash buffer blister 24 , a water blister 26 , a lysis reagent blister 28 , an air blister 30 , a binding agent blister 32 , and an oil blister 34 . Note that the number and types of blisters shown are merely exemplary. Each of the blisters may be interconnected with one or more other blisters and/or the fluid channel 18 by one or more fluid channels formed in or on the substrate 12 .
[0005] The liquid reagent module 10 may be processed by selectively compressing one or more of the blisters to completely or partially collapse the blister to displace the fluid therefrom. Instruments adapted to process the liquid reagent module 10 , or other devices with deformable fluid vessels, include mechanical actuators, e.g., typically pneumatically or electromechanically actuated, constructed and arranged to apply collapsing pressure to the blister(s). Typically, such actuator(s) is(are) disposed and are moved transversely to the plane of the module 10 —for example, if module 10 were oriented horizontally within an instrument, actuators may be provided vertically above and/or below the module 10 and would be actuated to move vertically, in a direction generally normal to the plane of the module. The liquid reagent module 10 may be processed in an instrument in which the module 10 is placed into a slot or other low profile chamber for processing. In such a slot, or low profile chamber, providing actuators or other devices that are oriented vertically above and/or below the module 10 and/or move in a vertical direction may not be practical. The pneumatic and/or electromechanical devices for effecting movement of such actuators require space above and/or below the module's substrate, space that may not be available in a slotted or other low profile instrument.
[0006] Accordingly, a need exists for methods, systems, and/or apparatus for effecting movement of an actuator for collapsing a vessel within a low profile component space of an instrument.
SUMMARY OF THE INVENTION
[0007] Aspects of the invention are embodied in an apparatus for processing a fluid module including a collapsible vessel supported on a planar substrate by applying a force compressing the vessel against the substrate. The apparatus comprises a first actuator component configured to be movable in a first direction that is generally parallel to the plane of the substrate, a second actuator component configured to be movable in a second direction having a component that is generally normal to the plane of the substrate, and a motion conversion mechanism coupling the first actuator component with the second actuator component and constructed and arranged to convert movement of the first actuator component in the first direction into movement of the second actuator component in the second direction.
[0008] According to further aspects of the invention, the first actuator component comprises an actuator plate configured to be movable in the first direction and including a cam follower element, the second actuator component comprises a platen configured to be movable in the second direction, and the motion conversion mechanism comprises a cam body having a cam surface. The cam body is coupled to the platen and is configured such that the cam follower element of the actuator plate engages the cam surface of the cam body as the actuator plate moves in the first direction thereby causing movement of the cam body that results in movement of the platen in the second direction.
[0009] According to further aspects of the invention, the cam follower element of the actuator plate comprises a roller configured to rotate about an axis of rotation that is parallel to the actuator plate and normal to the first direction, the motion conversion mechanism further comprises a chassis, and the cam body is pivotally attached at one portion thereof to the chassis and at another portion thereof to the platen.
[0010] According to further aspects of the invention, the cam surface of the cam body comprises an initial flat portion and a convexly-curved portion, and movement of the roller from the initial flat portion to the convexly-curved portion causes the movement of the cam body that results in movement of the platen in the second direction.
[0011] According to further aspects of the invention, the first actuator component comprises a cam rail configured to be movable in the first direction, the second actuator component comprises a platen configured to be movable in the second direction, and the motion conversion mechanism comprises a cam surface and a cam follower coupling the cam rail to the platen and configured to convert motion of the cam rail in the first direction into movement of the platen in the second direction.
[0012] According to further aspects of the invention, the cam surface comprises a cam profile slot formed in the cam rail, and the cam follower comprises a follower element coupling the platen to the cam profile slot such that movement of the cam rail in the first direction causes movement of the cam follower within the cam profile slot that results in the movement of the platen in the second direction.
[0013] Further aspects of the invention are embodied in an apparatus for displacing fluid from a fluid container. The fluid container includes a first vessel and a second vessel connected or connectable to the first vessel and including a sealing partition preventing fluid flow from the second vessel, and the fluid container further includes an opening device configured to be contacted with the sealing partition to open the sealing partition and permit fluid flow from the second vessel. The apparatus comprises a first actuator configured to be movable with respect to the first vessel to compress the first vessel and displace fluid contents thereof and a second actuator movable with respect to the opening device and configured to contact the opening device and cause the opening device to open the sealing partition, The second actuator is releasably coupled to the first actuator such that the second actuator moves with the first actuator until the second actuator contacts the opening device and causes the opening device to open the sealing partition, after which the second actuator is released from the first actuator and the first actuator moves independently of the second actuator to displace fluid from the first vessel.
[0014] Further aspects of the invention are embodied in a fluid container comprising a first vessel, a second vessel connected or connectable to the first vessel, a sealing partition preventing fluid flow from the second vessel, and a spherical opening element initially supported within the second vessel by the sealing partition and configured to be contacted with the sealing partition to open the sealing partition and permit fluid flow from the second vessel.
[0015] Further aspects of the invention are embodied in a fluid container comprising a first vessel, a second vessel connected or connectable to the first vessel, a sealing partition preventing fluid flow from the second vessel, and a cantilevered lance having a piercing point and disposed with the piercing point adjacent to the sealing partition and configured to be deflected until the piercing point pierces the sealing partition to permit fluid flow from the second vessel through the pierced sealing partition.
[0016] Further aspects of the invention are embodied in a fluid container comprising a first vessel, a second vessel connected or connectable to the first vessel, a sealing partition preventing fluid flow from the second vessel, and a cantilevered lance having a piercing point and being fixed at an end thereof opposite the piercing point, the cantilevered lance being disposed with the piercing point adjacent to the sealing partition and configured to be deflected until the piercing point pierces the sealing partition to permit fluid flow from the second vessel through the pierced sealing partition.
[0017] According to further aspects of the invention, the fluid container further comprises a substrate on which the first and second vessels are supported and which includes a chamber formed therein adjacent the sealing partition wherein an end of the cantilevered lance is secured to the substrate and the piercing point of the lance is disposed within the chamber.
[0018] Further aspects of the invention are embodied in a fluid container comprising a first vessel, a second vessel connected or connectable to the first vessel, a sealing partition preventing fluid flow from the second vessel, and a lancing pin having a piercing point and disposed with the piercing point adjacent to the sealing partition and configured to be moved with respect to the sealing partition until the piercing point pierces the sealing partition to permit fluid flow from the second vessel through the pierced sealing partition.
[0019] According to further aspects of the invention, the lancing pin has a fluid port formed therethrough to permit fluid to flow through the lancing pin after the sealing partition is pierced by the piercing point.
[0020] According to further aspects of the invention, the fluid container further comprises a substrate on which the first and second vessels are supported and which includes a chamber formed therein adjacent the sealing partition within which the lancing pin is disposed.
[0021] According to further aspects of the invention, the chamber in which the lancing pin is disposed comprises a segmented bore defining a hard stop within the chamber and the lancing pin includes a shoulder that contacts the hard stop to prevent further movement of the lancing pin after the piercing point pierces the sealing partition.
[0022] According to further aspects of the invention, the fluid container further comprises a fluid channel extending between the first and second vessels.
[0023] According to further aspects of the invention, the fluid container of further comprises a seal within the fluid channel, the seal being configured to be breakable upon application of sufficient force to the seal to thereby connect the first and second vessels via the fluid channel.
[0024] Further aspects of the invention are embodied in a fluid container comprising a first vessel, a second vessel disposed within the first vessel, a substrate on which the first and second vessels are supported and having a cavity formed therein adjacent the second vessel, a fixed spike formed within the cavity, and a fluid exit port extending from the cavity, wherein the first and second vessels are configured such that external pressure applied to the first vessel will collapse the second vessel and cause the second vessel to contact and be pierced by the fixed spike, thereby allowing fluid to flow from the first vessel through the pierced second vessel, the cavity, and the fluid exit port.
[0025] Further aspects of the invention are embodied in a fluid container comprising a collapsible vessel configured to be collapsed upon application of sufficient external pressure to displace fluid from the vessel, a housing surrounding at least a portion of the collapsible vessel, and a floating compression plate movably disposed within the housing. The housing includes an opening configured to permit an external actuator to contact the floating compression plate within the housing and press the compression plate into the collapsible vessel to collapse the vessel and displace the fluid contents therefrom.
[0026] Other features and characteristics of the present invention, as well as the methods of operation, functions of related elements of structure and the combination of parts, and economies of manufacture, will become more apparent upon consideration of the following description and the appended claims with reference to the accompanying drawings, all of which form a part of this specification, wherein like reference numerals designate corresponding parts in the various figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] The accompanying drawings, which are incorporated herein and form part of the specification, illustrate various, non-limiting embodiments of the present invention. In the drawings, common reference numbers indicate identical or functionally similar elements.
[0028] FIG. 1A is a top plan view of a liquid reagent module.
[0029] FIG. 1B is a side view of the liquid reagent module.
[0030] FIG. 2 is a perspective view of a blister compressing actuator mechanism embodying aspects of the present invention.
[0031] FIG. 3A is a partial, cross-sectional perspective view of the articulated blister actuator platen assembly in an initial, unactuated state.
[0032] FIG. 3B is a partial, cross-sectional side view of the articulated blister actuator platen assembly in the initial unactuated state.
[0033] FIG. 4A is a partial, cross-sectional perspective view of the articulated blister actuator platen assembly as the platen is about to be actuated.
[0034] FIG. 4B is a partial, cross-sectional side view of the articulated blister actuator platen assembly as the platen is about to be actuated.
[0035] FIG. 5A is a partial, cross-sectional perspective view of the articulated blister actuator platen assembly with the platen in a fully actuated state.
[0036] FIG. 5B is a partial, cross-sectional side view of the articulated blister actuator platen assembly with the platen in a fully actuated state.
[0037] FIG. 6A is a partial, cross-sectional perspective view of the articulated blister actuator platen assembly with the platen returned to the unactuated state.
[0038] FIG. 6B is a partial, cross-sectional side view of the articulated blister actuator platen assembly with the platen returned to the unactuated state.
[0039] FIG. 7A is a perspective view of an alternative embodiment of a blister compressing actuator mechanism in an unactuated state.
[0040] FIG. 7B is a perspective view of the blister compressing actuator mechanism of
[0041] FIG. 7A in the fully actuated state.
[0042] FIG. 8A is a partial, cross-sectional side view of a collapsible fluid vessel configured to facilitate opening of the vessel.
[0043] FIG. 8B is an enlarged partial, cross-sectional side view of a vessel opening feature of the collapsible fluid vessel.
[0044] FIGS. 9A-9D are side views showing an apparatus for opening a collapsible vessel configured to facilitate opening of the vessel in various states.
[0045] FIG. 10 is a side view of an alternative embodiment of an apparatus for opening a collapsible vessel configured to facilitate opening of the vessel.
[0046] FIG. 11 is a bar graph showing exemplary burst forces for fluid-containing blisters of varying volumes.
[0047] FIG. 12 is a load versus time plot of the compression load versus time during a blister compression.
[0048] FIG. 13A is a partial, cross-sectional side view of an alternative apparatus for opening a collapsible vessel configured to facilitate opening of the vessel.
[0049] FIG. 13B is a perspective view of a cantilever lance used in the embodiment of FIG. 13A .
[0050] FIG. 14 is a partial, cross-sectional side view of an alternative apparatus for opening a collapsible vessel configured to facilitate opening of the vessel.
[0051] FIG. 15A is a partial, cross-sectional side view of an alternative apparatus for opening a collapsible vessel configured to facilitate opening of the vessel.
[0052] FIG. 15B is a perspective view of a lancing pin used in the apparatus of FIG. 15A .
[0053] FIG. 16A is a partial, cross-sectional side view of an alternative apparatus for opening a collapsible vessel configured to facilitate opening of the vessel.
[0054] FIG. 16B is a perspective view of a lancing pin used in the apparatus of FIG. 16A .
[0055] FIG. 17 is an exploded, cross-sectional, perspective view of an apparatus for protecting and interfacing with a collapsible vessel.
[0056] FIG. 18 is a cross-sectional, side view of the apparatus for protecting and interfacing with a collapsible vessel in an unactuated state.
[0057] FIG. 19 is a cross-sectional, perspective view of the apparatus for protecting and interfacing with a collapsible vessel in fully actuated state.
DETAILED DESCRIPTION OF THE INVENTION
[0058] Unless defined otherwise, all terms of art, notations and other scientific terms or terminology used herein have the same meaning as is commonly understood by one of ordinary skill in the art to which this disclosure belongs. Many of the techniques and procedures described or referenced herein are well understood and commonly employed using conventional methodology by those skilled in the art. As appropriate, procedures involving the use of commercially available kits and reagents are generally carried out in accordance with manufacturer defined protocols and/or parameters unless otherwise noted. All patents, applications, published applications and other publications referred to herein are incorporated by reference in their entirety. If a definition set forth in this section is contrary to or otherwise inconsistent with a definition set forth in the patents, applications, published applications, and other publications that are herein incorporated by reference, the definition set forth in this section prevails over the definition that is incorporated herein by reference.
[0059] As used herein, “a” or “an” means “at least one” or “one or more.”
[0060] This description may use relative spatial and/or orientation terms in describing the position and/or orientation of a component, apparatus, location, feature, or a portion thereof. Unless specifically stated, or otherwise dictated by the context of the description, such terms, including, without limitation, top, bottom, above, below, under, on top of, upper, lower, left of, right of, in front of, behind, next to, adjacent, between, horizontal, vertical, diagonal, longitudinal, transverse, etc., are used for convenience in referring to such component, apparatus, location, feature, or a portion thereof in the drawings and are not intended to be limiting.
[0061] An actuator mechanism for compressing deformable fluid vessels—such as blisters on a liquid reagent module—embodying aspects of the present invention is shown at reference number 50 in FIG. 2 . The actuator mechanism 50 may include an articulated blister actuator platen assembly 52 and a sliding actuator plate 66 . The sliding actuator plate 66 is configured to be movable in a direction that is generally parallel to the plane of the liquid reagent module—horizontally in the illustrated embodiment—and may be driven by a linear actuator, a rack and pinion, a belt drive, or other suitable motive means. Sliding actuator plate 66 , in the illustrated embodiment, has V-shaped edges 76 that are supported in four V-rollers 74 to accommodate movement of the plate 66 in opposite rectilinear directions, while holding the sliding actuator plate 66 at a fixed spacing from the actuator platen assembly 52 . Other features may be provided to guide the actuator plate 66 , such as rails and cooperating grooves. A component 40 —which may comprise liquid reagent module 10 described above—having one or more deformable fluid vessels, such as blisters 36 and 38 , is positioned within the actuator mechanism 50 beneath the articulated blister actuator platen assembly 52 .
[0062] Further details of the configuration of the articulated blister actuator platen assembly 52 and the operation thereof are shown in FIGS. 3A-6B .
[0063] As shown in FIGS. 3A and 3B , the actuator platen assembly 52 includes a chassis 54 . A cam body 56 is disposed within a slot 57 of the chassis 54 and is attached to the chassis 54 by a first pivot 58 . A platen 64 is pivotally attached to the cam body 56 by means of a second pivot 60 . The cam body 56 is held in a horizontal, unactuated position within the slot 57 by means of a torsional spring 55 coupled around the first pivot 58 .
[0064] Cam body 56 further includes a cam surface 65 along one edge thereof (top edge in the figure) which, in the exemplary embodiment shown in FIG. 3B , comprises an initial flat portion 61 , a convexly-curved portion 62 , and a second flat portion 63 . The sliding actuator plate 66 includes a cam follow 68 (a roller in the illustrated embodiment) rotatably mounted within a slot 72 formed in the actuator plate 66 . In an embodiment of the invention, one cam body 56 and associated platen 64 and cam follower 68 are associated with each deformable vessel (e.g. blister 36 ) of the liquid reagent module 40 .
[0065] The actuator platen assembly 52 and the sliding actuator plate 66 are configured to be movable relative to each other. In one embodiment, the actuator platen assembly 52 is fixed, and the actuator plate 66 is configured to move laterally relative to the platen assembly 52 , supported by the V-rollers 74 . Lateral movement of the sliding actuator plate 66 , e.g., in the direction “A”, causes the cam follower 68 to translate along the cam surface 65 of the cam body 56 , thereby actuating the cam body 56 and the platen 64 attached thereto.
[0066] In FIGS. 3A and 3B , before the sliding actuator plate 66 has begun to move relative to the actuator platen assembly 52 , the cam follower 68 is disposed on the initial flat portion 61 of the cam surface 65 of the cam body 56 . In FIGS. 4A and 4B , the sliding actuator plate 66 has moved relative to the actuator platen assembly 52 in the direction “A” so that the cam follower 68 has moved across the initial flat portion 61 of the cam surface 65 and has just begun to engage the upwardly curved contour of the convexly-curved portion 62 of the cam surface 65 of the cam body 56 .
[0067] In FIGS. 5A and 5B , the sliding actuator plate 66 has proceeded in the direction “A” to a point such that the cam follower 68 is at the topmost point of the convexly-curved portion 62 of the cam surface 65 , thereby causing the cam body 56 to rotate about the first pivot 58 . The platen 64 is lowered by the downwardly pivoting cam body 56 and pivots relative to the cam body 56 about the second pivot 60 and thereby compresses the blister 36 .
[0068] In FIGS. 6A and 6B , sliding actuator plate 66 has moved to a position in the direction “A” relative to the actuator platen assembly 52 such that the cam follower 68 has progressed to the second flat portion 63 of the cam surface 65 . Accordingly, the cam body 56 , urged by the torsion spring 55 , pivots about the first pivot 58 back to the unactuated position, thereby retracting the platen 64 .
[0069] Thus, the articulated blister actuator platen assembly 52 is constructed and arranged to convert the horizontal movement of actuator plate 66 into vertical movement of the platen 64 to compress a blister, and movement of the platen does not require pneumatic, electromechanical, or other components at larger distances above and/or below the liquid module.
[0070] An alternative embodiment of a blister compression actuator mechanism is indicated by reference number 80 in FIGS. 7A and 7B . Actuator 80 includes a linear actuator 82 that is coupled to a cam rail 84 . Cam rail 84 is supported for longitudinal movement by a first support rod 96 extending transversely through slot 86 and a second support rod 98 extending transversely through a second slot 88 formed in the cam rail 84 . The first support rod 96 and/or the second support rod 98 may include an annular groove within which portions of the cam rail 84 surrounding slot 86 or slot 88 may be supported, or cylindrical spacers may be placed over the first support rod 96 and/or the second support rod 98 on opposite sides of the cam rail 84 to prevent the cam rail 84 from twisting or sliding axially along the first support rail 96 and/or the second support rail 98 .
[0071] Cam rail 84 includes one or more cam profile slots. In the illustrated embodiment, cam rail 84 includes three cam profile slots 90 , 92 , and 94 . Referring to cam profile slot 90 , in the illustrated embodiment, slot 90 includes, progressing from left to right in the figure, an initial horizontal portion, a downwardly sloped portion, and a second horizontal portion. The shapes of the cam profile slots are exemplary, and other shapes may be effectively implemented. The actuator mechanism 80 also includes a platen associated with each cam profile slot. In the illustrated embodiment, actuator 80 includes three platens 100 , 102 , 104 associated with cam profile slots 90 , 92 , 94 , respectively. First platen 100 is coupled to the cam profile slot 90 by a cam follower pin 106 extending transversely from the platen 100 into the cam profile slot 90 . Similarly, second platen 102 is coupled to the second cam profile slot 92 by a cam follower pin 108 , and the third platen 104 is coupled to the third cam profile slot 94 by a cam follower pin 110 . Platens 100 , 102 , 104 are supported and guided by a guide 112 , which may comprise a panel having openings formed therein conforming to the shape of each of the platens.
[0072] In FIG. 7A , cam rail 84 is in its furthest right-most position, and the platens 100 , 102 , 104 are in their unactuated positions. Each of the cam follower pins 106 , 108 , 110 is in the initial upper horizontal portion of the respective cam profile slot 90 , 92 , 94 . As the cam rail 84 is moved longitudinally to the left, in the direction “A” shown in FIG. 7B , by the linear actuator 82 , each cam follower pin 106 , 108 , 110 moves within its respective cam profile slot 90 , 92 , 94 until the cam follower pin is in the lower, second horizontal portion of the respective cam profile slot. Movement of each of the pins 106 , 108 , 110 downwardly within its respective cam profile slot 90 , 92 , 94 causes a corresponding downward movement of the associated platen 100 , 102 , 104 . This movement of the platens thereby compresses a fluid vessel (or blister) located under each platen. Each platen may compress a vessel directly in contact with the platen or it may contact the vessel through one or more intermediate components located between the vessel and the corresponding platen.
[0073] Thus, the blister compression actuator mechanism 80 is constructed and arranged to convert the horizontal movement cam rail 84 , driven by the linear actuator 82 , into vertical movement of the platens 100 , 102 , 104 to compress blisters, and movement of the platens does not require pneumatic, electromechanical, or other components at larger distances above and/or below the liquid module.
[0074] When compressing a fluid vessel, or blister, to displace the fluid contents thereof, sufficient compressive force must be applied to the blister to break, or otherwise open, a breakable seal that is holding the fluid within the vessel. The amount of force required to break the seal and displace the fluid contents of a vessel typically increases as the volume of the vessel increases. This is illustrated in the bar graph shown in FIG. 11 , which shows the minimum, maximum, and average blister burst forces required for blisters having volumes of 100, 200, 400, and 3000 microliters. The average force required to burst a blister of 400 or less microliters is relatively small, ranging from an average of 10.7 lbf to 11.5 lbf. On the other hand, the force required to burst a blister of 3000 microliters is substantially larger, with an average burst force of 43.4 lbf and a maximum required burst force of greater than 65 lbf. Generating such large forces can be difficult, especially in low profile actuator mechanisms, such as those described above, in which horizontal displacement of an actuator is converted into vertical, blister-compressing movement of a platen.
[0075] Accordingly, aspects of the present invention are embodied in methods and apparatus for opening a fluid vessel, or blister, in a manner that reduces the amount of force required to burst the vessel and displace the fluid contents of the vessel.
[0076] Such aspects of the invention are illustrated in FIGS. 8A and 8B . As shown in FIG. 8A , a fluid vessel (or blister) 122 is mounted on a substrate 124 and is connected by means of a channel 130 to a sphere blister 128 . In certain embodiments, channel 130 may be initially blocked by a breakable seal. A film layer 129 may be disposed on the bottom of the substrate 124 to cover one or more channels formed in the bottom of the substrate 124 to form fluid conduits. An opening device, comprising a sphere 126 (e.g., a steel ball bearing) is enclosed within the sphere blister 128 and is supported, as shown in FIG. 8A , within the sphere blister 128 by a foil partition or septum 125 . The foil partition 125 prevents fluid from flowing from the vessel 122 through a recess 127 and fluid exit port 123 . Upon applying downward force to the sphere 126 , however, a large local compressive stress is generated due to the relatively small surface size of the sphere 126 , and the foil partition 125 can be broken with relatively little force to push the sphere 126 through the partition 125 and into the recess 127 , as shown in FIG. 8B . With the foil partition 125 broken, a relatively small additional force is required to break a seal within channel 130 and force the fluid to flow from the vessel 122 through the fluid exit port 123 .
[0077] In FIG. 8B , the sphere blister 128 is shown intact. In some embodiments, a force applied to the sphere 126 to push it through the foil partition 125 would also collapse the sphere blister 128 .
[0078] An apparatus for opening a vessel by pushing a sphere 126 through foil partition 125 is indicated by reference number 120 in FIGS. 9A, 9B, 9C, 9D . In the illustrated embodiment, the apparatus 120 includes a ball actuator 140 extending through an opening formed through a blister plate, or platen, 132 . With the blister plate 132 and an actuator 138 configured for moving the blister plate 132 disposed above the vessel 122 , the ball actuator 140 is secured in a first position, shown in FIG. 9A , by a detent 136 that engages a detent collar 144 formed in the ball actuator 140 .
[0079] As shown in FIG. 9B , the blister plate 132 is moved by the actuator 138 down to a position in which a contact end 142 of the ball actuator 140 contacts the top of the of the sphere blister 128 . Actuator 138 may comprise a low profile actuator, such as actuator mechanisms 50 or 80 described above.
[0080] As shown in FIG. 9C , continued downward movement of the blister plate 132 by the actuator 138 causes the ball actuator 140 to collapse the sphere blister 128 , thereby pushing the opening device, e.g., sphere 126 , through a partition blocking fluid flow from the vessel 122 . In this regard, it will be appreciated that the detent must provide a holding force sufficient to prevent the ball actuator 140 from sliding relative to the blister plate 132 until after the sphere 126 has pierced the partition. Thus, the detent must provide a holding force sufficient to collapse the sphere blister 128 and push the sphere 126 through a partition.
[0081] As shown in FIG. 9D , continued downward movement of the blister plate 132 by the actuator 138 eventually overcomes the holding force provided by the detent 136 , and the ball actuator 140 is then released to move relative to the blister plate 132 , so that the blister plate can continue to move down and collapse the vessel 122 .
[0082] After the vessel 122 is collapsed, the blister plate 132 can be raised by the actuator 138 to the position shown in FIG. 9A . As the blister plate 132 is being raised from the position shown in FIG. 9D to the position shown in 9 A, a hard stop 146 contacts a top end of the ball actuator 140 to prevent its continued upward movement, thereby sliding the ball actuator 140 relative to the blister plate 132 until the detent 136 contacts the detent collar 144 to reset the ball actuator 140 .
[0083] An alternative embodiment of an apparatus for opening a vessel embodying aspects of the present invention is indicated by reference number 150 in FIG. 10 . Apparatus 150 includes a pivoting ball actuator 152 configured to pivot about a pivot pin 154 . A top surface 156 of the pivoting ball actuator 152 comprises a cam surface, and a cam follower 158 , comprising a roller, moving in the direction “A” along the cam surface 156 pivots the actuator 152 down in the direction “B” to collapse the sphere blister 128 and force the sphere 126 through the foil partition 125 . Pivoting actuator 152 may further include a torsional spring (not shown) or other means for restoring the actuator to an up position disengaged with the sphere blister 128 when the cam follower 158 is withdrawn.
[0084] FIG. 12 is a plot of compressive load versus time showing an exemplary load versus time curve for an apparatus for opening a vessel embodying aspects of the present invention. As the apparatus contacts and begins to compress the sphere blister 128 , the load experiences an initial increase as shown at portion (a) of the graph. A plateau shown at portion (b) of the graph occurs after the sphere 126 penetrates the foil partition 125 . A second increase in the force load occurs when the blister plate 132 makes contact with and begins compressing the vessel 122 . A peak, as shown at part (c) of the plot, is reached as a breakable seal within channel 130 between the vessel 122 and the sphere blister 128 is broken. After the seal has been broken, the pressure drops dramatically, as shown at part (d) of the plot, as the vessel 122 is collapsed and the fluid contained therein is forced through the exit port 123 (See FIGS. 8A, 8B ) supporting the sphere 126 .
[0085] An alternative apparatus for opening a vessel is indicated by reference number 160 in FIG. 13A . As shown in FIG. 13A , a fluid vessel (or blister) 162 is mounted on a substrate 172 and is connected by means of a channel—which may or may not be initially blocked by a breakable seal—to a dimple 161 . A film layer 164 may be disposed on the bottom of the substrate 172 to cover one or more channels formed in the bottom of the substrate 172 to form fluid conduits. An opening device comprising a cantilevered lance 166 is positioned within a lance chamber 170 formed in the substrate 172 where it is anchored at an end thereof by a screw attachment 168 .
[0086] A foil partition or septum 165 seals the interior of the dimple 161 from the lance chamber 170 . An actuator pushes the lance 170 up in the direction “A” into the dimple 161 , thereby piercing the foil partition 165 and permitting fluid to flow from the blister 162 out of the lance chamber 170 and a fluid exit port. The spring force resilience of the lance 166 returns it to its initial position after the upward force is removed. In one embodiment, the lance 166 is made of metal. Alternatively, a plastic lance could be part of a molded plastic substrate on which the blister 162 is formed. Alternatively, a metallic lance could be heat staked onto a male plastic post. A further option is to employ a formed metal wire as a lance.
[0087] A further alternative embodiment of an apparatus for opening a vessel is indicated by reference number 180 in FIG. 14 . A component having one or more deformable vessels includes at least one blister 182 formed on a substrate 194 . In the arrangement shown in FIG. 14 , an internal dimple 184 is formed inside the blister 182 . Internal dimple 184 encloses an opening device comprising a fixed spike 186 projecting upwardly from a spike cavity 188 formed in the substrate 194 . A film layer 192 is disposed on an opposite side of the substrate 194 . As an actuator presses down on the blister 182 , internal pressure within the blister 182 causes the internal dimple 184 to collapse and invert. The inverted dimple is punctured by the fixed spike 186 , thereby permitting fluid within the blister 182 to flow through an exit port 190 .
[0088] An alternative apparatus for opening a vessel is indicated by reference number 200 in FIG. 15A . As shown in FIG. 15A , a fluid vessel (or blister) 202 is mounted on a substrate 216 and is connected by means of a channel—which may or may not be initially blocked by a breakable seal—to a dimple 204 . An opening device comprising a lancing pin 206 having a fluid port 208 formed through the center thereof (see FIG. 15B ) is disposed within a segmented bore 220 formed in the substrate 216 beneath the dimple 204 . A partition or septum 205 separates the dimple 204 from the bore 220 , thereby preventing fluid from exiting the blister 202 and dimple 204 . An actuator (not shown) presses on a film layer 212 disposed on a bottom portion of the substrate 216 in the direction “A” forcing the lancing pin 206 up within the segmented bore 220 until a shoulder 210 formed on the lancing pin 206 encounters a hard stop 222 formed in the segmented bore 220 . A lancing point of the pin 206 pierces the partition 205 thereby permitting fluid to flow through the fluid port 208 in the lancing pin 206 and out of a fluid exit channel 214 .
[0089] An alternative embodiment of an apparatus for opening a vessel is indicated by reference number 230 in FIGS. 16A and 16B . As shown in FIG. 16A , a fluid vessel (or blister) 232 is mounted on a substrate 244 and is connected by means of a channel—which may or may not be initially blocked by a breakable seal—to a dimple 234 . An opening device comprising a lancing pin 236 is disposed within a segmented board 246 formed in the substrate 244 beneath the dimple 234 . A partition or septum 235 separates the dimple 234 from the segmented bore 246 . The upper surface of the substrate 244 is sealed with a film 240 before the blister 232 and dimple 234 are adhered. An actuator (not shown) pushes up on the lancing pin 236 in the direction “A” until a shoulder 238 formed on the lancing pin 236 encounters hard stop 248 within the bore 246 . The pin 236 thereby pierces the partition 235 and remains in the upper position as fluid flows out along an exit channel 242 formed on an upper surface of the substrate 244 . A fluid tight seal is maintained between the pin 238 and the bore 246 by a slight interference fit.
[0090] As the collapsible fluid vessels of a liquid reagent module are configured to be compressed and collapsed to displace the fluid contents from the vessel(s), such vessels are susceptible to damage or fluid leakage due to inadvertent exposures to contacts that impart a compressing force to the vessel. Accordingly, when storing, handling, or transporting a component having one or more collapsible fluid vessels, it is desirable to protect the fluid vessel and avoid such inadvertent contact. The liquid reagent module could be stored within a rigid casing to protect the collapsible vessel(s) from unintended external forces, but such a casing would inhibit or prevent collapsing of the vessel by application of an external force. Thus, the liquid reagent module would have to be removed from the casing prior to use, thereby leaving the collapsible vessel(s) of the module vulnerable to unintended external forces.
[0091] An apparatus for protecting and interfacing with a collapsible vessel is indicated by reference number 260 in FIGS. 17, 18, and 19 . A component with one or more collapsible vessels includes a collapsible blister 262 formed on a substrate 264 . A dispensing channel 266 extends from the blister 262 to a frangible seal 268 . It is understood that, in some alternative embodiments, the dispensing channel 266 may be substituted with a breakable seal, providing an additional safeguard against an accidental reagent release.
[0092] Frangible seal 268 may comprise one of the apparatuses for opening a vessel described above and shown in any of FIGS. 8-16 .
[0093] A rigid or semi-rigid housing is provided over the blister 262 and, optionally, the dispensing channel 266 as well, and comprises a blister housing cover 270 covering the blister 262 and a blister housing extension 280 covering and protecting the dispensing channel 266 and the area of the frangible seal 268 .
[0094] A floating actuator plate 276 is disposed within the blister housing cover 270 . In the illustrated embodiments, both the blister housing cover 270 and the floating actuator plate 276 are circular, but the housing 270 and the actuator plate 276 could be of any shape, preferably generally conforming to the shape of the blister 262 .
[0095] The apparatus 260 further includes a plunger 274 having a plunger point 275 at one end thereof. Plunger 274 is disposed above the blister housing cover 270 generally at a center portion thereof and disposed above an aperture 272 formed in the housing 270 .
[0096] The floating actuator plate 276 includes a plunger receiver recess 278 , which, in an embodiment, generally conforms to the shape of the plunger point 275 .
[0097] The blister 262 is collapsed by actuating the plunger 274 downwardly into the aperture 272 . Plunger 274 may be actuated by any suitable mechanism, including one of the actuator mechanisms 50 , 80 described above. Plunger 274 passes into the aperture 272 where the plunger point 275 nests within the plunger receiver recess 278 of the floating actuator plate 276 . Continued downward movement by the plunger 274 presses the actuator plate 276 against the blister 262 , thereby collapsing the blister 262 and displacing fluid from the blister 262 through the dispensing channel 266 to a fluid egress. Continued pressure will cause the frangible seal at 268 to break, or an apparatus for opening the vessel as described above may be employed to open the frangible seal. The plunger point 275 nested within the plunger point recess 278 helps to keep the plunger 274 centered with respect to the actuator plate 276 and prevents the actuator plate 276 from sliding laterally relative to the plunger 274 . When the blister is fully collapsed, as shown in FIG. 19 , a convex side of the plunger receiver recess 278 of the floating actuator plate 276 nests within a plunger recess 282 formed in the substrate 264 .
[0098] Accordingly, the blister housing cover 270 protects the blister 262 from inadvertent damage or collapse, while the floating actuator plate inside the blister housing cover 270 permits and facilitates the collapsing of the blister 262 without having to remove or otherwise alter the blister housing cover 270 . In components having more than one collapsible vessel and dispensing channel, a blister housing cover may be provided for all of the vessels and dispensing channels or for some, but less than all vessels and dispensing channels.
[0099] While the present invention has been described and shown in considerable detail with reference to certain illustrative embodiments, including various combinations and sub-combinations of features, those skilled in the art will readily appreciate other embodiments and variations and modifications thereof as encompassed within the scope of the present invention. Moreover, the descriptions of such embodiments, combinations, and sub-combinations is not intended to convey that the inventions requires features or combinations of features other than those expressly recited in the claims. Accordingly, the present invention is deemed to include all modifications and variations encompassed within the spirit and scope of the following appended claims.
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A fluid container comprises a first vessel, a second vessel connected or connectable to the first vessel, and a sealing partition preventing fluid flow from the second vessel. The container further includes a spherical opening element initially supported within the second vessel by the sealing partition and configured to be contacted with the sealing partition to open the sealing partition and permit fluid flow from the second vessel
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 61/500,194 filed Jun. 23, 2011, the contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention generally relates to faucet and plumbing fixtures. More particularly, this invention relates to an assembly for effectively extending faucet stems so as to facilitate the repair, maintenance and replacement of a faucet.
Currently, it can be very difficult to repair, maintain and replace faucet systems, since the hardware conventionally used to secure faucets to sinks or other structures is typically located within a tight space within a cabinet as a result of the sink to which the faucet is mounted. Therefore, there is a need to facilitate access to such hardware to facilitate the repair, maintenance and replacement of faucet assemblies.
BRIEF DESCRIPTION OF THE INVENTION
The present invention provides an extension assembly adapted to serve as an extension for a faucet stem. The assembly is applicable to any form of faucet, including but not limited to ball, disc, or compression faucets having one or more handles.
According to a first aspect of the invention, the extension assembly includes a stem extender having a hollow interior entirely therethrough, and an extension tube having a hollow interior entirely therethrough that is sized to fit over the stem extender. The stem extender includes an internal thread within an upper portion thereof and an external thread at a lower portion thereof. The internal thread is adapted for threadably coupling with a threaded stem of a faucet assembly. The extension assembly further includes a nut adapted to threadably couple with the external thread of the stem extender to secure the extension tube on the stem extender.
An optional aspect of the invention is the inclusion of an adapter for installation between the faucet stem and the stem extender. The adapter has an internal thread within an upper portion thereof for threadably coupling with the stem and an external thread at a lower portion thereof for threadably coupling with the internal thread within the upper portion of the stem extender.
Other aspects and advantages of this invention will be better appreciated from the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates an embodiment of an extension assembly of the present invention, as well as an example of conventional hardware for attaching a faucet assembly to a sink.
FIGS. 2 and 3 represent top view and cross-sectional views of an adapter for use with the extension assembly of FIG. 1 .
FIG. 4 is a side view of a stem extender of the extension assembly of FIG. 1 .
FIGS. 5 a and 5 b represent two cross-sectional views of alternative configurations for the stem extender of FIG. 4 .
FIG. 6 is a cross-sectional view of an extension tube of the extension assembly of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
To facilitate the following description, terms such as “upper,” “lower,” “above,” “below,” “right,” “left,” etc., will be used in reference to the view shown in FIG. 1 , and are relative terms that indicate the construction, installation and use of the invention and therefore help to define the scope of the invention.
FIG. 1 schematically depicts a faucet assembly 1 mounted to a sink 2 . As should be readily understood, the sink 2 may be of any type to which a faucet assembly might be mounted, and the sink 2 may be mounted to a cabinet or any other suitable structure. While shown as a single-handle faucet assembly whose handle 1 A is integrated into the spigot 1 B, from the following discussion it will become apparent that multiple-handle faucet assemblies are also within the scope of the invention. Furthermore, the faucet assembly 1 could be of the type that has a single handle or two handles spaced apart and to either or both sides of the spigot 1 B, as well as a sprayer that is separate from or integrated with the spigot 1 B. As is conventional, the faucet assembly 1 includes threaded stems 3 that extend downward through the top of the sink 2 , by which the faucet assembly 1 can be secured to the sink 2 . The area represented in FIG. 1 would typically be located behind a sink bowl 20 with which the faucet assembly 1 is installed. On the lefthand side of FIG. 1 , a conventional nut 4 is represented as being positioned for threading onto the lefthand stem 3 of the faucet assembly 1 . The stem 3 and nut 4 form a common configuration for fastening a faucet to a sink, and therefore will not be described in any further detail.
An exploded view of an extension assembly 5 according to an embodiment of the invention is represented in the righthand side of FIG. 1 . Various components of the assembly 5 are represented (not to scale) in FIGS. 2 through 6 . The extension assembly 5 is represented in FIG. 1 as including a stem extender 6 , a floating extension tube 7 , a nut 8 and an adapter 10 . For use with the single-handled faucet assembly represented in FIG. 1 , the invention utilizes the adapter 10 which, as more readily apparent in FIGS. 2 and 3 , has female threads 12 adapted to thread onto the external (male) threads of the stem 3 , and has male threads 11 adapted to thread into internal (female) threads located within a bore 9 in the upper end of the extender 6 . For certain types of faucets, for example, two-handled faucets, the adapter 10 is not required and the threaded bore 9 within the upper end of the stem extender 6 enables the extender 6 to be directly threaded onto the stem 3 .
The stem extender 6 is adapted for assembly with the extension tube 7 by sliding the tube 7 onto the exterior of the extender 6 . The lower end of the stem extender 6 is provided with male threads 14 , allowing the nut 8 to be threaded onto the extender 6 to secure the extension tube 7 on the extender 6 . By tightening the nut 8 , the upper end of the tube 7 is forced into engagement with the sink 2 to secure the faucet assembly 1 to the sink 2 .
FIG. 1 evidences the relative advantage provided by the current invention over the conventional method provided by the nut 4 and stem 3 . Those knowledgeable in the art will appreciated that access to the nut 4 is typically complicated by the presence of a sink bowl 20 (represented in phantom in FIG. 1 , which may extend a considerable distance downward from the sink 2 . In contrast, by installing the extension assembly 5 instead of the nut 4 , the length of the extension tube 7 effectively lowers the location of the nut 8 relative to that of the conventional nut 4 , with the result that the nut 8 of the extension assembly 5 is far more accessible and, as a result, much easier to fasten and loosen.
From the cross-sectional view of the stem extender 6 depicted in FIGS. 5 a and 5 b , it can be seen that, in addition to the threaded bore 9 in its upper end, the remainder of the stem extender 6 defines a hollow cavity 13 . In FIG. 5 a , a shoulder 15 is between the threaded bore 9 and the cavity 13 of the extender 6 , and the shoulder 15 defines an opening that fluidically connects the internally threaded upper end of the extender 6 with the cavity 13 within the remainder of the extender 6 . As required for conventional two-handle faucet installations in which each stem 3 is hollow and water flows through the stem 3 to the faucet, the opening defined by the shoulder 15 allows water to flow from the upper section to the lower section of the extender 6 , and then through a hose (not shown) to the faucet 1 . The shoulder 15 is preferably configured to accept a flat or cone washer 18 ( FIG. 1 ) that prevents leakage at the interface with the stem 3 . In FIG. 5 b , the shoulder 15 and its opening are omitted for use in a faucet assembly in which a waterline (not shown) is directly connected to the stem 3 , in which case it is preferred that the waterline extends entirely through the extender 6 to the stem 3 . Such a configuration for the extender 6 may be desired or necessary for single- and double-handle faucet assemblies whose handle or handles are spaced apart from a spigot, and may also be utilized for sprayers, soap dispensers and other devices that may be associated with the faucet and mounted directly to the sink or to a cabinet or counter top on which the sink is installed.
FIG. 6 is a cross-sectional view of the extension tube 7 . As evident from the foregoing, the extension tube 7 has a hollow interior 16 entirely therethrough to enable its installation over the exterior of the stem extender 6 . The tube 7 is free-floating in that it lacks any internal or external threads by which the tube 7 is directly secured to the extender 6 , enabling the tube 7 to move freely over the extender 6 . Each of the axial ends of the tube 7 is defined by a flange 17 , which in combination help to distribute the clamping force generated as the tube 7 is brought into engagement with the sink 2 when the nut 8 is tightened on the male threads 14 of the stem extender 6 .
The extension assembly 5 may be installed by first screwing the adapter 10 , if present, onto the extender 6 . Next, the adapter 10 and extender 6 are screwed onto the stem 3 of the faucet assembly 1 . The faucet assembly 1 is then installed on the sink 2 by sliding the extender 6 through the top of the sink 2 . The extension tube 7 is then slid over a portion of the extender 6 exposed under the sink 2 . Finally, the nut 8 is screwed on the end of the extender 6 to secure the faucet assembly 1 and extension assembly 5 to the sink 2 .
While the invention has been described in terms of a particular embodiment, it is apparent that other forms could be adopted by one skilled in the art. For example, the physical configuration of the components of the extension assembly 5 could differ from those shown, and the components could be fabricated from various materials using various processes. Therefore, the scope of the invention is to be limited only by the following claims.
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An extension assembly for effectively extending a faucet stem to facilitate the maintenance of a faucet assembly. The extension assembly includes a stem extender which connects to a faucet stem, an extension tube which fits over the stem extender and determines the length by which the faucet stem is extended, and an optional adapter for interfacing between the faucet stem and the stem extender.
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This application is a continuation of Ser. No. 115,062, Jan. 24, 1980, now U.S. Pat. No. 4,345,667.
FIELD OF THE INVENTION
The present invention relates to a new and improved method and apparatus for injecting viscous materials into narrow openings and cavities such as into wheel bearings. More particularly, the present invention relates to a simple tool for injecting grease, such as wheel bearing grease, around unexposed surfaces of a plurality of rollers disposed in a wheel bearing assembly.
BACKGROUND OF THE INVENTION
Vehicle wheel bearings are disposed around the vehicle axles and include a plurality of rollers or bearings to permit relatively frictionless rotation of wheels about the axles. Periodically, these rollers must be lubricated with a very viscous lubricant, commonly called wheel-bearing grease. Wheel bearings generally include an inner, or axle contacting, cylindrical member and a concentric, outer cylindrical member of large diameter, which is spaced apart from, and connected to the inner cylindrical member by virtue of a plurality of intermediate rollers or bearings. The rollers or bearings protrude, both below and above the outer cylindrical portion of the wheel bearing so that an innermost periphery of the bearings contact the outer surface of the axle contacting portion of the wheel bearing, and so that the outermost periphery of the bearings are adapted to contact an inner portion of the wheel for rotating movement. The space provided by the rollers or bearings between the inner cylindrical portion of the wheel bearing and the larger diameter outer cylindrical portion of the wheel bearing must be lubricated periodically in addition to lubricating the exposed portions of the rollers or bearings to provide for continuous rotation of these rollers or bearings during use. Accordingly, it is essential to inject wheel bearing grease between the inner and outer cylindrical wheel bearing members to provide for sufficient lubrication of the rollers during wheel rotation to prevent these rollers from freezing or locking up during vehicle movement. The space between the inner and outer cylindrical members of a wheel bearing is generally very narrow, on the order of 1/32 inch to 1/4 inch, and the injection of wheel bearing grease is further difficult because the rollers or bearings are disposed between the inner and outer cylindrical members, making the volume remaining for grease injection between the cylindrical members very small. Further, wheel bearing grease is very viscous, making it quite difficult to inject such material in small spaces.
Prior to the present invention, the most common way for greasing a wheel bearing has been to attempt to insert the grease by hand. Generally, the mechanic will locate a volume of grease in the palm of one hand and, taking the wheel bearing in the other hand, he will attempt to scoop the grease from his palm into the wheel bearing, and, in this manner, try to force the grease between the inner and outer cylindrical wheel bearing members. At the same time, the mechanic will apply grease over the outer exposed portions of the rollers and, by turning the rollers, will cause some grease to roll between the inner and outer cylindrical wheel bearing members. This method has been unsatisfactory because insufficient grease is forced within the wheel bearing necessitating periodic greasing and other wheel bearing maintenance.
Others have attempted to fabricate various devices for the purpose of inserting grease between wheel bearing components but these devices generally have been unsatisfactory because they are cumbersome, expensive and require far too much of a mechanic's time to grease a single wheel bearing. Further, many prior devices have required hydraulic force or other burdensome or expensive means for forcing the grease into the small cavities existing between wheel bearing rollers. Another drawback of prior art wheel bearing greasing devices has been, for example, that the wheel bearing being acted upon does not remain centered in the apparatus, resulting in uneven grease application around the circumference of the bearing, causing uneven bearing wear. Further, the inability of prior art devices to center the wheel bearing or maintain the wheel bearing centered during grease application has caused slippage of the wheel bearing, enabling some of the grease to circumvent the bearing, sometimes without notice by the mechanic.
In accordance with the present invention, a method and apparatus are provided for injecting grease or other viscous materials into contact with unexposed portions of wheel bearing rollers by providing a method and apparatus which is simple and inexpensive and can be used by any mechanic having access to a vice.
CROSS REFERENCE TO RELATED PATENT
This application is closely related to my prior U.S. Pat. No. 4,168,766 patented Sept. 25, 1979.
DESCRIPTION OF THE PRIOR ART
The following prior art U.S. Pat. Nos. disclose apparatus for injection of a material into openings or apertures:
______________________________________1,361,007 Brown1,991,542 Cavanaugh2,031,671 Rising2,168,746 Saal Et Al2,178,816 Sibley2,187,608 Kropp2,515,208 Fox Et Al2,601,169 Purvis2,968,362 Elliott3,469,655 Moreno3,717,222 Moline______________________________________
None of the injecting apparatus described in the above-identified patents is capable of being used with a common vice and none includes a piston capable of being adjusted for operative connection with vice jaws to compensate for the limited span of vice jaws. In accordance with an important object of the present invention, the apparatus described herein includes a piston member having a stem threadedly attached to a central aperture in the piston and a vice-contacting spool slidably disposed over the central stem and adjustable to provide for changes in grease depth to assure that the apparatus can be used repeatedly before re-filling the apparatus housing with grease. The spool can be adjusted inwardly when the housing is first filled with grease so that the apparatus is short enough to fit between fully open vice jaws and the spool can be adjusted outwardly to extend beyond the housing when the housing is almost empty to assure that the spool remains capable of contact with the vice jaws until the housing is emptied. The piston of the present invention is unique in that a central stem is provided for centering the apparatus to be filled with a viscous material and for operative connection to vice jaws over full movement of the piston to the bottom of the housing (or until the housing is substantially empty) while, at the same time, limiting the length of the stem to fit within the housing interior when fully depressed to the bottom of the housing, so that the apparatus can fit between a common vice when filled with grease. The above patents do not provide this capability.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a new and improved method and apparatus for greasing or lubricating an article having a grease-receiving slot, such as a wheel bearing.
Another object of the present invention is to provide a new and improved method and apparatus for injecting viscous material into an annular object having one or more apertures.
Another object of the present invention is to provide a method of inserting grease or other viscous material into a slot disposed between inner and outer cylindrical wheel bearing members by forming an annular seal along both the inner and outer cylindrical members and forcing grease to proceed through the slot, between the seals, by the force of a common vice.
Another object of the present invention is to provide a new and improved method and apparatus for packing wheel bearings with grease. The apparatus includes a piston having a central opening, said piston disposed to fit within a grease container so that by compressing the piston against the grease within the containers, grease will be forced outwardly through the central opening in the piston and between the inner and outer cylindrical portions of the wheel bearing.
Another object of the present invention is to provide wheel bearing packing apparatus, including a piston having a central stem for aligning and maintaining alignment of the wheel bearing during use of the apparatus.
Another object of the present invention is to provide wheel bearing greasing apparatus having a spool which fits over the central stem of the piston during operation, and which serves the dual functions of maintaining proper alignment, or centering of the wheel bearing during operation of the apparatus, and forming an inner seal around an inner periphery of the wheel bearing, to prevent grease from escaping through the central aperture of the wheel bearing, thereby causing the grease to be forced within and around the rollers or bearings.
Another object of the present invention is to provide wheel bearing greasing apparatus having an adjustable vice-contacting member adjustable for vice contact at varied distances from an apparatus piston member for repeated greasing operations over a relatively short vice jaw travel path.
Another object of the present invention is to provide a method of injecting a viscous material into a relatively narrow opening by using a simple vice to provide compressive forces needed to cause the material to flow into a desired area.
In brief, the present invention relates to a method and apparatus for injecting a viscous material, such as a lubricant and, particularly, wheel bearing grease, into small apertures, for example, those existing in vehicle wheel bearings. The apparatus or device of the present invention includes a housing defining an internal grease containing chamber, including an open, piston receiving end. A viscous material or lubricant such as wheel bearing grease is disposed within this housing, and a piston is inserted within the housing to sealingly engage interior walls of the housing. The piston is slidably mounted within the chamber and includes a central aperture partially obstructed by a threaded central stem. The stem is threadedly and centrally attached to the piston and provides the only passage for the escape of grease from the housing or grease chamber.
The stem includes a central opening for the passage of grease from the housing or grease chamber as the piston is forced down into the housing or chamber, while maintaining peripheral, sealing contact with the interior housing walls. The piston includes a tapered, bearing-contacting side for sealing engagement with an outer periphery of the wheel bearing. Accordingly, the tapered side of the piston creates a continuous seal completely around the outer cylindrical wheel bearing member through which the rollers or bearings protrude and are partially exposed.
The wheel bearing is disposed over the central upstanding stem of the piston, thereby confining the grease emerging from the aperture in the central stem to the interior of the wheel bearing. The apparatus of the present invention further includes a tapered spool adapted to engage and seal the wheel bearing completely around an interior edge of the inner cylindrical wheel bearing member. The tapered spool is inserted into the wheel bearing along its central access opening to engage the tapered, or conical spool surface completely around the interior of the inner cylindrical wheel bearing member. The spool prevents the grease emerging from the central piston opening, through the stem, from escaping through the central wheel bearing access opening, and thereby causes the grease to follow its only path of escape between the inner and outer cylindrical wheel bearing members. The spool includes a rounded, opposite end portion for engagement by a vice jaw. The bottom of the housing is also adapted to be inserted within an opposite vice jaw so that by compressing the spool and housing, the piston, slidably mounted within the housing, will be forced against the grease in the housing or grease chamber to cause the grease within the chamber to be forced through the central opening of the piston, out the aperture in the piston stem, and between the inner and outer cylindrical wheel bearing members.
It is an important object of the present invention to provide a method and apparatus for injecting grease or other viscous materials into relatively narrow openings or apertures by using a simple vice to provide the force necessary to push such difficulty moved materials into a desired area. Common vices used in car repair shops and by the average consumer have a relatively short vice jaw span. Accordingly, it is a very important object of the present invention to provide apparatus capable of dispensing grease or other viscous or difficulty flowable materials into a desired area by providing means for piston adjustment to provide piston movement greater than a predetermined range of vice jaw movement. This is provided by including a self-aligning spool, slidably disposed over a stem, attached to a central piston aperture, and providing the spool with a spool extension member adjustably connected to the spool for adjustment toward and away from the spool, for vice jaw contact at a desired distance from the apparatus housing. The threaded spool extension member can be adjusted inwardly, into the housing, when the housing is first filled with grease, and, after repeated grease applications, the extension member can be adjusted outwardly, so that the next successive greasing operation might carry the vice jaws over the same travel path as the previous greasing operation while pushing the piston closer to the bottom of the housing. This feature is very important for providing simple apparatus capable of use by the average car owner constructed such that a common vice can be used for operating the apparatus of the present invention.
The central piston stem cooperates with the tapered spool to centrally align the wheel bearing during operation of the apparatus to assure a uniform distribution of grease throughout the entire annular slot between the inner and outer cylindrical wheel bearing portions. During operation of the apparatus, the grease emerges from between wheel bearing rollers as continuous ribbons or bands of grease, emerging at substantially the same time and having substantially equal lengths, thereby illustrating and evidencing the uniform distribution of the grease to the wheel bearings by virtue of the method and apparatus disclosed herein. When the grease has emerged from between each of the rollers or bearings, as seen through the transparent or translucent, horizontally disposed housing, the operator of the apparatus knows that the greasing or packing operation has been completed.
The piston stem includes a pivotable handle for removing the piston after the grease within the chamber has dissipated. This handle can be pivoted to a stored position, generally confined within the stem, so that the handle does not interfere with the greasing operation while the apparatus is in use. Further, it has been found that during operation of the apparatus of the present invention, a slight vacuum condition will result between the bottom grease chamber wall and the lower piston surface after a portion of the grease has been removed from the housing or grease chamber. Accordingly, the lowermost piston surface can be provided with a plurality of spring biasing members to provide an upward biasing or piston removing force for piston removal. Further, the grease chamber can be provided with a check valve to permit air outside of the grease chamber to enter the grease chamber and against the lowermost piston surface, when a removing force is applied to the piston, to break the vacuum within the grease chamber when the piston must be removed for further grease insertion into the grease chamber.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, advantages and novel features of the present invention will become apparent from the following detailed description of a preferred embodiment of the invention illustrated in the accompanying drawings wherein:
FIG. 1 is an exploded perspective view of the various components of the apparatus of the present invention;
FIG. 2 is a vertical cross-sectional view of the apparatus of the present invention;
FIG. 3 is a view taken along the line 3--3 of FIG. 2; and
FIG. 4 is a view similar to FIG. 2 showing the importance of providing a spool extension member for permitting the entire apparatus of the present invention to fit between vice jaws when the grease chamber is substantially empty.
FIG. 5 is an enlarged view of a portion of FIG. 2 illustrating the flow of ribbons of grease between the inner and outer cylindrical members of a wheel bearing;
FIG. 6 is a view taken along the line 6--6 of FIG. 5;
FIG. 7 is a view of the apparatus of the present invention at the completion of the greasing operation;
FIG. 8 is a cross-sectional fragmentary view of the apparatus of the present invention illustrating that the apparatus is capable of greasing bearings of varying size;
FIG. 9 is a view similar to FIG. 8 illustrating a further variation of the size of a bearing being greased;
FIG. 10 is a side elevation view of the apparatus of the present invention illustrating the apparatus disposed within a vice during wheel bearing greasing, wherein the position of the apparatus shown in solid lines is the same as that position shown in FIG. 1, and the position of the apparatus shown in phantom lines indicates the position of the apparatus when the movable vice jaws are opened to their fullest;
FIG. 11 is a partially broken away, cross-sectional view similar to that shown in FIG. 1 showing an alternate embodiment, wherein the apparatus includes a plurality of compression springs mounted on the undersurface of the piston and the body and including tapered bores to retain the springs;
FIG. 12 is a view of a portion of FIG. 11 illustrating the lowermost position of the piston against the bottom grease chamber wall with the compression springs biased for piston removal;
FIG. 13 is a view similar to FIG. 12 showing the compression springs partially expanded and a check valve opened during piston removal;
FIG. 14 is a view illustrating an alternative embodiment illustrating a compression spring secured to the lowermost piston surface.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to the drawings, and initially to FIG. 1, there is illustrated apparatus, generally designated by the reference numeral 10, for injecting grease or other viscous material into one or more slots or apertures. In particular, this apparatus may be used to grease, or pack with lubricant, an article such as a wheel bearing used on a front wheel of an automobile. The apparatus 10 forces grease into small spaces or apertures between adjacent rollers or bearings, forming part of a vehicle wheel bearing assembly. The apparatus 10 is a low-cost device that can be used by mechanics and others who do not have access to more expensive greasing equipment. Accordingly, it is an important feature of the present invention that the lubricating apparatus of the present invention can be operated with a simple vice 12, illustrated in FIGS. 2, 4, 10 and 11 to provide the necessary compressive forces to cause grease to flow through narrow spaces surrounding rollers or bearings in a wheel bearing assembly. The apparatus 10 includes a cylindrical grease receptacle or housing 16, having an annular interior wall 17 which defines a generally cylindrical interior grease-containing chamber 18, having an open, piston receiving end 20 and a bottom or piston-contacting surface 22. The apparatus 10 further includes a piston, indicated generally by reference numeral 24, including a peripheral O-ring or sealing ring 28 for creating a seal between an outer peripheral surface 30 of the piston 24 and the interior housing wall 17. The piston 24, includes a lower, grease-contacting, generally planar surface 32, and an upper, dished, or generally concave or tapered surface 34, having an included angle of 80°-160°; for sealing a lower generally cylindrical outer edge 36 of an outer, cylindrical wheel bearing member 37, forming a part of a wheel bearing, indicated generally by reference numeral 38.
The piston 24 includes a central, threaded aperture 40 for receiving a stem 42, threaded complementary to the threaded aperture 40, for connection to the piston 24. The wheel bearing 38 is located in greasing position over stem 42 by disposing stem 42 through a central axle receiving aperture 44 to seal the cylindrical outer edge 36 of the outer, cylindrical wheel bearing member 37 against the upper, dished piston surface 34, when the apparatus is in operation. The stem 42 further includes a grease receiving passage 46 disposed at or near the dished surface 34 of piston 24 for the passage of grease from grease chamber 18 to the wheel bearing 38. In accordance with another embodiment of the present invention grease holes can be provided directly within piston 24 close to the stem 42 in addition to or in place of the grease receiving passage 46 for communicating grease from one side 32 of piston 24 to the dished side 34 of piston 24. The grease passage 46 extends along the axis of stem 42 and includes a transverse port or bore 48 to provide fluid communication between the grease chamber 18 and the wheel bearing axle receiving aperture 44. Transverse bore 48 directs the grease toward wheel bearing 38 when the wheel bearing 38 is operatively disposed on the dished surface 34 of piston 24. A retaining ring 49 retains the stem 42 within aperture 40.
The apparatus 10 further includes a spool 50 slidably mounted over stem 42 and having a central, elongated, annular aperture 52 slightly larger in diameter than stem 42 so that the spool 50 can be dropped over the stem 42, with wheel bearing 38 in position, to seal the inner surface 54 of an inner, cylindrical wheel bearing member 56. The spool 50 includes a lower, conically tapered surface 58, having an included angle of 50°-110°, to provide a seal against an upper, inner periphery of the inner, cylindrical wheel bearing member 56. Seals created at the outer surface of the outer, cylindrical wheel bearing member 37, and at the inner surface of the inner, cylindrical wheel bearing member 56 will cause grease emerging in the axle receiving wheel bearing aperture 44 from bore 48 to flow through an annular wheel bearing aperture 60, between rollers 62 (FIG. 1).
The spool 50 further includes an extension member 61 threadedly mounted within central, elongated aperture 52 for adjusting the distance d (FIG. 2) between an upper, vice-jaw-contacting, load bearing edge 63 of extension member 60, and a bottom vice-jaw-contacting, load bearing edge 64 of housing 16. The vice-contacting edge 63 of spool extension member 60 is slightly rounded to assure that the vice jaw force is directed centrally down the longitudinal axix of extension member 60. The threaded extension member 60 can be threadedly adjusted to vary the distance d (FIG. 2), as needed to assure that extension member load bearing surface 63 extends outwardly beyond the housing 16 (FIG. 4) so that vice jaws 12 can force piston 24 into grease chamber 18 and to minimize the distance d when the grease chamber 18 is full. Pin 66 prevents spool extension member 60 from being removed from the apparatus 10 when being adjusted to align the apparatus 10 between vice jaws 12.
In accordance with another embodiment of the present invention, the housing 16 can be made sufficiently short, or the spool 50 sufficiently long (while wide enough to receive an adequate quantity of grease) so that the spool extension member 61 is not needed. When the spool extension member is omitted, the spool 50 (preferably) is made with a rounded end (not shown) for vice contact similar to the rounded end surface 63 in extension member 61. When the spool extension member 61 is omitted, the spool needn't have the internal threads in annular aperture 52 but simply slides over the stem 42 as described.
OPERATION OF THE APPARATUS
Before greasing the wheel bearing 38, the grease, chamber 18 is partially filled with grease. The piston 24 is then positioned within the open end 20 of the housing 16 and forced by hand downwardly against the grease in the grease chamber 18. The spool 50 then is positioned around the stem 42 and the piston then is forced into the chamber 18 by applying hand pressure against extension member 63 until grease flows through the transverse aperture 48 in the stem 42. The spool 50 is then removed and the smaller diameter end 68 of spool 50 is placed around the stem 38 to seal the outer surface 36 of the outer, cylindrical wheel bearing member 37 against the concave face 34 of the piston 24. The spool 50 is then positioned around the stem 42 until the conical spool surface 58 sealingly engages the inner periphery 54 of the inner, cylindrical wheel bearing member 56.
Once assembled in this configuration, the apparatus 10 then is positioned within the vice 12 by threading the spool extension member 60 into spool 50 until the apparatus fits between vice jaws 12. When the extension member 61 is omitted, as described, this step is unnecessary. The vice jaws then are forced together until the wheel bearing is lubricated as evidenced by ribbons of grease emerging from between the annular slot 60 between inner, cylindrical wheel bearing member 56 and the outer, cylindrical wheel bearing member 37.
The closed bottom end 64 of the housing 16 is shaped to accommodate a vice jaw 12. Closing the vice jaws forced grease through the grease passage 46 and through the transverse aperture 48 to the wheel bearing axle receiving aperture 44. The inner and outer wheel bearing edges 36 and 54 sealingly engage the tapered spool surface 58 and the dished upper surface 34 of piston 24 when the vice jaws 12 are compressed. Grease is forced into and around the individual rollers 62 of the wheel bearing 38 through the annular slot 60. The vice jaws are compressed until the operator of the apparatus 10 observes new grease being forced through the annular slot 60 of the wheel bearing 38, between rollers 62 as continuous ribbons 69 (FIGS. 5 and 6) of substantially equal length. The operator then is assured that the old grease has been forced out of the wheel bearing 38 and new grease has been injected in and around each roller 62. FIG. 10 shows the travel path of vice jaws 12 from an initial position (phantom lines) to a position shown in solid lines when the housing 16 is substantially empty of grease.
At the conclusion of this greasing or packing operation, the piston 24 is abutting or spaced only a slight distance from the bottom surface 22 of grease chamber 18, as illustrated in FIG. 7. The spool 60 and the wheel bearing 38 then are removed from within the grease chamber 18. The stem 42 is provided with a handle 70 pivotable from its stored position about pin 73 in elongated slot 71, as illustrated in phantom lines in FIG. 7, to a removing position as illustrated in solid lines in FIG. 7. The handle 70 can be gripped with the fingers to withdraw the piston 24 from the grease chamber 18. The vice jaw compression operation creates a vacuum within the grease chamber 18 between the closed surface 22 of grease chamber 18 and the lower surface 32 of piston 24 making it difficult to remove the piston 24 by hand. In order to break this high vacuum, a relief valve, generally designated by the reference numeral 72 (FIG. 2) is disposed in the closed end 64 of the housing 16. The relief valve 72 includes a port 74 extending through the closed housing end 22. A ball element 76 is positioned within the port 74 to seal the ball valve 76 against a valve seat 78 within the port 74 during operation of the apparatus (FIG. 4). To relieve the vacuum created within the grease chamber 18 the stem 42 is threaded downwardly within the central piston aperture 26 by gripping handle 70, causing a lower end 82 of the stem 42 to abut against the bottom 22 of grease chamber 18 initially breaking the vacuum. As the stem end engages the housing end the piston 24 is forced away from the bottom surface 22 of grease chamber 18 and lifts the ball valve 26, breaking the vacuum. Pulling handle 70 for piston removal lifts the ball to prevent further vacuum from forming within grease chamber 18 during piston removal. The ball 76 is prevented from entering grease chamber 18 by a ball stop device 84 positioned away from the valve seat 78. The grease chamber 18 may be filled with grease after piston 24 is removed to perform further repeated greasing or packing operations.
In accordance with another embodiment of the present invention, as shown in FIGS. 11-14, springs 86 are secured to the bottom surface 32 of piston 24 to bias the piston 24 against the bottom surface 22 of grease chamber 18 when the housing is substantially empty. The springs 86 help initially to break the vacuum within grease chamber 18 for piston removal. Two alternate means for securing springs 86 to the undersurface of piston 24 are shown in FIGS. 11-14. As shown in FIGS. 11-13, the springs are fitted into tapered bores 88 to frictionally engage the outer surfaces of the uppermost spring coils 89 against the bottommost surface of the bore 88. In accordance with the embodiment set forth in FIG. 14, bores 90 made in the undersurface 32 of piston 24 include downwardly protruding tapered pegs or spring support posts 92 for frictionally engaging the inner surfaces of the uppermost spring coils 89 to secure the springs 86 to the undersurface of piston 24.
An annular wave spring (not shown) can be disposed at the bottom of the housing 16 as another embodiment of biasing the piston 24 against the bottom surface 22 of grease chamber 18 to aid in removing the piston. When one or more springs are used for this purpose, the stem 42 needn't be threaded into piston 24 and the piston and stem 42 can be an integral part or the stem 42 can be secured to the piston in any known manner. Since the stem need not be capable of downward travel to release the piston 24 after the chamber 18 is substantially devoid of grease.
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 other than as specifically described above.
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A method and apparatus are disclosed for greasing an article such as a wheel bearing in a common vice including a housing defining an internal grease chamber including a first open end; a dished piston slideably insertable into said chamber, including a threaded aperture; a stem threadably mounted in the piston aperture; and a tapered spool compression application member disposed over the stem for forcing the piston against the grease to cause grease to pass through the piston and into the bearing.
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RELATED APPLICATIONS
[0001] The present application is based on, and claims priority from, Taiwan Application Serial Number 94139006, filed Nov. 7, 2005, the disclosure of which is hereby incorporated by reference herein in its entirety.
BACKGROUND
[0002] 1. Field of Invention
[0003] The present invention relates to an auto-aligning and connecting structure. More particularly, the present invention relates to an auto-aligning and connecting structure between an electronic device and an accessory.
[0004] 2. Description of Related Art
[0005] With the popularization of personal computers, electronic devices have continued to develop and flourish substantially in recent years. Conventional personal computers integrate many functions, such as video or audio signal playing, image data processing, and network communications, etc. However, conventional personal computers are often too heavy and bulky. As a result, many portable electronic devices have been created for more convenient and specialized use, including MP3 players, digital cameras, cellular phones, and personal digital assistants (PDAs).
[0006] Recent advances in the design and fabrication of both software and hardware have generated a trend to integrate these mini-sized portable electronic devices into one single apparatus. For example, smart phones and PDAs are equipped not only with the functions of a normal cellular phone but also with digital cameras, music players etc. Portable electronic devices are becoming users' portable personal computers.
[0007] Since portable electronic devices have become smaller and lighter, it is foreseeable that more and more portable electronic device accessories will be designed to increase the accessibility and functionality of the devices. These accessories may also protect portable electronic devices from wear and tear. An external keyboard or a protective cover for the electronic device are examples.
[0008] No matter what kind of accessory is used, it must be physically compatible with the electronic device. For instance, a protective cover needs to cover the surface of the electronic device closely. Furthermore, some accessories need to be coupled electrically to the device's internal circuits at a predetermined and fixed angle for precise coupling. For example, a keyboard needs to couple electrically with the electronic device in a specific direction so that the keyboard can work as an interface of the electronic device. Therefore, this kind of accessory requires not only a proper connection but also the correct alignment.
[0009] Traditionally, connectors were utilized to facilitate the connection between the electronic device and the accessory of the electronic device. However, for some electronic devices and their accessories, the connectors such as mortises and tenon joints are too complicated to manufacture, too fragile, and too large. These connectors can no longer satisfy the connectivity and alignment needs of modern electronic devices and their associated accessories.
[0010] For the forgoing reasons, there is a need for a novel connecting and aligning structure that is small, light, and easy to fabricate to connect modern electronic devices to their accessories.
SUMMARY
[0011] The present invention provides an auto-aligning and connecting structure that facilitates the connection between an electronic device and an accessory. The structure is small, light, easy to fabricate, sturdy, and it allows users to connect and disconnect accessories from electronic devices in a quick and proper manner.
[0012] In accordance with the foregoing and other aspects of the present invention, an auto-aligning and connecting structure is provided that comprises a first surface installed with a plurality of first magnetic units, and a second surface installed with a plurality of second magnetic units. When the second surface approaches the first surface, some of the plurality of the second magnetic units and some of the first magnetic units are aligned and mutually attracted such that the second surface is attracted to connect to the first surface.
[0013] In the foregoing, it is seen that the mutual attraction between the first magnetic units and the second magnetic units facilitates the alignment and connection between the electronic device and its accessory.
[0014] In conclusion, the invention facilitates the connection between an electronic device and its accessory with the help of a simple structure adopting magnetic units.
[0015] Moreover, the invention implements alignment between the electronic device and its accessory with the help of the same simple structure adopting magnetic units.
[0016] In this auto-aligning and connecting structure, a magneto-resistance layer could further be provided to cover each of the first magnetic units and the second magnetic units for reducing interference with other electronic components and for improving practicability of the present auto-aligning and connecting structure.
[0017] These and other features, aspects, and advantages of the present invention will become better understood with reference to the following description, figures, and appended claims.
[0018] Is It is to be understood that both the foregoing general description and the following detailed description are by examples, and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The accompanying drawings are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification. The drawings illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention. In the drawings:
[0020] FIG. 1A is a diagram of an auto-aligning and connecting structure according to one preferred embodiment of this invention;
[0021] FIG. 1B is an assembly diagram of an electronic device and a display protective cover according to one preferred embodiment of this invention;
[0022] FIG. 2A is a diagram of an auto-aligning and connecting structure according to another preferred embodiment of this invention; and
[0023] FIG. 2B is an assembly diagram of an electronic device and a keyboard according to one preferred embodiment of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] An auto-aligning and connecting structure utilizing magnetic units and the related arrangement for implementing the alignment is herein introduced to solve the problems in the prior art.
[0025] Reference will now be made in detail to the present preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers are used in the drawings and the description to refer to the same or like parts.
[0026] FIG. 1A illustrates an embodiment of the auto-aligning and connecting structure of the present invention. A portable electronic device 100 and its protective cover 120 are used to implement the embodiment.
[0027] It is observed in FIG. 1A that a display 104 is set on a first surface 102 of the electronic device 100 . The portability of the electronic device 100 makes the display 104 more susceptible to damage. Hence a display protective cover 120 is needed to protect the display 104 . The display protective cover 120 has to be fixed at a specific position on the first surface 102 of the electronic device 100 to cover the whole display 104 and to provide sufficient protection to the display 104 . Therefore, in the present embodiment, the first magnetic units 106 a, 108 a, 110 a and 112 a comprise any kind of magnetic material, such as magnetic material, magnet, magnetic susceptible material, or electromagnetic inductive material, and the magnetic units 106 a, 108 a, 110 a and 112 a are set around the display 104 .
[0028] There are an equivalent number of second magnetic units 106 b, 108 b, 110 b and 112 b set on a second surface 122 of the display protective cover 120 that covers the display 104 . The magnetism of the second magnetic units 106 b, 108 b, 110 b, and 112 b are opposite to the magnetism of the first magnetic units 106 a, 108 a, 110 a, and 112 a, respectively. For instance, if the magnetism of the first magnetic units 106 a, 108 a, 110 a and 112 a are all positive, the magnetism of the second magnetic units 106 b, 108 b, 110 b and 112 b are all negative. In this way, when the second surface 122 of the display protective cover 120 and the first surface 102 of the electronic device 100 approach each other, they will be attracted to each other and connect with each other through the connection between the first magnetic unit 106 a and the second magnetic unit 106 b, the first magnetic unit 108 a and the second magnetic unit 108 b, the first magnetic unit 110 a and the second magnetic unit 110 b, and the first magnetic unit 112 a and the second magnetic unit 112 b, as demonstrated in FIG. 1B .
[0029] With an appropriate arrangement of the magnetisms, the aforementioned magnetic units are not only connecting structures that connect objects, but also aligning structures.
[0030] Please refer to FIG. 1A again. There is a window 124 on the display protective cover 120 for the user to observe the display status of the display 104 when the display protective cover 120 is connected to and covering the display 104 . If the electronic device 100 is designed such that the window 124 may be positioned in the direction 126 or the direction 128 when the display protective cover 120 is shut to the first surface 102 , the magnetisms of the first units 106 a and 112 a can be positive, and the magnetism of the first units 108 a and 110 a can be negative, while the magnetisms of the second units 106 b and 112 b can be negative, and the magnetism of the first units 108 b and 110 b can be correspondingly positive. Hence the display protective cover 120 can successfully connect to the electronic device 100 whether in the direction 126 or in the direction 128 .
[0031] However, if the electronic device 100 is designed such that the window 124 can be positioned only in the direction 126 as illustrated in FIG. 1B , the magnetisms of the first units 106 a and 108 a can be positive, and the magnetisms of the first units 110 a and 112 a negative, while the magnetisms of the second units 106 b and 108 b can be negative, and the magnetisms of the first units 110 b and 112 b correspondingly positive. Hence the display protective cover 120 can be successfully connected to the electronic device 100 only in the direction 126 . The display protective cover 120 will be repulsed and not able to connect to the electronic device 100 when the window 124 is rotated near the direction 128 . Hence the alignment is accomplished.
[0032] Another embodiment of the aligning and connecting structure of the present invention is shown in FIG. 2A . A portable electronic device 200 and its keyboard 220 are applied herein.
[0033] It is illustrated in FIG. 2A that there is a first contact 204 a on the electronic device 200 for electrically coupling with a second contact 204 b on the external keyboard 220 . Hence the keyboard 220 is capable of transmitting and receiving signals to and from the electronic device 200 . As displayed in FIG. 2A , the first contact 204 a is located on the first surface 202 of the electronic device 200 , and the second contact 204 b on the second surface 222 of the keyboard 220 . The alignment is even more important because the first contact 204 a and the second contact 204 b have to be in contact with each other for the keyboard 220 to function correctly.
[0034] As illustrated in the previous embodiment, there are a plurality of first magnetic units allocated on the first surface 202 of the electronic device 200 and a plurality of second magnetic units allocated on the second surface 222 of the electronic device 200 ; that is, the first magnetic units 206 a, 208 a and 210 a are installed on the first surface 202 of the electronic device 200 , and the second magnetic units 206 b, 208 b and 210 b are installed on the second surface 222 of the keyboard 220 . With the appropriate arrangement and design, these magnetic units are not only capable of attracting one another, but also able to connect the first contact 204 a and the second contact 204 b.
[0035] For example, when the polarities of the first magnetic units 206 a, 208 a and 210 a are positive, positive, and negative respectively, and the polarities of the second magnetic units 206 b, 208 b and 210 b are negative, negative, and positive respectively, the electronic device 200 and the external keyboard 220 can couple to each other only when the first magnetic unit 206 a and the second magnetic unit 206 b, the first magnetic unit 208 a and the second magnetic unit 208 b, and the first magnetic unit 210 a and the second magnetic unit 210 b connect to each other respectively such that the first contact 204 a and the second contact 204 b are connected to each other as illustrated in FIG. 2B . Otherwise, the alignment and connection between the electronic device 200 and the keyboard 220 cannot be fulfilled.
[0036] As the connecting structure of the present invention may be applied to any kind of electronic device, it must be considered that the influence of magnetism on components inside the electronic device is inevitable, especially for some portable electronic devices with components of high integration density. Therefore, a magneto-resistance layer surrounds each magnetic unit of the present embodiment to decrease the influence of the magnetism from the magnetic units on the components inside the electronic device. For instance, the magneto-resistance layer 206 c surrounding the magnetic units 206 a and 206 b concentrates the attractive magnetism so as not to interfere with other electronic components. The functions of the magneto-resistance layer 208 c surrounding the magnetic units 208 a and 208 b, and the magneto-resistance layer 210 c surrounding the magnetic units 210 a and 210 b are the same. Please note that the magneto-resistance layer can be made up of any kind of material that guides magnetism; metal, alloy, and ceramics are examples.
[0037] In addition, for the user to find the connecting position more quickly and more accurately, some non-magnetic assistant aligning structures are further installed around the magnetic units. For example, the first non-magnetic assistant aligning structures 212 a and 214 a are installed on the first surface 202 , and the second non-magnetic assistant aligning structures 212 b and 214 b are installed on the first surface 202 . In the present embodiment, the first non-magnetic assistant aligning structures 212 a and 214 a are concave structures, and the second non-magnetic assistant aligning structures 212 b and 214 b are convex structures that are able to be coupled with the first non-magnetic assistant aligning structures 212 a and 214 a respectively. Hence, the user can recognize the alignment position more easily and more clearly using these assistant aligning structures.
[0038] Although the present invention has been described in considerable detail with reference to certain preferred embodiments thereof, other embodiments are possible. For example, the numbers of the aforementioned magnetic units and assistant aligning structures are not limited to the present embodiments, and may be arranged and designed in various ways for different requirements. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred embodiments contained herein.
[0039] It will be apparent to those skilled in the art that various modifications and variations can be made to the structure of the present invention without departing from the scope or spirit of the invention. In view of the foregoing, it is intended that the present invention cover modifications and variations of this invention provided they fall within the scope of the following claims and their equivalents.
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An auto-aligning and connecting structure used to connect and align an electronic device and an accessory, wherein a plurality of first magnetic bodies are disposed on a first surface of the electrical device and a plurality of second magnetic bodies are disposed on a second surface of the accessory. The magnetic pole of the first magnetic bodies and the second magnetic bodies are appropriately arranged so the first magnetic bodies and the second magnetic bodies can attract each other when the first surface and the second surface approach each other. Then, the electronic device and the accessories are connected to each other when the first surface and the second surface connect.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The field of invention relates to drain conduit and snake routing structure, and more particularly pertains to a new and improved drain conduit router apparatus wherein the same is arranged for the cleaning and removal of mineral deposits within a drain conduit, particularly of a water cooler refrigeration structure.
2. Description of the Prior Art
Router apparatus of various types have been utilized throughout the prior art, such as exemplified in the U.S. Pat. Nos. 4,771,500; 4,604,603; 5,018,234; and 5,056,178.
The instant invention is directed to overcome the prior art by providing for a router structure arranged in a sized manner to effect the cleaning of conduits associated with swamp cooler structure 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 router apparatus now present in the prior art, the present invention provides a drain conduit router apparatus wherein the same is directed to the cleaning of conduit structure relative to refrigeration tubes. As such, the general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new and improved drain conduit router apparatus which has all the advantages of the prior art router apparatus and none of the disadvantages.
To attain this, the present invention provides a router structure arranged to effect the routing of tubular fluid conduits and more particularly, tubular fluid conduits such as available in water coolers and the like, wherein the routing of mineral deposits is effected by the projection of a flexible wire coil sized to be received within such conduit and rotated relative to a housing containing the flexible wire coil for rejection through an associated housing tube.
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 drain conduit router apparatus which has all the advantages of the prior art router apparatus and none of the disadvantages.
It is another object of the present invention to provide a new and improved drain conduit router apparatus which may be easily and efficiently manufacture and marketed.
It is a further object of the present invention to provide a new and improved drain conduit router apparatus which is of a durable and reliable construction.
An even further object of the present invention is to provide a new and improved drain conduit router 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 drain conduit router apparatus economically available to the buying public.
Still yet another object of the present invention is to provide a new and improved drain conduit router 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 side view of the invention.
FIG. 2 is an orthographic view, taken along the lines 2--2 of FIG. 1 in the direction indicated by the arrows.
FIG. 3 is an orthographic view, taken along the lines 3--3 of FIG. 2 in the direction indicated by the arrows.
FIG. 4 is an orthographic top view, taken along the lines 4--4 of FIG. 1 in the direction indicated by the arrows.
FIG. 5 is an isometric illustration of a modified aspect of the invention.
FIG. 6 is an orthographic view, taken along the lines 6--6 of FIG. 5 in the direction indicated by the arrows.
FIG. 7 is an orthographic view, taken along the lines 7--7 of FIG. 5 in the direction indicated by the arrows.
FIG. 8 is an isometric illustration of a modified top wall of the wire coil housing of the invention.
FIG. 9 is an orthographic view, taken along the lines 9--9 of FIG. 8 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 9 thereof, a new and improved drain conduit router apparatus embodying the principles and concepts of the present invention and generally designated by the reference numeral 10 will be described.
More specifically, the drain conduit router apparatus 10 of the instant invention essentially comprises a cylindrical primary housing 11, having a housing top wall 12 spaced from and parallel a housing bottom wall 13. A top wall handle 14 is rotatably and eccentrically mounted in an orthogonal relationship relative to the housing top wall 12 to effect rotation of the housing 11 upon rotation of the top wall 12 that is integrally secured to the housing 11. A housing tube 15 is medially and coaxially mounted relative to the housing bottom wall 13 oriented along in a symmetrical relationship relative to the housing axis 11a (see FIG. 1 for example). The bottom wall 13 is arranged to include a housing tube cavity 16 in communication with a primary housing cavity 17, with the primary housing 17 receiving and storing a coil of flexible wire coil 21 that is arranged for projection through the housing tube 15 from the primary housing 11. A housing tube end cap 19 is secured to the free distal end of the housing tube 15, to include an end cap fastener 20 directed through the end cap arranged for engaging the wire coil 21 within the primary housing cavity 17 in adjacency to the end cap opening 22 that is coaxially oriented relative to the axis 11a. The housing tube sleeve 18 rotatably and slidably mounted in surrounding relationship relative to the housing tube 15 between the housing bottom wall 13 and the end cap 19 permits manual grasping of the sleeve 18 to permit rotation of the wire coil 21 upon rotation of the housing 11 relative to the sleeve 18.
The FIGS. 5-7 indicate the further use of an extension tube 23 coaxially and fixedly mounted to the end cap 19 longitudinally aligned with the end cap 19, and more specifically the axis 11a. The cap extension tube 23 includes a cylindrical array of bristle brush members 24 directed substantially coextensive throughout the extension tube 23, having a brush bore 25 arranged to frictionally receive the wire coil 21 therethrough to effect cleaning of the wire coil when projected along and relative to the bristle brush array 24.
The FIGS. 8 and 9 indicate the further optional use of a bellows member 28 fixedly mounted to the housing top wall 12 coaxially aligned relative to a top wall bore 26. The top wall bore 26 is arranged in a spaced relationship relative to the axis 11a, with a resilient first valve plate 27 arranged to extend over the top wall bore 26 within the primary housing cavity 17. The first valve plate 27 is arranged for deflection relative to the top wall bore 26 upon pressurizing of a lubricating fluid such as oil 30 within the bellows fluid reservoir cavity 29 directed coextensively throughout the bellows. The bellows member 28 further includes a bellows top wall 31 having a bellows top wall cap 32 arranged for mounting over a bellows top wall fill port 36. The bellows top wall cap 32 includes a vent port 33 directed through the cap in communication with the fluid reservoir cavity 29 upon deflection of a bellows top wall resilient valve plate 34 arranged to extend over the bellows top wall fill port 36 in a first position and deflects relative to the bellows top wall fill port 36 when the bellows expands from a contracted position to compress the fluid reservoir cavity 29, deflect the first valve plate 27, and direct the lubricating fluid 30 into the primary housing cavity 17 for lubricating of the wire coil 21.
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 to 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 router structure is arranged to effect the routing of tubular fluid conduits and more particularly, tubular fluid conduits such as available in water coolers and the like, wherein the routing of mineral deposits is effected by the projection of a flexible wire coil sized to be received within such conduit and rotated relative to a housing containing the flexible wire coil for rejection through an associated housing tube.
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FIELD OF THE INVENTION
The present invention relates to abrasive cleaning devices that can remove and capture dirt and debris from a surface by using abrasive particles with mixture of high pressurized air and vacuum. More particularly, the invention relates to an abrasive-cleaning device utilizing a system having a central vacuum compressor with plurality of control panel units that can be placed in treatment stations to be used for unlimited number of users.
BACKGROUND OF THE INVENTION
Abrasive cleaning devices are well known as surfacing applicators to treat surfaces for cleaning, smoothing, etching and resurfacing a damaged area such as human skin. These devices operate on a high stream of a pressurized air or vacuum suction to carry abrasive particles to be impinged against the surface. The high pressures of abrasive particles removes dirt and debris from a surface and provides an extremely satisfactory cleaning means.
In spite of the advantages of these devices in prior art, there are some disadvantages and limitations that can not be delivered for the purpose of productivity. For example, only one operator at a time can use this device while using the applicator to treat a patient. The usage of the unit is entirely limited to a sole operator. In case of needing another operator for more productivity, additional unit must be purchased and that is not a cost-effective approach.
Another disadvantage of the prior art unit is that the vacuum compressor is built in with control panel and while the unit is operating, the compressor makes a loud noise and generates heat in the treatment room and it's very inconvenient. However, this invention overcomes the shortcomings of conventional units and provides a system that utilizes a central vacuum compressor with an option to expand the system and provide additional treatment stations for unlimited number of operators at very lower cost and achieve maximum productivity.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an improved abrasive cleaning system that utilizes a central vacuum compressor, at least one in-line filtration device and at least one control panel unit to be placed in a treatment station. Said compressor is placed in a separate room away from treatment stations to eliminate the compressor noise in treatment stations.
It is also an object of this invention to expand the system by adding two or more additional control panel units to the original system set up. The number of these additional control panel units depends upon the design layout of the system unit, which can be unlimited. Therefore by expanding the system unit, we can provide multi-treatment stations at very low cost to treat patients and to be productive.
In each treatment station, a control panel unit may be a wall mounted panel or a tabletop panel that includes a handpiece, a collection canister, a source canister, a vacuum adjustment knob and a control flow knob to adjust the flow of the abrasive particles. The in-line filtration device may also be included in this unit.
It is another object of this invention to provide in-line filtration device with this system to collectively capture particles and optionally be able to expand the filtration device with additional filters. It is preferable to have straight type fitting connections to the system to eliminate any loss of vacuum flow in 90 degrees angle and retain maximum vacuum source. However, the elbow connection fitting may be used in some system configurations for purpose of controlling the vacuum flow. Said in-line filtration device includes a least two proxy-filters connected at each end with a connecting part with a passage of flow between the two filters, two end caps with hose fittings connectors, and at least one translucent cover.
Further objects and advantages of this invention will become apparent from consideration of the drawings and description that follows.
BRIEF DESCRIPTION OF THE DRAWINGS
Exemplary embodiments of the invention will now be described in conjunction with the drawings in which:
FIG. 1 is a block diagram of the present invention showing a system unit in conjunction with multi-treatment stations.
FIG. 2A is a partial view of a control panel unit shown as a wall mount panel for each treatment station.
FIG. 2B is a partial view of a control panel unit shown as a tabletop panel for each treatment station.
FIG. 3 is an exploded view of the in-line filtration device.
FIG. 4 is a cross sectional view taken along line 4 — 4 in FIG. 1 .
FIG. 5 is a cross sectional view similar to FIG. 4 except an additional filter has been added and the caps are modified.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is showing an abrasive cleaning device 10 that utilizes a system that includes a central compressor 12 , an arrangement of at least one in-line filtration device 12 , an arrangement of at least one control panel unit 20 located in a treatment station 26 . The central compressor unit 12 has a number of vacuum ports 32 and an exhaust port 34 . Vacuum ports 34 may be connected to a manifold to distribute a vacuum suction from a central compressor 12 .
The compressor 12 at its vacuum port 32 is connected by a vacuum hose 40 to at least one in-line filtration device 14 at its outlet port 46 . The filtration device 14 is to capture sand type particles, So that the compressor runs smoothly and last longer. At the other end of the in-line filtration device 14 at its inlet port 48 , a connecting hose 36 is connected to control panel unit 20 .
Preferably, the compressor 12 separated from the control panel unit 20 , and it is located in a compressor room 44 to eliminate the noise extracted by the compressor 12 in a treatment station 26 where the patient is being treated for a medical procedure.
FIG. 1 is also illustrates the system unit in a basic and in comprehensive configuration. The basic configuration is designed for one treatment station 26 and can be expanded for two or more treatment stations 28 , 30 for comprehensive configuration that accommodate two or more control panel units 22 , 24 with possible two or more in-line filtration devices 16 and 18 using a central compressor 12 . This type of system unit has advantages over the prior art devices, because the system is expandable and cost-effective.
Referring to FIGS. 2A and 2B, showing a control panel unit 20 that can be a wall mounted panel 50 or a table top panel 100 . The control panel unit 20 includes a handpiece 56 , a collection canister 60 , a source canister 70 that contains abrasive particles, a vacuum adjustment knob 76 to control and adjust the vacuum source from the central compressor 12 , a control flow knob to adjust the flow of the abrasive particles from a source canister to the handpiece. This control panel unit 20 may also include the in-line filtration device 14 as part of this assembly.
The applied vacuum suction from the central compressor 12 , that is directed to the outlet port 64 of collection canister 60 activates the circulation of abrasive particle 72 in source canister 70 at its outlet port 75 to the handpiece 56 through a control flow knob 82 and a pair of vacuum tubes 52 , 54 . The handpiece 56 eject a mixture of high pressurized air with stream of abrasive particles at its tip 57 onto a surface 92 for cleaning means to remove the debris from the surface 92 . The pressure flow from the compressor exhaust may also be use in this control panel unit to circulate the abrasive particles 72 within the source canister 70 to provide better circulation of the abrasive particles in the system.
Another important device in this system unit is the in-line filtration device 14 as shown in FIG. 3 and FIG. 4 . This device comprises at least two filters 106 a and 106 b preferably proxy type filters, a connecting part 108 to connect or position the filters 106 a and 106 b at its end, two end caps 102 , 110 with connector fitting 114 , 112 preferably straight connector, and at least one translucent cover 104 to cover the filters 106 a , 106 b and the connecting part 108 to be assemble with the end caps 102 , 110 . Through the vacuum suction flow that is generated by the compressor, the in-line filtration device filters the abrasive particles. The flow passes through the inlet port 114 and move on to first filter 106 a . The end cap 110 has a number of projected tabs 116 that is abut with the end of the first filter. The vacuum suction flow passes through the opening created by these projected tabs 116 and forwarded to the chamber 150 a between the first filter 106 a and cover 104 a . Some of the particles are capture by the first filter and the remaining particles move on to the second chamber 150 b between the second filter 106 b and the cover 104 b to be capture completely. The connecting part 108 is positioned between the first filter 106 a and the second filter 106 b . This connecting part includes a number of projected tabs 120 for flow of vacuum suction to the second filter 106 b and it also has a central opening 122 .
The in-line filtration device 14 can be modifying for more than two filters as shown in FIG. 5 . Additional filter 106 c can be added to this device for better filtration to meet the system requirement for cleaner flow.
While this invention is susceptible of embodiments in many different forms, this specification and the accompanying drawings disclose only some specific forms as examples of the invention. The invention is not intended to be limited to the embodiments so described, however, the scope of the invention is pointed out in the appended claims
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An abrasive cleaning system that utilizes a central vacuum compressor, at least one in-line filtration device and at least one control panel unit to be placed in a treatment station. This system has an option to expand by adding two or more additional control panel units in two or more treatment stations. The number of these add on control panel units depends upon the design layout of the system unit which can be unlimited.
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CROSS REFERENCE TO RELATED APPLICATION
This is a continuation-in-part application of application Ser. No. 910,643 filed May 30, 1978, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates generally to medical specimen collection assemblies and, more particularly, to a medical specimen cup having a sealing cap member.
When using a medical specimen collection cup, such as for a urine sample, it is necessary to protect the specimen from contamination. The open end portion of the cup and the interior surfaces of the cap for such a cup are particularly vulnerable to hand and body contact or the like before, during, and after the collection of the specimen, which contact can ultimately contaminate the specimen. Conventional specimen cups do not shield these vulnerable areas from such contaminating contact in a simple manner, requiring no special handling.
SUMMARY OF THE INVENTION
It is one of the objects of this invention to shield the open end portion of a medical specimen collection cup from hand and body contact or the like to reduce the chances of contaminating the specimen.
It is another object of this invention to provide a cap for sealing a medical specimen collection cup, which cap also protects the interior surfaces of the cap, and thus the specimen itself, from contamination.
To achieve these and other objects, the invention provides a specimen collection assembly comprising a cup member having a body portion and an open end closure portion. The device further includes a cap member having a closure portion adapted for engagement with the cup closure portion to effectuate a seal between the cup member and the cap member. The cap member has a depending outer peripheral wall surrounding the cap closure portion and extending past and covering the outermost extremities of the cap closure portion. By virtue of this construction, the interior surfaces of the cap member are shielded from hand and body contact as the cap member is being engaged upon the cup member.
The cup member includes an outer protective wall extending past and covering the outermost extremities of the open end closure portion of the cup. The outer protective wall shields the open end closure portion from contaminating contact.
The outer protective wall on the cap member is in the form of a depending outer peripheral wall surrounding the cap closure portion and in which the outer protective wall on the cup member is in the form of an upstanding outer peripheral wall surrounding the cup closure portion. The upstanding outer peripheral protective wall on the cup member is a separate part adapted for snap engagement with the body of the cup member. The depending outer peripheral wall on the cap member surrounds the upstanding outer peripheral wall on the cup member when the cap and cup members are assembled in sealing engagement.
The cup member has a threaded open end closure portion and the closure portion of the cap member is similarly threaded to effectuate a threadable engagement between the cup member and the cap member.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevation view, partly in section, of a cup member of a first embodiment of a medical specimen collection assembly;
FIG. 2 is a fragmentary perspective view of a cap member for the medical specimen collection assembly which cap member is adapted to seal the cup shown in FIG. 1;
FIG. 3 is a front elevation view, partly in section, of the entire medical specimen collection assembly with the cap member of FIG. 2 threadably received by the cup member of FIG. 1;
FIG. 4 is a top view of the protective lip assembly shown in FIG. 1;
FIG. 5 is an elevation view, partly in section, of the cup member of a second embodiment of a medical specimen collection assembly (with the combination protective wall and handle member mounted thereon);
FIG. 6 is a sectional view of a cap member for the collection device which cap member is adapted to seal the cup shown in FIG. 5;
FIG. 7 is a sectional view of the combination protective wall and handle member shown in FIG. 5;
FIG. 8 is a top plan view of the combination protective wall and handle member shown in FIG. 7;
FIG. 9 is an elevation view, partially in section, of the assembled medical specimen collection device with the cap member of FIG. 6 threadably received on the cup member of FIG. 5; and
FIGS. 10 and 11 are fragmentary sectional views showing an alternate construction for sealing the cap member with the cup member.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A medical specimen collection assembly 8 is shown in FIG. 3. The invention perhaps finds its widest application in connection with a urine specimen collection cup, and the invention will hereafter be discussed in that environment. However, it should be appreciated that the specimen collection assembly 8 is applicable for use in other environments.
When used to collect urine samples the assembly includes a cap 14 and a cup 10 having a body portion 11 and an end closure portion 12. End closure portion 12 is provided with threads 13. Referring to FIG. 2, the cap 14 includes an outer peripheral wall 18, a top portion 20 and an oppositely spaced open end 22 which is adapted to accommodate the end portion 12 of the cup 10. Preferably, the cap 14 is made of polyethylene, while the cup 10 is made of polypropylene material.
Cap 14 has an integral closure portion 24 which extends from the top portion 20 towards the open end 22. Closure portion 24 is concentric with and entirely encircled by the outer peripheral wall 18 and includes threads 26 thereon for engagement with the externally threaded end portion 12 of the cup 10 (see FIG. 3).
As best shown in FIG. 2, the vertical length of the closure portion 24, as measured from the top portion 20, is less than the comparable vertical length of the outer peripheral wall 18. Thus, when the cap 14 is placed upon a flat surface, only the edges of the outer peripheral wall 18 contact the surface. The chance of contaminating the interior surfaces of the cap 14, and in particular the threaded closure portion 24, is significantly reduced. Furthermore, because outer perimeter wall 18 completely encircles the closure portion 24, hand contact with the interior surfaces of the cap 14, both before and during the collection of the specimen, is prevented, which further enhances the sanitary features of the screw cap 14.
The cap 14 further includes sealing means 28 for preventing leakage of the specimen from the cup 10 when the cap 14 is threadably received thereon. In the illustrated embodiment, the sealing means 28 includes an inner partition portion 30 extending from the top portion 20 toward the open end 22, which partition portion 30 is concentric with and completely encircled by the closure portion 24. The portions 24 and 30 are spaced apart and a channel 32 is formed therebetween. A ledge 34 spans a portion of the channel 32 thereby joining the portions 24 and 30. As can be seen in FIG. 3, when the cap 14 is threadably received by the cup 10, the threaded end portion 12 is received by the channel 32 and abuts against the underside of the ledge 34, thereby forming an impervious interface to prevent leakage of specimen from the cup 10.
Referring next to FIG. 1, the cup 10 includes a generally vertically extending protective lip 44 which is concentric with and completely encircles the externally threaded end portion 12. The protective lip 44 is an integral part of a handle assembly 16. The handle assembly 16 is preferably made of polystyrene material and includes a circular main body 38 having a handle appendage 42 and a plurality of inwardly facing tabs 40. The cup 10 includes a groove 36 about its periphery and the tabs 40 are adapted to be snap-fitted within the peripheral groove 36, thereby removably attaching the circular main body 38, and thus the protective lip 44, upon the cup 10. Just as the outer peripheral wall 18 of the cap 14 reduces the chance of contaminating the interior surfaces of the cap 14, the protective lip 44 shields the threaded end portion 12 of the cup 10 from hand contact and the like when the specimen is being taken, thereby enhancing the protection of the specimen from contamination. Furthermore, the tabs 40, in lieu of a continuous ledge, prevent trapping the specimen in the space between the protective lip 44 and the threaded end portion 12, thereby permitting drainage should accidental spill over occur.
As shown in FIG. 3, the cap 14 is adapted to accommodate the vertically projecting protective lip 44. Because the outer peripheral wall 18 and the first inner partition member 24 are spaced apart, a channel 46 is defined therebetween. The protective lip 44 is received by the channel 46 as the cap 14 is being threadably received by the cup 10.
It will be appreciated that while in the preferred embodiment described above, a screw-type closure between the cup and the cap is used, other types of closures such as a snap-type closure can be used without departing from the invention herein. Also, it will be appreciated, while in the preferred embodiment the protective lip 44 and handle assembly 16 is a separate part, such assembly can be made integrally with the body of the cup 10.
FIGS. 5-11 show a second embodiment of the present invention. Such second embodiment includes a cup member 50 (FIG. 5) and a cap member 52 (FIG. 6). Cup member 50 includes a body portion 54 and an end closure portion 56. End closure portion 56 is provided with threads 58 on the internal surface thereof and is also provided with a circular lip 86 around the upper edge thereof. As shown in FIG. 5, a combination protective wall and handle member 60 is mounted on the end closure portion 56.
As best shown in FIG. 6, cap member 52 includes a top portion 62 having a depending outer wall 64 and a concentric depending inner wall 66. Wall 66 has threads 68 on the external surface thereof.
Preferably, cap member 52 is made of polyethylene, cup member 50 is made of polypropylene and combination protective wall and handle member 60 is made of polystyrene.
As best shown in FIG. 6, the vertical length of outer peripheral wall 64 of the cap member is greater than that of the inner wall 66; thus, when the cap 52 is placed upon a flat surface, only the edges of the outer wall 64 will contact the supporting surface. The chance of contaminating the interior surface of the cap member is thereby significantly reduced. Furthermore, because outer wall 64 completely encircles the inner wall 66, hand contact with the interior surfaces of the cap 52 both before and during the collection of the specimen, is prevented. This further enhances the sanitary features of the cap member 52.
Combination protective wall and handle member 60 is comprised of a protective wall portion 70 and a handle portion 72. As best shown in FIG. 5, protective wall portion 70 has an inwardly extending circular belt portion 74 formed thereon which provides upwardly and downwardly facing shoulders 76 and 78.
Snap-on engagement of member 60 on cup member 50 is accomplished by means of the cooperative interrelationship of shoulders 78 on member 60 with a plurality of annularly spaced, radially extending retaining ribs 80 formed integrally with the exterior surface of cup 50. The circular belt portion 74 is provided with a plurality of annularly spaced grooves 82 (FIG. 8) positioned for alignment with ribs 80.
To assemble member 60 on cup 50, the cup is inserted through the top of member 60, grooves 82 are aligned with ribs 80 and then the parts are snapped into place as shown in FIG. 5, with the top surface of the ribs in engagement with the shoulder 78 on member 60. Removal of member 60 from the cup member 50 can be accomplished by the reverse procedure. A small tab 84 on member 60 is provided to facilitate the removal of member 60 from the cup 50.
Just as the outer peripheral wall 64 of cap 52 reduces the chance of contaminating the interior surfaces of the cap 14, the protective wall 70 on member 60 shields the threaded end portion 56 of cup 50. The circular lip 86 at the top of threaded end portion 56 cooperates with the shoulder 76 on member 60 to seal the parts together and thus prevent any accidental leakage of urine between member 60 and end portion 56.
A seal between cap 52 and cup 50 is provided by the cooperation of end surface 88 on wall 66 of cap 52 with a groove 90 in end portion 56 of cup 50. Thus, as the threads 58 and 68 on cup 50 and cap 52, respectively, are engaged by screwing the cap onto the cup, surface 88 will seat in groove 90 to thereby seal the cap to the cup.
An alternative seal arrangement is shown in FIGS. 10 and 11. A shown, a tapered edge portion 92 is provided on the end of wall 66 which is dimensioned to cooperate with a groove 94 in the cup. When the cap is screwed onto the cup as shown in FIG. 11, the end of the tapered edge portion 92 will move into sealing engagement with groove 94 as end portion 92 becomes slightly deformed. Also, the small shoulder 96 at the base of tapered edge portion 92 will seat against a cooperating shoulder stop surface 98 adjacent groove 94. The secondary seal is thus provided by the engagement of shoulder 96 on surface 98. Surface 98 also serves as a stop to control and limit the amount of deformation of the tapered edge portion 92 when the cap is screwed onto the cup as shown in FIG. 11.
In use, a specimen is taken with combination protective wall and handle member 60 installed on cup 50 as shown in FIG. 5. The cup is conveniently held by the user during the taking of the specimen by the use of handle portion 72 on member 60. As indicated previously, the abutting relationship of lip 86 against shoulder 76 prevents any accidental leakage of urine between member 60 and the closure portion 56 of cup 50. After the specimen is taken, cap 52 is screwed onto cup 50 causing surface 88 on wall 66 to seat in groove 90 to thereby establish a seal between the cup and the cap.
As previously explained, during the taking of the specimen and the installation of the cap on the cup, the interior surfaces of the cap and the cup are protected against touch contamination by protective wall 64 on the cap and the protective wall 70 on member 60.
After the cap is installed on the cup, the combination protective wall and handle member 60 has no further function and can be removed by simply pressing downwardly on handle portion 72 and tab 84 causing member 60 to be forced out of snap engagement with retaining ribs 80. Removal of member 60 facilitates further handling and storage of the cap and cup assembly. The ability to remove member 60 after sealing assembly of cap and cup results in a cleaner and safer handling procedure. Also with member 60 removed the specimen can be poured out of the cup over the previously protected and thus uncontaminated lip 86.
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A specimen collection assembly comprising a cup member having a body portion and an open end closure portion. The assembly also includes a cap member having a closure portion adapted for engagement with the cup closure portion to effectuate a seal between the cap member and the cup member to thereby seal the interior of the cup body portion. The cup and cap members each have an outer protective wall thereon extending past and covering the outermost extremities of the closure portions of the cup and cap members to protect the closure portions from hand and body contact.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to generally to computer systems, and, more particularly, to a method and apparatus for troubleshooting and configuring communications settings in a computer system.
[0003] 2. Description of the Related Art
[0004] The networking of individual computers to allow an application program and file resources to be shared by users of the computers is a well-known concept. In particular, business entities, from large corporations to relatively small companies, routinely set up local area networks (LANs) and wide area networks (WANs) to enable such application file sharing throughout the enterprise.
[0005] NetBIOS (network basic input/output system) was developed as an application programming interface (API) for client software to access network resources. NetBIOS standardizes the interface between applications and the operating capabilities of the network. PCs on a NetBIOS LAN communicate either by establishing a session or by using NetBIOS datagram or broadcast methods. These methods are well known and are not discussed further herein.
[0006] Setting up NetBIOS file sharing between two or more computers in the same domain (e.g., on the same side of a hardware firewall) is not always a straight-forward process. In addition to having to configure the software firewall settings, there are several operating system configuration values that must be set correctly. Failure to set any one of the values correctly can result in an inability to share files and/or directories and thus may require a significant amount of diagnostic or troubleshooting information to get the system operating properly.
[0007] For a network administrator, bringing up a computer on a network can typically be resolved by the network administrator trying a series of known troubleshooting options until one of them works. If the problem can be resolved using one of these known fixes, the computer can be brought up without much difficulty. However, if the network administrator goes through the known troubleshooting options and still cannot access the network, significant additional time can be wasted further troubleshooting the issue.
[0008] The problem is magnified when a general consumer, who does not have the knowledge and expertise of a network administrator, attempts to access the network. Operating systems are not very helpful in guiding the consumer through the process. This leaves the consumer frustrated and unable to connect to the network.
[0009] Accordingly, it would be desirable to have a method, system, and computer program product that assists users in diagnosing and correcting network connectivity problems.
SUMMARY OF THE INVENTION
[0010] The present invention provides a client and server tool that interrogates security attributes of a client/server system from both the client side and the server side. These attributes may include software firewalls, sharing policies, and security attributes. By interrogating the security attributes from both the client and server sides, network access problems emanating from entire side (client and server) can be discovered, and automated solutions can be presented to rectify any problems.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a block diagram of a typical computer network;
[0012] FIG. 2 illustrates the typical security layers that are established in a typical client server system;
[0013] FIG. 3 illustrates a solution to the above problem in accordance with the present invention;
[0014] FIG. 4 is a flowchart illustrating the steps performed by the client agent of the present invention;
[0015] FIG. 5 is a flowchart illustrating the same steps of FIG. 4 , but from the perspective of the server agent rather than the client agent; and
[0016] FIG. 6 is a flowchart illustrating operations performed by the comparison processor using the results from the testing steps performed by the client agent and server agent.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] Illustrative embodiments of the invention are described below. In the interest of clarity, not all features of an actual implementation are described in this specification. It will of course be appreciated that in the development of any such actual embodiment, numerous implementation-specific decisions will be made to achieve the developers specific goals, such as compliance with system-related and business-related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort would be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure.
[0018] Referring to FIG. 1 , a block diagram of a typical computer network 100 is shown. It is understood that the various connections between the elements of the network may be wired, wireless, or combinations thereof. The exact technique for coupling the elements of the system are those up to the discretion of the developer and are not critical to the inventive aspects described.
[0019] Referring to FIG. 1 , a server 102 is accessible to a plurality of client devices 106 , 108 , and 110 , via a network connection 104 . Network connection 104 can comprise any network connection, such as the Internet, a local area network (LAN) a wide area network (WAN), or the like. In a well known manner, server 102 and client devices 106 , 108 , and 110 can communicate with each other via the well-known ports that are available on a network system. Examples of such ports include, but are not limited to, network share, mail, FTP, and HTTP. When a client device connects to the server via one of these ports, a channel or conduit between the client device and the server is established.
[0020] FIG. 2 illustrates the typical security layers that are established in a typical client server system. Referring to FIG. 2 , a server 202 connects with a client 206 over a network connection 204 . Each element of the network (server, network connection, and client) are protected by security layers in a well known manner. In FIG. 2 , server security layers 220 (comprising, in this example, a net firewall layer 220 A, a sharing configuration layer 220 B, a policy layer 220 C, and an attributes layer 220 D) provide security protection for server 202 ; network security layers 222 provide security protection for network connection 204 ; and client security layers 224 (comprising, in this example, network service, layers 224 A, software firewall layers 224 B, at net layer 224 C) provide security protection for client 206 . The layers described by way of example are well known to those of ordinary skill in the art. It is understood that there are other layers of security that could be added to those given in this example and such variations are covered by the claims herein.
[0021] If client 206 wishes to connect to server 202 for the purpose of file sharing, client 206 must navigate through client security layers 224 and network security layers 222 to establish a file sharing channel 228 with network connection 204 . To complete the file sharing connection, file sharing conduit 226 must be established between network connection 204 and server 202 through network security layers 222 and server security layers 220 . To make this connection through the various security layers, the software firewall settings for the client, server, and routers allowing client 206 to navigate through software firewall layer 224 B must be configured properly, and there are several OS configuration values that must be set correctly, e.g., user authentication such as Keberos. Failure to set any one of the OS configuration values may result in a failure in the attempt to establish the file sharing conduit 226 .
[0022] Also illustrated FIG. 2 is a web conduit between client 206 and server to 202 via network connection 204 . The web ports for TCP/IP (ports 80 and 443 ) are almost always open and thus the security layers that must be traversed to establish a Web connection are typically very minimal. This is illustrated symbolically in FIG. 2 by the openings in client security layers 224 , network security layers 222 and server security layers 220 , through which web conduits 232 and 230 are established to link the client to the server for a web connection.
[0023] For one having knowledge of all of the configuration settings required to establish the file sharing conduit, it may not be too difficult to establish such a connection. A network administrator typically knows what the settings should be, and is also aware of the various troubleshooting steps to take in order to analyze any problems and come up with a solution that will eventually enable the establishment of the file sharing conduit. However, the average user (e.g., a mobile user who is attempting to configure a laptop to access a network in a remote location such as a hotel or office he or she is visiting) may not have the knowledge and skill required to go through the troubleshooting process. This average user typically will attempt to connect, will experience a problem, may try one or two solutions that have worked for them in the past, and then give up attempting to connect.
[0024] FIG. 3 illustrates a solution to the above problem in accordance with the present invention. Items in FIG. 3 that are identical to items in FIG. 2 are identified using the same numerals as used in FIG. 2 . Referring to FIG. 3 , server 202 and client 206 are each provided with a software agent (client software agents (CSA) 340 and server software agents (SSA) 342 , respectively). In a preferred embodiment at least two conduits are established between the client and server. The first is a main conduit that carries the user data, such as files that are being shared. In FIG. 3 , this main conduit comprises two file sharing conduits 226 and 228 . The second is an agent-to-agent conduit that should be an easy-to-access connection that has a high likelihood of being easily established. In the example of FIG. 3 , web conduit 230 and 232 provide a good agent-to-agent conduit, since web ports are almost always open, and users will complain (and thus alert administrators) if it goes down.
[0025] Each of the agents are configured with rules that interrogate the file sharing attributes of the respective components (client or server) including the software firewalls, the sharing policies, and the security attributes. To troubleshoot a network sharing issue, the agents are each configured to diagnose a section of the security layers accessible to them. For example, the firewall security layer of either the server or the client (or both) may be blocking the standard Windows share ports 137 to 139 . When the client tries to connect to the server, it would get no response if the firewall is blocking the ports; however, if the port is open but the server is not running the network sharing service, the server will return an indication that the port is closed. Using the probing technique of the present invention, the client agent can determine the status of the outer layer of the server security model (the firewall is always the outermost defense, and is sometimes referred to as a “boundary device”) and present multiple options for correcting any problems encountered, e.g., send instructions to the server over the agent-to-agent conduit to instruct it to run the network sharing service. All of this functionality can be accomplished using known techniques to define and execute the various probing operations discussed herein.
[0026] The server agent 340 will first test the components beneath its firewall (firewall layer 220 A), i.e., the inner layers 220 B, 220 C, and 220 D denoted in FIG. 3 . For example, the server agent 340 can check the policy and sharing configuration to see if they are set up correctly. Following is an example of a list of steps the server agent 340 can perform to test the security layers. The list is not exhaustive and is simply a list of common testing steps. The server agent 340 can check to see if a service is running for sharing (NetBIOS); check to see if sharing is enabled; check to see if at least one resource is shared; check to see if at least one user/group is enabled; check to see if permissions and policies are set; and perform client based activities through loop back.
[0027] The client agent 342 can perform internal tests to determine network availability. These may include NIC card configuration, the IP address configuration, and/or the NetBIOS service configuration. The client agent 342 can also perform external tests, including probing of the firewall, NetView data on the server, and NSlook up of server address data.
[0028] The tests listed above are given for purpose of example. Any tests that can be performed on the server and/or client can be performed by an agent configured to conduct the test(s). Installation of the server and client agent establishes, on both ends of the path to be monitored and tested, a testing and analysis means. The agents are configured with appropriate permissions to cross the security layers of the machine on which the agent is running, and can communicate directly with each other via, for example, the easily established web conduit. The agents use standard networking APIs including ping, Nslookup, net use, and NetView to heuristically analyze the data shared between clients and server. The result of this analysis can be shared between the agents, or individually output to external media for analysis by troubleshooters.
[0029] FIGS. 4 through 6 are flowcharts illustrating the basic operations of an exemplary embodiment of the present invention. FIG. 4 is a flowchart illustrating the steps performed by the client agent. The process begins at step 402 , and at step 404 the client agent performs tests to navigate through the client security layers. At step 406 , a determination is made as to whether or not the tests have passed. If one or more of the tests are not passed, at step 408 , a determination is made as to whether or not there is a possible solution available to correct the test failure.
[0030] If, at step 408 , is determined that there are possible solutions available to correct the test failure, at step 410 , the possible solutions are implemented and then the process proceeds back to step 402 to again perform the tests to navigate through the client security layers, to see if the problems have been resolved. If there are no possible solutions available, at step 420 the client agent stores this information and communicates the results to a “coordinating processor,” described in more detail below with respect to FIG. 6 .
[0031] If, at step 406 , it is determined that the client security layer tests have been passed, the process proceeds to step 412 , where the client agent performs tests to navigate through the server security layers. At step 414 , a determination is made as to whether or not the tests have been passed. If the tests indicate a failure, at step 416 a determination is made as to whether not there are possible solutions available to resolve the failure. If there are possible solutions available, at step 418 the possible solutions are implemented, and then the client agent retests the server security layers. If, at step 416 , it is determined that there are not any possible solutions available, information identifying failures and failed attempts at resolution are saved and communicated to the coordinating processor at step 420 .
[0032] If, at step 414 , all of the tests have passed, this is an indication that the connections between the client and server are functioning properly, and the process ends.
[0033] FIG. 5 is a flowchart illustrating the same steps of FIG. 4 , but from the perspective of the server agent rather than the client agent. Since the steps are essentially identical to those of FIG. 4 and are apparent from the drawing, they are not described in detail herein. The only difference between FIG. 4 and FIG. 5 is that in steps 504 and 512 , the server agent performs the tests rather than the client agent. It is noted that in the flowcharts of FIGS. 4 and 5 , only information regarding test results (e.g., pass/fail) and attempts to resolve problems are shown as being communicated to the coordinating processor. It is contemplated, however, that information regarding successful problem resolutions (i.e., not just attempts to resolve problems) and any other data available regarding the process steps of FIGS. 4 and 5 may be useful to the coordinating processor and thus any of this data may be communicated thereto.
[0034] FIG. 6 is a flowchart illustrating operations performed by the coordinating processor using the results from the testing steps performed by the client agent and server agent as described in FIGS. 4 and 5 . The coordinating processor can be a processor integrated or associated with the client, the server, or both; the coordinating processor can also be a processor that is independent from the client and server. In FIG. 3 , coordinatig processor 350 is shown in dotted lines to indicate that it is a functional illustration only; in a preferred embodiment, the coordinating processor is a processing function residing with and performed by the client agent. However, either the client agent or the server agent, or both, can be configured to function as a coordinating processor.
[0035] The coordinating processor is configured to perform the steps described herein using well-known programming techniques. At step 602 , the testing results and other troubleshooting results are received by the coordinating processor from the client agent and the server agent. At step 604 , the coordinating processor compares the results and analyzes them, and at step 606 it is determined if there are solutions available to resolve problems associated with any test failures that have been encountered. If there are solutions available, then at step 608 , the solutions are implemented by the coordinating processor, e.g., the coordinating processor might send an instruction to the client or server to open a particular port or to change a particular communication setting. If there are not solutions available, then at step 610 , an IT administrator or other responsible party is alerted, since problems have been encountered that require the assistance of administrative personnel.
[0036] The above-described steps can be implemented using standard well-known programming techniques. The novelty of the above-described embodiment lies not in the specific programming techniques but in the use of the steps described to achieve the described results. Software programming code which embodies the present invention is typically stored in permanent storage. In a client/server environment, such software programming code may be stored with storage associated with a server. The software programming code may be embodied on any of a variety of known media for use with a data processing system, such as a diskette, or hard drive, or CD-ROM. The code may be distributed on such media, or may be distributed to users from the memory or storage of one computer system over a network of some type to other computer systems for use by users of such other systems. The techniques and methods for embodying software program code on physical media and/or distributing software code via networks are well known and will not be further discussed herein.
[0037] It will be understood that each element of the illustrations, and combinations of elements in the illustrations, can be implemented by general and/or special purpose hardware-based systems that perform the specified functions or steps, or by combinations of general and/or special-purpose hardware and computer instructions.
[0038] These program instructions may be provided to a processor to produce a machine, such that the instructions that execute on the processor create means for implementing the functions specified in the illustrations. The computer program instructions may be executed by a processor to cause a series of operational steps to be performed by the processor to produce a computer-implemented process such that the instructions that execute on the processor provide steps for implementing the functions specified in the illustrations. Accordingly, FIGS. 1-2 support combinations of means for performing the specified functions, combinations of steps for performing the specified functions, and program instruction means for performing the specified functions.
[0039] Although the present invention has been described with respect to a specific preferred embodiment thereof, various changes and modifications may be suggested to one skilled in the art and it is intended that the present invention encompass such changes and modifications as fall within the scope of the appended claims.
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The present invention provides a client and server tool that interrogates file sharing attributes of a client/server system from both the client side and the server side. These attributes may include software fireballs, sharing policies, and security attributes. By interrogating the file sharing attributes from both the client and server sides, network access problems emanating from entire side (client and server) can be discovered, and automated solutions can be presented to rectify any problems.
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CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 61/080,466, filed on Jul. 14, 2008, in the United States Patent and Trademark Office, the entire content of which is incorporated herein by reference. The entire content of United States Patent Applications PROCESS AND APPARATUS FOR DRYING AND POWDERIZING MATERIAL (Attorney Docket No: T643-64003; application Ser. No. ______), HEAT RECOVERY AND PRESSURE CONTROL UNIT (Attorney Docket No: T643-64004; application Ser. No. ______), and ENERGY RECOVERY AND TRANSFER SYSTEM AND PROCESS (Attorney Docket No: T643-63990; application Ser. No. ______) filed on Jul. 14, 2009 in the United States Patent and Trademark Office is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates a method and apparatus for sterilizing and deodorizing air.
BACKGROUND OF THE INVENTION
[0003] Animal byproduct meals, fecal material, agricultural fertilizer, corn byproducts, wheat byproducts, wood pulp, and the like are high moisture content materials that may provide a rich source of energy when effectively dehydrated. Further, some of this material should be sterilized and deodorized before being discharged into the environment. However, animal meal contains a high level of moisture. Further, sewage is transported in water and this water must be removed by pressing the sewage, and the solids that remain after the pressing still contain about 70% to about 80% moisture and about 20% solids by weight. Corn byproducts, wheat byproducts, and wood pulp are other examples of materials that are a good source of energy but generally contain too much moisture to be useable as fuel in their raw state. These materials must be dried to about 5% moisture to be a high grade fuel. A large quantity of high temperature air is required to evaporate the moisture from the material, and the air may become contaminated with odors and pathogens from the material.
[0004] Therefore, there is a need for a method and apparatus for sterilizing and deodorizing air.
SUMMARY OF THE INVENTION
[0005] An embodiment of the present invention provides an apparatus for sanitizing and deodorizing air. The apparatus includes: a chamber including an inlet adapted to receive contaminated air, an outlet adapted to transport heated air, a baffle adapted to increase the length of a path traveled by air in the chamber, and an ash removal device adapted to remove ash from the chamber; and at least one combustor, wherein the combustor is adapted to combust a fuel to heat the air in the chamber so that the air is sterilized and deodorized, thereby generating such ash.
[0006] The ash removal device may include a blower adapted to blow the ash to an edge of a floor of the chamber. The blower may include at least one air conduit, and at least one nozzle coupled to the at least one air conduit and adapted to blow the ash to the edge. An opening of the at least one nozzle may be oval-shaped so that air from the nozzle is directed across the floor. The ash removal device may include an auger adapted to transport the ash out of the chamber.
[0007] The at least one combustor may include a combustor adapted to combust powdered organic fuel. The at least one combustor may include an alternate combustor adapted to combust an alternate fuel.
[0008] Another embodiment of the present invention provides a method for sanitizing and deodorizing air. The method includes: receiving contaminated air into a chamber through an inlet; heating the contaminated air in the chamber by combusting fuel with at least one combustor to sterilize and deodorize the air, thereby generating ash, wherein the chamber includes a baffle adapted to increase the length of a path traveled by the air in the chamber; transporting the heated air out of the chamber through an outlet, and removing the ash from the chamber with an ash removal device.
[0009] The removing of the ash may include blowing the ash to an edge of a floor of the chamber with a blower. The blower may include at least one air conduit, and at least one nozzle coupled to the at least one air conduit and adapted to blow the ash to the edge. An opening of the at least one nozzle may be oval-shaped so that air from the nozzle is directed across the floor. The removing of the ash may further include transporting the ash out of the chamber with an auger.
[0010] The at least one combustor may include a combustor adapted to combust powdered organic fuel. The at least one combustor may include an alternate combustor adapted to combust an alternate fuel.
[0011] An embodiment of the present invention provides an apparatus for removing ash. The apparatus includes: a chamber including an inlet adapted to receive air, a combustor adapted to heat the air, thereby generating such ash, an outlet adapted to transport heated air, and a blower adapted to blow the ash to an edge of a floor of the chamber wherein the blower comprises at least one conduit, and at least one nozzle coupled to the at least one conduit and adapted to blow the ash to the edge.
[0012] An opening of the at least one nozzle may be oval-shaped so that a medium from the nozzle is directed across the floor. The chamber may further include an auger adapted to transport the ash out of the chamber.
[0013] Another embodiment of the present invention provides a method for removing ash. The method includes: receiving air into a chamber through an inlet; heating the air in the chamber by combusting fuel, thereby generating such ash; transporting the heated air out of the chamber through an outlet; and removing the ash from the chamber by blowing the ash to an edge of a floor of the chamber with a blower, wherein the blower comprises at least one conduit, and at least one nozzle coupled to the at least one conduit and adapted to blow the ash to the edge.
[0014] An opening of the at least one nozzle may be oval-shaped so that a medium from the nozzle is directed across the floor. The removing of the ash may further include transporting the ash out of the chamber with an auger.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a perspective view of an apparatus for sterilizing and deodorizing air according to an embodiment of the present invention.
[0016] FIG. 2 is a cross-sectional perspective view of an apparatus for sterilizing and deodorizing air according to an embodiment of the present invention.
[0017] FIG. 3 is a flow chart of a process for sterilizing and deodorizing air according to an embodiment of the present invention.
DETAILED DESCRIPTION
[0018] The detailed description set forth below in connection with the drawings is intended as a description of embodiments of a method and apparatus for sterilizing and deodorizing air in accordance with the present invention and is not intended to represent the only forms in which the invention may be constructed or utilized. It is to be understood that the same or equivalent functions and structures may be accomplished by different embodiments that are also intended to be encompassed within the spirit and scope of the invention. As denoted elsewhere herein, like element numbers indicate like elements or features.
[0019] Some materials that must be dried to be a high grade fuel require a large quantity of high temperature air to evaporate the moisture from the material, and the air may become contaminated with odors and pathogens from the material.
[0020] A process for sterilizing and deodorizing air according to an embodiment of the present invention is shown in FIG. 3 . Here, contaminated air enters a chamber through an inlet 100 . The contaminated air is heated in the chamber 110 to a suitably high temperature for a suitably long period to sterilize and deodorize the air. The heating of the air may create ash, either as a result of the combusting of fuel to heat the air or the sterilization of contaminates in the air. For example, the ash may be similar to sand.
[0021] The heated air exits the chamber through an outlet 120 , where the air may be further processed or returned to the atmosphere. The ash is removed from the chamber by an ash removal device 130 .
[0022] An apparatus for sterilizing and deodorizing air according to an embodiment of the present invention is shown in FIGS. 1 and 2 . Here, contaminated air enters a chamber 10 through an inlet 12 . The contaminated air is heated by at least one combustor 24 , 26 .
[0023] In an embodiment of the present invention, a combustor 24 , e.g., a fuel injector or other suitable combustor, combusts powdered organic fuel to heat the air. For example, the powdered organic fuel may be generated from the material, such as sewage, that was dried with the preheated fresh air.
[0024] In an embodiment of the present invention where the material is sewage, the powdered organic fuel combusts at about 1100 degrees C. Once the powdered organic fuel is combusted, the ash left behind is basically sand, which may be utilized in many construction applications.
[0025] For example, the composition of the sand was experimentally found to be as follows:
[0000]
SiO 2
61.4%
Al 2 O 3
14.1%
Fe 2 O 3
5.5%
CaO
4.1%
MgO
1.7%
Na 2 O
3.4%
K 2 O
1.7%
TiO 2
1.0%
Mn 3 O 4
0.10%
SO 3
0.30%
P 2 O 5
4.10%
[0026] In an embodiment of the present invention, an alternate combustor 26 may combust an alternate fuel, such as liquid natural gas or any other suitable fuel, if the combustor 24 is not combusting powdered organic fuel.
[0027] The heating of the contaminated air may combust particulate or contaminates in the air, which may generate additional ash.
[0028] In an embodiment of the present invention, the chamber 10 may be refractory lined. For example, the lining of the chamber 10 may have a hard surface to prevent or reduce ash deposition, such as a hard surface ceramic faced insulation.
[0029] In an embodiment of the present invention, the contaminated air is heated to a suitably high temperature to sterilize and deodorize the air, e.g., to a temperature in a range from about 800 degrees C. to about 850 degrees C.
[0030] In an embodiment of the present invention, the temperature of the air in the chamber 10 may be measured with a thermostat. For example, the thermostat may be positioned at the outlet 14 or any other suitable location.
[0031] In an embodiment of the present invention, the air travels around a baffle 16 . The baffle 16 increases the length of the path traveled by the air in the chamber 10 , thus increasing the length of time that the air is in the chamber 10 . Here, the air in the chamber 10 travels through two passes to travel around the baffle 16 .
[0032] In an embodiment of the present invention, the contaminated air is retained in the chamber 10 for a suitable length of time for the air to be sterilized and deodorized, e.g., for a time period in a range from about one to about two seconds.
[0033] In an embodiment of the present invention, the baffle 16 is horizontally positioned across part of the chamber 10 . For example, the baffle 16 may be positioned so that the cross-sectional area of the chamber 10 through which the air flows or passes beneath the baffle 16 is 50% greater than the cross-sectional area through which the air flows or passes above the baffle 16 . Here, the flow velocity of the air beneath the baffle 16 will be lower than the velocity of the air above the baffle 16 . For example, the flow velocity of the air beneath the baffle 16 will be below the floating velocity of the ash so that the ash will drop out of suspension in the air and fall to the floor 28 of the chamber 10 .
[0034] The heated air exits the chamber 10 through an outlet 14 , where the air may be transported to be further processed or may be released to atmosphere.
[0035] Ash generated by the combusting of fuel and/or the combusting of particulate or contaminates in the air falls to the floor 28 of the chamber 10 . The ash is then removed by an ash removal device 30 .
[0036] In an embodiment of the present invention, the ash removal device 30 is a clean-in-place type device that allows for the removal of ash during the regular operation of the apparatus. Here, the ash removal device may be a blower that blows air, or another suitable gas or other medium, across the floor 28 of the chamber 10 to blow or otherwise move the ash to one edge of the floor 28 .
[0037] In an embodiment of the present invention, the blower includes at least one air conduit 18 and at least one nozzle 20 coupled to the air conduit 18 and adapted to blow the ash to one edge of the floor 28 . For example, the blower may include multiple (e.g., five) air conduits 18 , and multiple (e.g., three) nozzles 20 may be coupled to each air conduit 18 .
[0038] In an embodiment of the present invention, the opening of the at least one nozzle 18 may be oval-shaped with its longer diameter parallel to the plane of the floor so that the air blown through the nozzle 18 blows across the floor. Other shapes for the nozzle 18 suitable to directing air across the floor may also be used. Further, multiple nozzles 18 may be suitably spaced on the floor 28 so that ash is removed from the entire floor 18 .
[0039] In an embodiment of the present invention, the at least one air conduit 18 is coupled to an air supply source 34 . One of ordinary skill in the art will appreciate that the air utilized in the blower may be obtained from various suitable sources. For example, the air utilized in the ash removal device 30 may be air utilized in the processing of the material, or the air may be from some other suitable source.
[0040] In an embodiment of the present invention, the pressure of the air being blown from the ash removal device 30 has a suitable pressure, e.g., a suitably high pressure, to blow the ash to an edge of the floor 28 . For example, the pressure of the air being blown from the blower may be about 12″ wg (inches water gauge).
[0041] In an embodiment of the present invention, an auger 22 , or screw conveyor, is at the edge of the floor 28 where the ash is blown by the ash removal device 30 . The ash may be blown into the auger 22 , where the auger 22 removes the ash from the chamber 10 through an ash outlet 32 . The auger 22 may be powered or rotated by a motor. The auger rotates or removes ash from the chamber 10 at a suitable rate so that ash does not build up in the chamber 10 . Here, the ash may either be taken out of the system or further processed.
[0042] In an embodiment of the present invention, an insulation layer is on the floor 28 around the auger 22 and the ash removal device 30 . For example, the insulation layer may have a thickness so that a top of the insulation layer is just below the nozzle 18 and flush with the top of the auger 22 . For example, the insulation layer may be about eight inches thick, and the top of the insulation layer maybe within about ten mm from the bottom of the nozzle 18 .
[0043] In an embodiment of the present invention, the auger 22 has a hollow shaft into which air may be drawn to cool the auger 22 and/or the ash.
[0044] In an embodiment of the present invention, a conduit is sealed to the inlet 12 for the delivery of contaminated air, and another conduit is sealed to the outlet 14 for the removal of heated air.
[0045] Although the present invention has been described through the use of exemplary embodiments, it will be appreciated by those of skill in the art that various modifications may be made to the described embodiments that fall within the scope and spirit of the invention as defined by the claims and their equivalents appended hereto. For example, aspects shown above with particular embodiments may be combined with or incorporated into other embodiments.
|
An apparatus for sanitizing and deodorizing air. The apparatus includes: a chamber including an inlet adapted to receive contaminated air, an outlet adapted to transport heated air, a baffle adapted to increase the length of a path traveled by air in the chamber, and an ash removal device adapted to remove ash from the chamber; and at least one combustor, wherein the combustor is adapted to combust a fuel to heat the air in the chamber so that the air is sterilized and deodorized, thereby generating such ash.
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FIELD OF THE INVENTION
[0001] An all weather platform with self supporting flexible containment enclosure system for compromised shallow to deep water offshore oil and gas well systems and, other types of marine subsurface hydrocarbon emissions, operated as a submersible capable floating platform with attached co-located floating flare system, providing a means for the effective collection, containment and presentation of liquid and gaseous emissions for safe and efficient removal.
[0000]
References Cited
U.S. Patent Documents
4,283,159
August 1981
Johnson
4,290,714
September 1981
Strange
4,358,218
November 1982
Graham
4,531,860
July 1985
Barnett
5,114,273
May 1992
Anderson
5,195,842
March 1993
Sakow
BACKGROUND OF THE INVENTION
[0002] Oil leakage and or other environmentally sensitive hydrocarbon emissions originating from varied underwater compromised locations, including natural events, need to be addressed quickly and effectively to minimize damage. The longer the delay to respond and provide effective remediation for these situations, may cause unintended and exponential problems across economic, environmental and societal realms.
BRIEF DESCRIPTION OF THE INVENTION
[0003] The principle object of the invention is to provide a “life jacket or insurance” for the offshore oil and gas production industry and other responders with the advent of a readily deployable, effective and responsive system for compromised offshore subsurface wellheads, pipelines and associated systems or underground fissures to address the collection, containment and the presentation of the material emissions to responsible collection vessels that can manage and remove the product until the breached integrity has been corrected.
[0004] A featured object and embodiment of the floating platform if required, is the ability to perform submergence and resurfacing actions. The action to submerge said floating platform addresses increased levels of reliability and survivability to avoid heaving seas during hurricanes, tropical systems, other surface disturbances and or threats including potential above surface flammable situations.
[0005] The aforementioned feature places the platform safely below the surface at a desired depth where there is minimal or no turbulence providing minimal stress to the floating platform and the containment enclosure system and enabling the continuation of the containment activities of liquid material and the porting of gaseous material ensuring a significantly higher level of mission success.
[0006] Another object of the invention is the control, reduction or elimination of potential methane hydrates that may potentially block pipelines, risers and other processing or containment equipment, particularly when the product is under pressure and is combined with water frequently causing methane ice and sludge to form with the potential of creating production related issues. Reductions in methane icing and sludge is accomplished by an immediate pressure reduction and isolation from the water by the boundary barrier of the containment enclosure. This method provides an adequate volumetric chamber for any hydrates to reduce in volume by their naturally changing state by out gassing during ascent and benefiting by the lack of pressure in the containment enclosure.
[0007] The ship or tending vessel would either moor directly alongside the floating platform containment and collection system with appropriate bumpers or ideally be held at a distance from the ship(s) or tender(s) by lines and or outriggers. The management of the liquid and gaseous products may be ported and transferred to ship(s) or tenders(s) for storage and or flaring of the gaseous material.
[0008] Another subordinate feature of the invention required for gaseous emissions, is the included alternative flaring floating structure to distance the ported gaseous material away from the floating platform and other vessels in the area and to flare or burn off the gaseous material in a safe and low profile fashion in lieu of an appropriate vessel to stay on station to provide such capabilities.
[0009] Another feature of the invention is the volumetric capacity capabilities of the self supporting flexible enclosures that enables the enclosures to be partially evacuated by a crude carrier and to depart from the location with potentially a sufficient amount of time having lapsed before another crude carrier is required to be on station, to again partially evacuate the self supporting flexible enclosure system. A crude carrier vessel does not need to constantly be on station as reserve capacities are built into the floating platform containment enclosure system based on flow rates being contained.
[0010] The systems in this invention have foremost in priority by design, the ergonomic interfaces, safety considerations for personnel and the operations of underwater ROV s to efficiently install, manage and, manipulate the deployed system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 Top view of an all weather system floating platform.
[0012] FIG. 2 Side view of an all weather system floating platform.
[0013] FIG. 3A Front view of a flexible containment enclosure panel section.
[0014] FIG. 3B Front view of terminators to support upper and lower sections.
[0015] FIG. 3C Front view of terminators for an external accessory terminator.
[0016] FIG. 3D Flexible containment enclosure interior compression seal view.
[0017] FIG. 3E Flexible containment enclosure exterior compression seal view.
[0018] FIG. 4A Side view of I connection component for containment enclosures.
[0019] FIG. 4B Side view of Y connection component for containment enclosures.
[0020] FIG. 4C Side view of the I connection component with barrier enhancement.
[0021] FIG. 4D Side view of the Y connection component with barrier enhancement.
[0022] FIG. 4E Side view of multiple Y connection layers.
[0023] FIG. 4F Side view of multiple I connection layers.
[0024] FIG. 5A Illustrates a deployed system—partial view of moorings, PONBADs.
[0025] FIG. 5B Expands on the PONBAD attachment method and terminators.
[0026] FIG. 6A View of a deployed self supporting flexible enclosure terminus.
[0027] FIG. 6B Typical terminus showing the containment panel connection plate.
[0028] FIG. 6C Typical terminus top view of containment panel connection plate.
[0029] FIG. 7A Side view of multiple enclosure lower section terminus and ports.
[0030] FIG. 7B Side view of terminus showing containment panel connection plate.
[0031] FIG. 7C Top view of containment panel connection plate.
[0032] FIG. 8 Side view of multiple enclosure top section bridge.
[0033] FIG. 9A Side view of suspended flexible enclosure terminus over a fissure.
[0034] FIG. 9B Side view of terminus weighted panel skirt.
[0035] FIG. 10A Side view of Floating Flare Platform.
[0036] FIG. 10B Top view of Floating Flare Platform.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Drawing Group 1 and Discussion
[0037] FIG. 1 provides a top view and illustrates a floating platform 1 structure.
[0038] The flotation vessels 1 A are major components and foundation of the floating platform 1 to build upon and provide the attachment of other systems and components. The requirements for enhanced structural integrity and reliability in the design and fabrication is paramount with the flotation vessels 1 A including all aspects of the floating platform 1 , subordinate components and systems.
[0039] Preferably the structural metal embodiments of this invention utilize significant amounts of 5086 marine grade aluminum alloy and is constructed in such a manner as to eliminate or minimize the movement of connected adjacent structural sections or components and potential creation of fatigue points.
[0040] A featured embodiment of the floating platform 1 is a capability to submerge for a prolonged period and to resurface when required. This submergence capability provides an increased level of reliability for said floating platform 1 enabling the avoidance or minimal impact due to heaving seas prior to and the duration of hurricanes, tropical systems, other surface disturbances or threats, including, but not limited to potential above surface flammable situations.
[0041] The aforementioned feature places the platform 1 safely below the surface at a desired depth where there is minimal or no turbulence providing less stress to said floating platform 1 and subordinate systems that it supports, continuing the containment activities of the liquid material and the venting of gaseous materials thereby ensuring a significantly higher level of mission success.
[0042] The flotation vessels 1 A that support the floating and submersible platform 1 preferably contain a plurality of interior bulkheads, baffles and interfaces for the controlled and specific movement of liquid or gas to provide the desired buoyancy required and to enhance the stability of the floating platform 1 by the uniform distribution and controlled movement of liquid ballast to preclude instability due to agitation and external movements by varying sea conditions.
[0043] The flotation vessels 1 A may be made from aluminum, steel, PVC or other materials that prove to be adequate in performance and application and of other shapes and dimensions.
[0044] The floating platform structure 1 and flotation vessels 1 A preferably are constructed substantially from materials to include a super corrosion resistant marine grade aluminum 5086 alloy, 316 stainless steel fasteners and or other appropriate materials.
[0045] Other materials may be considered providing varying levels of structural integrity include steel, fiberglass, plastic, thick wall PVC enclosures and or other types of fabricated vessels and or bladders to include a suitable control system to enable the floating platform 1 to selectively stay surfaced or to become a submersible platform 1 being able to withstand such elements the system may be exposed to for prolonged durations either surfaced or submerged.
[0046] The preferred embodiment describing the Control System Logic and Ballast Management is provided in FIG. 11 . The controls and support systems may be mounted within a watertight enclosure 9 FIG. 1 with the appropriate ingress and egress connections to facilitate air, water, power and control functions. The controls may be manually or remotely controlled by internal and or external actions in respect to the said enclosure 9 FIG. 1 and the required functions therein.
[0047] The action of submergence is performed by enabling logic function S 2 FIG. 11 to activate and open valves to displace the air within the flotation vessels 1 A FIG. 1 and to replace said air by the ingress of ballast water by means with such an amount as to achieve the desired displacement and buoyancy values within said flotation vessels 1 A FIG. 1 obtaining the proper depth or draft required for the floating platform 1 FIG. 1 when at such time, the logic condition S 2 in FIG. 11 is disabled.
[0048] The opposite action enabling logic function S 1 in FIG. 11 to perform the action of surfacing or a rising function is the egress of ballast water being displaced with pressurized air to achieve the level of buoyancy required and at such time the logic condition S 1 in FIG. 11 is disabled and the valves would be deactivated and closed.
[0049] The aforementioned preferred ballast management for the floating platform 1 FIG. 1 may be locally or remotely controlled and operated by the use of one or more of the following systems and components: a battery storage system, telemetry signaling control, switches, manual valves, electric solenoid valves, pneumatic valves, hydraulic control valves, check valves, filters, hoses, pipes, tubes and pumps for introducing into or removing from the floating platform 1 FIG. 1 buoyant tanks with air or other gaseous material from compressed tanks 8 FIG. 1 or a hose to provide such a level of flotation and to control any specific amount of liquid to be introduced or removed to allow a level of submergence required. The compressed air tanks 8 FIG. 1 may be recharged from a built in compressor when the floating platform is surfaced or recharged by external means.
[0050] The one or more watertight equipment enclosures 9 FIG. 1 mounted to the floating platform 1 provide a proper environment and containment of one or many and not limited to the following items inside or externally connected to include check valves, manual valves, inlet ports, outlet ports, solenoid valves that may be electric, hydraulic or pneumatic, both for the control of liquid and gaseous material, relays, switches, pumps, sensors, controllers, telemetry and control circuits along with regulators and power controllers for the storage battery systems.
[0051] Externally and connected to the enclosures 9 FIG. 1 are the following interfaces and not limited to, visual and acoustic navigation aids including mooring lights, strobe lights, solar panel(s) 7 FIG. 1 for charging the storage battery systems, light sensor(s), sensors, antennas and inlet valves for pressurized air tanks 8 FIG. 1 , piping, flexible tubing, ports, valves and filter(s),
[0052] Internally the control systems components are contained within one or more watertight enclosures 9 FIG. 1 mounted to the floating platform 1 FIG. 1 to provide a suitable environment for the containment of batteries, relays, valves, pumps, and associated components that may further include and not limited to devices for the control and operation of visual and acoustic navigation aids, data loggers, sensors, beacons, GPS and control systems, computers, externally connected dusk to dawn light sensors, antennas and solar panel connections for charging of the storage battery systems and other requirements as may be dictated with the appropriate watertight bulkhead interfaces.
[0053] The floating platform upper deck surface 1 B FIG. 1 may be constructed of marine grade approved materials preferably being a grated and or perforated decking to allow water to flow downwardly or upwardly through and to provide additional mounting locations as required for other topside components or devices.
[0054] The preferred embodiments and configuration drawing in FIG. 1 indicate a surface deck 1 B on the floating platform 1 with the ported rigid enclosure 2 having two or more ports for presenting the liquid to a port 5 and or gaseous material to a port 6 , one or more solar panels 7 , compressed gas bottles 8 and, may also include the following and not limited to stanchions with cable or rope for safety, mooring posts, cleats, eye hooks, navigation lights, antennas.
[0055] The apparatus and included embodiments may make use of a plurality of appropriate and sufficient structural members that are welded together and or joined with fasteners providing the structural integrity, seaworthiness required, support and mechanical attachment points for the flotation vessel components 1 A to and comprising the floating platform 1 providing a structural foundation for other mounted and attached devices or systems.
[0056] The floating platform 1 components and all metal materials used in fabrication would be selected, preferably by design requirements as not to be affected by environments to which they are exposed to and, to minimize or eliminate any and all potential fatigue points caused by movement or abrasion.
[0057] The embodiments may further contain such additional mechanical and mooring connection points on other surfaces of the floating platform 1 to include tethered lines, mooring lines and or mountings for other suspended and or elevated devices.
Drawing Group 2 and Discussion
[0058] FIG. 2 illustrates a side profile of the floating platform 1 that incorporates a rigid enclosure 2 mounted to the floating platform 1 structure providing an opening below for the downwardly directed self supporting flexible containment enclosure 1 E to be attached from and within the inner circumference of said rigid enclosure 2 and additionally provides the ability to port either liquid product 5 and or gaseous product 6 individually for the extraction of such materials from the flexible containment enclosure 1 E and said rigid enclosure 2 .
[0059] FIG. 2 side profile does not show the Solar Panels indicated in FIG. 1 .
[0060] The gaseous emission component is percolated, expelled or bubbled and breaks away from the liquid surface caused by a vertical upward flow and distribution of dispersed gaseous bubbles contained within the self supporting flexible containment enclosure 1 E and such gaseous material is constrained within the rigid enclosure 2 and vented to a port 6 for proper and safe handling.
[0061] The liquid emission component is provided to a separate port 5 from a submerged conduit 3 below the water surface of sufficient depth and preferably to be additionally guyed 4 and or supported by members for enhanced rigidity and structural integrity.
[0062] FIG. 2 . also illustrates the PONBAD devices 20 extended with the tethered support lines 20 A that are normally stowed within the perimeter PONBAD locater buoy support enclosures 10 along with the PONBAD device 20 when the floating platform 1 structure is not submerged.
[0063] When the floating platform 1 is in the submerged mode, the floating PONBAD locater devices 20 are constrained and limited to no further exceed a depth as defined by the length of line 20 A that is attached to the PONBAD 20 and to the submerged platform 1 . The locater suffix to the PONBAD term is a reference to that of being a visual aid where the floating platform is located when submerged.
[0064] The PONBAD buoyant devices 20 connected to the floating platform 1 would be constructed preferably from a 5086 Aluminum Alloy of appropriate dimensions and designed to more than adequately exceed the buoyancy requirements for the total mass of the floating platform 1 and suspended attachments when fully submerged.
[0065] The PONBAD buoyant devices 20 would further require the structural robustness and integrity required of said PONBAD buoyant device that may potentially be exposed to collisions, shock, impact and potentially a flammable situation and thus being able to withstand and survive such exposures repeatedly.
[0066] The aforementioned PONBAD buoyant devices 20 would preferably be attached with lines 20 A using a stainless steel multi-strand cablelaid coated aircraft cable that provides the required strength and flexibility for stowing and reliable self deployment.
[0067] The aforementioned cable assembly 20 A may be a predetermined fixed length or a variable deployed amount such as that contained on a drum or winch; wherein the tethered cable(s) will be attached to a PONBAD 20 buoy of sufficient size and number to provide a buoyancy component to prevent further submergence in depth by the floating platform 1 .
[0068] The preferred embodiment described primarily addresses the ported and separated gaseous material from port 6 away from the floating platform 1 by optional flaring considerations with two preferable methods and options supported, option one is by a separate and integrated flaring system FIG. 10A and FIG. 10B or, two is to hand off to a operator managed support vessel capable of flaring or storage of the material.
[0069] All though not preferable by design or recommended, a flaring tube could potentially be constructed and extended directly from the floating platform 1 in such a manner as to port the gaseous material directly from the rigid enclosure 2 port 6 . This option could be contemplated if the floating platform was of significant size and capabilities as to ensure the safe handling and the required mechanical structure of the connected flare to be considered in association with the additional requirements and activities. At this time it is strongly discouraged.
[0070] The preferable method is supported by a separate and integrated flaring system FIG. 10A and FIG. 10B or handed off to a support vessel for flaring or storage if such a vessel is available on station.
[0071] The preferred embodiment addresses one method for the crude oil liquid product port interface 5 or other liquid material emissions as illustrated in drawing FIG. 2 . where a suction or sump conduit from a tending vessel or a crude carrier tanker or other means would remove the product as required when the volumetric storage capacities of the self supporting flexible containment enclosure 1 E are such that require such removal of material in a timely fashion.
Drawing Group 3 and Discussion
[0072] The floating platform 1 and the rigid enclosure 2 of FIG. 2 have attached from within and suspended downwardly, one or more in line consecutively attached containment enclosure segments 1 E with the material components shown in FIG. 3A , with a primary component preferably being a qualified type of heavy duty geomembrane industrial fabric 14 constructed with the appropriate coating and material thickness to provide a sufficient boundary between liquids containing emissions including a broad range of hydrocarbon liquids and or gaseous products to be segregated from the uncontaminated fresh or sea water marine environment.
[0073] The construction and material of one or more self supporting flexible containment enclosures sections 1 E may be comprised of one or more panel sections and scaled in size and length to accomplish the objectives of containment, volumetric requirements and, the number of such sections that are required to achieve the distance to the target.
[0074] FIGS. 3A , 3 B and, 3 C illustrate a preferable embodiment in the construction and design of one flexible containment enclosure panel section 14 . A self supporting flexible containment enclosure section 1 E may consist of one or a plurality of panel sections 14 connected edge to edge to form one enclosure section and, may be further joined with one or many additional enclosure sections vertically, providing the necessary circumferential size to achieve the length and volumetric requirements.
[0075] The preferred embodiment for the construction of the self supporting containment enclosures 1 E is enhanced by creating a continuous weldment for the panel 14 material side edges when joining panel 14 sections creating a secure and tight seam.
[0076] The application of a support strap 19 folded over and sewn to the panel 14 weldment seam along its length and connecting to terminators 17 to interconnect additional completed containment enclosure 1 E sections and provide the ability to include and connect terminators 18 for other attachments.
[0077] The application of a horizontal seam and weldment to the panel 14 material additionally provides a physical means for attaching a strap and the connecting and mating interface at the top and bottom of the enclosure sections 1 E for the purpose of interconnecting said enclosure sections.
[0078] The top section of panel 14 preferably will use the Y connection 15 FIG. 4B and referenced as 15 as in FIG. 3A and other applicable drawings. The bottom section of panel 14 preferably will use the I connection 16 of FIG. 4A and referenced as 16 as in FIG. 3A and other applicable drawings.
[0079] FIG. 3A illustrates the additional placement of eyelets or grommets 19 A attached periodically along the length of the strap 19 section. The eyelets, grommets and terminators may be provided with tethered loop handles, rings or carabiners attached to allow the ROV systems or others to easily handle, tow and manipulate the self supporting flexible containment enclosure 1 E.
[0080] FIG. 3B further illustrates a strap termination point ( 17 ) using a 316 Stainless Steel or other suitable material comprising a terminator strap connector with a bolt hole for connecting two strap segments 19 by appropriate fasteners. FIG. 3C illustrates an additional 316 Stainless Steel or suitable material protruding termination 18 at a right angle with a bolt hole for connecting by an appropriate fastener, and is affixed to provide for the attachments of a PONBAD and or a mooring rode system as shown in 20 , 21 and 22 of FIG. 5 . The strap terminators 17 and terminators 18 are fashioned preferably in having a small radius formed on all edges externally, including the internal cutouts for the strap materials or other objects to minimize any abrasion.
[0081] An enhanced corner section interface sealing method for the self supporting flexible containment enclosure is described below.
[0082] FIG. 3D illustrates an interior corner compression assembly 141 constructed preferably using a thick wall aluminum plate 14 C or other rigid material, and fabricated in such a manner along the longitudinal length to create a partial and uniform elliptical end. The exterior surface 14 C having a secured gasket material 14 A covering and further using a single or plurality of fastening members 14 B to mate said interior compression assembly 141 with a similar exterior corner compression assembly illustrated as 14 E FIG. 3E .
[0083] FIG. 3E illustrates an exterior corner compression assembly 14 E constructed preferably using a thick wall aluminum plate 14 D or other rigid material, and fabricated in such a manner along the longitudinal length to create a partial and uniform elliptical end. The interior underside surface having secured a corresponding gasket material 14 A covering the interior surface 14 D with corresponding holes provided for the previously mentioned fastening members to attach both assemblies with appropriate fasteners and provide the compression for both gasket material surfaces to each side of the flexible enclosure panel corner section located and placed between the assemblies 14 E FIGS. 3D and 14I FIG. 3E .
[0084] FIG. 3E and FIG. 3D are designed to be easily positioned and connected to each other during deployment, providing for an effective flexible gasket if required.
[0085] The interior radius of the arc or the interior diameter for assembly 14 E of FIG. 3E will be such that it will fit without gaps over the exterior radius or the outside diameter of assembly 141 of FIG. 3D .
Drawing Group 4 and Discussion
[0086] FIG. 4A and FIG. 4B indicate a preferred embodiment in this invention for the connection and closure of the self supporting flexible containment enclosures and other attachments. The embodiments are characterized by the symbolic shapes of the letter Y and is referenced as 15 typically and shown as a detail ( 14 , 15 ) FIG. 4B and, the letter I and is referenced as 16 typically and shown as a detail ( 14 , 16 ) FIG. 4A .
[0087] The two details noted typically as 15 and 16 are used in multiple discussion points and are referenced in other drawings or figures as a form of connection.
[0088] A connection member for a lower panel 14 section is represented by the letter symbol I with the hook material 16 of FIG. 4A . A connection member for the upper portion of the adjoining lower panel 14 section is represented by the letter symbol Y with the loop material 15 of FIG. 4B .
[0089] A connection for a Y ( 14 , 15 ) shaped design having the loop material sewn or physically attached to both inside flaps of the top inside of the Y ( 14 , 15 ) formed symbol descending downward to the bottom of the Y ( 14 , 15 ) symbol where the two upright lines protruding outwardly form an angle at the lower section and joined together. The Y ( 14 , 15 ) formed symbol may include additional material within the interior of panel material 14 or adjacent, to provide additional interfacing thickness, stiffening and stability.
[0090] A corresponding mating portion for the adjoining connecting panel section having the hook material sewn or physically attached to both sides of a vertical member shaped letter symbol I ( 14 , 16 ) that is used to mate with the loop material for the opposing Y ( 14 , 15 ) formed symbol shape. The I ( 14 , 16 ) formed symbol may include additional material within the interior of panel material 14 or adjacent, to provide additional interfacing thickness, stiffening and stability.
[0091] A flat piece of panel material 14 with hook material on both sides of the I ( 14 , 16 ) symbol would then be placed in between the flaps of the loop material inside the Y ( 14 , 15 ) symbol and compressed for closure.
[0092] The example describes a method using a six inch wide section of hook and loop material and illustrates the doubling of shear force, providing an efficient method for connecting and securing the self supporting flexible enclosure sections.
[0093] Example calculations for a Y ( 14 , 15 ) and I ( 14 , 16 ) connection follows below. A single sided application of the hook and loop material may possess 14 psi of separating shear strength. A 6 inch by 1 inch single sided piece of said hook and loop material by itself would have approximately 84 pounds of shear strength. With this method of hook and loop material being affixed and doubled with both sides of the I ( 14 , 16 ) and Y ( 14 , 15 ) shaped inside flaps utilized, the shear force is approximately 168 pounds for a 6 inch by 1 inch piece of mating connection.
[0094] The 168 pounds of shear force would then be multiplied by the linear length of the adjoining section in inches for connection purposes. A six inch wide connection by 140 inches lengthwise would figuratively yield 23,520 pounds of shear force required to separate the two mated panel section surfaces using the Y and I connection method described.
[0095] FIG. 4C illustrates another embodiment in the invention with capabilities and means if required based on the viscosities encountered to significantly reduce or to eliminate seepage of material by the inclusion of a resilient and springy type elliptical, rectangular or other appropriate shape, consisting of a material being a silicon, neoprene or other appropriate type material and may have an outward protruding portion of material formed such that it may be incorporated and secured within or between members of panel material 14 and or the hook material 16 during fabrication.
[0096] FIG. 4D further illustrates the two mating Y ( 14 , 15 ) and I ( 14 , 16 ) components in relative position prior to closure by means of compression. The Y shaped symbol ( 14 , 15 ) in FIG. 4D has a similar type of a flexible, elastic type elliptical or rectangular material being a silicon, neoprene or other appropriate material having a protruding flat edge of material formed such that it may be incorporated and attached between the members of panel material 14 and loop material 15 during fabrication and or may be secured by special adhesives or other methods.
[0097] The membrane material 15 A and 16 A shown in FIG. 4D provide a barrier that is compressed by the adjacent hook and loop material providing a liquid and gas seal.
[0098] Mentioned previously, and an additional embodiment in the configuration of the I and Y connection and closure method may include additional material within the interior of panel material 14 and or between panel material 14 and the hook or loop material attached to provide additional interfacing thickness, stiffening and stability.
[0099] FIG. 4E further illustrates a female mating connection containing multiple members of a loop material for receiving a corresponding male group of mating members of a hook material illustrated in FIG. 4F . Essentially any number or combination of interfacing hook and loop materials and associated external flaps or members may be configured to accomplish a significantly robust closure and sealing method. The method may further entail exterior panels or strips of either a hook or loop and the corresponding material to provide a final seal enclosing a single or a plurality of internal connections.
Drawing Group 5 and Discussion
[0100] In FIG. 5A the quantity, dimensions, material selections and the intended locations for the PONBAD 20 buoyancy attachments are carefully calculated to provide the desired slight positive or negative buoyancy for each section or sections of the self supporting flexible containment enclosure 1 E and other associated attachments.
[0101] The said self supporting flexible containment enclosure sections 1 E can be made of any length with regard to the practicality and limitations of transportation, handling and deployment. The preference for a typical design is approximately a 500 foot section 1 E comprising a weight just over 2200 pounds. Calculations specifically designed for the attached PONBADs 20 , the buoyancy value may be established for a net positive 100 pounds per section, whereas the calculations for the fabrication of the PONBADs 20 could provide any required value of buoyancy.
[0102] The PONBAD 20 requirements are based on exacting calculations of the dimensions and material types required to achieve the desired amount of sufficiency based on F=Vw (Force=Volume Displaced×Weight of the Liquid Medium the buoyancy device is displacing). Considerations are required for the type of material, location of use, environmental, mechanical capabilities, depth requirements and other factors.
[0103] FIG. 5A illustrates an example of a deployed floating platform 1 and rigid enclosure 2 with the self supporting flexible containment enclosure 1 E descending and connected to the targeted area 23 on the seabed 22 being supported periodically along the length by PONBAD 20 attachments. A view is indicated of just one group of mooring lines 21 , where a plurality of mooring lines 21 or distributed groups of said mooring lines 21 may be utilized and determined by situational requirements. Where said mooring lines 21 are connected to suitable anchors 22 A and secured to the seabed 22 .
[0104] The illustration represented in FIG. 5A show an arbitrary number of self supporting flexible containment enclosure 1 E sections and is not limited by the number of said self supporting flexible enclosure 1 E sections.
[0105] If requirements exists for rode mooring lines 21 FIG. 5A or other such additions to the self supporting flexible containment enclosure, the increase in the attached weight may be compensated for by the appropriate sizing of, or additional PONBAD 20 devices attached by terminator 20 B or additional mounting points on terminator 18 as shown in FIG. 5B .
[0106] FIG. 5B further illustrates the connection of the support straps 19 and termination points for the flexible enclosure sections 1 E and the PONBAD 20 with the PONBAD attachment line 20 A and mooring line 21 secured to terminator 18 being mechanically connected to the terminators 17 of said flexible enclosure section panel end illustrated in FIG. 3B and FIG. 3C .
[0107] FIG. 5A further indicates the targeted area 23 that may be further evaluated in detail by FIG. 6A showing said self supporting flexible containment enclosure 1 E bottom terminator section to interface with the compromised situation as an example being a wellhead or a Blow Out Preventer.
[0108] An example for a containment and collection solution addressing a 5000 foot deep, below the surface wellhead failure may be represented by, a self supporting flexible containment enclosure 1 E, comprising of 4 panels, 144 inch width for each with 2 inch seams to form one flexible containment enclosure section 1 E, a quantity consisting of 12-500 foot long sections 1 E with a total length of 6000 feet. Provisions of an extra 20% increase in length account for currents and or slight deviations allowed from being directly on station. The aforementioned configuration provides an approximate capacity of 185,000 barrels plus or 7.7 million gallons plus of liquid product.
[0109] A defined and limited amount of slack is advisable and is readily accommodated by using additional sectional lengths that are adequate for the application, anticipated weather conditions, water column current strengths, drag force coefficients, depths and location. Anticipations, planning and subsequent deployment considerations increase the reliability of the total system.
[0110] The floating platform 1 FIG. 5A can optionally stay on station by one or more partial rode mooring 21 or guy lines 21 descending to the sea floor and by means of anchoring 22 A said mooring lines 21 connected or affixed to the sea floor 22 by means of many known techniques such as dead weight, mushroom or screw in moorings. The mooring lines 21 may provide the appropriate counteractions to water current and wind drift issues. The anchor 22 A and mooring lines 21 may also be affixed at predetermined distances as required along the length of the self supporting flexible containment enclosure 1 E or where the PONBAD 20 FIG. 5B terminators 18 FIG. 5B are located. A partial rode system of anchoring would be appropriate for the self supporting flexible containment enclosure 1 E as illustrated in FIG. 5A where one or more sets of lines 21 specified will maintain an on station position if not tethered or moored to surface tenders or ships.
[0111] Another embodiment of the floating platform 1 system is that it can be guyed, moored and or make use of attached thrusters or like type motors operated by a control system to further assist in keeping the floating platform 1 on station in a surfaced or submerged state.
Drawing Group 6 and Discussion
[0112] One example of a preferred embodiment of a containment enclosure terminator section interfacing with a compromised well-head or BOP is illustrated in the drawing FIG. 6A .
[0113] The well head or BOP riser assembly could very well be cutoff leaving a short stub where the ROV could easily place the terminator FIG. 6A by using the handles 28 and manipulate said terminator FIG. 6A over the riser stub, and securing said terminator FIG. 6A by tightening the tapered pointed set bolts 30 onto the riser stub section.
[0114] The ROV would remove a plug preferably made of paraffin or rubber or other such material from the lower conduit section 27 of the terminator FIG. 6A prior to securing it on the BOP riser stub. The purpose of a plug is to prevent the unnecessary entrance of water into the containment enclosure 1 E during its deployment and descent. Any entrapped air in the containment enclosure 1 E during the deployment would rise to the surface and said containment enclosure 1 E would essentially be collapsed and ready to engage the containment of the compromised emissions.
[0115] Prior to deployment the assemblage of the end point terminator panel enclosure may be accomplished topside by the following method.
[0116] The terminator components 26 , 27 , 28 , 29 and 30 shown in FIG. 6B form a vertical terminator conduit assembly. The terminator panel enclosure section assembly 25 FIG. 6A is placed on the deck with the opening at the bottom center of the panel enclosure located such that the vertical terminator conduit assembly is placed upright within the opening in the center of said panel enclosure 25 FIG. 6A .
[0117] The panel enclosure section is pulled substantially upward toward the panel terminator plate 26 FIG. 6B until it will not ascend any further. This is due to the intentional design of the opening of said terminator panel enclosure section assembly 25 FIG. 6A being smaller in circumference compared to said terminator plate 26 FIG. 6B . This design method will provide a sufficient seal with the split plates 26 C FIG. 6D and the compression straps 26 D FIG. 6D secured by fasteners 26 B indicated by the plurality of mounting positions 26 A illustrated in the underside view of plate 26 FIG. 6C .
[0118] There may be a number of variations on the attachment and the assemblage of the end point termination assembly without deviating from the general intent of the invention and designs.
[0119] The example illustrated provides a relatively simple and robust assembly that can be quickly configured topside before deployment.
[0120] The terminator plate 26 is designed to be extremely smooth with rounded edges to eliminate wear and chaffing and is larger in length and width than the circumferential lower opening of the terminator panel material 25 that is secured to said terminator plate 26 .
[0121] FIG. 6A further illustrates an upper section eye bolt 29 providing for the attachment of guy lines 24 A between the terminator conduit and the tapered flexible containment enclosure to reduce any unnecessary forces between the vertical terminator conduit 27 and the panel enclosure 25 assembly.
[0122] FIG. 6A further illustrates a lower section eye bolt 29 providing for the attachment of guy lines 29 A between the terminator conduit 27 and the object that the terminator is connected to, such as a BOP riser stub to further provide redundancy to the tapered pointed set bolts 30 on the terminator connection where 29 A may be mounted to any secure attachment point on the lower portion of the BOP.
[0123] The aforementioned completed terminator assembly FIG. 6A would typically be constructed and integrated topside before deployment and then attached to the first flexible containment enclosure sections 1 E with FIG. 6A as the first section to go submerged with the suggested and previously mentioned paraffin or rubber plug.
Drawing Group 7-8 and Discussion
[0124] An additional embodiment of this invention is found in the bridging capabilities illustrated in FIG. 7A and FIG. 8 where combining below the floating submersible platform 1 FIG. 1 a plurality of self supporting containment enclosures 1 E connected together providing a significant increase in the volumetric capacity of liquid product and or the ability to interface with other distribution systems.
[0125] Additionally by crafting such enclosures to perform the function of multiple self supporting flexible containment enclosures 1 E being ported apart and then combined again to form a single enclosure at a sufficient depth below and attached in a normal singular enclosure section to the floating platform 1 FIG. 1 provides a significant increase storage capacity. Additionally, a number of configurations with multiple self supporting flexible containment enclosures sections 1 E are able to be achieved including connections to one or many terminus sections.
[0126] The aforementioned expansion capabilities of the self supporting flexible containment enclosures 1 E connected in parallel are illustrated in FIG. 7A being the lower section interface and FIG. 8 being the upper section interface to combine the two said self supporting containment enclosures back to a single said self supporting flexible containment enclosure being connected to the floating platform 1 illustrated in FIG. 1 .
[0127] The additional said self supporting flexible containment enclosures 1 E may be attached to a lower terminator section as is shown in FIG. 7A being provisioned with a tee section 27 A or manifold with valves 27 B to enable and control the flow to a plurality of additional connections and said pair of self supporting flexible containment enclosures 1 E to be connected and secured in a parallel fashion.
[0128] A flanged port 27 D and valve 27 B from the tee 27 A or manifold could be configured to present the liquid and gaseous material product to a conduit routed to a new or existing sea floor distribution system line. A plurality of ports and valves connected to the tee or manifold would enable additional volumes of material to be contained and presented to the floating platform 1 FIG. 1 or temporarily stored in larger bladder enclosures.
Drawing Group 9 and Discussion
[0129] FIG. 9 further illustrates yet another preferred embodiment in this invention with a lower terminator 25 section connected to the self supporting flexible containment enclosure section 1 E to address a sub sea floor fissure with liquid and or gaseous emissions and, providing an extensible method of positioning and securing the terminator enclosure section.
[0130] The said self supporting containment enclosure section 1 E may terminate to a larger enveloped canopy enclosure 25 terminus of any practical size, area and height where said enveloped canopy enclosure terminus 25 is held in position by mooring lines 21 connected to termination points 24 and to 22 B a magnetic attachment device that are magnetically engaged by a lever action to the positioned plates of steel 22 C or iron, steel I-Beams, or other ferromagnetic material including steel or iron distribution pipes. The magnetic attachment devices when engaged can provide upwards of 4000 pounds of attachment force.
[0131] FIG. 9A further illustrates the attachment of guy lines 24 A between the lower and upper terminators 24 incorporated in the enveloped canopy enclosure 25 terminus.
[0132] The guy lines 24 A reduce unnecessary tension and forces on said enveloped canopy enclosure 25 terminus enclosure between the lower terminus sea floor mounting points and the self supporting containment enclosure 1 E assembly.
[0133] The tension and forces can be calculated, constructed and minimized by the exacting values in the PONBAD devices used in the overall self supporting flexible containment enclosure system.
[0134] Another embodiment of the invention is illustrated in FIG. 9B with the accessory to perform as a weighted skirt attachment 15 FIG. 9B using the hook and loop mating and closure method and connecting to 16 FIG. 9A . The attachment comprising of 15 A and 15 FIG. 9B is fabricated with a sleeved opening along the length of the skirt attachment providing the ability to place a chain or other weighted material within said sleeve 15 A FIG. 9B .
[0135] The extensibility of the sea floor 25 terminus enclosure example is further enhanced by the ability to incorporate the connection of additional panel segments illustrated in FIG. 4A and FIG. 4B by using the Y and I mating connection method and attaching said additional segments to the extending connection point 16 FIG. 9 . along the perimeter of said sea floor terminus enclosure and constructing outwardly to achieve a larger coverage area if required.
[0136] The flexible containment enclosure 1 E may incorporate various forms of one or many connected terminations to optimally address the type of and, method required to attach various receiving type adapters for gaseous and or liquid product that need to be contained and removed by the self supporting flexible containment enclosure 1 E. This may include sub-surface weights to hold down and position larger enveloped areas, an example of such may include one or many sub-sea floor fissures.
[0137] The attached termination devices may be tethered, anchored or suspended, to provide a physically, mechanically, magnetically, connecting or enveloping a targeted area.
[0138] An additional embodiment may also include a requirement for a termination section containing a remotely powered rotating vane, spiral or multi-bladed system or a means to include the introduction and injection of a widely dispersed gaseous material to create and assist in providing the required updraft or movement of material within the self supporting flexible containment enclosure from very low pressure or seeping emission locations possibly having varied material types and viscosities to deal with.
Drawing Group 10 and Discussion
[0139] FIG. 10A and FIG. 10B illustrate a preferred embodiment being a subordinate accessory feature as referred to in Claim 12 in this invention providing for an integrated apparatus to flare or to burn off such gaseous emissions that are directed from the gaseous port 6 in FIG. 1 or FIG. 2 by the movement of such gaseous material from said port 6 through a tethered flexible conduit 46 FIG. 10A to the floating flare buoyant system 40 FIG. 10A located at an approximal distance on the water surface 40 W. The flexible conduit 46 FIG. 10A may also have attached to it other transport lines to convey liquid, air, gas and electricity. An additional and primary consideration is for the purpose of enhancing the electrical grounding and to minimize static and to provide lightning protection and providing a means to produce the water spray if required for cooling the flare tube and the electrical powering of navigation aids and or other requirements.
[0140] The tethered conduit 46 FIG. 10A is supported by one or plurality of guyed hangers 47 and collars 47 A connected to flotation enclosures 40 where the gaseous emissions are further directed and connected into conduit 42 and flare conduit 41 that are supported by a plurality of structural members 50 FIG. 10B being substantially submerged and positioned under the waterline.
[0141] The flare conduit 41 of FIG. 10A and FIG. 10B emerging from the waterline in a vertical fashion and said flare conduit 41 of FIG. 10A being further secured below with structural members 50 FIG. 10B and a plurality of structural members or guy lines 47 FIG. 10A connected and or secured to a plurality of connected collars 47 A FIG. 10A or with fasteners to the lower portion of conduits 41 and 42 of FIG. 10A .
[0142] The upper and exposed member of conduit 41 FIG. 10A indicates yet another feature embodiment and may include an outwardly beveled collar 45 attached to preclude substantial amounts of cooling water from entering said conduit 41 by the use of optional water spray 49 nozzles or jets mounted on the floating flare platform and directed toward and for the purpose of cooling said vertical conduit member 41 .
[0143] If required, said water jets or nozzles that project a spray 49 of water would obtain their water supply and pressure from a hose or conduit member 48 FIG. 10A that may be powered by a pump on the floating flare system platform 40 or as illustrated in FIG. 10A from the floating platform 1 of FIG. 1 or may be powered by external vessels or by other sources.
[0144] Another feature in the embodiment may also include a tapered annulus 43 as illustrated in FIG. 10A connected to a conduit 44 for the removal of any condensate by means of air pressure or a submerged pump 44 A including an optional check and or solenoid valve that may be operated periodically by a hall effect sensor or high impedance switch or other such means that detects the presence of accumulated liquid and will operate only for such time to remove said liquid.
[0145] Another feature in the embodiment not shown, may include a remotely controlled battery operated spark igniter to ignite the flare function adjacent to the opening of conduit 41 connected to the beveled collar 45 where such igniter electrodes are mounted near the opening to initiate said flare and the actual spark generating control is mounted away from any damaging heat source.
Drawing Group 11 and Discussion
[0146] FIG. 11 is primarily a logic drawing, it does however show a cutaway side view of one flotation vessel 1 A containing two ports, the port with the long vertical conduit being the water port and the port with the short vertical conduit is the air port with both mounted from the top of the buoyancy vessel 1 A. Solenoid valves that are not active are normally closed with the logic condition being 0 or not enabled.
[0147] The action and process of submergence is performed by enabling logic function S 2 in FIG. 11 will cause activation of a valve to displace the air within the flotation vessels 1 A FIG. 1 and to replace the air with the ingress of such an amount of ballast water by a pump and a valve to control specifically the amount of displacement and buoyancy within the said flotation vessels 1 A FIG. 1 to achieve the proper depth or draft desired for the floating platform 1 FIG. 1 when at such time the logic condition S 2 in FIG. 11 is disabled and the associated valves and the pump would be deactivated or closed.
[0148] The opposite action enabling logic function S 1 in FIG. 11 to perform the action of surfacing or a rising function is the egress of ballast water being displaced with pressurized air to achieve the level of buoyancy required and at such time the logic condition S 1 in FIG. 11 being disabled and the associated valves would be deactivated or closed.
[0149] The two ports mentioned may be mounted at other locations if required, preferably within the interior perimeter of the floating platform 1 FIG. 1 plurality of flotation vessels 1 A FIG. 1 and to the exterior upper vertical surface of said flotation vessels 1 A FIG. 1 mid-position located at the highest location on the vertical surface.
[0150] In accordance with the aforementioned and described embodiments of the present invention there may be inclusions, omissions or alterations that may be made without departure from the intended spirit thereof.
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A rapidly deployable flexible enclosure system for the collection, containment and presentation of hydrocarbon emissions from compromised shallow or deepwater oil and gas well systems, pipelines, including subsea fissures.
The flexible containment enclosure can accommodate any depth and adapt to any collection terminator configuration required.
The flexible containment enclosure system is connected to the floating platform and supported by positive offset neutral buoyancy attachment devices.
The floating platform may be assembled onshore and towed, ferried or assembled on site.
Liquid and gaseous materials are directed to separate ports for removal from the rigid enclosure cavity integrated within the floating platform. Gaseous emissions may optionally be directed to a tethered floating flare system.
The systems all weather capabilities include the ability to submerge for extended durations and resurface on demand by transmitted signal or manually providing operations during hurricanes, heaving seas, and other surface threats.
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This application is a continuation of application Ser. No. 08/361,005 filed Dec. 21, 1994 now abandoned which is a continuation of application Ser. No. 08/099,676 filed Jul. 29, 1993 now abandoned.
BACKGROUND OF INVENTION
This invention is related to the preparation of hydrofluorocarbons (HFCs). Specifically, it relates to the manufacture of 1,1,1,3,3-pentafluoropropane, CF 3 CH 2 CF 2 H, which is referred to in the art as HFC-245fa.
HFCs are of current interest due to their potential to replace ozone depleting CFCs and HCFCs which are used in a variety of applications including refrigerants, propellants, blowing agents, and solvents. The compound CF 3 CH 2 CF 2 H has physical properties, including a boiling point of about 14° C., which makes it particularly attractive as a blowing agent or propellant. Its ability to function in a manner similar to CFC-11 (CCl 3 F, bp 24° C.), a well known aerosol propellant at the time, was noted by Smith and Woolf in U.S. Pat. No. 2,942,036 (1960). Ger. Often, DE 3,903,336, 1990 (EP 381 986 A) also states (using a generic formula) that CF 3 CH 2 CF 2 H may be used as a propellant or blowing agent. The use of HFC-245fa as a heat transfer agent is also mentioned in Jpn. Kokai Tokyo Koho JP 02,272,086 (Chem. Abstr. 1991, 114, 125031q).
1,1,1,3,3-Pentafluoropropane was first made by the reduction of CF 3 CCl 2 CF 2 Cl over a palladium catalyst (Smith and Woolf, U.S. Pat. No. 2,942,036, 1960). Materials exiting the reaction zone including CF 3 CH 2 CHF 2 , CF 3 CH═CF 2 , CF 3 CCl═CF 2 , and unreacted starting material. The desired CF 3 CF 2 CF 2 H was formed in yields up to about 60%, but the source of the starting material was not disclosed. Reduction of 1,1,1,3,3-pentafluoropropene was disclosed by Knunyants et al. (Chem. Abstr., 1961, 55, 349f). The yield of pentafluoropropane was 70%. The only other preparation of CF 3 CF 2 CF 2 H we are aware of, is its formation, in low yield, during the elemental fluorination of tetrahydrofuran (Burdon et al., J. Chem. Soc., C, 1969, 1739).
It is the object of this invention to provide a means of manufacturing 1,1,1,3,3-pentafluoropropane which is economical and amenable to large scale, using readily available raw materials. The process of this invention involves three basic steps, of which any step or combination thereof is novel in the art.
The three steps of the process of this invention are as follows:
1) the formation of CCl 3 CH 2 CCl 3 by the reaction of CCl 4 with vinylidene chloride;
2) the conversion of CCl 3 CH 2 CCl 3 to CF 3 CH 2 CF 2 Cl by reaction with HF in the presence of a fluorination catalyst, selected from TiCl 4 , SnCl 4 or mixtures thereof; and
3) reduction of CF 3 CH 2 CF 2 Cl to CF 3 CH 2 CF 2 H.
Each step is conducted onder process conditions, i.e. temperarture and pressure, sufficient to produce te desired product as discussed herein.
DETAILED DESCRIPTION
The telomerization of vinylidene chloride by reaction with CCl 4 is known in the art and has been studied in some detail. The telomerization reaction produces compounds of the formula CCl 3 (CH 2 Cl) n Cl, where n varies as needed for the products desired. The telomerization of vinylidene chloride can be initiated by several means, but initiation with metal salts, particularly of copper, has distinct advantages for the process of this invention. The copper salts are believed to initiate the reaction by first reacting with CCl 4 to produce a trichloromethyl radical which then combines with vinylidene chloride, initiating the telomerization (see for example, Assher and Vofsi, J. Chem. Soc., 1961, 2261 for a discussion of the mechanism). The copper salts also terminate the telomerization by chlorine atom transfer to the growing radical chain. Thus, the chain lengths are shortened considerably, compared to e.g. peroxide initiated telomerizations. For the reactions of interest here, telomers having 3 to 9 carbon atoms are obtained in execellent yield. Some control of the telomer distribution is feasible by controlling the reaction conditions, notably the ratio of CCl 4 to vinylidene chloride and the type of copper salt used (see for example Belbachir et al., Makromol. Chem. 1984, 185, 1583-1595). Thus it is possible to obtain CCl 3 CH 2 CCl 3 with very little higher molecular weight telomers (see Example 1).
A variety of catalysts have been used in telomerization processes. To a large degree, many of these telomerization catalysts, including mixtures thereof, can be equivalent, and the choice of catalyst depends on cost, availability, and solubility in the reaction medium. For the telomerization reaction of this invention, it was discovered that salts of copper and iron are preferred. Overall, for the reaction of interest here, the more preferred catalysts are cuprous chloride, cupric chloride, or mixtures of the two or cuprous iodide. The amount of catalysts used in the telomerization reaction is at least about 0.1 mmol, and preferably, about 0.1 to about 50 mmol, per mole of saturated halogenated hydrocarbon (e.g., CCl 4 or CCl 3 CH 2 CCl 3 ) used. At very low concentrations, the reaction rate may be unacceptably slow, and very high catalyst concentrations may be wasteful due to the fact that the solubility limit may have been reached at even lower catalyst to CCl 4 ratios. Consequently, the more preferred amount of catalyst is about 1 to 20 mmol, per mole of saturated halogenated hydrocarbon.
It is also noted that a co-catalyst can be used in the telomerization process. Amines may be employed as co-catalysts, preferably in concentration of 1 to 10 moles per mole of metal catalyst (i.e. copper salt). Such amine co-catalysts include alkanol amines, alkyl amines and aromatic amines, for example ethanolamine, butyl amine, propyl amine, benzylamine, pyridine and the like.
The ratio of CCl 4 to vinylidene reactant will substantially alter the degree of polymerization ,i.e. average value of n for compounds of the formula CCl 3 (CH 2 Cl) n Cl. Thus, for example, if the desired product has only one more --CH 2 CCl 2 -- unit than the starting material, the ratio of CCl 4 (or CCl 3 CH 2 CCl 3 ) to vinylidene chloride should be relatively high (at least about 2, and preferably, about 2 to 5), so that higher molecular weight telomers are minimized. If the desired product has two or more --CH 2 CCl 2 -- units than the starting material (e.g. CCl 3 (CH 2 CCl 2 ) 2 Cl from CCl 4 ), smaller ratios of CCl 4 to vinylidene chloride (about 0.3 to 1) should be used. The same rationale is used for a system employing vinylidene fluoride.
Useful temperatures for the telomerization reaction range from about 25° to about 225° C., preferably 80° to about 170° C., so that, depending on reactant concentrations and catalyst activity, convenient reaction times will vary from a few hours to about one day. More preferred temperatures are in the 125° to 140° C. range.
Finally a variety of solvents can be used. Any solvent which is inert to the reactants and the desired product can be used. Illustrative of such are acetonitrile, dimethylsulfoxide, dimethylformamide, tetrahydrofuran isopropanol, and tertiary butanol. We prefer acetonitrile due to its low cost, stability, easy recovery via distillation, and ability to dissolve sufficient amounts of inorganic catalyst salts. Primarily for the latter consideration, the amount of solvent is preferably from about one fourth to two thirds of the total volume, and more preferably one third to one half of the total volume. Otherwise, the amount of dissolved catalyst may be relatively low, or the output of product per run will be adversely affected due to a dilution effect.
In the second step, CCl 3 CH 2 CCl 3 is fluorinated to provide CF 3 CH 2 CF 2 Cl. Previously, CF 3 CH 2 CF 2 Cl has been prepared, along with CF 2 ClCH 2 CF 2 Cl, by fluorination of CCl 3 CH 2 CF 2 Cl with antimony halides (Chem. Abstr., 1981, 94: 174184u). This method, however, is unsuitable for large scale manufacture due to the cost of the fluorinating agent. The preparation of CF 3 CH 2 CF 2 Cl by the BF 3 -catalysted addition of HF to CF 3 CH═CFCl is also known (R. C. Arnold, U.S. Pat. No. 2,560,838; 1951), but the source of CF 3 CH═CFCl was not disclosed. We have also found that HF alone or gave relatively low yields of the desired CF 3 CH 2 CF 2 Cl.
Surprisingly, fluorination (of CCl 3 C 2 H 2 CCl 3 ) with HF is the presence of either TiCl 4 , or SnCl 4 as catalysts can provide the desired CF 3 CH 2 CF 2 Cl in synthetically useful yield. Due to the temperature required for this reaction about (75° to 175° C., and, more preferrably, 115° to 135° C.,) the reactions are conducted under pressure. The pressure may be controlled by release of by-product HCl, during the reaction process in order to provide a margin of safety if needed depending on the limitations of the equipment being used. We have found it convenient to operate at pressures of about 150 to 500 psig. The upperlimit for pressure is generally a limitation of the available equipment. The reactor consisted of a stirred autoclave fitted with a packed column attached to a condenser maintained at 0° to -20° C. Excess pressure (HCl) is vented through a valve at the top of the condenser into a scrubber. At the end of the heating period, the product and remaining HF are vented through a valve on the autoclave head, which in turn is connected to an acid scrubber and cold traps to collect the product. Under fluorinated materials, such as CF 2 ClCH 2 CF 2 Cl may be recycled along with CCl 3 CH 2 CCl 3 in subsequent batch runs.
While both TiCl 4 and SnCl 4 gave similar yields of the desired CF 3 CH 2 CF 2 Cl, TiCl 4 is preferred due to its lower cost, lower toxicity, and availability in bulk.
The mole ratio of HF to organic should be about 4/1 to about 20/1, preferably 5/1 to about 9/1. Since over-fluorinated material, CF 3 CH 2 CF 3 is generally not desired, it is more advantageous to allow more under-fluorinated material (which can be recycled) in the crude product. Over-fluorinated product is keep low by smaller HF/organic ratios and lower reaction temperatures. The reaction temperatures range from 75° to about 150° C., while the preferred temperatures range from about 115° to about 135° C. Under these conditions, the reaction times range from about one to about 25 hours, and can be monitored by the rate of pressure (HCl) increase.
In the last step, CF 3 CH 2 CF 2 Cl is reduced to 1,1,1,3,3-pentafluoropropane, which is unknown in the art. The reduction can be conveniently accomplished in a continuous flow system by passing vapors of CF 3 CH 2 CF 2 Cl, along with hydrogen, over a catalyst.
The latter include nickel, palladium, platinum and rhodium, which are usually supported on inert materials, such as carbon or alumina. These catalysts are available commercially and generally can be obtained having 0.5 to 20% by weight of the metal on the support material. More commonly, loadings of 0.5 to 5% weight percent are employed. Examples include 1% palladium on activated carbon granules and 0.5% platinum on 1/8" alumina pellets. The more preferred catalyst is palladium due to its lower cost compared to either platinum or rhodium.
While it is most convenient to operate to atmospheric pressure, this is not required. Both subatmospheric pressures or pressures up to 100 atmospheres may be used, the latter especially in batch operations.
In the fluorination step it may be preferable to utilize a solvent, such as methanol, ethanol and acetic acid. A base may also be beneficial to neutralize the HCl produced. Any neutralizing agent can be used, e.g. sodium hydroxide, potassium hydroxide, sodium acetate and sodium carbonate.
Useful temperatures for vapor phase reductions range from about 100° to 350° C., more preferred ranges are 150° to 250° C.
Based on reaction stoichiometry, the required ratio of hydrogen to organic is 1 mole of organic is 1 mole of hydrogen per mole of organic. From 1 to about 50 times the stoichiometric ratio may be used. A ratio of 2 to 30 times the stoichiometric amounts can be used with satisfactory results.
The most desirable conditions for the reduction will vary and will depend, in part, on the activity of the catalyst (which depends on the type of metal used, its concentration on the support material, and the nature of the support material), and the contact or residence time in the reactor. Residence times may be adjusted by changing the reaction temperature, the catalyst volume, and the flow rates of hydrogen and/or organic material to be reduced. Useful contact times range from about 0.1 sec to about 2 minutes, In the present case, more preferred contact times range from about 10 to 40 seconds at 200°-225° C. and atmospheric pressure.
In the reduction of CF 3 CH 2 CF 2 Cl at atmospheric pressure and at temperatures of about 100° to 325° C., both CF 3 CH 2 CF 2 H and CF 3 CH 2 CF 2 Cl are generally present in the reactor effluent stream. The ratio of CF 3 CH 2 CF 2 H to CF 3 CH 2 CF 2 Cl increases with increasing reaction temperature. Continuous operation at high temperatures (>250° C.) is not very advantageous, due to potential gradual loss of the original catalyst activity. Consequently, the preferred method to achieve relatively high conversions of CF 3 CH 2 CF 2 Cl to CF 3 CH 2 CF 2 H is to increase the contact time, or equivalently, to recycle the product stream until the desired conversion is obtained. After separating the desired CF 3 CH 2 CF 2 H from CF 3 CH 2 CF 2 Cl, the CF 3 CH 2 CF 2 Cl may be fed into the reactor again.
EXAMPLE 1
Preparation of CCl 3 CH 2 CCl 3
A teflon-lined, magnetically stirred autoclave (575 mL capacity) was charged with 150 mL CCl 4 , 150 mL CH 3 CN, 0.51 g CuCl and 0.51 g CuCl 2 dihydrate. The autoclave was closed and evacuated briefly. Vinylidene chloride (57.7 g, 0.595 mol) was added via syringe and a rubber septum over a ball valve on the autoclave. The autoclave was then pressurized with nitrogen to 20 psig at room temperature. The mixture was heated over 1.75 h to 150° C and maintained at 150° C. for 2 h. The stirrer speed was maintained at 350 rpm. After cooling the autoclave and contents to about 15° C., the contents were removed, diluted with 400 mL water, and the organic layer separated. The aqueous layer was extracted with 50 mL methylene chloride, and the combined organic layers washed with 100 mL brine. After drying (Na 2 SO 4 ), the organic layer was concentrated by rotary evaporation to give 140.4 g crude product. Distillation at 2.7 mm Hg gave 114.3g CCl 3 CH 2 CCl 3 , bp 63°-65° C. (77% yield based on vinylidene chloride added). Its purity by GC analysis was 99.97%. 1H NMR (CDCl 3 ): singlet at 4.17 δ.
EXAMPLE 2
HF Fluorination with TiCl 4
A 600 mL, magnetically stirred, model autoclave fitted with a condenser (maintained at -10° C.), was evacuated, cooled to about -40° C., and charged with 0.6.9 g (0.036 mol) TiCl 4 followed by 64 g (0.255 mol) CCl 3 CH 2 CCl 3 , and 102.5 g (5 mol) HF. The temperature was increased to 120° C. and maintained at that temperature for a total of 22 h. During the heating period, pressure in excess of 400 psig was periodically vented to an aqueous KOH scrubber which was attached to two -78° C. cold traps. At the end of the heating period, the remainder of the autoclave contents were slowly vented. The cold traps contained 36.1 g material which by GC analysis, contained 14.5% CF 3 CH 2 CF 3 and 84.0% CF 3 CH 2 CF 2 Cl, corresponding to a yield for CF 3 CH 2 CF 2 Cl of 69%.
EXAMPLE 3
HF Fluorination with SnCl 4
In the manner and apparatus described in Example 2, 63.5 g CCl 3 CH 2 CCl 3 , 101.4 g HF, and 13.5 g (0.052 mol) SnCl 4 were heated to 125° C. for 23.5 h. The cold trap contained 41.5 g material, which by GC analysis contained 13.4% CF 3 CH 2 CF 3 , 66.3% CF 3 CH 2 CF 2 Cl, and 20.3% CF 3 CH 2 CFCl 2 , corresponding to a yield for CF 3 CH 2 CF 2 Cl of 65%. The crude products from Examples 3 and 4 were combined and distilled to give 99.4% pure (GC) CF 3 CH 2 CF 2 Cl, bp 27°-30° C. 1H NMR (CDCl 3 ): δ3.2 tq (J=9 and 12 Hz).
EXAMPLE 4
Reduction of CF 3 CH 2 CF 2 Cl --at 200° C.
The reactor used in this Example consisted of an electrically heated glass column containing a catalyst bed comprised of a mixture of 10 cc 1% Pd on activated carbon (4-8 mesh) and 15 cc glass helices. Hydrogen was passed over the catalyst at 140 cc/min and CF 3 CH 2 CF 2 Cl was introduced at a rate of 2.25 g/h. The reaction temperature was 200° C. The material exiting the reactor was collected in a cold trap and consisted of approximately 1/3 CF 3 CH 2 CF 2 H and 2/3 unreacted CF 3 CH 2 CF 2 Cl by GC analysis,
EXAMPLE 5
Reduction of CF 3 CH 2 CF 2 Cl at 225° C.
Example 4 was repeated, except that the reaction temperature was increased to 225° C. The volatile material which collected in the cold trap consisted, by GC analysis, of 51% CF 3 CH 2 CF 2 H. The remainder was primarily unreacted CF 3 CH 2 CF 2 Cl. Distillation gave CF 3 CH 2 CF 2 H, bp 14° C. the recovered CF 3 CH 2 CF 2 Cl was recycled to provide additional CF 3 CH 2 CF 2 H.
EXAMPLE 6
Reduction of CF 3 CH 2 CF 2 Cl at room temperature
An autoclave was charged with a solution of 10 g KOH in 60 mL methanol, 0.5 g 1% Pd on carbon, and 25 g (0.15 mol) CF 3 CH 2 CF 2 Cl. Stirring was begun and the autoclave pressurized to 250 psig with hydrogen. After 20 hours, the contents were cooled to 0° C. and excess hydrogen was bled off. The remaining volatile organic material was then transferred to a cold receiver under vacuum. Distillation of the crude material so obtained gave CF 3 CH 2 CHF 2 .
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This invention is related to the preparation of hydrofluorocarbons (HFCs). Specifically, it relates to the manufacture of 1,1,1,3,3-pentafluoropropane, CF 3 CH 2 CF 2 H (HFC-245fa) by the steps comprising (1) the formation of CCl 3 CH 2 CCl 3 by the reaction of CCl 4 with vinylidene chloride; (2) the conversion of CCl 3 CH 2 CCl 3 to CF 3 CH 2 CF 2 Cl by reaction with HF in the presence of a fluorination catalyst, selected from TiCl 4 , SnCl 4 or mixtures thereof; and (3) reduction of CF 3 CH 2 CF 2 Cl to CF 3l CH 2 CF 2 H.
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BACKGROUND OF THE INVENTION
Egg trays and incubator trays as well as trays used in the baking industry and elsewhere are generally formed of metallic or plastic materials. In order to recycle such trays and maintain them in a clean sanitary condition, they must be washed from time to time. However, most plastic and metallic materials are hydrophobic with the result that washing liquids tend to cling to the articles in the form of droplets instead of spreading out in a thin film for ready evaporation. It is therefore particularly difficult to dry plastic or metallic trays after washing and the duration of any conventional drying operation employed is materially prolonged. As a result, the drying step in the conveyor system unduly delays the unit cycle time of the entire system.
It is, of course, common practice to remove water from clothing, liquid slurries and other materials by centrifuging operations using a perforated drum into which the material to be dried is charged as exemplified by U.S. Pat. Nos. 930,898 and 3,300,871. However, such equipment is not adapted for use in drying plastic or metal trays or containers. In particular such equipment is not capable of use with a conveyor for supplying and removing articles to be dried.
Previous methods of drying these trays include a high speed blower for exposing the trays to hot air, but this system was quite time consuming and required a considerable output of energy to both heat the air and run the blower. The present invention therefore accomplishes not only a shortening of the drying cycle time but also substantially decreases energy consumption.
SUMMARY OF THE INVENTION
The present invention may be used with a conveyor or other similar transporting device which is adapted to carry an egg tray or other tray-like receptable into a drying zone. Positioned below the empty wet tray in the drying zone, is a carriage assembly which has a tray support member in the upper portion thereof. The tray support member is adapted to contact the undersurface of a tray by studs or the like protruding therefrom such that when the entire carriage assembly is moved upward, the stud members protrude into the indentations in the irregularly shaped undersurface of the egg trays. The bottom surface of most standard egg trays are usually structured with irregular protrusions and indentations such that the stud members can be chosen in an orientation to mate therewith or, in the alternative, special trays can be chosen to facilitate use with a chosen configuration of studs.
The support member is rotatably mounted within a body such that when the body is moved upwardly, the studs in the tray support member contact the wet trays and lift them out of the drying zone and up into a hood which is positioned immediately above the drying zone. Once the wet tray is in the hood, the support member is rotated at a speed sufficient to expell any liquid from the tray and fling it outward against the inside surface of the hood. After the rotated member stops, the body is then moved downwardly and the tray is replaced in the drying zone and carried away by the conveyor.
The support is mounted upon a shaft which is rotatably mounted in the body and is secured at the lower end thereof to the rotational control means. The rotational control means causes rotation of the shaft, the support and the tray whenever the body is in the up position and additionally provides a braking force to reduce the speed of rotation of the support member to bring it quickly to a predetermined position. The rotational control means preferably includes an orientation means for assuring replacement of the tray into the spin station in identical rotational position every time. To accomplish these varied functions, the rotational control means preferably is an electromagnetic structure.
A vertical moving means such as a pneumatic cylinder or the like can be mounted to the body to cause vertical movement of the support and tray. When used within a total conveyor system, the actuation of the vertical movement means will be synchronized with the washer or other conveyor assembly upstream in the system from the drying station and with a stacking station downstream from the drying station.
BRIEF DESCRIPTION OF THE DRAWINGS
While the inventon is particularly pointed out and distinctly claimed in the concluding portions herein, a preferred embodiment is set forth in the following detailed description which may be best understood when read in connection with the accompanying drawing, in which:
FIG. 1 is a plan view of a preferred embodiment of the present invention as used with an entire conveying system;
FIG. 2 is an end view of a portion of the embodiment of the present invention shown in FIG. 1;
FIG. 3 is an end view of the carriage and rotational control assembly of another embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention comprises an apparatus and process for drying plastic or metallic trays which can be used in association with or without a conveying system such as an egg conveying system as shown in FIG. 1. A pair of oppositely traveling conveyors 2 and 4 are connected by a reversing ramp 6 such that the egg trays 8 which may have dirty eggs deposited therein are carried by conveyor 2 to ramp 6 and then urged onto oppositely moving conveyor 4. The eggs are dirty since they pass directly from the chicken houses to the trays and are often covered with feathers, blood and chicken waste. These trays and eggs proceed to egg removal station 10 where the suction elements 12 lift the eggs from the trays 8 and place them on egg collecting conveyor 14 for further processing such as washing etc. The empty and dirty trays 16 are thereafter carried by conveyor 4 to tray removal station or transfer ramp 18 where the trays are moved onto conveyor 20 in the direction shown by arrows 22.
The trays 24 proceed to wash station 26 which can be adapted to accept two rows of dirty trays 24 as shown in FIG. 1. Any convenient washing method can be utilized at a washing station 26 such as a standard spraying system using high pressure washing liquid and soaps. After washing, the wet trays travel to spin drying station 28 and thereafter to stacker 30. Preferably the movement of transfer conveying, spin drying, stacking and washing are synchronously operated to achieve a rapid and effective total overall system.
Within the spin station 28 is a tray receiving area or chute area generally designated as 32. The empty egg tray 34 is carried by conveyor 20 from the washing station 26 and placed in the tray receiving area 32 while still wet. Since plastic materials resist air drying due to the hydrophobic nature of its surface, a spin drying apparatus is utilized which expells the water by centrifugal force. When properly located in the area 32 the tray 34 is positioned directly above the carriage assembly which comprises a rotatable support member 36 and a body section 38. When moved upwardly the support 36 is adapted with studs 37 to lift plastic trays 34 out of the tray receiving area and up into the hood 40. It should be appreciated that similar mechanical expedients can be utilized to drop the tray into a lower hood rather than lift the tray up into a hood. The support 36 and therefor the tray 34 are then rotated at a speed sufficient to expell any droplets of washing or rinsing solution which remain on the surface of the tray 34. Since all spinning is conducted within the hood 40, all water circumferentially sprayed from the support and the tray is collected by the interior surface of the cylindrical hood and drains therefrom as a waste material.
The support member 36 is fixedly mounted to a shaft 42 which is rotatably mounted within body 38. In this embodiment the shaft 42 includes a lower section 44 which protrudes below the body 38 and is rigidly mounted on a rotational control means generally designated as 46. By means of shaft 42 this rotational control means achieves the desired rotational speed of tray support 36 as well as tray 34. The rotational control means can comprise a field member 48 and an armature member 50 to which shaft 42 and 44 are affixed. The distance between elements 48 and 50 can be chosen to be extremely small to thereby increase the electromagnetic forces therebetween. As shown in FIGS. 2 and 3, the electromagnetic rotational control means can be secured firmly to the body by conveniently available fastening devices such as bolts 52. In this configuration the rotational control means 46 will travel upwardly with the entire carriage assembly when the egg tray 34 is being lifted up into hood 40.
At full vertical extension the shaft 42 and support 36 will be caused to initiate rotation. The control means 46 causes braking of the rotational velocity of the carriage and then proper orientation and alignment when this velocity is zero. Then the carriage starts to move downward and the tray 34 is returned to the drying zone 32.
Vertical movement of the carriage and rotational control means is effected by a vertical moving means, generally designated as 52, which preferably is a pneumatically powered device having an air cylinder 54 which houses an air piston rod 56. The cylinder 54 may be secured to a bottom flange 58 through a coupling 60. The flange 58 is firmly mounted upon a stationary chasis element 62. Piston rod 56 is connected to a top flange 64 through a coupling 66. Flange 64 is secured to a shoulder 68 of body 38 such that as piston rod 56 is pneumatically extended, the entire carriage and rotational control assembly will be urged upwardly.
In a typical structure, the vertical moving means 52 will be positioned in the center of the drying station 28 as shown in dotted outline 70 of FIG. 1. Therefor, the shoulder 68 will form a fixed brace between two such bodies 38, which are individually associated with one or two lines of trays 24 which are passing to spin station 28. Thus, the vertical moving means is positioned equidistant between each of the two identical carriage assemblies. To further clarify the view in FIG. 2, it should be appreciated that the shoulder 68 will extend to the right as shown by the arrow 72 and form the shoulder element of another identical carriage assembly, rotational control assembly, and chute and hood structure. To maintain stability in the orientation of the carriage with respect to the area 32 and hood 40 during vertical movement, a plurality of guides in the form of vertically extending pins 74 are provided which protrude through apertures 76 in the support plate 75. As the carriage is moved in the vertical direction, the body is guided by the pins 74 such that lateral wobble is prevented during extension and retraction of the piston rod 56. It must be expected that some degree of lateral wobble will occur in any piece of mechanical apparatus as large as present in this invention and therefor the couplings 60 and 66 in the pneumatic cylinder linkage can be chosen to be flexible connections such as hinges or even universal joints.
In a typical embodiment the conveyor 20 will carry the trays 34 through the drying zone 32 by entering immediately adjacent to the wash station 26 and exiting out the opposite side of the spin dryer generally designated as 28 to the stackers 30. The conveyor may be moved in cyclical manner such that the conveyor movement is halted when a tray is placed directly above the carriage in the pickup position in zone 32. In the halted position the arrangement of the washer 26 is positioned such that a washing operation can take place upon a tray positioned within the washer during operation of the spin drying process on another tray.
During operation an empty egg tray will enter the zone 32 and be advanced to a position directly above the carriage and then halted by the conveyor. As soon as the conveyor stops moving the pneumatic cylinder 54 will be actuated to urge piston rod 56 upward. In response thereto the body 38 will move vertically and carry therewith the control means 46 and the carriage as shown in FIG. 2 as well as another identical assembly which is mounted to the shoulder 68 at the position indicated by arrow 72. During the upward movement cycle, the studs 35 will contact the bottom surface of tray 34 and lift it off the conveyor. This complete assembly will proceed to the fully extended vertical position in which the tray 34 will be located within hood 40. At this time, the motor or rotational control means will be activated to cause rotation of shaft 42 and consequently support 36 and tray 34.
The configuration of the mating sections of the under surface of the trays and the configuration of the studs 35 are preferably related such that during the spinning operation, the tray will remain positioned on the support. In this respect, studs 35 should be oriented to protrude into the identations 39 which are present in the bottoms of standard egg trays.
The spinning operation usually takes merely a few seconds to reach the desired maximum speed which is on the order of 1750 revolutions per minute. In order to decrease the cycle time per operation, the rotational control means can be adapted to act as a electromagnetic braking means to increase the rate of deceleration of the rotating element. Also, each time the shaft is about to stop, the field elements 48 can repeatedly place armature 50 in the same relative alignment as it was when the tray was picked up and thereby the tray 34 will be replaced into the drying zone 32 in the same orientation as shown when it was picked up.
When the rotational speed of the shaft 42 stops, the cylinder 54 allows piston rod 56 to collapse downward until the tray 34 is replaced onto the conveyor 37 in the same orientation (exactly the same or 180° out of the rotation which achieves the same relative position) due to the orientation capability of rotational control means 46. The return of the tray to its exact previous position is further assured by the apertures 76 which slide up and down on the pins 74 and thereby maintain the vertical orientation of the vertically reciprocating assembly. After depositing the tray upon the conveyor 20 in the chute 32, this assembly proceeds downwardly to the bottom position to a point where the piston rod 56 has fully collapsed within the cylinder 54. Now the dryer is in the position preparatory to initiating another cycle.
While particular embodiments of this invention have been shown in the drawings and described above, it will be apparent, that many changes may be made in the form, arrangement and positioning of the various elements of the combination. In consideration thereof it should be understood that the preferred embodiments of this invention disclosed herein are intended to be illustrative only and not intended to limit the scope of the invention.
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Equipment for use in washing articles such as egg trays and the like wherein the articles after being washed are moved by a conveyor to a drying zone for being picked up by a rotatable carriage by which they are lifted into a hood and rotated at high speed to discharge water or other washing liquid therefrom. The movement of the conveyor and the rotation of the carriage are coordinated to start and stop the rotation of the carriage so as to dry one article after another as it is advanced to the drying zone and onto the carriage by the conveyor. The rotatable carriage includes a system for orientation of the trays or the like for discharge to the conveyor and a brake assembly for quickly decreasing the rotational velocity of the carriage.
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RELATED APPLICATION
This application is a continuation of application Ser. No. 09/075,813, filed on May 12, 1998, now U.S. Pat. No. 6,090,144.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a knee prosthesis.
2. Description of Related Art
The knee joint or articulation may be considered two condyloid joints, lateral and medial, between femur and tibia, and one arthrodial joint between the patella and the femur. The chief movements at the knee are flexion (decrease in the angle between two bones) and extension (increase in the angle between two bones) and rotation. These movements can be referred to as asymmetrical in that the movement of the left knee joint differs from the movement of the right knee joint. The individual displacement of the right and left knee joint during flexion and extension is also asymmetrical.
The knee joint combines a wide range of movement in one direction with a great weight-bearing capacity and considerable stability. The superior end of the tibia is the largest weight-bearing surface of the human skeleton. Its two articulating condyles or menisci are thickened and convex on their peripheral borders, and thin, concave, and free on their opposite borders. They are connected anteriorly and peripherally by transverse ligaments, and by part of the capsule of the knee joint, to the head of the tibia. These menisci lend some stability to the joint. Additional stability is given by the strong anterior and posterior cruciate ligaments which connect the tibia and femur inside of the joint and cross each other like the letter “X”. The anterior cruciate ligament extends from the front of the intercondylar eminence of the tibia, upward and backward to the medial side of the lateral condyle of the femur. The posterior cruciate ligament extends from the posterior intercondylar fossa of the tibia, upward and forward to the lateral side of the medial condyle of the femur. The stability of the knee is secured by the muscles of the thigh, the joint capsule (system of tendons and ligaments that pass over the knee joint) and four ligaments—the two lateral ligaments and two cruciate ligaments.
Injuries to the knee are very common. The injuries often result to the menisci or the ligaments that hold them. Significant research and development in recent years has been directed to the development of knee prostheses that are reliable, i.e., prostheses that are not subject to unacceptable dislocation, not subject to bearing failure, not subject to loosening from the bones, and which provide a substantial duplication of the motion of the natural joint. In general, knee replacement prostheses are indicated for bi-cruciate retention application, unicondylar applications and for posterior cruciate retention applications. Other prostheses are indicated where neither posterior nor anterior cruciate ligaments are retained. The types of knee prostheses available can generally be classified as fixed prostheses and mobile prostheses.
Generally, either a fixed or mobile knee prosthesis involves a femoral component, a meniscal component, and a tibial component. The meniscal component generally is seated between the femoral component and the tibial component, each mated with the femur and tibia, respectively. The reference to either fixed or mobile prostheses generally concerns the meniscal component. In the fixed system, the meniscal component is fixedly attached to the femur or tibia. In the mobile system, prior art knee prostheses offer some limited range of symmetrical motion for each of the right and left knee joint prosthesis.
The fixed prosthesis is generally used on patients where there is severe damage to the femur and/or tibia around the knee joint or where neither the posterior or anterior cruciate ligaments of the knee joint cannot be retained. The fixed prosthesis generally does not allow any movement of the motion of the femur on the tibia, e.g., the “sliding-rolling” motion of the femur on the tibia. Instead, the meniscal component is fixed to the tibial component and/or the femoral component. This fixation generally includes screw and bands. The fixed prosthesis also does not allow correction for a misplacement in rotation of the tibia component. Finally, the fixed prosthesis contributes to accelerated wear of the generally polyethylene meniscal component.
Mobile, i.e., sliding or moving, knee prostheses generally accommodate some movement by the meniscal component or the tibial component during knee joint movement. As noted above, the individual biomechanical displacement of the right and left knee joint during flexion and extension is asymmetrical. The natural meniscal displacement of a knee joint during extension, for example, is approximately 15 millimeter (mm) for the external (lateral) meniscus and 5 mm for the internal (medial) meniscus.
The general interest in the mobile prosthesis is to obtain a dimunition of the constraint on the meniscal component by delivering a proper positioning of the meniscal component on the tibial component during and after movement. In most instances, the motions of prior art prostheses are limited to a simple rotation (flexion/extension) which is in some instances combined with anterior-posterior clearance. These protheses generally offer no lateral translation or anterior-posterior translation of the components, e.g., the meniscal component. The range of motion of the components for the displacement is limited generally because the guidance is accomplished on rails or the motion around a fixed axis. The existing mobile motions are also symmetrical and non-conforming to human biomechanical movements. For example, most mobile knee prostheses have an axis of rotation about which movements of flexion and extension take place[lace]. In these systems, the displacement of the meniscal component about the axis of rotation is symmetrical. For example, displacement of the external (lateral) portion of the meniscal component is equivalent to the displacement of the internal (medial) portion for extension and flexion. During flexion, this type of symmetrical displacement will cause the femoral component to strike and erode the internal meniscal component and reduce flexion.
Prior art mobile prostheses also offer no rotational misalignment correction, such as, for example, where the meniscal component is misaligned between the femoral and tibial components. This is especially true in those systems that provide guide rails in the seat of the tibial component for placement of the meniscal component. The mobile prostheses further provide a lack of simple transformation toward a fixed tibial plate in cases of lateral instability, risk of incorrect positioning, luxation of the meniscal component, and rupture of the posterior cruciate ligament. In this instance, additional surgery is necessary to place a fixed knee prosthesis.
The invention seeks to address the limitations inherent in prior art knee prostheses.
SUMMARY OF THE INVENTION
A fixed knee prosthesis and a mobile knee prosthesis are disclosed. The knee prosthesis includes a tibial component and a meniscal component adapted to be engaged to the tibial component in an asymmetrical manner. The mobile knee prosthesis of the invention is adapted for and addresses the biomechanical movements of a right and a left knee joint or articulation separately. In one embodiment, the tibial component of the knee prosthesis of the invention includes a tibial seat including a Y-shaped cavity having a first arm and a second arm intersecting at a base. The meniscal component includes a meniscal plate selectively configured about a sagittal plane for either a right or left knee and a protuberance extending from a bottom surface of the meniscal plate.
The protuberance of the meniscal plate has a shape adapted to conform in some measure with the base and one of the first arm and the second arm of the cavity of the tibial seat, according to whether the prosthesis is adapted for the right or left knee joint of the patient. In one embodiment, the engagement of the protuberance of the meniscal component with the cavity of the tibial component is such that the protuberance is free to move within a portion of the cavity in conformance with the biomechanical movements of a natural knee joint, e.g., larger displacement of exterior (lateral) meniscal component than the interior (medial) portion of the meniscal component. In this manner, the invention provides a knee prosthesis or system with asymmetrical movements that emulate the asymmetrical movements of natural biomechanics.
An alternative embodiment of the invention describes a meniscal component including a meniscal plate including a Y-shaped cavity having a first arm and a second arm intersecting at a base. In this embodiment, the tibial component includes a tibial seat and a protuberance extending from a top surface of the tibial seat. The protuberance of the tibial component has a shape adapted to conform in some measure with the base and either the first arm or the second arm of the cavity of the meniscal plate according to whether the replacement is for the right or left knee joint of the patient. Accordingly, in one embodiment, the protuberance of the tibial component and the shape of the meniscal component, particularly about a sagittal plane, is specific for a left or a right knee joint prosthesis. In one embodiment, the cavity of the meniscal component is adapted to move about the protuberance in the tibial component in accordance with the asymmetrical movements of natural biomechanics.
Additional features and benefits of the invention will become apparent from the detailed description, figures, and claims set forth below.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side sectional view of a knee prosthesis in accordance with an embodiment of the invention.
FIG. 2 is an exploded side sectional view of a knee prosthesis in accordance with an embodiment of the invention.
FIG. 3 is a top perspective view of the tibial component of the knee prosthesis with a Y-shaped cavity in accordance with an embodiment of the invention.
FIG. 4 is a top or superior side view of the left meniscal component of a knee prosthesis in accordance with an embodiment of the invention.
FIG. 5 is a bottom or inferior side view of the left meniscal component of a knee prosthesis with a protuberance adapted to conform with a portion of the Y-shaped cavity of the tibial component in accordance with an embodiment of the invention.
FIG. 6 is a top or superior side view of the right meniscal component of a knee prosthesis in accordance with an embodiment of the invention.
FIG. 7 is a bottom or inferior side view of the right meniscal component of a knee prosthesis with a protuberance adapted to conform with a portion of the Y-shaped cavity of the tibial component in accordance with an embodiment of the invention.
FIG. 8 is a top cross-sectional view of the right meniscal component of a knee prosthesis inserted into the Y-shaped cavity of the tibial component in a first position in accordance with an embodiment of the invention.
FIG. 9 is a top cross-sectional view of the right meniscal component of a knee prosthesis inserted into the Y-shaped cavity of the tibial component in a second position in accordance with an embodiment of the invention.
FIG. 10 is a top cross-sectional view of the right meniscal component of a knee prosthesis inserted into the Y-shaped cavity of the tibial component in a third position in accordance with an embodiment of the invention.
FIG. 11 is a top or superior side view of a meniscal component for a fixed knee prosthesis with a Y-shaped protuberance adapted to conform to the Y-shaped cavity of the tibial component in accordance with an embodiment of the invention.
FIG. 12 is an exploded side sectional view of a knee prosthesis in accordance with a second embodiment of the invention.
FIG. 13 is a bottom or inferior view of the meniscal component of a knee prosthesis with a Y-shaped cavity in accordance with a second embodiment of the invention.
FIG. 14 is a top perspective view of the tibial component of a left knee prosthesis with a protuberance adapted to conform with a portion of the Y-shaped cavity of the meniscal component in accordance with a second embodiment of the invention.
FIG. 15 is a top perspective view of the tibial component of a right knee prosthesis with a protuberance adapted to conform with a portion of the Y-shaped cavity of the meniscal component in accordance with a second embodiment of the invention.
FIG. 16 is a top perspective view of the tibial component of a knee prosthesis with a Y-shaped protuberance adapted to conform with the Y-shaped cavity of the meniscal component in accordance with a second embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The invention relates to a knee prosthesis. The knee prosthesis provides three degrees of liberty in accordance with biomechanical movement data. An anterior-posterior translation is obtained as well as a median lateral motion. The knee prosthesis achieves these goals through the use of asymmetrical components specific for either the left or right knee. The invention is also designed to allow simple transformation, for example, from a mobile knee system to a fixed knee system.
FIG. 1 shows a side sectional view of a knee prosthesis according to an embodiment of the invention. FIG. 2 is an exploded view of the knee prosthesis of FIG. 1 . Knee joint prosthesis 10 is functionally secured to a tibia and a femur of a human leg. Knee joint prosthesis 10 includes femoral component 15 that is rigidly connected to the superior end of a femur, generally after the femur has been resected in a manner that is well known in the art. Femoral component 15 includes a condylar portion 17 that contacts or engages meniscal component 20 , which is more fully described below. Superiorly adjacent to condylar portion 17 on femoral component 15 is femoral stem 18 that acts as a fixing device to fix femoral component 15 to a femur.
In one embodiment, femoral component 15 is made of a biocompatible metal, such as, for example, titanium, titanium alloy, or cobalt-chromium alloy, or made of a biocompatible ceramic, such as, for example, alumina ceramic or zirconia ceramic. Femoral component 15 is fixed to a femur, for example, by cement or a hydroxyaptite coating on femoral stem 18 . The hydroxyaptite coating is used in the instance to induce bone growth. It is to be appreciated that the femoral component is not required in the knee prosthesis of the invention. Instead, the meniscal component can be adjusted to conform and be compatible with the femur of the patient. However, to increase the longevity of the knee prosthesis and to avoid damage to the femur, femoral component 15 is generally recommended.
Meniscal component 20 is located between femoral component 15 and tibial component 25 . The overall shape of meniscal component or plate 20 will be described in detail below, but here it is notable that meniscal component 20 has a generally planar inferior surface with protuberance (here labeled reference numeral 60 ) selectively chosen for the left or right knee, respectively, of a patient. In one embodiment, a superior surface of meniscal component or plate 20 has a generally condylar (concave) shape to match the opposing condylar (convex) surface of a femur or femoral component 15 . In this manner, meniscal component 20 is able to articulate with condylar portion 17 of femoral component 15 . The top surface of meniscal component 20 may also be configured to conform to prior art femoral components. In one embodiment, meniscal component 20 is made from biocompatible ultra-high molecular weight polyethylene (UHMWP) It is to be appreciated, however, that other suitable materials may be used consistent with the properties of biocompatibility and durability.
Meniscal component 20 is connected to tibial component 25 by inferiorly extending protuberance 60 that fits in a receiving cavity (not shown) of tibial component 25 depending upon whether knee prosthesis 10 is to be assembled in the left or right leg of a patient, respectively. Tibial component 25 is described in detail below, but here it is notable that tibial component 25 contains tibial seat 30 having a generally planar superior surface 27 to support the generally planar inferior surface 22 of meniscal component 20 . Inferior surface 28 of tibial seat 30 contains inferiorly extending tibial keel 45 which is secured to the tibia of a patient.
In one embodiment, tibial component 25 is made of a biocompatible high-strength metal such as, for example, titanium, titanium alloy, or cobalt-chromium alloy or a biocompatible ceramic such as, for example, alumina ceramic or zirconia ceramic. Tibial component 25 is fixed to a tibia of a patient by, for example, making a hole in the tibia to support tibial keel 45 and cementing keel 45 to the tibia. In another embodiment, tibial component 25 is secured to the tibia of a patient by applying a hydroxyaptite coating on keel 45 to induce bone growth onto tibial component 25 .
FIG. 3 shows an embodiment of tibial component 25 in accordance with the invention. Tibial component 25 includes tibial seat 30 having a generally planar superior surface 27 . In one embodiment, the shape of tibial seat 30 resembles a painter's-pallet with an elliptic configuration incurvated or indented at one side. Indentation 36 defines tibial seat 30 with medial condylar portion 32 and lateral condylar portion 34 . In this configuration, one skilled in the art will realize that the knee prosthesis of the invention can be affixed to a patient without the destruction of a viable posterior cruciate ligament. Indentation 36 between medial condylar portion 32 and lateral condylar portion 34 allows for posterior cruciate ligament retention.
The width of tibial seat 30 may be made to be specific for a patient. In one instance, for example, tibial seat 30 will have a standard thickness of, for example, approximately 5 millimeters (mm). In another instance, where more of a patient's tibia requires resection for placement of the knee prosthesis or system of the invention, tibial seat 30 may have a thickness of 10 mm or more. In the embodiment where the meniscal component is made of UHMWP, it is appreciated that conforming the meniscal components to the specifics of the patient's knee is much more cost effective than machining or casting a specific tibial component.
Tibial seat 30 has a substantially Y-shaped cavity 35 with a first arm and a second arm intersecting at a base. The base is proximally adjacent indentation 36 between medial condylar portion 32 and lateral condylar portion 34 . In one embodiment, Y-shaped cavity 35 is formed with substantially arcuate surfaces and arcuate or softened edges throughout. In this embodiment, central axis 37 bisects cavity 35 between medial condylar portion 32 and lateral condylar portion 37 .
Extending from inferior surface 28 of tibial seat 30 of tibial component 25 is keel 45 . An upper portion 40 of keel 45 includes a cavity extending about and having the same shape as Y-shaped cavity 35 of tibial seat 30 . In this manner, the opening through cavity 35 extends into upper portion 40 of keel 45 . This extension of the Y-shaped cavity allows the stability and range of motion of the meniscal component to be adjusted, for example, by modifying the thickness or depth of protuberance 60 —a deep or thick protuberance will be more stable and allow less meniscal component 20 motion, while a shallow or thin protuberance will be less stable but allow greater meniscal component 20 motion. In one embodiment, keel 45 is a fixed length such as, for example, approximately 12 mm. In another embodiment, keel 45 is modular and can be made of varying lengths.
FIGS. 4-7 show different views of meniscal components for a left and right knee prosthesis, respectively. FIG. 4 shows superior surface 55 of meniscal component 20 for a left knee prosthesis. Left meniscal component 20 has an asymmetrical shape similar to a painter's-pallet with an elliptic configuration incurvated or indented at one side. It is noted that the shape of left meniscal component 20 , in this embodiment is not identical to the shape of tibial seat 30 . The symmetrical shape of tibial seat 30 is presented in outline form beneath meniscal component 20 to demonstrate this difference. Similar to tibial seat 30 , meniscal component has two condylar portions, medial condylar portion 56 and lateral condylar portion 57 , to preserve a posterior collateral ligament. In one embodiment, superior surface 55 has concave condylar shapes to accommodate opposing convex condylar portions of femoral component 15 . The shape of meniscal component 20 is chosen, in this embodiment to provide the closest duplication of human biomechanics by the movement of meniscal component 20 about cavity 35 .
As shown in FIG. 6, right meniscal component 21 has an asymmetrical painter's-pallet (elliptical) shape to preserve a posterior collateral ligament. The shape is compared in the figure with the symmetrical shape of tibial seat 30 . Meniscal component 21 includes medial condylar portion 66 and lateral condylar portion 67 . In one embodiment, superior surface 65 of meniscal component 21 has concave condylar shapes to accommodate opposing convex condylar portions of femoral component 15 .
FIG. 5 shows an inferior view of left meniscal component 20 . Inferior surface 58 is substantially planar to match substantially planar superior surface 27 of tibial seat 30 . Inferior surface 58 includes protuberance 60 having a shape adapted to conform in part with the base and one arm of cavity 35 of tibial seat 30 but to allow some movement or play in this portion of the cavity. As shown in FIG. 7, inferior surface 68 of right meniscal component 21 similarly has a substantially planar surface and protuberance 70 adapted to conform in part with the base and the other arm of cavity 35 of tibial seat 30 . In this manner, meniscal components 20 and 21 are specific for a left and a right knee of a patient, respectively.
Protuberances 60 and 70 have an asymmetrical shape with a mirror symmetry for the left and right meniscal components 20 and 21 , respectively. The shape of protuberances 60 and 70 is of an asymmetrical bean form with a larger internal portion to mate with the base of Y-shaped cavity 35 of tibial component 25 and a smaller external portion to mate with an arm portion of Y-shaped cavity 35 . The shape of protuberances 60 and 70 and the shape of meniscal components 20 and 21 shift the axis of displacement of meniscal component 20 or 21 on tibial seat 30 to a more medial or more lateral position, respectively. As noted, in this embodiment, protuberances 60 and 70 do not fit snugly in Y-shaped cavity 35 of tibial component 25 , but instead are slightly smaller, particularly at their external ends, to allow movement of meniscal component 20 and 21 once the knee prosthesis is placed in the left or right leg of a patient, respectively. In one embodiment, protuberances 60 and 70 also have rounded edges to facilitate the movement of the protuberance in tibial cavity 35 .
The asymmetrical shape of meniscal components 20 and 21 and protuberances 60 and 70 , respectively, creates a controlled complex motion that includes a rotation combined with an anterior-posterior and a lateral translation. The range of motion duplicates the biomechanics of the human knee by privileging a larger displacement on the external portion of meniscal component 20 and 21 while limiting the displacement of the internal portion of meniscal component 20 and 21 .
FIGS. 8-10 illustrate the controlled complex motion of right meniscal component 21 in tibial seat 30 . Each of these figures present top or superior cross-sectional views of right meniscal component 21 seated in tibial seat 30 . FIG. 8 illustrates a neutral position, FIG. 9 a flexion, and FIG. 10 an extension. Referring to FIG. 8, there is presented protuberance 70 mated with an arm portion and the base of cavity 35 of tibial seat 30 . Bean-shaped protuberance 70 does not conform precisely to the dimensions of an arm and the base of cavity 35 . Instead, protuberance 70 is able to move about a portion of cavity 35 . The neutral position of FIG. 8 presents some point between flexion and extension.
As noted, FIG. 9 demonstrates the movement of meniscal component 21 after a flexion. The displacement of meniscal component 21 may be characterized as follows. Medial condylar portion 66 moves anteriorly along medial condylar portion 32 of tibial seat 30 . Lateral condylar portion 67 of meniscal component 21 moves posteriorly about lateral condylar portion 34 of tibial seat 30 . At the same time, meniscal component 21 rotates in a clockwise direction as illustrated in FIG. 9 . There is also a medial translation.
FIG. 10 is directly opposite FIG. 9 . FIG. 10 shows an extension having the following movements. Medial condylar portion 66 moves posteriorly along medial condylar portion 32 of tibial seat 30 . Lateral condylar portion 67 of meniscal component 21 moves anteriorly about lateral condylar portion 34 of tibial seat 30 . At the same time, meniscal component 21 rotates in a counter-clockwise direction as illustrated in FIG. 10 . There is also a lateral translation.
The range of motion and the asymmetry of the motion of the knee prosthesis of the invention is created by the asymmetrical shape of meniscal component and 21 and the relationship of the symmetrical shape of cavity 35 of tibial seat 30 of tibial component 25 with the bean shape of protuberance 60 and 70 of left meniscal component 20 and right meniscal component 21 , respectively. In the embodiment described, the asymmetrical shape of meniscal component 20 and 21 allows the external (lateral) portion (e.g., lateral condylar portion 66 ) to be displaced a greater distance than the internal (medial) portion (e.g., medial condylar portion 67 ). In one embodiment, for example, condylar portion 66 of meniscal component 21 may be displaced 14 mm while medial condylar portion 67 may be displaced 4 mm in the same flexion/extension displacement.
By placing either left meniscal component 20 or right meniscal component 21 on tibial component 25 , protuberance 60 or 70 , respectively, will be positioned in cavity 35 and have a range of controlled motion that will privilege an asymmetrical displacement of, for example, meniscal component 21 (lateral condylar portion 66 and medial condylar portion 67 ) on tibial component 25 . It is to be appreciated that, in certain instances, the asymmetry described above with greater displacement privilege on, for example, lateral condylar portion 66 than medial condylar portion 67 , can be reversed to obtain a larger displacement on the medial condylar portion and positioning the axis of displacement in a more lateral position on tibial plate 30 .
In other instances, it may be necessary to limit the motion of the meniscal component. A surgeon may desire, for example, to place a fixed knee prosthesis or the patient's diagnois may require additional posterior stabilization, such as, for example, where the posterior cruciate ligament may not be retained. FIG. 11 shows an embodiment of the invention wherein meniscal component 23 is configured as a fixed insert. FIG. 11 shows the inferior side view of meniscal component 23 . In this embodiment, meniscal component 23 has an elliptical shape similar to the shape of tibial seat 30 of tibial component 25 , i.e., symmetrical. Extending from inferior surface 78 of meniscal component 23 is Y-shaped protuberance 75 . Y-shaped protuberance 75 is symmetrical and complementary with Y-shaped cavity 35 of tibial seat 30 of tibial component 25 . In one embodiment, Y-shaped protuberance 75 fits snugly in a conformal tibial cavity, such as tibial cavity 35 of tibial component 25 of FIG. 3 .
The embodiment described with reference to FIG. 11 demonstrates an advantage of the configuration of the invention: the conversion, for example, from a mobile knee prosthesis or system to a fixed knee prosthesis or system does not require a new tibial component. Instead, the conversion is accomplished by replacing, for example, meniscal component 20 with meniscal component 23 .
FIGS. 12-15 show a knee prosthesis according to another embodiment of the invention. FIG. 12 is an exploded side sectional view of a knee prosthesis according to this embodiment. Knee prosthesis 100 includes femoral component 15 that is rigidly connected to the superior end of a femur as described above with respect to FIGS. 1 and 2 and the accompanying text. Meniscal component 120 is located between femoral component 15 and tibial component 125 . Meniscal component 120 has a generally planar lower surface and, in one embodiment, a superior surface with a generally condylar (concave) shape to match the opposing condylar (convex) surface of a femur or femoral component 15 . In one embodiment, meniscal component 20 is made from biocompatible UHMWP.
Meniscal component 120 is connected to tibial component 125 by a superiorly extending protuberance from tibial seat 130 . The protuberance (labeled here as reference numeral 160 ) fits in a portion of a receiving cavity on the inferior side of meniscal component 120 depending upon whether knee prosthesis 100 is to be assembled in the left or right leg of the patient, respectively. Similar to the first embodiment, tibial component 125 includes tibial seat 130 having a generally planar superior surface 127 . Tibial seat 130 resembles a painter's-pallet with an elliptic configuration incurvated or indented at one side. The indentation defines tibial seat 130 with two condylar portions. Extending from superior surface 127 of tibial seat 130 is protuberance 160 , the orientation of which depends upon whether the knee prosthesis is for the left or right leg of a patient, respectively. It is to be noted here, unlike the first embodiment where meniscal component 20 was configured to be placed in one of a left or right knee prosthesis, respectively, in this embodiment, tibial component 125 is configured to be placed in either the left or right knee prosthesis, respectively. Alternatively, protuberance 160 may be modular and, thus, exchangeable allowing a single tibial component 125 for each of a right leg and a left leg and an individual protuberance selective for each articulation. Extending from inferior surface 128 of tibial seat 130 of tibial component 125 is keel 145 to affix tibial component 125 to a tibia.
FIG. 13 shows a view of inferior surface 138 of meniscal component 120 . Meniscal component 120 resembles a painter's pallet with an elliptic configuration incurvated or indented at one side. The indentation defines two condylar portions: lateral condylar portion 166 and medial condylar portion 167 . The shape of lateral condylar portion 166 and medial condylar portion 167 are not symmetrical in this embodiment. FIG. 13 is an embodiment of meniscal component 120 for a right knee prosthesis. In this instance, when viewed in a sagittal plane, lateral condylar portion 166 is slightly smaller or narrower than medial condylar portion 167 to allow more movement of lateral condylar portion 166 .
In this embodiment shown in FIG. 13, inferior surface 138 of meniscal component 120 is generally planar with a substantially Y-shaped cavity 135 with a first arm portion and a second arm portion intersecting at a base. The base is proximally adjacent indentation 136 between the condylar portions of meniscal component 120 . In this embodiment, axis of displacement 137 does not bisect cavity 135 , but is slightly offset toward lateral condylar portion 166 . It is to be appreciated that in some instances, it may be desirable to reverse the range of motion such that medial condylar portion 167 has a larger displacement. This may be accomplished by mirroring meniscal component 120 and shifting the axis of displacement for a right knee prosthesis.
FIGS. 14 and 15 shows top perspective views of embodiments of tibial components for a left and right knee prosthesis, respectively. Superior surface 127 of tibial seat 130 is substantially planar to match substantially planar superior surface 138 of meniscal component 120 . In FIG. 14, superior surface 127 includes protuberance 160 having a shape adapted to conform in part with the base and an arm of cavity 135 of meniscal component 120 . FIG. 14 is, for example, for a left knee prosthesis. FIG. 15 shows a similar tibial component having protuberance 170 extending from a superior surface of the tibial seat for a right knee prosthesis. In this manner, tibial components 125 and 126 are specific for a left and a right knee of a patient, respectively. Protuberances 160 and 170 have an asymmetrical shape with a mirror symmetry for the left and right tibial components, respectively. The shape of protuberances 160 and 170 is of an asymmetrical bean form with a larger internal portion to mate in part with the base of Y-shaped cavity 135 of meniscal component 120 and a smaller external portion. In this embodiment, protuberances 160 and 170 do not fit snugly in Y-shaped cavity 135 of meniscal component 120 , but instead are slightly smaller, particularly at their external ends, to allow movement of meniscal component 120 once the knee prosthesis is placed in the left or right leg of a patient, respectively. In one embodiment, protuberances 160 and 170 have rounded edges to facilitate the movement of the protuberance in meniscal cavity 135 .
The asymmetrical shape of meniscal component 120 and of the protuberances of tibial components 125 and 126 create a controlled complex motion that includes the rotation combined with an anterior-posterior and a lateral translation similar to that described above with reference to FIGS. 8-10 and the accompanying text. The significant difference is in the location of Y-shaped cavity (meniscal component) and protuberance (tibial seat). Once again, however, the range of motion duplicates the biomechanics of, for example, the human knee by privileging a larger displacement on the external (lateral) portion of meniscal component 120 while limiting the displacement of the internal (medial) portion of meniscal component 120 .
FIG. 16 shows an embodiment of tibial component 122 that may be used in a fixed knee prosthesis configuration. Extending from the superior surface of tibial seat 146 of tibial component 122 is Y-shaped protuberance 165 . Y-shaped protuberance 165 is symmetrical and complementary with a Y-shaped cavity of symmetrical meniscal component 123 . In one embodiment, Y-shaped protuberance 165 fits snugly in the meniscal cavity.
It is to be appreciated that in the second embodiment, the height of the protuberance extending from the tibial seat is such that it sits within meniscal cavity 135 so that inferior surface 138 of meniscal component 120 contacts superior surface 127 of tibial seat 130 . It is to be appreciated that meniscal component 120 may be made of different thicknesses to accommodate the proper placement and positioning of a knee prosthesis in a patient.
The use of the knee prosthesis of the invention can be used as a primary or revision knee system, for example, where a prior knee prosthesis failed. Further, the knee prosthesis of the invention allows a surgeon to make a decision during surgery whether to put a moving meniscal component or a fixed meniscal component into a knee prosthesis simply by choosing an appropriate meniscal component. Thus, the invention offers an asymmetrically designed knee prosthesis or system that in one sense mimics the biomechanical movements of a natural knee and in another is relatively easy to configure to an individual patient's needs.
The above embodiments described a Y-shaped cavity, protuberances that mate with a portion of the Y-shaped cavity, and asymmetric meniscal components. The invention is not to be interpreted as limited to any particular shape of meniscal component or cavity/protuberance. Instead, the invention recognizes the importance of an asymmetrical design, particularly in a mobile knee prosthesis or system (i.e., the asymmetrical design of the meniscal component relative to the tibial component or vice versa) commensurate with natural biomechanics. FIGS. 1-10 and 12 - 15 and the accompanying text presented various embodiments for a mobile knee prosthesis. The invention, however, recognizes that other designs based on the principles described herein are conceivable that capture this asymmetry and are therefore within the scope of the invention. Similarly, FIGS. 11 and 16 and the accompanying text presented various embodiments of a fixed knee system. These embodiments are particularly suitable for transformation from one of the mobile knee prostheses described herein. The invention recognizes that other designs based on the principles described herein are similarly conceivable and within the scope of the invention.
In summary, the preceding detailed description, described the invention 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 knee prosthesis including a tibial component and a meniscal component adapted to be engaged through the tibial component through an asymmetrical engagement.
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BACKGROUND OF THE INVENTION
(A) Field of the Invention
The present invention, which relates generally to liquid pumping units comprising multiple centrifugal pump elements incorporated in a common body, is particularly concerned with apparatus for controlling the passage of the liquid between several channels inside the pump body and with the adjustment of the flow-rate produced by these pumping units. The present invention is also concerned with the mounting of these passage and flow-rate control devices in a pumping unit, such as a central-heating booster pump.
(B) Discussion of the Prior Art
In order to reduce the cost of industrial or domestic heating installations, it is advantageous to fabricate pumping units which comprise several discrete pump elements combined in a common pump body. Advantageously, the pump elements are mass-produced and they need not have the same shape and operating characteristics. Manufacturers currently produce modules which group two, three or even more similar pump elements in modular form. The grouping of two identical pump elements in a common pump body is perhaps the most common configuration for such pumping units which are known as twin pumps. When used for industrial or domestic central heating, they are commonly known as twin booster pumps.
The twin pump or booster pump is advantageous since it assures high reliability for the heating system in which it is installed. Consider, however, an installation using a single pump which has failed. Replacing the failed pump by a new pump is in itself an easy operation, but requires that the heat be turned off and the pipes drained. These factors seriously disturb operation, especially during cold spells. The use of a twin pump, however, protects the installation from such problems. The centrifugal pump elements are typically identical. Their operating characteristics, and in particular the power of each, are selected so as to satisfy the requirements of the installation. The twin pump is intended for alternate operation, i.e. each pump element is operated alternately. In the event of a failure in one of the elements, the other automatically takes over.
In general, in order to avoid unequal wear of the pump elements, both elements are operated on a 50% duty cycle. The work loads are thus balanced. Naturally, if one element fails, the installation is not disturbed in any way. Normal operation can quickly be re-established by merely replacing the defective pump element with a new element, without draining the plumbing. Finally, the use of a twin pump considerably reduces the risk of failure, since it is extremely rare for both elements to fail simultaneously. This conventional solution is today used frequently in most new installations.
For the manufacturer, the production of these pumping units raises two kinds of problem. First, it is necessary to provide a pump element which alternates the flow in the channels feeding the pumps in a virtually automatic manner. Second, it is advantageous to provide a pump component to vary the flow-rate of either pump in order to adjust the flow-rate to the installation served. The flow-rate is controlled by an adjustable shutter, known as a variator, located in a duct known as the discharge duct between the outlet and inlet. At first blush, this conventional arrangement would seem to call for as many variators, on as many discharge ducts, as there are pump elements.
In order to satisfy the first of the above requirements, the manufacturer typically incorporates valve systems in the common pump body to automatically control the alternated passage of liquid to or from either element.
The French Pat. No. 2,105,733 filed by the present applicant, discloses an adjustable-flow, multiple-booster pump, including a twin booster in which the element which controls the passage of the liquid in the outlet is a spring-loaded valve 22. As shown in FIG. 4 of that patent which is hereby incorporated by reference, the valve automatically controls the outlet 23' in volute 18' of the left pump element when the right volute 18 delivers liquid to the common outlet chamber to the general orifice 15. This valve, which is freely mounted on a shaft perpendicular to the plane of the figure, is held in position by a return spring designed to yield to the liquid pressure on the surface opposite that on which the return spring is mounted. On the inlet, the supply is controlled by a four-way valve, as shown in FIG. 1.
In order to meet the second of the above requirements, the above-mentioned patent describes, for regulating the twin booster output, a single variator whose control knob 9 operates simultaneously on the position of two planetary parts, each installed in a manner providing communication between the inlet duct 20 and outlet duct 21 for the corresponding pump element. The variator described simultaneously provides effective regulation of the flow of both pump elements by means of a single control and, therefore, regulation of the twin booster pump output.
The saving in space which is achieved as a result of replacing at least two complete pumps connected in cascade by a pumping unit containing at least two pump elements incorporated in a common body is nervertheless still limited, since it is necessary to adapt to the common body on the outlet side, according to the invention mentioned above, at least one system of valves and at least a control mechanism with complex gears on the discharge ducts of the pump elements.
SUMMARY OF THE INVENTION
In order to save further space and to simplify the distribution and flow rate controls in the common body of a twin centrifugal pumping unit, the present invention proposes a device characterized by the fact that it possesses at least one valve which can rotate about a shaft and a rotating key of the spigot tap type whose shaft is coincident with that of the valve, and by the fact that the valve and key, both mounted on a common shaft, each act on two passages accessible to the circulating liquid for shutting off or adjusting the degree of communication between at least two circulating liquid chambers inside the pump body.
Other features of the invention will become evident from the detailed description below when taken with the drawing. It should be understood that the description and the drawings are by way of example only and in no way limit the scope of the invention.
DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a pump according to the invention and comprises a vertical section in a plane parallel to the front surface of the twin pump body.
FIG. 2 illustrates the device shown in FIG. 1 by a vertical section in a diametrical plane perpendicular to the front surface of the twin pump.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows the structure of an illustrative pump body 1 according to the invention. The section shown is parallel to the front surface of the pump in a plane containing centre-line A'A which, of course, is common to the inlet and outlet orifices. The inlet chamber 2 is at the bottom. The outlet chamber 3 is at the top. The general structure is symmetrical with respect to centre-line AA' through the pump inlet 5 and outlet 6. Each of these orifices is common to both elements of the twin pump which are located symmetrically, the section showing both the right volute 4 and left volute 4' and their respective inlets 42 and 42'. Fluid flows in the direction of arrows F1 and F2 shown in the right volute 4 and is driven by impellers 7 and 7'. The compact shape of pump 1 is apparent, in particular, the increasing width of the outlet chamber 3 above the throat 11 of the top orifice 6. The internal wall of the pump body possesses a part which protrudes inwardly close to outlets 13 and 13' of volutes 4 and 4' respectively. This protruding part is terminated at the top by an edge 12 constituting a half-flat, practically perpendicular to the top internal wall 14. It is terminated at the bottom by the volute. By forming the outlets 13 and 13' towards the outlet orifice, the right and left volutes 4 and 4' constitute a body 16 whose internal wall 15 has a circular section contour centred about 0 and possessing a top orifice 17 and a bottom orifice 18.
According to the invention, provision is made for mounting a cylindrical control shaft 20 centred at 0 and coaxial with the body 16. The two valves 8 and 9 are mounted on this shaft. These valves are similar, and are slightly curved, as shown by the vertical section in FIG. 1. The curvature ensures that the underside of each valve correctly matches the edge of each volute outlet, such as edges 19 and 12, against which they bear when in the closed position.
FIG. 2 is a vertical section perpendicular to the section of FIG. 1, and shows a side view which clarifies the shape of one of the valves, valve 9. The shape of this valve matches that of the orifice which comprises the outlet of volute 4' in outlet chamber 3. Naturally, the surface of the valve exceeds that of the orifice to be shut off, thus ensuring a proper seal. As illustrated in both FIGS. 1 and 2, the top surface of each valve is held down by a return spring, such as spring 21, whose coiled part is placed over shaft 20. The valves rotate freely about shaft 20. As seen in FIG. 2, each valve is carried by a pair of arms 22 mounted without friction on shaft 20 by means of two sleeves, such as sleeve 24. The free end 23 of spring 21 bears on the front surface of valve 9. It can slide on this surface, guided by the rib 25 on the valve surface. The free ends, such as end 23, end naturally in the same manner as the corresponding free part of the spring of valve 8, and both are bowed, as may be seen in the section drawing of FIG. 1. The arms 26 and sleeves 24' of valve 8, shown by dashed lines in FIG. 2, alternate with arms 22 and sleeves 24 of valve 9. When assembled, the arms are slid onto shaft 20 such that they can rotate freely without friction.
In addition, a key 10 is mounted in the body 16 and is locked to the control shaft 20 with which it can rotate about the axis of rotation BB' perpendicular at point 0 to axis A'A (see FIG. 1). The key is locked to shaft 20 by means of a rigid mechanical attachment during assembly. This attachment can be obtained by pinning or any other method. In addition, the common shaft 20 is also locked to control knob 31 whose handle 32 is external to pump body 1. This attachment can be provided by moulding the control shaft 20 into the knob 31 when the latter, as illustrated in the figures, is made of mouldable plastic material. The assembly of the knob and key locked to the control shaft as illustrated in FIG. 2 includes two washers 33 and 34 placed on shaft 20 either side of a split lock-ring 35 inserted in grooves 36 of shaft 20, holding the washers in position. Finally, a perfect seal to the right of control knob 31 is provided on the front surface of the pump by a O-ring 37.
The pump body is open to the rear. After installation, the opening is blanked by a plate 38 assembled on a flat gasket 39.
Once fully assembled, the pump is completely watertight.
In operation, the pump performs two functions; the first consists of automatically controlling the volute outlets to the outlet chamber. For example, if the right-hand pump is operating, the circulating liquid passes through volute 4 in the direction of arrow F 2 shown in FIG. 1. The pressure of the liquid at outlet 13 pushes against the underside of valve 8. The force of the return spring of this valve is designed to be slightly less than that produced by the pressure of the fluid. Valve 8, pushed by the greater force produced by the fluid, rotates towards the centre-line A'A, thereby opening the passage to the outlet chamber 3. This situation is illustrated in FIG. 1, where outlet 13 of volute 4 is open, while outlet 13' of volute 4' is held closed by the return spring 21 against which no pressure operates, since the left-hand pump is not operating. This prevents the circulating liquid from flowing back through the left-hand pump which is not operating.
The second function permits the user to adjust a pump flow irrespective of which pump is operating. It is seen that key 10 can occupy any possible position with respect to orifice 18 which is terminated by the internal edges 40 and 41 of the inlet duct. When the key leaves this orifice open, communication is provided between the inlet chamber 2 and outlet chamber 3. If the key leaves the orifice partially open, partial communication is established between the inlet chamber 2 and outlet chamber 3. Finally, this communication can be completely cut off between the inlet and outlet chambers when the key is in the position shown in FIG. 1, completely closing orifice 18. Control knob 31 thus provides full flow adjustment, regardless of which pump is operating.
It is apparent that the location of the variator device is such that the adjustment is identical and simultaneous for both pump elements because of its symmetry. This configuration also has the advantage of simplifying the construction of the twin pump body, since formerly the use of a flow variator necessitated the provision of as many discharge ducts as pump elements. The use of the instant invention avoids the need to provide any dischrage duct, thereby simplifying constuction.
Finally, placing the valves, key and variator control knob on a single, common shaft results in a one-piece assembly for two functions and considerably simplifies the twin pump body.
Such simplification results in appreciable cost savings and an advantageous decrease of physical dimensions.
It should be mentioned that a twin pump in accordance with that described above, can also operate correctly, though perhaps less advantageously, when both pumps are running. In this case, valves 8 and 9 are half-open with no particular disadvantage, since the circulating liquid cannot flow back through either one of the pump elements. Simultaneous operation is thus possible as in the case of prior art twin pumps, but this mode of operation and in of itself offers little advantage which would lead to its wider use. The real advantage of multiple pumps, and in particular twin pumps, is that of alternate operation.
Although the principles of the present invention are described above in relation with specific practical examples, it should be clearly understood that the said description is given as an example only and does not limit the scope of the invention.
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A symmetrical, twin centrifugal pump includes a pair of valves mounted about a common shaft. The valves are capable of independent operation thus allowing either or both of the pump elements to operate. A key is also mounted to the shaft to allow overall regulation of the pump by selectively impeding the flow of liquid from the pump inlet to pump outlet.
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BACKGROUND OF THE INVENTION
[0001] In the production of vinyl alcohol, or vinyl acetate based polymers or ethylene vinyl alcohol/acetate copolymers, methyl acetate is a byproduct formed. It is desirable to recover the methyl acetate for reuse. The methyl acetate typically produced is impure having a mixture of methyl acetate, methanol, acetic acid, water, solids, and other light impurities. Disclosed is a process wherein prior to use, the methyl acetate is purified.
[0002] Methyl acetate can be used for a variety of applications, among them, the production of acetic acid, acetic anhydride or a coproduction of each. The following references provide background regarding production of these materials.
PRIOR ART
[0003] U.S. Pat. No. 4,234,718—a cyclic integrated process for production of cellulose acetate from methanol, cellulose, and carbon monoxide is disclosed.
[0004] U.S. Pat. No. 4,234,719—a cyclic integrated process for production of cellulose acetate from methanol, cellulose, and carbon monoxide is disclosed.
[0005] U.S. Pat. No. 4,352,940—hydrolysis of methyl acetate to acetic acid.
[0006] U.S. Pat. No. 4,544,511—process for producing acetic anhydride.
[0007] U.S. Pat. No. 5,144,068—Rh catalyzed methanol carbonylation process.
[0008] U.S. Pat. No. 5,001,259—Rh catalyzed methanol carbonylation process.
[0009] U.S. Pat. No. 5,206,434—purification process for methyl acetate.
[0010] U.S. Pat. No. 5,770,770—reactive distillation process and equipment for the production of acetic acid and methanol from methyl acetate hydrolysis.
[0011] U.S. Pat. No. 5,831,120—Production of Rh or Ir catalyzed methanol carbonylation acetic acid and replacing at least a portion of the methanol feed with a component selected from the group consisting of methyl acetate, dimethyl ether, acetic anhydride and mixtures thereof. The recovered effluent from this and other processes may be purified of carboxylic acid by reactive distillation with at least one C1 to C3 alcohol.
[0012] EP 108437—use of methyl acetate and/or dimethyl ether with carbon monoxide or a mixture of carbon monoxide and hydrogen to form ethylidene diacetate and/or acetic acid anhydride.
[0013] EP 087 870—process for the production of acetic anhydride with or without the net coproduction of acetic acid, in a series of esterification, carbonylation, and separation steps.
[0014] EP 1061063—(process application); method of producing carboxylic acid and alcohol by obtaining a reaction product liquid by hydrolysis of a carboxylic acid ester in the presence of an acid catalyst and separating said product liquid. Carboxylic acid ester is methyl acetate.
[0015] Jp 60-60107—discloses manufacture of poly vinyl alcohol including the saponification of byproduct methyl acetate with carbon monoxide for form acetic anhydride. (English abstract only).
[0016] GB 2013184—preparation of vinyl acetate wherein methanol, acetaldehyde and carbon monoxide are reacted in a cyclic integrated process wherein methyl acetate is carbonylated in the first step of the process.
[0017] Finch, CA, Polyvinyl Alcohol Developments, “Hydrolysis of Polyvinyl Acetate to Polyvinyl Alcohol,” Section 3.3.6—Methyl Acetate Recovery and Acetic Acid Production. John Wiley & Sons, p 71-73, (1992).
[0018] Jones, Jane H., The Cativa™ Process for the Manufacture of Acetic Acid, Platinum Metals Review, V 44, July 2000, No. 3, 95-105.
DETAILED DESCRIPTION OF THE INVENTION
[0019] Polyvinyl alcohol is commercially produced by the reaction of vinyl acetate with a radical initiator and methanol to produce polyvinyl acetate. The poly vinyl acetate is then reacted with methanol in the presence of a base to produce poly vinyl alcohol and methyl acetate. The byproduct of the reaction is methyl acetate. The methyl acetate produced is typically co-mingled in a stream containing methyl acetate, methanol (excess reactant in the above mentioned reaction), light organic impurities, and potentially polymer solids and water.
[0020] The methyl acetate is typically converted to acetic acid by hydrolysis. The acetic acid is then sold or can be recycled into vinyl acetate production.
[0021] The process to hydrolyze methyl acetate contained in a stream as described above is costly due to capital equipment and energy (operating costs) requirements because of the multiple distillation/separation steps required and expensive materials of construction required by the corrosive environment.
[0022] A process in which the methyl acetate stream could be sent directly to a carbonylation process to produce acetic acid (or acetic anhydride or co-production of the acetic acid and acetic anhydride) would eliminate the need for the equipment and energy requirement for hydrolysis. However, the methyl acetate stream is not suitable to be directly fed to the carbonylation process. The art generally does not address the issue of impure methyl acetate and the need to purify prior to recycle in a cyclic integrated process. The methyl acetate itself is unsuitable as feed to a carbonylation unit without removal or treatment of impurities. If not removed, the methyl acetate impurities lead to problems in downstream use. The polymer solids must be removed, as the solids would foul the carbonylation process. The water content must be adjusted to be appropriate for the product being produced. For example, if acetic acid is being produced by carbonylation, then no more than one molecular unit of water may enter the reactor per unit of methyl acetate. Otherwise, dry acetic acid is not produced.
[0023] The present invention relates to integrating the processes of vinyl alcohol or ethylene vinyl alcohol based- or vinyl acetate based-polymer or copolymers, e.g., polyvinyl alcohol production with a carbonylation process so that methyl acetate produced in the first process, for example the poly vinyl alcohol production, is converted to a saleable product at a significant reduction in energy cost, or alternatively can be fed into the reaction system for use in the production of acetic acid, acetic anhydride, or coproduction of each.
[0024] Alternatively, the present invention is directed to use of methyl acetate produced as a byproduct in the polyvinyl alcohol process in the reaction to produce acetic acid, anhydride, or coproduction of each. An exemplified integrated process would involve production of acetic acid, which would be used to produce vinyl acetate. The vinyl acetate produced would be used in the reaction to produce polyvinyl alcohol. The methyl acetate byproduct would be purified and fed directly to the production of acetic acid, anhydride, or coproduction thereof. Hence the process is integrated from acetic acid production through polyvinyl alcohol production, including use of byproducts formed in intermittent reactions.
[0025] To effect the process integration, a suitable purification step is required for the methyl acetate. A process has been demonstrated wherein streams from the polyvinyl alcohol polymer process were recovered and refined for feed to a methanol carbonylation acetic acid process. For example, the stream containing methyl acetate, methanol, water, light impurities, and polymer solids was purified by separation/distillation. Excess water and polymer solids were removed while organic losses in the aqueous stream kept to a low level. Other aqueous/organic streams which contain a subset of the above listed components could also be purified/processed. The product of the purification step is a stream generally containing methanol, methyl acetate, acceptable level of impurities, essentially no polymer solids, and sufficiently low amounts of water. The impurities or amounts thereof, as well as the water concentration can vary based on the desired application and the equipment in use. Typically, for methyl acetate to be used in a methanol carbonylation unit for production of acetic acid, it is recommended that no more than about one molecular unit of water per molecular unit of methyl acetate be present in the stream.
[0026] The invention will be described with more particularity in relation to the production of acetic acid from polyvinyl alcohol but it is recognized by those of skill in the art that production of acetic anhydride or coproduction of acetic acid and acetic anhydride can also be produced from the methyl acetate formed. Acetic acid, anhydride, or coproduction of each may be produced by a variety of methods well known in the art. The present invention is not directed with the manner of making the acid or coproduction of acid and anhydride, but with the integrated process allowing use of a purified or treated methyl acetate.
[0027] When acid, anhydride or coproduction of each is produced by the method of methanol carbonylation, either employing rhodium or iridium as a catalyst, water and impurity levels in the methyl acetate are a concern. This is because the rate of generation of water by methanation of the methanol and/or reactive derivative in the carbonylation reactor is relatively high and can be greater than the rate of consumption of water by the water gas shift reaction in the carbonylation reactor. The methanolysis can be shown as:
[0000] CH 3 OH+H 2 →CH 4 +H 2 O
[0000] The water gas shift reaction can be shown as:
[0000] CO+H 2 O→CO 2 +H 2
[0000] Water may accumulate in the continuous production of acetic acid or acetic anhydride or coproduction thereof, by direct or indirect ingress into the reactor system. The removal of excess water or control of the water balance in carbonylation processes is the subject of numerous references. However, a problem with water removal is the simultaneous removal of components such as methyl iodide. The methyl iodide can be recycled into the reaction, or disposed. If disposed, it must be disposed of properly due to environmental concerns. It is desirable that the methyl acetate employed in the present process has minimal amounts of water. It is critical in making acetic acid in a carbonylation unit that the water be present in less than stoichometric proportion relative to the methyl acetate content. If making acetic anhydride, it is desired that no water, or methanol, be present. With respect to methanol during the production of acetic acid, methanol concentration is not as large a concern as water concentration.
[0028] An additional concern with the use of methyl acetate from a vinyl- or ethylene- alcohol or vinyl acetate- based process is the carbonyl content in the stream. Carbonyl impurities include acetaldehyde, acetone, methyl ethyl ketone, butyraldehyde, crotonaldehyde, 2-ethyl crotonaldehyde, and 2-ethyl butyraldehyde and the like, as well as unsaturated aldehydes. Additional impurities to be considered in the methyl acetate stream can include toluene, benzene, acetone, dimethyl acetal, 3-methyl-2-pentanone, propionic acid, ethyl acetate and ethanol.
[0029] An embodiment of the present invention involves a process for using a methyl acetate stream in a methanol carbonylation process comprising:
a) producing a vinyl acetate based polymer or copolymer which is hydrolyzed; or b) alternatively producing a polymer or copolymer of vinyl alcohol which undergoes a subsequent methanolysis; c) forming a methyl acetate byproduct; d) directing the methyl acetate to a purification process; e) directing the purified methyl acetate to a methanol carbonylation process.
[0035] The above embodiment may also be performed utilizing an alkene, or more particularly ethylene as a comonomer.
[0036] The methyl acetate by product formed may be a mixture of methanol, acetic acid, water, light organic impurities, and some polymer solids. Methods to purify the methyl acetate include, but are not limited to, separation of the water, impurities and solids via distillation, extraction, filtration or crystallization.
[0037] An alternate embodiment of the invention involves a process for using methyl acetate comprising
[0038] a) producing acetic acid;
[0039] b) contacting the acetic acid with reactants under conditions sufficient to form vinyl acetate;
[0040] c) contacting the vinyl acetate under conditions sufficient to form poly vinyl acetate;
[0041] d) contacting the poly vinyl acetate with a base and methanol under conditions sufficient to form poly vinyl alcohol and methyl acetate as a byproduct;
[0042] e) treating the methyl acetate sufficient to remove at least some of the impurities therewith;
[0043] f) directing the methyl acetate to an acetic acid production process.
[0044] Yet another embodiment of the invention involves a process for using methyl acetate comprising
[0045] a) producing acetic anhydride;
[0046] b) contacting the acetic anhydride with reactants under conditions sufficient to form vinyl acetate;
[0047] c) contacting the vinyl acetate in under conditions sufficient to form poly vinyl acetate;
[0048] d) contacting the poly vinyl acetate with a base and methanol under conditions sufficient to form poly vinyl alcohol and methyl acetate as a byproduct;
[0049] e) treating the methyl acetate sufficient to remove at least some of the impurities therewith;
[0050] f) directing the methyl acetate to an acetic anhydride production process.
[0051] Yet another embodiment of the invention involves a process for using methyl acetate comprising
[0052] a) coproducing acetic acid and acetic anhydride;
[0053] b) contacting the acetic acid and acetic anhydride with reactants under conditions sufficient to form vinyl acetate;
[0054] c) contacting the vinyl acetate in under conditions sufficient to form poly vinyl acetate;
[0055] d) contacting the poly vinyl acetate with a base and methanol under conditions sufficient to form poly vinyl alcohol and methyl acetate as a byproduct;
[0056] e) treating the methyl acetate sufficient to remove at least some of the impurities therewith;
[0057] f) directing the methyl acetate to a coproduction process for production of acetic acid and acetic anhydride.
[0058] In the production of poly vinyl alcohol (PVOH), the resultant methyl acetate formed is considered a mother liquor to be ultimately purified and fed to a methanol carbonylation reactor for the production of acetic acid. The crude methyl acetate mixture is directed to a mother liquor column for purification to remove impurities such as light organic components, polymeric solids and water. The column is operated at elevated pressure, and heated, to remove essentially all of the methyl acetate in an overhead stream in purified form, and over 95% of the methanol from the impure methyl acetate crude mixture. The reflux of the column is adjusted to maintain about one mole of water for every mole of methyl acetate in the column overhead. The polymeric solids typically consist of poly vinyl acetate, poly vinyl alcohol, and sodium acetate and exit from the bottom of the mother liquor column as a residue.
[0059] By operating the Mother Liquor Column at an elevated pressure, the overhead components or overheads can be used as a heat source for other recovery columns in the polyvinyl alcohol plant. Operating at about 55 psig allows for over 50% of the energy used in this tower to be recovered. Other streams may additionally be sent to the mother liquor column for separation. For example, a stream containing water and methanol from the extractive distillation of vinyl acetate and methanol, which is often used in the PVOH process can also be sent to the mother liquor column for separation.
[0060] When the proposed mother liquor column is used, a column to separate methanol and water could be retained in the PVOH process. The stream from the extractive distillation could be forwarded to the methanol water column, or a mother liquor column. The mother liquor column, or an extractive distillation, could then be operated in a mode where a portion or all of the methanol in the feed was allowed to exit the column bottom with the water and solids. The column bottoms, or residue could be forwarded to the methanol water column. This mode of operation may find use in the overall plant cost optimization if the cost of transporting the mother liquor column overhead stream was large.
EXAMPLES
Example 1
[0061] A distillation was conducted using streams from a PVOH process. In the laboratory, a 40 tray Oldershaw column was employed at elevated pressure and temperature. A mother liquor stream containing 0.24 wt% solids was fed about midway on the column, while an aqueous methanol stream containing 0.13 wt% solids was fed to the column about one third from the base. In the atmospheric distillation the overhead and the base temperatures were 68 C and 100 C, respectively. The mother liquor feed rate was 13.7 g/min and the aqueous methanol feed rate was 11.5 g/min. The reflux ratio was maintained at about 0.23. No foaming or major fouling problems in the reboiler were observed during the distillation. Dark brown/black staining or fouling was observed from around tray 15 to the base. However, this minor fouling did not plug the small tray holes or downcomers of the Oldershaw column. The trays above the mother liquor feed were clean.
[0062] The analysis of the feed, overhead methanol/methyl acetate product, and the wastewater residue is given in Table 1 below.
[0063] Purified methyl acetate was employed in the production of methanol carbonylation acetic acid Acetic acid was produced having no atypical impurities or impurity profile.
[0000] TABLE 1 Analysis of laboratory experiment on distillation of feed methanol/ methyl acetate mixture. Mother Aqueous Component Liquor Feed Methanol Feed Product Residue Water (wt %) 21.4 82.5 5.3 100 Methanol (wt %) 55.3 17.5 66.8 0.0656 Methyl Acetate 27.1 Nd 27.9 nd (wt %) Ethanol (ppm) 1476 75 1704 nd Acetone (ppm) nd Nd Nd 16 Dimethyl Acetal 17 Nd 22 nd (ppm) Ethyl Acetate (ppm) 315 Nd 366 nd Acetaldehyde (ppm) 248 Nd 313 nd Toluene (ppm) nd Nd 74 nd Acetic Acid (ppm) 45 Nd Nd 87 Alkanes (ppm) <100 781 3 932 Nd = non-detected; values are not normalized. Product = Methyl Acetate, Methanol Product of Invention
The example illustrates that a methanol/methyl acetate stream could be purified at a low reflux ratio with less than 1000 ppm methanol and less than 2600 ppm alkanes in the waste water.
Example 2
[0064] The methanol/methyl acetate product of example 1 was fed to an experimental carbonylation unit in the following manner: Prior to feeding the material from example 1 to the methanol carbonylation experimental unit, the experimental unit was brought to steady state using pure methanol feed at 195° C., 1100 ppm Rh, 2.2 wt% MeOAc, 2.2 wt% H 2 O, 6.5 wt% Mel. The resulting space time yield was 20 mols/L/hr. Reaction conditions were held constant and the distillate from example 1 replaced MeOH as feed to the experimental unit. Water was added to the experimental unit such that total water in the feed was equimolar to the total methyl acetate in the feed. These conditions were maintained for three days. The reaction rate remained unchanged at 20 mols/L/hr. The composition of the acetic acid product from the experimental unit is listed in the table below. The concentration of propionic acid (HOPr) in the product increased after feeding material from example 1.
[0000]
TABLE 2
Product From Example 2
methanol
189 ppm
methyl acetate
53 ppm
crotonaldehyde
1.4 ppm
butyraldehyde
6 ppm
2-ethylcrotonaldehyde
5.2 ppm
propionic acid
1601 ppm
Acctic Acid
Balance
|
The present invention is directed to using methyl acetate from a vinyl acetate-based or a vinyl-or ethylene-alcohol based polymer or copolymer process directly for use in a methanol carbonylation production process to produce acetic acid, acetic anhydride, or a coproduction of each.
Methyl acetate is a by-product of commercial polyvinyl-alcohol or alkene vinyl alcohol copolymer-based processes. Generally, this material is processed to recover methanol and acetic acid. Discussed herein is a cost-saving scheme to by-pass the methyl acetate processing at production or plant facilities and utilize the methyl acetate in an integrated methanol carbonylation unit. The scheme discussed eliminates an expensive hydrolysis step often associated with the polymer process.
| 8
|
This application is a non-provisional application claiming priority from U.S. Provisional Application No. 60/433,015 filed Dec. 13, 2002 and U.S. Provisional Application No. 60/459,268 filed Apr. 2, 2003.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method and apparatus for performing public key cryptography.
2. Description of the Prior Art
When communicating over public networks, it is often necessary to secure communications in order to prevent interception or fraud by a third party. Cryptographic schemes often use intractable mathematical problems to ensure security of communications. In private key systems, two correspondents share a secret key prior to initiating communications. They can then employ an encryption algorithm using the secret value to keep their communication private from those who do not know the secret value. However, with such systems it is necessary for the two correspondents to agree on the secret beforehand, which may be as difficult as communicating securely in the first place.
Public key cryptosystems address the problem of distributing keys by assigning a pair of keys to each user. Each user has a private key and a corresponding public key, which are mathematically related so that it is computationally infeasible to derive the private key from the public key. The public key may be published and therefore made widely available to all users. To encrypt a message for a particular recipient, the sender uses the recipient's public key. Only the recipient knows the corresponding private key and therefore is the only party able to decrypt the message.
NTRU is a public key encryption system described in U.S. Pat. No, 6,081,597. The NTRU system uses a mathematical structure called a truncated ring of polynomials, which is denoted by R. The NTRU system uses four publicly known system parameters to initially set up the system. These are the degree of polynomials N, two moduli p, q, and the window parameter T. Typically, p is chosen to be 3 or X+2, and q is chosen to be a power of 2. The elements of the ring R may be represented as polynomials of a degree less than N. Operations in the ring are performed by polynomial addition and multiplication with the additional identity that X N =1.
To generate keys in the NTRU system, each user chooses secret polynomials f and g in the ring R. From the polynomial f, the user computes inverses modulo p and q which are denoted as f q −1 and f p −1 respectively. The user can then compute its public key h as f q −1 g. The private key consists of the polynomials f and f p −1 .
When a second user wants to send the first user an encrypted message, it uses the first user's public key h. The second user also has access to the system parameters. A message m is encrypted as e=m+prh (mod q). The value r is randomly chosen for each encryption.
Upon receipt of an encrypted message m, the recipient decrypts the message by computing a=ef(mod q). The recipient then establishes a window in the range
- q 2 to q 2 .
The recipient selects coefficients for a in the window. The recipient computes m=a f p −1 (mod p). The recipient then checks that m is in the set of valid messages. If m is in the set of valid messages, then the message has been recovered. Otherwise, the recipient chooses a new window and proceeds to select coefficients in the new window. The four mentioned steps are repeated. This may continue for multiple windows until a valid message is found. Once a valid message is found, execution will stop. If all of the possible windows are exhausted and no valid message has been found, then the recipient will experience an error condition and report that the message cannot be deciphered.
In order to avoid indecipherable messages, it has been suggested that the parameter T be chosen to be at least 30, and as large as 150. Since a large number of windows may be tested, it is likely that a valid message will be found eventually. In most cases however it is not necessary to check all of the windows.
SUMMARY OF THE INVENTION
The inventors have recognised a vulnerability in the NTRU decryption process which may be exploited to determine private keys. The vulnerability exploits indecipherable messages in order to determine multiple bits of the secret key.
The attack proceeds by first finding one message m and one random value r such that the encryption e=m+prh (mod q) is indecipherable. This step is performed by choosing random messages and values r and sending them to the victim for decryption. When decryption fails, it can be noted that the message is indecipherable. In the alternative, the time required to process the message may be measured. Indecipherable messages will require many windows to be tested during decryption, and accordingly will require more time than valid messages. It will be recognised that this attack requires that the victim decrypt messages of the attacker's choosing.
Once the attacker has determined one particular message m and a corresponding value r which yield an indecipherable encryption, the attacker then proceeds to find further indecipherable messages. The attacker proceeds by choosing a new random value r 1 , and then encrypting m with r 1 . The attacker then tests if m+pr 1 h can be decrypted. If this message cannot be decrypted, then it is saved for further use in the attack. The attacker then repeats the step of choosing a new random value and proceeds to find random values r 2 , r 3 , etc. before proceeding with the next phase of the attack.
Once the attacker has contained a large enough number of decipherable messages, the attacker examines the r 1 values which have been found. The attacker looks at each co-ordinate, and counts the number of values which occur for each co-ordinate. Because of the structure of the encryption equation, there is likely to be a correlation between the coefficients of these values r 1 , and the coefficients of the private polynomial g. Once the statistics have been accumulated, the attacker predicts a value of g from the distribution of the coefficients of the r 1 values. This value of the polynomial g may then be used to determine the value of f q −1 from the equation for the public key h. The attacker may thus determine all of the private values of the cryptosystem and therefore break the system
The inventors have recognised that avoiding the above attack may be performed by having the decryptor perform a constant amount of work for each decryption. This is accomplished by always testing all possible windows even when a valid message has already been found. The attacker therefore cannot determine which messages are actually indecipherable and the attack will be avoided. Preferably, the value of T is chosen to be less than 30 and more preferably less than 10 in order that the additional work from testing all windows is minimised. Ideally, the value of T will be chosen to be 1, 2, or 3.
According to one aspect there is provided a method of decrypting a message encrypted using a truncated ring cryptosystem. The method comprises selecting a window parameter T determining a plurality of windows of a predetermined size, each window being shifted by an amount less than or equal to the window parameter T. A decryption candidate is determined for each possible window. Each decryption candidate is tested to determine whether it is a valid message. The result of the decryption is chosen to be a valid message found in the previous step or if no valid message is found it is indicated that the message could not be decrypted. By this method, a constant number of decryption candidates are determined for each decryption.
According to another aspect, there is provided a method of decrypting a message encrypted using a truncated ring cryptosystem. The method comprises generating a random sequence of integers less than a fixed value, each integer corresponding to a window of a predetermined size and being shifted by the amount of the integer. Decryption candidates are successively determined for each possible window, and tested until a valid message is found, and the valid message is chosen as the result of the decryption. If no valid message is found after each possible window is used, it is indicated that the message could not be decrypted.
According to a further aspect, there is provided a method of selecting system parameters for a truncated ring cryptosystem. The method comprises selecting an initial set of parameters, generating private keys, testing the vulnerability of each private key to an attack on the cryptosystem based on determining indecipherable messages and when the cryptosystem is vulnerable, repeatedly increasing the value of one of the parameters and re-testing the vulnerability until the vulnerability has been reduced.
According to yet another aspect, there is provided a method of encryption with a truncated ring cryptosystem. The method comprises using first, second and third cryptographic hash functions to obtain a first string from a message and a number. The number is used as a second string. The first cryptographic hash function is used to obtain a third string from the message and the number. A padded message is formed from the first, second, and third strings. The padded message is encrypted with an encryption function.
According to a yet further aspect, there is provided a truncated ring cryptographic system comprising system parameters selected by testing the vulnerability of randomly chosen private keys to an attack based on determining indecipherable messages, an encryption engine, and a decryption engine.
According to still another aspect, there is provided a truncated ring cryptographic system comprising system parameters including a window parameter less than 30, an encryption engine, and a decryption engine.
According to a still further aspect, there is provided a decryptor for a truncated ring cryptographic system comprising a window parameter T determining a plurality of windows of a predetermined size, each window being shifted by an amount less than the window parameter T. The decryptor includes a calculator to determine a decryption candidate for each possible window and a tester to determine whether each decryption candidate is a valid message. A selector chooses the result of the decryption to be a valid message or if no valid message is found indicates that the message could not be decrypted.
According to yet another aspect, there is provided a decryptor for a truncated ring cryptographic system comprising a random sequence of integers less than a fixed value, each integer corresponding to a window of a predetermined size and being shifted by the amount of the corresponding integer. The decryptor includes a calculator to determine a decryption candidate for each possible window and a tester to determine whether each decryption candidate is a valid message. A selector chooses the first valid message found by the tester as the result of the decryption.
According to still another aspect, there is provided a system parameter selector for a truncated ring cryptographic system comprising an initial set of parameters, a private key generator, an attack engine to determine the vulnerability of each private key to an attack on the cryptosystem based on determining indecipherable messages, and a parameter updater to repeatedly increase the value of one of the parameters and run the attack engine until the vulnerability of the system to the attack has been reduced.
According to a still further aspect, there is provided an encryptor to encrypt a message in a truncated ring cryptographic system comprising a first, a second, and a third cryptographic hashbrown function, and a generator to generate a number. A message paddler is configured to form a padded message from a first string computed using the first, second and third cryptographic hash functions on the message and the number, a second string formed from the number and a third string computed using the first cryptographic hash function on the message and the number. An encryptor is provided to encrypt the padded message using an encryption function.
According to one aspect there is provided a data carrier containing instructions to direct a processor to decrypt a message encrypted using a truncated ring cryptosystem. The data carrier includes instructions top select a window parameter T determining a plurality of windows of a predetermined size, each window being shifted by an amount less than or equal to the window parameter T. A decryption candidate is determined for each possible window. Each decryption candidate is tested to determine whether it is a valid message. The result of the decryption is chosen to be a valid message found in the previous step or if no valid message is found it is indicated that the message could not be decrypted. A constant number of decryption candidates are determined for each decryption.
According to another aspect, there is provided a data carrier containing instructions to direct a processor to decrypt a message encrypted using a truncated ring cryptosystem. The data carrier includes instructions to generate a random sequence of integers less than a fixed value, each integer corresponding to a window of a predetermined size and being shifted by the amount of the integer. Decryption candidates are successively determined for each possible window, and tested until a valid message is found, and the valid message is chosen as the result of the decryption. If no valid message is found after each possible window is used, it is indicated that the message could not be decrypted.
According to a further aspect, there is provided a data carrier containing instructions to direct a processor to select system parameters for a truncated ring cryptosystem. The data carrier includes instructions to select an initial set of parameters, generate private keys, test the vulnerability of each private key to an attack on the cryptosystem based on determining indecipherable messages and when the cryptosystem is vulnerable, repeatedly increase the value of one of the parameters and re-testing the vulnerability until the vulnerability has been reduced.
According to yet another aspect, there is provided a data carrier containing instructions to direct a processor to encrypt a message using a truncated ring cryptosystem. The data carrier includes instructions to use first, second and third cryptographic hash functions to obtain a first string from a message and a number. The number is used as a second string. The first cryptographic hash function is sued to obtain a third string from the message and the number. A padded message is formed from the first, second, and third strings. The padded message is encrypted with an encryption function.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features of the preferred embodiments of the invention will become more apparent in the following detailed description in which reference is made to the appended drawings wherein:
FIG. 1 is a schematic representation of a communication system;
FIG. 2 is a schematic representation of a method of encryption;
FIG. 3 is a schematic representation of a method of decryption;
FIG. 4 is a schematic representation of a method of an attack on the system of FIG. 1 ;
FIG. 5 is a schematic representation of an alternate method of decryption;
FIG. 6 is a schematic representation of a method of parameter selection;
FIG. 7 is a schematic representation of a method of padding;
FIG. 8 is a schematic representation of a circuit used to pad messages;
FIG. 9 is a schematic representation of a method of padding using the circuit of FIG. 8 ;
FIG. 10 is a schematic representation of a circuit used to recover a message from a padded message; and
FIG. 11 is a schematic representation of a method performed by the circuit of FIG. 10 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1 , a communication system 10 includes correspondents 12 , 14 connected by a communication channel 16 . The correspondent 12 wishes to send messages to the correspondent 14 , and for this purpose has access to certain public parameters of the correspondent 14 . The correspondent 14 has system parameters 22 , private parameters 24 and a public key 26 . The system parameters include a degree N, two moduli p, q and a window parameter T. The private parameters include randomly chosen polynomials f, g and inverses of f modulo q and modulo p. The public key is a value h computed from f q −1 g.
The correspondents 12 , 14 also include cryptographic processors 28 , 30 for performing cryptographic calculations. The correspondent 12 has a copy of a system parameters 18 and the public 20 of correspondent 14 . The correspondent 12 can therefore use these parameters in order to send encrypted messages to the correspondent 14 .
The NTRU cryptosystem as presented in U.S. Pat. No. 6,081,597 depends on four parameters (N, p, q, T) and four sets of integer polynomials of degree less than N. The sets include a message space L m , two key spaces L f , L g , and a nonce space L r . All of the integer polynomials belong to the ring R=Z[x]/(X N −1) and * denotes multiplication in R. The elements of the ring R may be represented as polynomials of a degree less than N. Operations in the ring are performed by polynomial addition and multiplication with the additional identity that X N =1. The parameter q is selected to be a positive integer. The parameter p can then either be a positive integer considerably smaller than q or a small polynomial (in the sense the p(1) is small, in both cases p is required to be relatively prime to q in R.
Polynomials in R will occasionally be reduced modulo q or p. When q and p are integers, this means reducing each coefficient modulo q or p respectively. If p is a polynomial then reducing x modulo p means finding a specific predetermined representative from the set x+Rp={x+yp, y∈R}. Let:
L
(
d
1
,
d
2
)
=
{
z
∈
R
:
{
z
has
d
1
coefficients
equal
to
1
,
d
2
coefficients
equal
to
-
1
and
the
remaining
coefficients
equal
to
0
}
.
If p is an integer then the window parameter T is usually selected to be zero and L f , L g , L r , and L m are defined as follows. Define the message space L m as
L m = { m ∈ R : m has all coefficients in [ ⌊ p - 1 2 ⌋ , ⌈ p - 1 2 ⌉ ] }
and define the key spaces L f , L g , and the nonce space L r as
L f =L ( d f , d f −1) L g =L ( d g , d g ), and L r =L ( d r , d r ),
where d f , d g , and d r are positive integers, whose values depend on N, q, and p.
If p is a polynomial then define L m to be the unique representatives of the sets x+Rp used in reducing modulo p. Note that to aid in decryption the representatives from x+Rp are selected so that the coefficients of polynomials in L m are small. The sets L f , L g , L r , and the integer T are then selected to allow the decryption algorithm to have a good probability of success. Generally this requires the coefficients of polynomials in L f , L g , and L r to be small.
Key-pairs are generated by selecting two polynomials f∈L f and g∈L g such that there exist polynomials f p −1 and f q −1 satisfying
f*f p −1 =1 (mod p) and
f*f q −1 =1 (mod q)
The private key comprises the polynomials f and f p −1 . The public key is the polynomial h=f q −1 g (mod q).
Referring to FIG. 2 , a method of encrypting a message is shown by the numeral 100 . At step 102 , the correspondent 12 uses the system parameters N, p, q and T. The input parameters are a message m which the correspondent 12 wishes to send to the correspondent 14 and the public key h of the correspondent 14 . The correspondent 12 then chooses the random value r at step 104 . The sender then computes e=m+prh (mod q) at step 106 .
Upon receipt of an encrypted message e the correspondent 14 performs the steps shown in FIG. 3 by the numeral 200 . The correspondent 14 first receives the encrypted message e at step 202 . It then calculates at step 204 a≡ef(mod q). It then sets a window at step 206 . The window is initially set to the range
- q 2 to q 2 .
Then, at step 208 the correspondent 14 selects coefficients of a in the current window. At step 210 , the correspondent 14 computes M=af p −1 (mod p). Then, at step 212 the correspondent 14 checks that M is in the set L m of valid messages. If the message M is valid at step 214 then the correspondent 14 uses the message as the recovered message at step 218 . If however the message is not valid at step 214 , then the correspondent 14 chooses a new window at step 216 and returns to step 208 to select new coefficients.
Given a public key h and a message m∈L m , encryption E proceeds as follows. Select a random element r∈L r and calculate e=m+prh (mod q). Encryption may be denoted by E h (m; r)=e.
Given a ciphertext e=m+prh (mod q), decryption D f,f p −1 proceeds as follows. First calculate:
a
≡
ef
(
mod
q
)
≡
mf
+
prhf
(
mod
q
)
≡
mf
+
prg
(
mod
q
)
Now convert the modular reduction above to an integer polynomial by choosing integer representatives for the coefficients of a.
The NTRU parameters were selected in such a way that, for the vast majority of m and r, all the coefficients of mf+prg fall in a range of width q centered at a value that can be determined from e. (Typically the center is the expected value of the coefficients of mf+prg). Thus for most m and r, a equals mf+prg.
In this case, decryption continues as follows:
a f p - 1 ( mod p ) ≡ ( mf + prg ) f p - 1 ( mod p ) ≡ ( mf ) f p - 1 ( mod p ) ≡ m ( mod p )
By definition of the message space, if m∈L m then m=m (mod p) and thus a recovers the message m.
If the above does not recover a valid message m, the range of width q is shifted by 1 and the above reduction modulo q is repeated. If this does not recover a valid message, the range is shifted by −1 and the above modular reduction repeated. In the absence of a valid message being recovered, the shifting and reduction by 2, −2, and so on up to a shift by −T at which point decryption is said to fail with a gap failure. The ciphertext in question is said to be an “indecipherable valid ciphertext.”
Thus if E h N (m; r)=e then D f,f p −1 (e) equals m precisely when a=ef(mod q) reduced to the expected range (shifted up to ±T, if need be) equals mf+prg. This can be used to find a good characterisation for which valid ciphertext will not decipher correctly.
Referring to FIG. 4 , the method of attacking the NTRU system is shown generally by the numeral 300 . The attacker first finds one message m and a nonce r such that e=m+prh (mod q) is indecipherable. The attacker then chooses the random value r i at step 304 . The attacker then encrypts the message m using the random value r i at step 306 . The attacker then tests if m+pr i h can be decrypted at step 308 . This is performed by sending the message to the victim. It may be necessary to monitor the amount of time that the victim requires to attempt to decrypt. At step 310 , the attacker saves the pair m, r i if the result of encrypted message is indecipherable. The attacker then repeats 312 , the choice of random values at step 304 and step 306 , 308 and 310 until it has accumulated sufficient values r i . The attacker then examines the co-ordinates of the r i values which have been found at step 314 . The attacker then predicts the value of the private polynomial g from the distribution of the coefficients in the r i values at step 316 .
The attack proceeds in two stages. Stage 1: Randomly search through pairs (m,r)∈L m ×L r until the ciphertext generated from the pair (m,r) is an indecipherable valid ciphertext. In practice, this is carried out by encrypting a message to another party, transmitting the ciphertext, and observing whether the ciphertext is rejected as indecipherable. Because a successful decryption with few shifts happens with high probability, it suffices to note the time interval before rejection and assume that any ciphertext not rejected almost at once is indecipherable.
Stage 2: Given the pair (m,r) found in Stage 1, let y=mf. Typically y will have one co-efficient j which is closer to the boundary of decipherability than any other co-efficient. In this case, for random r , there will be a bias in the co-ordinates of mf+p r g that may cause the (m,r)-ciphertext to be indecipherable.
The attack proceeds by randomly selecting many r and recording the value r for which e=m+p r g (mod q) was indecipherable. Because of the bias in the “bad” co-ordinates of mf+p r g, the values in the recorded r will have a correlation with the secret value g. This allows g to be recovered by analysing the distributions of the values in the recorded r . The private key can then be recovered. (First, recover the value of f from g and h; second, determine f p −1 from f.)
To limit the number of indecipherable (m, r ) pairs required to determine g from the r , the attack can be combined with lattice techniques.
If y=mf does have a large co-efficient then the rate at which the (m, r ) are indecipherable will be noticeably larger than the random m and r. Thus by analysing the rate at which r are found, we can determine whether y has no large co-efficients, at which point we can simply return to Stage 1. If y=mf has two or more large coefficients which are equally close to the decipherable boundary then the distributions of values in the r may not reveal g and the attack will need to return to Stage 1. Note that in this latter case, some information about g may still be determined. In practice, for randomly determined indecipherable (m,r,) there is a good chance that y=mf has the desired properties. Thus we expect that the need to loop to Stage 1 will be infrequent.
Referring to FIG. 5 , an embodiment of the invention in which alternate decryption is used is shown generally by the numeral 400 . The recipient first receives an encrypted message e at step 402 . It then calculates a≡ef (mod q) at step 404 . The recipient then selects co-efficients in the current window at step 406 . At step 408 the recipient computes M=af p −1 (mod p). The recipient then checks if M is in the set of valid messages at step 410 . If the message is valid at step 412 , then the recipient records the valid message at step 414 . It then proceeds to repeat the steps for each window at step 416 . If the message is not valid then the recipient also repeats the steps for each window at step 416 . In this way, the recipient performs the same number of operations regardless of how soon it finds a valid message.
To protect against timing attacks, such as the above, it will be recognised that the decryption algorithm has been modified so that a constant amount of work is always done per ciphertext. This is accomplished by proceeding with the decryption steps for each of the 2T+1 possible reduction ranges for a regardless of whether or not the message has been recovered.
In an alternative embodiment, randomness is introduced into the sequence of windows. The possible windows 1, −1, 2, −2, . . . , −T, −T are randomly rearranged. This selection of windows will reduce the information revealed by an indecipherable ciphertext since the attacker will not know which windows have been tried and in which order
In another embodiment of the invention, shown in FIG. 6 by the numeral 500 , the system parameters are chosen in order to reduce the likelihood of finding an indecipherable message. The likelihood of finding indecipherable messages is related to the system parameters N, p, q, and T. Values for these parameters are initially chosen 502 to set up the cryptosystem. Once a private key and public key are generated, 504 , the likelihood of finding indecipherable messages is calculated 506 . If this value is more than a predetermined value 508 , then one of the system parameters is modified 510 . If not, then the parameters are used 512 . The process may be repeated until desirable parameters are found. Preferably, q is increased in order to expand the window for coefficients modulo q.
In an alternative embodiment, the decryptor monitors received encrypted messages, When a large number of indecipherable messages are detected, the decryptor selects new system parameters. Preferably, the new parameters provide a lower likelihood of obtaining indecipherable messages.
In another embodiment, messages m ( 602 ) are padded with the nonce ( 604 ) as shown in FIG. 7 in order to provide randomness throughout the message, This may be done by splitting the message into two parts m 1 , m 2 and the nonce into two parts r 1 , and r 2 . Then the encrypted operation is performed on the concatenation m 1 ∥r 1 ∥m 2 ∥r 2 ( 606 , 608 , 610 , 617 ). Additional parts may be used to further mix bits of m with bits of r.
In a further embodiment shown in FIGS. 8 and 9 , an alternative method of padding messages is used. Referring to FIG. 8 , a circuit is shown generally by the numeral 700 . The circuit 700 includes registers 702 and 704 which hold a message M and a random string κ, respectively. The number of bits in the message m is denoted by k 1 , and the number of bits in the random string R is denoted by k 2 . The circuit 700 outputs a padded message m and a padded nonce r of bit lengths mlen and rlen respectively. The length mien is at least k 1 +k 2 . The circuit uses a hash function F 706 , a hash function G 714 and a hash function H 708 . The hash functions F and H take as input a binary string of length k 1 +k 2 . The output of F is k 3 =mlen−k 1 −k 2 bits, hash function G takes input of k 2 +k 3 bits and produces output of k 1 bits. The hash functions F and H are connected to a concatenation of registers 702 and 704 to receive input of the binary string M∥R of length k 1 +k 2 . The output of the hash function F 706 is a value a=F(M∥R) 710 . The hash function G 714 uprights on a concatenation of R 704 and a 710 of bit length k 2 . The output of the hash function G 714 is a value G(R∥a 716 ) of k 1 bits. The register 716 is connected to an XOR gate 718 . The register M 702 is also connected to the XOR gate 718 . The output of the XOR gate 718 is a register 720 containing bM+G (R∥a) of k 1 bits. The resulting message m is a concatenation of registers 720 , 704 , and 710 of k 1 +k 2 +k 3 bits. Notationally, m=b∥R∥a. The output of the hash function H 708 is a value d=H(M∥R) 712 of rlen bits. The value of d is used as the nonce r.
In operation of the circuit 700 , the steps 800 to FIG. 9 are performed. First, at step 802 , a message M is obtained. Then, a random string R is obtained at step 804 . Then the value a is computed at step 806 . The value a is equal to the value of the hash function F applied to M∥R, the concatenation of M and R. The value b is then computed at step 808 as M⊕G (R∥a). At step 810 , the values c and d are computed, where c=b∥R∥a and d=H(M∥R). Finally, the result in values m and r are encrypted at step 812 . Once the values have been encrypted as shown in FIG. 9 , a recipient will be able to decrypt them and obtain the original message M. Because of the padding, the additional steps of FIGS. 10 and 11 will be used by the recipient.
Referring therefore to FIG. 10 , a circuit for recovering the message from the padded message is shown generally by the numeral 900 . The circuit 900 takes as input an encrypted message 902 . The circuit then applies the NTRU decryption method 904 . The result of the decryption is a padded message m and a padded nonce r in registers 906 , 908 respectively. Assuming the decryption is successful, these values will be equal to the values encrypted by the sender. The circuit 900 then splits the register 906 into three values b, R, a in registers 910 , 912 and 914 respectively. The hash function G 714 is connected to the registers 912 and 914 to produce a value G(R∥a) stored in register 920 . An XOR gate 918 is connected to the values b, and register 910 and the register 920 . The XOR gate produces a value in register 922 which is equal to b⊕G (R∥a). The hash function F 706 is connected to the registers 922 and 912 to produce a value of F(M∥R) in register 924 . A comparator 926 operates to compare register 924 to the value a in register 914 .
Referring to FIG. 11 , the steps performed by the circuit 900 are shown generally by the numeral 1000 . An encrypted message is first obtained at step 1002 . Then the encrypted message is decrypted with NTRU at step 1004 . At step 1006 the value m is split into its components b, R and a. Then the value M=b⊕G(R∥a) is computed at step 1008 . At step 1010 , the value F (m∥R) is compared to the value a. If the values are not the same, then the message is reported as invalid and step 1012 , otherwise, these values are equal and the messages reported as valid at step 1014 . The value M is then returned at step 1016 as the result of the decryption.
Now consider the control over m and r of an attacker who can select M and R. Since r is generated from d=H (M∥R) the attacker has no direct control over any of the bits which determine r. The attacker does have control over R and thus since m is generated from c=b∥R∥a the attacker can control at least k 2 of the mlen bits used to form m Since a=F(M∥R) and b=M⊕G (R∥a) the attacker does not have direct control over any of the bits of a or b (The bits of a and b will change randomly when any of the bits of R or M change). This said, die attacker can exert some control over the bits of a, b and d repeatedly trying M, R combinations. However, as a, b, and d will change randomly for each M and R this control is limited by the amount of work which an adversary can perform.
It is recognized that there are many variations of this padding scheme which provide the desired features. These include permuting the orders of the bit strings concatenated to form a, b, c, or d, as well as replacing b with M⊕G′ (a) and d with H′(M⊕G (a)), H′(M∥a) or H′(R∥a), (where G′ and H′ are hash functions of the appropriate lengths.
Although the invention has been described with reference to certain specific embodiments, various modifications thereof will be apparent to those skilled in the art without departing from the spirit and scope of the invention as outlined in the claims appended hereto.
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A method of decrypting a message encrypted using a truncated ring cryptosystem. The method comprises selecting a window parameter T determining a plurality of windows of a predetermined size, each window being shifted by an amount less than or equal to the window parameter T. A decryption candidate is determined for each possible window. Each decryption candidate is tested to determine whether it is a valid message. The result of the decryption is chosen to be a valid message found in the previous step or if no valid message is found it is indicated that the message could not be decrypted. By this method, a constant number of decryption candidates are determined for each decryption.
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BACKGROUND OF THE INVENTION
In the area of biomaterials design, two major material characteristics are noted to be of importance. These are the chemical and the mechanical properties of the biomaterial. Chemical properties dictate whether a biomaterial is toxic, carcinogenic, reactive, or degradable within the bio-system. Mechanical properties determine a biomaterial's capabilities as a load-bearing device, tissue augmentation device, or tissue replacement device. It is generally known that the flexure properties of a biomaterial must match closely that of juxtaposed tissue in order for long term implant success to occur. Stiff or rigid implant material joined to softer tissues will cause immediate tissue response including encapsulation of the implant. Of additional importance are the density of the biomaterial, the porosity of the biomaterial, the creep resistance of the biomaterial, and the elasticity characteristics of the biomaterial. Relative porosity allowing permeability of the biomaterial to biomolecules such as albumin, fibrinogen, lipoprotein, and macroglobulin is also important for the long term success of the biomaterial.
Following implantation of most biomaterials, the immediate response of a bio-system, such as the human body, is to expel the biomaterial. Biomaterials can either be extruded from the body or walled-off if the materials cannot be removed. These responses are related to the healing process of the wound where the biomaterial is present as an additional factor. A typical response is that inflammation-activating leukocytes quickly appear near the biomaterial followed by giant cells which try to engulf the material. If the biomaterial is inert enough, foreign body giant cells may not appear near the biomaterial, lowering the overall inflammatory response.
Silicone polymers continue to be used commercially as biomaterials in both short-term and long-term implant devices. The relative chemical inertness of silicone makes it a fairly non-toxic biomaterial for long term implantation with relatively few complications reported. The elastic mechanical property of the silicone polymer allows the material to be used in load bearing applications without appreciable problems of material creep or tearing. While permeable to certain gases such as oxygen and carbon dioxide, silicone polymers are relatively impermeable to biological proteins, fluids or cells.
Open-structure, highly-crystalline porous materials such as micro-porous expanded polytetrafluoroethlyene or ePTFE are used as biomaterials to manufacture medical devices as well. Vascular grafts, soft tissue patches, sutures, ligaments, tissue augmentation membranes, and burn membranes are such devices made of ePTFE. The chemical inertness or non-reactive nature of polytetrafluoroethylene provides for a very non-toxic biomaterial. Expanded PTFE is characterized by its low density of typically less than 1 gm/cc, its high crystallinity, and its fibril and node open structure of average pore size typically greater than 30 micrometers. Implant products made of micro-porous ePTFE are typically designed to allow for cellular infiltration or tissue ingrowth during implantation. While cellular ingrowth is sometimes desirable, complications may result. These complications include but are not limited to infection, increase in implant rigidity leading to tissue compliance problems, and difficulty in removing the implant should the need arise. In addition, the highly crystalline nature of ePTFE presents mechanical compliance problems in many biomaterial applications due to the inherent stiffness of ePTFE medical devices.
BRIEF DESCRIPTION OF THE INVENTION
The invention described herein is a highly-amorphous soft and flexible nano-porous polytetrafluoroethylene or nPTFE material that is molecularly porous to biomolecules and gases. The invention provides biomaterial products which demonstrate excellent biocompatibility and tissue compliance. The preferred invention is characterized by a relatively high density from about 1.2 gm/cc to about 2.0 gm/cc, a high amorphous or non-crystalline content, and a nano-porosity from about 5 nanometers to about 5,000 nanometers to about 5,000 nanometers.
DETAILED DESCRIPTION OF THE INVENTION
The goal of this invention is to provide a non-toxic soft and flexible biomaterial that is preferentially porous to certain biomolecules and gases while excluding cellular components such as blood cells and fibroblasts. In addition, this invention is soft and compliant such that biocompatibility is enhanced due to better tissue compliance match. This goal is accomplished firstly by a process involving extrusion of resin-paste. Polytetrafluoroethylene resin is mixed with an extrusion-aid such as mineral spirits and compressed at relatively low pressures into an extrusion pellet. The pellet is then extruded at slow rates in a ram extruder. In this device, the ram serves mainly to further compact the resin and extrusion-aid paste and feed it into a die. The resin extrusion aid paste is subjected to very high pressure and shear forces within the die such that the resin solidifies into a cohesive shaped article.
The high pressure and shearing action within the die tends to align the high-molecular weight polytetrafluoroethylene chains along the longitudinal axis of the extrudate such that longitudinal strength is greatly enhanced and transverse strength is noticeably lowered. This extruded strength-orientated material is the precursor to the invention herein.
The preferred invention utilizes the extruded strength-orientated material described in the paragraph above. When this strength-orientated material is formed and compressed by multiple passes through a calender device at slow rates and high pressure, the aligned polytetrafluoroethylene chains separate one from another in a parallel or semi-parallel fashion. This separation process provides openings or voids of various dimensions between the polymer chains. The structure provided by this chain separation provides significant space for passage of biomolecules and gases. Increases in average intermolecular chain distance are dependent on the amount of compression, the rate of compression, the orientation of polymer chains relative to the direction of calender compression, the temperature of the material, the number of passes through the calender device, and the amount of lubricant within the material during the calender process. Lubricant is removed from the invention by drying at a temperature slightly above the boiling point of the lubricant, generally at about 150° C., and far below the sintering or coalescing temperature of the polymer, generally at about 327° C. The relatively low temperature drying process prevents the preferred invention from coalescing into a rigid, very high-density polytetrafluoroethylene material with a density of about 2.2 gm/cc and a nature of highly crystalline non-porous structure.
The nano-porous structure of the invention consists of separated chains of amorphous polytetrafluoroethylene with average interchain distances from about 50 nanometers to about 5,000 nanometers or 5 microns. Longitudinal strength along the chain-orientation is about 500 pounds per square inch or psi and transverse strength is about 250 psi. Both nano-porosity and strength can be significantly affected by the calendering process. A process of high pressure and large number of passes through the calender device typically results in greater interchain distances and highly orientated material strengths. Higher strengths are also possible and are dependent on the type of polytetrafluoroethylene resin used and the amount of lubricant used in the extrusion process. By controlling the extrusion and calendering process steps, it is possible to produce any desired nPTFE material comprised of a desired structure specific for a particular biomaterial product.
In certain biomaterial applications, it is desirable to provide a material that exhibits highly orientated strength in more than one direction. The invention can be manufactured according to the following methods to accomplish this goal. Firstly, for bi-directional strength, two extruded materials are layered such that their strength-orientation is 90° relative to one another. This layered assembly is then calendered with high pressure and multiple passes until a desired final thickness is attained. Chain separation is accomplished as described before. The final strength of the nPTFE invention is enhanced in two directions along the orientations of the two strength-orientated extruded materials. Secondly, for multi-directional strength, three or more strength-orientated extruded materials are layered such that their strength-orientations are directed in three or more directions relative one to another. This layered assembly is then calendered with high pressure and multiple passes until a desired final thickness is attained. Chain separation is accomplished as described before. The final strength of the nPTFE invention is enhanced in multiple directions along the strength-orientations of the extruded materials. An important result of the multi-layered calendar process of high pressure and multiple passes is that the layers of extruded material will be forced together such that the layers will not separate easily.
BRIEF DESCRIPTIONS OF THE DRAWINGS
FIG. 1 is a three dimensional view of the preferred invention depicting chain separation and direction of strength.
FIG. 2 is a schematic of an apparatus that may be used to manufacture the invention.
FIG. 3 is a sectional view of the multilayered invention depicting chain separation and directions of strength.
DETAILED DESCRIPTIONS OF THE DRAWINGS
As shown in FIG. 1, the nPTFE invention is characterized by nano-porosity formed by parallel voids 1 in the structure created by separated polymeric chains 2 of polytetrafluoroethylene. The direction of high strength is along the longitudinal orientation 3.
FIG. 2 describes a typical apparatus configuration for the continuous manufacture of the invention. Extruded material 4 is unrolled into an initial calender device 5 consisting of rollers 6,7 held in place with high forces 8,9. High pressure is applied to the extruded material as the thickness of the extruded material 10 is greater than the distance between the rollers 6,7. The thinner calendered material 11 passes from the first calender device 5 to the second device 12 that further processes the material. It is important to note that many more calender devices may be incorporated into the apparatus configuration to obtain the desired number of passes, pressure, thickness, and size distribution of the nano-porous voids. A drying roller 13 applies low heat to the material to remove extrusion aid. A final take-up reel 14 stores the invention 15.
FIG. 3 shows the invention as a bi-layered nPTFE material. The top layer 16 is characterized by molecular porosity formed by parallel to semi-parallel voids 17 created by separated polymeric chains 18 of polytetrafluoroethylene. The bottom layer 19 is characterized by similar chains 20 that are at 90° orientation to chains in the top layer 16. Strength is aligned in two directions 21,22 along the orientation of the polymer chains 18,20.
EXAMPLE 1
Low Porosity Highly Amorphous nPTFE Biomaterial
Polytetrafluoroethylene resin was mixed with extrusion aid and made into a paste. The paste was made into a pre-extrusion pellet with a ram pelletizer. The pellet was then extruded with high pressure though a die to form a highly chain-orientated, flat extrudate tape of about 2 mm thickness. The extrudate tape was then calendered by multi-passes through a calender device to a final material thickness of about 0.05 mm with a reduction in thickness of about 40 to 1. Orientation of the polytetrafluoroethylene chains was maintained at 90° relative to the calender roller axes during all of the passes. The final biomaterial was then dried at about 150° C. for about 1 hour, a process that removed all of the extrusion aid. The lower density of the final 0.05 mm biomaterial was about 1.2 gm/cc as compared to the initial about 1.7 gm/cc extrudate tape. The nPTFE biomaterial was very supple and flexible indicating a non-crystalline or highly amorphous material.
The 0.05 mm nPTFE biomaterial was manufactured into a medical packing device configured such that an internal sponge component of the device was sealed within the nPTFE biomaterial. It was found that the device was water tight due to the strong hydrophobic nature of the polytetrafluoroethylene. The nPTFE packing device was then implanted for about 2 weeks in the human mastoid cavity following a radical mastoidectomy. Upon removal from the cavity, the nPTFE packing device was found to contain biological proteins and fluids soaked into the sealed sponge material such that the weight of the retrieved packing was about 6 times the original weight of the original packing. The nPTFE biomaterial itself was filled with significant amounts of biomolecules including the important blood plasma proteins albumin, lipoprotein, fibrinogen, and macroglobulin. Cells did not permeate the nPTFE biomaterial. The nano-porosity voids from about 50 nanometers to about 5,000 nanometers of the PTFE biomaterial allowed passage of the biomolecules while excluding cells, including red and white blood cells, according to TABLE I.
TABLE I______________________________________ Overall DimensionsBiomaterial (nanometers) Result______________________________________Human Albumin about 4 × 15 permeated the nPTFEFibrinogen about 10 × 50 permeated the nPTFELipoprotein about 10 × 25 permeated the nPTFEMacroglobulin about 20 × 50 permeated the nPTFERed Blood Cells about 2,000 × 8,000 excluded by nPTFEGranulocytes about 10,000 × 12,000 excluded by nPTFELymphocytes about 5,000 × 8,000 excluded by nPTFEMonocutes about 9,000 × 15,000 excluded by nPTFEPlatelets disk diameter about excluded by nPTFE 4,000______________________________________
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The invention provides for a nano-porous highly amorphous polytetrafluoroethylene biomaterial which is soft, flexible, permeable to various biomolecules and gases, and high in strength in one or more directions. The invention can be made into many desired shapes as product needs dictate and multidirectional strength can be attained by layering the invention.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Patent Application No. 61/652,549 filed 29 May 2012, which application is herein specifically incorporated by reference in its entirety.
SEQUENCE LISTING
This application incorporates by reference the sequence listing submitted in computer readable form as file 8150A_ST25.txt created on May 6, 2013 (206,331 bytes).
FIELD
The invention relates to a cell or cells expressing a recombinant stress-response lectin for the improved production of a multi-subunit protein. Specifically, the invention provides a mammalian cell and cell-line derived therefrom containing a gene encoding EDEM2, and which yields antibody at a high titer.
BACKGROUND
The manufacture of therapeutically active proteins requires proper folding and processing prior to secretion. Proper folding is particularly relevant for proteins, such as antibodies, which consist of multiple subunits that must be properly assembled before secretion. Eukaryotic cells have adapted a system that ensures the proper folding of proteins and the removal of misfolded proteins from the secretory pathway. This system is called the unfolded protein response (UPR) pathway, and it is triggered by the accumulation of misfolded proteins in the endoplasmic reticulum (ER).
An early event of the UPR is the activation of the transcription factor Xbp1, which in turn activates the transcription of endoplasmic reticulum degradation-enhancing alpha-mannosidase-like protein 2 (EDEM2), a member of the endoplasmic reticulum associated degradation (ERAD) pathway. EDEM2 facilitates the removal of misfolded proteins. The ERAD pathway comprises five steps: (1) chaperone-mediated recognition of malformed proteins, (2) targeting of malformed proteins to the retrotranslocation machinery or E3-ligases, which involves EDEM2, (3) intitiation of retrotranslocation; (4) ubiquitylation and further retrotranslocation; and (5) proteosome targeting and degradation.
Antibodies are multi-subunit proteins comprising two heavy chains and two light chains, which must be properly folded and associated to form a functional heterotetramer. Any improvement in the efficient and accurate processing of the heavy and light chains to improve the yield or titer of functional antibody heterotetramers is desired.
SUMMARY
Applicants made the surprising discovery that the ectopic expression of EDEM2 in a protein-manufacturing cell line increases the average output of protein per cell, increases the titer of protein secreted into the media, and increases the integrated cell density of production cell lines.
Thus, in one aspect, the invention provides a cell containing (a) a recombinant polynucleotide that encodes a stress-induced mannose-binding lectin and (b) a polynucleotide that encodes a multi-subunit protein. In some embodiments, the stress-induced mannose-binding lectin is an EDEM2 protein, non-limiting examples of which are provided in Table 1, and the multi-subunit protein is an antibody. In other embodiments, the cell also contains a polynucleotide that encodes the active spliced form of XBP1, non-limiting examples of which are provided in Table 2. In one embodiment, the cell is a mammalian cell, such as a CHO cell used in the manufacture of biopharmaceuticals.
In another aspect, the invention provides a cell line derived from the cell described in the previous aspect. By “derived from”, what is meant is a population of cells clonally descended from an individual cell and having some select qualities, such as the ability to produce active protein at a given titer, or the ability to proliferate to a particular density. In some embodiments, the cell line, which is derived from a cell harboring the recombinant polynucleotide encoding a stress-induced mannose-binding lectin and a polynucleotide encoding a multi-subunit protein, is capable of producing the multi-subunit protein at a titer of at least 3 grams per liter of media (g/L), at least 5 g/L, or at least 8 g/L. In some embodiments, the cell line can attain an integrated cell density (ICD) that is at least 30% greater, at least 50% greater, at least 60% greater, or at least 90% greater than the integrated cell density attainable by a cell line derived from what is essentially the same cell but without the recombinant polynucleotide encoding the stress-induced mannose-binding lectin.
In another aspect, the invention provides an isolated or recombinant polynucleotide comprising a nucleic acid sequence encoding an EDEM2 protein, which is operably linked (cis) to a constitutive and ubiquitously expressed mammalian promoter, such as the ubiquitin C promoter. In some embodiments, the EDEM2 protein has the amino acid of SEQ ID NO: 8, or an amino acid sequence that is at least 92% identical to any one of SEQ ID NO: 1-7. In some embodiments, the polynucleotide comprises a nucleic acid sequence of SEQ ID NO: 16. In one particular embodiment, the polynucleotide consists of a nucleic acid sequence of SEQ ID NO: 14; and in another particular embodiment, SEQ ID NO: 15.
In another aspect, the invention provides an isolated or recombinant polynucleotide comprising a nucleic acid sequence encoding an XBP1 protein, which is operably linked to (in cis) a constitutive and ubiquitously expressed mammalian promoter, such as the ubiquitin C promoter. In some embodiments, the XBP1 protein has the amino acid of SEQ ID NO: 13, or an amino acid sequence that is at least 86% identical to any one of SEQ ID NO: 9-12. In some embodiments, the polynucleotide comprises a nucleic acid sequence of SEQ ID NO: 18. In one particular embodiment, the polynucleotide consists of a nucleic acid sequence of SEQ ID NO: 17.
In another aspect, the invention provides a cell that contains an EDEM2-encoding polynucleotide, as described in the prior aspect, and a polynucleotide that encodes a multi-subunit protein, such as an antibody. In some embodiments, the cell also contains an XBP1-encoding polynucleotide, as described in the preceding aspect. In one embodiment, the multi-subunit protein is an antibody, and the heavy chain of the antibody comprises an amino acid sequence of SEQ ID NO: 43 and SEQ ID NO: 44, and the light chain of the antibody comprises an amino acid sequence of SEQ ID NO: 45 and SEQ ID NO: 46. In this and several embodiments, each polypeptide subunit of the multi-subunit protein is encoded by a separate polynucleotide. Thus, for example, a polynucleotide encoding an antibody may include a polynucleotide encoding a heavy chain and a polynucleotide encoding a light chain, hence two subunits. In some embodiments, the cell is a chinese hamster ovary (CHO) cell.
In one embodiment, the encoded multi-subunit protein is an anti-GDF8 antibody having a heavy chain variable region amino acid sequence of SEQ ID NO: 20 and a light chain variable region amino acid sequence of SEQ ID NO: 22. In one embodiment, the anti-GDF8 antibody comprises a heavy chain having an amino acid sequence of SEQ ID NO: 19 and a light chain having an amino acid sequence of SEQ ID NO: 21. In one embodiment, the polynucleotide that encodes the heavy chain of the anti-GDF8 antibody comprises a nucleic acid sequence of SEQ ID NO: 23; and the polynucleotide that encodes the light chain of the anti-GDF8 antibody comprises a nucleic acid sequence of SEQ ID NO: 25. In one embodiment, the polynucleotide that encodes the heavy chain of the anti-GDF8 antibody consists of a nucleic acid sequence of SEQ ID NO: 24; and the polynucleotide that encodes the light chain of the anti-GDF8 antibody consists of a nucleic acid sequence of SEQ ID NO: 25.
In another embodiment, the encoded multi-subunit protein is an anti-ANG2 antibody having a heavy chain variable region amino acid sequence of SEQ ID NO: 28 and a light chain variable region amino acid sequence of SEQ ID NO: 30. In one embodiment, the anti-ANG2 antibody comprises a heavy chain having an amino acid sequence of SEQ ID NO: 27 and a light chain having an amino acid sequence of SEQ ID NO: 29. In one embodiment, the polynucleotide that encodes the heavy chain of the anti-ANG2 antibody comprises a nucleic acid sequence of SEQ ID NO: 31; and the polynucleotide that encodes the light chain of the anti-ANG2 antibody comprises a nucleic acid sequence of SEQ ID NO: 33. In one embodiment, the polynucleotide that encodes the heavy chain of the anti-ANG2 antibody consists of a nucleic acid sequence of SEQ ID NO: 32; and the polynucleotide that encodes the light chain of the anti-ANG2 antibody consists of a nucleic acid sequence of SEQ ID NO: 34.
In another embodiment, the encoded multi-subunit protein is an anti-ANGPTL4 antibody having a heavy chain variable region amino acid sequence of SEQ ID NO: 36 and a light chain variable region amino acid sequence of SEQ ID NO: 38. In one embodiment, the anti-ANGPTL4 antibody comprises a heavy chain having an amino acid sequence of SEQ ID NO: 35 and a light chain having an amino acid sequence of SEQ ID NO: 37. In one embodiment, the polynucleotide that encodes the heavy chain of the anti-ANGPTL4 antibody comprises a nucleic acid sequence of SEQ ID NO: 39; and the polynucleotide that encodes the light chain of the anti-ANGPTL4 antibody comprises a nucleic acid sequence of SEQ ID NO: 41. In one embodiment, the polynucleotide that encodes the heavy chain of the anti-ANGPTL4 antibody consists of a nucleic acid sequence of SEQ ID NO: 40; and the polynucleotide that encodes the light chain of the anti-ANGPTL4 antibody consists of a nucleic acid sequence of SEQ ID NO: 42.
In another aspect, the invention provides a method of manufacturing a multi-subunit protein, by culturing a cell of the previous aspect in a medium, wherein the multi-subunit protein is synthesized in the cell and subsequently secreted into the medium. In some embodiments, the multi-subunit protein is an antibody, such as for example anti-GDF8, anti-ANG2, anti-ANGPTL4, or an antibody having a heavy chain sequence of SEQ ID NO: 43 and 44, and a light chain sequence of SEQ ID NO: 45 and 46. In some embodiments, the multi-subunit protein attains a titer of at least 3 g/L, at least 5 g/L, at least 6 g/L, or at least 8 g/L. In some embodiments, the cell proliferates in the medium and establishes an integrated cell density of about ≧5×10 7 cell-day/mL, about ≧1×10 8 cell-day/mL, or about ≧1.5×10 8 cell-day/mL.
In another aspect, the invention provides a multi-subunit protein, which is manufactured according to the method described in the preceding aspect. In one embodiment, the manufactured protein is an antibody. In some embodiments, the antibody consists of a heavy chain, which comprises an amino acid sequence of SEQ ID NO: 43 and SEQ ID NO: 44, and a light chain, which comprises an amino acid sequence of SEQ ID NO: 45 and SEQ ID NO: 46. In one specific embodiment, the manufactured multi-subunit protein is an anti-GDF8 antibody having a heavy chain variable region amino acid sequence of SEQ ID NO: 20 and a light chain variable region amino acid sequence of SEQ ID NO: 22. In another specific embodiment, the manufactured multi-subunit protein is an anti-ANG2 antibody having a heavy chain variable region amino acid sequence of SEQ ID NO: 28 and a light chain variable region amino acid sequence of SEQ ID NO: 30. In yet another specific embodiment, the manufactured multi-subunit protein is an anti-ANGPTL4 antibody having a heavy chain variable region amino acid sequence of SEQ ID NO: 36 and a light chain variable region amino acid sequence of SEQ ID NO: 38.
DESCRIPTION
Before the present invention is described, it is to be understood that this invention is not limited to particular methods and experimental conditions described, as such methods and conditions may vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting, since the scope of the present invention will be limited only by the appended claims.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. As used herein, the term “about”, when used in reference to a particular recited numerical value or range of values, means that the value may vary from the recited value by no more than 1%. For example, as used herein, the expression “about 100” includes 99 and 101 and all values in between (e.g., 99.1, 99.2, 99.3, 99.4, etc.).
Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, the preferred methods and materials are now described. All publications mentioned herein are incorporated herein by reference in their entirety.
As used herein, the term “recombinant polynucleotide”, which is used interchangeably with “isolated polynucleotide”, means a nucleic acid polymer such as a ribonucleic acid or a deoxyribonucleic acid, either single stranded or double stranded, originating by genetic engineering manipulations. A recombinant polynucleotide may be a circular plasmid or a linear construct existing in vitro or within a cell as an episome. A recombinant polynucleotide may be a construct that is integrated within a larger polynucleotide molecule or supermolecular structure, such as a linear or circular chromosome. The larger polynucleotide molecule or supermolecular structure may be within a cell or within the nucleus of a cell. Thus, a recombinant polynucleotide may be integrated within a chromosome of a cell.
As used herein, the term “stress-induced mannose-binding lectin” refers to a mannose-binding protein, which means a protein that binds or is capable of binding mannose, derivatives of mannose, such as mannose-6-phosphate, or a glycoprotein that expresses mannose or a mannose derivative in its glycocalyx; and whose activity is upregulated during stress. Cellular stress includes inter alia starvation, DNA damage, hypoxia, poisoning, shear stress and other mechanical stresses, tumor stress, and the accumulation of misfolded proteins in the endoplasmic reticulum. Exemplary stress-induced mannose-binding lectins include the EDEM proteins EDEM1, EDEM2 and EDEM3, Yos 9, OS9, and XTP3-B (see Vembar and Brodsky, Nat. Rev. Mol. Cell. Biol. 9(12): 944-957, 2008, and references cited therein).
As used herein, the term “EDEM2” means any ortholog, homolog, or conservatively substituted variant of endoplasmic reticulum degradation-enhancing alpha-mannosidase-like protein. EDEM2 proteins are generally known in the art to be involved in endoplasmic reticulum-associated degradation (ERAD), being up-regulated by Xbp-1 and facilitating the extraction of misfolded glycoproteins from the calnexin cycle for removal. (See Mast et al., Glycobiology 15(4): 421-436, 2004; Olivari and Molinari, FEBS Lett. 581: 3658-3664, 2007; Olivari et al., J. Biol. Chem. 280(4): 2424-2428, 2005; and Vembar and Brodsky 2008, which are herein incorporated by reference.) Exemplary EDEM2 sequences are depicted in Table 1, which is cross-referenced to the Sequence Listing.
TABLE 1
Animal
SEQ ID NO:
% id human
% id mouse
% id hamster
Mouse
1
93
100
96
Rat
2
94
98
96
Hamster
3
93
96
100
Human
4
100
93
93
Chimpanzee
5
99
94
93
Orangutan
6
97
92
92
Zebra fish
7
69
70
69
Consensus
8
100
100
100
As used herein, the term “Xbp1”, also known as XBP1 or X-box binding protein 1, means any ortholog, homolog, or conservatively substituted variant of Xbp1. Xbp1 is a transcription factor and functional element of the UPR. ER stress activates both (1) the transcription factor ATF6, which in turn upregulates the transcription of Xbp1 mRNA, and (2) the ER membrane protein IRE1, which mediates the splicing of the precursor Xbp1 mRNA to produce active Xbp1. As mentioned above, activated Xbp1 in turn upregulates the activity of EDEM2. (See Yoshida et al., Cell Structure and Function 31(2): 117-125, 2006; and Olivari, 2005.) Exemplary Xbp1 amino acid sequences are depicted in Table 2, which is cross-referenced to the Sequence Listing.
TABLE 2
Animal
SEQ ID NO
% id human
% id mouse
% id hamster
Mouse
9
86
100
92
Hamster
10
86
92
100
Human
11
100
86
86
Zebra fish
12
47
47
48
Consensus
13
100
100
100
As used herein, the term “antibody” is generally intended to refer to immunoglobulin molecules comprising four polypeptide chains, two heavy (H) chains and two light (L) chains inter-connected by disulfide bonds, as well as multimers thereof (e.g., IgM); however, immunoglobulin molecules consisting of only heavy chains (i.e., lacking light chains) are also encompassed within the definition of the term “antibody”. Each heavy chain comprises a heavy chain variable region (abbreviated herein as HCVR or VH) and a heavy chain constant region. The heavy chain constant region comprises three domains, CH1, CH2 and CH3. Each light chain comprises a light chain variable region (abbreviated herein as LCVR or VL) and a light chain constant region. The light chain constant region comprises one domain (CL1). The VH and VL regions can be further subdivided into regions of hypervariability, termed complementary determining regions (CDRs), interspersed with regions that are more conserved, termed framework regions (FR). Each VH and VL is composed of three CDRs and four FRs, arranged from amino-terminus to carboxy-terminus in the following order: FR1, CDR1, FR2, CDR2, FR3, CDR3, FR4. An “isolated antibody” or “purified antibody” may be substantially free of other cellular material or chemicals.
The term “specifically binds”, or the like, means that an antibody or antigen-binding fragment thereof forms a complex with an antigen that is relatively stable under physiologic conditions. Specific binding can be characterized by a dissociation constant of at least about 1×10 −6 M or greater. Methods for determining whether two molecules specifically bind are well known in the art and include, for example, equilibrium dialysis, surface plasmon resonance, and the like. An isolated antibody that specifically binds human GDF8 (for example) may, however, have cross-reactivity to other antigens, such as GDF8 molecules from other species (orthologs).
Various antibodies are used as examples of multi-subunit proteins secreted by cells harboring the polynucleotide encoding a stress-induced mannose-binding lectin. Those examples include anti-GDF8, anti-ANG2, and anti-ANGPTL4 antibodies. These and similar antibodies are described in US Pat. Apps. No. 20110293630, 20110027286, and 20110159015 respectively, which are incorporated herein by reference.
As used herein, the term “cell” refers to a prokaryotic or eukaryotic cell capable of replicating DNA, transcribing RNA, translating polypeptides, and secreting proteins. Cells include animal cells used in the commercial production of biological products, such as insect cells (e.g., Schneider cells, Sf9 cells, Sf21 cells, Tn-368 cells, BTI-TN-5B1-4 cells; see Jarvis, Methods Enzymol. 463: 191-222, 2009; and Potter et al., Int. Rev. Immunol. 10(2-3): 103-112, 1993) and mammalian cells (e.g., CHO or CHO-K1 cells, COS or COS-7 cells, HEK293 cells, PC12 cells, HeLa cells, Hybridoma cells; Trill et al., Curr. Opin. Biotechnol. 6(5): 553-560, 1995; Kipriyanov and Little, Mo. Biotechnol. 12(2): 173-201, 1999). In one embodiment, the cell is a CHO-K1 cell containing the described UPR pathway polynucleotides. For a description of CHO-K1 cells, see also Kao et al., Proc. Nat'l. Acad. Sci. USA 60: 1275-1281, 1968.
As used herein, the term “promoter” means a genetic sequence generally in cis and located upstream of a protein coding sequence, and which facilitates the transcription of the protein coding sequence. Promoters can be regulated (developmental, tissue specific, or inducible (chemical, temperature)) or constitutively active. In certain embodiments, the polynucleotides that encode proteins are operably linked to a constitutive promoter. By “operably linked”, what is meant is that the protein-encoding polynucleotide is located three-prime (downstream) and cis of the promoter, and under control of the promoter. In certain embodiments, the promoter is a constitutive mammalian promoter, such as the ubiquitin C promoter (see Schorpp et al., Nucl. Acids Res. 24(9): 1787-1788, 1996); Byun et al., Biochem. Biophys. Res. Comm. 332(2): 518-523, 2005) or the CMV-IE promoter (see Addison et al., J. Gen. Virol. 78(7): 1653-1661, 1997; Hunninghake et al., J. Virol. 63(7): 3026-3033, 1989), or the hCMV-IE promoter (human cytomegalovirus immediate early gene promoter) (see Stinski & Roehr, J. Virol. 55(2): 431-441, 1985; Hunninghake et al., J. Virol. 63(7): 3026-3033, 1989).
As used herein, the phrase “integrated cell density”, or “ICD” means the density of cells in a culture medium taken as an integral over a period of time, expressed as cell-days per mL. In some embodiments, the ICD is measured around the twelfth day of cells in culture.
As used herein, the term “culture” means both (1) the composition comprising cells, medium, and secreted multi-subunit protein, and (2) the act of incubating the cells in medium, regardless of whether the cells are actively dividing or not. Cells can be cultured in a vessel as small as a 25 mL flask or smaller, and as large as a commercial bioreactor of 10,000 liters or larger. “Medium” refers to the culture medium, which comprises inter alia nutrients, lipids, amino acids, nucleic acids, buffers and trace elements to allow the growth, proliferation, or maintenance of cells, and the production of the multi-subunit protein by the cells. Cell culture media include serum-free and hydrolysate-free defined media as well as media supplemented with sera (e.g., fetal bovine serum (FBS)) or protein hydrolysates. Non-limiting examples of media, which can be commercially acquired, include RPMI medium 1640, Dulbecco's Modified Eagle Medium (DMEM), DMEM/F12 mixture, F10 nutrient mixture, Ham's F12 nutrient mixture, and minimum essential media (MEM).
As used herein, the phrase “conservatively substituted variant”, as applied to polypeptides, means a polypeptide having an amino acid sequence with one of more conservative amino acid substitutions. A “conservative amino acid substitution” is one in which an amino acid residue is substituted by another amino acid residue having a side chain (R group) with similar chemical properties (e.g., charge or hydrophobicity). In general, a conservative amino acid substitution will not substantially change the functional properties of a protein. In cases where two or more amino acid sequences differ from each other by conservative substitutions, the percent or degree of similarity may be adjusted upwards to correct for the conservative nature of the substitution. Means for making this adjustment are well known to those of skill in the art. See, e.g., Pearson (1994) Methods Mol. Biol. 24: 307-331, which is herein incorporated by reference. Examples of groups of amino acids that have side chains with similar chemical properties include 1) aliphatic side chains: glycine, alanine, valine, leucine and isoleucine; 2) aliphatic-hydroxyl side chains: serine and threonine; 3) amide-containing side chains: asparagine and glutamine; 4) aromatic side chains: phenylalanine, tyrosine, and tryptophan; 5) basic side chains: lysine, arginine, and histidine; 6) acidic side chains: aspartate and glutamate, and 7) sulfur-containing side chains: cysteine and methionine. Preferred conservative amino acids substitution groups are: valine-leucine-isoleucine, phenylalanine-tyrosine, lysine-arginine, alanine-valine, glutamate-aspartate, and asparagine-glutamine. Alternatively, a conservative replacement is any change having a positive value in the PAM250 log-likelihood matrix disclosed in Gonnet et al. (1992) Science 256: 1443-45, herein incorporated by reference. A “moderately conservative” replacement is any change having a nonnegative value in the PAM250 log-likelihood matrix.
EMBODIMENTS
The Cell
In one aspect, the invention provides a cell useful in the production of a protein having therapeutic or research utility. In some embodiments, the protein consists of multiple subunits, which must be properly folded and assembled to produce sufficient quantities of active protein. Antibodies are an example of multi-subunit proteins having therapeutic or research utility. In some embodiments, the cell harbors a recombinant genetic construct (i.e., a polynucleotide) that encodes one or more of the individual subunits of the multi-subunit protein. In other embodiments, the genetic construct encoding the individual polypeptide subunits is naturally occurring, such as for example the nucleic acid sequences encoding the subunits of an antibody in a B cell.
To facilitate the proper assembly and secretion of the multi-subunit protein, the cell contains a recombinant polynucleotide that encodes a stress-induced mannose-binding lectin, which in some embodiments is a component of the ERAD. In some embodiments, the stress-induced mannose-binding lectin is an endoplasmic reticulum degradation-enhancing alpha-mannosidase-like protein 2 (EDEM2). It is envisioned that any encoded EDEM2 or conservatively-substituted variant can be successfully employed in the instant invention. Table 1 lists some examples of vertebrate EDEM2 proteins. A multiple pairwise comparison of those protein sequences, which was performed using the Clustal W program of Thompson et al., Nucl. Acids Rev. 22(22): 4673-80, 1994 (see also Yuan et al., Bioinformatics 15(10): 862-3, 1999), revealed that each of the disclosed EDEM2 polynucleotide sequences is at least 69% identical to each other EDEM2 sequence. A Clustal W comparison of the disclosed mammalian EDEM2 sequences revealed that each sequence is at least 92% identical to the other. Thus, in some embodiments, the cell contains a polynucleotide that encodes an EDEM2 polypeptide having a sequence that is at least 92% to any one of a mammalian EDEM2. A consensus EDEM2 amino acid sequence was built by aligning a mouse, rat, hamster, chimpanzee, and human EDEM2 polypeptide amino acid sequences. That consensus sequence is depicted as SEQ ID NO: 8. Thus, in some embodiments, the cell contains a polynucleotide that encodes an EDEM2 polypeptide having an amino acid sequence of SEQ ID NO: 8.
In various embodiments, the cell contains a recombinant polynucleotide that encodes an EDEM2 polypeptide having an amino acid sequence that is at least 92% identical to the mouse EDEM2 (mEDEM2) amino acid sequence; and in a particular embodiment, the polypeptide is mEDEM2 or a conservatively substituted variant thereof.
In some embodiments, the multi-subunit protein is an antibody, and the cell contains a polynucleotide encoding any one or more of a polypeptide comprising an amino acid sequence of SEQ ID NO: 43, SEQ ID NO: 44, SEQ ID NO: 45, and SEQ ID NO: 46. SEQ ID NO: 43 and 44 each represent consensus sequences of the roughly N-terminal and C-terminal portions, respectively, of particular antibody heavy chains. Thus, the polynucleotide encoding a protein subunit in one embodiment encodes a polypeptide comprising both SEQ ID NO: 43 and SEQ ID NO: 44. SEQ ID NO: 45 and 46 each represent consensus sequences of the roughly N-terminal and C-terminal portions, respectively, of particular antibody light chains. Thus, the polynucleotide encoding a protein subunit in one embodiment encodes a polypeptide comprising both SEQ ID NO: 45 and SEQ ID NO: 46. In some embodiments, in addition to the recombinant polynucleotide encoding the EDEM2 protein, the cell contains at least two polynucleotides, each of which encodes a particular subunit of the multi-subunit protein. For example, and as exemplified below, the cell contains a polynucleotide encoding an antibody heavy chain comprising an amino acid sequence of SEQ ID NO: 43 and SEQ ID NO: 44, and another polynucleotide encoding an antibody light chain comprising an amino acid sequence of SEQ ID NO: 45 and SEQ ID NO: 46.
In some embodiments, the cell, in addition to containing the stress-response polynucleotide and one or more polynucleotides encoding a polypeptide subunit, as described above, also contains a polynucleotide that encodes an unfolded protein response transcription factor that operates upstream of EDEM2. The upstream transcription factor is in some cases the spliced form of an XBP1. It is envisioned that any encoded XBP1 can be successfully employed in the instant invention. Table 2 lists some examples of sequences of vertebrate XBP1 spliced-form polypeptides. A multiple pairwise comparison of those polypeptide sequences, which was performed using Clustal W (Thompson 1994; Yuan 1999), revealed that each of the disclosed spliced XBP1 polynucleotide sequences is at least 48% identical to each other XBP1 sequence. A Clustal W comparison of the disclosed mammalian XBP1 sequences revealed that each sequence is at least 86% identical to the other. Thus, in some embodiments, the cell contains a polynucleotide that encodes a spliced-form of an XBP1 polypeptide having a sequence that is at least 86% to any one of a mammalian spliced XBP1. A consensus XBP1 amino acid sequence was built by aligning a mouse, hamster, and human XBP1 amino acid sequences. That consensus sequence is depicted as SEQ ID NO: 13. Thus, in some embodiments, the cell contains a polynucleotide that encodes an XBP1 polypeptide having an amino acid sequence of SEQ ID NO: 13.
In various embodiments, the cell contains a polynucleotide that encodes an XBP1 polypeptide having an amino acid sequence that is at least 86% identical to the mouse XBP1 (mXBP1) amino acid sequence (SEQ ID NO: 9); and in a particular embodiment, the polypeptide is mXBP1, or a conservatively substituted variant thereof.
The invention envisions that any cell may be used to harbor the lectin-encoding polypeptide for the production of a properly folded and active multi-subunit protein. Such cells include the well-known protein production cells such as the bacterium Escherichia coli and similar prokaryotic cells, the yeasts Pichia pastoris and other Pichia and non- pichia yeasts, plant cell explants, such as those of Nicotiana , insect cells, such as Schneider 2 cells, Sf9 and Sf21, and the Trichoplusia ni -derived High Five cells, and the mammalian cells typically used in bioproduction, such as CHO, CHO-K1, COS, HeLa, HEK293, Jurkat, and PC12 cells. In some embodiments, the cell is a CHO-K1 or a modified CHO-K1 cell such as that which is taught in U.S. Pat. Nos. 7,435,553, 7,514,545, and 7,771,997, as well as U.S. Published Patent Application No. US 2010-0304436 A1, each of which is incorporated herein by reference in its entirety.
In some particular embodiments, the invention provides ex vivo a CHO-K1 cell that contains (1) a mEDEM2-encoding polynucleotide comprising a nucleotide sequence of SEQ ID NO: 16, (2) an XBP1-encoding polynucleotide comprising a nucleotide sequence of SEQ ID NO: 18, (3) an antibody heavy chain-encoding polynucleotide comprising a nucleotide sequence that encodes a polypeptide comprising the amino acid sequences of SEQ ID NO: 43 and 44, and (4) an antibody light chain-encoding polynucleotide comprising a nucleotide sequence that encodes a polypeptide comprising the amino acid sequences of SEQ ID NO: 45 and 46.
In one particular embodiment, the invention provides ex vivo a CHO-K1 cell that contains (1) a mEDEM2-encoding polynucleotide comprising a nucleotide sequence of SEQ ID NO: 16, (2) an XBP1-encoding polynucleotide comprising a nucleotide sequence of SEQ ID NO:18, (3) an antibody heavy chain-encoding polynucleotide comprising a nucleotide sequence of SEQ ID NO: 23, and (4) an antibody light chain-encoding polynucleotide comprising a nucleotide sequence of SEQ ID NO: 25.
In another particular embodiment, the invention provides ex vivo a CHO-K1 cell that contains (1) a mEDEM2-encoding polynucleotide comprising a nucleotide sequence of SEQ ID NO: 16, (2) an XBP1-encoding polynucleotide comprising a nucleotide sequence of SEQ ID NO: 18, (3) an antibody heavy chain-encoding polynucleotide comprising a nucleotide sequence of SEQ ID NO: 31, and (4) an antibody light chain-encoding polynucleotide comprising a nucleotide sequence of SEQ ID NO: 33.
In yet another particular embodiment, the invention provides ex vivo a CHO-K1 cell that contains (1) a mEDEM2-encoding polynucleotide comprising a nucleotide sequence of SEQ ID NO: 16, (2) an XBP1-encoding polynucleotide comprising a nucleotide sequence of SEQ ID NO: 18, (3) an antibody heavy chain-encoding polynucleotide comprising a nucleotide sequence of SEQ ID NO: 39, and (4) an antibody light chain-encoding polynucleotide comprising a nucleotide sequence of SEQ ID NO: 41.
The Cell Line
In another aspect, the invention provides a cell line, which comprises a plurality of cells descended by clonal expansion from a cell described above. At least 50%, at least 60%, at least 70%, at least 80%, at least 90%, at least 95%, at least 98%, at least 99%, or about 100% of the constituent cells of the cell line contain a recombinant polynucleotide that encodes a stress-induced mannose-binding lectin, which in some embodiments is a component of the ERAD. In some embodiments, the stress-induced mannose-binding lectin is an endoplasmic reticulum degradation-enhancing alpha-mannosidase-like protein 2 (EDEM2). It is envisioned that any encoded EDEM2 or conservatively-substituted variant thereof can be successfully employed in the instant invention. Table 1, as discussed in the previous section, lists some examples of vertebrate EDEM2 proteins. In some embodiments, the constituent cell contains a polynucleotide that encodes an EDEM2 polypeptide having a sequence that is at least 92% identical to any mammalian EDEM2. In some embodiments, the constituent cell contains a polynucleotide that encodes an EDEM2 polypeptide having the mammalian consensus amino acid sequence of SEQ ID NO: 8. In some embodiments, the constituent cell contains a recombinant polynucleotide of SEQ ID NO: 1 or a conservatively substituted variant thereof.
In some embodiments, the multi-subunit protein that is produced by the cell line is an antibody, and the constituent cell of the cell line contains a polynucleotide encoding any one or more of a polypeptide comprising an amino acid sequence of SEQ ID NO: 43 and SEQ ID NO: 44 (which represent consensus sequences of the N-terminal and C-terminal portions, respectively, of particular antibody heavy chains), and SEQ ID NO: 45 and SEQ ID NO: 46 (which represent consensus sequences of the N-terminal and C-terminal portions, respectively, of particular antibody light chains). In some embodiments, in addition to the recombinant polynucleotide encoding the EDEM2 protein, the constituent cell of the cell line contains at least two polynucleotides, each of which encodes a particular subunit of the multi-subunit protein. For example, the constituent cell contains a polynucleotide encoding an antibody heavy chain comprising an amino acid sequence of SEQ ID NO: 43 and SEQ ID NO: 44, and another polynucleotide encoding an antibody light chain comprising an amino acid sequence of SEQ ID NO: 45 and SEQ ID NO: 46.
In some embodiments, the constituent cell, in addition to containing the stress-response polynucleotide and one or more polynucleotides encoding a polypeptide subunit, as described above, also contains a polynucleotide that encodes an unfolded protein response transcription factor, which operates upstream of EDEM2, such as a spliced form of an XBP1. It is envisioned that any encoded XBP1 can be successfully employed in the instant invention. Table 2, as discussed in the preceding section, lists some examples of sequences of vertebrate XBP1 spliced-form polypeptides. Clustal W analysis of those sequences revealed that each of the disclosed spliced XBP1 polynucleotide sequences is at least 48% identical to each other XBP1 sequence; and a comparison of the mammalian XBP1 sequences revealed that each sequence is at least 86% identical to the other. Thus, in some embodiments, the constituent cell of the cell line contains a polynucleotide that encodes a spliced-form of an XBP1 polypeptide having a sequence that is at least 86% to any one of a mammalian spliced XBP1. In some embodiments, the constituent cell contains a polynucleotide that encodes an XBP1 polypeptide having a consensus amino acid sequence of SEQ ID NO: 13.
In various embodiments, the cell contains a polynucleotide that encodes an XBP1 polypeptide having an amino acid sequence that is at least 86% identical to the mouse XBP1 (mXBP1) amino acid sequence (SEQ ID NO: 9); and in a particular embodiment, the polypeptide is mXBP1 of SEQ ID NO: 9, or a conservatively substituted variant thereof.
The invention envisions that the cell line comprises constituent cells whose parent is selected from a list of well-known protein production cells such as, e.g., the bacterium Escherichia coli and similar prokaryotic cells, the yeasts Pichia pastoris and other Pichia and non- pichia yeasts, plant cell explants, such as those of Nicotiana , insect cells, such as Schneider 2 cells, Sf9 and Sf21, and the Trichoplusia ni -derived High Five cells, and the mammalian cells typically used in bioproduction, such as CHO, CHO-K1, COS, HeLa, HEK293, Jurkat, and PC12 cells. In some embodiments, the cell is a CHO-K1 or a modified CHO-K1 cell, such as that which is taught in U.S. Pat. Nos. 7,435,553, 7,514,545, and 7,771,997, as well as U.S. Published Patent Application No. US 2010-0304436 A1.
In some embodiments, the cell line, which is cultured in media, is capable of producing the multi-subunit protein and secreting the properly assembled multi-subunit protein into the media to a titer that is at least 3 g/L, at least 5 g/L, or at least 8 g/L.
Furthermore, the constituent cells of the cell line are capable proliferating in culture to such an extent as to attain an integrated cell density that is about 30% greater than the integrated cell density of a cell line that does not contain the recombinant polynucleotide encoding the stress-induced mannose-binding lectin. In some cases, the cell line is able to attain an integrated cell density that is at least about 50% greater, at least 60% greater, or at least 90% greater than the integrated cell density of a cell line that does not contain the recombinant polynucleotide that encodes a stress-induced mannose-binding lectin. In some embodiments, the integrated cell density of the cell line is assessed after about 12 days in culture.
In some particular embodiments, the invention provides a cell-line comprising clonally-derived constituent cells, wherein the constituent cell is a CHO-K1 cell that contains (1) a mEDEM2-encoding polynucleotide comprising a nucleotide sequence of SEQ ID NO: 16, (2) an XBP1-encoding polynucleotide comprising a nucleotide sequence of SEQ ID NO: 18, (3) an antibody heavy chain-encoding polynucleotide comprising a nucleotide sequence that encodes a polypeptide comprising the amino acid sequences of SEQ ID NO: 43 and 44, and (4) an antibody light chain-encoding polynucleotide comprising a nucleotide sequence that encodes a polypeptide comprising the amino acid sequences of SEQ ID NO: 45 and 46.
In one particular embodiment, the invention provides a cell-line comprising clonally-derived constituent cells, wherein the constituent cell is a CHO-K1 cell that contains (1) a mEDEM2-encoding polynucleotide comprising a nucleotide sequence of SEQ ID NO: 16, (2) an XBP1-encoding polynucleotide comprising a nucleotide sequence of SEQ ID NO: 18, (3) an antibody heavy chain-encoding polynucleotide comprising a nucleotide sequence of SEQ ID NO: 23, and (4) an antibody light chain-encoding polynucleotide comprising a nucleotide sequence of SEQ ID NO: 25.
In another particular embodiment, the invention provides a cell-line comprising clonally-derived constituent cells, wherein the constituent cell is a CHO-K1 cell that contains (1) a mEDEM2-encoding polynucleotide comprising a nucleotide sequence of SEQ ID NO: 16, (2) an XBP1-encoding polynucleotide comprising a nucleotide sequence of SEQ ID NO: 18, (3) an antibody heavy chain-encoding polynucleotide comprising a nucleotide sequence of SEQ ID NO: 31, and (4) an antibody light chain-encoding polynucleotide comprising a nucleotide sequence of SEQ ID NO: 33.
In yet another particular embodiment, the invention provides a cell-line comprising clonally-derived constituent cells, wherein the constituent cell is a CHO-K1 cell that contains (1) a mEDEM2-encoding polynucleotide comprising a nucleotide sequence of SEQ ID NO: 16, (2) an XBP1-encoding polynucleotide comprising a nucleotide sequence of SEQ ID NO: 18, (3) an antibody heavy chain-encoding polynucleotide comprising a nucleotide sequence of SEQ ID NO: 39, and (4) an antibody light chain-encoding polynucleotide comprising a nucleotide sequence of SEQ ID NO: 41.
The EDEM2 Polynucleotide
In another aspect, the invention provides a polynucleotide that encodes an EDEM2 protein. The EDEM2-encoding polynucleotide is recombinant and can be manufactured, stored, used or expressed in vitro, as in a test tube, or an in vitro translation system, or in vivo, such as in a cell, which can be ex vivo, as in a cell culture, or in vivo, as in an organism. In some embodiments, the EDEM2-encoding polynucleotide is within a gene, meaning that it is under the control of and down stream of a promoter, and up stream of a polyadenylation site. The EDEM2-encoding polynucleotide or gene can be within a plasmid or other circular or linear vector. The EDEM2-encoding polynucleotide or gene can be within a circular or linear DNA construct, which can be within a cell as an episome or integrated into the cellular genome.
As described above, the EDEM2-encoding polynucleotide encodes any ortholog, homolog or conservatively substituted EDEM2 polypeptide of Table 1, or an EDEM2 polypeptide having an amino acid sequence that is at least 92% identical to any one of SEQ ID NO: 1-5 and 8, including the mammalian consensus sequence of SEQ ID NO: 8.
In some cases, the recombinant or isolated EDEM2-encoding polynucleotide is operably linked to a mammalian promoter. The promoter can be any promoter, but in some cases it is a mammalian promoter, such as for example a ubiquitin C promoter.
In a particular embodiment, the EDEM2-encoding polynucleotide essentially consists of, from 5′ to 3′, a promoter, such as a ubiquitin C promoter, followed by an optional intron, such as a beta globin intron, followed by an EDEM2 coding sequence, followed by a polyadenylation sequence, such as an SV40pA sequence. A specific example, which is also a particular embodiment, of such an EDEM2-encoding polynucleotide is described by SEQ ID NO: 16. Conserved variants of that sequence are also envisioned to be embodiments of the invention.
In some cases, the recombinant EDEM2-encoding polynucleotide is part of a plasmid, which can be linear, circular, episomal, integrated, a static DNA construct, or a vector for delivering the EDEM2 gene or expressing the EDEM2 protein. In one particular embodiment, the plasmid contains (1) an EDEM2 gene, which is under the control of a ubiquitin C promoter and terminates with an SV40 polyadenylation signal, and (2) a selectable marker, such as a polynucleotide encoding a polypeptide that confers resistance to zeocin or a polynucleotide encoding a polypeptide that confers resistance to neomycin, under the control of a promoter, such as an SV40 promoter, and terminated with a polyadenylation sequence, such as a PGK pA sequence. In one particular embodiment, the plasmid comprises, in a circular format running in a 5′ to 3′ direction, a ubiquitin C promoter, a beta globin intron, an EDEM2 coding sequence, an SV40 pA sequence, an SV40 promoter, a neomycin-resistance coding sequence, and a PGK pA sequence. A specific example of this embodiment is exemplified by a plasmid having the sequence of SEQ ID NO: 14. In another particular embodiment, the plasmid comprises, in a circular format running in a 5′ to 3′ direction, a ubiquitin C promoter, a beta globin intron, an EDEM2 coding sequence, an SV40 pA sequence, an SV40 promoter, a zeocin-resistance coding sequence, and a PGK pA sequence. A specific example of this embodiment is exemplified by a plasmid having the sequence of SEQ ID NO: 15.
The XBP1 Polynucleotide
In another aspect, the invention provides a polynucleotide that encodes an XBP1 protein. The XBP1-encoding polynucleotide is recombinant and can be manufactured, stored, used or expressed in vitro, as in a test tube, or an in vitro translation system, or in vivo, such as in a cell, which can be ex vivo, as in a cell culture, or in vivo, as in an organism. In some embodiments, the XBP1-encoding polynucleotide is within a gene, meaning that it is under the control of and down stream of a promoter, and up stream of a polyadenylation site. The XBP1-encoding polynucleotide can be within a plasmid or other circular or linear vector. The XBP1-encoding polynucleotide or gene can be within a circular or linear DNA construct, which can be within a cell as an episome, or integrated into the cellular genome.
As described above, the XBP1-encoding polynucleotide encodes any ortholog, homolog or conservatively substituted XBP1 polypeptide of Table 2, or an XBP1 polypeptide having an amino acid sequence that is at least 86% identical to any one of SEQ ID NO: 9, 10, and 11, including the mammalian consensus sequence of SEQ ID NO: 13.
In some cases, the recombinant or isolated XBP1-encoding polynucleotide is operably linked to a mammalian promoter. The promoter can be any promoter, but in some cases it is a mammalian promoter, such as for example a ubiquitin C promoter.
In a particular embodiment, the XBP1-encoding polynucleotide essentially consists of, from 5′ to 3′, a promoter, such as a ubiquitin C promoter, followed by an optional intron, such as a beta globin intron, followed by an XBP1 coding sequence, followed by a polyadenylation sequence, such as an SV40 pA sequence. SEQ ID NO: 18 describes an example of an XBP1-encoding polynucleotide. Conserved variants of that exemplary sequence are also envisioned to be embodiments of the invention.
In some cases, the recombinant XBP1-encoding polynucleotide is part of a plasmid, which can be linear, circular, episomal, integrated, a static DNA construct, or a vector for delivering the XBP1 gene or expressing the spliced and active XBP1 protein. In one particular embodiment, the plasmid contains (1) an XBP1 gene, which is under the control of a ubiquitin C promoter and terminates with an SV40 polyadenylation signal, and (2) a selectable marker, such as a polynucleotide encoding a polypeptide that confers resistance to zeocin or a polynucleotide encoding a polypeptide that confers resistance to neomycin, under the control of a promoter, such as an SV40 promoter, and terminated with a polyadenylation sequence, such as a PGK pA sequence. In one particular embodiment, the plasmid comprises, in a circular format running in a 5′ to 3′ direction, a ubiquitin C promoter, a beta globin intron, an XBP1 coding sequence, an SV40 pA sequence, an SV40 promoter, a zeocin-resistance coding sequence, and a PGK pA sequence. A specific example of this embodiment is exemplified by a circular plasmid having the sequence of SEQ ID NO: 17.
The Antibody Heavy and Light Chain-Encoding Polynucleotides
In another aspect, the invention provides a polynucleotide that encodes an antibody heavy chain polypeptide (HC). The HC-encoding polynucleotide is recombinant and can be manufactured, stored, used or expressed in vitro, as in a test tube, or an in vitro translation system, or in vivo, such as in a cell, which can be ex vivo, as in a cell culture, or in vivo, as in an organism. In some embodiments, the HC-encoding polynucleotide is within a gene, meaning that it is under the control of and down stream from a promoter, and up stream of a polyadenylation site. The HC-encoding polynucleotide may be within a plasmid or other circular or linear vector. The HC-encoding polynucleotide or gene may be within a circular or linear DNA construct, which may be within a cell as an episome or integrated into the cellular genome.
In some cases, the recombinant or isolated HC-encoding polynucleotide is operably linked to a mammalian promoter. The promoter can be any promoter, but in some cases it is a mammalian promoter, such as for example a ubiquitin C promoter or an hCMV-IE promoter.
In a particular embodiment, the HC-encoding polynucleotide is an HC gene, which essentially comprises, from 5′ to 3′, a promoter, for example an hCMV-IE promoter, followed by an optional intron, such as a beta globin intron, followed by a heavy chain coding sequence, such as for example a sequence encoding an amino acid sequence of SEQ ID NO: 43 and 44, SEQ ID NO: 19, SEQ ID NO: 27, or SEQ ID NO: 35, followed by a polyadenylation sequence, for example an SV40 pA sequence. A specific example of an HC gene is described by SEQ ID NO: 23, SEQ ID NO: 31, or SEQ ID NO: 39. Conserved variants of any one of these sequences are also envisioned to be embodiments of the invention.
In some cases, the recombinant HC-encoding polynucleotide is part of a plasmid, which can be linear, circular, episomal, integrated, a static DNA construct, or a vector for delivering the heavy chain gene or expressing the heavy chain subunit. In one particular embodiment, the plasmid contains (1) an HC gene, which is under the control of an hCMV-IE promoter and terminates with an SV40 polyadenylation signal, and (2) a selectable marker, such as a polynucleotide encoding a polypeptide that confers resistance to hygromycin, under the control of a promoter, such as an SV40 promoter, and terminated with a polyadenylation sequence, such as a PGK pA sequence. In one particular embodiment, the plasmid comprises, in a circular format running in a 5′ to 3′ direction, an hCMV-IE promoter, a beta globin intron, an antibody heavy chain coding sequence (which encodes a HC having an amino acid of SEQ ID NO: 43 and 44, SEQ ID NO: 19, SEQ ID NO: 27, or SEQ ID NO: 35), an SV40 pA sequence, an SV40 promoter, a hygromycin-resistance coding sequence, and a PGK pA sequence. A specific example and particular embodiment of such a plasmid containing an HC gene is described by SEQ ID NO: 24, SEQ ID NO: 32, or SEQ ID NO: 40. Conserved variants of any one of these sequences are also envisioned to be embodiments of the invention.
In another aspect, the invention provides a polynucleotide that encodes an antibody light chain polypeptide (LC). The LC-encoding polynucleotide is recombinant and can be manufactured, stored, used or expressed in vitro, as in a test tube, or an in vitro translation system, or in vivo, such as in a cell, which can be ex vivo, as in a cell culture, or in vivo, as in an organism. In some embodiments, the LC-encoding polynucleotide is within a gene, meaning that it is under the control of and down stream from a promoter, and up stream of a polyadenylation site. The LC-encoding polynucleotide or gene may be within a plasmid or other circular or linear vector. The LC-encoding polynucleotide or gene may be within a circular or linear DNA construct, which may be within a cell as an episome or integrated into the cellular genome.
In some cases, the recombinant or isolated LC-encoding polynucleotide is operably linked to a mammalian promoter. The promoter can be any promoter, but in some cases it is a mammalian promoter, such as, e.g., a ubiquitin C promoter or an hCMV-IE promoter.
In a particular embodiment, the LC-encoding polynucleotide is an LC gene, which essentially comprises, from 5′ to 3′, a promoter, for example an hCMV-IE promoter, followed by an optional intron, such as a beta globin intron, followed by a light chain coding sequence, such as for example a sequence encoding an amino acid sequence of SEQ ID NO: 45 and 46, SEQ ID NO: 21, SEQ ID NO: 29, or SEQ ID NO: 37, followed by a polyadenylation sequence, such as an SV40 pA sequence. A specific example and particular embodiment of such an LC gene is described by SEQ ID NO: 25, SEQ ID NO: 33, or SEQ ID NO: 41. Conserved variants of any one of these sequences are also envisioned to be embodiments of the invention.
In some cases, the recombinant LC-encoding polynucleotide is part of a plasmid, which may be linear, circular, episomal, integrated, a static DNA construct, or a vector for delivering the light chain gene or expressing the light chain subunit. In one particular embodiment, the plasmid contains (1) an LC gene, which is under the control of an hCMV-IE promoter and terminates with an SV40 polyadenylation signal, and (2) a selectable marker, such as a polynucleotide encoding a polypeptide that confers resistance to hygromycin, under the control of a promoter, such as an SV40 promoter, and terminated with a polyadenylation sequence, such as a PGK pA sequence. In one particular embodiment, the plasmid comprises, in a circular format running in a 5′ to 3′ direction, an hCMV-IE promoter, a beta globin intron, an antibody light chain coding sequence (which encodes a LC having an amino acid of SEQ ID NO: 45 and 46, SEQ ID NO: 21, SEQ ID NO: 29, or SEQ ID NO: 37), an SV40 pA sequence, an SV40 promoter, a hygromycin-resistance coding sequence, and a PGK pA sequence. A specific example and particular embodiment of such a plasmid containing an LC gene is described by SEQ ID NO: 26, SEQ ID NO: 34, or SEQ ID NO: 42. Conserved variants of any one of these sequences are also envisioned to be embodiments of the invention.
Methods of Manufacturing Multi-subunit Proteins
In another aspect, the invention provides a method for manufacturing a multi-subunit protein by culturing a cell, or a constituent cell of a cell line, which is capable of producing and secreting relatively large amounts of a properly assembled multi-subunit protein, in a medium, wherein the multi-subunit component is secreted into the medium at a relatively high titer. The cell utilized in this manufacturing process is a cell described in the foregoing aspects, which contains an ERAD lectin-encoding polynucleotide described herein.
Methods of culturing cells, and in particular mammalian cells, for the purpose of producing useful recombinant proteins is well-known in the art (e.g., see De Jesus & Wurm, Eur. J. Pharm. Biopharm. 78:184-188, 2011, and references cited therein). Briefly, cells containing the described polynucleotides are cultured in media, which may contain sera or hydrolysates, or may be chemically defined and optimized for protein production. The cultures may be fed-batch cultures or continuous cultures, as in a chemostat. The cells may be cultured in lab bench size flasks (˜25 mL), production scale-up bioreactors (1-5 L), or industrial scale bioreactors (5,000-25,000 L). Production runs may last for several weeks to a month, during which time the multi-subunit protein is secreted into the media.
The subject cell has an enhanced ability to produce and secrete properly assembled multi-subunit proteins. In some embodiments, the multi-subunit protein, for example an antibody, is secreted into the media at a rate of at least 94 ρg/cell/day, at least 37 ρg/cell/day, or at least 39 ρg/cell/day. In some embodiments, the multi-subunit protein attains a titer of at least at least 3 g/L, at least 5 g/L, at least 6 g/L, or at least 8 g/L after about twelve days of culture.
Furthermore, the subject cell has an enhanced ability to proliferate and attain a relatively high cell density, further optimizing productivity. In some embodiments, the cell or cell-line seed train attains an integrated cell density in culture of at least 5×10 7 cell-day/mL, at least 1×10 8 cell-day/mL or at least 1.5×10 8 cell-day/mL.
Optionally, the secreted multi-subunit protein is subsequently purified from the medium into which it was secreted. Protein purification methods are well-known in the art (see e.g., Kelley, mAbs 1(5):443-452). In some embodiments, the protein is harvested by centrifugation to remove the cells from the liquid media supernatant, followed by various chromatography steps and a filtration step to remove inter alia viruses and other contaminants or adulterants. In some embodiments, the chromatography steps include an ion exchange step, such as cation-exchange or anion-exchange. Various affinity chromatographic media may also be employed, such as protein A chromatography for the purification of antibodies.
Optionally, the manufacturing method may include the antecedent steps of creating the cell. Thus, in some embodiments, the method of manufacturing the multi-subunit protein comprises the step of transfecting the cell with the vector that encodes the stress-induced mannose-binding lectin, as described above, followed by selecting stable integrants thereof. Non-limiting examples of vectors include those genetic constructs that contain a polynucleotide that encodes an EDEM2 having an amino acid sequence of any one of SEQ ID NO: 1-8, an amino acid sequence that is at least 92% identical to any one of SEQ ID NO: 1-8, or any one of a conservatively substituted variant of SEQ ID NO: 1-8. Useful vectors also include, for example, a plasmid harboring the gene of SEQ ID NO: 16, the plasmid of SEQ ID NO: 15, and the plasmid of SEQ ID NO: 14. One should keep in mind that the plasmid sequences (e.g., SEQ ID NO: 14, 15, 17, 24, 26, 32, 34, 40, and 42) are circular sequences described in a linear manner in the sequence listing. Thus, in those cases, the 3-prime-most nucleotide of the written sequence may be considered to be immediately 5-prime of the 5-prime-most nucleotide of the sequence as written. In the example of the plasmid of SEQ ID NO: 14, transformants are selected through resistance to neomycin; for SEQ ID NO: 15, by selection through ZEOCIN resistance.
Detailed methods for the construction of polynucleotides and vectors comprising same, are described in U.S. Pat. Nos. 7,435,553 and 7,771,997, which are incorporated herein by reference, and in, e.g., Zwarthoff et al., J. Gen. Virol. 66(4):685-91, 1985; Mory et al., DNA. 5(3):181-93, 1986; and Pichler et al., Biotechnol. Bioeng. 108(2):386-94, 2011.
The starting cell, into which the vector that encodes the stress-induced mannose-binding lectin is placed, may already contain the constructs or genetic elements encoding or regulating the expression of the subunits of the multi-subunit protein, or XBP1 for those embodiments utilizing XBP1. Alternatively, the vector that encodes the stress-induced mannose-binding lectin may be put inside the cell first, and followed by the other constructs.
Multi-Subunit Proteins Manufactured by the Process
In another aspect, the invention provides a multi-subunit protein that is made according to the process disclosed herein. Given the inclusion of one or more elements that facilitate the proper folding, assembly, and post-translational modification of a multi-subunit protein, such as an antibody, one of ordinary skill in the art would reasonably expect such a protein to have distinct structural and functional qualities. For example, an antibody manufactured by the disclosed process is reasonably believed to have a particular glycosylation pattern and a quantitatively greater proportion of non-aggregated heterotetramers.
EXAMPLES
The following examples are presented so as to provide those of ordinary skill in the art with a complete disclosure and description of how to make and use the methods and compositions of the invention, and are not intended to limit the scope of what the inventors regard as their invention. Efforts have been made to ensure accuracy with respect to numbers used (e.g., amounts, temperature, etc.) but some experimental errors and deviations should be accounted for. Unless indicated otherwise, parts are parts by mole, molecular weight is average molecular weight, percent concentration (%) means the mass of the solute in grams divided by the volume of the solution in milliliters times 100% (e.g., 10% substance X means 0.1 gram of substance X per milliliter of solution), temperature is in degrees Centigrade, and pressure is at or near atmospheric pressure.
Example 1
Cell Lines
CHO-K1 derived host cell line was transfected with two plasmids encoding heavy and light chain of a human antibody. Both plasmids contain the hph gene conferring resistance to hygromycin B (Asselbergs and Pronk, 1992, Mol. Biol. Rep., 17(1):61-70). Cells were transfected using LIPOFECTAMIN reagent (Invitrogen cat. #18324020). Briefly, one day before transfection 3.5 million cells were plated on a 10 cm plate in complete F12 (Invitrogen cat. #11765) containing 10% fetal bovine serum (FBS) (Invitrogen cat. #10100). On the day of transfection the cells were washed once and medium was replaced with OPTIMEM from (Invitrogen cat. #31985). DNA/Lipofectamin complexes were prepared in OPTIMEM medium and then added to the cells. The medium was changed again to the complete F12 with 10% FBS 6 hours later. The stable integration of the plasmids was selected using hygromycin B selection agent at 400 μg/ml. Clonal antibody expressing cell lines were isolated using the FASTR technology (described in the U.S. Pat. No. 6,919,183, which is herein incorporated by reference).
The antibody expressing lines were then re-transfected with the EDEM2 encoding plasmid. EDEM2 plasmids contained either neomycin phosphotransferase (plasmid construct designated “p3”) or sh ble (plasmid “p7”) genes to confer resistance to either G418 or zeocin respectively. The same transfection method was used. Depending on the selectable marker, cells were selected with either G418 or zeocin at 400 μg/ml or 250 μg/ml, respectively. The clonal cell lines were then isolated using FASTR technology.
TABLE 3
Cell Lines
Name
Enhancers
Constructs
Protein
C1
EDEM2 + XBP1
HC/LC = p1/p2
αAng2
C2
XBP1
EDEM2 = p3
XBP1 = p4
C3
EDEM2 + XBP1
HC/LC = p5/p6
αGDF8
C4
XBP1
EDEM2 = p7
C5
EDEM2
XBP1 = p4
C6
EDEM2 + XBP1
HC/LC = p8/p9
αAngPtl4
C7
XBP1
EDEM2 = p3
XBP1 = p4
Example 2
The antibody production was evaluated in a scaled-down 12-day fed batch process using shaker flasks. In this method the cells were seeded in a shaker flask at the density of 0.8 million cells per mL in the production medium (defined media with high amino acid). The culture was maintained for about 12 days, and was supplemented with three feeds as well as glucose. The viable cell density, and antibody titer were monitored throughout the batch.
To determine the effect of mEDEM2 on enhanced protein production, the production of proteins by CHO cell lines containing mEDEM2 and mXBP1 were compared to production by control cells that contained mXBP1, but not mEDEM2. Protein titers were higher in those cell lines expressing mEDEM2 versus those cell lines that did not express mEDEM2.
TABLE 4
TITERS
Production rate
Titre g/L
Cell Line
Enhancers
(ρg/cell/day)
(% increase)
C1
EDEM2 + XBP1
39
8.1 (93)
C2
XBP1
39
4.2
C3
EDEM2 + XBP1
37
5.9 (55)
C8
XBP1
32
3.8
C6
EDEM2 + XBP1
94
5.3 (152)
C7
XBP1
52
2.1
C5
EDEM2
29
3.1 (343)
C9
—
9
0.7
Example 3
Integrated Cell Days
Integrated Cell Days (“ICD”) is a phrase used to describe the growth of the culture throughout the fed batch process. In the course of the 12-day production assay, we monitored viable cell density on days 0, 3, 5, 7, 10, and 12. This data was then plotted against time. ICD is the integral of viable cell density, calculated as the area under the cell density curve. EDEM2 transfected lines have higher ICD in a 12-day fed batch process (see Table 5).
TABLE 5
INTEGRATED CELL DENSITIES
ICD 10 6 cell-day/mL
Cell Line
Enhancers
(% increase)
C1
EDEM2 + XBP1
205 (93)
C2
XBP1
106
C3
EDEM2 + XBP1
157 (34)
C4
XBP1
117
C6
EDEM2 + XBP1
56 (51)
C7
XBP1
37
C5
EDEM2
116 (59)
C9
—
73
Example 4
Anti-GDF8 Antibody Production
The effect of ectopic expression of EDEM2, XBP1, or both on the production of an anti-GDF8 antibody having a heavy chain sequence of SEQ ID NO: 19 and a light chain sequence of SEQ ID NO: 21 was examined. Individual cell-lines were examined for titer and integrated cell density and placed into “bins”, or ranges of values. Ectopic expression of EDEM2 significantly increased the number of cell lines that express antibody in the 5-6 g/L titer range. The combination of XBP1 and EDEM2 showed more than an additive effect toward the increase in high titer cell lines. The expression of EDEM2 in the antibody secreting cells also significantly increased the number of cell lines that attain a high ICD (see Table 6).
TABLE 6
ICD Bins
con-
Titre Bins (g/L)
(10 6 cell-day/mL)
struct
<1
1-3
3-5
5-6
30-50
50-100
100-200
E + X
0%
33.3%
44.4%
22.2%
11.1%
50%
38.9%
X
0%
37.5%
54%
8.3%
14.3%
85.7%
0%
E
0%
33%
60%
7%
0%
27%
73%
—
82%
18%
0%
0%
13%
67%
21%
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The present invention relates to discovery of the ectopic expression of EDEM2 in a production cell to improve the yield of a useful multi-subunit protein. Thus, the present invention provides for production cell lines, such as the canonical mammalian biopharmaceutical production cell—the CHO cell, containing recombinant polynucleotides encoding EDEM2. Also disclosed is a production cell containing both an EDEM2-encoding polynucleotide as well an XBP1-encoding polynucleotide. Improved titers of antibodies produced by these cell lines are disclosed, as well as the improved cell densities attained by these cells in culture.
| 2
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This is a division, of application Ser. No. 06/558,471, filed Dec. 6, 1983 now U.S. Pat. No. 4,529,812.
BACKGROUND OF INVENTION
The present invention relates to certain novel organic compounds. In particular this invention relates to certain novel 3-oxaprostaglandin derivatives of Formula VII. In addition, this invention relates to certain trialkylsilyl intermediates of Formula VIII.
The novel compounds of the present invention display valuable pharmacological properties as is exemplified by their ability to inhibit the gastric secretion stimulated by secretogogues such as histamine and pentagastrin. In addition, these compounds possess the remarkable ability to protect the gastric and intestinal mucosa against the damaging effects of such agents as ethanol and aspirin. This effect has been termed "cytoprotection" (see A. Robert et al., Gastroenterology, 77, 433 (1979)). Furthermore, these compounds have the surprising advantage of substantially decreased undesirable side effects such as diarrhea and uterine stimulant activity displayed by related substances. The gastric antisecretory activity is determined by standard laboratory means.
Gastric antisecretory agents may be used to treat such diseases as hypersecretion of gastric acid and peptic ulcer. A number of methods to control these conditions exist including, gastric antacids, antimuscarinic drugs, H 2 -receptor blockers and prostaglandins (PG). Goodman and Gilman, Sixth Ed., 1980, pgs. 997, 632, 995-997 and 678.
PG analogs are all known to cause side effects, notably diarrhea. However, the capacity to suppress gastric secretion by these compounds is well documented.
Prostanoic acid is well known and has the structure and numbering as follows. ##STR1##
The compounds are more particularly derivatives of PGE 2 . For background on prostaglandins, see for example Bergstrom et al., Pharmacol. Rev. 20, 1 (1968).
PRIOR ART
Derwent abstract 60337V/34 corresponding to German Offenlegungsschrift 2,406287 depicts 3-oxaprostaglandins of the E 2 series, specifically as 15-hydroxy compounds.
SUMMARY OF THE INVENTION
The present invention particularly provides a compound according to formula: ##STR2## Wherein R 1 is:
(a) hydrogen;
(b) alkyl of 1 to 6 carbon atoms, inclusive;
(c) trifluoromethyl;
(d) trichloromethyl;
(e) alkenyl; or
(f) alkynyl;
wherein R 2 is straight chain alkyl of 1 to 6 carbon atoms inclusive; wherein R 3 is:
(a) --COOR 4 ;
(b) --CH 2 OH; or
(c) --C(O)CH 2 OH;
wherein R 4 is alkyl of 1 to 6 carbon atoms inclusive and wherein n is an integer of from 1 to 6 inclusive.
In addition the invention also relates to novel intermediates of the formula: ##STR3## Where n, R 1 and R 2 are as described above and alkyl relates to alkyl of 1 to 6 carbon atoms inclusive.
Examples of alkyl 1 to 6 carbon atoms, inclusive, are methyl, ethyl, propyl, butyl, pentyl and hexyl and isomeric forms thereof.
Also included in the invention are the individual stereoisomers, and mixtures of the isomers.
Optional bonds are indicated as dashed lines.
Further, alpha configurations are represented by a hatched line, and beta configurations are represented by a solid line, in all formulas.
The specific assay used to detect gastric antisecretory activity is described as follows:
Adult female beagle dogs weighing 13-20 kg are prepared with denervated fundic Heidenhain pouches. After a recovery period of at least 4 weeks following surgery, the animals are fasted for approximately 20 hours, then are placed in Pavlov stands and infused intravenously with saline solution. The pouched secretions are collected every 15 minutes and measured for volume and total acidity by titration with 0.1N sodium hydroxide to pH 7.0. Following a 30 minute basal secretion the dogs are infused with a saline solution of histamine dihydrochloride at a dose of 1.0 mg/hr. The volume of the diffusion is kept at approximately 13 ml/hr. A steady state plateau of gastric secretion is obtained approximately 1 hour following the start of histamine infusion, at the end of which time the test compound dissolved in an ethanolic iso-osmotic phosphate buffer solution is administered by a single intravenous injection. The duration of the anti-secretory effects is determined and the side-effects, if any, recorded. The compound is rated active if statistically significant inhibition of secretory parameters occur following compound treatment.
Cytoprotective activity is tested as follows. Male, Charles River rats, weighing 180 to 220 g, which are food deprived for 24 hours are administered a test compound. Thirty minutes later, each rat is given 1.0 ml of absolute ethanol intragastrically. The rats are sacrificed sixty minutes after alcohol administration and gastric mucosae are visually examined for the presence of lesions. Objective scoring is based on the presence or absence of lesions and data recorded as the number of rats per group completely protected from lesion formation.
Compounds of this invention were tested as above and found to be antisecretory and cytoprotective. By virtue of these activities, the compounds of Formula VII are useful in treating and alleviating gastric ulcers in mammals.
The compounds of the present invention are formulated into pharmaceutically acceptable dosage forms by conventional methods known to the pharmaceutical art. For example, the compounds can be administered in oral unit dosage forms such as tablets, capsules, pills, powders, or granules. They also may be administered rectally or vaginally in such forms as suppositories or bougies; they may also be introduced in the form of eye drops, intraperitoneally, subcutaneously, or intramuscularly, using forms known to the pharmaceutical art. In general the preferred form of administration is oral.
An effective but non-toxic quantity of the compound is employed in treatment. The dosage regimen for preventing or treating symptoms by the compounds of this invention is selected in accordance with a variety of factors including the type, age, weight, sex, and medical condition of the mammal, the severity of the symptoms, the route of administration and the particular compound employed. An ordinarily skilled physician or veterinarian will readily determine and prescribe the effective amount of the agent to prevent or arrest the progress of the condition. In so proceeding, the physician or veterinarian could employ relatively low dosages at first, subsequently increasing the dose until a maximum response is obtained.
Initial dosages of the compounds of the invention are ordinarily in the area of 0.25 μg/kg up to at least 50 μg/kg orally. When other forms of administration are employed equivalent doses are administered.
The compounds of this invention can also be administered as pharmacologically acceptable alkali metal salts such as lithium, sodium and potassium and the like, and hydrates thereof.
The compounds of Formula VIII are useful in preparing compounds of Formula VII.
The compounds of this invention are prepared by the general methods illustrated in the accompanying Charts A through F. Chart A: Furfural, Formula I, reacts with omega-alkynyl magnesium halides, Grignard reagents prepared by methods known to those skilled in the art from omega-haloalk-1-ynes, II, to form the intermediate compounds of Formula III. Where n is greater than 1, the acetylene group of the Grignard is protected by a trialkylsilyl group that can later readily be removed by aqueous potassium fluoride treatment. Where n is 1, R may be hydrogen and no deprotection is necessary to yield compound III. Preferred reaction conditions include addition at ca. 0° of a tetrahydrofuran solution of compound I to a diethyl ether solution of the freshly prepared Grignard reagent. Compounds III are typically purified by distillation at reduced pressure. The intermediates III rearrange upon heating under acidic conditions to form cyclopentenyl compounds of Formula IV. Preferred conditions include heating at ca. 80°-85° in aqueous dioxane containing p-toluenesulfonic acid. Crude compounds IV are typically purified by extraction and column chromatography on silica gel. Compound III further rearranges under acidic or basic conditions to form the isomeric compounds of Formula V. Preferred conditions include treatment of compounds IV with basic Grade III alumina at room temperature. Protection of alcohol intermediates V, using a protecting group (R 10 ) such as trialkylsilyl or tetrahydropyranyl by reaction in an inert organic solvent affords the protected derivatives, Formula VI. Preferred reagents and conditions include triethylsilyl chloride and imidazole in dimethylformamide at room temperature. The intermediate compounds VI are typically purified by column chromatography on silica gel.
Chart B: Compounds VI react first with organocopper reagents, Formula XI (prepared by the general method described in U.S. Pat. No. 4,271,314) and then with suitable silylating reagent to form intermediates of Formula XII. Preferred conditions include reaction of VI and XI at ca. -60° in diethyl ether, followed by addition of a trialkyl silyl chloride, preferably with at least one bulky alkyl group (e.g. t-butyldimethylsilyl chloride) which will increase yields and stability, and hexamethylphosphoric triamide, with warming to ca. -20°. After extracting into an organic solvent, such as diethyl ether, and stripping volatiles, the crude intermediates XII are typically purified by column chromatography on silica gel. The acetylenic intermediates XII, after treatment with a strong nonaqueous base in an inert organic solvent, react with dry paraformaldehyde to form isolable intermediates which in turn may be treated with alkyl haloacetates to form intermediates of Formula XIII. Preferred conditions include reaction of XII with butyllithium in tetrahydrofuran at ca. -20°, followed next by addition of paraformaldehyde, and then by addition of alkyl bromoacetates and hexamethylphosphoric triamide. Intermediates XIII are typically purified by column chromatography on silica gel. Hydrolysis of protected compounds XIII under acidic conditions affords acetylenic compounds of this invention, Formula XIV. Preferred hydrolytic conditions include a 3:1:1 mixture of acetic acid/tetrahydrofuran/water stirred at room temperature initially and then warmed to ca. 45°-50°. Acetylenic compounds XIV are typically purified by column chromatography on silica gel.
Analogous alkenyl compounds of this invention, Formula XV, are prepared by catalytic hydrogenation of compounds XIV, using such catalysts as palladium, platinum, ruthenium, and rhodium which have been suitably attenuated or Raney Nickel. Preferred reduction conditions employ hydrogen at atmospheric pressure, cyclohexane/toluene containing quinoline, and 5% palladium/calcium carbonate catalyst. Alkenyl compounds XV are typically purified by column chromatography on silica gel.
An alternative conversion of intermediate XIII to alkenyl compounds XV is illustrated in Chart C: Compound XIII is initially hydrogenated by the general method described in Chart B. Hydrogenation conditions are similar, except that the preferred catalyst is 5% palladium/barium sulfate. Hydrolysis of resultant intermediates, Formula XXI, under acidic conditions affords alkenyl compounds XV. Preferred hydrolytic conditions include a 3:1:1 acetic acid/tetrahydrofuran/water mixture.
The carboxylate function of acetylenic or alkenyl compounds of Formulas XIII and XXI may be reduced to corresponding alcohol functions, as illustrated in Chart D. Reductions are effected with any of various active metal hydrides by methods known to those skilled in the art. Preferred conditions include reaction at ca. 0° with lithium aluminum hydride in diethyl ether. Silyl protecting groups are removed by hydrolysis under acidic conditions, preferably 3:1:1 acetic acid/tetrahydrofuran/water, giving compounds of Formula XXXI. The compounds are typically purified by column chromatography on silica gel.
Charts E and F illustrate methods for preparing hydroxymethylketone analogs from the furan intermediate III (wherein n is 1) described above. (See Chart A.) Chart E: The hydroxyl function of III is protected with an acid-labile group for subsequent reactions. A preferred protecting group is tetrahydropyranyl, added to compounds III by reaction with dihydropyran under acidic conditions by methods known to those skilled in the art. The protected intermediate is converted to acetylenic intermediates XLI by reactions first with paraformaldehyde in strongly basic medium and then with alkyl haloacetates, as described above. (See Chart B.) Corresponding alkenyl intermediates, Formula XLII, are prepared by catalytic reduction of acetylenic compounds XLI, as described above. (See Charts B and C.) A preferred hydrogenation catalyst is 5% palladium/calcium carbonate.
Chart F: Rearrangements of acetylenic or alkenyl compounds, Formulas XLI and XLII, to cyclopentenyl compounds, Formula LI, are effected by the same general methods used to convert compound III to compound V, described above. (See Chart A.) The preferred basic conditions for the second rearrangement, however, employ aqueous sodium carbonate containing a small quantity of hydroquinone. Reaction of intermediates LI with a hindered trialkylsilyl halide, preferably t-butyldimethylsilyl chloride, affords intermediates of Formula LII. The ester function of LII is converted to the hydroxymethylketone function of LIII by the general method described by A. Wissner, J. Org. Chem., 44, 4617 (1979). Intermediates LII, are converted to the corresponding acyl halides, preferably by reaction with oxalyl chloride and dimethylformamide in an inert organic solvent such as dichloromethane. The unisolated acyl halides react with tris(trimethylsilyloxy)ethylene to form unisolated intermediates which, upon heating in acidic medium, hydrolyze and decarboxylate to intermediate alcohols LIII, which are typically purified by column chromatography on silica gel. Silylation of compounds LIII affords protected compounds, Formula LIV. Preferred silylation conditions include reaction of LIII with triethylsilyl chloride in dimethylformamide containing imidazole. Reaction of intermediates LIV with organocopper compounds of Formula XI as described above (See Chart B.), followed by hydrolysis, preferably using 3:1:1 acetic acid/tetrahydrofuran/water as described above (See Chart B.), affords hydroxymethylketone compounds of this invention, Formula LV. Compounds LV are typically purified by column chromatography on silica gel.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
EXAMPLE 1
Preparation of α-(2-propynyl)-2-furanmethanol
Propargyl magnesium bromide was prepared by adding a solution of propargyl bromide (as 145.5 g of 80%, by weight, solution in toluene; 0.976 mole) in 150 ml of diethyl ether to a slurry of 26 g (1.07 mole) of iodine-activated magnesium and 340 mg of mercuric chloride in 450 ml of ether. The rate of addition was adjusted to maintain a vigorous reflux. After addition was complete, the reaction mixture was stirred at room temperature for one hour and then cooled at 0°. A solution of 75 g (0.78 mole) of 2-furancarboxaldehyde in 400 ml of tetrahydrofuran was added dropwise, and the reaction mixture was stirred at room temperature for fifteen minutes, then poured onto a cold saturated ammonium chloride solution and stirred vigorously. The layers were separated and the aqueous layer was extracted with ether. The organic phase was washed with saturated ammonium chloride solution and with brine, dried over sodium sulfate, filtered, and concentrated to dryness. Distillation of the crude material at 1.0 torr gave 100.6 g of the title compound, b.p. 68°-72°. Structure assignment was confirmed by the proton nmr spectrum: 2.05 (t, J=2-3 HZ, .tbd.C--H), 2.59 (d of d, J=2-3 and 5-6 Hz, --CH 2 --C.tbd.), 4.80 (q, J=5-6 Hz, --CHOH--), 6.27 and 7.32 ppm (furan). ##STR4##
EXAMPLE 2
4-hydroxy-2-(2-propynyl)-2-cyclopenten-1-one
To a solution of 40.2 g (0.295 mole) of the title compound of Example 1 in 800 ml of a 8:1 dioxane/water mixture was added 4 g (0.21 mole) of p-toluenesulfonic acid. The reaction mixture was heated at 83° for 36 hours under argon, cooled, and diluted with 500 ml of ethyl acetate. The organic phase was washed once with water and two times each with 5% sodium bicarbonate solution and brine solution. The aqueous washes were combined and extracted with ethyl acetate. The combined organic phases were dried over sodium sulfate, filtered, and concentrated. Chromatography of the combined crude materials on silica gel (using 25% ethyl acetate in hexane as eluent) gave 12.45 g of the intermediate compound 4-hydroxy-5-(2-propynyl)-2-cyclopenten-1-one as a viscous oil. Structure assignment was confirmed by the proton nmr spectrum.
A solution of 14.5 g (0.11 mole) of the cyclopentenone intermediate in 50 ml of ether was poured into a column packed with 282 g of Grade III alumina (6% water by weight). The column was closed and allowed to stand at room temperature for twenty four hours. The product was eluted from the column with ether and ethyl acetate to give 7.3 g of the title compound as a viscous oil. Structure assignment was confirmed by the proton nmr spectrum: ##STR5## 4.98 (--CHOH), 2.16 (t, J=2-3 Hz, .tbd.C--H), 3.07 ppm (mult, J--CH 2 --C.tbd.). ##STR6##
EXAMPLE 3
2-(2-propynyl)-4-[(triethylsilyl)oxy]-2-cyclopenten-1-one
A solution of 250 mg (1.84 mmole) of the title compound of Example 2 in 4 ml of dimethylformamide was treated successively with 200 mg (3 mmole) of imidazole and 300 mg (2 mmole) of triethylsilyl chloride. After stirring for thirty minutes, the reaction mixture was diluted with ether, washed with water, dried over sodium sulfate, filtered, and concentrated to dryness. The crude material was chromatographed on silica gel to give 0.37 g of the title compound as an oil. Structure assignment was confirmed by the proton nmr spectrum: 2.13 (t, J=2 Hz, .tbd.C--H), 3.08 (mult, --CH 2 --C.tbd.), 4.90 (mult, C-11), ##STR7##
EXAMPLE 4
(1,1-dimethylethyl)dimethyl[[3β-[4-methyl-4-[(trimethylsilyl)oxy]-1E-octenyl]-2-(2-propynyl)-4α-[triethylsilyl)oxy]-1-cyclopenten-1-yl]oxy]silane
A solution of 10 g (0.02 mole) trimethyl[1-methyl-1-[3-(tributylstannyl)-2E-propenyl]pentoxy]silane in 25 ml of tetrahydrofuran was cooled to -60° under an argon atmosphere, and 11.8 ml of a 1.7M solution of n-butyllithium is hexane (0.02 mole) was added. The reaction mixture was stirred for forty five minutes, after which a solution of 2.62 g (0.02 mole) of copper-1-pentyne and 6.4 g (0.04 mole) of hexamethylphosphorus triamide in 75 ml of ether was added dropwise. After ten minutes, a solution of 2.4 g (0.01 mole) of the title compound of Example 3 in 20 ml of ether was added, and the reaction mixture was stirred an additional 45 minutes. A solution of 3 g (0.02 mole) of t-butyldimethylsilyl chloride in 15 ml of ether was added, followed by the addition of 25 ml of hexamethylphosphoric triamide. The temperature was allowed to rise to - 20°, where it was maintained for one hour. The reaction mixture was poured into 1N hydrochloric acid and ether. The layers were separated and the organic phase was washed with water, dried over sodium sulfate, filtered, and concentrated to dryness. The crude material was chromatographed on silica gel to give 4 g of the title compound as a viscous oil. Structure assignment was confirmed by the proton nmr spectrum: 1.80 (t, J=1-2 Hz, .tbd.C--H), 4.95-5.80 (mult, C-13, 14), 0.90 ppm (t-Bu). ##STR8##
EXAMPLE 5
methyl[[4-[2-[[(1,1-dimethylethyl)dimethylsilyl]oxy]-5β-[4-methyl-4-[(trimethylsilyl)oxy]-1E-octenyl]-4α-[(triethylsilyl)oxy]-1-cyclopenten-1-yl]-2-butynyl]oxy]acetate
A solution of 434 mg (0.75 mmole) of the title compound of Example 4 in 5 ml of tetrahydrofuran was cooled to -20° under a nitrogen atmosphere, and 0.49 ml of a 1.7M solution of n-butyllithium in hexane (0.83 mmole) was added. After stirring for one hour at -20°, 27 mg (0.89 mmole) of solid, dried paraformaldehyde was added, and the reaction mixture was warmed to 0°. After stirring for ninety minutes at 0°, the reaction mixture was recooled to -20°, and 147 mg (0.96 mmole) of methyl bromoacetate and 1 ml of hexamethylphosphoric triamide were added. The reaction mixture was stirred at -20° for 75 minutes, then allowed to warm to room temperature before being poured onto 45 ml of water. The product was extracted into ether, which was then washed with brine, dried over sodium sulfate, filtered, and concentrated to dryness. Chromatography of the crude material on silica gel afforded 90.7 mg of the title compound. Structure assignment was confirmed by the proton nmr spectrum: 0.95 (t-Bu), 1.42 (C-16 CH 3 ), 4.00 (C-11), 4.15 (C-2), 4.25 (C-4), 3.75 ppm (MeO). ##STR9##
EXAMPLE 6
methyl[[4-[3α-hydroxy-2β-(4-hydroxy-4-methyl-1E-octenyl)-5-oxo-1α-cyclopentyl]-2-butynyl]oxy]acetate
A mixture of 106 mg (0.17 mmole) of the title compound of Example 5 in 8 ml of a 3:1:1 solution of acetic acid/tetrahydrofuran/water was stirred at room temperature for four hours and heated at 45°-50° for 1 hour. The reaction mixture was poured onto 80 ml of water and extracted with ether. The organic phase was washed with water, 5% sodium bicarbonate solution, again with water, dried over sodium sulfate, filtered, and concentrated to dryness. The crude material was chromatographed on silica gel to yield 21.3 mg of the title compound as an oil. Structure assignment was confirmed by the proton nmr spectrum: 0.92 (C-20), 1.19 (C-16 CH 3 ), 3.75 (--OCH 3 ), 4.15 (C-2), 4.25 (C-4), 4.00 (mult, C-11), 5.15-6.00 ppm (mult, C-13, 14). ##STR10##
EXAMPLE 7
1,1-dimethylethyl-[[4-[2-[[(1,1-dimethylethyl)dimethylsilyl]oxy]-5β-[4-methyl-4-[(trimethylsilyl)oxy]-1E-octenyl]-4α-[(triethylsilyl)oxy]-1-cyclopenten-1-yl]-2-butynyl]oxy]acetate
The title compound was prepared by the method of Example 6 using 611 mg (1.06 mmole) of the title compound of Example 4 in a mixture of 10 ml of tetrahydrofuran, 0.75 ml (1.28 mmole) of n-butyllithium solution, 36 mg (1.19 mmole) of paraformaldehyde, 215 mg (1.10 mmole) of t-butyl bromoacetate and 1 ml of hexamethylphosphoric triamide. Chromatography of the crude material on silica gel gave 151 mg of the pure title compound and 149 mg of slightly impure compound which was used for subsequent reactions without further purification. Structure assignment was confirmed by proton nmr spectrum: 0.92 (Si-t-Bu), 1.48 (-O-t-Bu), 1.18 (C-16 CH 3 ), 4.03 (C-2), 4.23 ppm (C-4). ##STR11##
EXAMPLE 8
1,1-dimethylethyl-[[4-[3α-hydroxy-2β-(4-hydroxy-4-methyl-1E-octenyl)-5-oxo-1α-cyclopentyl]-2-butynyl]oxy]acetate
The title compound was prepared by the method of Example 6 using 63 mg (0.092 mmole) of the title compound of Example 7 in 2 ml of the 3:1:1 acetic acid/tetrahydrofuran/water solution. An additional 2 ml of the acetic acid/tetrahydrofuran/water solution was added after twenty four hours and the reaction mixture was heated at 45°-50° for one hour. The reaction mixture was concentrated and diluted with ether. The organic phase was washed with water, 5% sodium bicarbonate solution, and water, then dried over sodium sulfate, filtered, and concentrated to dryness. Chromatography of the crude material on silica gel afforded 15 mg of the title compound. Structure assignment was confirmed by the proton nmr spectrum: 0.90 (C-20), 1.15 (C-16 CH 3 ), 1.45 (t-Bu), 3.98 (C-2), 4.20 ppm (C-4). ##STR12##
EXAMPLE 9
methyl[[4-[2-[[1,1-dimethylethyl)dimethylsilyl]oxy]-5β-[4-methyl-4-[trimethylsilyl)oxy]-1E-octenyl]-4α-[(triethylsilyl)oxy]-1-cyclopenten-1-yl]-2Z-butenyl]oxy]acetate
A solution of 83 mg (0.13 mmol) of the title compound of Example 5 in 50 ml of toluene, to which had been added 0.95 ml of 5% quinoline in toluene, was hydrogenated at atmospheric pressure and room temperature over 5% palladium/barium sulfate catalyst. After filtration the reaction mixture was concentrated to an oil containing residual quinoline. The title compound exhibited the expected proton nmr spectrum and was used without further purification: 0.89 (Si-t-Bu), 1.15 (C-16 CH 3 ), 3.74 (--OCH 3 ), 4.03 (C-2), 4.15 (C-4), 5.0-5.75 ppm (C-13, 14 and 5,6). ##STR13##
EXAMPLE 10
methyl[[4-[3α-hydroxy-2β-(4-hydroxy-4-methyl-1E-octenyl)-5-oxo-1α-cyclopentyl]-2Z-butenyl]oxy]acetate
The title compound was prepared by the method of Example 6 using 97 mg of the title compound of Example 9 (contaminated with quinoline) and 8 ml of a 3:1:1 acetic acid/tetrahydrofuran/water mixture, with stirring at room temperature for 22 hours. The crude material was chromatographed on silica gel to yield 31.8 mg of the title compound as an oil. Structure assignment was confirmed by the proton nmr spectrum: 3.75 (--OCH 3 ), 4.10 (C-2), 1.15 (C-16 CH 3 ), 5.15-6.0 ppm (C-13, 14, and C-5,6). ##STR14##
EXAMPLE 11
1,1-dimethylethyl-[[4-[3α-hydroxy-2β-(4-hydroxy-4-methyl-1E-octenyl)-5-oxo-1α-cyclopentyl]-2Z-butenyl]oxy]acetate
A solution of 22 mg (0.052 mmole) of the title compound of Example 8 in 3 ml of 1:1 cyclohexane/toluene, to which was added 1.8 ml of 0.1% quinoline in toluene, was hydrogenated at atmospheric pressure at 0° using 5% palladium/calcium carbonate catalyst. After filtration to remove catalyst, the reaction mixture was concentrated to dryness. Chromatography on silica gel yielded 12.6 mg of the title compound as an oil. Structure assignment was confirmed by the proton nmr spectrum: 1.15 (C-16 CH 3 ), 1.45 (t-Bu), 3.93 (C-2), 4.10 (d, J=6 Hz, C-4), 5.15-6.0 ppm (mult, C-13, 14 and C-5, 6). ##STR15##
EXAMPLE 12
4α-hydroxy-2α-[4-(2-hydroxyethoxy)-2Z-butenyl]-3β-(4-hydroxy-4-methyl-1E-octenyl)cyclopentanone
To a solution of 683 mg of the title compound of Example 9 cooled to 0°, is added 40 mg of lithium aluminum hydride. After 15 minutes at 0°, the reaction mixture is poured into diethyl ether and water. The ether layer is separated and washed with water, dried over sodium sulfate, filtered and concentrated to dryness. The residue is dissolved in 15 ml of a 3:1:1 acetic acid/water/tetrahydrofuran mixture and stirred overnight at room temperature. After diluting the reaction mixture with diethyl ether, it is washed with water, dried over sodium sulfate, filtered and evaporated to dryness. Chromatography of the residue on silica gel (using ethyl acetate as eluent) gives the title compound. ##STR16##
EXAMPLE 13
4α-hydroxy-2α-[4-(2-hydroxyethoxy)-2-butynyl]-3β-(4-hydroxy-4-methyl-1E-octenyl)cyclopentanone
The title compound is prepared by the method of Example 12 using 68 mg of the title compound of Example 5 as starting material. ##STR17##
EXAMPLE 14
2-[1-(2-furanyl)-3-butynyloxy]tetrahydro-2H-pyran
To a solution of 10 g (0.073 mole) of the title compound of Example 1 in 40 ml of tetrahydrofuran is added 10 g (0.12 mole) of dihydropyran and 100 mg of p-toluenesulfonic acid monohydrate. The reaction mixture is stirred at room temperature for 4 hours, then diluted with water and 5 ml of 5% aqueous sodium hydroxide. After removal of the solvent, the residue is extracted three times with diethyl ether. The organic layers are washed with brine, dried over sodium sulfate, filtered and concentrated to dryness. The residue is chromatographed on silica gel (using ethyl acetate/hexane as eluent) to give the title compound NMR: 2.78 (d of d, J=6, 2.5 Hz, --CH 2 --C.tbd.), 1.92 (t, J=2 Hz, .tbd.CH), 3.18-4.08 (mult, --CH 2 --O), 7.49 and 6.33 ppm (furan). ##STR18##
EXAMPLE 15
1,1-dimethylethyl-[[5-(2-furanyl)-5-[(tetrahydro-2H-pyran-2-yl)oxy]-2-pentynyl]oxy]acetate
The title compound is prepared by the method of Example 5 using 1 g of the title compound of Example 14 in 10 ml of tetrahydrofuran, one equivalent of n-butyllithium, 0.16 g of paraformaldehyde, 1 ml of hexamethylphosphoric triamide, and 1.06 g of t-butyl bromoacetate. ##STR19##
EXAMPLE 16
1,1-dimethylethyl[[5-(2-furanyl)-5-[(tetrahydro-2H-pyran-2-yl)oxy]-2Z-pentenyl]oxy]acetate
The title compound is prepared by the method of Example 11 using 1 g of the title compound from Example 15 and 150 mg of 5% palladium/calcium carbonate catalyst. ##STR20##
EXAMPLE 17
[[4-(3-hydroxy-5-oxo-1-cyclopenten-1-yl)-2-butynyl]oxy]acetic acid
The title commpound is prepared by the method of Example 2 using 1 g of the title compound of Example 15, with the exception that the intermediate cyclopentenone is rearranged using aqueous sodium carbonate solution (pH 10-11) containing 1% hydroquinone. After stirring for 24 hours at room temperature, the reaction mixture is acidified to pH 2-3 with dilute hydrochloric acid and extracted with ether. The combined extracts are washed with brine, dried over sodium sulfate, filtered, and concentrated to dryness. The residue is chromatographed on Biosil A (using ethyl acetate/hexane as eluent) to afford the title compound. ##STR21##
EXAMPLE 18
4-[(triethylsilyl)oxy]-2-[4-[2-oxo-3-[(triethylsilyl)oxy]propoxy]-2-butynyl]-2-cyclopenten-1-one
A solution of 500 mg of the title compound from Example 17 and 600 mg of imidazole in 8 to 10 ml of dimethylformamide is treated at room temperature with 800 mg of t-butyldimethylsilyl chloride. After 1 hour, the reaction mixture is poured into a mixture of hexane/ether (1:1) and water. The organic layer is washed with water three times, dried over sodium sulfate and concentrated in vacuo. Chromatagraphy on silica gel (using 10% ethyl acetate/hexane as eluent) yields the intermediate product, a bis silyl ether.
A solution of 600 mg of the silyl ether in 5 ml of methylene chloride cooled to 0° is treated with 2-3 drops of dimethylformamide and then with a solution of 200 mg of oxalyl chloride in one ml of methylene chloride. The reaction mixture is allowed to warm to room temperature and after one hour the solution is blown to dryness. The residue is dissolved in 6 ml of chlorobenzene, treated with 700 mg of tris(trimethylsilyloxy)ethylene prepared as described by A. Wissner, J. Org. Chem., 44, 4617 (1979), and refluxed under argon for 3 to 4 hours. The mixture is cooled, concentrated to a paste which is dissolved in 3 to 4 ml of tetrahydrofuran, and treated with one ml of 1N hydrochloric acid. After refluxing under argon for one hour, the solution is cooled, diluted with ethyl acetate, and washed with brine solution. The aqueous wash is extracted twice with chloroform and the combined extracts are dried over sodium sulfate, filtered and concentrated to dryness. Chromatography of the residue on silica gel (using 80% ethyl acetate/20% hexane as eluent) gives an oil.
The oil (110 mg) is dissolved in 2 ml of dimethylformamide containing 150 mg of imidazole and then is treated with 150 mg of triethylsilyl chloride. The reaction mixture is stirred at room temperature for one hour and is diluted with diethyl ether, washed with water three times, and then dried over sodium sulfate. Filtration and removal of the solvent gives the title compound. ##STR22##
EXAMPLE 19
4α-hydroxy-3β-(4-hydroxy-4-methyl-1E-octenyl)-2α-[4-(3-hydroxy-2-oxopropoxy)-2-butynyl]cyclopentanone
The title compound is prepared by the methods of Examples 4 and 6 using 500 mg of the title compound of Example 18, except that the copper enolate is not trapped with t-butyldimethylsilyl chloride but is worked up directly. ##STR23##
EXAMPLE 20
[[4-(3-hydroxy-5-oxo-1-cyclopenten-1-yl)-2Z-butenyl]oxy]acetic acid
The title compound is prepared by the method of Example 17 using 1 g of the title compound of Example 16. ##STR24##
EXAMPLE 21
4-[(triethylsilyl)oxy]-2-[4-[2-oxo-3-[(triethylsilyl)oxy]propoxy]-2Z-butenyl]-2-cyclopenten-1-one
The title compound is prepared by the method of Example 18 using 500 mg of the product from Example 20. ##STR25##
EXAMPLE 22
4α-hydroxy-3β-(4-hydroxy-4-methyl-1E-octenyl)-2α-[4-(3-hydroxy-2-oxopropoxy)-2Z-butenyl]cyclopentanone
The title compound is prepared by the method of Examples 4 and 6 using 500 mg of the product from Example 21. ##STR26##
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This invention relates to novel 3-oxa-15-desoxy-16-hydroxy-16-alkyl prostaglandins of the E 2 series and the 5,6-acetylene derivatives thereof. These compounds are useful for their gastric antisecretory, cytoprotective, antiulcer, and antihypertensive activity. In addition the invention also discloses certain novel trialkylsilyl acetylenic intermediates.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application No. 61/387,799 filed on Sep. 29, 2010, entitled “Market Basket System”
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to grocery transport baskets and collapsible hand carts for improved collection and transport of grocery items.
[0004] 2. Description of the Prior Art
[0005] Traditional methods of grocery shopping include use of a store-owned hand basket or shopping cart. Organization and separation of food within these structures is nearly impossible, causing cold items to mix with warm ones, and hazardous cleaning supplies to be placed next to edible food. Items are often placed in a common area until check-out, leading to damaged goods or contaminated food products.
[0006] After collecting and paying for the desired groceries, the items are generally placed in non-recyclable plastic bags for transportation home. These bags are extremely harmful to the environment, as most are made from material not readily disposable in an eco-friendly manner. Additionally, they tend to be composed of very thin material, which does not support load imparted from heavy or multiple-contained items. This necessitates the need to either double-bag or place fewer items in each bag, both of which increase material usage and eventual waste. Optionally-requested paper bags are sometimes used, which are often supported with an exteriorly-wrapped plastic bag. However, these bags do not provide adequate lateral support for groceries in transport, allowing items to escape or spill out. This is especially true while transporting plastic bagged or paper bagged items in a vehicle, where sudden changes in momentum cause items to shift suddenly.
[0007] Traditional methods of collecting and transporting groceries are both inefficient and potentially harmful. In addition to the environmental concerns of grocery bags, the carts used to transport articles of food within the store can be problematic. First, they are commonly stored outdoors, which can leave them covered in dirt and residue, which is a health risk for transporting food. Secondly, they are generally well-used, and often do not function as intended. Wheels are frequently dysfunctional and cause the cart to steer awkwardly, and their upper trays do not always extend properly if damaged. Additionally, the carts must be returned to the store after being used, which involves taking the cart to a collection point or leaving it in the parking lot for others to avoid.
[0008] Several solutions to these problems have been suggested in the art. U.S. Pat. No. 4,560,096 to Lucas describes a shopping cart-attachable bag system that is useful for storing and organizing retail items. The bags in this patent are comprised of flexible sheet material with lift handles and optionally attachable support members for the rails of the shopping cart. While these are useful for organizing items within a shopping cart, there are no means for containing or supporting the purchased items while transporting the bags home in a car. The flexible bags provide no lateral support, and can lead to spilled or damaged items.
[0009] Patents with similar drawbacks include U.S. Pat. No. 5,533,361 to Halpren, which describes an insulated cooler for keeping groceries cold while shopping. This cooler also comprises flexible walls, along with attachment means for a standard shopping cart. Similar to the aforementioned patents, this bag also does not provide adequate support for securely transporting groceries outside of a shopping cart. U.S. Pat. No. 7,270,338 to Edgar describes an insulated compartment for frozen items within a grocery cart, in which an open container is fit snugly inside the forward frame of the cart. The open section of this container does not properly organize and secure items either while shopping or transporting the products in a vehicle.
[0010] Several patents exist which describe modular hand carts or dollies, which can be used to move heavy loads using a plurality of wheels and an extended handle. The devices described in the art are useful for stackably hauling goods, however most are not convenient or useful for shopping for groceries, specifically those delicate items which may crush if stacked. U.S. Pat. No. 6,131,927 to Krawczyk and U.S. Pat. No. 7,044,484 to Wang describe hand carts with these drawbacks. Grocery basket attachments along the rails of these carts are not described, which would separate items and prevent them from crushing one another.
[0011] Still Other known devices in the field of shopping cart systems include those with combined shopping baskets and carts. These tend to be bulky devices with minimal collapsibility, which limits a consumer's willingness to use them for everyday shopping. These devices include U.S. Pat. No. 5,203,578 to Davidson and U.S. Pat. No. 7,703,776 to Nugent. These patents use baskets to collect products, and a cart device to transport these items. However the carts themselves do not substantially collapse, and are therefore less practical for everyday use.
SUMMARY OF THE INVENTION
[0012] In view of the foregoing disadvantages inherent in the known types of combination hand cart and grocery basket systems now present in the prior art, the present invention provides a new combination hand cart and grocery basket system wherein the same can be utilized for providing convenience for the user when collecting and transporting groceries in the marketplace and on the way home.
[0013] It is therefore an object of the present invention to provide a basket suitable for use within a traditional shopping cart for collecting and organization of items, and one which can be outfitted with insular or cloth bag liners.
[0014] Another object of the present invention is to provide a collapsible hand cart suitable for attaching grocery baskets for improved mobility and transport of products in the store and on the way home.
[0015] Yet another object of the present invention is to provide a method of grocery shopping that includes using a hand cart and basket system that utilizes no non-reusable material and provides improved collection and transport qualities through product check-out and return home.
[0016] Other objects, features and advantages of the present invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTIONS OF THE DRAWINGS
[0017] FIG. 1 shows a forward view of the market basket system, wherein the baskets are attached to a collapsible hand cart.
[0018] FIG. 2 shows a side view of the market basket system, including the method of attachment for the baskets a detailed view of the hand cart.
[0019] FIG. 3 shows an embodiment of the market basket system, wherein the baskets are utilized independently of the hand cart for collecting and organizing grocery items within a standard shopping cart.
[0020] FIG. 4 shows a side view of the hand cart without the attached market baskets.
[0021] FIG. 5 is an angled view of the hand cart in is collapsed state.
DETAILED DESCRIPTION OF THE INVENTION
[0022] Referring now to FIG. 1 , there is shown a forward view of the first embodiment of the market basket system. Two market baskets 1 and 2 are removably attached to a hand cart 6 . The baskets 1 and 2 are stacked vertically and with a gap between them to allow for placement of items in either basket while attached to the hand cart 6 . A plurality of handles 3 on each basket 1 and 2 allow the user to easily remove and transport the baskets 1 and 2 in either a filled or empty condition. The handles 3 rotate about their connection to the baskets 18 to form a unified handle above each basket 1 and 2 for the user. The baskets 1 and 2 are composed of a lightweight material such as plastic, wicker or other common material such as decorative wire. The baskets 1 and 2 may also be perforated for ventilation and visibility or be solid in structure, as shown in the figure. Lips 19 on the upper portion of each basket 1 and 2 allow for another grip point for the user for moving the baskets, and a ledge to tuck an interiorly placed cloth or insular liner 7 around the rim of the baskets 1 and 2 .
[0023] Referring now to FIG. 2 , there is shown a side view of the first embodiment of the market basket system. Two market baskets 1 and 2 are supported by a hand cart 6 . Both baskets 1 and 2 are supported using a latch device 5 which is secured circumferentially around the upper and lower rails 8 and 9 of the hand cart 6 . Mounted on the back side of each basket 1 and 2 is a U-shaped attachment bar 4 , which mates securely with the hand cart latches 5 to support load from the baskets 1 and 2 and their contents. The lower basket 2 is supported by this bar and latch device 4 and 5 as well as the base platform 13 of the hand cart. Removable braces 17 on the outboard edges of the base platform 13 increase the structural stability of the platform while preventing it from folding in on itself. The additional support from the base platform 13 and the braces 17 provides the lower basket 2 with a larger allowable weight capacity than the upper basket 1 , as less stress is placed on the bar and latch device 4 and 5 .
[0024] Referring now to FIG. 3 , there is shown the second embodiment of the market basket system in which the market baskets 1 and 2 are utilized independently from the hand cart 6 . The baskets 1 and 2 fit into a standard shopping cart to organize and separate items while shopping. Interior liners 7 may be optionally placed inside the baskets 1 and 2 to keep them clean, allow easy removal of the groceries once back home, as well as add insulation to the baskets 1 and 2 to keep frozen items cold during transport.
[0025] Referring now to FIG. 4 , there is shown a side view of the collapsible hand cart 6 in its working configuration. Two parallel lower rails 9 extend vertically and terminate at a junction box 15 . Two parallel upper rails 8 extend above the junction box 15 , bend toward each other and meet to form a U-shaped handle 16 for the user to handle the cart. Two sets of latches 5 are attached to the cart 6 , one on each of the lower rails 9 and one on each of the upper rails 8 . These latches mate to the profile of the rails and are securely fastened in place. The upper rails 8 are narrower in outer diameter than the inner diameter of the lower rails 9 to permit the upper rails 8 to slide inside the inner diameter of the lower rails 9 for collapsibility. Upper rails 8 are secured into place while in their working, extended position. When collapsing, the user releases the securing means and pushes down on the handle 16 , forcing the upper rails 8 to be inserted into the lower rails 9 .
[0026] Two wheels 10 and 11 are rotatably mounted to the lower rails 9 . The wheels 10 and 11 are capable of rotation about their center point, which permits the wheels to roll and the cart to move. The wheel attachment brackets 12 are rotatably mounted to the lower rails 9 to allow the wheels 10 and 11 to rotate inwards for collapsing the hand cart 6 . The base platform 13 is shown in its extended position, and is supported by a support brace 17 . The base platform 13 can fold towards the lower rails 9 when not in use. Together, the upper rails 8 , wheel attachment brackets 12 , and the base platform 13 can fold together to permit collapsing of the cart 6 .
[0027] Referring now to FIG. 5 , there is shown an angled view of the hand cart in its collapsed position. As described above, the base platform 13 is folded towards the lower rails 9 , the wheels 10 and 11 are folded inward, and the upper rails 8 are condensed into the lower rails 9 . This configuration provides a compact configuration for storing and transporting the cart when not in use.
[0028] In use an individual uses the market basket system as a method to replace store-owned shopping carts and environmentally harmful grocery bags. The conscious shopper can employ the market baskets in conjunction with the hand cart to grocery shop in a manner that produces no environmentally harmful waste, while also reducing cost for the consumer and the store. This method of shopping illuminates the cost of the bags, the cost of the shopping carts and the cost of paying someone to collect the shopping carts after their use.
[0029] The market baskets can also be used independently from the hand cart if a store-owned cart is preferred, or if fewer items are needed to be purchased. The basket handles allow the user to carry items with one hand, or they can be placed inside the grocery cart to organize and separate food. After check-out, the baskets are useful for supporting the items in a vehicle and preventing them from falling or spilling out. Optional cloth or insular liners are capable of being incorporated into the baskets as well.
[0030] Using the market baskets in conjunction with the hand cart is also helpful for those that live in urban areas, where transporting goods from the market is difficult in one trip. Multiple paper or plastic bags are difficult to carry over long distances, and often necessitates several trips to bring all items into the home. The hand cart reduces this stress, and improves transportability of multiple items. The baskets can carry heavy loads, while the two-wheeled cart can traverse long distances, uneven terrain, and even steps if necessary. A smaller person can also move larger loads with less personal strain and anxiety.
[0031] 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.
[0032] 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 modular basket system, accompanying hand cart, and method for collecting and transporting grocery items. A series of rectangular baskets placed inside a standard shopping cart provide storage and organization for groceries while shopping. Handles on the baskets allow easy transfer in and out of the shopping cart. Optionally, a collapsible hand cart provides a means to secure the baskets and transport them without a standard grocery cart. The hand cart is a two-wheeled structure that movably supports load, and comprises a collapsible handle and foldable frame for improved storage. The baskets may be additionally lined with removable bags or insular liners to preserve frozen foods between the market and home.
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REFERENCE TO RELATED APPLICATION
[0001] Priority is hereby claimed to provisional application Ser. No. 60/810,083, filed Jun. 1, 2006, which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This disclosure relates to the field of combustion turbine engines. Specifically, the described devices can be used as a means of efficiently utilizing an alternative fuel, e.g., hydrogen, gas turbines while keeping the generation and emissions of nitrogen oxides to very low levels. More specifically, the present invention is a fuel/air premixing fuel injector or “premixing injector” which supports combustion in gas turbines with control of nitrogen oxide production.
DESCRIPTION OF THE PRIOR ART
[0003] Hydrogen use as a fuel in gas turbine engines has many benefits. In addition to being a renewable fuel, there are no carbon emissions from hydrogen combustion. Of available gas turbine fuels, hydrogen allows the widest range of combustible fuel-air mixtures, thus providing a superior opportunity for reduced flame temperature lean combustion.
[0004] In a typical gas turbine engine, the combustion chamber, fuel delivery system, and control system are designed to ensure that the correct proportions of fuel and air are injected and mixed within one or more combustors, typically a metal container, or compartment, where the fuel and air are mixed and burned. With diffusion flames in the combustor, there is typically a set of localized zones where peak combustion temperatures are achieved. These peak temperatures may reach temperatures in the range of 4000-5000° F.
[0005] Typically, to prevent thermal distress or damage to these combustors, a significant amount of the compressor discharge air passes along and through the walls of the combustor for cooling, and to dilute the exhaust gases. The heated compressed air, which then drives the turbine, is a combined mix of the hot combustion gasses and the cooling air. The resulting hot gas yield, which is admitted to the inlet of the turbine, is delivered at a very high temperature. The resultant products and emissions from the hydrogen combustion process are water vapor and oxides of nitrogen (NO x ), a known pollutant, which is exhausted into the atmosphere. NO x is a harmful product of combustion, and is regulated by environmental laws. Low NO x emission is a goal, and in many cases, a requirement for both power generation and aero propulsion gas turbines.
[0006] One method for controlling NO x formation in the combustion processes of gas turbine engines is to premix the compressor discharge air and the fuel in a premixing injector before they enter the combustor. In this manner, the medium entering the combustion chamber is a homogeneous mixture of the fuel and compressor discharge air. This will allow lean combustion, keeping the combustion product temperature low, which reduces NO x formation.
[0007] Multiple efforts have been made for the design of premixing injectors for gaseous hydrocarbon fuels, but very few designs have been made for operation with hydrogen fuel. In addition to achieving optimal fuel/air mixture, the issue of premixed flame stabilization in the proper position is paramount to avoid structural damage to the premixing injector and combustor. Challenges of conventional premixing designs include prevention of flashback and design flow breakdown in the premixing injectors. The term “flashback,” as used in this disclosure refers to the ignition and combustion of the fuel-air mixture within the premixing injector discharge channel, rather than in the combustor. A sustained flashback event will damage the premixing injector.
SUMMARY OF THE INVENTION
[0008] The present invention involves a unique lean premixing injector for a gas turbine engine which provides stable hydrogen fuel combustion with low NO x production to solve the aforementioned problems associated with existing technology. These premixing injectors incorporate:
swirl for uniform fuel-air premixing and flame stabilization that supports low equivalence ratio combustion and low NO x production; choked fuel injection for isolation of combustion pressure oscillations from the fuel injection system; geometry that provides no internal flame holding sites for fuel-air combustion, thus preventing flashback; an integral bluff body flame holding site external to the injector, which is provided as a feature of the overall design concept; and internal channel structure designed to create internal regenerative cooling to improve the lifespan and preserve the longevity of the premixing injector.
[0014] In order to illustrate some of the unique features of the invention, the following is a brief summary of the preferred versions of the injector. More specific details regarding the preferred version are found in the Detailed Description with further reference to the Drawings. The claims at the end of this document define the various versions of the invention in which exclusive rights are secured.
[0015] Reference is now made to the attached FIGS. 1-6 for exemplary embodiments of the premixing injector of the present invention. The premixing injector, depicted in assembly, exploded, and sectional views as 10 in FIGS. 1-3 and 10 a in FIGS. 4-6 , is shown in two embodiments with Embodiment 1 illustrated at 10 in FIGS. 1-3 and Embodiment 2 illustrated at 10 a in FIGS. 4-6 . Similar structures in each embodiment will be referenced by the same reference numbers with the reference numbers in Embodiment 2 being followed by a lowercase “a.”
[0016] The premixing injector 10 , 10 a includes an outer casing 12 , 12 a having a first inlet end 14 , 14 a and a second outlet end 16 , 16 a . The outer casing 12 , 12 a surrounds a center body 20 , 20 a , which includes a first open end 22 , 22 a extending from the first end 14 , 14 a of the outer casing 12 , 12 a , a second closed end 24 , 24 a at the second end 16 , 16 a of the outer casing 12 , 12 a , an exterior wall 26 , 26 a , an interior wall 28 (illustrated in FIG. 3 ), 28 a and an endcap 30 . An exterior annular mixing channel 40 , 40 a is defined by the exterior wall 26 , 26 a of the center body 20 , 20 a and the interior wall 18 , 18 a of the outer casing 12 , 12 a . The mixing between the compressor discharge air and the fuel occurs in the exterior annular mixing channel 40 , 40 a . The area of the exterior annular mixing channel 40 , 40 a is constant over the length of the premixing injector 10 , 10 a to discourage low velocity regions and thus flashback within the premixing injector. A unique feature of the present design is that there are no bluff bodies or flow separation zones within the premixing injector downstream of the fuel injection point to provide flame holding for a flashback. Thus, flashback is discouraged, and easy recovery is provided should a transient flashback occur.
[0017] The center body 20 , 20 a also includes a fuel inlet duct 42 , 42 a having a first inlet end 44 , 44 a , a second outlet end 46 , 46 a , and an open passageway 48 , 48 a extending from the first inlet end 44 , 44 a to the second outlet end 46 , 46 a . The fuel inlet duct 42 , 42 a extends to the second end 24 , 24 a of the center body 20 , 20 a.
[0018] As illustrated in FIGS. 2 and 5 , the center body 20 , 20 a is further defined by an annular sleeve 23 , 23 a positioned on the center body 20 , 20 a at the first open end 22 , 22 a . In Embodiment 1, the annular sleeve 23 is solid, as the airflow enters the bell mouth air inlet ducts 60 . Swirl is generated by the tangential velocity component of the air produced by the angled location of the air inlet(s). The fuel enters through choked fuel injector ports 54 , 54 a.
[0019] In Embodiment 2, the annular sleeve 23 a is hollow, allowing air to enter the swirler region 70 a , which generate the required swirl. Fuel is introduced downstream of the swirler region 70 a through choked fuel injector ports 54 a . Referring specifically to FIG. 5 , it is noted that the annular sleeve 23 a is normally in a position covering the vanes 74 situated on the center body 20 . To allow disclosure of the vane 74 in FIG. 5 , the annular sleeve has been positioned at the second end 46 a of the center body 20 a . FIG. 6 illustrates the correct located of annular sleeve 23 a.
[0020] As illustrated in FIGS. 3 and 6 in the assembled version of the premixing injector 10 , 10 a , the fuel inlet duct 42 , 42 a is positioned within the center body 20 , 20 a in such a manner as to form an interior fuel channel 50 , 50 a which is connected to the open passageway 48 , 48 a by a conduit 52 , 52 a . The interior fuel channel 50 , 50 a extends longitudinally and in parallel alignment with the exterior annular channel 40 , 40 a from the conduit 52 , 52 a to a choked fuel injection port 54 , 54 a . The choked fuel injection port 54 , 54 a allows the introduction of fuel to the exterior annular mixing channel 40 , 40 a . In addition, the choked fuel injection port 54 , 54 a inhibits any backflow of fuel and/or air into the upstream portion of the premixing injector 10 , 10 a.
[0021] In this manner, fuel is introduced into the premixing injector 10 , 10 a by way of the passageway 48 , 48 a of the fuel inlet duct 42 , 42 a at the inlet end 44 , 44 a . The fuel is then directed to the interior fuel channel 50 , 50 a by way of the conduit 52 , 52 a.
[0022] A unique aspect of this system is that the flow of fuel through the conduit allows the cooler fuel gas to cool the closed second end 24 , 24 a of the center body 20 , 20 a . As can be seen in FIGS. 3 and 6 , the passageway 48 , 48 a directs fuel to the endcap 30 , 30 a of the center body 20 , 20 a where heat radiated and convected from the combustion flame will be transferred from the endcap 30 , 30 a of the center body 20 , 20 a into the fuel gas. The fuel will then continue to flow by way of the conduit 52 , 52 a to the interior fuel channel 50 , 50 a and through the choked fuel injection ports 54 , 54 a where the fuel will be introduced into the exterior annular mixing channel 40 , 40 a through the choked fuel injection ports 54 , 54 a . The mass flow of the gaseous fuel is used to cool the center body 20 , 20 a as a regenerative effect.
[0023] From the choked fuel injection port 54 , 54 a , the fuel then enters the swirling region 70 of the exterior annular mixing channel 40 , 40 a through the choked fuel injection ports 54 , 54 a where the fuel is mixed with the passing compressor discharge air which enters the premixing injector 10 via the air inlet ports 60 , 60 a . The choked fuel injection ports 54 , 54 a are by design choked, thereby decoupling the fuel delivery system from downstream pressure fluctuations. In Embodiment 1 ( FIGS. 1-3 ), the choked fuel injection ports 54 are oriented to inject the fuel in the axial outwardly direction. In Embodiment 2 ( FIGS. 4-6 ), the choked fuel injection ports 54 a are oriented to inject the fuel in the radially outward direction. The choked fuel injection ports 54 , 54 a are designed to be aerodynamically choked during all modes of operation of the gas turbine engine. Advantageously, this eliminates the chance of combustion instabilities coupling to the fuel supply.
[0024] The air inlet ports of the premixing injector 10 of Embodiment 1 include at least one and preferably four air inlet ducts 60 for channeling compressor discharge air to the exterior annular mixing channel 40 . By design, the location of the air inlet duct 60 advantageously turns the external flow of air gradually into the premixing injector 10 in order to minimize pressure losses due to a sudden contraction.
[0025] In Embodiment 2, air inlet is accomplished with a single bell mouth-shaped air inlet duct 60 a on the annular sleeve 23 a and outer casing 12 a which introduces the air well upstream of where the flow enters the guide vanes 74 . The annular sleeves 23 a may be fabricated integrally with the center body 20 a without change to the operating principles of the premixing injector 10 a.
[0026] Another significant feature of the premixing injector 10 , 10 a is that the closed second end 24 , 24 a of the center body 20 , 20 a ends in relatively the same plane as the second end 16 , 16 a of the outer casing 12 , 12 a . This feature allows the flame within the combustor chamber 90 ( FIG. 7 ) to stabilize near the second end 24 , 24 a of the center body 20 , 20 a by providing a low-pressure wake region, which supports the flame holding vortex shear layer previously described.
[0027] The premixing injector 10 , 10 a also includes a swirler region 70 , 70 a for mixing the fuel and the compressor discharge air in the exterior annular mixing channel 40 , 40 a , and an outlet 80 , 80 a for expelling the thoroughly swirled and mixed fuel and air to the combustor 90 .
[0028] Referring now to Embodiment 1, illustrated in FIGS. 1-3 , the swirler region 70 is comprised of a series of air inlet ducts 60 extending from the outer casing 12 of the premixing injector 10 to the external annular mixing channel 40 downstream of the choked fuel injection ports 54 .
[0029] Referring to Embodiment 2, illustrated in FIGS. 4-6 , the swirler region 70 a is defined by a series of serpentine guide vanes 74 positioned within the swirler region 70 a formed by the outer casing 12 a and the center body 20 a and extending axially to the exterior annular mixing channel 40 a . The trailing edge 77 of the guide vanes 74 includes a discharge angle preferably determined with respect to the axis of the outer casing 12 a . The guide vane discharge angles are defined by a selected radial equilibrium condition to be substantially 45-60 degrees with respect to the axis of the outer casing 12 a of the premixing injector 10 a . The guide vanes 74 are intended to impart a tangential velocity component (swirl) to the incoming air and to provide structural support for the center body 20 a.
[0030] Both the premixing injector 10 , 10 a of Embodiment 1 and Embodiment 2 are intended for injection of a lean premixed gaseous hydrogen fuel/air mixture into the combustor region 90 of a gas turbine engine; however, natural gas or any other gaseous fuel can be used with the premixing injectors of the present invention. The combustible mixture produced by both designs is predicted to have a uniformly distributed fuel-to-air mass ratio at the exit 80 , 80 a of the premixing injector 10 , 10 a . The lean premixed combustion of the mixture produces lower combustion temperatures than diffusion combustion of the fuel and air. These lower temperatures produce low NO x levels in the products of the combustion. The premixing injector 10 , 10 a is also designed to mix the fuel and air at high axial velocities to eliminate the occurrence of flashback of the reaction zone into the premixing injector 10 , 10 a.
[0031] An additional unique aspect of the present invention is that the premixing injector 10 , 10 a has the feature of cooling the closed end 24 , 24 a of the center body 20 , 20 a as discussed previously. This feature reduces the thermal loading on the center body 20 , 20 a , which will prolong the life of the premixing injector 10 , 10 a.
[0032] An additional unique feature of the present invention is that the premixing injector 10 , 10 a is designed with choked fuel inlet ports 54 , 54 a . This choked feature allows the fuel supply to be decoupled from any type of combustion instability which may arise in the combustor of the engine.
[0033] Another unique feature of the present invention is that the passage of the air from the air inlet duct 60 , 60 a to the exterior annular mixing channel 40 , 40 a has been designed to reduce pressure losses that may occur when air enters the exterior annular mixing channel 40 , 40 a . For Embodiment 1 of the current invention, this is accomplished by a smooth flared air inlet duct 60 , which gradually accelerates the air flow. For Embodiment 2, this is accomplished with the annular sleeve 23 a on the elongated center body 20 a and a bell mouth-shaped rounded edge on the air inlet ducts 60 a that extends in front of the swirl vanes 74 .
[0034] Another significant advantage of the premixing injector of the present invention is that the second closed end 24 , 24 a of the center body 20 , 20 a ends in the same plane as the second end 16 , 16 a of the outer casing 12 , 12 a . This feature allows for a flame stabilization zone past the end of the premixing injector 10 , 10 a.
[0035] Furthermore, the premixing injector 10 a is designed with a mathematically specified radial equilibrium constraint on the guide vanes 74 . This feature alone allows for a large decrease in pressure losses through the premixing injector 10 a and control of the axial velocity profile as compared to vanes without this constraint. This feature also creates a desirable axial velocity distribution across the exterior annular mixing channel 40 a.
[0036] Summarizing the invention, unique fuel/air premixing injectors have been conceived and developed for the purpose of supporting fuel and compressor discharge air injection as the medium for combustion, resulting in the production of single digit parts per million (ppm) levels of NO x as a by-product, a wide range of stable operation, and suitability for integration into gas turbines.
[0037] In view of the foregoing, this disclosure relates to unique operation of the invention in the field of combustion in gas turbine engines. More specifically, the invention can be used as a means of utilizing alternative fuels that will perform in gas turbines while keeping emissions of nitrogen oxides below established target levels.
[0038] The features and advantages of the invention will be illustrated more fully in the following detailed description of the preferred embodiment of the invention made in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] FIG. 1 is a perspective view showing the overall design of the first embodiment of the premixing injector of the present invention (“Embodiment 1”).
[0040] FIG. 2 is an exploded view of the premixing injector of FIG. 1 .
[0041] FIG. 3 is a cross-sectional view of the premixing injector of FIG. 1 taken along lines 3 - 3 of FIG. 1 .
[0042] FIG. 4 is a perspective view of a second embodiment of the premixing injector of the present invention (“Embodiment 2”).
[0043] FIG. 5 is an exploded view of the premixing injector of FIG. 4 .
[0044] FIG. 6 is a cross-sectional view of the premixing injector of FIG. 4 taken along lines 6 - 6 of FIG. 4 .
[0045] FIG. 7 is a partial perspective view of a combustor illustrating the positioning of the premixing injectors of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0046] As previously noted, Embodiment 1 of the present invention, referenced in FIGS. 1-3 , uses a combination of an angled air jet producing tangential and axial velocity components in the mixing region to achieve the condition of a premixed swirl stabilized flame. It was determined that for the correct balance of pressure losses and mixing, a hybrid scheme of a jet in crossflow and ajet in coflow should be used. Ajet in crossflow is defined as a seeder stream (generally fuel) being injected perpendicular to the bulk stream (generally air). A jet in coflow is defined as the seeder stream and the bulk stream in a coaxial configuration. The hybrid scheme means that the angle between the two streams is between 0 and 90 degrees. In this embodiment, the angle was set at 60 degrees. This design is well-suited for most gas turbine engines because it is adaptable to standard combustor designs and, with the predicted operation, will keep the production of NO x low and produce a properly stabilized flame.
[0047] Referring to FIGS. 1-3 , the premixing injector 10 of the present invention is defined by the exterior annular mixing channel 40 comprising three main structures: the outer casing 12 , the center body 20 and the air inlet duct 60 . The center body 20 is nested within the outer casing 12 , and the air inlet duct 60 is nested within the center body 20 to form the premixing injector 10 . Preferably, the three parts to the premixing injector 10 are welded together to form the single unit premixing injector 10 .
[0048] As illustrated in FIGS. 1-3 , the outer casing 12 is a generally cylindrical tube having a first inlet end 14 , a second outlet end 16 , and an external surface 17 and an internal surface 18 . The outer casing 12 includes a flange 19 , which allows the attachment of the premixing injector 10 to a gas turbine engine combustor liner 91 ( FIG. 7 ) by bolts or other means. It is within the scope of the present invention to have other means for attaching the premixing injector 10 to the gas turbine engine combustor line 91 . As illustrated in FIG. 1 , the attachment flange 19 is situated near the second outlet end 16 of the outer casing 12 .
[0049] Embodiment 1 illustrates four tangential circular air inlet ducts 60 , which serve as the inlet stream of air (or other oxidizer), which is to be fed from a compressor or another source (not illustrated). The ends 62 of the air inlet ducts 60 are flared at an angle, preferably 45 degrees. The inner walls 64 of the flared ends 62 are rounded. These two features allow the airflow to accelerate gradually, thereby reducing the pressure losses and increasing the efficiency of the premixing injector 10 . The air inlet ducts 60 deliver the compressor air into the premixing injector 10 . The air inlet ducts 60 are also at an angle of preferably 60 degrees relative to the axial flow direction to reduce the pressure losses.
[0050] Referring now to FIGS. 2 and 3 , the center body 20 is a generally cylindrical structure having a first open end 22 and a second closed end 24 . As illustrated in FIG. 2 , the second end includes an endcap 30 . The center body 20 includes an exterior wall 26 and an interior wall 28 . The exterior annular mixing channel 40 is created between the internal surface 18 of the outer casing 12 and the exterior wall 26 of the center body 20 and forms the exterior annular mixing channel 40 .
[0051] As illustrated in FIG. 2 , the first open end 22 of the center body 20 includes a sold annular sleeve 23 with a larger diameter such that the diameter of the annular sleeve 23 is approximately the same as the internal diameter of the outer casing 12 . This allows for a smooth press fit between the center body 20 and the outer casing 12 .
[0052] The transition zone between the exterior wall 26 and the choked fuel injection point 54 is known as the constant radius fillet 56 . The constant radius fillet 56 is necessary to reduce the pressure losses in the premixing injector 10 . The constant radius fillet 56 reduces the area for separation for the inlet air stream, and helps gradually turn the airflow. The air enters from the air inlet ducts 60 and the constant radius fillet 56 guides the flow axially.
[0053] The fuel enters from the choked fuel injection port 54 and enters the exterior annular mixing channel 40 at the area of the constant radius fillet 56 .
[0054] The smoother this transition, the less pressure loss occurs. Therefore, a curved radius of the constant radius fillet 56 is preferable to a right angle. It allows smoother blending of the gas/air mixture. The choked fuel injector ports 54 are choked to eliminate the possibility of downstream pressure fluctuations from propagating upstream into the fuel delivery system.
[0055] The fully assembled premixing injector 10 contains a series of chambers within the premixing injector 10 including the open passageway 48 of the fuel inlet duct 42 , the interior fuel channel 50 , a plenum 62 , and the exterior annular mixing channel 40 . In addition, there is a choked fuel injection port 54 formed between the plenum 62 and the exterior annular mixing channel 40 .
[0056] The fuel system will be at an elevated pressure to satisfy the choked flow requirement in the fuel injection ports 60 and the overall fuel mass flow requirement. The plenum 62 is an open area designed to settle out velocity profiles of the fuel.
[0057] In the exterior annular mixing channel 40 , the fuel/air mixture has both a tangential and axial velocity component creating a swirling structure. The air inlet ducts 60 are positioned such that the air enters the exterior annular mixing channel 40 at an angle which forces the air and fuel mixture to propagate through the exterior annular mixing channel 40 in a helical fashion. The swirl of the air/fuel mixture and the fact that the mixture is premixed is important in keeping the flame shortened in the combustor 90 .
Operation
[0058] The fuel, generally pressurized gaseous fuel, enters the fuel inlet duct 42 of the premixing injector 10 via the fuel inlet duct 48 . The fuel then travels the length of the passageway 48 to the conduit 52 where the fuel provides back wall cooling to the endcap 30 of the center body 20 . Backwall cooling reduces the thermal load on the center body 20 . This prolongs the life of the premixing injector 10 . Another term for this process is “regenerative cooling.”
[0059] Once the fuel reaches the endcap 30 , it is channeled from the passageway 48 to the interior fuel channel 50 via the conduit 52 and toward the plenum 62 , thereby increasing the heat transfer to the fuel, and conditioning internal velocity profiles.
[0060] At the plenum 62 area, the fuel flows through the choked fuel injection ports 54 into the exterior annular mixing channel 40 at the area of the constant radius fillet 56 where the compressor discharge air entering through the air inlet ducts 60 is mixed with the fuel. The choked fuel injection port 54 eliminates the possibility that downstream pressure fluctuations will affect the fuel delivery flow rate. Additionally, the high-speed fuel jet penetrates farther into the incoming air stream because the momentum ratio (fuel jet/air) is high. This enhances the mixing between the two streams.
[0061] At this point, the fuel air mixture propagates in a helical vortex structure around the exterior surface 26 of the center body 20 in the exterior annular mixing channel 40 toward the exit end 80 of the premixing injector 10 where it is passed into the engine. This feature is important for flame placement. The design velocities are such that flashback is eliminated. Finally, the fuel/air mixture, now fully premixed and swirling, enters the combustion region through the exit end.
[0062] The premixing injector 10 provides a swirling and well-mixed reactant stream of fuel and air to the combustor. The premixing injector 10 produces stable combustion and low NO x emissions. The current design was sized to accommodate hydrogen as a fuel; however it is within the scope of the present invention to consider other forms of gas, such as natural gas with or without hydrogen, gas mixtures resulting from coal gasification, ethylene, propane and other forms of gaseous fuel with this design.
[0063] Reference is now made to FIGS. 4-6 for an alternative Embodiment 2 of the premixing injector of the present invention. Referring to FIG. 4 , the premixing injector 10 a is comprised of an outer casing 12 a , a center body 20 a having an exterior wall 26 a , between which is defined the exterior annular mixing channel 40 a , and a fuel inlet duct 42 a.
[0064] A plurality of air guide vanes 74 are securely affixed to the center body 20 a and extend radially outward from the center body 20 a toward the outer casing 12 a . Each vane 74 has an inner end 75 and an outer end 76 . The inner end 75 is proximate to the center body 20 a relative to the outer end 76 . Each vane 74 includes a leading edge 78 and a trailing edge 77 . The leading edge 78 is upstream of the flow path relative to the trailing edge 77 , which is downstream of the leading edge 78 . The vane 74 is radially arranged with respect to the center body 20 a to facilitate manufacturing and produce the required flow. Each vane 74 is curved in the same direction.
[0065] The purpose of these guide vanes 74 is to add structural support to the premixing injector 10 a as well as to provide the desired tangential and axial velocity components to the air entering the premixing injector 10 a . The vanes 74 are designed to produce a specific radial equilibrium condition to control the swirling velocity distribution and minimize flow losses. Air enters the exterior annular mixing channel 40 a upstream of the guide vanes 74 at the swirl region 70 a and, following mixing with the injected fuel, exits the premixing injector 10 a at the downstream end 16 a of the exterior annular mixing channel 40 a.
[0066] Gaseous fuel enters the premixing injector 10 a through the passageway 48 a within the fuel inlet duct 42 a and is introduced to the exterior annular mixing channel 40 a through choked radial fuel ports 54 a , initiating mixing with the passing air stream. Before the gaseous fuel reaches the passing air stream, it will be accelerated to sonic velocities through the radial fuel ports 54 a . The gaseous fuel is introduced into the airflow downstream of the guide vanes 74 to eliminate the possibility of flame stabilization inside the premixing injector 10 a.
[0067] The combustion zone is expected to stabilize downstream of the exterior annular mixing channel 40 a . With the combustion zone close to the exterior annular mixing channel 40 a , the endcap 30 a of the center body 20 a will experience high temperatures. To counter this effect, the premixing injector 10 a is designed to transfer heat from the endcap 30 a of the center body 20 a to the incoming gaseous fuel. After the fuel enters the core of the center body 20 a , it is directed toward the endcap 30 a of the center body 20 a where heat transfer occurs. This provides a form of regenerative cooling for the second closed end 24 of the center body 20 a.
[0068] Reference is now made to FIG. 7 which illustrates a gas turbine engine pressure casing 89 . The pressure casing 89 encompasses the combustor 90 which contains the annular combustion liner 91 . The combustion liner 91 is conventional in design and will not be described in detail except to note that the combustion liner 91 may be modified to ensure that the desired amount of the compressor discharge air flows through the premixing injectors 10 and the combustion liner 91 once the premixing injectors 10 are installed. Two premixing injectors 10 are shown in FIG. 7 . However it is within the scope of the present invention to include one or a plurality of premixing injectors 10 depending on the requirements of the gas turbine engine. Multiple combustion chambers 90 can also be provided, if necessary or desirable. In addition, while the premixing injector 10 will be described with respect to the combustion liner 91 , it should also be understood that premixing injector 10 a can also be provided with the combustion chamber 91 .
[0069] The combustion liner 91 is generally defined as a sheet metal object which is generally annular in shape that has a domed end 92 with circular openings 94 of a size and shape to receive the premixing injector 10 . The combustion liner 91 must be matched with the premixing injectors 10 . For example, the openings 94 can be slightly larger than the outer diameter of the premixing injector 10 to allow a small amount of cooling compressor discharge air to flow around the outer casing 12 of the premixing injector 10 to allow for management of the combustion liner 91 temperature. This could take advantage of the fact that a premixed flame utilizing gaseous fuel is much shorter than a diffusion flame. The premixing injectors 10 will remain in the correct orientation through the use of two locator pins (not illustrated) per premixing injector 10 .
[0070] Opposite the domed end 92 on the combustion liner 91 , there is an open end 95 which allows the combustion products exiting the combustion liner 91 to enter the turbine guide vanes (not illustrated). If desired, dilution air inlets 96 are present in the combustion liner 91 to introduce additional compressor discharge air to prevent the excessive heating of the combustion liner 91 itself due to the combustion process, and to cool the combustion products sufficiently so as not to destroy the turbine vanes and blades.
[0071] In operation, the fuel, e.g., hydrogen, enters a fuel manifold port 98 . Each fuel manifold port 98 is connected to a hydrogen or fuel source (not illustrated). Each fuel manifold port 98 is in turn connected to the fuel inlet duct 42 of the premixing injector to admit the fuel through the premixing injector 10 and allow mixing with the compressor discharge air entering through the air inlet ducts 60 as described above. The thoroughly mixed and swirling fuel/air mixture exits the premixing injectors 10 through the second end 16 within the openings 94 in the domed end 92 of the combustion liner 91 wherein it is diverted via a series of baffles (not illustrated) known to the art through the combustion chamber 90 to the turbine inlet.
EXAMPLE
[0072] The following Example is included solely for the purpose of providing a more complete and consistent understanding of the invention disclosed and claimed herein. The Example does not limit the scope of the invention in any fashion.
[0073] The design specifications for the premixing injector 10 enabled its use in a Pratt and Whitney PT6-20 turboprop engine. Since varying operating conditions of the engine (take off, cruise, and full power) are possible, there are multiple possible optimizations for the injector. The cruise condition was chosen for the optimization due to the normal high percentage of operational time at cruise. Table 1 shows the overall design constraints and the constraints per nozzle for the cruise condition of the engine. The fuel flow rate was determined by the equivalent energy flow rate based on lower heating value of hydrogen and kerosene. The number of premixing injectors 10 was chosen to ensure relative spatial uniformity in the engine liner. The equivalence ratio constraint is from a desire to have low emissions. These constraints define the flow rates of both the fuel and air to each premixing injector 10 . Using the aforementioned tangential entry swirl design concept, a prototype was developed.
TABLE 1 Overall design Constraints for the Premixing Injector 10 Design Constraint Value Power 410 kW Fuel flow rate 14.5 g/s Equivalence Ratio 0.4 Number of Nozzles 18 Upstream Pressure 537 kPa
[0074] The engineering design process needed both the listed quantities above and additional design constraints. The constraints that were added include the following: the axial velocity within the premixing injectors 10 must exceed 100 m/s, the swirl number must be above 0.8 for a “high swirl” injector, pressure losses must not exceed 10%, and there must not be any instability in the operational range of the injector. The high swirl number and the high velocity requirement were set such that the flame will stabilize outside the nozzle in the shear layer between the vortices and not within the injector. The pressure loss requirement is present because pressure losses are parasitic to the engine efficiency and must be minimized. Finally, the instability requirement is present because in the presence of instabilities pressure forces can damage hardware, the increased convection and radiation has the potential of melting the hardware, and local regions with high equivalence ratios are formed, raising emissions, and the overall combustion efficiency decreases.
[0075] Referring to FIGS. 1-3 , the four air inlet ports 60 are designed such that the fabrication would necessitate standard ¼″ tubing. The minor diameter of the air inlet ports 60 is 4.57 mm and has a 45° rounded bell mouth opening 64 . The reason for the opening 64 is to accelerate the compressor discharge air flow gradually and reduce the pressure losses associated with the air inlet ports 60 . The fuel inlet duct 42 is oriented in the axial direction, located at the upstream end of the premixing injector 10 .
[0076] Another feature that reduces the pressure loss is located inside the swirler region 70 , illustrated in FIG. 3 . Early simulations showed that the area near the first inlet end 14 of the premixing injector 10 at the center body 20 caused a significant separation zone and a void where fuel/hydrogen accumulation was possible. A 6.25 mm constant radius fillet 56 was placed on the center body 20 to fill the void and gradually turn the mixing flow into the swirler region 70 .
[0077] The swirler region 70 has an outer diameter of 21.18 mm and an inner diameter of 15.24 mm, yielding an exit area of 0.0001699 m 2 . Using the mass flow rate and the area, the area average velocity is approximately 113 m/s based on ideal gas behavior. This high velocity is good flashback prevention because the turbulent flame speed will not approach such a high value.
[0078] The fuel side design decisions were made as precautions to address failures and problems typically seen in premixing injectors 10 . With the flame zone for a premixing injector 10 being close to the end cap 30 of the center body 20 , there is potential for the thermal failure of the endcap 30 . To alleviate this problem the hydrogen fuel provides convective back wall cooling before it is introduced into the exterior annular mixing channel 40 . To achieve this, the fuel is routed from the open passageway 48 of the fuel inlet duct 42 to conduit 52 located at the endcap 30 of the center body 20 . Here, the fuel provides the back wall cooling to the endcap 30 and is routed to the plenum 62 of the premixing injector 62 , and finally through the exterior annular mixing channel 40 to the downstream end 16 of the premixing injector 10 .
[0079] To circumvent thermoacoustic instabilities in the combustor 90 caused by equivalence ratio perturbations associated with acoustic wave propagated upstream through the fuel delivery system, the premixing injector 10 is provided with choked radial fuel ports 54 (Mach=1). Choking the radial fuel ports 54 eliminates the possibility for equivalence ratio perturbations, but mixing perturbations can still exist leading to instabilities. It is however important that the bulk mixing qualities remain constant, which are determined in part by the momentum flux ratio defined as
j = ρ f V f 2 ρ a V a 2
where the subscripts a and f refer to the air and fuel respectively. In a choked passage the mass flow rate is determined by the pressure, which positively correlates to the density. It is important that the fuel stream does not over penetrate into the air crossflow, thus disrupting the mixing processes. Therefore the area of the choked radial fuel ports 54 was chosen to be the largest area in which the passage remained choked during the idle condition of the gas turbine engine. The idle condition of the gas turbine engine is the lowest mass flow rate of fuel that is required. The calculated choked radial fuel port size is 0.406 mm. The diameter ratio between the air inlet ports 60 and the choked radial fuel ports 54 is 11.24, which is relatively small. A benefit for making the choked radial fuel ports 54 larger is that the surface area on the windward side of the fuel jet becomes large, aiding in the fuel shedding and mixing process. An additional benefit of maximizing the choked radial fuel ports 54 is that the fuel inlet pressure is minimized. This could potentially be a parasitic loss on the engine power, depending on the storage method of the hydrogen.
[0080] In summary, the design choices for the premixing injector 10 were all derived from the gas turbine engine requirements. The power desired at cruise needed determined the design flow rate of hydrogen/fuel. The equivalence ratio specification to reduce NO x determined the air flow rate and thus the exterior annular mixing channel 40 , 40 a cross-sectional area.
[0081] It is understood that the invention is not confined to the particular construction and arrangement of parts herein illustrated and described, but embraces such modified forms thereof as come within the scope of the following claims. Thus, the invention encompasses all different versions that fall literally or equivalently within the scope of the claims.
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A premixing injector for use in gas turbine engines assists in the lean premixed injection of a gaseous fuel/air mixture into the combustor of a gas turbine. The premixing injector is designed to mix fuel and air at high velocities to eliminate the occurrence of flashback of the combustion flame from the reaction zone into the premixing injector. The premixing injector includes choked gas ports, which allow the fuel supply to be decoupled from any type of combustion instability which may arise in the combustor of the gas turbine and internal passages to provide regenerative cooling to the device.
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RELATED APPLICATIONS
[0001] This international application claims benefit of priority to U.S. Provisional Patent Application No. 61/731,109, filed on Nov. 29, 2012, and entitled, “Methods for Preparing and Repairing Chemically-Resistant Coatings,” which is incorporated herein by reference in its entirety.
FIELD OF INVENTION
[0002] This invention relates to methods for preparing and repairing chemically-resistant coatings, such as those known as porcelain enamels and vitreous enamels. This invention also relates to articles having a chemically-resistant coating.
BACKGROUND OF THE INVENTION
[0003] It is known, for example from U.S. Pat. No. 5,387,439, to manufacture porcelain enamel coatings on steel substrates. The '439 patent addresses a known problem of such coatings: they generally have poor impact strength. Thus, when tools, hardware, debris, or other material forcefully contacts the coating, or the article is subject to rough handling, the coating may be damaged. If a damaged coating encounters a harsh chemical environment such as is present in a chemical manufacturing process, the underlying steel substrate could be etched, and the process would be contaminated by the etched steel. Moreover, the steel substrate ultimately would fail, and the chemical process would no longer be contained or protected from the ambient conditions outside of the steel. The '439 patent discloses coatings having improved impact strength due to the incorporation of inorganic fibrous material into the coating.
[0004] Nonetheless, porcelain enamel coatings are still vulnerable to chipping, cracking, and other mechanical damage. The '439 patent teaches that a damaged coating on a process vessel can be corrected with a complete reglassing of the vessel (col. 2, II. 38-41), or by the use of a tantalum (metal and/or oxide) plug (col. 8, II. 14-19). As can be appreciated, reglassing of the entire vessel represents an enormous expense in both repair effort and process downtime, at least because the vessel must be disassembled from the process, typically transported to a repair site that includes a large oven or kiln, reglassed, transported back, and re-assembled into the process. Also, a tantalum patch, usually affixed over the damage site with an epoxy, may alter the chemistry of the process environment. Any repair to glass-lined equipment employing material other than glass is considered temporary. Therefore, methods for repairing damage to a porcelain enamel coating resulting in a chemically-resistant coating are desired. Also, methods for repairing such damage that do not require a complete reglassing are also desired. Methods that can be performed in situ or with minimal disassembly are also desired. Furthermore, methods for easily preparing a chemically-resistant coating in the first place are also sought. Articles having a chemically-resistant coating, such as a chemically-resistant coating that is easily repaired, are also desired. The various embodiments of the present invention may meet one or more of those desires, thereby solving the underlying technical problems with current coating manufacturing and repair technology.
SUMMARY OF THE INVENTION
[0005] Now, unexpectedly, applicant has found new methods to prepare and repair chemically-resistant coatings. In some embodiments, those methods involve forming a ground coat in a softened state, and then flame-spray depositing a coating material onto the softened ground coat, followed by cooling the coating slowly to relieve stress. Those methods can be used to manufacture a chemically-resistant coating in the first place, or to repair a damaged coating, whether or not the original coating was made according to the inventive method. Advantageously, some embodiments of the present invention allow the formation of a new protective chemically-resistant coating on a portion of the substrate that blends well with adjacent pre-existing coating. In further embodiments, the methods can be used to completely reglass an article such as a reactor vessel, a cover for a reactor vessel or other vessel, a baffle, a thermowell, an agitator, an agitator shaft, a pipe, a heat exchanger, a storage tank, or other process equipment as needed. Additional embodiments of the present invention include articles containing a chemically-resistant coating made according to the present invention.
[0006] Thus, some embodiments of the present invention relate to methods for preparing a chemically-resistant coating on a substrate having a ground coat thereon, comprising: heating the substrate to a first temperature thereby forming a softened ground coat; flame-spray depositing a coating material onto the softened ground coat; and cooling the substrate slowly, thereby forming the chemically-resistant coating on the substrate.
[0007] Other embodiments relate to methods of repairing a chemically-resistant coating on a substrate in need thereof, comprising: applying a composition to a damage site on the substrate, wherein the composition: (a) comprises a ground coat material in the form of particles having a particle size distribution such that at least about 5 weight percent of the particles are smaller than 44 microns and at least about 20 weight percent of the particles are larger than 150 microns, and (b) the ground coat material comprises a frit material comprising from about 48 to about 58 weight percent of silica, from about 12 to about 22 weight percent of boric oxide, from about 1 to about 9 weight percent of potassium oxide, and from about 1 to about 9 weight percent of alumina;
[0008] firing the composition to form a softened ground coat on the substrate;
[0009] flame-spray depositing a coating material onto the softened ground coat, wherein the coating material: (a) is in the form of particles having an average size ranging from about 74 to about 177 microns, and (b) comprises from about 68 to about 74 weight percent of silica, from about 0.5 to about 2.5 weight percent of alumina, from about 7 to about 15 weight percent of sodium oxide, from about 1 to about 5 weight percent of lithium oxide, and from about 2 to about 9 weight percent of zirconium oxide; and cooling the substrate slowly, thereby repairing the chemically-resistant coating on the substrate.
[0010] Further embodiments relate to methods of preparing a chemically-resistant coating on a substrate, comprising: applying a composition to the substrate, wherein the composition: (a) comprises a ground coat material in the form of particles having a particle size distribution such that at least about 5 weight percent of the particles are smaller than 44 microns and at least about 20 weight percent of the particles are larger than 150 microns, and (b) the ground coat material comprises a frit material comprising from about 48 to about 58 weight percent of silica, from about 12 to about 22 weight percent of boric oxide, from about 1 to about 9 weight percent of potassium oxide, and from about 1 to about 9 weight percent of alumina; firing the composition to form a softened ground coat on the substrate;
[0011] flame-spray depositing a coating material onto the softened ground coat, wherein the coating material: (a) is in the form of particles having an average size ranging from about 74 to about 177 microns, and (b) comprises from about 68 to about 74 weight percent of silica, from about 0.5 to about 2.5 weight percent of alumina, from about 7 to about 15 weight percent of sodium oxide, from about 1 to about 5 weight percent of lithium oxide, and from about 2 to about 9 weight percent of zirconium oxide; and cooling the substrate slowly, thereby preparing the chemically-resistant coating on the substrate.
[0012] Additional embodiments relate to articles of manufacture comprising: (a) a metal substrate; (b) a ground coat comprising silica, boric oxide, potassium oxide, and alumina; and (c) a coating in the form of splats comprising silica, alumina, sodium oxide, lithium oxide, and zirconium oxide. Such articles can be reactor vessels, covers, baffles, thermowells, agitators, agitator shafts, pipes, heat exchangers, storage tanks, and other components useful in the chemical, petrochemical, food, pharmaceutical, plastics, cosmetic, municipal water treatment, and related industries, and anywhere a chemically-resistant surface is desirable.
DETAILED DESCRIPTION
[0013] 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 that may be embodied in various forms. The figures are not necessarily to scale, some features may be exaggerated to show details of particular components. 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.
The Substrate
[0014] As stated above, some embodiments of the present invention provide methods for preparing or repairing a chemically-resistant coating on a substrate. Any suitable substrate can be used, such as, for example, a metal or metal alloy. In some cases, the substrate comprises steel. In one embodiment, the substrate is a cold-rolled low-carbon steel which contains less than 0.25 weight percent of carbon. Thus, as is disclosed in A.S.M.E. Specification SA285, Grade B, or SA285M-82, Grade B, this steel often contains no more than 0.22 weight percent of carbon, no more than 0.9 weight percent of manganese, no more than 0.035 weight percent of phosphorous, no more than 0.04 weight percent of sulfur, and at least about 98 weight percent of iron. In further embodiments, the substrate is a ferrous metal or alloy thereof such as those materials disclosed on pages 23-45 to 23-46 of Robert H. Perry et al.'s “Chemical Engineers' Handbook,” Fifth Edition (McGraw-Hill Book Company, New York, 1973). Thus, for example, the substrate may consist essentially of Inconel Alloy 600, Inconel Alloy 610, Inconel Alloy 625, Inconel Alloy 700, Inconel Alloy 702, Inconel Alloy 705, Inconel Alloy 713, Inconel Alloy 721, Inconel Alloy 722, Inconel Alloy X-750, and the like.
[0015] Whether the coating is being prepared or repaired on the substrate, the substrate may need to be cleaned and prepared beforehand. Any previous chemically-resistant coating can be removed, in whole or in part. For example, an area surrounding a defect or chip in the coating can be de-enameled, exposing the raw metal. The surface of the substrate often contains many imperfections, especially after it has been fabricated and is being finished or refinished. Thus, it is desired to prepare such surface by mechanical blasting to remove imperfections such as oxides, scales, pits, tool marks, etc.
[0016] In one embodiment, it is possible to prepare the surface of the substrate by blasting. As is disclosed on pages 198 to 211 of Andrew I. Andrews' “Porcelain Enamels: The Preparation, Application, and Properties of Enamels,” Second Edition (Garrard Press, Champaign, Ill., 1961), one may prepare such surface by mechanical blasting, by compressed air blasting, and the like. One may use conventional abrasives such as sand, steel grit, alumina grit, and the like. In one embodiment, alumina grit with a particle size smaller than 40 mesh is used. Certain embodiments provide cleaning the substrate by sand blasting, grit blasting, or a combination of both. Blasting may be continued until visual inspection reveals that the surface of the substrate has a clean, uniform grey appearance, indicating that it has been cleaned sufficiently to promote adherence between the ground coat and the substrate.
The Ground Coat
[0017] The ground coat can be any suitable material. As is known in the art, a ground coat in certain embodiments can be an alkali borosilicate glass composition which is used to develop high adherence between the substrate and subsequent coatings on the substrate. In still further embodiments, a ground coat can contain from about 10 to about 20 weight percent of boric oxide, from about 40 to about 60 weight percent of silica, and from about 15 to about 25 weight percent of alkali metal oxide(s) selected from the group consisting of the oxides of lithium, sodium, potassium, rubidium, cesium, francium, and mixtures thereof.
[0018] In one embodiment, ground coat comprises from about 60 to about 65 weight percent of silica. In another embodiment, the ground coat comprises from about 10 to about 22 weight percent of boric oxide. A further embodiment provides a ground coat comprising from about 1 to about 9 weight percent of potassium oxide. An additional embodiment includes a ground coat comprising from about 1 to about 9 weight percent of alumina. Still other embodiments include a ground coat comprising calcium oxide, cobalt oxide, nickel oxide, manganese oxide, one or more alkali metal oxides such as lithium oxide, sodium oxide, rubidium oxide, cesium oxide, francium oxide, or a combination thereof.
[0019] A ground coat composition can be prepared in any suitable manner. For example, a mixer can be used. Optionally, a suitable mixer can also comminute, that is, pulverize, or further reduce the particle size of the composition. Or a separate pulverizer can be employed. Thus, in one embodiment, a suitable mixer is a tumbling mill such as, e.g., a tube mill, a compartment mill, a rod mill, a pebble mill, a ball mill, and the like. See, e.g., pages 8-25 to 8-28 of Robert H. Perry et al.'s “Chemical Engineers' Handbook,” Fifth Edition (McGraw-Hill Book Company, New York, 1973).
[0020] A ground coat composition, which is applied to the substrate and then fired to form a softened ground coat, can take the form of a slurry. In some embodiments, a sufficient amount of liquid is added to the mixer with the solid material so that a slurry containing from about 60 to about 70 weight percent of solid material is formed. That is, the slurry comprises from about 30 to about 40 weight percent liquid. The liquid can include any suitable liquid such as water, lower alcohols such as methanol, ethanol, propanol, or butanol, or combinations of any of the foregoing. Milling of this slurry in a mixer, in certain embodiments, is continued until a substantially homogeneous mixture with a particle size distribution such that at least five weight percent of the particles in the slurry are smaller than 44 microns and at least about 20 weight percent of the particles in the slurry are larger than 150 microns is produced, in some embodiments. Samples may be periodically removed from the mixer and subjected to particle size analysis to determine whether the slurry has the desired particle size distribution. See, for example, U.S. Pat. No. 4,282,006 for a discussion of the measurement of particle size distribution.
[0021] In some cases, a ground coat material can be prepared, for example, by charging into a mixer a glass batch containing from about 48 to about 58 weight percent (by total weight of the glass batch, dry basis) of silica, from about 12 to about 22 weight percent of boric oxide, from about 9 to about 19 weight percent of sodium oxide, from about 1 to about 9 weight percent of potassium oxide, and from about 1 to about 9 weight percent of alumina. In addition, this glass batch also may contain from about 1 to about 6 weight percent of calcium fluoride, from about 0.2 to about 6 weight percent of cobalt oxide, from about 0.2 to about 4 weight percent of nickel oxide, and from about 0.2 to about 3 weight percent of manganese oxide. Optionally, one may also add various suspending agents, electrolytes, and other materials and fluids to the mixer; see, e.g., pages 360-365 of the aforementioned Andrews text.
[0022] A ground coat composition may be applied to the substrate via any suitable method, such as, for example, dipping, slushing, spraying, and combinations thereof. Any conventional spraying means may be used; see, e.g., pages 394 to 403 of the aforementioned Andrews reference. It is possible to apply the ground coat composition to the prepared substrate in such a manner that one obtains a uniform thickness after firing of from about 0.25 millimeters to about 0.5 millimeters. To achieve this goal, in general a wet film of from about 0.3 to about 0.75 millimeters can be applied to the substrate.
[0023] Once the ground coat composition is applied to the substrate, the composition may be dried if it is in the form of a slurry. Any suitable drying method can be used, including air drying, heated drying, forced air drying, force drying in an oven, and combinations thereof. Moisture content of a dried ground coat composition, in some cases, is less than about 10 weight percent, or less than about 1 weight percent in other cases. Then the ground coat composition is fired at any suitable temperature. Firing the ground coat composition can employ any suitable method, such as, for example, induction heating, placing the workpiece in an oven or kiln, or combinations thereof. Induction heating, comprising placing one or more induction coils in proximity to the substrate, can be employed in certain embodiments of the present invention. The induction coil heats the metal substrate, which in turn heats the ground coat composition. The ground coat composition is heated to a temperature at which it vitrifies. Some embodiments provide the ground coat so formed is heated to or held at a temperature at which the ground coat is softened. Such a temperature can be above the ground coat's glass transition temperature, in certain embodiments. Other embodiments provide a softened ground coat at a temperature at which the ground coat does not significantly flow or deform on the time scale of the manufacturing operation that applies the coating material.
[0024] In some embodiments, the optionally-dried ground coat composition on the substrate is subjected to a temperature ranging from about 810 to about 910 degrees Centigrade for a time ranging from about 20 to about 150 minutes. It is possible to subject the dried substrate to a temperature ranging from about 850 to about 880 degrees Centigrade for a time ranging from about 20 to about 150 minutes, in certain embodiments. Still other embodiments provide firing the ground coat composition at a temperature ranging from about 1,500 to about 1,600 degrees Fahrenheit (about 816 to about 871 degrees Centigrade).
The Coating Material
[0025] The coating material that is deposited onto the softened ground coat to form the chemically-resistant coating can be any suitable material. In some embodiments, the coating material comprises silica, alumina, sodium oxide, lithium oxide, and zirconium oxide. In other embodiments, the coating material comprises from about 68 to about 74 weight percent of silica. Further embodiments provide a coating material comprising from about 0.5 to about 2.5 weight percent of alumina. Additional embodiments include a coating material comprising from about 7 to about 15 weight percent of sodium oxide. Yet other embodiments include a coating material comprising from about 1 to about 5 weight percent of lithium oxide. Still further embodiments provide a coating material comprising from about 2 to about 9 weight percent of zirconium oxide. In one embodiment, the frit contains from about 70 to about 72 weight percent of silica, from about 1 to about 2 weight percent of alumina, from about 11 to about 14 weight percent of sodium oxide, from about 1 to about 3 weight percent of lithium oxide, and from about 2 to about 6 weight percent of zirconium oxide.
[0026] The coating material can also contain suspending agents such as montmorillonitic type clays, for example. Some embodiments provide from about 0.1 to about 0.6 weight percent of such suspending agent(s), by weight of solid material. Any conventional electrolyte (such as potassium chloride, barium chloride, aluminum chloride, calcium chloride, and the like) may be used, in additional embodiments, in any suitable amount. In some cases, from about 0.02 to about 0.6 weight percent of such electrolyte (by weight of dry solid material) may be used.
[0027] The coating material can be prepared in any suitable manner. As explained for the ground coat, the raw ingredients for the coating material can be introduced into a mixer that also comminutes, in some embodiments. Once mixed, the ingredients can be vitrified into a frit, quenched, dried, and then reduced to particles again. In preparation for flame-spray deposition, a particle size of 80-200 mesh can be used in certain embodiments. In other embodiments, a mesh size of 100-200 is used. In still other embodiments, a mesh size of 80-100 is employed. As is known in the art, 80 mesh corresponds to a particle size of about 177 microns, 100 mesh corresponds to a particle size of about 149 microns, and 200 mesh corresponds to a particle size of about 74 microns. In still other embodiments, the coating material is in the form of particles having an average size ranging from about 115 to about 125 microns.
Forming the Chemically-Resistant Coating
[0028] The substrate and the workpiece can be heated by any suitable method for any purpose requiring heat. In addition, each of heating the substrate, firing, optionally maintaining the temperature of the softened ground coat by heating, and cooling the substrate slowly, can be accomplished by the same or different heating methods. The ground coat in one embodiment can be formed in a kiln or oven. A heat gun can maintain the temperature of the softened ground coat, if necessary, before and during flame-spray deposition. Then an induction coil can be used to apply induction heating to the substrate to allow the substrate to cool slowly, thereby allowing the coating material and the ground coat to relieve any stresses.
[0029] Applicant has found that certain embodiments of the present invention afford a previously unavailable degree of freedom. Because of the ease of employing those embodiments, and the robust nature of the resulting chemically-resistant coatings, repairs of damaged coatings in the field are now possible. Some embodiments employ induction heating as the sole or primary heat source. In certain cases, induction heating obviates the need to disassemble, transport, and deglass process equipment that has a damaged porcelain enamel coating. Thus, in one embodiment, heating the substrate comprises applying induction heating. In a further embodiment, providing a softened ground coat comprises applying induction heating. In another embodiment, cooling the substrate slowly comprises applying induction heating.
[0030] Flame-spray deposition of the coating material can occur according to any suitable method. Commercially-available flame spray equipment can be used in some embodiments. The coating material is loaded in the flame sprayer, and then deposited onto the softened ground coat. Optionally, the temperature of the softened ground coat is maintained by heating, such as for example, by applying induction heating to the substrate. In another embodiment, the flame-spray deposition occurs rapidly after firing of the ground coat under circumstances that allow the ground coat to maintain a softened state throughout the flame-spray deposition. In some cases, the ground coat is maintained at a temperature greater than about 1450 degrees Fahrenheit (about 788 degrees Centigrade) during flame-spray depositing. In other cases, the ground coat is maintained at a temperature greater than about 1480 degrees Fahrenheit (about 804 degrees Centigrade) during flame-spray depositing.
[0031] Some embodiments provide a different process in lieu of or in addition to flame-spray depositing known as hot dusting. In such embodiments, the coating material in particulate form is heated and dusted on the softened ground coat. Then the substrate is cooled slowly, as described elsewhere herein. Accordingly, some embodiments relate to methods for preparing or repairing a chemically-resistant coating on a substrate having a ground coat thereon, comprising: heating the substrate to a first temperature thereby forming a softened ground coat; hot-dust depositing a coating material onto the softened ground coat; and cooling the substrate slowly, thereby preparing or repairing the chemically-resistant coating on the substrate.
[0032] Flame-spray depositing the coating material onto the softened ground coat will cause the coating material to form a layer of “splats” in some embodiments. Upon microscopic inspection of a cross-section of certain chemically-resistant coatings of the present invention, those splats will appear as flattened or deformed spheres characteristic of flame-spray deposition. In some embodiments, the splats have an average volume ranging from about 2.1×10 −13 m 3 to about 2.9×10 −12 m 3 . In other embodiments, the splats have an average volume ranging from about 2.1×10 −13 m 3 to about 1.7×10 −12 m 3 . In still other embodiments, the splats have an average volume ranging from about 7.9×10 −13 m 3 to about 1.0×10 −12 m 3 .
[0033] Some embodiments therefore provide a coating material in the form of splats, wherein the splats comprise from about 68 to about 74 weight percent of silica. Other embodiments include splats comprising from about 0.5 to about 2.5 weight percent of alumina. Further embodiments involve splats comprising from about 7 to about 15 weight percent of sodium oxide. Still other embodiments include a coating in the form of splats that comprise from about 1 to about 5 weight percent of lithium oxide. Additional embodiments of the present invention contain splats that comprise from about 2 to about 9 weight percent of zirconium oxide.
[0034] The thickness of the layer of coating material can be any suitable dimension. In some embodiments, the thickness of the coating material ranges from about 0.5 to about 1.0 millimeter.
[0035] Another aspect of the invention relates to the relief of stress in the chemically-resistant coating. Such stress can appear in the ground coat, in the flame-spray deposited coating material, another layer of material the skilled artisan has chosen to employ with the foregoing materials, or a combination thereof. Such stress can be relieved, for example, by holding the workpiece or a portion thereof where the chemically-resistant coating is being formed at an elevated temperature. In some cases, that elevated temperature is at or above the glass transition temperature of the ground coat. In other cases, that elevated temperature is at or above the glass transition temperature of the flame-spray deposited coating material. In still other cases, that elevated temperature is at or above the glass transition temperature of both the ground coat and the flame-spray deposited coating material. Sometimes, the skilled artisan may prefer to use the annealing temperature range of one or more materials as a reference point. Accordingly, in some cases, that elevated temperature is at or above the annealing temperature range of the ground coat. In other cases, that elevated temperature is at or above the annealing temperature range of the flame-spray deposited coating material. In still other cases, that elevated temperature is at or above the annealing temperature ranges of both the ground coat and the flame-spray deposited coating material.
[0036] The time it takes to cool the substrate slowly may depend on one or more factors, such as, for example, the size of the workpiece or the portion of the workpiece having new or repaired chemically-resistant coating, the mass and thickness of the coating, the geometry of the workpiece (substantially planar, concave, convex, or complex), and the physical properties of the substrate, ground coat, and coating material (glass transition temperature, coefficient of thermal expansion). In some embodiments, therefore, cooling the substrate slowly comprises allowing the substrate to pass through the glass transition temperature of the ground coat in a time period of not less than thirty minutes after the flame-spray depositing. Other embodiments allow the substrate to pass through the glass transition temperature of the coating material in a time period of not less than thirty minutes, not less than one hour, or not less than two hours after the flame-spray depositing.
[0037] Some embodiments of the present invention provide additional layers. For example, more than one ground coat can be applied before the flame-spray deposition. One or more intermediate coats can be included as well. More than one layer of flame-spray deposited coating materials also appear in certain embodiments. Such additional layers can comprise any suitable materials and exhibit any suitable characteristics. For example, in a few embodiments, the various layers of material have coefficients of thermal expansion such that each layer has a coefficient numerically between the adjacent materials, so that the overall coating performs adequately upon heating and cooling. It is desirable in further embodiments that the flame-spray deposition occurs onto a layer of material that is in a softened state.
Testing the Chemically-Resistant Coating
[0038] Chemically-resistant coatings of the present invention can be characterized and distinguished from other coatings in numerous ways. To determine the identity and relative amount of the ingredients in a coating, any suitable method can be used. It is possible, in some circumstances, to employ energy-dispersive X-ray spectroscopy (“EDX”), X-ray fluorescence (“XRF”), various forms of electron microscopy, petrography, optical microscopy, and other analytical techniques to determine the identity and amount of components of a coating. In addition, it is possible to calculate the composition of a coating from the relative amounts of raw ingredients used to make the ground coat material, the frit, if any, of the ground coat material, the mill additions, if any, of the ground coat material, the frit, if any, of the coating material, the mill additions, if any, of the coating material, and any other ingredients. Two methods of such calculations may be mentioned, and both are fully explained in Chapter 6, Enamel Calculations, of the Andrews text. The first is the so-called “Factor Method,” because it employs numerical factors for estimating the amount of material formed from a given raw material. For example, it is estimated that 1 gram of soda ash (Na 2 CO 3 ) will yield 0.585 grams of sodium oxide (Na 2 O) after firing, so the factor used to calculate the relative amount of sodium oxide in the final coating from the amount of soda ash added is 0.585. See Andrews, Table 23, page 218. The second is the so-called “Chemical Method,” which relies on sorting the resulting oxides into basic oxides having the formula R 2 O or RO, intermediate oxides having the formula R 2 O 3 , and acidic oxides having the formula RO 2 . See Andrews, page 230. Those methods are known to those having ordinary skill in the art, so are not further elucidated here.
[0039] The coefficients of thermal expansion of the substrate, ground coat, and coating material can be any suitable values. For example, in one embodiment, the chemically-resistant coating has a coefficient of thermal expansion ranging from about 85 to about 89×10 −7 centimeters per centimeter per degree centigrade. In this embodiment, the substrate to be coated may be, e.g., a concave surface such as, e.g., the inside of a reactor vessel. In another embodiment, the chemically-resistant coating has a coefficient of thermal expansion ranging from about 100 to about 105×10 −7 centimeters per centimeter per degree centigrade. In this embodiment, the substrate to be coated may be a convex surface such as, e.g., the blade of an agitator. In still other embodiments, the substrate comprises low carbon steel, and has a coefficient of thermal expansion of about 125×10 −7 centimeters per centimeter per degree centigrade. An additional embodiment provides a ground coat having a coefficient of thermal expansion of about 100×10 −7 centimeters per centimeter per degree centigrade. Still another embodiment provides a coating material having a coefficient of thermal expansion of about 80×10 −7 centimeters per centimeter per degree centigrade.
[0040] The glass transition temperature of the coating, or of the ground coat, coating material, or any component thereof, can be measured using differential scanning calorimetry and thermal dilatometry, as is known in the art.
[0041] The acid resistance of the coated substrate may be tested in substantial accordance with the test described in U.S. Pat. No. 4,407,868. The standard test JIS R-4301 discussed in EXAMPLE 6 of such patent is substantially the same test as described in DIN 2743. The afore-mentioned Andrews text describes on page 586 the acid resistance test known as ASTM Desig. C 283-54 (1954). Such a test is also acceptable, as are any other suitable tests.
[0042] When the testing of the coated substrate is done in accordance with DIN 2743 and the substrate is exposed to a vapor of 20 volume percent of hydrochloric acid, the chemically-resistant coating may lose no more than about 0.3 grams per square meter per day, in some embodiments of the present invention.
[0043] The thermal shock properties of the chemically-resistant coating may be tested in accordance with A.S.T.M. Standard Test C385-58. An impact resistance test may be conducted with the apparatus illustrated in FIG. 3 of the '439 patent. An electrical test apparatus also may be utilized. The electrical test apparatus can be a 20,000 volt alternating current test spark tester supplied by the DeDietrich Co. of Corpus Christi, Tex. Using such an apparatus, a chemically-resistant coating of the present invention can be subject to a 20 KV spark test to test the integrity of the coating. Different areas of the coating can be tested to measure the overall quality of the coating.
EXAMPLES
[0044] The following examples are presented to illustrate the claimed invention but are not to be deemed limitative thereof. Unless otherwise specified, all parts are by weight and all temperatures are in degrees Centigrade. The equipment, materials, volumes, weights, temperatures, sources of materials, manufacturers of equipment, and other parameters are offered to illustrate, but not to limit, the invention. All such parameters can be modified within the scope of the claimed invention.
Example 1
Ground Coat on a Steel Substrate
[0045] To a tumbling mill (such as those manufactured by the Curtis Manufacturing Company or U.S. Stoneware of East Palestine, Ohio) is charged 36.34 parts of feldspar (sold by the Pacer Corporation of Custer, S. Dak., as “Custer Feldspar”), 23.65 parts of dehydrated borax (sold by the U.S. Borax Corporation of Death Valley, Calif. as “anhydrous borax”), 2.16 parts of fluorspar (sold by READE Advanced Materials of East Providence, R.I. as “ fluorspar powder”), 2.03 parts of potassium nitrate (sold by the Interstate Chemical Company of West Middlesex, Pa. as “potash niter”), 9.02 parts of sodium carbonate (sold by the Interstate Chemical Company as “soda ash”), 25.11 parts of quartz (sold by Short Mountain Silica of Mooresburg, Tenn. as “glass sand”), 0.85 parts of cobalt oxide (sold by Atlantic Equipment Engineers of Bergenfield, N.J. as “black cobalt oxide powder,” Item # CO-601), 0.47 parts of nickel oxide (sold by Atlantic Equipment Engineers as “green nickel oxide powder,” Item # NI-601), and 0.38 parts of manganese oxide (sold by Atlantic Equipment Engineers as “manganese dioxide powder,” Item # MN-601). Thereafter, these reagents are mixed by tumbling them for two hours at a speed of 30 revolutions per minute.
[0046] The mixture thus produced is then charged to a 5200 mL cylindrical crucible comprised of 92 per cent alumina; this crucible can be obtained from Antaeus Hi-Tech, Zhengzhou City, Henan Province, China. The crucible containing the glass batch is then charged to a Harper Furnace, model number H4S121412EKA30S (manufactured by the Harper Electric Furnace Corporation of Lancaster, N.Y.); both the crucible and the furnace are preheated to a temperature of 1,400 degrees Centigrade (2,552 degrees Fahrenheit) prior to the time the batch was charged to the crucible or placed into the furnace.
[0047] The glass batch is heated at 1,400 degrees Centigrade for 4.0 hours. At the end of this time, a fiber is pulled from the glass batch to check that the material is fully smelted and in solution. Thereafter, the material is poured from the crucible into a thirty-gallon quenching kettle at a temperature of 55 degrees Fahrenheit (12.8 degrees Centigrade) which is filled with 25 gallons of water, thereby quenching the molten glass.
[0048] Water is removed from the kettle, and the quenched frit is then dried in the kettle to a moisture content of less than 1.0 weight percent.
[0049] To a number 2 jar mill (manufactured by U.S. Stoneware Corporation) is charged 100 parts of the dried frit, 7 parts of OM4 ball clay (sold by Great Lakes Clay of Elgin, Ill.), 40 parts of number 3 glass sand, 0.155 parts of sodium nitrite (sold by the Interstate Chemical Corporation as sodium nitrite), 0.155 parts of anhydrous borax, and 44 parts of deionized water. The total weight of the charge to the jar mill, dry basis, is 3,234 grams; the grinding media used is 6,600 grams of 1.25 inch high-density alumina balls and 3,300 grams of 1.0 inch high-density alumina balls. The mixture is then milled at a rate of 34 revolutions per minute for two hours.
[0050] The slurry thus produced is checked for particle size distribution by passing it through a series of 100 mesh Tyler and 325 mesh Tyler steel sieves; milling is continued until 20 weight percent of the particles in the slurry are retained on the 100 mesh sieve, and 75 percent of the particles are retained on the 325 mesh sieve.
[0051] Deionized water is added to the slurry until its specific gravity was 1.78. Thereafter, the slurry is placed into a DeVilbiss JGV560 Spray Gun (manufactured by the DeVilbiss Company of Toledo, Ohio).
[0052] A 6″×6″×0.5″ thick steel plate (SA285, Grade B steel, such as is available from the Nucor Corporation of Charlotte, N.C. is used as the substrate for the ground coat composition. Before deposition, the plate is grit blasted with minus 40 mesh alumina at 80 pounds per square inch until a clean sample is obtained. Thereafter, the clean sample is sprayed with the ground coat slurry material until a wet film with a wet film thickness of 0.62 millimeters is obtained. The coated substrate is then allowed to air dry under ambient conditions for 2.0 hours.
[0053] The dried plate is then charged to Cooley BL4 Electric Furnace which is preheated to a temperature of 870 degrees Centigrade. The plate is subjected to this temperature for a period of 40 minutes.
Example 2
Preparing Coating Material
[0054] The coating material is prepared as follows. To the aforementioned tumbling mill is charged 9.09 parts of the aforementioned feldspar, 1.52 parts of calcium carbonate (sold by Interstate Chemical Company), 3.57 parts of magnesium carbonate (sold by American Elements of Los Angeles, Calif., as magnesium carbonate), 4.24 parts of potassium nitrite (sold by Interstate Chemical Company as potassium nitrite), 5.00 of sodium nitrate (sold by American Elements as sodium nitrate), 16.79 parts of the aforementioned sodium carbonate, 5.9 parts of zirconium silicate (sold by the Tam Ceramic Products Corporation of Niagara Falls, N.Y. as “Zircosil”), 2.17 parts of the aforementioned anhydrous borax, 4.2 parts of lithium carbonate (sold by American Elements as lithium carbonate), 62.18 parts of the aforementioned quartz, 1.0 parts of the aforementioned cobalt oxide, and 1.2 parts of black iron oxide (sold by Atlantic Equipment Engineers as “black iron oxide (magnetite),” Item # FE-602). The mixture is then mixed for 2.0 hours at a speed of 30 revolutions per minute.
[0055] The mixture thus produced is charged to a crucible comprised of 92 per cent alumina; this crucible can be obtained from Antaeus Hi-Tech, Zhengzhou City, Henan Province, China. The crucible containing the glass batch is then charged to a Harper Furnace, model number H4S121412EKA30S (manufactured by the Harper Electric Furnace Corporation of Lancaster, N.Y.); both the crucible and the furnace are preheated to a temperature of 1,400 degrees Centigrade prior to the time the batch is charged to the crucible or placed into the furnace.
[0056] The glass batch is heated at 1,400 degrees Centigrade for 4.0 hours. At the end of this time, a fiber is pulled from the glass batch to check that the material is fully smelted and in solution. Thereafter, the material is poured from the crucible into a thirty-gallon quenching kettle at a temperature of 55 degrees Fahrenheit which is filled with 25 gallons of water, thereby quenching the molten glass. Water is removed from the kettle, and the quenched frit is then dried in the kettle to a moisture content of less than 1.0 weight percent.
[0057] To a number 2 jar mill (manufactured by U.S. Stoneware Corporation) is charged 100 parts of the dried frit, 0.62 parts of purified Wyoming bentonite (sold by Wyo-Ben, Inc., of Billings, Mont.), 0.62 parts of potassium chloride (sold by Interstate Chemical Company as potassium chloride), and 35 parts of deionized water. The total weight of the charge to the jar mill, dry basis, is 2,334.8 grams; the grinding media used is 6,600 grams of 1.25 inch high-density alumina balls and 3,300 grams of 1.0 inch high-density alumina balls. The mixture is then milled at a rate of 34 revolutions per minute for two hours.
[0058] The mixture thus produced is charged to a crucible comprised of 90 percent alumina as described above; this crucible is then charged to the Harper Furnace. Both the crucible and the furnace are preheated to a temperature of 1,400 degrees Centigrade prior to the time the batch is charged to the crucible or placed into the furnace.
[0059] The mixture is heated at 1,400 degrees Centigrade for 4.0 hours. At the end of this time, a fiber is pulled to check that the material is fully smelted and in solution. Thereafter, the now-formed coating material is poured from the crucible into a thirty-gallon quenching kettle at a temperature of 55 degrees Fahrenheit which is filled with 25 gallons of water, thereby quenching the molten coating material. Water is removed from the kettle, and the quenched coating material is then dried in the kettle to a moisture content of less than 1.0 weight percent.
[0060] The coating material thus produced is returned to the jar mill and milled until an appropriate particle size distribution results. The coating material is checked for particle size distribution by passing it through a series of 100 mesh Tyler and 325 mesh Tyler steel sieves; milling continues until 10 weight percent of the particles are retained on the 100 mesh sieve, and 80 percent of the particles are retained on the 325 mesh sieve. Alternatively, particles having a size distribution ranging from about 115 microns to about 125 microns can be chosen through selective use of appropriate sieves.
Example 3
Coating Material Flame-Spray Deposited onto the Heated, Softened Ground Coat
[0061] The coating material particles are loaded into a flame sprayer, and flame-spray deposited on the substrate. The aforementioned, ground-coated 6″×6″×0.5″ thick steel plate with the ground coat thereon was used as the target. The steel plate is coated immediately upon removal from the electric furnace. Optionally, an induction coil also maintains the substrate at about 1450 to about 1480 degrees Fahrenheit (about 788 to about 804 degrees Centigrade). A suitable temperature detection device, such as a thermocouple or an infrared laser temperature detector, may monitor the temperature. The flame sprayer deposits the coating material onto the softened ground coat. Additional layers of various alike or different compositions can be added, optionally while the ground coat remains in a softened state.
[0062] Then the substrate is allowed to cool slowly by the application of an induction coil to heat the substrate. After two hours, the substrate cools below the glass transition temperature of the coating material. The substrate is then allowed to cool to room temperature at a rate of about 120 degrees Fahrenheit (about 67 degrees Centigrade) per hour.
Example 4
Testing the Chemically-Resistant Coating
[0063] The coated steel plate from Example 3 is checked for electrical conductivity using the 20,000 volt test procedure; the plate should be an effective insulator.
[0064] The coating thickness is measured by a Fisher Deltascope thickness meter, and the mean thickness likely ranges from about 1.28 to about 1.52 millimeters; 32 readings are taken.
[0065] The sample is tested in accordance with the impact resistance test described in the specification of the '439 patent. Following each impact, the sample is tested by the aforementioned Electric Spark Test, using 20,000 volts.
Example 5
Convex Substrate
[0066] In substantial accordance with the procedure of Examples 1-3, a coated substrate is prepared, with the exceptions that (1) the target used is a convex-shaped steel substrate (SA-285), (2) the coating material is made from a glass batch which comprised 2.3 parts of potassium oxide, 15.3 parts of sodium oxide, 4.0 parts of barium oxide, 1.0 parts of calcium oxide, 1.3 parts of zinc oxide, 2.6 parts of lithium oxide, 69.8 parts of silica, and 3.7 parts of alumina. The coated and fired substrate should have properties comparable to the coated substrate of Example 3.
VARIOUS EMBODIMENTS
Embodiment 1
[0067] A method for preparing a chemically-resistant coating on a substrate having a ground coat thereon, comprising:
[0068] heating the substrate to a first temperature thereby forming a softened ground coat; flame-spray depositing a coating material onto the softened ground coat; and cooling the substrate slowly, thereby forming the chemically-resistant coating on the substrate.
Embodiment 2
[0069] The method of embodiment 1, wherein the substrate comprises steel.
Embodiment 3
[0070] The method of any one of embodiments 1-2, wherein the ground coat comprises from about 60 to about 65 weight percent of silica.
Embodiment 4
[0071] The method of any one of embodiments 1-3, wherein the ground coat comprises from about 10 to about 22 weight percent of boric oxide.
Embodiment 5
[0072] The method of any one of embodiments 1-4, wherein the ground coat comprises from about 1 to about 9 weight percent of potassium oxide.
Embodiment 6
[0073] The method of any one of embodiments 1-5, wherein the ground coat comprises from about 1 to about 9 weight percent of alumina.
Embodiment 7
[0074] The method of any one of embodiments 1-6, wherein the ground coat comprises calcium oxide, cobalt oxide, nickel oxide, manganese oxide, one or more alkali metal oxides, or a combination thereof.
Embodiment 8
[0075] The method of any one of embodiments 1, 2, or 7, wherein the coating material comprises from about 68 to about 74 weight percent of silica, from about 0.5 to about 2.5 weight percent of alumina, from about 7 to about 15 weight percent of sodium oxide, from about 1 to about 5 weight percent of lithium oxide, and from about 2 to about 9 weight percent of zirconium oxide.
Embodiment 9
[0076] The method of any one of embodiments 1, 2, or 7, wherein the coating material comprises from about 68 to about 74 weight percent of silica.
Embodiment 10
[0077] The method of any one of embodiments 1, 2, 7, or 9, wherein the coating material comprises from about 0.5 to about 2.5 weight percent of alumina.
Embodiment 11
[0078] The method of any one of embodiments 1, 2, 7, 9, or 10, wherein the coating material comprises from about 7 to about 15 weight percent of sodium oxide.
Embodiment 12
[0079] The method of any one of embodiments 1, 2, 7, 9-11, wherein the coating material comprises from about 1 to about 5 weight percent of lithium oxide.
Embodiment 13
[0080] The method of any one of embodiments 1, 2, 7, 9-12, wherein the coating material comprises from about 2 to about 9 weight percent of zirconium oxide.
Embodiment 14
[0081] The method of any one of embodiments 1-13, wherein heating the substrate comprises applying induction heating.
Embodiment 15
[0082] The method of any one of embodiments 1-14, wherein cooling the substrate slowly comprises applying induction heating.
Embodiment 16
[0083] The method of any one of embodiments 1-15, wherein cooling the substrate slowly comprises allowing the substrate to pass through the glass transition temperature of the ground coat in a time period of not less than thirty minutes after the flame-spray depositing.
Embodiment 17
[0084] The method of any one of embodiments 1-16, wherein cooling the substrate slowly comprises allowing the substrate to pass through the glass transition temperature of the coating material in a time period of not less than thirty minutes after the flame-spray depositing.
Embodiment 18
[0085] The method of any one of embodiments 1-17, wherein cooling the substrate slowly comprises allowing the substrate to pass through the glass transition temperature of the coating material in a time period of not less than one hour after the flame-spray depositing.
Embodiment 19
[0086] The method of any one of embodiments 1-18, wherein cooling the substrate slowly comprises allowing the substrate to pass through the glass transition temperature of the coating material in a time period of not less than two hours after the flame-spray depositing.
Embodiment 20
[0087] A method of repairing a chemically-resistant coating on a substrate in need thereof, comprising:
[0088] applying a composition to a damage site on the substrate, wherein the composition: (a) comprises a ground coat material in the form of particles having a particle size distribution such that at least about 5 weight percent of the particles are smaller than 44 microns and at least about 20 weight percent of the particles are larger than 150 microns, and
[0089] (b) the ground coat material comprises a frit material comprising from about 48 to about 58 weight percent of silica, from about 12 to about 22 weight percent of boric oxide, from about 1 to about 9 weight percent of potassium oxide, and from about 1 to about 9 weight percent of alumina;
[0090] firing the composition to form a softened ground coat on the substrate;
[0091] flame-spray depositing a coating material onto the softened ground coat, wherein the coating material:
[0092] (a) is in the form of particles having an average size ranging from about 74 to about 177 microns, and
[0093] (b) comprises from about 68 to about 74 weight percent of silica, from about 0.5 to about 2.5 weight percent of alumina, from about 7 to about 15 weight percent of sodium oxide, from about 1 to about 5 weight percent of lithium oxide, and from about 2 to about 9 weight percent of zirconium oxide; and
[0094] cooling the substrate slowly, thereby repairing the chemically-resistant coating on the substrate.
Embodiment 21
[0095] The method of embodiment 20, wherein the firing comprises applying induction heating.
Embodiment 22
[0096] The method of any one of embodiments 20-21, wherein the cooling the substrate slowly comprises applying induction heating.
Embodiment 23
[0097] The method of any one of embodiments 20-22, wherein cooling the substrate slowly comprises allowing the substrate to pass through the glass transition temperature of the coating material in a time period of not less than thirty minutes after the flame-spray depositing.
Embodiment 24
[0098] The method of any one of embodiments 20-23, wherein cooling the substrate slowly comprises allowing the substrate to pass through the glass transition temperature of the coating material in a time period of not less than one hour after the flame-spray depositing.
Embodiment 25
[0099] The method of any one of embodiments 20-24, wherein cooling the substrate slowly comprises allowing the substrate to pass through the glass transition temperature of the coating material in a time period of not less than two hours after the flame-spray depositing.
Embodiment 26
[0100] The method of any one of embodiments 20-25, wherein the composition is in the form of a slurry and comprises from about 30 to about 40 weight percent liquid.
Embodiment 27
[0101] The method of embodiment 26, wherein the liquid comprises water.
Embodiment 28
[0102] The method of any one of embodiments 20-27, further comprising drying the composition before the firing.
Embodiment 29
[0103] The method of any one of embodiments 20-28, wherein the coating material in the form of particles has an average size ranging from about 115 to about 125 microns.
Embodiment 30
[0104] The method of any one of embodiments 20-29, further comprising cleaning the damage site before applying the composition.
Embodiment 31
[0105] The method of embodiment 30, wherein the cleaning comprises sand blasting, grit blasting, or a combination of both.
Embodiment 32
[0106] The method of any one of embodiments 20-31, wherein the frit material further comprises calcium oxide, cobalt oxide, nickel oxide, manganese oxide, lithium oxide, sodium oxide, rubidium oxide, cesium oxide, francium oxide, or a combination thereof.
Embodiment 33
[0107] A method of preparing a chemically-resistant coating on a substrate, comprising:
[0108] applying a composition to the substrate, wherein the composition:
[0109] (a) comprises a ground coat material in the form of particles having a particle size distribution such that at least about 5 weight percent of the particles are smaller than 44 microns and at least about 20 weight percent of the particles are larger than 150 microns, and
[0110] (b) the ground coat material comprises a frit material comprising from about 48 to about 58 weight percent of silica, from about 12 to about 22 weight percent of boric oxide, from about 1 to about 9 weight percent of potassium oxide, and from about 1 to about 9 weight percent of alumina;
[0111] firing the composition to form a softened ground coat on the substrate;
[0112] flame-spray depositing a coating material onto the softened ground coat, wherein the coating material:
[0113] (a) is in the form of particles having an average size ranging from about 74 to about 177 microns, and
[0114] (b) comprises from about 68 to about 74 weight percent of silica, from about 0.5 to about 2.5 weight percent of alumina, from about 7 to about 15 weight percent of sodium oxide, from about 1 to about 5 weight percent of lithium oxide, and from about 2 to about 9 weight percent of zirconium oxide; and
[0115] cooling the substrate slowly, thereby preparing the chemically-resistant coating on the substrate.
Embodiment 34
[0116] The method of embodiment 33, wherein the firing comprises applying induction heating.
Embodiment 35
[0117] The method of any one of embodiments 33-34, wherein the cooling the substrate slowly comprises applying induction heating.
Embodiment 36
[0118] The method of any one of embodiments 33-35, wherein cooling the substrate slowly comprises allowing the substrate to pass through the glass transition temperature of the coating material in a time period of not less than thirty minutes after the flame-spray depositing.
Embodiment 37
[0119] The method of any one of embodiments 33-36, wherein cooling the substrate slowly comprises allowing the substrate to pass through the glass transition temperature of the coating material in a time period of not less than one hour after the flame-spray depositing.
Embodiment 38
[0120] The method of any one of embodiments 33-37, wherein cooling the substrate slowly comprises allowing the substrate to pass through the glass transition temperature of the coating material in a time period of not less than two hours after the flame-spray depositing.
Embodiment 39
[0121] The method of any one of embodiments 33-38, wherein the composition is in the form of a slurry and comprises from about 30 to about 40 weight percent liquid.
Embodiment 40
[0122] The method of embodiment 39, wherein the liquid comprises water.
Embodiment 41
[0123] The method of any one of embodiments 33-40, further comprising drying the composition before the firing.
Embodiment 42
[0124] The method of any one of embodiments 33-41, wherein the coating material in the form of particles has an average size ranging from about 115 to about 125 microns.
Embodiment 43
[0125] The method of any one of embodiments 33-42, further comprising cleaning the substrate before applying the composition.
Embodiment 44
[0126] The method of embodiment 43, wherein the cleaning comprises sand blasting, grit blasting, or a combination of both.
Embodiment 45
[0127] The method of any one of embodiments 33-44, wherein the frit material further comprises calcium oxide, cobalt oxide, nickel oxide, manganese oxide, lithium oxide, sodium oxide, rubidium oxide, cesium oxide, francium oxide, or a combination thereof.
Embodiment 46
[0128] An article comprising:
[0129] (a) a metal substrate;
[0130] (b) a ground coat comprising silica, boric oxide, potassium oxide, and alumina; and
[0131] (c) a coating in the form of splats comprising silica, alumina, sodium oxide, lithium oxide, and zirconium oxide.
Embodiment 47
[0132] The article of embodiment 46, wherein the metal substrate comprises steel.
Embodiment 48
[0133] The article of any one of embodiments 46-47, wherein the splats have an average volume ranging from about 2.1×10 −13 m 3 to about 2.9×10 −12 m 3 .
Embodiment 49
[0134] The article of any one of embodiments 46-48, wherein the splats have an average volume ranging from about 2.1×10 −13 m 3 to about 1.7×10 −12 m 3 .
Embodiment 50
[0135] The article of any one of embodiments 46-49, wherein the splats have an average volume ranging from about 7.9×10 −13 m 3 to about 1.0×10 −12 m 3 .
Embodiment 51
[0136] The article of any one of embodiments 46-50, wherein the article is a reactor vessel.
Embodiment 52
[0137] The article of any one of embodiments 46-50, wherein the article is a cover.
Embodiment 53
[0138] The article of any one of embodiments 46-50, wherein the article is a baffle.
Embodiment 54
[0139] The article of any one of embodiments 46-50, wherein the article is a thermowell.
Embodiment 55
[0140] The article of any one of embodiments 46-50, wherein the article is an agitator.
Embodiment 56
[0141] The article of any one of embodiments 46-50, wherein the article is an agitator shaft.
Embodiment 57
[0142] The article of any one of embodiments 46-50, wherein the article is a pipe.
Embodiment 58
[0143] The article of any one of embodiments 46-50, wherein the article is a heat exchanger.
Embodiment 59
[0144] The article of any one of embodiments 46-50, wherein the article is a storage tank.
Embodiment 60
[0145] The article of any one of embodiments 46-59, wherein the ground coat comprises from about 60 to about 65 weight percent of silica.
Embodiment 61
[0146] The article of any one of embodiments 46-60, wherein the ground coat comprises from about 10 to about 22 weight percent of boric oxide.
Embodiment 62
[0147] The article of any one of embodiments 46-61, wherein the ground coat comprises from about 1 to about 9 weight percent of potassium oxide.
Embodiment 63
[0148] The article of any one of embodiments 46-62, wherein the ground coat comprises from about 1 to about 9 weight percent of alumina.
Embodiment 64
[0149] The article of any one of embodiments 46-63, wherein the ground coat comprises calcium oxide, cobalt oxide, nickel oxide, manganese oxide, one or more alkali metal oxides in addition to potassium oxide, or a combination thereof.
Embodiment 65
[0150] The article of any one of embodiments 46-64, wherein the coating in the form of splats comprises from about 68 to about 74 weight percent of silica.
Embodiment 66
[0151] The article of any one of embodiments 46-65, wherein the coating in the form of splats comprises from about 0.5 to about 2.5 weight percent of alumina.
Embodiment 67
[0152] The article of any one of embodiments 46-66, wherein the coating in the form of splats comprises from about 7 to about 15 weight percent of sodium oxide.
Embodiment 68
[0153] The article of any one of embodiments 46-67, wherein the coating in the form of splats comprises from about 1 to about 5 weight percent of lithium oxide.
Embodiment 69
[0154] The article of any one of embodiments 46-68, wherein the coating in the form of splats comprises from about 2 to about 9 weight percent of zirconium oxide.
[0155] As previously stated, 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 that may be embodied in various forms. It will be appreciated that many modifications and other variations are within the intended scope of this invention as claimed below. Furthermore, the foregoing description of various embodiments does not necessarily imply exclusion. For example, “some” embodiments may include all or part of “other” and “further” embodiments within the scope of this invention. In addition, “a” does not mean “one and only one;” “a” can mean “one and more than one.”
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The present invention provides methods for preparing or repairing a chemically-resistant coating such as a porcelain enamel on a metal substrate. One such method involves forming a softened ground coat on the substrate by heating to or maintaining an elevated temperature, followed by flame-spray depositing a coating material onto the softened ground coat. Then, the substrate is allowed to cool slowly so the chemically-resistant coating can form with less stress. Optionally, an induction coil is used to heat the substrate, both to form the softened ground coat and to slow the cooling of the substrate. Such methods allow for easier and faster repairs, and even in situ repairs of articles such as chemical reactor vessels, covers, baffles, thermowells, agitators, agitator shafts, pipes, heat exchangers, and storage tanks. Articles having a chemically-resistant coating also form a part of the invention.
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BACKGROUND OF THE INVENTION
Slide switches have long been used on flashlights to close the circuit between the power source and the lamp, usually by forward movement by the user's thumb. Characteristically these switches operate on either of two positions, ON or OFF, or three positions, ON, OFF or PRESS TO FLASH. In either of these versions, the slider usually includes protuberances which depress one overlying leaf spring into contact with the second. Various means have been used in the past to extend the electrical contact from the leaf springs onto the battery pack and the lamp. This has been done by electrical wire connections or flat conductors. In certain cases, the slider is directly mechanically connected to a movable electrical strap or buss member which is moved forward actually into direct physical contact with the electrical socket assembly for the lamp. In the case of metal body flashlights, the body itself can act as one of the conductors, usually from the base of the stack batteries through their retainer spring, the rear cap and the barrel, while the front contact of the slider switch must be insulated. It is desirable that the switch be assembled as a separate assembly from the flashlight, and when attached mechanically, the electrical connection completed as well. This, however, has not been effectively accomplished in the past.
BRIEF STATEMENT OF THE INVENTION
In accordance with this invention, a switch assembly has been developed by employing the minimum number of parts and each of simple design, and one in which the spring elements constituting the electrical contact members are mechanically secured to the switch body in such a position that they are electrically connected into the flashlight circuit merely by the screw attachment of the switch assembly to the barrel of the flashlight. Further, by the manufacture of the switch, the complete assembly with its only electrical connections constituting the mounting screws can be effectively sealed against moisture and the barrel of the flashlight is similarly so sealed. Simplicity of assembly is also achieved.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete understanding of this invention may be had by reference to the following detailed description and by reference to the drawing in which:
FIG. 1 is a side view of a flashlight designed particularly for police and military use incorporating my invention;
FIG. 2 is a perspective view of the switch assembly in accordance with my invention;
FIG. 3 is a vertical sectional view through the switch assembly of FIG. 2, taken along lines 3--3;
FIG. 4 is an exploded view of the switch assembly of FIG. 2;
FIG. 5 A, B and C are three simplified views of this invention showing the three operating conditions of the switch of FIGS. 1 and 2;
FIG. 6 is an enlarged fragmentary vertical sectional view of the screw mounting details in accordance with this invention; and
FIG. 7 is an enlarged fragmentary perspective view of a switch contact in accordance with this invention showing its relationship to the mounting screw.
DETAILED DESCRIPTION OF THE INVENTION
Now referring to FIG. 1 showing a typical flashlight 10 which is incorporated in this invention, the flashlight 10 includes a base cap 11 which secures the outer end of the hollow barrel 12 and provides a recess for storage of an additional lamp. The barrel 12 includes a switch assembly 13 extended generally parallel to the axis of the barrel 12 whichterminates at a head 14 containing a lamp and reflector assembly. To all intents and purposes, the assembly of FIG. 1 appears to constitute a standard flashlight. The significant difference is the use of the improvedswitch 13 appearing in more detail in FIG. 2. It includes a body assembly 15 having a pair of side protective wings 16 and 17 which extend above thebody and protect a thumb slider 20 from inadvertant movement. The body 15 includes a pair of ledges or platforms 21 and 22 at the front and rear having respective openings 23 and 24 therethrough which serve for mountingof the switch assembly to the barrel 12 of the flashlight 10 of FIG. 1. Theunderside of the switch assembly 15, not shown in FIG. 2, may be flat or itmay be contoured to match the barrel 12 surface.
Of great significance and barely visible in FIG. 2 is the fact that there are a pair of tabs 30 and 31 which extend through the respective opening 23 and 24 and overlie the respective platform 21 and 22. Since the opening23 and 24 receive the securing means, for example, a screw or rivet for theswitch, the tabs 30 and 31 are in position to be in direct electrical contact with any metal fastener. Also, as may be seen more clearly in connection with FIGS. 3, 4 and 7, the tabs 30 and 31 have connection portions 32 and 33, best seen in FIG. 4. As may be seen in FIGS. 4 and 6, connecting portions 32 and 33 extend along the one wall of the respective openings 23 and 24. Thus, the tab 30, with its associated connection portion 32 and the tab 31 with its associated connection portion 33, will engage mechanically and electrically any metal fastener passing through the respective opening 23 and 24. By this means, electrical contact may betransferred from the switch assembly to the flashlight proper. Moreover, the tabs are mechanically secured to the switch body 15.
This arrangement is visible more clearly in FIGS. 3 and 6. The tabs 30 and 31 overlie the platform 21 or 22 so that the fastening means, such as screw 40, contacts the connecting means 32 and the underside of the head of screws 40 and 41 bears directly against the upper surface of the tab 30and 31. Effective electrical contact is thereby achieved.
Where the openings 23 and 24 are small enough in diameter and a screw fastener is used, the threads of screws 40 and 41 will bite into the connecting portions 32 and 33 to provide even more effective electrical contact. This redundant connection is extremely important.
FIGS. 3 and 4 also illustrate more clearly the fact that the tabs 30 and 31constitute actual integral continuations of the switch contact members 42 and 43 which are overlying leaf springs.
Also, the configuration of the slider 20 is visible in FIGS. 3 and 4. It includes basically a domed thumb engaging portion 20awhich passes through a rectangular opening 50 in the body 15, best seen in FIG. 2, and a planarportion 20b which underlies the switch body 15 and carries a protuberance 52 which is the actual switch operator. When slider 20 is moved forward, to the right in the drawing, protuberance 52 forces a ramp portion 53 of the contact 43 into engagement with the spring contact 42 to close the electrical circuit. Another feature of this invention is apparent in FIG. 3. The thumb slider 20, when in the OFF position, need only be depressed to provide momentary electrical contact closure. When the downward pressure is released, the momentary contact is opened. Therefore, in the OFF position, signalling may be accomplished employing this switch withoutthe need to move the slider 20 to any intermediate position. The three operating positions of the switch are illustrated in FIG. 5 with FIG. 5A constituting the OFF position with the two spring contacts 42 and 43 out of engagement. In FIG. 5B, the slider has been moved downward and has brought the contact spring 43 into momentary engagement with the contact spring 42. In FIG. 5C, the slider 20 has been advanced to the right in thedrawing as is apparent and the protuberance 52 is now operative to hold thetwo contact springs 43 and 42 into engagement and the flashlight ON.
FIG. 7 illustrates in more particularity the relationship of the spring contacts 42 and 43 to the fastening screws 40 and 41. It should be noted that the tab portion 30 of the spring contact 42 is directly under the position of the head of the screw 40 and its connection portion 42 is engaging the threads of screw 40. It is also particularly apparent from FIG. 7 that tab 30 and its connection portion 32 are formed integrally by punching and bending from the metal strip constituting the spring contact 42 and therefore is produced at virtually the same cost encountered in punching to provide an opening for the fastening screw 40. One other factor of this invention which should be apparent is that it is necessary to insulate one of the two screws from the conducting body of a metal flashlight. In such case, a collar or sleeve 60 of insulating material is used. In this case, as illustrated in FIGS. 4 and 6, the opening through the barrel 12 which receives screw 40 must therefore be large enough to receive the sleeve 60 as well.
It is therefore seen in accordance with this invention that I have producedan improved unitary switch assembly which the simple mechanical steps of mechanically attaching the switch to the flashlight electrically engages it as well. Also, the interior may be sealed merely by the addition of a rubber gasket on the underside.
The above described embodiments of this invention are merely descriptive ofits principles and are not to be considered limiting. The scope of this invention instead shall be determined from the scope of the following claims including their equivalents.
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A slide switch designed to be attached to the barrel of the flashlight by a pair of screws which serve the further function of interconnecting the switch to the electrical circuit of the flashlight. The switch body is of insulating material. It includes a pair of side ears protecting the switch operator and a pair of screw holes through the body. Two leaf springs constituting the contact elements include reentrant tabs extending through the screw openings of the body whereby the reentrant tabs engage both the shank and the underside of the head of the mounting screws.
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[0001] The present invention relates to a method for generating an oscillation with a nominal frequency by means of a PLL (phase locked loop) circuit according to the preamble of patent claim 1 .
BACKGROUND OF THE INVENTION
[0002] Previous PLL circuits comprise an oscillator, hereinafter referred to as a reference oscillator, for making a reference frequency available, a voltage-controlled oscillator, hereinafter referred to as a VCO (voltage control oscillator), which generates an oscillation which has an output frequency which is regulated to a nominal frequency. Furthermore, the PLL circuit has one or a plurality of frequency dividers, which divide the tappable output frequency at the output of the VCO in order to compare the oscillation obtained in this way with the reference oscillation, which is also obtained via a frequency divider, in respect of its phase and thus also its frequency, a phase detector, which performs this comparison, and a drive comprising a charging pump and a loop filter which converts the pulse of the phase detector into a direct voltage. This direct voltage serves as the control voltage for the VCO. The output frequency of the freely oscillating VCO is stepped down with at least one of the frequency dividers to a first comparison frequency, and fed to the phase detector together with a highly constant second comparison frequency which is supplied from the reference oscillator via one of these downstream frequency dividers.
[0003] The disadvantage with this is that this circuit has unfavorable changeover characteristics. The transient time becomes very long if low reference frequencies are selected. Higher comparison frequencies and thus larger increments must be selected in order to achieve short transient times.
[0004] In order to suppress system-caused interference, such as the phase noise of a PLL circuit for example, the PLL circuit should have a high time constant in the loop filter together with a low comparison frequency. However, this conflicts with the fact that a fast frequency change requires the smallest possible time constant in the loop filter.
[0005] In order to obtain the fastest possible frequency change under the given conditions, either the current in the charging pump can be switched over during the change or the filter can be switched over during the frequency change. In both cases, the time constant of the filter is reduced in order to perform a faster frequency change with temporarily increased phase noise.
[0006] In DE 40 08 245 A1, the control voltage of the VCO is tapped in order to perform a fast frequency change and, via a distribution amplifier with a high impedance input and always one capacitor, fed to the inputs of the controllable current sources, in particular charging pumps.
[0007] A circuit arrangement is disclosed in DE 35 44 622 A1 for a conventional PLL circuit with a reduced locking-in time, in which a control device amplifies the control signal for the VCO as a function of the output signal of the phase detector.
[0008] A PLL circuit is disclosed in DE 42 32 609 A1 in which the frequency dividers have synchronization inputs and synchronization devices which emit a synchronization pulse at a defined time after the frequency change.
[0009] However, the disadvantage of this method is that the minimum time for the frequency change in this method is still limited by the comparison frequency, because the change to the new frequency requires a minimum number of frequency comparisons before the new frequency is tuned in.
[0010] Furthermore, the cost and circuit requirements for fast PLL circuits with low phase noise are high.
[0011] The object of the invention is to perform a fast frequency change despite a specified low comparison frequency with a low circuit requirement.
SUMMARY OF THE INVENTION
[0012] The object of the invention is solved by the features described in the characterizing clause of patent claim 1 . In which the divider factors of the frequency dividers are first lowered for the coarse adjustment in order to temporarily raise the comparison frequency, and then the unchanged divider factors are used for the fine tuning, for which the comparison frequency is so low that the required increment is achieved.
[0013] The advantage of the invention lies in the elimination of the restriction imposed by the comparison frequency. Fast frequency changes can be performed without suffering worse phase noise. The two comparison frequencies can also be synchronized more quickly. Furthermore, this accelerated transient oscillation of the output frequency to the desired nominal frequency can be performed economically and simply.
[0014] Advantageous further developments are derived from the subclaims. In which the PLL circuit is equipped with at least one switch with which the divider factors for adjusting the comparison frequency can be raised simultaneously. Furthermore, the switching device is automatically controlled by the phase detector. In doing so, the comparison frequency does not increase by just one factor, but the factor for raising the comparison frequency is changed as a function of the result of the phase detector during a tuning process. The method is not only particularly advantageous in conjunction with a conventional PLL circuit, but can even be improved with the aid of a fractional PLL circuit.
[0015] The invention is described in more detail in the following with the aid of two embodiments and figures. They show:
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] [0016]FIG. 1: fast PLL circuit
[0017] [0017]FIG. 2: fast fractional PLL circuit
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] [0018]FIG. 1 shows a fast PLL circuit. In which a voltage-controlled oscillator 1 , hereinafter referred to as VCO, generates an oscillation with the variable frequency f OUT , which is available at the output of the PLL circuit. This output frequency f ouT is to be regulated to a nominal frequency f NOM . In the embodiment, the output frequency f OUT =80 MHz and the nominal frequency to be set is f NOM =100.0125 MHz. Divider factors R and N are assigned to each nominal frequency f NOM in one or a plurality of memories 7 , 10 , as only fractions of the frequencies should be compared with one another because of the increments required. In this embodiment, one divider factor R is assigned to a reference frequency f REF and the other divider factor N to the output frequency f ouT The reference frequency f REF is generated in a reference oscillator 4 . It is constant and is characterized by being very pure and stable. In the embodiment f REF =4 MHz. The divider factors R, N determine the division ratio of the frequency dividers 5 , 8 with which the reference frequency f REF and the output frequency f OUT change, in particular they are lowered. In the embodiment, the divider factors for a nominal frequency f NOM =100.0125 MHz are: N=8001 and R=320. If the switching devices 6 , 9 are not activated, then the frequency divider 5 generates a constant first comparison frequency f C1 =12.5 kHz from the constant reference frequency f REF =4 MHz, and the other frequency divider 8 generates a second changeable comparison frequency=9.99875 kHz from the changeable output frequency f OUT =80 MHz. These two comparison frequencies f C1 , f C2 are compared in the phase detector 3 . The digital phase detector 3 is linked to a drive 2 with which the VCO 1 is driven. Digital phase detectors emit a control signal whose direction and duration correspond to the phase shift of the two comparison frequencies f C1 , f C2 . In the simplest case, three signals may be available at the output of the phase detector as a result of the comparison, such as “+1”,“−1”, “0”, for example. In the case “+1”, the voltage in the drive 2 , comprising charging pump and loop filter, is raised for the VCO 1 , whereby the output frequency f OUT of the VCO 1 is also raised. In the case “−1”, the voltage in the drive 2 for the VCO 1 is lowered, whereby the output frequency of the VCO is also lowered, and in the case “0”, the phases of the comparison frequencies f C1 , f C2 coincide. In order to accelerate this control procedure until the phases of the two comparison frequencies f C1 , f C2 coincide, the two divider factors R and N, which determine the division ratios of the frequency dividers 5 , 8 , are additionally reduced by the same factor e.g.: K=4 via a switch 11 , which is linked to the phase detector 3 . This switch 11 is always activated if:
[0019] a frequency change to another nominal frequency is performed and/or
[0020] the phase detector detects a larger difference between the two comparison frequencies f C1 , f C2 .
[0021] The switch 11 , which is linked to two further switching devices 6 and 9 , activates the coarse adjustment of the nominal frequency f NOM by simultaneously activating the two switching devices 6 , 9 , which increase the divider factors R, N by the same factor K. In the simplest case, shift registers 6 , 9 , which can shift the divider factors bit by bit, are used for this. If the divider factors are thereby reduced by a factor of K=4, for example, then this gives new divider factors in which N=2000 and R=80, and thus higher comparison frequencies f CG1 =50 kHz and f CG2 =40 kHz for the phase detector. The transient oscillation to the first higher comparison frequency f CG , takes place more quickly because more phase comparisons per second are possible at the higher frequencies f CG2 , f CG1 . The frequencies are synchronized more quickly. Once the transient procedure has been completed on the basis of the higher comparison frequencies f CG2 , f CG1 , that means f CG2 =f CG1 , then the switch 11 either switches itself off automatically, e.g. with the aid of the phase detector 3 , or it is switched off manually, so that the frequency dividers 6 , 9 are reset to their original division ratio with the original divider factors N=8001 and R=320. Nevertheless, the two lower comparison frequencies f C2 , f C1 then lie very close to one another, f C2 ≈f C1 , so that the frequency tuning takes place very quickly in small increments as fine tuning. If the phase detector 3 then indicates that the phases of the two reference voltage match, then the output frequency f OUT is equal to the nominal frequency f NOM . In order to perfect this method, it is also conceivable to vary the factor K, by which the comparison frequencies f C2 , f C1 are increased, several times during tuning and in fact, for example, as a function of the difference between the nominal frequency and the output frequency f NOM , f OUT .
[0022] [0022]FIG. 2 shows a fast fractional PLL circuit. In which a voltage-controlled oscillator 1 , hereinafter referred to as VCO, generates an oscillation with the variable frequency f OUT , which is available at the output of the PLL circuit. This output frequency f OUT should be regulated to a nominal frequency f NOM . In the embodiment, the output frequency is f OUT =80 MHz and the nominal frequency to be set is f NOM =100.0125 MHz. Divider factors R, N and AC are assigned to each nominal frequency f NOM in one or a plurality of memories 7 , 10 , as only fractions of the frequencies should be compared with one another because of the increments required. The two divider factors N and AC serve to determine the average value of the N− and N+1 fractions of the output frequency, as is usual for fractional PLL circuits. The average value is determined with the aid of the AC value available at the ACCU. This gives the second comparison frequency f C2 , which is set exactly to the fraction of the reference frequency. In this embodiment, the second comparison frequency is set exactly to the first comparison frequency. One of the divider factors R is assigned to the reference frequency f REF and the other divider factor N or N+1 simultaneously to the output frequency f OUT . The reference frequency f REF is generated in a reference oscillator 4 . It is constant and is characterized by being very pure and stable. In the embodiment this f REF =4 MHz. The divider factors R, N and AC determine the division ratio of the frequency dividers 5 , 8 with which the reference frequency f REF and the output frequency f OUT are changed. In the embodiment, the divider factors for a nominal frequency f NOM =100.0125 MHz are: N=8001 or AC=0 R=320.
[0023] If the switching devices 6 , 9 are not activated, then the frequency divider 5 generates a constant first reference frequency f C1 =12.5 kHz from the constant reference frequency f REF =4 MHz, and the other frequency divider 8 generates a second changeable reference frequency=9.99875 kHz from the changeable output frequency f OUT =80 MHz. In the fractional PLL circuit, the frequency divider 8 is linked to an N, N+1 switch 13 , which, in turn, is influenced by an L-bit ACCU 12 and the desired nominal frequency. The L-bit ACCU 12 is controlled from the switch 0 by the second comparison frequency at the output of the frequency divider 8 and by the desired nominal frequency. These two comparison frequencies f C1 , f C2 are compared in the phase detector 3 . The phase detector 3 is linked to a drive 2 with which the VCO 1 is driven. The phase detector emits a control signal whose direction and duration correspond to the phase shift of the two comparison frequencies f C1 , f C2 . In the simplest case, three signals may be available at the output of the phase detector as a result of the comparison, such as “+1”, “−1”, “0” for example. In the case “+1”, the voltage in the drive 2 is raised for the VCO 1 , whereby the output frequency f OUT of the VCO 1 is also raised. In the case “−1”, the voltage in the drive 2 for the VCO 1 is lowered, whereby the output frequency of the VCO is also lowered, and in the case “0”, the phases of the comparison frequencies f C1 , f C2 coincide. In order to accelerate this control procedure until the phases of the two comparison frequencies f C1 , f C2 coincide, the two divider factors R and N, which determine the division ratios of the frequency dividers 5 , 8 , are additionally reduced by the same factor, e.g.: K=4 via a switch 11 , which is linked to the phase detector 3 . At the same time, the value AC is set to the remainder of the N/K division. This switch 11 is always activated if:
[0024] a frequency change to another nominal frequency is performed and/or
[0025] the phase detector detects a larger difference between the two comparison frequencies f C1 , f C2 .
[0026] The switch 11 , which is linked to two further switching devices 6 and 9 , activates the coarse adjustment of the nominal frequency f NOM by simultaneously activating the two switching devices 6 , 9 , which increase the divider factors R, N by the same factor K and simultaneously determine the value AC. The “fractional” mode is thus activated. In the simplest case, shift registers 6 , 9 , which can shift the divider factors bit by bit, are used for this. If the divider factors are thereby reduced by a factor of K=4, for example, then this gives new divider factors in which N=2000 and N+1=2001 AC=1 and R=80, and thus higher comparison frequencies f CG1 =50 kHz and f CG2 ≈39.99 kHz for the phase detector. The transient oscillation to the first higher comparison frequency f CG10 takes place more quickly because more phase comparisons per second are possible at the higher frequencies f CG2 , f CG1 . The frequencies are synchronized more quickly. Once the transient procedure has been completed on the basis of the higher comparison frequencies f CG2 , f CG1 , that means f CG2 =f CG1 , the switch 11 either switches itself off automatically, e.g. with the aid of the phase detector 3 or it is switched off manually, so that the frequency dividers 6 , 9 are reset to their original division ratio with the original divider factors N=8001 and R=320. With a fractional PLL circuit, in contrast to the embodiment shown in FIG. 1, the two lower comparison frequencies f C2 , f C1 are then exactly the same and f C2 =f C1 , so that a fine tuning is no longer necessary. The phase detector 3 will now indicate a still faster tuning of the phases of the two lower reference voltages f C2 , f C1 , whereby the adjustment of the output frequency f OUT to the nominal frequency f NOM is completed. The reduced transient time of a fractional PLL can thereby be used without having to accept its disadvantages in continuous operation. In order to perfect this method, the factor K, by which the comparison frequencies f C2 , f C1 are raised, may be varied several times during a tuning process and in fact, for example, as a function of the difference between the nominal frequency and the output frequency f NOM , f OUT .
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1. Method for generating a frequency by means of a PLL circuit
2.1. In known PLL circuits, the output signal at the phase detector is changed in order to accelerate the transient oscillation to the desired frequency.
2.2. In this method, the two comparison frequencies, which are fed to the phase detector, are simultaneously changed by factors via at least one switch. For coarse adjustment, the comparison frequencies are raised by a factor which accelerates the tuning process. Then, the increased comparison frequencies are lowered again by a factor for fine tuning, which defines the increments.
2.3. The method for frequency tuning PLL circuits is primarily used where a frequency change must take place quickly and inaudibly, for example in RDS applications in radio devices where it is advantageous.
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This is a continuation of application Ser. No. 716,983 filed Mar. 28, 1985, now abandoned.
BACKGROUND
1. Field of the Invention
This invention relates to temporary indicators affixed to light transmitting substrates.
2. Description of the Prior Art
Light transmitting substrates in the form of transparencies, x-ray film, positive photograhic film and the like are useful in conveying information. In use, these substrates are viewed with a source of light placed behind them. Very often, to call attention to a portion of the substrate, a person would touch the surface of the substrate with a finger, a pointing device, pencil or marker. This practice can, and often does, result in permanent scratches and nicks on the substrate surfaces The use of grease pencils and china markers often results in marks which are most difficult to remove. By the same token, the marks made by felt tipped pens and ball point pens are seldom removed without permanent damage to the substrate surface. Any of the foregoing damage is most objectionable when the substrate is an x-ray, positive film or the like that cannot be replaced. The marks are also objectionable to the further use of the x-ray and its diagnostic value simply because they obscure, if not completely masks out, the data on the substrate. Additionlly, marks can be misleading when the substrate is referred to a second party for independent consideration. Thus, a means for pointing out portions of interest on the substrate and yet both lessen damage and increase useability of substrate data is needed. The pointing means must be useable at all degrees of elevation from the horizontal since overhead viewers are designed for use with a flat, horizontal transparency and x-rays are typically viewed with a view box having a generally vertical viewing surface.
SUMMARY OF THE INVENTION
In accordance with this invention there is provided an indicating means for use on light transmitting substrates which comprises a flat, rigid, translucent base member, whose width is substantially greater than its thickness, coated with a light transmitting temporary adhesive on one of the flat width surfaces.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top (plan) view of the indicating means of this invention 10 in the shape of an arrow.
FIG. 2 is an enlarged cross section of the indicating arrow of FIG. 1 taken along line AA.
FIG. 3 is the enlarged cross section of the indicating arrow of FIG. 2 to which a separating member has been added.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in FIG. 1 the indicating means of this invention 10 may have the shape of a conventional arrow. The shape may, however, be varied to any desired configuration so long as it visually directs or focuses the viewer's attention to the desired area of the x-ray, film or other transparency. Thus, the indicating means 10 may also be the letter C in which case the gap between the ends of the letter would point out the section to be highlighted. Indicating means 10 may also have a delta wing or pencil shape; hence, any vision directing shape may be employed. Indicating means 10 has two flat sides 13, 14 which are greater in width than its thickness. Additionally, the length is greater than the width.
The indicating means 10 is made from a translucent rigid plastic such as polymethacrylate, polyacrylate, polystyrene, copolymers of methacrylates and acrylates, polycarbonates, cellulose acetate butyrate and the like. The indicating means 10 can be cut or stamped from a sheet of the desired plastic, formed by injection molding, or other methods well known in the fabricating art. A convenient but not critical thickness for indicating means 10 is about 1/16 of an inch (about 1.5 mm). Indicating means 10 contains small amounts of coloring agent, e.g. a dye or pigment, so that it is translucent but does not obscure the x-ray or other transparency. The color selected is one of choice, however greater effectiveness is achieved when a light color, e.g. yellow or white, is used with a dark transparency and a darker color, e.g. some greens or orange, are used with lighter, e.g. "thinner", transparencies.
As shown in FIG. 2 indicating means 10 is lightly coated on flat side 14 with a low tack, cold setting, transparent or translucent adhesive 11. The exact composition of the adhesive is not critical. The adhesive 11 should permit removing the indicting means 10 from the transparency by simple grasping indicating means 10 with the user's fingers. Additionally, the adhesive 11 should not lift or remove the information, design, etc., intended to be permamently maintained on the transparency, e.g., not remove the emulsion coating of the x-ray or photographic film. Suitable adhesives 11 include paper (rubber) cement, artist's repositioning cement and the like. Typically these adhesives contain benzene, xylene, methylene chloride, hexane, aliphatic hydrocarbons, turpentine and mixtures thereof as a solvent. Natural rubber, various synthetic rubbers, elastomeric resins, polyesters and acrylates and the like alone or in combinations thereof are useful adherents for these adhesives. As is well known in the art, the adhesive 11 may be applied by spraying, roller coating or other convenient means.
The indicating means 10 is affixed to the desired x-ray or positive photographic film by lightly pressing the adhesive side 11 against the transparency. The doctor, radiologist or other primary health care provider when interpreting the x-ray mounted on the view box for the benefit of patients or other medical personnel, applies the indicating device 10 to that part of the x-ray to which attention is called. A differently colored indicating device 10 can be affixed to x-ray to high light the next area of concern. This process is continued until all points of concern have been marked and discussed. The indicating means 10 can be left on for future radiographic studies or removed without damaging the x-ray as the interpreter desires This indicating device 10 can be easily removed, stored by lightly pressing the adhesive coated side 14 against the side of the x-ray view box, then removed, used and stored again and again until the adhesive value is exhausted.
Because the indicating means 10 may be prepared and used in different locations or simply stored for sometime before use, it is desirable to apply to the exposed adhesive layer 11 a separator 12 as shown in FIG. 3. The separator can be a film, e.g. polyester such as that sold by E. I. du Pont Company under the registered trademark MYLAR, or a silicone treated paper. The separator 12 is stripably removed just prior to use of indicating means 10.
The foregoing methods have been described above for the purpose of illustratuion and not limitation. Many other modifications and ramifications will naturally suggest themselves to those skilled in the art based on this disclosure. These are intended to be comprehended as within the scope of this invention.
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An indicating device for use with x-rays and similar light transmitting substrates is constructed as a flat, rigid, translucent material coated on one side with a light transmitting temporary adhesive which will temporarily secure the indicator to the substrate at the point of interest.
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[0001] The present invention relates to the selection of sunflower genotypes with high oleic acid content in seed oil. The invention concerns more particularly molecular markers useful for a rapid and easy selection of sunflower lines and then sunflower hybrids capable of producing seeds having high oleic acid content.
[0002] In the present description, the expression “high oleic acid content seeds” designates seeds containing more than 60% of oleic acid.
BACKGROUND OF THE INVENTION
[0003] Since the 1960s, vegetable oils rich in unsaturated fatty acids have become particularly important due to the relationship established between the saturated fatty acids present notably in animal fats and the cholesterol level increase.
[0004] Most of the fatty acids in vegetable oils are fatty acids having 16 or 18 carbon atoms. The C16-fatty are generally saturated fatty acids (16:0=palmitic acid). Conversely, the C18 fatty acids are either saturated (18:0=stearic acid) or unsaturated having 1, 2 or 3 double bonds (18:1=oleic acid; 18:2=linoleic acid; 18:3=linolenic acid).
[0005] Certain unsaturated fatty acids, notably linolenic acid, are not synthesized by the human body and are of an insufficient amount in fats of animal origin. Among the unsaturated fatty acids, the mono-unsaturated 18:1 oleic acid, has properties which is particularly suitable for preventing cardiovascular diseases. Moreover, High oleic acid content oils are more resistant to heating and are thus recommended for frying.
[0006] The fatty acids composition in vegetable oils deriving from seeds is variable depending on the oleaginous plant. Olive oil has naturally high 18:1 content (around 70%), nevertheless, its non-lipid part of the oil decreases the interest of this oil. Normal sunflower (hereinafter named LO varieties) oil contains mainly linoleic acid and high levels of phytosterols and tocopherol conferring hypocholesterolemic and anti-oxidant properties to the non-lipid part of the oil. Sunflower lines and hybrids, which have high 18:1 content in their seeds (hereinafter named HO varieties) have been obtained by selection programs from the HO Pervenets mutant, said mutant being obtained by chemical mutagenesis (1). They are particularly interesting since they have the combined benefits of oleic acid and the non-lipid part of the sunflower oil (phytosterol and tocopherol). They therefore respond to the requirement of quality by consumers.
[0007] In addition to their dietary benefits, vegetable oils are of significant industrial interest. Indeed, they represent a source of fatty acids as starting material used in the lipochemical industry (detergents, paints, cosmetics). Vegetable oil from the HO sunflower type is a substantially pure industrial source of 18:1, that reduces the purification steps.
[0008] In order to respond to the needs of vegetable oils of food or industrial interest, the improvement of the oleaginous varieties is concerned with the control and the change of their fatty acid compositions by means of conventional selection programs, but also by mutagenesis and transgenesis.
[0009] The chemical mutagenesis carried out by Soldatov in 1976 (1) on a sunflower population allowed the Pervenets mutant population to be obtained. The average content of 18:1 of the seeds from this population is higher than 65%, the individual contents being between 60 and 80% whereas in normal LO varieties this content is about 20%. The Pervenets population was distributed throughout the world and used in many selection programs in order to convert selected genotypes with low 18:1 content into genotypes having 18:1 content in their seeds higher than 80%.
[0010] During the conversion process of the normal LO material into HO one, the selection is generally based on the 18:1 content of the seeds. This phenotypic determination does not allow a rapid and early detection of HO genotypes and cannot distinguish between homozygote and heterozygote genotypes for the mutation. It is therefore necessary to have selection markers at genomic level allowing earlier and rapid determination of the HO phenotype homozygous for the mutation during conversion process.
[0011] The accumulation of the 18:1 in the seeds is mainly dependent on two enzymatic reactions: the upstream desaturation of 18:0 into 18:1 and the downstream desaturation of 18:1 into 18:2. Studies carried out by Garcés and Mancha in 1989 and 1991 (2, 3) demonstrated that the HO phenotype is associated with a marked activity decrease of the Δ12-desaturase enzyme, which catalyses the desaturation of 18:1 into 18:2 in the HO seeds during the critical stages of constructing the lipidic stocks, explaining the 18:1 accumulation. Kabbaj et al (4) subsequently demonstrated that one HO genotype presents a significant decrease in the Δ12-desaturase mRNA levels in the seeds during the critical stages of producing the lipidic stocks compared to 2 LO genotypes. This decrease explains the decrease of the amount of enzyme and therefore of Δ12-desaturase activity already demonstrated. Hongtrakul et al. (5) and then Lacombe et al. (6, 7) showed that HO lines derived from Pervenets mutant carry specific restriction fragment length polymorphisms (RFLPs) revealed using a Δ12-desaturase cDNA as a probe. These RFLPs determine the Δ12 HO specific allele, Δ12HOS. The normal LO lines do not carry the Δ12HOS allele but another allele named Δ12LOR at this locus (named Δ12HL locus) (6, 7). Studying the inheritance of the phenotype HO in an F2 population, Lacombe et al. (6) revealed that the HO phenotype co-segregated with the Δ12HOS allele pointing out that the Pervenets mutation is carried or genetically tightly linked to the Δ12HOS allele. In another segregating population (recombinant inbred lines F6 population), Lacombe et al. (2) showed that all the HO lines carry the Δ12HOS allele. However, the recombinant lines carrying Δ12HOS are equally shared into HO or LO classes. The absence of HO plants carrying the Δ12LOR allele eliminates the occurrence of a recombination event between the Δ12HL locus and the locus containing the Pervenets mutation. In the genetic background of this population, the HO phenotype is therefore due to two independent loci: the Δ12HL locus carrying the Δ12HOS allele and consequently the Pervenets mutation, and another locus, where an allele suppresses the effect of the Δ12HOS allele leading to restore the LO phenotype.
[0012] Once the coincidence or the very tightly genetic linkage between the Pervenets mutation and the Δ12HOS allele revealed, Lacombe et al. (8) established physical maps of the Δ12HOS and Δ12LOR alleles at the Δ12HL locus ( FIG. 1 ). For this purpose, they used the HO and LO RFLP profiles revealed with the Δ12-desaturase cDNA used as a probe. The Δ12LOR allele in LO genotypes corresponds to a 5.8 kb EcoRI and to a 8 kb HindIII fragments carrying Δ12-desaturase like sequences. The double digest with EcoRI+HindIII leads to a 2.2 kb fragment. For the Δ12HOS allele in HO genotypes, the 5.8 kb EcoRI fragment is still present but another 7.9 kb EcoRI extra fragment is also revealed. With HindIII, the 8 kb fragment revealed in LO genotypes lengthens to 16 kb in HO genotypes. With the EcoRI+HindIII double digest, the Δ12HOS allele displayed the 2.2 kb fragment revealed in Δ12LOR allele plus the 7.9 kb EcoRI extra fragment. According to all these data, the Δ12HOS and Δ12LOR allele physical maps were established. The Δ12LOR allele carries one region whereas the Δ12HOS allele carries 2 adjacent regions with Δ12-desaturase like sequences: the Δ12HOS/Δ12LOR common region determined by the common 5.8 kb EcoRI fragment and a HO specific region determined by the 7.9 kb EcoRI extra fragment ( FIG. 1 , ref 8).
[0013] Studying genomic clones carrying Δ12-desaturase like sequence from a HO genotype genomic library, Lacombe et al. (8) revealed that the Δ12HOS/Δ12LOR common fragment should carry a functional Δ12-desaturase gene interrupted by a 1686 bp intron in the 5′UTR part of the gene.
SUMMARY OF THE INVENTION
[0014] The present invention relates to molecular markers that are strictly linked to genetic factors involved in 18:1 accumulation in seed oil of HO genotypes of sunflower: the Pervenets mutation and another independent factor, the supole factor.
[0015] The invention relates to PCR molecular markers that partly amplify the Pervenets mutation. It also relates to a SSR marker (15-17 TTA motifs) in the intron of the Δ12-desaturase functional gene adjacent to the mutation that enables to map the gene locus in most of segregating populations and to select genotypes carrying the Pervenets mutation.
[0016] The invention also relates to specific markers of a genetic factor suppressing the Pervenets mutation effect. The presence of the suppressor (supole) is revealed in genotypes by combining the presence of the Δ12HOS allele and the low 18:1 content in seed oil.
[0017] All these molecular markers may represent advantageous and useful tools in selection programs for rapid screening and early detection of HO genotypes producing seeds with a high 18:1 content, carrying the Pervenets mutation without the unfavourable supole factor by means of the PCR technology.
[0018] The invention also relates to processes for the selection of sunflower producing seeds with a high oleic acid content.
[0019] The present invention also relates to primers useful for nucleic acid amplification and to combinations thereof.
[0020] Finally, the invention concerns the test kits for selecting sunflower having seeds with a high content of oleic acid which contain at least one of the above combinations.
DETAILED DESCRIPTION OF THE INVENTION
[0021] The present invention relates to Pervenets mutation specific molecular markers located in a 29 kb region, a map thereof is represented on FIG. 2 . This region carrying these molecular markers is divided in 3 sequences, from 5′ to 3′:
sequence N1 having 6.662 kb: Δ12HOS/Δ12LOR common part carrying a Δ12-desaturase gene (SEQ ID NO:1); sequence N2: HO specific insertion; (this sequence has been partially sequenced (SEQ ID NO:2); sequence N3: the 3′ adjacent part of the HO specific insertion fragment.
[0025] The molecular marker of the invention comprises the isolated nucleic acid SEQ ID No 3 having 872 bp or a sequence having a high degree of homology with sequence SEQ ID No 3. Said nucleic acid sequence is a part of sequence SEQ ID NO:4 having 3026 bp and being identified as sequence N1/2 on FIG. 2 . The marker having SEQ ID NO:3 is located between 2154 bp and 3026 bp of SEQ ID NO:4.
[0026] In the present description, a high degree of homology denotes a homology (ratio of the identical nucleotides to the total number of nucleotides) of at least 85%, and preferably 90%, for the nucleotide sequences when they are aligned according to the maximum homology by the optimal sequence alignment method of ALIGN. This method is used especially in the GCG software of Devereux et al. (9).
[0027] The invention also relates to the isolated nucleic acid fragments having 10-30 bp and which hybridize with SEQ N2 (SEQ ID NO:2). Said fragments are particularly useful tools as primers for nucleic acid amplification, for example PCR amplification.
[0028] Examples of said fragments are the fragments having the following sequences:
[0000]
(SEQ ID N o 7)
sequence N2-1R: 5′-AGCGGTTATGGTGAGGTCAG-3′
(SEQ ID N o 8)
sequence N2-2R: 5′-ACAAAGCCCACAGTGTCGTC-3′
(SEQ ID N o 9)
sequence N2-3R: 5′-GCCATAGCAACACGATAAAG-3′
[0029] The invention also relates to the primer pairs useful for nucleic acid amplification, which comprise:
[0030] 1) as the first member of the pair a nucleic acid fragment having 1 to 30 bp and which hybridises with sequence N1 (SEQ ID No 1) and
[0031] 2) as the second member of the pair a nucleic acid fragment having 10 to 30 bp and which hybridises with SEQ ID NO:2.
[0032] Examples of such pairs of primers comprise as:
[0000]
1) first member:
(SEQ ID N o 5)
sequence N1-2F: 5′-CAAACCAACCACCCACTAAC-3′
or
(SEQ ID N o 6)
sequence N1-3F: 5′-GAGAAGAGGGAGGTGTGAAG-3′
2) second member:
(SEQ ID N o 7)
sequence N2-1R: 5′-AGCGGTTATGGTGAGGTCAG-3′
(SEQ ID N o 8)
sequence N2-2R: 5′-ACAAAGCCCACAGTGTCGTC-3′
(SEQ ID N o 9)
sequence N2-3R: 5′-GCCATAGCAACACGATAAAG-3′
[0033] In the present description, acid nucleic sequences codes end by a number whereas acid nucleic fragments useful as primers end by F or R depending on they are designed forward or reverse, respectively. These references are reported on the map of the 29 kb region ( FIG. 2 ).
[0034] The invention also relates to the isolated SSR nucleic acid sequence SEQ ID No 10 having 45 bp with 16 TTA repeat microsallelites TTA. This sequence involving a polymorphism associated with the Pervenets mutation may be used in selection programs for rapidly identifying the locus of the Pervenets mutation.
[0035] Said SSR sequence is located in the intron of the oleate-desaturase gene besides the Pervenets insertion.
[0036] Therefore, said SSR sequence is very useful for mapping the oleate-desaturase gene in the genome of sunflower plants to be selected.
[0037] The invention also concerns the molecular marker specific for mapping the oleate-desaturase gene in the genome of the sunflower to be selected which comprises the nucleic acid sequence SEQ ID No 10 or a sequence having a high degree of homology with sequence SEQ ID No 10.
[0038] The invention also concerns the isolated nucleic acid fragments SEQ ID No 11 and SEQ ID No 12. Said fragments are useful as primers for amplifying the above SSR sequence:
[0000]
(SEQ ID N o 11)
sequence N1-1F: 5′-TTGGAGTTCGGTTTATTTAT-3′
(SEQ ID N o 12)
sequence N1-1R: 5′-TTAGTAAACGAGCCTGAAC-3′
[0039] All the isolated nucleic acid sequences and fragments of the invention may be obtained by chemical synthesis following the conventional methods well known by the person skilled in the art.
[0040] The invention also relates to a process for selecting sunflower having seeds with a high content of oleic acid which comprises the steps of:
extracting the genomic DNA; amplifying said genomic DNA by means of primer pair, said pair being constituted with a first member of nucleic acid fragment having 10 to 30 bp, which hybridises with sequence N1 (SEQ ID NO:1) and a second member of nucleic acid fragment having 10 to 30 bp, which hybridises with sequence N2 (SEQ ID NO:2); hybridizing the amplified DNA fragment with the labelled sequence SEQ ID No 3 and isolating the genotypes giving a positive hybridisation signal.
[0045] This process allows the selection of genotypes having the Pervenets mutation without needing to determine the oleic acid content of the seeds, which considerably reduces the selection time.
[0046] Following an advantageous embodiment of this process, the Pervenets mutation is firstly mapped in most of progenies (most of sunflower line couples display polymorphism for the SSR) by a process comprising the steps of:
extracting the genomic DNA; amplifying said genomic DNA by means of primers SEQ ID No 11 and SEQ ID No 12; isolating the clones having a DNA fragment length which is different from a reference clone without the Pervenets mutation.
[0050] The thus selected clones have the Pervenets mutation and are used as such in the above invention process.
[0051] Examples of the primer pairs useful in the invention process are the:
isolated nucleic acid fragments SEQ ID NO:5 and SEQ ID NO:6 as first member of said pair, and isolated nucleic acid fragments SEQ ID NO:7 to SEQ ID NO:9 as second member of said pair.
[0054] The invention also relates to the molecular marker constituted by the isolated nucleic sequence SEQ ID NO:13 having 763 bp, which is common to LO and HO regions and located over the insertion point of the Pervenets mutation. The insertion point is located between the bp 83 and bp 366 of SEQ ID NO:13.
[0055] The invention also relates to the isolated nucleic acid fragments having 10-30 bp and which hybridise with SEQ ID NO:13. Said fragments are also useful tools as primers for nucleic acid amplification, for example for PCR amplification.
[0056] Examples of said fragments are the fragments having the following sequences:
[0000]
(SEQ ID N o 14)
sequence N2-1F:
5′-TTTTACTCTTTGTTATAATAG-3′
(SEQ ID N o 16)
sequence N2-2F:
5′-ACACTAACACTCATTACATTCG-3′
(SEQ ID N o 18)
sequence N2-3F:
5′-AAAGCAAAAAACACCGTGATTC-3′
(SEQ ID N o 15)
sequence N3-1R:
5′-TTTTTAGTTCATGGAATCAC-3′
(SEQ ID N o 17)
sequence N3-2R:
5′-CCTAAAGCTCTGTAGATTTT-3′
(SEQ ID N o 19)
sequence N3-3R:
5′-GGTGTTATTATTCAGCCTGAA-3′
(SEQ ID N o 20)
sequence N3-3′R:
5′-GATGTTATTATTCAGCCTGAA-3′
[0057] The invention also relates to the process for amplifying the region across the insertion Pervenets mutation site both in LO and HO genotypes. Said process comprises the steps of:
extracting the genomic DNA; amplifying said genomic DNA by means of primer pair, said pair being constituted with a first member of nucleic acid fragments having 10 to 30 bp which hybridises with sequence N1 (SEQ ID NO:13).
[0060] In all the invention processes, the amplification step may be carried out by any nucleic amplification method known by the person skilled in the art, for example by the well-known PCR amplification method.
[0061] A 6662 kb region carrying the Δ12HOS and Δ12LOR common part in RHA 345 HO line (SEQ N1) was cloned, sequenced and characterized. It was shown that it carries a putative functional Δ12-desaturase gene (SEQ N1-Δ12). Indeed, the TATAAA and CAAT consensus promoter elements are present at positions −92 bp and −42 bp upstream the +1 transcriptional point, respectively. Because of its sequence and its position, the AAGTAA sequence, 16 nt before the end of the transcribed part, corresponds to a poly-A signal AATAAA, except for one nucleotide. The Δ12-desaturase gene is interrupted by a 1686pb intron between nt 83 and nt 1767 upstream the +1 transcriptional point. The consensus splicing sites GT and AG are present at the intron extremities. A 16 repeats of a TTA SSR motive is revealed in the intron sequence between nt 784 and 832 upstream the +1 transcriptional point. Using primer pairs enabling this SSR amplification (SEQ N1-1F and SEQ N1-1R), size polymorphism at this locus in a set of 42 HO and LO genotypes was tested (Table 1).
[0000]
Sequence N1-1F = 5′-TTGGAGTTCGGTTTATTTAT-3′
Sequence N1-1R = 5′-TTAGTAAACGAGCCTGAAC-3′
[0062] PCR amplification leads to 237/240/243 bp fragments corresponding to 15/16/17 SSR repeats, respectively. In the 174 individuals segregating population already studied (7), a strict co-segregation between the SSR polymorphism of the HO parental line (16 motifs) and the Δ12HOS allele (EXAMPLE 2) was revealed. So, this SSR sequence displays a polymorphism tightly linked to the Pervenets mutation. Consequently, it can be used to map the locus of the Δ12-desaturase gene in sunflower genome in most of crosses. Moreover, it may be used in selection programs for fast screening of genotypes carrying the Pervenets mutation by PCR method.
[0063] The invention relates to this SSR nucleic acid sequence present in SEQ ID N1 and SEQ ID N1-Δ12. The invention also relates to sequences having a high degree of homology with sequence SEQ ID N1 or N1-Δ12 and nucleic acid fragments that can be used as PCR primers to amplify the SSR motive such as SEQ ID N1-1F and SEQ ID N1-1R leading to a PCR fragment carrying the 15, 16 or 17 TTA motives.
[0064] In order to select molecular markers corresponding to the Pervenets mutation itself, parts of the 7.9 kb EcoRI HO specific fragment that should carry the Pervenets mutation was cloned, sequenced and characterized. Primer pairs on both side of the 5′ Pervenets mutation insertion point: SEQ ID N1-2F located on SEQ N1 and SEQ ID N2-1R located on the SEQ N2 and designed in Δ12-desaturase cDNA were selected.
[0000]
Sequence N1-2F = 5′-CAAACCAACCACCCACTAAC-3′
Sequence N2-1R = 5′-AGCGGTTATGGTGAGGTCAG-3′
[0065] Because of their positions, these primers lead to a 3026 bp PCR amplification fragment only in RHA 345 HO genotype compared to LO4 and other LO genotypes. Subsequently, we cloned sequenced and characterised this PCR fragments carrying the 5′ Pervenets mutation insertion point (SEQ ID N1/2) was cloned, sequenced and characterized. The organisation of this sequence is, from 5′ to 3′:
A 2576 bp HO/LO common region the 5′ insertion point HO specific Δ12-desaturase gene like sequence: part of the intron (239 bp) and part of the coding region (211 bp).
[0069] Based on this characterisation, new primers were computed (SEQ ID N1-3F located on SEQ ID N1, SEQ ID N2-2R and SEQ ID N2-3R designed on Δ12-desaturase cDNA sequence).
[0000]
Sequence N1-3F = 5′-GAGAAGAGGGAGGTGTGAAG-3′
Sequence N2-2R = 5′-ACAAAGCCCACAGTGTCGTC-3′
Sequence N2-3R = 5′-GCCATAGCAACACGATAAAG-3′
[0070] These primer pair combinations lead to HO specific amplification fragments of about 870 bp (SEQ ID N1-3F+SEQ ID N2-1R), 1000 bp (SEQ ID N1-3F+SEQ ID N2-2R) and 1400 bp (SEQ ID N1-3F+SEQ ID N2-3R) in PCR experiments involving 42 HO and LO genotypes (EXAMPLE 1). In the 174 recombinant inbred line population, a strict co-segregation between the SEQ ID N1-3F+N2-1R HO specific fragment and the Δ12HOS allele (EXAMPLE 2) was revealed.
[0071] The invention relates to SEQ N1/2 (SEQ ID NO:1) corresponding to part of the Δ12-desaturase HO specific fragment, and sequences having a high degree of homology with SEQ N1/2 (SEQ ID NO:1). The invention also relates to nucleic acid fragments which can be used as PCR primers to amplify genomic region having a high degree of homology with SEQ ID N1/2 such as combinations of SEQ ID N1-2F or SEQ ID N1-3F with SEQ ID N2-1R, SEQ ID N2-2R and SEQ ID N2-3R. These primer pair combinations enable to obtain fragment lengths of 3026 bp (sequence N1-2F+sequence N2-1R), 870 bp (sequence N1-3F+sequence N2-1R), 1000 bp (sequence N1-3F+sequence N2-2R) and 1400 bp (sequence N1-3F+sequence N2-3R), respectively. Those primer sequences are coded:
[0000]
Sequence-N1-2F = 5′-CAAACCACCACCCACTAAC-3′
Sequence-N1-3F = 5′-GAGAAGAGGGAGGTGTGAAG-3′
Sequence-N2-1R = 5′-AGCGGTTATGGTGAGGTCAG-3′
Sequence-N2-2R = 5′-ACAAAGCCCACAGTGTCGTC-3′
Sequence-N2-3R = 5′-GCCATAGCAACACGATAAAG-3′
[0072] As above-mentioned the invention also relates to a sequence common to LO and HO regions which is localised over the insertion point of the Pervenets mutation. This sequence SEQ ID NO:13 was isolated by RAGE PCR and the sequences of the cloned LO and HO fragments clearly displays the break-up at the insertion point. Primer pairs were defined to amplify across the insertion Pervenets mutation point.
[0000]
Sequence N2-1F = 5′-TTTTACTCTTTGTTATAATAG-3′
Sequence N3-1R = 5′-TTTTTAGTTCATGGAATCAC-3′
Sequence N2-2F = 5′-ACACTAACACTCATTACATTCG-3′
Sequence N3-2R = 5′-CCTAAAGCTCTGTAGATTTT-3′
Sequence N2-3F = 5′-AAAGCAAAAAACACCGTGATTC-3′
Sequence N3-3R = 5′-GGTGTTATTATTCAGCCTGAA-3′
Sequence N3-3′R = 5′-GATGTTATTATTCAGCCTGAA-3′
[0073] The use of these primers respectively leads to
a fragment of 170 bp (SEQ ID NO: 14 and SEQ ID NO:15) a fragment of 160 bp (SEQ ID NO: 16 and SEQ ID NO:17) a fragment of 170 bp (SEQ ID NO: 18 and SEQ ID NO:19) a fragment of 170 bp (SEQ ID NO: 18 and SEQ ID NO:20)
[0078] We also demonstrated that sunflower carries also a duplicated sequence at a second locus but where there is no insertion. Thus, the use of these primer pair combinations always revealed these short fragments whatever the LO or HO genotypes. However, this region enables to further characterize revertant mutant that still carry a short insertion that cannot silence the wild desaturase gene, since these were still LO.
[0079] Combination of primers amplifying the SSR, the Δ12HOS allele and the sequence across the insertion site will boost improvement of sunflower with high oleic oil content.
[0080] Troubles faced by breeders to improved HOAC sunflower are mainly due to the instability of the Pervenets mutation that seems to disappear for two reasons:
[0081] 1) There is a reversion, corresponding to a deletion in the insertion (several have been characterized) that may lead to the LO phenotype when the silencing mechanism is stopped.
[0082] 2) There is a suppressor that prevents the silencing mechanism and consequently, the phenotype is LO.
[0083] For the reversion the combination of the markers (SSR, Δ12HOS allele and that across the insertion site) enables to unravel what happened. Since there is no genetic recombination between the SSR locus and the Δ12HL locus, the SSR allele will be always linked (in the same phasis) to the Δ12HL allele that was present. If it reverts the Δ12LOR allele will be found linked to the incorrect SSR allele.
[0084] Moreover, when the reversion leaves a small DNA fragment in the insertion site, it is possible to directly detect it with the primer pairs described that amplify the sequence over the insertion site.
[0085] Changes in the length of the insertion were found in twelve out of 174 recombinant inbred lines. Thus it is frequent and may disturb the expected frequency ratio for HO/LO.
[0086] In the progenies, ten individuals carried the SSR of the HO parent (RHA345) linked with a modified insertion. Once corrected the HO LO ratio fits the Mendelian proportion that was distorted since ten LO progenies were in fact revertant.
[0087] The suppressor is detected when the presence of the Δ12HOS allele does not lead to the HO phenotype.
DESCRIPTION OF THE FIGURES
[0088] FIG. 1 Δ12HOS and Δ12LOR physical maps established according to EcoRI and/or HindIII RFLP profiles revealed with the Δ12-desaturase cDNA (8).
[0089] FIG. 2 Outcome map of the 29 kb region with SEQ positions in HO genotypes (B) and in LO genotypes (A).
[0090] FIG. 3 HO specific PCR amplifications in a set of HO and LO genotypes using primer pair combination SEQ ID N1-3F+SEQ ID N 2-1R (A), SEQ ID N1-3F+SEQ ID N 2-2R (B), SEQ ID N1-3F+SEQ ID N 2-3R (C).
DESCRIPTION OF MATERIALS AND METHODS
Materials
[0091] Plant Materials
[0092] a. Diversity Analysis:
[0093] 42 HO and LO genotypes to test SSR and other PCR amplification polymorphisms were selected from different public and private institutes in order to represent a wide sunflower genetic diversity. The HO RHA345 and the LO LO4 genotypes (Table 1) were used for long PCR experiments.
[0000]
TABLE 1
List of genotypes used to test SSR and other PCR amplification
polymorphisms with their pedigree, origin and phenotype.
PHENOTYPE
CODE
PEDIGREE
ORIGIN
HO/LO
LO1
Monsanto
LO
LO2
Monsanto
LO
LO3
Monsanto
LO
LO4
Monsanto
LO
LO5
Monsanto
LO
LO11
Monsanto
LO
LO14
Monsanto
LO
LO17
Monsanto
LO
LO36
Monsanto
LO
LO38
Monsanto
LO
LO40
Monsanto
LO
HA89A
VNIIMK8931
Russia
LO
BD70080
Monsanto
LO
HO1
Monsanto
HO
HO2
Monsanto
HO
HO5
Monsanto
HO
HO9
Monsanto
HO
HO19
Monsanto
HO
HO22
Monsanto
HO
HO24
Monsanto
HO
HO26
Monsanto
HO
HO37
Monsanto
HO
HO39
Monsanto
HO
HO41
Monsanto
HO
HO42
Monsanto
HO
HO43
Monsanto
HO
OPA1
PAC2 × RHA344
INRA - France
HO
R-OL1
Cordoba
HO
OPA2
PAC2 × RHA344
INRA - France
HO
BE73201-1
Monsanto
HO
BE-73201-4
Monsanto
HO
BE-73201-5
Monsanto
HO
RHA345
USA
HO
RHA346
USA
HO
RHA347
USA
HO
LG26
Russia
HO
S1 Pervenets
VNIIMK 8931
Russia
HO
S1 Pervenets
VNIIMK 8931
Russia
HO
S1 Pervenets
VNIIMK 8931
Russia
HO
RHA 345
USA
HO
VNIIMK 8931
Russia
LO
[0094] b. Segregating Recombinant Inbred Line Population:
[0095] The (LO) line 83HR4 (INRA), male-sterilized by gibberellin, was crossed with the (HO) line RHA345 (USA) in the INRA nursery during the summer of 1996. Nine F 1 hybrid seeds were obtained and the F 1 plants were inter-crossed to produce a F 2 generation in a greenhouse during the following winter. 174 F 6 progenies were obtained from these F 1 plants. These progenies were used to determine 18:1 content separately on half of a cotyledon of five seeds for each F 6 family. These seeds were sown in Jiffypots and after 6 days in a greenhouse they were transferred to the field. For each F 6 family, plant number 2 in the field was selected for molecular characterizations (RFLP and PCR genotyping). 83HR4 and RHA345 parental lines were included as controls.
[0096] Probes
[0097] Δ12-desaturase cDNA used in the following example has 1458 bp and is similar to the complete Δ12-desaturase cDNA deposited in the GenBank under n o U91341 and described by Hongtrakul et al (5).
[0098] Methods
[0099] 18:1 Oleic Acid Measurement
[0100] Oil composition measurement and 18:1 content determination were performed on half a cotyledon using gas chromatography as described by Conte et al. (10).
[0101] Extraction of the Genomic DNAs.
[0102] The DNA was extracted from 5 g of ground leaves in liquid nitrogen according to the method disclosed by Gentzbittel (11).
[0103] After the addition of 9 ml of a sodium sulphate solution (28 mg/ml) prepared in the buffer CTAB 2× (CTAB 2% (w/v), Tris-HCl 10 mM pH8, Na 2 EDTA 100 mM pH8, NaCl 1.4 M, PVP 1% (w/v)), the mixture was incubated at 65° C. for 30 minutes. Five ml of chloroform/isoamylic alcohol (24/1, v/v) was added before centrifugation at 10.000 rpm, 10 min. The supernatant was recovered and incubated at 37° C. for 30 min after the addition of 500 mg RNase A, then for one hour also at 37° C. after the addition of 4 mg of proteinase K. One ml of CTAB 10× (CTAB 10% (w/v), NaCl 0.7 M) and 7 ml of chloroform/isoamylic alcohol (24/1, v/v) was added before centrifugation at 10.000 rpm, 10 min. The supernatant was recovered in a precipitation buffer, the volume of which corresponds to two volumes of the supernatant (CTAB 1% (w/v), Tris-HCl 50 mM pH8, EDTA 100 mM pH8).
[0104] After centrifugation at 12.000 rpm, for 15 min., the pellet was recovered and dissolved in 3 ml of TE High buffer (Tris-HCl 10 mM pH8, Na 2 EDTA 1 mM pH8, NaCl 1M) and two volumes of 95% cold ethanol, before a further centrifugation at 12,000 rpm, for 15 min. The pellet containing the DNA was dissolved in 1 ml of TE 0.1× (Tris-HCl 1 mM pH8, Na 2 EDTA 0.1 mM).
[0105] The amount of DNA is determined using an absorbance spectrophotometer (DO) at 260 nm.
[0106] RFLP Techniques
[0107] Southern Blot
[0108] Eight μg of DNA of each genotype were restricted with EcoRI and/or HindIII enzymes according to the provider recommendations (Boehringer). Eight enzyme units per μg of DNA were used and each restriction reaction was carried out at 37° C. for 6 hours.
[0109] The restriction products were separated by gel electrophoresis on Agarose 0.8% (w/v) gel in the 0.5×TBE buffer (Tris-HCl 45 mM pH8, boric acid 45 mM, EDTA pH8 1 mM) at 1 v/cm for 16 hours. The gel was then colored in EtBr bath (1 μg/ml). The migration profiles were made visible under UV light (at 312 nm).
[0110] After 30 min of partial depurination of the DNA by a 0.25 N HCl solution, the samples were transferred onto a Nylon membrane (Appligene). The transfer was made under reduced pressure at 60 mbar during 2 hours using a vacuum transfer apparatus (Appligene). A 0.4 N NaOH solution was used as a transfer solution. The membranes were then washed in a 2×SSC solution (NaCl 3M, sodium citrate 0.3 M pH 7). The DNA was fixed on the membranes by incubation at 80° C. for two hours. The membranes were stocked at 4° C. until using them for hybridization.
[0111] Hybridization
[0112] The radioactive labelling of the probes was carried out by the random primer elongation in the presence of a desoxyribonucleotide labelled by a radioactive isotype, α 32 P-dCTP according to the method described by Feinberg and Volgelstein (12). The prehybridization and the hybridization were carried out in the same buffer containing SDS 7% (w/v), Sodium Phosphate buffer 0.5 M (pH 7.2), EDTA 1 mM (pH 8), stirring at 62° C. for 1 hour (prehybridization) and 12 hours (hybridization). Two washes for 10 min. at 60° C. were carried out using a buffer containing SDS 1% (w/v), Sodium Phosphate buffer 40 mM (pH 7.2), EDTA 1 mM (pH 8) according to methods described by Sambrook et al. (13). The conditions of Na + molarity and of temperature determine stringence conditions high enough to ensure specific hybridizations. An autoradiographic film was then exposed to the membrane at −70° C. for a duration, which depends on the intensity of the radioactive signals emitted by the membrane.
[0113] Specific PCR Amplification
[0114] Each PCR amplification was carried out starting from 80 ng of genomic DNA in a final volume of 30 μl containing Tris-HCl 10 mM (pH 8.3); KCl 50 mM, MgCl 2 1.5 mM; dNTPs 200 μM; 1 μM of each primer, Taq polymerase 1U (Sigma). The amplifications were carried out using a PTC 100 thermocycler (MJ Research) according to the following program:
[0000]
denaturation:
94° C.; 4 min.
production (35 cycles):
94° C.; 1 min.
55° C.; 1 min.
72° C.; 1 min.
final elongation:
72° C.; 5 min.
[0115] The amplification products were then either separated by electrophoresis on Agarose gel or purified in order to be cloned and sequenced. The electrophoresis was carried out on 1.2% (w/v) Agarose gel in TBE 0.5× buffer (10 v/cm) for two hours. Purification of the amplification products was carried out with the Wizard PCR Prep DNA Purification Systems kit (Promega).
[0116] Amplification of SSR Fragments.
[0117] The amplification using the SSR primers was carried out using 40 ng of genomic DNA in a final volume of 25 μl containing Tris-HCl 10 mM (pH 8.3), KCl 50 mM, MgCl 2 1.5 mM, dNTPs 200 μM, 1 μM of each primer; Taq polymerase 1U (Sigma). The amplifications were carried out using a PTC 100 thermocycler (MJ Research) according to the following program:
[0000]
Denaturation:
94° C.; 5 min.
production (35 cycles):
94° C.; 30 s.
50° C.; 1 min.
72° C.; 1 min.
final elongation:
72° C.; 5 min.
[0118] Amplification product were loaded onto 6% denaturing polyacrylamide gels containing 7.5 M urea, 6% acrylamide and 1×TBE buffer (Tris-HCI 90 mM pH8, boric acid 90 mM, EDTA pH8 2 mM). Gels were run in a 1×TBE buffer for 90 min at 60V. SSR amplifications were visualized by sliver staining with a commercial kit from Promega.
[0119] Long PCR Amplification
[0120] In order to amplify PCR fragment from genomic DNA longer than 2 kb, we used the Expend Long Template PCR System from Roche Applied Science. The long PCR were made according to the provider instructions.
EXAMPLE 1
Diversity Analysis with the HO Specific PCR Fragment Across the Insertion Pervenets Point
[0121] The Pervenets mutation was labelled by HO specific PCR amplifications across the 5′ insertion point using designed primer pair combinations (SEQ ID N1-3F located on SEQ ID N1 with SEQ ID N2-1R, -2R or -3R designed on Δ12-desaturase cDNA sequence).
[0000]
sequence N1-3F = 5′-GAGAAGAGGGAGGTGTGAAG-3′
sequence N2-1R = 5′-AGCGGTTATGGTGAGGTCAG-3′
sequence N2-2R = 5′-ACAAAGCCCACAGTGTCGTC-3′
sequence N2-3R = 5′-GCCATAGCAACACGATAAAG-3′
[0122] Forty-two HO and LO genotypes were used for these PCR experiments. These genotypes were previously genotyped using Δ12-desaturase cDNA as a probe to reveal RFLPs. All the HO genotypes displayed the Δ12HOS allele whereas the LO genotypes displayed the Δ12LOR one (6). PCR amplification products of about 870 bp (SEQ ID N1-3F+SEQ ID N2-1R), 1000 bp (SEQ ID N1-3F+SEQ ID N2-2R) and 1400 bp (SEQ ID N1-3F+SEQ ID N2-3R) were specifically revealed in HO genotypes carrying the Pervenets mutation ( FIG. 3 A, B and C, respectively). All the 42 genotypes were categorized into LO or HO without any error according to these HO specific PCR amplifications.
EXAMPLE 2
Pervenets Mutation Labelling in the Recombinant Inbred Line Population
[0123] The recombinant inbred line families were obtained by crossing the lines 83HR4 (LO) by RHA 345 (HO) according to the method described above. Using Δ12-desaturase as a probe to reveal RFLP, we showed that the RHA 345 HO parent line carries the Δ12HOS allele whereas the 83HR4 LO parental line displayed the Δ12LOR allele. In the 174 recombinant inbred line population, the Δ12HOS/Δ12LOR alleles segregated as 78/96.
[0124] The Pervenets mutation was labelled by the 870 bp PCR fragment across the 5′ insertion point and by the polymorphism of the SSR locus located on the Δ12-desaturase gene intron. Moreover this SSR polymorphism labelled the Δ12-desaturase gene itself.
[0125] 870 bp HO specific PCR amplification: We used designed primer pair combination SEQ ID N1-3F with SEQ ID N2-1R:
[0000]
sequence N1-3F = 5′-GAGAAGAGGGAGGTGTGAAG-3′
sequence N2-1R = 5′-AGCGGTTATGGTGAGGTCAG-3′
[0126] In the 174 recombinant inbred line population, it leads to PCR amplification of about 870 bp only in genotypes carrying the Δ12HOS allele and thus the Pervenets mutation.
[0127] Amplification of the SSR sequence: The SSR polymorphism between RHA 345 and 83HR4 parental line was revealed by PCR amplification using the primer pair SEQ ID N1-1F/SEQ ID N1-1R. This PCR amplification leads to 237 bp (15 SSR motives) and 240 bp (16 SSR motives) in 83HR4 and RHA 345, respectively. The segregation of this SSR polymorphism was tested in the 174 recombinant inbred line population. All the genotypes carrying the Δ12HOS allele displayed the HO RHA 345 SSR polymorphism (16 SSR motives) whereas genotypes carrying the Δ12LOR allele displayed the LO 83HR4 SSR polymorphism (15 SSR motives).
[0128] PCR methods with these primer pairs enabling to amplify either the Pervenets mutation itself or the SSR locus, lead to distinguish between genotypes carrying the Pervenets mutation and genotypes without the mutation. Consequently, the SSR sequence and the HO PCR specific fragment may be used in selection programs to identify genotypes carrying the Pervenets mutation. Moreover, the SSR polymorphism can be used to map the Δ12-desaturase gene.
REFERENCES
[0000]
(1) Soldatov K I. (1976). Chemical mutagenesis in sunflower breeding. In Proc. VII th Int. Sunflower Conference , Jun. 27-Jul. 3, 1976, Krasnodar.
(2) Garcès R, Garcia J, Mancha M. (1989). Lipid characterization in seeds of a high oleic acid sunflower mutant. Phytochemistry 28 (10): 2597-2600.
(3) Garcés R et Mancha M. (1991). In vitro oleate desaturase in developing sunflower seeds. Phytochemistry 30:2127-2130.
(4) Kabbaj A. et al. (1996). Polymorphism in Helianthus and expression of stearate, oleate and linoleate desaturase genes in sunflower with normal and high oleic content. Helia 19:1-18.
(5) Hongtrakul V, Slabaugh M B, Knapp S J (1998). A seed specific □12 oleate-desaturase gene is duplicated, rearranged and weakly expressed in high oleic acid sunflower lines. Crop Science 38:1245-1249
(6) Lacombe S et Bervillé A (2001). A dominant mutation for high oleic acid content in sunflower ( Helianthus annuus L.) seed oil is genetically linked to a single oleate-desaturase RFLP locus. Molecular Breeding 8:129-137.
(7) Lacombe S et al. (2001). An oleate-desaturase and a suppressor locus direct high oleic acid content of sunflower ( Helianthus annuus L.) oil in the Pervenets mutant. CR. Acad. Sci., Sciences de la vie 324:839-845.
(8) Lacombe et al. (2002) Genetic, molecular and expression feature of the Pervenets mutant leading to high oleic acid content of seed oil in sunflower. OCL 9:17-23
(9) Devereux, Haeberli and Smithies (1984). A Comprehensive Set of Sequence Analysis Programs for VAX. Nucleic Acids Research 12(1); 387-395
(10) Conte et al. (1989) Half seed analysis: rapic chromatographic determination of the main fatty acids of sunflower seeds. Plant Breeding 102:158-165
(11) Gentzbittel et al. (1994) RFLP studies of genetic relationships among inbred lines of cultivated sunflower ( Helianthus annuus L.): evidence of distinct restorer and maintener germplasm pools. Theor. App. Genet 89:419-425.
(12) Feinberg A P et Vogelstein B. (1983). A technic for radiolabelling DNA restriction endonuclease fragments to high specific activity. Analytical Biochemistry 132: 6-13.
(13) Sambrook J, Fritsch E F, Maniatis T. (1989). Molecular cloning: a laboratory manual (2 nd edn). Cold Spring Harbor Laboratory Press, Cold Spring Harbor, N.Y.
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The present invention relates to the selection of sunflower genotypes with high oleic acid content in seed oil. The invention concerns more particularly molecular markers useful for a rapid and easy selection of sunflower lines and then sunflower hybrids capable of producing seeds having high oleic acid content.
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[0001] The present invention relates to an apparatus for controlling a hydraulic circuit for a clutch of motor vehicles, especially of motorcycles and the like.
BACKGROUND OF THE INVENTION
[0002] It is known that the action to be exerted on the pack of the clutch diks is made easier by means of a hydraulic circuit which comprises a pump and a piston acting on the disks' pack. In the motorcycles, for example, a lever is provided for operating said pump whose activation determines the displacement of the piston.
[0003] In the motorcycles provided with a traditional apparatus of this type, a drawback is due to the relative difficulty of adjusting the idle stroke of the control lever. In fact, in the existing devices, the lever is connected to a piston sliding into a respective chamber exhibited by the pump and, in order to adjust the idle stroke of the lever it is currently necessary to move axially the piston with respect to the chamber inside which it slides. This approach is however very complex structurally, and affects negatively the constructional simplicity of the device and its robustness upon use, besides raising the relevant production cost thereof.
SUMMARY OF INVENTION
[0004] The main object of the present invention is to provide an easily adjustable apparatus for controlling hydraulic circuits.
[0005] This result has been achieved, according to the invention, by adopting the idea of making an apparatus having the characteristics disclosed in the claim 1 .
[0006] Further characteristics being set forth in the dependent claims.
[0007] Among the advantages of the present invention there is the fact that it is possible to adjust the idle stroke for the operation of the clutch's hydraulic circuit with greatest ease; that the controlled circuit maintains its original characteristics; that no protruding parts are provided likely to be damaged or be a danger for the driver of the vehicle being equipped with the apparatus; that the apparatus has extremely limited overall dimensions and, therefore, gives the handlebar a greater compactness; that a more attractive appearance is conferred to the handlebar; that the apparatus keeps its characteristics unchanged also after a prolonged service life.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] These and other advantages and characteristics of the invention will be best understood by anyone skilled in the art from a reading of the following description in conjunction with the attached drawings given as a practical exemplification of the invention, but not to be considered in a limitative sense, wherein:
[0009] FIG. 1 shows a view in longitudinal section of a possible exemplary embodiment of an apparatus for controlling hydraulic circuits according to the invention, in association with a portion of the handlebar;
[0010] FIG. 2 is an enlarged detail of the embodiment of FIG. 1 , in which some lines in the drawing have been omitted for the sake of simplicity;
[0011] FIG. 3 is a perspective view from below of the apparatus of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
[0012] With reference to the example shown in the attached figures, an apparatus 1 according to the present invention can be associated with a portion of a motorcycle or the like, such as a handlebar, for example, by means of suitable fixing means (not shown). The present apparatus comprises a body 3 (shown only partially) inside which a cavity 88 is formed defining the reservoir for the fluid of the hydraulic circuit. The said reservoir 88 results positioned between the handlebar, to which the body 3 is fixed, and a lever for operating the pump acting on the hydraulic circuit of the clutch. The clutch-operating lever (not shown) results linked with a connecting rod 86 having spherical head, as represented on the left side of the attached figures.
[0013] Shown in FIG. 1 is a conduit 7 making part of the hydraulic circuit and connecting the apparatus 1 to the piston 77 which acts upon the clutch disks, the latter being schematically represented by the block 70 in FIG. 1 .
[0014] The conduit 7 is connected downstream of a pump 8 in correspondence of an outlet port 87 through which the fluid of the hydraulic circuit is pushed when acting on the clutch's control. The pump 8 is defined by a chamber 80 included in the body 3 and inside which a piston 89 slides. The piston 89 is connected to the control lever via the connecting rod 86 which is disposed, relative to the piston, on the side opposite to the position of port 87 in the chamber 80 . The actuation of the control lever is cause for the displacement of the piston 89 (from left to right when referring to arrow F of FIG. 1 ) towards the port 87 . The return of piston 89 to its rest position is determined by a spring 82 whose reaction is in a direction opposite to that indicated by arrow F in FIG. 1 .
[0015] As best shown in FIG. 2 , keeping the piston 89 within the chamber 80 is ensured by the presence of a bush 10 provided with a relevant gasket 11 .
[0016] The bush 10 is solid to the piston 89 and, for this reason, the piston 89 can rotate together with the bush 10 relative to chamber 80 . Solid to the bush 10 , that is, made as one body therewith, is a knob 16 disposed radially with respect to the longitudinal development of the chamber 80 , that is, substantially orthogonal to the longitudinal axis X-X of the chamber 80 . The rotation of the knob 16 determines a corresponding rotation of the piston 89 within the chamber 80 .
[0017] The chamber 80 is connected with a reservoir 88 via two ports 83 and 84 which are disposed in a region acted upon by the piston's slide. In a manner known per se, the fluid is made to pass bidirectionally through the ports 83 and 84 between the reservoir and the chamber 80 during the axial displacement of the piston 89 , that is, during the actuation of the pump 8 .
[0018] Fitted on the piston 89 is a gasket 9 having circumferential development. The gasket 9 , along its circumferential profile, exhibits a different extension in axial direction. In practice, the gasket 9 has a longitudinal development with a height varying therealong. Indicated by D 9 in FIG. 2 is the difference between the height of the overlying edge 99 and the corresponding extent of the underlying edge 98 . In other words, the plane of said edges 98 , 99 forms an acute angle, that is, an angle lower than 90°, with the said axis X-X.
[0019] This particular shape of gasket 9 is cause for a different interaction of the piston 89 with respect to the ports 83 and 84 of reservoir 88 . In other words, the interaction front of the gasket 9 with the ports 83 and 84 is displaced in the axial direction; in practice, by rotating in one direction or the other the piston 89 (which can be obtained by means of knob 16 ), the gasket 9 closes in advance or with delay the port 83 , that is, before or after the intervention on the clutch. There is thus obtained an adjustment of the idle stroke of the relevant lever through an extremely simple and effective solution.
[0020] Advantageously, moreover, the reservoir 88 is defined by a corresponding cavity formed in the body 3 of the apparatus 1 . In particular, reference being made to FIG. 3 , the body 3 of the apparatus 1 has a concave, substantially semicylindrical surface 30 and is so shaped as to be complementary with the profile of a tubular element of the handlebar. The reservoir 88 is closed on top by a lid 38 . The lid is provided with screws 5 going therethrough to fix the apparatus 1 to the handlebar 2 . Moreover, the lid 38 is of concave shape so that it can fit complementarily with the profile of the handlebar tube 2 . This characteristic allows the reservoir 88 to be seated stably in a region protected against bumps and tampering with.
[0021] On the body 3 , on either side of said surface 30 , there are provided seats 39 for receiving corresponding screws 5 allowing the attachment of the apparatus 1 to the handlebar. The apparatus 1 also comprises a semicollar 4 having a concavity 40 of substantially semicylindrical shape so as to fit complementarily with the handlebar. Provided on the semicollar 4 are through holes to receive the said screws 5 .
[0022] This undoubtly provides a further advantage in terms of safety inasmuch as no protruding parts are present that could be damaged or cause a danger for the driver of the vehicle. Besides, the apparatus has extremely reduced overall dimensions, thereby confering a greater to the handlebar compactness and a more attractive appearance.
[0023] The construction details may vary in any equivalent way as far as the shape, dimensions, elements disposition, nature of the used materials are concerned, without nevertheless departing from the scope of the adopted solution idea and, thereby, remaining within the limits of the protection granted to the present patent.
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Apparatus for controlling a hydraulic circuit to be used for operating hydraulic clutches with a pump ( 8 ) connected with a relevant reservoir ( 88 ) for the fluid of the hydraulic circuit and comprising a piston ( 89 ) sliding within a relevant chamber ( 80 ) provided with one or more ports ( 83, 84 ) for connection to said reservoir ( 88 ), the said piston being so shaped as to close/open the said ports ( 83, 84 ) upon its stroke along said chamber ( 80 ), apparatus being characterized in that the idle stroke of the piston ( 89 ) within said chamber ( 80 ) is adjustable through a rotation of the same piston ( 89 ) about its longitudinal axis.
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FIELD OF THE INVENTION
This invention relates to the field of characterizing the existence of a disease state; particularly to the utilization of mass spectroscopy to elucidate particular biopolymer markers indicative of disease state, and most particularly to specific biopolymer sequences having a unique relationship to at least one particular disease state.
BACKGROUND OF THE INVENTION
Methods utilizing mass spectrometry for the analysis of a target polypeptide have been taught wherein the polypeptide is first solubilized in an appropriate solution or reagent system. The type of solution or reagent system, e.g., comprising an organic or inorganic solvent, will depend on the properties of the polypeptide and the type of mass spectrometry performed and are well-known in the art (see, e.g. Vorm et al. (1994) Anal. Chem. 66:3281 (for MALDI) and Valaskovic et al. (1995) Anal. Chem. 67:3802 (for ESI)). Mass spectrometry of peptides is further disclosed, e.g. in WO 93/24834 by Chait et al.
In one prior art embodiment, the solvent is chosen so that the risk that the molecules may be decomposed by the energy introduced for the vaporization process is considerably reduced, or even fully excluded. This can be achieved by embedding the sample in a matrix, which can be an organic compound, e.g., sugar, in particular pentose or hexose, but also polysaccharides such as cellulose. These compounds are decomposed thermolytically into CO 2 and H 2 O so that no residues are formed which might lead to chemical reactions. The matrix can also be an inorganic compound, e.g., nitrate of ammonium which is decomposed practically without leaving any residues. Use of these and other solvents are further disclosed in U.S. Pat. No. 5,062,935 by Schlag et al.
Prior art mass spectrometer formats for use in analyzing the translation products include ionization (I) techniques, including but not limited to matrix assisted laser desorption (MALDI), continuous or pulsed electrospray (ESI) and related methods (e.g., IONSPRAY or THERMOSPRAY), or massive cluster impact (MCI); these ion sources can be matched with detection formats including linear or non-linear reflection time-of-flight (TOF), single or multiple quadropole, single or multiple magnetic sector, Fourier Transform ion cyclotron resonance (FTICR), ion trap, and combinations thereof (e.g., ion-trap/time-of-flight). For ionization, numerous matrix/wavelength combinations (MALDI) or solvent combinations (ESI) can be employed. Subattomole levels of protein have been detected, for example, using ESI (Valaskovic, G. A. et al., (1996) Science 273:1199–1202) or MALDI (Li, L. et al., (1996) J. Am. Chem. Soc. 118:1662–1663) mass spectrometry.
ES mass spectrometry has been introduced by Fenn et al. (J. Phys. Chem. 88, 4451–59 (1984); PCT Application No. WO 90/14148) and current applications are summarized in recent review articles (R. D. Smith et al., Anal. Chem. 62, 882–89 (1990) and B. Ardrey, Electrospray Mass Spectrometry, Spectroscopy Europe, 4, 10–18 (1992)). MALDI-TOF mass spectrometry has been introduced by Hillenkamp et al. (“Matrix Assisted UV-Laser Desorption/Ionization: A New Approach to Mass Spectrometry of Large Biomolecules,” Biological Mass Spectrometry (Burlingame and McCloskey, editors), Elsevier Science Publishers, Amsterdam, pp. 49–60, 1990). With ESI, the determination of molecular weights in femtomole amounts of sample is very accurate due to the presence of multiple ion peaks which all could be used for the mass calculation.
The mass of the target polypeptide determined by mass spectrometry is then compared to the mass of a reference polypeptide of known identity. In one embodiment, the target polypeptide is a polypeptide containing a number of repeated amino acids directly correlated to the number of trinucleotide repeats transcribed/translated from DNA; from its mass alone the number of repeated trinucleotide repeats in the original DNA which coded it, may be deduced.
U.S. Pat. No. 6,020,208 utilizes a general category of probe elements (i.e., sample presenting means) with Surfaces Enhanced for Laser Desorption/Ionization (SELDI), within which there are three (3) separate subcategories. The SELDI process is directed toward a sample presenting means (i.e., probe element surface) with surface-associated (or surface-bound) molecules to promote the attachment (tethering or anchoring) and subsequent detachment of tethered analyte molecules in a light-dependent manner, wherein the said surface molecule(s) are selected from the group consisting of photoactive (photolabile) molecules that participate in the binding (docking, tethering, or crosslinking) of the analyte molecules to the sample presenting means (by covalent attachment mechanisms or otherwise).
PCT/EP97/04396 (WO 98/07036) teaches a process for determining the status of an organism by peptide measurement. The reference teaches the measurement of peptides in a sample of the organism which contains both high and low molecular weight peptides and acts as an indicator of the organism's status. The reference concentrates on the measurement of low molecular weight peptides , i.e. below 30,000 Daltons, whose distribution serves as a representative cross-section of defined controls. Contrary to the methodology of the instant invention, the '396 patent strives to determine the status of a healthy organism, i.e. a “normal” and then use this as a reference to differentiate disease states. The present inventors do not attempt to develop a reference “normal”, but rather strive to specify particular markers which are evidentiary of at least one specific disease state, whereby the presence of said marker serves as a positive indicator of disease. This leads to a simple method of analysis which can easily be performed by an untrained individual, since there is a positive correlation of data. On the contrary, the '396 patent requires a complicated analysis by a highly trained individual to determine disease state versus the perception of non-disease or normal physiology.
Richter et al, Journal of Chromatography B, 726(1999) 25–35, refer to a database established from human hemofiltrate comprised of a mass database and a sequence database. The goal of Richter et al was to analyze the composition of the peptide fraction in human blood. Using MALDI-TOF, over 20,000 molecular masses were detected representing an estimated 5,000 different peptides. The conclusion of the study was that the hemofiltrate (HF) represented the peptide composition of plasma. No correlation of peptides with relation to normal and/or disease states is made.
As used herein, “analyte” refers to any atom and/or molecule; including their complexes and fragment ions. In the case of biological molecules/macromolecules or “biopolymers”, such analytes include but are not limited to: proteins, peptides, DNA, RNA, carbohydrates, steroids, and lipids. Note that most important biomolecules under investigation for their involvement in the structure or regulation of life processes are quite large (typically several thousand times larger than H 2 O.
As used herein, the term “molecular ions” refers to molecules in the charged or ionized state, typically by the addition or loss of one or more protons (H + )
As used herein, the term “molecular fragmentation” or “fragment ions” refers to breakdown products of analyte molecules caused, for example, during laser-induced desorption (especially in the absence of added matrix).
As used herein, the term “solid phase” refers to the condition of being in the solid state, for example, on the probe element surface.
As used herein, “gas” or “vapor phase” refers to molecules in the gaseous state (i.e., in vacuo for mass spectrometry).
As used herein, the term “analyte desorption/ionization” refers to the transition of analytes from the solid phase to the gas phase as ions. Note that the successful desorption/ionization of large, intact molecular ions by laser desorption is relatively recent (circa 1988)—the big breakthrough was the chance discovery of an appropriate matrix (nicotinic acid).
As used herein, the term “gas phase molecular ions” refers to those ions that enter into the gas phase. Note that large molecular mass ions such as proteins (typical mass=60,000 to 70,000 times the mass of a single proton) are typically not volatile (i.e., they do not normally enter into the gas or vapor phase). However, in the procedure of the present invention, large molecular mass ions such as proteins do enter the gas or vapor phase.
As used herein in the case of MALDI, the term “matrix” refers to any one of several small, acidic, light absorbing chemicals (e.g., nicotinic or sinapinic acid) that is mixed in solution with the analyte in such a manner so that, upon drying on the probe element, the crystalline matrix-embedded analyte molecules are successfully desorbed (by laser irradiation) and ionized from the solid phase (crystals) into the gaseous or vapor phase and accelerated as intact molecular ions. For the MALDI process to be successful, analyte is mixed with a freshly prepared solution of the chemical matrix (e.g., 10,000:1 matrix:analyte) and placed on the inert probe element surface to air dry just before the mass spectrometric analysis. The large fold molar excess of matrix, present at concentrations near saturation, facilitates crystal formation and entrapment of analyte.
As used herein, “energy absorbing molecules (EAM)” refers to any one of several small, light absorbing chemicals that, when presented on the surface of a probe, facilitate the neat desorption of molecules from the solid phase (i.e., surface) into the gaseous or vapor phase for subsequent acceleration as intact molecular ions. The term EAM is preferred, especially in reference to SELDI. Note that analyte desorption by the SELDI process is defined as a surface-dependent process (i.e., neat analyte is placed on a surface composed of bound EAM). In contrast, MALDI is presently thought to facilitate analyte desorption by a volcanic eruption-type process that “throws” the entire surface into the gas phase. Furthermore, note that some EAM when used as free chemicals to embed analyte molecules as described for the MALDI process will not work (i.e., they do not promote molecular desorption, thus they are not suitable matrix molecules).
As used herein, “probe element” or “sample presenting device” refers to an element having the following properties: it is inert (for example, typically stainless steel) and active (probe elements with surfaces enhanced to contain EAM and/or molecular capture devices).
As used herein, “MALDI” refers to Matrix-Assisted Laser Desorption/Ionization.
As used herein, “TOF” stands for Time-of-Flight.
As used herein, “MS” refers to Mass Spectrometry.
As used herein “MALDI-TOF MS” refers to Matrix-assisted laser desorption/ionization time-of-flight mass spectrometry.
As used herein, “ESI” is an abbreviation for Electrospray ionization.
As used herein, “chemical bonds” is used simply as an attempt to distinguish a rational, deliberate, and knowledgeable manipulation of known classes of chemical interactions from the poorly defined kind of general adherence observed when one chemical substance (e.g., matrix) is placed on another substance (e.g., an inert probe element surface). Types of defined chemical bonds include electrostatic or ionic (+/−) bonds (e.g., between a positively and negatively charged groups on a protein surface), covalent bonds (very strong or “permanent” bonds resulting from true electron sharing), coordinate covalent bonds (e.g., between electron donor groups in proteins and transition metal ions such as copper or iron), and hydrophobic interactions (such as between two noncharged groups).
As used herein, “electron donor groups” refers to the case of biochemistry, where atoms in biomolecules (e.g, N, S, O) “donate” or share electrons with electron poor groups (e.g., Cu ions and other transition metal ions).
With the advent of mass spectroscopic methods such as MALDI and SELDI, researchers have begun to utilize a tool that holds the promise of uncovering countless biopolymers which result from translation, transcription and post-translational transcription of proteins from the entire genome.
Operating upon the principles of retentate chromatography, SELDI MS involves the adsorption of proteins, based upon their physico-chemical properties at a given pH and salt concentration, followed by selectively desorbing proteins from the surface by varying pH, salt, or organic solvent concentration. After selective desorption, the proteins retained on the SELDI surface, the “chip”, can be analyzed using the CIPHERGEN protein detection system, or an equivalent thereof. Retentate chromatography is limited, however, by the fact that if unfractionated body fluids, e.g. blood, blood products, urine, saliva, and the like, along with tissue samples, are applied to the adsorbent surfaces, the biopolymers present in the greatest abundance will compete for all the available binding sites and thereby prevent or preclude less abundant biopolymers from interacting with them, thereby reducing or eliminating the diversity of biopolymers which are readily ascertainable.
If a process could be devised for maximizing the diversity of biopolymers discernable from a sample, the ability of researchers to accurately determine the relevance of such biopolymers with relation to one or more disease states would be immeasurably enhanced.
SUMMARY OF THE INVENTION
The instant invention is characterized by the use of a combination of preparatory steps in conjunction with SELDI mass spectroscopy and time-of-flight detection procedures to maximize the diversity of biopolymers which are verifiable within a particular sample. The cohort of biopolymers verified within a sample is then viewed with reference to their ability to evidence at least one particular disease state; thereby enabling a diagnostician to gain the ability to characterize either the presence or absence of said at least one disease state relative to recognition of the presence and/or the absence of said biopolymer.
Although all manner of biomarkers related to all disease conditions are deemed to be within the purview of the instant invention and methodology, particular significance was given to those markers and diseases associated with the complement system and Syndrome X and diseases related thereto.
The complement system is an important part of non-clonal or innate immunity that collaborates with acquired immunity to destroy invading pathogens and to facilitate the clearance of immune complexes from the system. This system is the major effector of the humoral branch of the immune system, consisting of nearly 30 serum and membrane proteins. The proteins and glycoproteins composing the complement system are synthesized largely by liver hepatocytes. Activation of the complement system involves a sequential enzyme cascade in which the proenzyme product of one step becomes the enzyme catalyst of the next step. Complement activation can occur via two pathways: the classical and the alternative. The classical pathway is commonly initiated by the formation of soluble antigen-antibody complexes or by the binding of antibody to antigen on a suitable target, such as a bacterial cell. The alternative pathway is generally initiated by various cell-surface constituents that are foreign to the host. Each complement component is designated by numerals (C1–C9), by letter symbols, or by trivial names. After a component is activated, the peptide fragments are denoted by small letters. The complement fragments interact with one another to form functional complexes. Ultimately, foreign cells are destroyed through the process of a membrane-attack complex mediated lysis.
The C4 component of the complement system is involved in the classical activation pathway. It is a glycoprotein containing three polypeptide chains (α, β, and γ). C4 is a substrate of component C1s and is activated when C1s hydrolyzes a small fragment (C4a) from the amino terminus of the α chain, exposing a binding site on the larger fragment (C4b).
The native C3 component consists of two polypeptide chains, α and β. As a serum protein, C3 is involved in the alternative pathway. Serum C3, which contains an unstable thioester bond, is subject to slow spontaneous hydrolysis into C3a and C3b. The C3f component is involved in the regulation required of the complement system which confines the reaction to designated targets. During the regulation process, C3b is cleaved into two parts: C3bi and C3f. C3bi is a membrane-bound intermediate wherein C3f is a free diffusible (soluble) component.
Complement components have been implicated in the pathogenesis of several disease conditions. C3 deficiencies have the most severe clinical manifestations, such as recurrent bacterial infections and immune-complex diseases, reflecting the central role of C3. The rapid profusion of C3f moieties and resultant “accidental” lysis of normal cells mediated thereby gives rise to a host of auto-immune reactions. The ability to understand and control these mechanisms, along with their attendant consequences, will enable practitioners to develop both diagnostic and therapeutic avenues by which to thwart these maladies.
In the course of defining a plurality of disease specific marker sequences, special significance was given to markers which were evidentiary of a particular disease state or with conditions associated with Syndrome-X. Syndrome-X is a multifaceted syndrome, which occurs frequently in the general population. A large segment of the adult population of industrialized countries develops this metabolic syndrome, produced by genetic, hormonal and lifestyle factors such as obesity, physical inactivity and certain nutrient excesses. This disease is characterized by the clustering of insulin resistance and hyperinsulinemia, and is often associated with dyslipidemia (atherogenic plasma lipid profile), essential hypertension, abdominal (visceral) obesity, glucose intolerance or noninsulin-dependent diabetes mellitus and an increased risk of cardiovascular events. Abnormalities of blood coagulation (higher plasminogen activator inhibitor type I and fibrinogen levels), hyperuricemia and microalbuminuria have also been found in metabolic syndrome-X.
The instant inventors view the Syndrome X continuum in its cardiovascular light, while acknowledging its important metabolic component. The first stage of Syndrome X consists of insulin resistance, abnormal blood lipids (cholesterol and triglycerides), obesity, and high blood pressure (hypertension). Any one of these four first stage conditions signals the start of Syndrome X.
Each first stage Syndrome X condition risks leading to another. For example, increased insulin production is associated with high blood fat levels, high blood pressure, and obesity. Furthermore, the effects of the first stage conditions are additive; an increase in the number of conditions causes an increase in the risk of developing more serious diseases on the Syndrome X continuum.
A patient who begins the Syndrome X continuum risks spiraling into a maze of increasingly deadly diseases. The next stages of the Syndrome X continuum lead to overt diabetes, kidney failure, and heart failure, with the possibility of stroke and heart attack at any time. Syndrome X is a dangerous continuum, and preventative medicine is the best defense. Diseases are currently most easily diagnosed in their later stages, but controlling them at a late stage is extremely difficult. Disease prevention is much more effective at an earlier stage.
Subsequent to the isolation of particular disease state marker sequences as taught by the instant invention, the promulgation of various forms of risk-assessment tests are contemplated which will allow physicians to identify asymptomatic patients before they suffer an irreversible event such as diabetes, kidney failure, and heart failure, and enable effective disease management and preventative medicine. Additionally, the specific diagnostic tests which evolve from this methodology provide a tool for rapidly and accurately diagnosing acute Syndrome X events such as heart attack and stroke, and facilitate treatment.
Accordingly, it is an objective of the instant invention to define a disease specific marker sequence which is useful in evidencing and categorizing at least one particular disease state.
It is another objective of the instant invention to evaluate samples containing a plurality of biopolymers for the presence of disease specific marker sequences which evidence a link to at least one specific disease state.
It is a further objective of the instant invention to elucidate essentially all biopolymeric moieties contained therein, whereby particularly significant moieties may be identified.
It is a further objective of the instant invention provide at least one purified antibody which is specific to said disease specific marker sequence.
It is yet another objective of the instant invention to teach a monoclonal antibody which is specific to said disease specific marker sequence.
It is a still further objective of the invention to teach polyclonal antibodies raised against said disease specific marker.
It is yet an additional objective of the instant invention to teach a diagnostic kit for determining the presence of said disease specific marker.
It is a still further objective of the instant invention to teach methods for characterizing disease state based upon the identification of said disease specific marker.
Other objectives and advantages of this invention will become apparent from the following description taken in conjunction with the accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. The drawings constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a representation of derived data which characterizes a disease specific marker having a particular sequence, SEQ ID NO:1, useful in evidencing and categorizing at least one particular disease state; and
FIG. 2 is the characteristic profile derived via SELDI/TOF MS of the disease specific marker, SEQ ID NO:1.
DETAILED DESCRIPTION OF THE INVENTION
Serum samples from individuals were analyzed using Surface Enhanced Laser Desorption Ionization (SELDI) using the Ciphergen PROTEINCHIP system. The chip surfaces included, but were not limited to IMAC-3-Ni, SAX2 surface chemistries, gold chips, and the like.
Preparatory to the conduction of the SELDI MS procedure, various preparatory steps were carried out in order to maximize the diversity of discernible moities educable from the sample. Utilizing a type of micro-chromatographic column called a C18-ZIPTIP available from the Millipore company, the following preparatory steps were conducted.
1. Dilute sera in sample buffer;
2. Aspirate and dispense ZIP TIP in 50% Acetonitrile;
3. Aspirate and dispense ZIP TIP in Equilibration; solution;
4. Aspirate and Dispense in serum sample;
5. Aspirate and Dispense ZIP TIP in Wash solution;
6. Aspirate and Dispense ZIP TIP in Elution Solution.
Illustrative of the various buffering compositions useful in the present invention are:
Sample Buffers (various low pH's): Hydrochloric acid (HCl), Formic acid, Trifluoroacetic acid (TFA),
Equilibration Buffers (various low pH's): HCl, Formic acid, TFA;
Wash Buffers (various low pH's): HCl, Formic acid, TFA;
Elution Solutions (various low pH's and % Solvents): HCl, Formic acid, TFA;
Solvents: Ethanol,Methanol, Acetonitrile.
Spotting was then performed, for example upon a Gold Chip in the following manner:
1. spot 2 μl of sample onto each chip
2. let sample partially dry
3. spot 1 μl of matrix, and let air dry.
HiQ Anion Exchange Mini Column Protocol
1. Dilute sera in sample/running buffer;
2. Add HiQ resin to column and remove any air bubbles;
3. Add ultrafiltered (UF) water to aid in column packing;
4. Add sample/running buffer to equilibrate column;
5. Add diluted sera;
6. Collect all the flow-through fraction in EPPENDORF tubes until level is at resin;
7. Add sample/running buffer to wash column;
8. Add elution buffer and collect elution in EPPENDORF tubes.
Illustrative of the various buffering compositions useful in this technique are:
Sample/Running buffers: including but not limited to Bicine buffers of various molarities, pH's, NaCl content, BIS-TRIS buffers of various molarities, pH's, NaCl content, Diethanolamine of various molarities, pH's, NaCl content, Diethylamine of various molarities, pH's, NaCl content, Imidazole of various molarities, pH's, NaCl content, Tricine of various molarities, pH's, NaCl content, Triethanolamine of various molarities, pH's, NaCl content, TRIS of various molarities, pH's, NaCl content.
Elution Buffer: Acetic acid of various molarities, pH's, NaCl content, Citric acid of various molarities, pH's, NaCl content, HEPES of various molarities, pH's, NaCl content, MES of various molarities, pH's, NaCl content, MOPS of various molarities, pH's, NaCl content, PIPES of various molarities, pH's, NaCl content, Lactic acid of various molarities, pH's, NaCl content, Phosphate of various molarities, pH's, NaCl content, Tricine of various molarities, pH's, NaCl content.
Chelating SEPHAROSE Mini Column
1. Dilute Sera in Sample/Running buffer;
2. Add Chelating SEPHAROSE slurry to column and allow column to pack;
3. Add UF water to the column to aid in packing;
4. Add Charging Buffer once water is at the level of the resin surface;
5. Add UF water to wash through non bound metal ions once charge buffer washes through;
6. Add running buffer to equilibrate column for sample loading;
7. Add diluted serum sample;
8. Add running buffer to wash unbound protein;
9. Add elution buffer and collect elution fractions for analysis;
10. Acidify each elution fraction.
Illustrative of the various buffering compositions useful in this technique are: Sample/Running buffers including but not limited to Sodium Phosphate buffers at various molarities and pH's;
Charging buffers including but not limited to Nickel Chloride, Nickel Sulphate, Copper II Chloride, Zinc Chloride or any suitable metal ion solution;
Elution Buffers including but not limited to Sodium phosphate buffers at various molarities and pH's containing various molarities of EDTA and/or Imidazole.
HiS Cation Exchange Mini Column Protocol
1. Dilute sera in sample/running buffer;
2. Add HiS resin to column and remove any air bubbles;
3. Add ultrafiltered (UF) water to aid in column packing;
4. Add sample/running buffer to equilibrate column for sample loading;
5. Add diluted sera to column;
6. Collect all flow through fractions in EPPENDORF tubes until level is at resin;
7. Add sample/running buffer to wash column;
8. Add elution buffer and collect elution in EPPENDORF tubes.
Illustrative of the various buffering compositions useful in this technique are:
Sample/Running buffers: including but not limited to Bicine buffers of various molarities, pH's, NaCl content, BIS-TRIS buffers of various molarities, pH's, NaCl content, Diethanolamine of various molarities, pH's, NaCl content, Diethylamine of various molarities, pH's, NaCl content, Imidazole of various molarities, pH's, NaCl content, Tricine of various molarities, pH's, NaCl content, Triethanolamine of various molarities, pH's, NaCl content, TRIS of various molarities, pH's, NaCl content.
Elution Buffer: Acetic acid of various molarities, pH's, NaCl content, Citric acid of various molarities, pH's, NaCl content, HEPES of various molarities, pH's, NaCl content, MES of various molarities, pH's, NaCl content, MOPS of various molarities, pH's, NaCl content, PIPES of various molarities, pH's, NaCl content, Lactic acid of various molarities, pH's, NaCl content, Phosphate of various molarities, pH's, NaCl content, Tricine of various molarities, pH's, NaCl content.
The procedure for profiling serum samples is described below:
Following the preparatory steps illustrated above, various methods for use of the PROTEINCHIP arrays, available for purchase from Ciphergen Biosystems (Palo Alto, Calif.), may be practiced. Illustrative of one such method is as follows.
The first step involved treatment of each spot with 20 ml of a solution of 0.5 M EDTA for 5 minutes at room temperature in order to remove any contaminating divalent metal ions from the surface. This was followed by rinsing under a stream of ultra-filtered, deionized water to remove the EDTA. The rinsed surfaces were treated with 20 ml of 100 mM Nickel sulfate solution for 5 minutes at room temperature after which the surface was rinsed under a stream of ultra-filtered, deionized water and allowed to air dry.
Serum samples (2 ml) were applied to each spot (now “charged” with the metal-Nickel) and the PROTEINCHIP was returned to the plastic container in which it was supplied. A piece of moist KIMWIPE was placed at the bottom of the container to generate a humid atmosphere. The cap on the plastic tube was replaced and the chip allowed to incubate at room temperature for one hour. At the end of the incubation period, the chip was removed from the humid container and washed under a stream of ultra-filtered, deionized water and allowed to air dry. The chip surfaces (spots) were now treated with an energy-absorbing molecule that helps in the ionization of the proteins adhering to the spots for analysis by Mass Spectrometry. The energy-absorbing molecule in this case was sinapinic acid and a saturated solution prepared in 50% acetonitrile and 0.05% TFA was applied (1 ml) to each spot. The solution was allowed to air dry and the chip analyzed immediately using MS (SELDI).
Serum samples from patients suffering from a variety of disease states were analyzed using one or more protein chip surfaces, e.g. a gold chip or an IMAC nickel chip surface as described above and the profiles were analyzed to discern notable sequences which were deemed in some way evidentiary of at least one disease state.
In order to purify the disease specific marker and further characterize the sequence thereof, additional processing was performed.
For example, Serum (20 ml) was (diluted 5-fold with phosphate buffered saline) concentrated by centrifugation through a YM3 MICROCON spin filter (AMICON) for 20 min at 10,000 RPM at 4° C. in a Beckman MICROCENTRIFuge R model bench top centrifuge. The filtrate was discarded and the retained solution, which contained the two peptides of interest, was analyzed further by Tandem mass spectrometry to deduce their amino acid sequences. Tandem mass spectrometry was performed at the University of Manitoba's (Winnipeg, Manitoba, Canada) mass spectrometry laboratory using the procedures that are well known to practitioners of the art.
As a result of these procedures, the disease specific marker having a sequence identified as amino acid residues 2–25 of SEQ ID NO:1 was found. This marker is characterized as a Serum Albumin having a molecular weight of about 2753 daltons. The characteristic profile of the marker is set forth in FIG. 2 . As easily deduced from the data set forth in FIG. 1 , this marker is indicative of insulin resistance.
In accordance with various stated objectives of the invention, the skilled artisan, in possession of the specific disease specific marker as instantly disclosed, would readily carry out known techniques in order to raise purified biochemical materials, e.g. monoclonal and/or polyclonal antibodies, which are useful in the production of methods and devices useful as point-of-care rapid assay diagnostic or risk assessment devices as are known in the art.
The specific disease markers which are analyzed according to the method of the invention are released into the circulation and may be present in the blood or in any blood product, for example plasma, serum, cytolyzed blood, e.g. by treatment with hypotonic buffer or detergents and dilutions and preparations thereof, and other body fluids, e.g. cerebrospinal fluid (CSF), saliva, urine, lymph, and the like. The presence of each marker is determined using antibodies specific for each of the markers and detecting specific binding of each antibody to its respective marker. Any suitable direct or indirect assay method may be used to determine the level of each of the specific markers measured according to the invention. The assays may be competitive assays, sandwich assays, and the label may be selected from the group of well-known labels such as radioimmunoassay, fluorescent or chemiluminescence immunoassay, or immunoPCR technology. Extensive discussion of the known immunoassay techniques is not required here since these are known to those of skill in the art. See Takahashi et al. (Clin Chem 1999; 45(8): 1307) for S100B assay.
A monoclonal antibody specific against the disease marker sequence isolated by the present invention may be produced, for example, by the polyethylene glycol (PEG) mediated cell fusion method, in a manner well-known in the art.
Traditionally, monoclonal antibodies have been made according to fundamental principles laid down by Kohler and Milstein. Mice are immunized with antigens, with or without, adjuvants. The splenocytes are harvested from the spleen for fusion with immortalized hybridoma partners. These are seeded into microtitre plates where they can secrete antibodies into the supernatant that is used for cell culture. To select from the hybridomas that have been plated for the ones that produce antibodies of interest the hybridoma supernatants are usually tested for antibody binding to antigens in an ELISA (enzyme linked immunosorbent assay) assay. The idea is that the wells that contain the hybridoma of interest will contain antibodies that will bind most avidly to the test antigen, usually the immunizing antigen. These wells are then subcloned in limiting dilution fashion to produce monoclonal hybridomas. The selection for the clones of interest is repeated using an ELISA assay to test for antibody binding. Therefore, the principle that has been propagated is that in the production of monoclonal antibodies the hybridomas that produce the most avidly binding antibodies are the ones that are selected from among all the hybridomas that were initially produced. That is to say, the preferred antibody is the one with highest affinity for the antigen of interest.
There have been many modifications of this procedure such as using whole cells for immunization. In this method, instead of using purified antigens, entire cells are used for immunization. Another modification is the use of cellular ELISA for screening. In this method instead of using purified antigens as the target in the ELISA, fixed cells are used. In addition to ELISA tests, complement mediated cytotoxicity assays have also been used in the screening process. However, antibody-binding assays were used in conjunction with cytotoxicity tests. Thus, despite many modifications, the process of producing monoclonal antibodies relies on antibody binding to the test antigen as an endpoint.
The purified monoclonal antibody is utilized for immunochemical studies.
Polyclonal antibody production and purification utilizing one or more animal hosts in a manner well-known in the art can be performed by a skilled artisan.
Another objective of the present invention is to provide reagents for use in diagnostic assays for the detection of the particularly isolated disease specific marker sequences of the present invention.
In one mode of this embodiment, the marker sequences of the present invention may be used as antigens in immunoassays for the detection of those individuals suffering from the disease known to be evidenced by said marker sequence. Such assays may include but are not limited to: radioimmunoassay, enzyme-linked immunosorbent assay (ELISA), “sandwich” assays, precipitin reactions, gel diffusion immunodiffusion assay, agglutination assay, fluorescent immunoassays, protein A or G immunoassays and immunoelectrophoresis assays.
According to the present invention, monoclonal or polyclonal antibodies produced against the disease specific marker sequence of the instant invention are useful in an immunoassay on samples of blood or blood products such as serum, plasma or the like, spinal fluid or other body fluid, e.g. saliva, urine, lymph, and the like, to diagnose patients with the characteristic disease state linked to said marker sequence. The antibodies can be used in any type of immunoassay. This includes both the two-site sandwich assay and the single site immunoassay of the non-competitive type, as well as in traditional competitive binding assays.
Particularly preferred, for ease and simplicity of detection, and its quantitative nature, is the sandwich or double antibody assay of which a number of variations exist, all of which are contemplated by the present invention. For example, in a typical sandwich assay, unlabeled antibody is immobilized on a solid phase, e.g. microtiter plate, and the sample to be tested is added. After a certain period of incubation to allow formation of an antibody-antigen complex, a second antibody, labeled with a reporter molecule capable of inducing a detectable signal, is added and incubation is continued to allow sufficient time for binding with the antigen at a different site, resulting with a formation of a complex of antibody-antigen-labeled antibody. The presence of the antigen is determined by observation of a signal which may be quantitated by comparison with control samples containing known amounts of antigen.
All patents and publications mentioned in this specification are indicative of the levels of those skilled in the art to which the invention pertains. All patents and publications are herein incorporated by reference to the same extent as if each individual publication was specifically and individually indicated to be incorporated by reference.
It is to be understood that while a certain form of the invention is illustrated, it is not to be limited to the specific form or arrangement herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown and described in the specification and drawings/figures.
One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objectives and obtain the ends and advantages mentioned, as well as those inherent therein. The oligonucleotides, peptides, polypeptides, biologically related compounds, methods, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in the art are intended to be within the scope of the following claims.
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The instant invention involves the use of a combination of preparatory steps in conjunction with mass spectroscopy and time-of-flight detection procedures to maximize the diversity of biopolymers which are verifiable within a particular sample. The cohort of biopolymers verified within such a sample is then viewed with reference to their ability to evidence at least one particular disease state; thereby enabling a diagnostician to gain the ability to characterize either the presence or absence of at least one disease state relative to recognition of the presence and/or the absence of the biopolymer.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a Continuation-in-Part application of U.S. patent application Ser. No. 11/311,683, filed Dec. 19, 2005, now abandoned, the entire contents of which are incorporated herein by reference.
[0002] This application is based upon and claims the benefit of priority from prior Japanese Patent Applications No. 2005-176463, filed Jun. 16, 2005; and No. 2006-163337, filed Jun. 13, 2006, the entire contents of both of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention relates to an ink jet head driving method and driving apparatus for changing the capacity of a pressure chamber in which ink has been filled by a piezoelectric element in response to a print signal, and then, ejecting an ink droplet from a nozzle which communicates with the pressure chamber by the resulting pressure change, thereby printing a character or an image and the like on a printing medium.
[0005] 2. Description of the Related Art
[0006] A description will be given with a conventional print head with reference to FIG. 13 . In FIG. 13 , reference numeral 1 denotes an ink jet print head. This ink jet print head 1 is composed of: a plurality of pressure generating chambers in which ink is filled; a nozzle plate 11 provided at one end of each of these pressure generating chambers 17 ; a nozzle 15 for ejecting an ink droplet 19 formed in correspondence with each of the pressure generating chambers 17 on this nozzle plate 11 ; a piezoelectric actuator 14 provided in correspondence with each of the pressure generating chambers 17 to apply vibration to the pressure generating chambers 17 via a vibration plate 13 , and then, eject ink from the nozzle 15 by a capacity change inside of the pressure generating chambers 17 due to the applying of this vibration; and an ink chamber 18 or the like provided in communication with each of the pressure generating chambers 17 , the ink chamber being adopted to supply the ink to the pressure generating chamber 17 via an ink supply passage 16 from an ink tank not shown. With such a construction, when the piezoelectric actuator 14 is driven, a pressure vibration is applied to the pressure generating chamber 17 , the capacity inside of the pressure generating chamber 17 is changed by this pressure vibration, and the ink droplet 19 is ejected from the nozzle 15 . This ink droplet 19 is deposited onto a printing medium such as printing sheet of paper, and a dot is formed on the printing medium. By continuous forming of such dots, a predetermined character or image and the like based on image data is printed.
[0007] In general, in an ink jet printer, in the case where high quality printing is carried out, there is used an area gradation system such as a dither system, for forming one pixel by producing a matrix with a plurality of dots without changing the size of an ink droplet, and expressing gradation based on a difference in the number of dots in pixel. In this case, resolution must be sacrificed in order to allocate a certain number of gradations. In addition, there is provided a density gradation system for changing the density of one dot by varying the size of an ink droplet. In this case, although resolution is not sacrificed, there is a problem that a technique for controlling the size of an ink droplet is difficult.
[0008] Further, there is a so called multi-drop driving system for carrying out density gradation by varying the number of ink droplets to be printed with respect to one dot without changing the size of an ink droplet. In this case, resolution is not sacrificed, and there is no need to control the size of an ink droplet, thus making it possible to comparatively easily carry out this driving system.
[0009] A method for driving an ink jet head in a multi-drop system is also known (refer to Jpn. Pat. No. 2931817). Further, an ink jet type printing apparatus is known as reducing a cycle of a drive signal so as to speed up printing (refer to Jpn. Pat. Appln. KOKAI Publication No. 2001-146003). Furthermore, an ink jet printing apparatus for, when a repetition time for ejecting ink droplets variously changes, efficiently ejecting a predetermined amount of ink from an ejecting port is also known (refer to Jpn. Pat. Appln. KOKAI Publication No. 2000-177127).
[0010] In this multi-drop driving system, in the case where a plurality of ink droplets are continuously ejected, an ejection speed of second and subsequent droplets can be increased more significantly than that in a first ink droplet by using residual pressure vibration of the droplets just ejected before.
[0011] On the other hand, in general, the first ink droplet becomes lower in ejection speed than the second and subsequent ink droplets because a pressure vibration is applied in a state in which meniscus is stationary. Thus, there is a problem that ejection becomes unstable or print quality is degraded because of a small amount of ejection.
[0012] In order to avoid such a problem, there is an option for increasing an applied voltage, and then, increasing a pressure vibration entirely applied to a pressure chamber, thereby increasing a first-drop ejection speed. However, there is a problem that power consumption is increased, and a heating rate is increased by increasing a voltage. In addition, there is a problem that ejection becomes unstable because the ejection speed of the second and subsequent droplets becomes too high or print quality is degraded due to displacement in ink deposition between gradations, resulting from the increased difference in ejection speed of each droplet.
[0013] In addition, another method for avoiding a problem that an amount of ejection is small and print quality is degraded includes increasing a first-drop ejection speed by applying a fine pressure vibration to an extent that a ink droplet is not ejected before a first-drop drive pulse (hereinafter, such a drive pulse is referred to as a boost pulse). This boost pulse is redundantly applied, whereby a time of an entire drive cycle is extended, and therefore, such an extended time is disadvantageous for high speed printing.
BRIEF SUMMARY OF THE INVENTION
[0014] It is an object of the present invention to provide an ink jet head driving method and driving apparatus which is capable of improving unstable ejection or degraded print quality while the uniformed ejection speed and ejection quantity of each drop are achieved by increasing the ejection speed of ink drops from a first drop to subsequent several drops in multi-drop driving, and which is capable of achieving high speed printing by applying a boost pulse only in the case where the number of ink droplets is small and by disabling applying of the boost pulse in the case where the number of ink droplets is large.
[0015] According to one aspect of the present invention, there is provided an ink jet head driving method for applying a drive pulse to an actuator to change capacities of a plurality of pressure chambers in which ink has been filled, ejecting an ink droplet from a nozzle formed in communication with the pressure chamber to print onto a printing medium, and moreover, controlling the number of ink droplets ejected according to the number of drive pulses to carry out gradation printing, the method comprising: making control so as to, in the case where the number of the ink droplets is smaller than a predetermined number N (where 1<N≦M and M is the number of ink droplets in maximum gradation), apply a boost pulse to amplify a pressure vibration of the pressure chamber prior to a drive pulse for ejecting a first ink droplet; and in the case where the number of ink droplets is equal to or greater than the predetermined number N, disable applying of the boost pulse.
[0016] According to another aspect of the present invention, there is provided an ink jet head driving apparatus comprising: a plurality of pressure chambers in which ink has been filled; an ink jet head configured to change the capacity of each of the pressure chambers by applying a drive pulse to an actuator, eject an ink droplet from a nozzle formed in communication with the pressure chamber to print onto a printing medium, and control the number of ink droplets ejected according to the number of drive pulses so as to carry out gradation printing; and drive signal generating section configured, in the case where the number of the ink droplets is smaller than a predetermined number N (where 1<N≦M and M is the number of ink droplets in maximum gradation), to apply a boost pulse to amplify a pressure vibration of the pressure chamber prior to a drive pulse for ejecting a first ink droplet; and in the case where the number of ink droplets is equal to or greater than the predetermined number N, to disable applying of the boost pulse.
[0017] Additional objects and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out hereinafter.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0018] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiment of the invention, and together with the general description given above and the detailed description of the embodiment given below, serve to explain the principles of the invention.
[0019] FIG. 1 is a view showing a construction of essential portions in an ink jet printing apparatus according to an embodiment of the present invention;
[0020] FIG. 2 is a sectional view taken along the line A-A of FIG. 1 ;
[0021] FIG. 3 is a view showing a detailed construction of drive signal generating means shown in FIG. 1 ;
[0022] FIG. 4 is a waveform chart showing an example of a drive pulse generated by the drive signal generating means according to the embodiment;
[0023] FIG. 5 is a waveform chart showing an example of a boost pulse and a drive pulse generated by the drive signal generating means according to the embodiment;
[0024] FIG. 6 is a view showing a part of a circuit which configures the drive signal generating means according to the embodiment;
[0025] FIG. 7 is a view showing the drive pulse and an ink pressure change in a pressure chamber according to the embodiment;
[0026] FIG. 8 is a view showing the boost pulse, drive pulse, and ink pressure change in the pressure chamber according to the embodiment;
[0027] FIG. 9 is a graph depicting a relationship between the number of drops and an ejection speed in the case where a boost pulse is applied and in the case where no boost pulse is applied;
[0028] FIG. 10 is a graph depicting a relationship between the number of drops and an ejection speed in the embodiment;
[0029] FIG. 11 is a waveform chart of a drive pulse in a conventional driving method;
[0030] FIG. 12A is a waveform chart of a drive pulse in a driving method according to the embodiment;
[0031] FIG. 12B is a waveform chart of a drive pulse in the driving method according to the embodiment; and
[0032] FIG. 13 is a schematic cross-sectional view of an ink jet driving head according to the conventional technique.
DETAILED DESCRIPTION OF THE INVENTION
[0033] Hereinafter, an embodiment of the present invention will be described with reference to the accompanying drawings. FIGS. 1 and 2 are views each showing a construction of essential portions in an ink jet printing apparatus. FIG. 2 is a sectional view taken along the line A-A of FIG. 1 .
[0034] In FIGS. 1 and 2 , reference numeral 1 denotes an ink jet head; and reference numeral 2 denotes drive signal generating means. The ink jet head 1 is formed while a plurality of pressure chambers 31 housing ink is partitioned by a bulkhead 32 , and nozzles 33 for ejecting ink droplets are provided in the pressure chamber 31 , respectively. A bottom face of each of the pressure chambers 31 is formed of a vibration plate 34 , and a plurality of piezoelectric members 35 is fixed in correspondence with each of the pressure chambers at the lower face side of the vibration plate 34 . The vibration plate 34 and the piezoelectric member 35 constitute an actuator ACT, and the piezoelectric member is electrically connected to an output terminal of the drive signal generating means 2 .
[0035] A common pressure chamber 36 communicating with each of the pressure chambers 31 is formed at the ink jet head 1 . To this common pressure chamber 36 , ink is injected from ink supply means (not shown) via an ink supply port 37 so as to fill the ink in the common pressure chamber 36 , each pressure chamber 31 , and nozzle 33 . When the ink is filled in the pressure chamber 31 and the nozzle 33 , whereby ink meniscus is formed in the nozzle 33 .
[0036] Now, a detailed construction of the drive signal generating means 2 will be described with reference to FIG. 3 . In FIG. 3 , reference numeral 41 denotes a drive pulse number generating section by which the number “n” of drive pulses is generated. This drive pulse number generating section generates the number of drive pulses based on gradation data on print to be input from a host computer 50 via an interface 51 . The number “n” of drive pulses corresponds to the number of ink droplets.
[0037] The number “n” of drive pulses outputted from this drive pulse number generating section 41 is sent to a judging section 42 , and, at this judging section 42 , it is judged whether or not the number “n” of drive pulses is a predetermined number N or more (where 1<N≦M and M is an ink droplet number of a maximum gradation). Here, when the ink droplet number M of the maximum gradation is set at 7, and the predetermined number N is set at 4, for example. A value of the predetermined number N stored in advance in the judging section 42 may be in the range of 1<N≦M, and can be externally changed at the operating panel of an ink jet printing apparatus or a host computer, for example at the host computer 50 , via the interface 51 .
[0038] A judgment result obtained by this judging section 42 is output to a drive sequence generating section 43 . Here, the number “n” of drive pulses generated by the drive pulse number generating section 41 is also input to the drive pulse sequence generating section 43 .
[0039] The drive sequence generating section 43 controls waveform selection at a waveform selecting section 44 . To this waveform selecting section 44 , there are input: a drive pulse Pd output from a drive pulse waveform generating section 45 (refer to FIG. 4 ); and a boost pulse Pb output from a boost pulse waveform generating section 46 (refer to FIG. 5 ), respectively. A waveform output section 47 is composed of the drive sequence generating section 43 and the waveform selecting section 44 .
[0040] In the drive sequence generating section 43 , in the case where the number “n” of drive pulses is smaller than a predetermined number N (for example, N=4), namely, the number 3 or less, the waveform output section 47 controls the waveform selecting section 44 so as to select and output the drive pulse Pd “n” times after the boost pulse Pb is selected once.
[0041] On the other hand, in the case where the number “n” of drive pulses is equal to or greater than a predetermined number N (for example, N=4), namely, the number is 4 or more, the drive sequence generating section 43 controls the waveform selecting section 44 so as to select and output the drive pulse Pd “n” times.
[0042] The waveform output from this waveform selector 44 is output to drive output means 48 described in detail with reference to FIG. 6 . Then, an output 1 and an output 2 of this drive output means 48 are connected to an actuator ACT.
[0043] When the boost pulse Pb from the drive signal generating means 2 is applied to the piezoelectric member 35 of the actuator ACT, meniscus is vibrated to an extent that no ink droplet is ejected.
[0044] When the drive pulse Pd from the drive signal generating means 2 is applied to the piezoelectric member 35 , this piezoelectric member 35 displaces the vibration plate 34 and changes the capacity of the pressure chamber 31 , whereby a pressure wave is generated in the pressure chamber 31 , and an ink droplet is ejected from the nozzle 33 .
[0045] Now, referring to FIG. 4 , a description will be given with respect to a waveform chart of the drive pulse Pd generated from the drive signal generating means 2 . This drive pulse Pd consists of: an expansion pulse p 1 for expanding the capacity of the pressure chamber 31 ; a contraction pulse p 2 for contracting the capacity of the pressure chamber 31 ; and a pause time t 3 . The expansion pulse p 1 is produced as a negatively polar rectangular wave having a voltage amplitude of Vaa at a power conducting time of t 1 and the contraction pulse p 2 is produced as a positively polar rectangular wave having a voltage amplitude of Vaa which is equal to the expansion pulse p 1 when the power conducting time is t 2 .
[0046] In a multi-drop driving system, this drive pulse Pd is continuously generated by the number of ink droplets to be ejected. In the present embodiment, all the drive pulses of each drop are formed in the same shape without being limited thereto.
[0047] Here, when a pressure propagation time is defined as Ta when a pressure wave in ink propagates the inside of the pressure chamber from a common pressure chamber at a rear end to a nozzle tip end, the power-conducting time t 1 of the expansion pulse p 1 is set in the proximity of Ta; and the power conducting time t 2 of the contraction pulse p 2 is set in the range of 1.5 Ta to 2 Ta. In addition, the pause time t 3 is set in the range of 0 to Ta.
[0048] FIG. 6 shows a part of a circuit of the drive signal generating means 2 shown in FIG. 1 . There is employed a system for producing the expansion pulse p 1 and the contraction pulse p 2 by changing polarity at a single drive power source. As shown in FIG. 6 , FET 1 and FET 2 serial circuits are connected between a Vaa power supply terminal and a grounding terminal. An output 1 from a connection point between these FET 1 and FET 2 is connected to one electrode terminal of the piezoelectric member 35 . FET 3 and FET 4 serial circuits are connected between the Vaa power supply terminal and a grounding terminal, and an output 2 from a connection point between these FET 3 and FET 4 is connected to the other electrode terminal of the piezoelectric member 35 . In the case where the expansion pulse p 1 shown in FIG. 4 is applied, FET 1 is turned on, FET 2 is turned off, FET 3 is turned off, and FET 4 is turned on. In the case where the contraction pulse 2 is applied, FET 1 is turned off, FET 2 is turned on, FET 3 is turned on, and FET 4 is turned off, thereby changing the polarity of a voltage applied to the piezoelectric member.
[0049] Now, referring to FIG. 7 , a description will be given with respect to a power conducting waveform “q” applied to the pressure chamber 31 in the case where the drive pulse Pd has been applied and a pressure vibration waveform “r” generated in the pressure chamber 31 . In the figure, the power conducting time t 1 of the expansion pulse p 1 is set to time Ta required for the pressure wave generated in the pressure chamber 31 to propagate from one end to the other end of the pressure chamber 31 ; the power conducting time t 2 of the contraction pulse p 2 is set to 2 Ta which is twice the time Ta; and the pause time t 3 is also set to Ta.
[0050] First, when a voltage −Vaa is applied between electrodes of the piezoelectric member 35 , the piezoelectric member 35 is deformed so as to rapidly increase the capacity of the pressure chamber 31 so that a negative pressure is momentarily generated in the pressure chamber 31 . This pressure is inverted to a positive pressure when a pressure propagation time Ta has elapsed.
[0051] Next, when a voltage +Vaa having opposite polarity is applied between electrodes of the piezoelectric member 35 , the piezoelectric member 35 is deformed so as to rapidly contract the capacity of the pressure chamber 31 from the expanded state, whereby a positive pressure is momentarily generated in the pressure chamber 31 . The pressure wave generated by this pressure coincides with a first generated pressure wave in phase so that the amplitude of the pressure wave is rapidly increased. At this time, an ink droplet is ejected from a nozzle.
[0052] Then, when the time 2 Ta which is twice the pressure propagation time has elapsed, the pressure in the pressure chamber 31 changes in a direction from positive to negative, and then, positive. At this time, the voltage between the electrodes of the piezoelectric member 35 is reset to zero, whereby the contracted capacity of the pressure chamber reverts to its original state, and the pressure in the pressure chamber 31 momentarily decreases. Thus, the amplitude of the pressure wave is weakened, and then, the residual pressure vibration decreases.
[0053] Further, when the pause time Ta has elapsed the pressure vibration during this period changes in a direction from positive to negative. At this time, when the second-drop expansion pulse p 1 is continuously applied, the capacity of the pressure chamber 31 is rapidly increased again, and a negative pressure is momentarily applied again in the pressure chamber 31 . At this time, the next pressure vibration is applied in a state in which the residual pressure vibration of the first drop still remains. Thus, the pressure in the pressure chamber 31 is obtained as a negative pressure which is greater than the case of the first drop.
[0054] Therefore, when the next pressure propagation time Ta has elapsed, the inverted positive pressure also increases. Further, the contraction pulse p 2 is applied, whereby a pressure required for the second-drop ejection becomes greater than that required for the first-drop. Here, the pause time t 3 is set to a proper time, whereby a value of the residual vibration can be changed. An ejection speed can be increased or decreased by increasing the pressures required for the second-drop ejection more significantly than the first-drop.
[0055] In general, a drive voltage can be reduced more significantly, enabling efficient driving by making control such that the second-drop pressure is increased more significantly than the first-drop pressure.
[0056] Now, referring to FIG. 5 , a description will be given with respect to a waveform obtained by adding the boost pulse Pb prior to the first-drop drive pulse Pd.
[0057] The boost pulse Pb consists of a contraction pulse Bp for contracting the capacity of the pressure chamber 31 and a pause time Bt 2 , and the contraction pulse Bp is produced as a rectangular wave having a voltage amplitude of +Vaa when a power conducting time is Bt 1 . The succeeding first drop and subsequent pulses Pd are identical to those shown in FIG. 4 .
[0058] In addition, when the pressure propagation time is set to Ta, the power conducting time Bt 1 of the contraction pulse Bp is set to 2 Ta, and the pause time Bt 2 is set in the order of 2 Ta.
[0059] In the present embodiment, although the form of the boost pulse Pb has the contraction pulse Bp and the pause time Bt 2 , the contraction pulse may be an expansion pulse and the pause time may be eliminated without being limited thereto.
[0060] Now, referring to FIG. 8 , a description will be given with respect to a power conducting waveform “q” in the case where the boost pulse Pb shown in FIG. 5 has been applied and a pressure vibration waveform “r” generated in the pressure chamber 31 . In the figure, the power conducting time Bt 1 of the contraction pulse Bp of the boost pulse Pb is set to 2 Ta which is twice the pressure propagation time; the pause time Bt 2 is also set to 2 Ta; and the power conducting time of the drive pulse Pd is identical t 1 , t 2 , and t 3 to that shown in FIG. 7 .
[0061] When a voltage +Vaa is applied between the electrodes of the piezoelectric member 35 by means of the boost pulse Pb, the piezoelectric member 35 is deformed so as to rapidly contract the capacity of the pressure chamber 31 . Thus, a positive pressure is momentarily generated in the pressure chamber. This pressure changes in a direction from positive to negative, and then, to positive while a time 2 Ta has elapsed. Next, the voltage between the electrodes of the piezoelectric member 35 is reset to zero, whereby the capacity of the pressure chamber 31 reverts to its original state rapidly. Thus, the pressure in the pressure chamber is momentarily inverted in phase from positive to negative.
[0062] Then, while the pause time 2 Ta has elapsed, the pressure changes in a direction from negative to positive, and then, to negative in turn. When a voltage −Vaa is applied between the electrodes of the piezoelectric member 35 by means of the first-drop expansion pulse p 1 , the piezoelectric member 35 is deformed so as to rapidly increase the capacity of the pressure chamber 31 . Thus, a negative pressure is momentarily applied to the inside of the pressure chamber 31 .
[0063] At this time, the residual pressure vibration caused by the boost pulse Pb still remains in the pressure chamber 31 , and thus, greater pressure amplitude is produced as compared with a case in which no boost pulse Pb is applied. Therefore, when next pressure propagation time Ta has elapsed, the inverted positive pressure also increases. Further, a voltage +Vaa is applied between the electrodes of the piezoelectric member 35 by means of the contraction pulse p 2 , and the piezoelectric member 35 is deformed so as to rapidly contract the capacity of the pressure chamber 31 from its expanded state, whereby a positive pressure is momentarily applied in the pressure chamber 31 . Further, the pressure amplitude increases more significantly than a case in which no boost pulse Pb is applied. The boost pulse Pb is thus applied, whereby a pressure required for the first-drop ejection can be increased by the residual pressure vibration.
[0064] FIG. 9 shows advantageous effect of the boost pulse Pb. This figure also shows a relationship between the number of drops and ejection speed in the case where the boost pulse Pb is applied or not prior to the first-drop drive pulse Pd in a 7-drop, 8-gradation multi-drop driving system.
[0065] As shown in FIG. 9 , in the case where no boost pulse Pb is applied, the ejection speed is lowered in the first one to three drops for which the ink droplet number N is smaller than 4. However, the ejection speed can be increased by applying the boost pulse Pb. In addition, there is no great difference in ejection speed when the number of ink droplets is 4 regardless of whether the boost pulse Pb is applied or not. In addition, the ejection speed is almost the same when the number of ink droplets is 5 to 7 regardless of whether the boost pulse Pb is applied or not.
[0066] In this manner, although the boost pulse Pb has an affect on the first several drops, it is found that the boost pulse Pb hardly has an affect on 4 or more drops since the predetermined number N is 4. As described above, with respect to the predetermined number N, it is found that an ink ejection speed from the nozzle is measured in both cases in which the boost pulse is applied and not applied for each number of ink droplets, and then, the number of ink droplets in which a difference therebetween is substantially eliminated may be set as N. However, applying the boost pulse Pb leads to an increase of power consumption.
[0067] From this fact, there can be attained an advantageous effect that, when the predetermined number is set at N=4, an increase of power consumption can be reduced to its minimum by applying the boost pulse Pb to only one to three drops from which a sufficient advantageous effect can be attained and by disabling applying of the boost pulse to four or more drops from which the advantageous effect of the boost pulse Pb cannot be attained so much.
[0068] Here, although the number of drops for which the boost pulse Pb hardly has an effect has been set at a predetermined number N=4, such a value of N is different depending on the shapes of the pressure generating chamber and nozzles, physical property of ink, the shape of a drive pulse and the like. Thus, on a head by head basis, as shown in FIG. 9 , an advantageous effect of the boost pulse Pb may be verified by means of measurement, and the number of ink droplets for which a difference in ejection speed is substantially eliminated may be set at a predetermined number N.
[0069] In the meantime, in the case where the number “n” of drive pulses is smaller than a predetermined number N(=4), namely, the number is 3 or less, the drive signal generating means 2 selects the boost pulse Pb one time, and then, outputs the drive pulse Pd to the actuator ACT by “n” times.
[0070] On the other hand, in the case where the number “n” of drive pulses is equal to or greater than a predetermined number N(=4), the drive signal generating means 2 selects and outputs the drive pulse Pd to the actuator ACT by “n” times.
[0071] In one to three drops in which the number of ink droplets is smaller than the predetermined number N= 4 , the boost pulse Pb is applied prior to the drive pulse Pd. In four to seventh drops in which the number of ink droplets is equal to or greater than the predetermined number N=4, a relationship between the number of drops and an ejection speed in the case where no boost pulse Pb is applied is obtained as shown in FIG. 10 . This result is almost identical to that in the case where the boost pulse is applied as shown in FIG. 9 .
[0072] FIG. 11 shows a conventional drive waveform in which, even in the case where a maximum number of ink droplets is 7 drops, the boost pulse Pb is applied prior to the drive pulse Pd of the first drop. In this case, the drive cycle is a time obtained by adding a pause time for attenuating the boost pulse Pb, a drive pulse Pd for 7 drops, and the residual vibration.
[0073] FIGS. 12A and 12B shows a drive waveform in the case where, when the number of ink droplets is smaller than a predetermined number N=4 according to the present embodiment, the boost pulse is applied, and when the number of ink droplets is equal to or greater than the predetermined number N=4, no boost pulse Pb is applied.
[0074] FIG. 12A shows a drive waveform in three drops when the number of ink droplets is smaller than the predetermined number N=4. In this case, the boost pulse Pb is applied. In contrast, FIG. 12B shows a drive waveform in seven drops that are a maximum number of ink droplets. In this case, no boost pulse Pb is applied, and thus, the drive cycle is obtained as a time obtained by adding the drive pulse Pd and a pause time for seven drops. The drive cycle time can be reduced by the absence of the boost pulse Pb in comparison with the conventional drive waveform shown in FIG. 11 .
[0075] The drive cycle of the ink jet head is limited to a drive cycle when the number of ink droplets in maximum gradation is obtained. Thus, in improvement of the ejection speed using the boost pulse Pb, the drive cycle time can be shortened compared with the conventional case, enabling high speed printing.
[0076] Although, in the present embodiment, a description has been given with respect to a case in which the predetermined number N is “4”, the predetermined number N may be “5” or may be “7” as indicated by the dotted waveform in FIG. 12A . The dotted waveform shows a case in which driving has been carried out when N=7 and the number of drive pulses Pd is n=6. In the case where N=5 to 7, even if power consumption somewhat increases, there is an advantageous effect that a difference in ejection speed in the first drop to the seventh drop can be further reduced and unstable ejection or degraded print quality can be further improved. Even if the boost pulse Pb is added when N=7, the drive cycle time obtained by adding the boost pulse Pb, the drive pulse Pd for six drops, and a pause time for the residual vibration to attenuate is almost equal to the drive cycle time obtained by adding the drive pulse Pd for seven drops and the pause time, as shown in FIG. 12B . Thus, there is no problem in promoting high speed printing.
[0077] Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and representative embodiment shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents.
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In an ink jet head driving method for applying a drive pulse to an actuator ACT to change capacities of a plurality of pressure chambers in which ink has been filled, ejecting an ink droplet from a nozzle formed in communication with the pressure chamber to print onto a printing medium, and moreover, controlling the number of ink droplets ejected according to the number of drive pulses to carry out gradation printing, a control is made such that, in the case where the number of ink droplets is small, a boost pulse Pb for amplifying a pressure vibration of the pressure chamber is applied prior to a drive pulse for ejecting a first ink droplet, and in the case where the number of ink droplets is large, applying of the boost pulse Pb is disabled.
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BACKGROUND OF THE INVENTION
The present invention relates to a detachable chain and method of producing the same.
Referring to FIG. 1, a typical detachable chain is generally designated at a reference numeral 1. The detachable chain 1 is provided at its one end with a pin and at its other end with a barrel 3. The pin 2 and the barrel 3 are connected to each other through side links 4. The barrel 3 is provided with a hook 5 which extends transversely of the barrel 3. A notch 6 is provided in one end of the pin 2. The pin 2 is detachably inserted into the hook 5 from the side of the notch 6. The pin, however, does not come off the hook 5 during the operation of the detachable chain.
The chain is simple both in construction and handling and, therefore, is broadly used as a power transmitting chain or conveyor chain with fittings for conveying various articles.
The conventional detachable chain is usually made of black heart malleable cast iron so that the strength thereof is often insufficient. Therefore, this conventional detachable chain is only able to bear a light load when used as a conveyor chain and can only run at low speeds when used as a power transmitting chain.
SUMMARY OF THE INVENTION
Accordingly, an object of the invention is to provide a detachable chain having an improved rupture load and a reduced weight, as well as improved service life, as compared with the conventional detachable chain made of black heart malleable cast iron.
Another object is to provide a method of producing such a detachable chain.
To this end, according to an aspect of the invention, there is provided a detachable chain having chain links of an integrated construction produced by casting, characterized in that the link of said chain is made of a nodular graphite cast iron having a matrix constituted by a mixture structure of bainite and austenite.
According to another aspect of the invention, there is provided a method of producing detachable chain having chain links of an integrated construction, comprising the steps of: forming the link of said detachable chain by casting from nodular graphite cast iron; heating said chain link at 830° to 900° C. for 0.5 to 3 hours; and subjecting the same to an austemper treatment which comprises quenching the chain link down to 200° to 400° C. and holding the same for a period not shorter than 0.5 hour after holding the chain link at 830°-900° C. for 0.5-3 hours; whereby a matrix having a mixture structure of bainite and austenite is obtained.
The above and other objects, features and advantages of the invention will become clear from the following description of the preferred embodiment when the same is read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a detachable chain embodying the invention;
FIG. 2 is a photograph of a microstructure of the link of the chain of FIG. 1;
FIG. 3 is a graph showing the result of a wear test;
FIG. 4 is a plan view of another detachable chain for water treatment, embodying the invention;
FIG. 5 is a side elevationa view of the chain of FIG. 4;
FIG. 6 is a sectional view taken along the line A--A of FIG. 4;
FIG. 7 is a photograph of a microstructure of the link thereof; and
FIG. 8 is a graph showing the result of a wear test.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A description will be made hereinunder as to an embodiment of the method of the invention for producing a detachable chain.
The material composition of the link of the detachable chain embodying the invention is the same as nodular graphite cast iron which is known per se, so that detailed description in this connection will be omitted. Roughly speaking, however, the material has a composition containing 3.5 to 3.7 wt % of C, 2.0 to 2.3% of Si, 0.3 to 0.4 wt % of Mn, not more than 0.3 wt % of P, not more than 0.01 wt % of S, and 0.03 to 0.05 wt % of Mg.
According to the method of the invention, a chain link made of a nodular graphite cast iron having an ordinary composition is subjected to austenitizing treatment comprises holding the detachable chain link at 830° to 900° C. for 0.5 to 3 hours, subjecting the detachable chain link to a bainite transformation treatment which comprises quenching the detachable chain link by immersion in a salt bath or fluidized bed of 200° to 400° C. for a period of time not shorter than 30 minutes, and cooling the detachable chain link to room temperature.
An explanation will be made hereinunder as to the reasons for the limitation of the austemper treatment. The above-mentioned austenitizing conditions comprises heating at 830° to 900° C. for 0.5 to 3 hours. A heating at a temperature below 830° C. requires an impractically long period of time for austenitizing particularly when having a large wall thickness. A heating at a temperature above 900° C. undesirably makes the austenite crystal grains coarse, resulting in reduced strength.
The heating period of time may vary in dependence on the wall thickness of the chain link. The minimum time required for austenitizing, however, is 0.5 hour when the wall thickness is small and 3 hours is enough even when the wall thickness is large.
On the other hand, the above-mentioned isothermal transformation treatment condition comprises heating at 200° to 400° C. for a period of time not shorter than 0.5 hour. A heating at a temperature below 200° C. undesirably increases hardness and reduces the toughness, while a heating at a temperature above 400° C. does not bring about the increase in wear resisting property while resulting in a rise in costs due to wasteful use of heating energy.
The invention will be more fully understood from the following description of Examples.
EXAMPLE 1
(1) Chemical Composition
A detachable chain link of the integrated construction type shown in FIG. 1 was produced from a material consisting of the constituents shown in the following Table 1, iron, and incidental impurities. The pouring temperature was between 1,400° and 1,420° C.
TABLE 1______________________________________(wt. %)C Si Mn P S Cu Mo Mg______________________________________3.68 2.13 0.43 0.025 0.012 0.51 0.32 0.042______________________________________
(2) Heat Treatment
The detachable chain link thus produced was held at 870° C. for 2 hours, and was quenched down to 380° C. and held at this temperature for 1 hour, followed by air cooling.
(3) Mechanical Properties
The mechanical properties of the detachable chain link obtained after the series of treatment mentioned above are shown in the following Table 2.
TABLE 2______________________________________Tensile Proofstrength stress Elongation Hardness(kgf/mm.sup.2) (kgf/mm.sup.2) (%) HV______________________________________99.1 74.5 10.7 27.3______________________________________
(4) Structure
FIG. 2 is a photograph of microstructure (magnification 400) of the detachable chain link finished in accordance with the production method of the invention. It will be seen that a good matrix having a bainite-austenite mixture structure has been attained.
(5) Rupture Strength Test
Three pieces of the chain link in accordance with the invention were connected in series to form a chain which was then subjected to a rupture strength test. The result of the test is shown in the following Table 3.
TABLE 3______________________________________Sample Rupture Mean ruptureNo. load (kg) load (kg)______________________________________1 11,1702 10,6603 11,2404 10,8705 10,690 10,8906 10,6807 10,7308 10,8209 10,78010 11,260______________________________________
It was confirmed that a conventinal detachable chain (#124) made of black heart malleable cast iron (FCMB32) and having the same shape as the chain of the invention shows a mean rupture strength on the order of 5,400 kg. Thus, the chain of the invention has a strength which is twice or more that shown by the conventional chain.
(6) Wear Test
A test was conducted to compare the chain of the invention with the conventional chain composed of chain links made from black heart malleable cast iron, as to the amount of wear of the barrel during continuous operation of the chain. FIG. 3 shows the result of this test. It will be seen from this Figure that the product of the invention has a superior wear resistance.
EXAMPLE 2
An explanation will be made hereinunder as to an example of the chain composed of the detachable chain link of the invention applied to water treatment, particularly to a sedimentation basin for a sewage treating system.
(1) Chemical Composition
Chains as shown in FIGS. 4, 5 and 6 were produced from a material consisting of constituents shown in Table 4, iron and incidental inpurities. The pouring temperature of a melt was 1,400° to 1,420° C.
TABLE 4______________________________________(wt. %)C Si Mn P S Cu Mo Mg______________________________________3.66 2.14 0.42 0.028 0.012 0.52 0.30 0.042______________________________________
(2) Heat Treatment
The thus obtained chain link made of nodular graphite cast iron was held at 870° C. for 2 hours, and was quenched down to 380° C. The chain was then held at this temperature for one hour followed by air cooling.
(3) Mechanical Properties
The mechanical properties of the heat-treated chain link is shown in Table 5 below.
TABLE 5______________________________________Tensile Proofstrength stress Elongation Hardness(kgf/mm.sup.2) (kgf/mm.sup.2) (%) (HV)______________________________________99.6 74.7 10.5 274______________________________________
(4) Structure
FIG. 7 shows the metallurgical microscopic photo (magnification 400) of the structure of this chain link. From this Figure, it will be seen that chain link of the invention has a good matrix having a mixture structure of bainite and austenite.
(5) Rupture Strength
Three pieces of chain links of the invention were connected to form a chain which was subjected to a rupture strength test. The result of this test is shown in Table 6.
TABLE 6______________________________________ RuptureSample strength Mean ruptureNo. (kg) strength______________________________________1 11,3702 10,5703 11,8304 10,4405 11,290 10,9026 10,5507 10,4908 11,3509 10,48010 10,650______________________________________
(6) Wear Test
A comparison was made between the detachable chain link of the invention and a conventional chain made of pearlite malleable cast iron. As will be seen from FIG. 8 which shows the result of the wear test, the chain composed of the detachable chain link of the invention exhibits a superior wear resistance as compared with the conventional articles.
(7) Weight
A chain composed of 20 pieces of chain link of the invention weighs 23.6 kg, whereas a conventional chain made of pearlite malleable cast iron weighs 28.8 kg. This means that the weight of the chain of the invention can be reduced by about 18% for an equal strength.
(8) Other Properties
Other properties of the chain composed of the chain links in accordance with the invention are shown in Table 7 below, in comparison with the properties of the conventionally used chain composed of chain links made of pearlite malleable cast iron (FCM P50).
TABLE 7______________________________________ Conventional Chain ofItems chain Invention______________________________________Material FCMP 50 NMS-100BAsymbolTensile strength 50 kg/mm.sup.2 or 100 kg/mm.sup.2 or higher higherProof stress 31 kg/mm.sup.2 or 65 kg/mm.sup.2 or higher higherElongation 4% or greater 10% or greaterHardness HV 175 to 241 HV 301 to 339Barrel hardness HV 425 or HV 301 to 339 greaterChain pitch 152.4 mm 152.4 mmBarrel diameter 38.1 mm 35 mmDiameter of pin 19 mm 16 mmBarrel wall 9.05 mm 9 mmthicknessSprocket 29 mm 27 mmteeth widthMean rupture 19,000 kg 10,000 kgstrengthWeight 1.44 kg/l 0.78 kg/lService life approx. 10 years or 8 to 10 years longer______________________________________
As will be seen from Table 7, the chain composed of the detachable chain link of the invention exhibits a mean rupture strength of 10,000 kg, which is about a half that (19,000 kg) of the conventional chain. However, the slurry scraping capacity of the chain, when used in a sedimentation basin of a sewage treatment system, is not reduced substantially because the tensile strength is increased to a double while the weight is reduced to a half. The work for connecting and disconnecting the chain links for assembly and disassembly of the chain, as well as handling, is very much facilitated partly because the weight of the chain link is reduced and partly because no connecting pin is used.
The detachable chain in accordance with the invention offers the following advantages.
(1) The chain link exhibits superior self-lubricating property and high affinity by virtue of the fact that the material of the chain link contains nodular graphite structure. In consequence, the service life of the sprocket wheel is improved remarkably.
(2) The bainite-austenite matrix structure ensures superior mechanical properties.
(3) The wear resistance of the sprocket wheel is further improved by the work-hardening due to contact with the sprocket wheel.
(4) The application field thereof is remarkably increased by virtue of improvement in the mean rupture strength.
As will be understood from the foregoing description, according to the invention, the detachable chain in accordance with the invention exhibits a large mean rupture strength, as well as high wear resistance, thus meeting the major requirements for the detachable chain. This effect is very remarkable from an industrial point of view.
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A detachable chain composed of chain links is broadly used as a conveyor chain with attachments for various kinds of articles to be conveyed, or as a power transmitting chain. The conventional chain of this type, however, could convey only light load when used as a conveyor chain and could run only at a low speed when used as a power transmitting chain. This invention provides a detachable chain improved both in the rupture strength and service life, as well as a method of producing the same.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to a lithography process, and in particular, to replacing a conventional photomask with an ink pattern during the exposure step of the lithography process.
[0003] 2. Description of the Related Art
[0004] In the semiconductor field, patterning of all types of layered material is one of a number of important topics. Certain methods cannot selectively pattern selective areas of the layered material, such as methods for forming the layered material such as deposition, evaporation, and sputtering, methods for removing the layered material such as dry or wet etching, and methods for doping the layered material such as ion implantation. Therefore, lithography is utilized for forming a patterned photoresist layer to further pattern the layered material. Modifying the lithography process is a continuing effort in the field, which includes modifying the light source wavelength of the exposure, the composition of the photoresist, and factors of the development flows. Nevertheless, all modifications still need a photomask during exposure. Generally, the photomask substrate is quartz or glass, and the shielding pattern formed on the substrate is metal such as chromium. If the described layered material is formed on a planar object such as silicon wafer, the transmitting area of the photomask pattern may reach a circle with a 12 inch diameter. If the described layered material is formed on a curved object such as a cylinder, the curved photomask and multiple exposures will be necessary and enormously enhance costs. For the LCD panel industry, large area lithography considerably enhances costs due to the large photomask used and corresponding equipment, with the lithography process also reducing plant utilization ratio. In addition, the metal such as chromium of the photomask results in environmental pollution, thereby failing to meet restriction of hazardous substances (RoHS) in places like Europe. Thus, it is expected that costs of improving the photomask material, should the photomask material be improved, would be enhanced. Lastly, the expensive conventional photomask increases test costs of research and development.
[0005] For solving the problems of the conventional photomask, U.S. Pat. No. 6,872,321 discloses an ink pattern serving as a passivation layer during copper film etching. However, different layered materials require different ink patterns, such that the ink of the method for one material cannot be applied on other various materials. For example, when copper film is replaced with silicon oxide, the ink pattern applied on the copper film may not efficiently adhere to the silicon oxide or serve as a passivation layer during silicon oxide etching.
[0006] Accordingly, a method to solve the problem for the conventional photomask is called for.
SUMMARY OF THE INVENTION
[0007] The invention provides a method for patterning a photoresist layer, comprising providing an object, forming a photoresist layer on the object, printing an ink pattern on the photoresist layer, processing an exposure to the photoresist layer shielded by the ink pattern, and processing a development to pattern the photoresist layer.
[0008] A detailed description is given in the following embodiments with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The invention can be more fully understood by reading the subsequent detailed description and examples with references made to the accompanying drawings, wherein:
[0010] FIGS. 1-5 are schematic views showing the processes of patterning the photoresist layer in one embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0011] The following description is of the best-contemplated mode of carrying out the invention. This description is made for the purpose of illustrating the general principles of the invention and should not be taken in a limiting sense. The scope of the invention is best determined by reference to the appended claims.
[0012] As shown in FIG. 1 , an object 1 is provided. The object 1 in FIG. 1 is planar, however, in other embodiments, the object 1 can be curved such as a cylinder, a cone, a sphere, or other suitable shapes. The object 1 can be organic material such as plastic, rubber, or polymer, or inorganic material such as metal, metal oxide, or silicon wafer, or composites thereof.
[0013] As shown in FIG. 2 , a layered material 3 is subsequently formed on the surface of the object 1 . The composition of the layered material 3 and the object 1 may be similar or different. The layered material 3 includes described organic material, inorganic material, or composites thereof. In one embodiment, the layered material 3 is a single-layered structure. In another embodiment, the layered material 3 is a multi-layered structure.
[0014] As shown in FIG. 3 , a photoresist layer 5 is subsequently formed on the layered material 3 . The photoresist layer 5 can be positive type photoresist or negative type phoitoresist. For clarity of the descriptions, the photoresist layer 5 is a positive type photoresist in following Figs. It is understood that the negative type photoresist can be used in the invention. In one embodiment, the positive type photoresist is AZ4620 or AZ5214E commercially available from the Hoechst Celanese Corp. In another embodiment, the negative type photoresist is JSR-120N commercially available from the JSR Corp. The photoresist layer has a thickness of 1 μm to 80 μm. For example, the photoresist layer of AZ52141 has a thickness of 1 μm, and the double layered coating photoresist layer of JSR-120N has a thickness of 80 μm. The photoresist layer can be formed by spin-on.
[0015] The ink pattern 7 is then formed on the photoresist layer 5 . The source of the ink in the invention depends on requirement. The ink can be commercial inkjet ink, or combinations of solvent, pigment, and additives. To smoothly print the ink from the printer to form the ink pattern 7 , the ink composition should meet requirements of low viscosity and high surface tension. To efficiently shield the light source of the following exposure, the ink pattern 7 has an optical density (hereinafter OD) of 2.5 to 4.9. The OD of the chromium-containing photomask reaches 4 . 8 , however, the light-shielding layer with an OD of 2.5 to 4.9 is effective. In one embodiment, the ink has an OD of 3.2. The OD of the ink pattern 7 is in direct proportion to the thickness of the ink pattern 7 , and the OD can be changed by tuning the pigment concentration of the ink. The higher the ink concentration ink is, the higher the light-shielding effect is with a thinner ink pattern 7 . In one embodiment, the ink pattern 7 has a thickness of 0.5 μm to 2 μm. Theoretically, the ink pattern 7 and the photoresist layer 5 have a contact angle equal to 90 degrees. Practically, the contact angle is less than 90 degrees, thereby causing the light-shielding difference between the center and edge of the ink pattern 7 . If the light-shielding effect of the edge in the ink pattern is not enough, the photoresist layer 5 will be overexposed with narrower line width (positive type photoresist) or wider line width (negative type photoresist). The light-shielding effect can be improved by increasing the OD of the ink pattern 7 , such as greater than 2.5. Lastly, the ink pattern 7 and the photoresist layer 5 do not dissolve with each other.
[0016] As shown in FIG. 4 , an exposure is subsequently processed. The light source 9 of the exposure can be UV of the common photolithography process. As described above, the photoresist layer 5 in the Figures is positive type, and part of the photoresist layer 5 not shielded by the ink pattern 7 will be dissolved in the exposure. If the photoresist layer 5 adopts negative type photoresist, part of the photoresist layer 5 not shielded by the ink pattern 7 will be crosslinked in the exposure to form a reverse pattern.
[0017] As shown in FIG. 5 , a development is then processed to remove part of the photoresist layer not shielded by the ink pattern 7 . The type of developer solution depends on the type of the photoresist layer. In one embodiment, the ink pattern 7 will be removed in the development. In another embodiment, the ink pattern 7 is removed by an extra step. In a further embodiment, the ink pattern 7 can be retained without influencing the following processes and device performance. The patterned photoresist layer is completed whether the ink pattern 7 is retained or removed. Subsequently, the layered material 3 can be processed by etching, ion implantation, or any other commonly known steps if necessary. Note that the described processes has a layered material 3 disposed between the object 1 and the photoresist layer 5 , however, the photoresist layer 5 can be directly formed on the surface of the object 1 . After patterning of the photoresist layer 5 , subsequently steps such as etching or ion implantation can be directly processed on the surface of the object 1 .
[0018] Compared with the conventional photomask, the method for patterning the photoresist layer of the invention has the following advantages. First, the replacement of the chromium-containing photomask with ink reduces metal pollution. Next, the invention can be applied in a non-planar object with minimal required the new or updated equipment. Third, the invention is suitable for large area exposures. Lastly, ink costs are lower than photomask costs, especially when comparing the test stage.
[0019] While the invention has been described by way of example and in terms of preferred embodiment, it is to be understood that the invention is not limited thereto. To the contrary, it is intended to cover various modifications and similar arrangements (as would be apparent to those skilled in the art). Therefore, the scope of the appended claims should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements.
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The disclosed is a method for patterning a photoresist layer. An object is provided, a photoresist layer is formed on the object, and an ink pattern is printed on the photoresist layer. Shielded by the ink pattern, the photoresist is exposed and developed to be patterned. In addition, a layered material is optionally formed between the object and the photoresist layer.
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BACKGROUND OF THE INVENTION
This invention relates to certain novel cyclic terpenoid amines, their preparation, and their uses.
While preparing unsaturated terpene alcohols according to the Kane and Von Genk process (U.S. Pat. No. 3,932,539), it was discovered unexpectedly that terpenoid amines subjected to the hydration step of such process were cyclized rather than hydrated when such hydration step was practiced at higher temperatures of above about 80° C. and advantageously above about 100° C. The novel cycloterpenoid amines disclosed herein are useful in the synthesis of fragrances and carotenoids, for example. In a preferred embodiment of the present invention, the cyclized amines can be converted into beta-cyclogeraniol and further into beta-cyclocitral for synthesis of beta-ionone and Vitamin A. Additionally, other novel cyclic terpenoid compounds, which are useful as fragrances and as intermediates in other synthesis work, are made during the above synthesis.
BROAD STATEMENT OF THE INVENTION
The cyclic terpenoid amines disclosed herein can be represented conventionally by the following general structures: ##STR1## where R 1 is hydrogen or a C 1-4 aliphatic group (advantageously a C 1-4 alkyl group), and R 2 is hydrogen or a monovalent radical, usually a monovalent organic radical; or R 1 , R 2 are joined as a heterocyclic residue. Suitably monovalent radicals can be saturated, can contain unsaturation, and/or can be substituted with a wide variety of groups as disclosed herein. Advantageously, R 2 is a C 1-4 alkyl group.
Such cyclic terpenoid amines can be prepared from neryl/geranyl amines represented by T A NR 1 R 2 , where T A is a neryl group or a geranyl group, by maintaining an acidic aqueous solution of the neryl/geranyl amine at a temperature of at least about 80° C. until cyclization occurs. In the reaction solution, there is at least 1.1 equivalents of acid per equivalent of the neryl/geranyl amine.
Also, cyclic terpenoid esters of carboxylic acids represented by the following general structure: ##STR2## where R 3 is an aliphatic hydrocarbon and advantageously a C 1-4 alkyl group, can be prepared by reacting the foregoing cyclic terpenoid amines, which can be represented by GNR 1 R 2 , where G is the cyclogeranyl group, with a carboxylic acid anhydride at a temperature between about 70° and 250° C. until the cyclic ester is formed. A unique feature of this process is that only the beta-isomer (I) reacts to form the ester as the alpha and gamma isomers (II and III) do not react with the anhydride. The anhydride can be represented by the following structure: ##STR3## where R 3 is an aliphatic moeity or group.
A minor by-product of the cyclic terpenoid carboxylic acid ester process is "cyclolinalyl" ester of the carboxylic acid which can be represented conventionally by the following general structure: ##STR4## where R 3 is an aliphatic hydrocarbon. The "cyclolinalyl" ester can be converted into "cyclolinalool" by a hydrolysis reaction. "Cyclolinalool" (1,3,3-trimethyl-2-methylene-1-cyclohexanol) can be represented conventionally as follows: ##STR5##
DETAILED DESCRIPTION OF THE INVENTION
The cycloterpenoid amines of the present invention are primary, secondary or tertiary amines containing the cyclogeranyl radical. A novel method of preparing such cyclic amines involves the cyclization of neryl/geranyl amine. Starting materials of this cyclization reaction may be prepared conveniently by reacting neryl/geranyl halide, preferably chloride, with a primary or secondary amine. In this reaction, the reactivity of the amine with the terpene chloride will depend upon electronic considerations and steric considerations. Some amines, particularly those connected to an aromatic system, e.g. N-methylaniline, are less readily alkylated by the terpene chloride than are aliphatic or benzylic amines. Also, rather large and bulky groups attached to the amine can be expected to sterically hinder the alkylation of the amine by the terpene chloride. One such unreactive, sterically hindered amine for this alkylation reaction is diisopropylamine. The starting amine, then, to be useful, must be alkylated at a reasonable rate by the neryl/geranyl chloride. Examples of suitable neryl/geranyl amines which can be prepared by this alkylation reaction, and subsequently cyclized, include: ##STR6## Alternatively, terpene dialkylamines can be prepared by the addition of a secondary amine, such as diethylamine or the like, directly to myrcene in the presence of special catalysts such as sodium naphthalenide according to the process proposed by Watanabe et al in the Australian Journal of Chemistry, 1974, Volume 27, Pages 531-535. Also, N,N-diethylnerylamine may be prepared by the telomerization of isoprene with diethylamine in the presence of n-butyl-lithium catalyst according to the process of Takabe et al, Tetrahedron Letters, No. 34, Pages 3005-3006, 1975. Geranyl/neryl amines may be prepared additionally by the reduction of citral oxime as taught in U.S. Pat. No. 4,017,634, or by the Gabriel synthesis as described in the Journal of Organic Chemistry, 1972, Volume 37, Pages 4036-4039. The disclosures of the foregoing references are incorporated herein expressly by reference.
Regardless of how the terpenoid amines are prepared, cyclization is practiced by maintaining an acidic aqueous solution of the terpenoid amine until cyclization occurs. At least 1.1 equivalents of acid per equivalent of said amine salt is used in this reaction, advantageously at least about 2 equivalents of acid, and preferably about 2 to 3 equivalents of the acid. While more than 3 equivalents of the acid can be used, such amounts tend to be less convenient to handle and more costly to use. Typically, about a 20% to 30% acid concentration in the aqueous solution will be found to be useful for the instant cyclization reaction. Appropriate acids for this reaction include, for example, hydrochloric acid, sulfuric acid, phosphoric acid, hydrobromic acid, and the like. The cyclization reaction preferably is carried out at temperatures above about 80° C., usually between about 80° and 120° C., preferably under reflux conditions. Temperatures higher than 120° C. can be practiced and are advantageous for faster reaction rates; however, this would require use of pressurized equipment for conducting the reaction. Temperatures of about 100°-120° C. are quite useful when a 20% to 30% acid concentration is maintained in the reaction solution. Inert solvents such as ethers, cellosolves, and the like can be used as is necessary or desirable.
The progress of the cyclization reaction can be followed conveniently by periodic removal and analysis of samples from the reaction solution. The cyclized amine product usually is a mixture of alpha, beta, and gamma cyclogeranyl isomers with the beta isomer form usually predominating with extended times of reaction. The cyclized terpenoid amines can be liberated conveniently from the reaction mixture by neutralization of the reaction solution with a suitable base, such as an alkali metal hydroxide or the like. Further purification of the cyclic amine products by fractional distillation or fractional crystallization can be practiced conventionally as desired or required.
The following are additional examples of neryl/geranyl amines which can be expected to cyclize according to the instant cyclization process: ##STR7##
A prime use of the instant cyclic terpenoid amines is in the preparation of beta-cycloterpenoid esters of carboxylic acids [Structure (IV)]. This process reacts the cyclic tertiary amines with a carboxylic acid anhydride at about 70° to 250° C., advantageously about 100° to 180° C., and preferably about 100° to 120° C., until the cycloterpenoid ester is formed. Typically, the molar ratio of anhydride to cyclic tertiary amine is from about 0.2 to 20, and preferably from about 1 to 3. Appropriate carboxylic acid anhydrides can be represented conventionally as follows: ##STR8## where R 3 is an aliphatic group or moeity. This reaction is performed generally according to that procedure disclosed in Japanese Kokai 116411/75, the disclosure of which is incorporated herein by reference. This general procedure also is reported by Fujita et al in Aust. J. Chem.; 1974, 27, 531-535, which is incorporated herein expressly be reference. A unique feature of this process is that the alpha and gamma-cyclogeranyl amines are virtually unreactive and, surprisingly, essentially only the beta- form ester results. Consequently, the isomer mixture of cyclic amines need not be purified rigorously for separation of the pure beta isomer. Instead, the unreacted alpha and gamma insomers can be isomerized to produce an equilibrium mixture rich in the beta isomer for admission to the process to form more of the ester. Illustrative of the foregoing reaction is the production of beta-cyclogeranyl acetate as follows: ##STR9## Of course, primary and secondary beta-cyclogeranyl amines can be used in the foregoing ester formation reaction provided that they are first alkylated to a tertiary amine with an appropriate alkylating agent, such as an alkyl halide or an alkyl sulfate, for example.
The foregoing beta-cycloterpenoid esters can be conventionally saponified with alkali, for example, to replace the ester group with the hydroxyl group, i.e. produce beta-cyclogeraniol. Reaction conditions for this saponification reaction include temperatures of about 80° to about 140° C. and use of about 1.05 to 2.0 moles of alkali metal hydroxide of about 5% to 50% concentration in water. Beta-cyclogeraniol is an especially valued product since it can be oxidized to beta-cyclocitral which is useful in the synthesis of beta-ionone, Vitamin-A, and various carotenoids. The oxidation of beta-cyclogeraniol to beta-cyclocitral can be performed according to the Ehmann process as described in commonly assigned copending application Ser. No. 682,113 of May 30, 1975. Beta-cyclocitral is useful in the synthesis of Vitamin A according to the Mukaiyama et al process reported in Chemistry Letters, pp. 1201-1202, 1975 (The Chemical Society of Japan). Beta-cyclogeraniol also can be converted into Vitamin A through the Wittig route according to the procedure outlined by Pommer in Angew. Chem. International Edition/Sample Issue, pages 31-40 (1960). The above references are incorporated herein expressly by reference.
A minor by-product formed by the reaction of beta-cyclogeranyl dimethylamine with acetic anhydride (as outlined above), is "cyclolinalyl acetate" which can be hydrolyzed with acid or base into "cyclolinalool". These products can be represented as follows: ##STR10## Both of the foregoing compounds can have uses as fragrances and as intermediates in the synthesis of cartenoids, for example. Consequently, a new class of compounds, "cyclolinalyl" esters of carboxylic acids and the corresponding alcohol, "cyclolinalool", are encompassed within the scope of the present invention.
The following Examples show in detail how the present invention can be practiced but should not be construed as limiting. In this application, all temperatures are in degrees Centigrade and all percentages are weight percentages, unless otherwise expressly indicated.
EXAMPLE I
Preparation of Neryl/Geranyl Dimethylamine
One thousand two hundred twenty grams of beta-pinene pyrolysate, containing approximately 75% myrcene, was converted to a mixture of neryl/geranyl chlorides by hydrochlorination of the pyrolysate at 0° C. in the presence of cuprous chloride catalyst. The reaction consumed about 280 grams of hydrogen chloride. One thousand five hundred thirty-nine grams of 40% aqueous dimethylamine was added to 1500 grams of the myrcene hydrochlorination product at 18°-25° C. over a period of 2 hours. The reaction mixture was held at 20°-25° C. for an additional 4 hours under stirring, followed by the addition of 500 grams of 50% aqueous sodium hydroxide solution. The reaction mixture then was heated at 90° C. to drive off excess dimethylamine and the reaction mixture cooled. The cooled reaction mixture separated into a lower aqueous phase and an upper oil pase. The two phases were separated and the recovered oil phase weighing 1635 grams was determined to contain approximately 60% of product neryl/geranyl dimethylamine. The recovered oil layer then was distilled under reduced pressure and 720 grams of purified neryl/geranyl dimethylamine of 91% purity was recovered.
EXAMPLE II
Cyclization of Neryl/Geranyl Dimethylamine
To 520 grams of a 19% aqueous hydrochloric acid solution was added 250 grams of neryl/geranyl dimethylamine. The homogeneous solution was heated at about 90° C. and samples of the solution were periodically removed for analysis. The samples were analyzed by treatment with excess sodium hydroxide solution followed by gas chromatographic analysis of the oil phase. The following table summarizes the progress of the cyclization reaction over the course of the reaction.
__________________________________________________________________________Hour: 1 2 4 8 16 32 64__________________________________________________________________________GC Analysis (weight percent)alpha-Cyclogeranyl Dimethylamine 23.5 37.9 39.5 35.3 25.0 23.2 23.0beta-Cyclogeranyl Dimethylamine 3.4 6.8 17.7 30.5 47.5 51.2 52.3gamma-Cyclogeranyl Dimethylamine 20.8 19.7 15.1 12.7 10.1 8.4 8.0Uncyclized Amine & Unknowns 11.9 11.4 10.7 10.8 10.6 10.8 9.7Amino Alcohols 39.1 23.0 14.0 8.39 6.3 5.7 6.2__________________________________________________________________________
After 64 hours of reaction time, the reaction mixture was made basic by the addition of 250 grams of 50% aqueous sodium hydroxide solution. The oil layer which formed was separated and fractionally distilled at reduced pressure to yield a distillate of beta-cyclogeranyl dimethylamine of about 90% purity. The structure of the beta-cyclogeranyl dimethylamine was confirmed by NMR (nuclear magnetic resonance) analysis.
EXAMPLE III
Cyclization of Neryl/Geranyl Dimethylamine
To 640 grams of a 20% aqueous hydrochloric acid solution was added 250 grams of neryl/geranyl dimethylamine. The solution was heated at 100° C. for 16 hours, after which the cyclogeranyl amine products were recovered from the solution. Gas chromatographic analysis of the product indicated that the beta-cyclogeranyl dimethylamine content was about 52.8% and that the reaction was substantially complete.
The reaction was repeated as above indicated, except that the aqueous acid used was 400 grams of 19% aqueous hydrochloric acid. After a reaction time of 32 hours, it was determined that the beta-cyclogeranyl dimethylamine content of the product was 51% and that the reaction was substantially complete.
EXAMPLE IV
Preparation and Cyclization of Neryl/Geranyl Dimethylamine
Neryl/geranyl dimethylamine was prepared by bubbling anhydrous dimethylamine gas (404 grams) through 1500 grams of myrcene hydrochloride (from Example 1) over a 4 hour period at a temperature of 30°-35° C. At the end of the addition, there was added 400 grams of water and 800 cc of a 37% hydrochloric acid solution. The reaction was cohobated for about 24 hours. The cohobated oil weighed 373 grams. Gas chromatographic analysis indicated that the oil was primarily a mixture of terpene hydrocarbons. The solution was made basic by the addition of 865 grams of 50% aqueous sodium hydroxide solution. The reaction was cohobated again. 526 grams of oil was recovered from the reaction mixture and subjected to gas chromatographic analysis. The oil was determined to contain 23% alpha-cyclogeranyl dimethylamine, 53% beta-cyclogeranyl dimethylamine, 10% gamma-cyclogeranyl dimethylamine, 2% amino alcohols, and 12% miscellaneous compounds.
EXAMPLE V
Preparation of Neryl/Geranyl Dibutylamine
Seven hundred forty grams of myrcene hydrochloride (prepared as described in Example I) was added gradually over a one hour period to 488 grams of dibutylamine at 70°-75° C. The reaction mixture was held at this temperature for 2 hours and then 750 grams of 15% aqueous sodium hydroxide solution added thereto. The neutralized reaction mixture was refluxed for an additional 4 hours. The oil phase, after separation, weighed 1011 grams and by gas chromatographic analysis was determined to contain 63.8% neryl/geranyl dibutylamine. The crude cyclic amine product was distilled and a main fraction obtained at 102°-104° C. at 0.4 mm pressure. This fraction weighed 577 grams and was determined to be 98% pure neryl/geranyl dibutylamine.
EXAMPLE VI
Cyclization of Neryl/Geranyl Dibutylamine
Two hundred sixty-five grams of neryl/geranyl dibutylamine from Example V was added to a solution of 465 grams of 16% aqueous hydrochloric acid and refluxed for 35 hours. The solution then was cooled and neutralized by the addition of 200 grams of 50% aqueous sodium hydroxide solution. Gas chromatographic analysis of the liberated oil phase indicated that the content of beta-cylogeranyl dibutylamine was 45.3%. The cyclic amine products were fractionally distilled at reduced pressure and the structure of products confirmed by NMR analysis.
EXAMPLE VII
Conversion of beta-Cyclogeranyl Dibutylamine to beta-Cyclogeranyl Acetate
A 5 gram fraction containing 46.3% beta-cyclogeranyl dibutylamine and 53.7% of alpha- and gamma-cyclogeranyl dibutylamine was reacted with 9 grams of acetic anhydride at 130° C. for about 50 hours. Gas chromatographic analysis of the product indicated that only the beta-isomer reacted to give beta-cyclogeranyl acetate with some gamma-pyronene also being formed. The alpha- and gamma-cyclogeranyl dibutylamine isomers were substantially unreacted.
EXAMPLE VIII
Preparation of Mono and Di-Neryl/Geranyl Monobutylamine
Seven hundred forty grams of myrcene hydrochloride was reacted with 220 grams of n-butylamine at 65°-70° C. for 2 hours, the reaction mixture neutralized with sodium hydroxide, and then refluxed for an additional 4 hours. The separated oil phase was purified by fractional distillation to give 133 grams of neryl/geranyl monobutylamine and 245 grams of di-neryl/geranyl monobutylamine.
EXAMPLE IX
Cyclization of Neryl/Geranyl Monobutylamine
Twenty-five grams of neryl/geranyl monobutylamine was added to 50 grams of 18% aqueous hydrochloric acid solution and the mixture refluxed at 105° C. for 6.5 hours. Addition of 25 grams of 50% aqueous sodium hydroxide solution liberated 24 grams of cyclized product, which by gas chromatographic analysis was determined to contain: 50% beta-cyclogeranyl monobutylamine and lesser amounts of corresponding alpha and gamma isomers. Fractional distillation resulted in a purified beta-cyclogeranyl monobutylamine product, which structure was confirmed by NMR analysis.
EXAMPLE X
Fifty grams of a fraction containing 90% beta-cyclogeranyl dimethylamine, 2% alpha-cyclogeranyl dimethylamine, 4.9% gamma-cyclogeranyl dimethylamine, and 2% related cyclic isomers was heated with 93 grams of acetic anhydride at 110°-115° C. for 3 hours. The reaction mixture was neutralized wth sodium hydroxide and the recovered product subjected to gas chromatographic analysis. The following composition of the product was determined: 3.4% deltapyronene, 35% gamma-pyronene, 1.7% alpha-cyclogeranyl dimethylamine, 0.4% betacyclogeranyl dimethylamine, 5.9% gamma-cyclogeranyl dimethylamine, 3.1% other cyclic amines, 4.3% "cyclolinalyl acetate", and 44.5% beta-cyclogeranyl acetate.
The foregoing crude reaction product mixture was washed with sodium hydroxide solution, saponified by refluxing with 50% aqueous sodium hydroxide solution, and then distilled at reduced pressure. The structures of purified fractions of "cyclolinalool" and beta-cyclogeraniol were confirmed by NMR analysis.
EXAMPLE XI
Isomerization of alpha- and gamma-Cyclogeranyl Dimethylamines to beta-Cyclogeranyl Dimethylamine
Two hundred twenty-seven grams of a mixture of 36% beta-cyclogeranyl dimethylamine, 50% alpha-cyclogeranyl dimethylamine, and 11% gamma-cyclogeranyl dimethylamine was refluxed with 565 grams of a 19% aqueous hydrochloric acid solution for 36 hours. The reaction mixture was made basic by the addition of 300 grams of 50% aqueous sodium hydroxide solution. The recovered oil phase weighed 225 grams and by gas chromatographic analysis, was determined to contain 70% betacyclogeranyl dimethylamine, 15% alpha-cyclogeranyl dimethylamine, and 8% gammacyclogeranyl dimethylamine.
EXAMPLE XII
Cyclization of Neryl/Geranyl Dimethylamine
Twenty-five grams of neryl/geranyl dimethylamine were heated at 90° C. with the solution of 104 grams of 13% aqueous sulfuric acid solution for 64 hours. Gas chromatographic analysis of the separated and neutralized oil phase indicated that the following products were present: 29% alpha-cyclogeranyl dimethylamine, 2.2% beta-cyclogeranyl dimethylamine, 26.8% gamma-cyclogeranyl dimethylamine, 7.7% unknown cyclic amines, and 33.5% amino alcohols. The lower conversion of neryl/geranyl dimethylamine to product beta-cyclogeranyl dimethylamine probably resulted from the lower concentration of sulfuric acid used in this reaction.
EXAMPLE XIII
Conversion of beta-Cyclogeraniol to beta-Ionone
The first step is the oxidation of beta-cyclogeraniol to beta-cyclocitral according to the process of William J. Ehmann in Ser. No. 582,113, cited above. Three grams of 99% pure beta-cyclogeraniol was heated at 40°-45° C. with a solution of 5 grams of furfural, 7 milliliters of benzene, and 1 gram of aluminum isopropoxide catalyst. After three hours of reaction time, gas chromatographic analysis of the reaction mixture indicated the following composition: 31% furfural, 21% furfuryl alcohol, 26% beta-cyclocitral, and 11% beta-cyclogeraniol.
To the reaction mixture then was added 70 grams acetone, 2.5 grams sodium hydroxide, and 25 grams methanol. The reaction mixture was stirred at 40°-45° C. for about 2 hours; 5 cc of acetic acid then was added to neutralize the sodium hydroxide catalyst. Analysis of the crude reaction product mixture indicated the following products: 20% furfuryl alcohol, 99% beta-cyclogeraniol, 49% furfuralacetone condensation products, and 22% of the desired beta-ionone product.
The crude reaction product was distilled under reduced pressure and the presence of beta-ionone was confirmed by infrared and mass spectroscopy analysis of the resulting distillation fractions.
EXAMPLE XIV
Preparation of Neryl/Geranylamine and its Cyclization
The starting geranylamine was prepared by reduction of citral oxime with lithium aluminum hydride reagent. The purified amine contained 26% of the neryl- and 66% of the geranyl-isomer. To 11.9 g of 17% hydrochloric acid solution was added 4.5 g of the neryl/geranylamine. This homogeneous solution was refluxed at 107° C. After one hour, a sample was removed and the amine product liberated by the addition of 10% sodium hydroxide solution. Gas chromatographic analysis indicated a ratio of 65% beta-cyclogeranylamine to 35% of the alpha- and gamma-isomers. After 8 hours reaction, the ratio determined by gas chromatography was 75% of the beta-cyclogeranylamine and 25% of the alpha- and gamma-isomers. The cyclogeranylamine was isolated from the reaction by steam distillation after the addition of sufficient 10% sodium hydroxide solution to render the reaction mixture strongly basic.
The product was then analyzed by NMR, which confirmed the presence of alpha-, beta- and gamma-cyclogeranylamines.
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Disclosed are novel cyclic terpenoid amines which can be prepared by cyclizing the corresponding acyclic terpenoid amine.
CROSS REFERENCE TO RELATED APPLICATIONS
This application is related to applicant's commonly owned copending application Ser. No. 916,966 filed 19 June 1978, now U.S. Pat. No. 4,179,468 dated 18 Dec. 1979 and entitled Cyclic Terpenoid Onium Salts, Their Preparation and Uses.
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FIELD
The present disclosure is directed to planning and confirming a procedure performed on a subject, and particularly to a method and system to assist in achieving a selected procedure and confirming the procedure.
BACKGROUND
This section provides background information related to the present disclosure which is not necessarily prior art.
A procedure can be performed on any appropriate subject. For example, a procedure can be performed on a patient to position an implant in the patient. Though procedures can also include assembling any appropriate work piece or installing members into a work piece, such as an airframe, autoframe, etc. Regardless of the subject, generally the procedure can have a selected result that is efficacious. The efficacious result may be the desired or best result for the procedure.
A procedure on a human patient can be a surgical procedure performed to insert an implant, such as a pedicle screw. The pedicle screw can be placed in the patient according to appropriate techniques, such as an open procedure where a surgeon can view the procedure. The surgeon can then view images of the implanted screw in the patient to analyze placement of the screw. The images acquired of the patient and the screw, however, may include artifacts due to the imaging technique and the material of the implant.
SUMMARY
This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.
A system is provided that can be used to confirm or determine a position of an implant. During a procedure, such as a surgical procedure, an implant or member can be placed in a subject. After the procedure is complete, an image can be acquired of the subject. A pre-formed model (such as a computer aided or assisted design (CAD) model) can be overlayed or superimposed on the acquired image data at the determined location of the implanted member to confirm placement of the implant. The overlayed image can be used to confirm completion of a planned procedure as well.
According to various embodiments, a surgical procedure can be performed with a navigation system. During a navigated procedure an instrument, such as a surgical instrument or implant, can be tracked relative to a patient. A planning procedure or system can also be provided and used that can illustrate and/or determine a procedure to be performed on a patient. In addition, a planning module can include a system that can execute instructions to illustrate and determine a procedure for achieving a result in a patient. A database storage system can be used to save and accumulate preferred portions of a procedure, such as entry points and trajectories.
In addition, image data can be acquired of the patient prior to implantation and subsequent to implantation, both of which can be either intra-, pre-, and post-operatively acquired, to assist in confirming placement of an implant. For example, as discussed further herein, pedicle screws can be placed in one or more vertebra of a patient. The placement of the pedicle screws can be confirmed or checked with the use of image data acquired of the patient. Further, computer aided or assisted design (CAD) models can be used to assist in viewing a placement of implants relative to the patient.
Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.
FIG. 1 is an environmental view of an operating theatre including an optional imaging system and a navigation system;
FIG. 2 is a flow chart illustrating a procedure for performing and confirming placement of an implant in a patient;
FIGS. 3A-3C illustrate image data of a spine of a patient from various perspectives;
FIG. 4 is an illustration of a detail of an instrument for inserting an implant into a patient;
FIG. 5 is a view of a display device showing image data of a patient and an icon of an implant relative to the image data;
FIG. 6 is a display illustrating image data of a portion of patient with an implant implanted;
FIG. 7 is a view of a display with an augmented image data with a model superimposed on implant image data;
FIG. 8 is a view of a display with image data and model of an implant superimposed on the image data; and
FIG. 9 is a view of a display showing a plan for a procedure.
Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.
DETAILED DESCRIPTION
Example embodiments will now be described more fully with reference to the accompanying drawings.
FIG. 1 is a diagram illustrating an overview of a navigation system 10 that can be used for various procedures. The navigation system 10 can be used to track the location of an item, such as an implant or an instrument (as discussed herein), relative to a subject, such as a patient 14 . It should further be noted that the navigation system 10 may be used to navigate any type of instrument, implant, or delivery system, including: guide wires, arthroscopic systems, orthopedic implants, spinal implants, deep brain stimulation (DBS) probes, etc. Moreover, the instruments may be used to navigate or map any region of the body. The navigation system 10 and the various tracked items may be used in any appropriate procedure, such as one that is generally minimally invasive or an open procedure.
The navigation system 10 can interface with an imaging system 12 that is used to acquire pre-operative, intra-operative, or post-operative, or real-time image data of the patient 14 . It will be understood, however, that any appropriate subject can be imaged and any appropriate procedure may be performed relative to the subject. In the example shown, the imaging system 12 comprises an O-arm® imaging device sold by Medtronic Navigation, Inc. having a place of business in Louisville, Colo., USA. The imaging device 12 may have a generally annular gantry housing 20 that encloses an image capturing portion 22 . The image capturing portion 22 may include an x-ray source or emission portion 26 and an x-ray receiving or image receiving portion 28 located generally or as practically possible 180 degrees from each other and mounted on a rotor (not illustrated) relative to a track of the image capturing portion 22 . The image capturing portion 22 can be operable to rotate 360 degrees during image acquisition. The image capturing portion 22 may rotate around a central point or axis, allowing image data of the patient 14 to be acquired from multiple directions or in multiple planes. The imaging system 12 can include those disclosed in U.S. Pat. Nos. 7,188,998; 7,108,421; 7,106,825; 7,001,045; and 6,940,941; all of which are incorporated herein by reference. Other possible imaging systems can include C-arm fluoroscopic imaging systems which can also generate three-dimensional views of the patient 14 .
The position of the image capturing portion 22 can be precisely known relative to any other portion of the imaging device 12 . In addition, as discussed herein, the precise knowledge of the position of the image capturing portion 22 can be used in conjunction with a tracking system 29 to determine the position of the image capturing portion 22 and the image data relative to the tracked subject, such as the patient 14 .
The tracking system 29 can include various portions that are associated or included with the navigation system 10 . The tracking system 29 can also include a plurality of types of tracking systems including an optical tracking system that includes an optical localizer 40 and/or an EM tracking system that can include an EM localizer 42 . Various tracking devices, including those discussed further herein, can be tracked with the tracking system 29 and the information can be used by the navigation system 10 to allow for a display of a position of an item. Briefly, tracking devices, such as a patient tracking device 48 , an imaging device tracking device 50 , and an instrument tracking device 52 , allow selected portions of the operating theater to be tracked relative to one another with the appropriate tracking system, including the optical localizer 40 and/or the EM localizer 42 .
It will be understood that any of the tracking devices 48 - 52 can be optical or EM tracking devices, or both, depending upon the tracking localizer used to track the respective tracking devices. It will be further understood that any appropriate tracking system can be used with the navigation system 10 . Alternative tracking systems can include radar tracking systems, acoustic tracking systems, ultrasound tracking systems, and the like.
An exemplarily EM tracking system can include the STEALTHSTATION® AXIEM™ Navigation System, sold by Medtronic Navigation, Inc. having a place of business in Louisville, Colo. Exemplary tracking systems are also disclosed in U.S. patent application Ser. No. 10/941,782, filed Sep. 15, 2004, and entitled “METHOD AND APPARATUS FOR SURGICAL NAVIGATION”; U.S. Pat. No. 5,913,820, titled “Position Location System,” issued Jun. 22, 1999 and U.S. Pat. No. 5,592,939, titled “Method and System for Navigating a Catheter Probe,” issued Jan. 14, 1997, all herein incorporated by reference.
Further, for EM tracking systems it may be necessary to provide shielding or distortion compensation systems to shield or compensate for distortions in the EM field generated by the EM localizer 42 . Exemplary shielding systems include those in U.S. patent application Ser. No. 10/252,258, filed on Sep. 23, 2002, published as U.S. Pat. App. Pub. No. 2003/0117135 and U.S. Pat. No. 6,747,539, issued on Jun. 8, 2004; distortion compensation systems can include those disclosed in U.S. patent application Ser. No. 10/649,214, filed on Jan. 9, 2004, published as U.S. Pat. App. Pub. No. 2004/0116803, all of which are incorporated herein by reference.
With an EM tracking system, the localizer 42 and the various tracking devices can communicate through an EM controller 44 . The EM controller can include various amplifiers, filters, electrical isolation, and other systems. The EM controller 44 can also control the coils of the localizer 42 to either emit or receive an EM field for tracking. A wireless communications channel, however, such as that disclosed in U.S. Pat. No. 6,474,341, entitled “Surgical Communication Power System,” issued Nov. 5, 2002, herein incorporated by reference, can be used as opposed to being coupled directly to the EM controller 44 .
It will be understood that the tracking system may also be or include any appropriate tracking system, including a STEALTHSTATION® TRIA®, TREON®, and/or S7™ Navigation System having an optical localizer, similar to the optical localizer 94 , sold by Medtronic Navigation, Inc. having a place of business in Louisville, Colo. Further alternative tracking systems are disclosed in U.S. Pat. No. 5,983,126, to Wittkampf et al. titled “Catheter Location System and Method,” issued Nov. 9, 1999, which is hereby incorporated by reference. Other tracking systems include an acoustic, radiation, radar, etc. tracking or navigation systems.
The imaging system 12 can include a support housing or cart 56 . The imaging system 12 can further include a separate image processing unit 58 that can be housed in the cart 56 . The navigation system 10 can include the navigation processing unit 60 that can communicate or include a navigation memory 62 . The navigation processing unit 60 can receive information, including image data, from the imaging system 12 and tracking information from the tracking systems 29 , including the respective tracking devices 48 - 52 and the localizers 40 - 42 . Image data can be displayed as an image 64 on a display device 66 of a workstation or other computer system 68 . The workstation 68 can include appropriate input devices, such as a keyboard 70 . It will be understood that other appropriate input devices can be included, such as a mouse, a foot pedal or the like.
The image processing unit 58 processes image data from the imaging system 12 and transmits it to the navigation processor 60 . It will be further understood, however, that the imaging system 12 need not perform any image processing and it can transmit the image data directly to the navigation processing unit 60 . Accordingly, the navigation system 10 may include or operate with a single or multiple processing centers or units that can access single or multiple memory systems based upon system design. The patient 14 can be fixed onto an operating table 72 , but is not required to be fixed to the table 72 . The table 72 can include a plurality of straps 74 . The straps 74 can be secured around the patient 14 to fix the patient 14 relative to the table 72 . Various apparatuses may be used to position the patient 14 in a static position on the operating table 72 . Examples of such patient positioning devices are set forth in commonly assigned U.S. patent application Ser. No. 10/405,068 entitled “An Integrated Electromagnetic Navigation And Patient Positioning Device”, filed Apr. 1, 2003 which is hereby incorporated by reference. Other known apparatuses may include a Mayfield® clamp.
Also, the position of the patient 14 relative to the imaging system 12 can be determined by the navigation system 10 with the patient tracking device 48 and the imaging system tracking device 50 . Accordingly, the position of the patient 14 relative to the imaging system 12 can be determined. An exemplary imaging system, such as the O-arm® can know its position and be repositioned to the same position within about 10 microns. This allows for a substantially precise placement of the imaging system 12 and precise determination of the position of the imaging device 12 . Precise positioning of the imaging portion 22 is further described in U.S. Pat. Nos. 7,188,998; 7,108,421; 7,106,825; 7,001,045; and 6,940,941; all of which are incorporated herein by reference. Subject or patient space and image space can be registered by identifying matching points or fiducial points in the patient space and related or identical points in the image space. The imaging device 12 , such as the O-arm® imaging device sold by Medtronic, Inc., can be used to generate image data at a precise and known position. This can allow image data that is automatically or “inherently registered” to the patient 14 upon acquisition of the image data. Essentially, the position of the patient 14 is known precisely relative to the imaging system 12 due to the accurate positioning of the imaging system 12 . This allows points in the image data to be known relative to points of the patient 14 because of the known precise location of the imaging system 12 .
Alternatively, manual or automatic registration can occur by matching fiducial points in image data with fiducial points on the patient 14 . Registration of image space to patient space allows for the generation of a translation map between the patient space and the image space. According to various embodiments, registration can occur by determining points that are substantially identical in the image space and the patient space. The identical points can include anatomical fiducial points or implanted fiducial points. Exemplary registration techniques are disclosed in Ser. No. 12/400,273, filed on Mar. 9, 2009, incorporated herein by reference.
Once registered, the navigation system 10 with or including the imaging system 12 , can be used to perform selected procedures. Selected procedures can use the image data generated or acquired with the imaging system 12 . Further, the imaging system 12 can be used to acquire image data at different times relative to a procedure. As discussed herein, image data can be acquired of the patient 14 subsequent to a selected portion of a procedure for various purposes, including confirmation of the portion of the procedure.
With continuing reference to FIG. 1 , the imaging system 12 can generate actual or virtual three dimensional images of the patient 14 . The patient 14 can be placed relative to the imaging system 12 to allow the imaging system 12 to obtain image data of the patient 14 . To generate 3D image data, the image data can be acquired from a plurality of views or positions relative to the patient 14 . The 3D image data of the patient 14 can be used alone or with other information to assist in performing a procedure on the patient 14 or an appropriate subject. It will be understood, however, that any appropriate imaging system can be used, including magnetic resonance imaging, computed tomography, fluoroscopy, etc.
With reference to FIG. 2 , and FIGS. 3A-8 , a flow chart 100 illustrates a method for confirming placement of an implant after an implantation procedure as illustrated in FIGS. 3A-8 . It will be understood that although the flowchart 100 describes and is directed to a method of placing pedicle screws 120 ( FIG. 3 ) in a vertebra 124 ( FIG. 4 ), the procedure can be used to confirm placement of any appropriate implant in any appropriate portion of the anatomy, such as an intramedullary (IM) rod in a long bone (e.g. a femur), a knee or hip replacement prosthesis, or any other appropriate procedure. Accordingly, the method in flowchart 100 will be understood to encompass selected procedures beyond pedicle screw placement. In addition, it will be understood that the method of the flowchart 100 can be used to confirm placement of any appropriate member in any appropriate structure. For example, placement of a member, including a spike, into a radio lucent work piece, such as a wood board, can also be confirmed with the procedure in the flowchart 100 .
The method in the flowchart 100 can begin at start block 102 . A procedure can then be selected in block 104 . The procedure can be any appropriate procedure, such as the placement of the pedicle screw within the vertebra 124 of a patient 14 . It will be understood that the placement of the pedicle screw 120 in the vertebra 124 of the patient 14 can be performed for any appropriate procedure, such as spinal fusion or vertebral rigidity. Regardless of the procedure selected in block 104 , first image data of a subject can be acquired in block 106 .
The image data 64 can be any appropriate image data, such as x-ray image data of a single vertebra, illustrated in FIG. 3A . The image data 64 can be displayed on the display 66 or can be acquired and saved in the memory or storage system 62 of the navigation system 10 , can be used for later confirmation of a procedure, or can be used for both. Briefly, a first image data of the subject can be image data acquired of the subject or the patient 14 prior to any portion of a surgical intervention being performed. For example, the patient 14 can be imaged with the imaging system 12 substantially immediately after entering an operating theatre and prior to performing any surgical procedures, such as forming an incision. It will be further understood that the first image data of the subject acquired in block 106 can be acquired prior to the patient 14 entering the surgical theatre. Regardless of the timing of acquiring the first image data, the first image data is image data of the patient or subject 14 having been unaltered by a surgical procedure. As discussed further herein, in relation to the method in the flowchart 100 , this image data can be used along with later or second acquired image data and a model (e.g. a CAD model) of an implant for confirmation of placement of an implant in the patient 14 . The first acquired image data can be subtracted from the second acquired image data to substantially define only the anatomy of the patient 14 that has not been affected by a surgical procedure or artifacts that may be induced by an implant member in the image data.
After the first image data is acquired in block 106 , the first image data can be optionally transferred to a data processor in block 112 . The image data transferred to the data processor in block 112 can be all first image data acquired of the patient 14 in the first image data from block 106 . As illustrated in FIGS. 3A-3C , image data can be acquired of the patient 14 from a plurality of perspectives or viewpoints.
The first image data acquired in block 106 can be saved or transferred to any appropriate processing core or system, or can simply be directly transferred or maintained to be accessed by a single processing unit. As discussed above, the imaging processing unit 58 can be incorporated in the imaging system 12 and the navigation processor 60 can be included with the navigation workstation 68 . Accordingly, the two processing units can communicate and image data can be transferred between. Alternatively, the image data can be simply acquired and transferred to the navigation processor 60 . Regardless, it will be understood that the navigation system 10 can process the image data with a single or multiple processing unit or cores as understood by one skilled in the art.
Once the first image data is acquired in block 106 and optionally transferred to a processor in block 112 , the selected procedure can be performed in block 114 . As illustrated in FIG. 4 , the procedure can include placement of a pedicle screw 120 into the patient 14 . As is generally understood, the anatomy of the patient 14 can include a vertebra 124 into which the pedicle screw 120 can be positioned or implanted. The pedicle screw 120 can be implanted with an appropriate surgical instrument, such as a screw gun 126 or can be implanted with an appropriate manual driver (not illustrated) such as the CD Horizon® Legacy™ System manual driver, sold by Medtronic Spine and Biologics having a place of business in Minneapolis, Minn. Regardless of the instrument used to implant the pedicle screw 120 , the instruments or the pedicle screw can include a tracking device 52 . The tracking device 52 can be tracked by within the navigation system 10 , such as with either or both of the tracking systems including the optical localizer 40 or the EM localizer 42 during the surgical procedure.
The tracking device 52 allows the navigation system 10 to determine and illustrate a position of the pedicle screw 120 , the implantation instrument 126 , or combinations thereof relative to image data acquired of the patient 14 . For example, as illustrated in FIG. 5 , an icon 120 i can be superimposed on the first acquired image data 64 a of the patient 14 as the pedicle screw 120 is moved towards the vertebra 124 of the patient 14 . As illustrated in FIG. 5 , as the pedicle screw 120 moves towards the vertebra 124 , an icon 120 i can be illustrated to move towards and into the vertebra image data 64 a . The icon 120 i can be a preformed CAD model of the screw including a priori precise dimension information. The preformed model can be stored in the navigation memory device 62 can be accessed by an appropriate processor, such as the navigation processor 60 . It will also be understood that the image data 64 a of the vertebra can include other information such as a centerline icon 140 that can be automatically or manually determined relative to the image data 64 a.
The navigation system 10 , by tracking the pedicle screw 120 either directly or through a navigated instrument, can be used to illustrate or determine a position of the pedicle screw 120 relative to the vertebra 124 . By illustrating an icon 120 i superimposed on the image data 64 a of the patient 14 , the user 54 can guide or be given feedback regarding the position of the pedicle screw 120 relative to the patient 14 and the vertebra 124 . Accordingly, at a selected time, the user can select to stop driving the pedicle screw 120 into the patient's 14 vertebra 124 based upon the position of the icon 120 i or other appropriate information.
Once the user 54 determines to stop driving the pedicle screw 120 into the vertebra 124 , second image data 154 of the subject can be acquired in block 150 . The second image data acquired of the patient 14 in block 150 can be image data that is acquired with the imaging system 12 , or any appropriate imaging system, of the patient 14 after the pedicle screw 120 is positioned within the vertebra 124 . As illustrated in FIG. 6 , the second image data of the vertebra 124 can include image data of the vertebra 124 ′ and image data of one or more pedicle screws 120 ′. The image data of the pedicle screws 120 ′ can be or may be distorted or include artifacts due to the type of imaging modality used by the imaging system 12 . For example, the pedicle screw 120 can be formed of a metal which can generate artifacts in x-ray image data acquired of the patient 14 . The artifacts can generate a fuzzy or distorted image of the true dimensions of the pedicle screw 120 in the second acquired image data.
After the second image data has been acquired of the patient 14 in block 150 , the image data can be displayed as a second image 154 on the display 66 , as illustrated in FIG. 6 , and/or transferred to in the appropriate processor (e.g. the imaging processor 58 or the navigation processor 60 ) block 156 of the flowchart 100 . It will be understood, as discussed above, that transferring the image data to a second image data processor is not required. Rather the second image data can also be processed in the processing unit 58 of the imaging system 12 or in the navigation processing unit 60 , or in any appropriate processing unit. As discussed above, the inclusion of multiple processors can be used to speed processing and specialization of processing tasks. It will be understood, however, that a single processor can execute various program modules to process image data, navigate, track instruments, and track devices and the like. Accordingly, including more than one processing unit is not a requirement.
The second image data, which can be referred to herein by the second image 154 formed by the second image data, can be compared or subtracted from the first image data, which can be referred to herein by the first image 64 a - c formed by the image data. As illustrated in FIG. 6 , the second image data 154 can include image data of both the vertebra 124 , such as an x-ray image 124 ′, and can also include image data of the pedicle screw 120 , as pedicle screw shadows 120 ′. It will be understood that more than one pedicle screw can be implanted into a single vertebra for a single procedure. According to various embodiments, the imaging device 12 can cause artifacts in the image data 154 after the implant 120 is positioned within the anatomy of the patient 14 .
As illustrated schematically in FIG. 6 , the shadows of the pedicle screws 120 ′ are indistinct or lack sharp edges. The fuzziness can be caused due to artifacts in the imaging process of the implants 120 , via processing artifacts, or other imaging issues with imaging the implants 120 . Regardless, the second image data 154 that includes image data relating to the implants 120 that have an implant into the patient 14 while performing the selected procedure in block 114 can lead to an imprecise determination of position of the implants 120 in the patient 14 with the second image data 154 .
Subtraction of the first image data from the second image data in block 158 can be performed to identify or eliminate from the second image data 154 substantially all of the second image data 154 that is not related to the implants 120 in the vertebra 124 . Also, tracking information and a priori information regarding the dimensions of the implant or interaction of the implant can be used to determine more precisely the position of the screws 120 . A priori information can include precise screw or other implant dimensions, including width, length, etc. A priori information can include interactions such as dilation of the anatomy from the screw, etc.
The screws are tracked relative to the patient 14 that has been registered to the image data 64 , 154 , as discussed above. Thus, a position of the screw 120 can be determined in the image data 154 based on the tracked position of the screw 120 . The dimensions of the screw 120 , based on the a priori information in the CAD model (or other model information) can be used with the determined location to assist in determining the position of the screw 120 ′ in the second image data 154 . This can also help with the subtraction, as discussed herein.
As illustrated in FIG. 7 , subtraction of the anatomical image data included in the first image data 64 can be used to generate augmented second image data of the implanted member in block 160 . The generated augmented second image data of the implant, as illustrated in FIG. 7 , can include image data which only occurs in the second image data 154 after the procedure is performed. Generally, the first image data 64 can be subtracted from the second image data 154 to generate the augmented image data 154 ′. In addition, the a priori information can be used to assist in the subtraction of the second image data that does not occur due to the implant image 120 ′.
The generated augmented second image of the implanted member in block 160 can generate augmented second image data 154 ′. The augmented second image data 154 ′ can include substantially only the image data as it relates to the placement or is caused by the implants 120 positioned in the patient 14 . In the augmented second image data 154 ′, the shadows of the implants 120 ′ can be illustrated on the display 66 , either alone or with other icons, as discussed further herein.
In addition, the generation of the augmented second image data of the implanted member in block 160 can also be generated using information relating to the navigation (including location and orientation, sometimes referred together as position) of the implants 120 into the vertebra 124 . As discussed above, the instrument 126 can be tracked as the procedure is performed. The position of the screws 120 can be illustrated relative to the first image data 64 , as illustrated in FIG. 5 where the pedicle screw icon 120 i is shown relative to the vertebra image 124 ′. The position of the pedicle screw 120 can therefore be determined, via tracking the screw 120 with the tracking device 52 , relative to the patient 14 . As discussed above, the patient 14 can be registered to the image data 64 and tracked with the patient tracking device 48 . In addition, various landmarks, such as the centerline 140 , can be determined relative to the tracked position of the pedicle screws. Accordingly, the position of the pedicle screw 120 that is tracked relative to the patient 14 can also be used in identifying and determining the portion of the second image data 154 that substantially defines the pedicle screw 120 alone. Moreover, the known or a priori structure of the pedicle screw 120 can be inputted into the system, such as the navigation system 10 , and further be used to identify the portion of the second image data 154 that is the pedicle screw 120 . For example, a pedicle screw can be known to have a selected length X maximum width Y and a thread width TW that can also be used to identify the portion of the second image data that relates to the pedicle screw 120 . The dimensions of the screw 120 can be part of a pre-formed model (e.g. a CAD model) including a priori dimension information of the screw 120 .
All of the information, including the tracking data, the dimensions of the pedicle screw 120 , and the subtraction of the first image data 64 can be used to generate the augmented second image data 154 ′. Once the augmented second image data 154 ′ has been generated in block 160 , the portion of the image data that is the pedicle screw 120 ′ can be overlaid or replaced with the pre-formed or CAD model of the implanted member in block 166 . The CAD model can include or be the icon 120 i of the screw being implanted that is overlaid substantially on the augmented second image data 154 ′ that identifies the implanted positions of the screws 120 . The CAD model can include the precise dimensions of the implanted member 120 and can be overlaid on the augmented image data 154 ′ at the positions identified as the area relating to the implants 120 . It will be understood that the image data 64 , the second image data 154 , and the augmented image data 154 ′ can all be two dimensional and/or three dimensional data. Further, the icons 120 i can also include three dimensional structures or information and can be overlaid in orientation and location relative to the acquired image data 154 ′ and landmarks therein, such as the centerline 140 . Therefore, the icons 124 i can be overlaid at the determined position of the implanted members 120 in the image data.
After the CAD representation of the implants 120 i has been overlaid or positioned at the identified position of the implants in block 166 , the augmented or generated second image data 154 ′ can be removed in block 170 leaving substantially only the icons 120 i representing the CAD models. A determination of the position of the implanted member can be made in block 172 which can include the tracked information regarding the implanted implants 120 , the augmented image data 154 ′, and other information. The position of the implants can be used for confirmation, as discussed below.
Once the overlaid or determined position of the icons 120 i ′ is determined, they can be superimposed onto the second image data 154 and displayed on the display 66 in block 180 . The user 54 can then observe the second image data with the superimposed icons in block 182 . The second image data 154 , as discussed above, is acquired after the implantation of the implant 120 has occurred. Accordingly, the second image data 154 is a substantially concurrent or current image of the patient 14 . Therefore, having the icons 120 i superimposed on the second image data 154 can provide a substantially clear indication to the user 54 of the precise location of the implanted members 120 in the vertebra 124 . Because the position of the implants 120 was determined substantially precisely via the image subtraction, the tracking information, and other information, the icons 120 i are superimposed on the second image data 154 at substantially the precise location where they are implanted in the patient 14 . The icons 120 i , however, do not suffer from any artifacts or blurring due to imaging artifacts of the implants 120 . Accordingly, the icons 120 i provide a substantially precise and clear image to the user 54 of the position of the implants 120 in the vertebra 124 .
The position of the implants 120 in the vertebra 124 can be confirmed to ensure non-perforation and proper placement of the implants 120 in the vertebra 124 . Perforation of a vertebra by the implant 120 may be undesirable for various purposes known to one skilled in the art. Thus, the icons 120 i can be used by the user 54 to ensure that a procedure has occurred according to the plan of the user 54 or according to preferences of the user 54 . The confirmation procedure can then end in block 184 .
The confirmation procedure can be used to assist in determining that a selected procedure has occurred or that an implant has been positioned in the patient 14 as selected by the user 54 . According to various embodiments, a procedure can be planned based upon a pre-planned or generated planned procedure that can include inputs and substantially automatically generate a plan for a selected procedure, such as positioning the pedicle screw 120 into the vertebra 124 .
A program or algorithm can be executed based upon various inputs to identify a plan for achieving or performing a selected procedure. For example, as illustrated in FIG. 9 , an algorithm can be used to identify a proposed entry point 200 , a proposed path of implantation 202 , the centerline or other anatomical feature of the vertebra 140 , an angle 204 relative to the centerline 140 , selected implant for implantation (e.g. specific dimension, model, etc.), and other appropriate features of a planned procedure. The proposed entry point 200 and the proposed path of implantation 202 can be maintained or input as a planned entry point 200 and a planned path of implantation 202 . The proposed entry point 200 and the proposed path of implantation 202 can become planned based on agreement by the user 54 , such as a surgeon or automatically. Additionally, the algorithm can be executed by a processor automatically based on a plurality of saved instructions that can be saved on an appropriate storage device or medium.
The plan, as illustrated on the display 66 , can be based upon preferences from the user 54 . For example, the algorithm can include accessing a database of preferences of the user 54 , such as preferred instrumentation, preferred implant models, preferred entry points, preferred angles, and other appropriate user preferences. The user preferences can be accessed by the algorithm to identify an appropriate or preferred entry point 200 for the user 54 for the specific patient 14 . For example, the user 54 may prefer to have an entry angle 204 of about 10 degrees. The database accessed by the algorithm can access the user preferences of having the approximately 10 degree entry angle and identify entry points 200 and trajectories to achieve the preferred entry angle. Accordingly, the algorithm can identify and assist in planning a procedure.
Preferences of the user 54 can be input or generated in a selected manner. For example, prior to a procedure the user 54 can input user preferences, such as selecting an implant, entry point, etc. The user 54 may be presented with a form and enter in the appropriate information on the form. The form may be on a monitor (to allow the user 54 to input the preferences directly) or the form can be written and the preferences can be entered by an appropriate data entry person.
Preferences of the user 54 can also be stored or “generated” by the planning algorithm. A procedure may be performed by the user 54 and the selected implants, entry point, angle and/or path of implantation, and other parameters can be stored by the memory device. The processor executing the planning algorithm can then access the memory device and retrieve the parameters of one or more previous similar or identical procedures. As more procedures are completed by the user 54 the planning algorithm can better predict or select proposed and/or planned entry points, implants, and other parameters for a new or subsequent procedure performed by the user 54 . Additionally, a plurality of users can access the same database of past procedures so that plans need not be based on only the experiences of one user.
The pre-planned procedure can also be used to assist in confirming placement of the implant 120 in the vertebra 124 . The confirmation can be used to ensure that the planned procedure has occurred and the implant, such as the pedicle screw 120 , has been positioned in the planned position. For example, the user 54 can select or generate a plan based upon preferred and optimal positioning. The second image data 154 with the superimposed models can be compared to the generated plan for confirmation.
The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the invention, and all such modifications are intended to be included within the scope of the invention.
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A system and method for a procedure that can be performed on any appropriate subject. Procedures can include assembling any appropriate work piece or installing members into a work piece, such as an airframe, autoframe, etc. Regardless of the subject, generally the procedure can have a selected result that is efficacious. The efficacious result may be the desired or best result for the procedure. The system and method can be used in confirming a selected result that can be efficacious.
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This application is a 371 filing of International Patent Application PCT/EP2008/067072 filed Dec. 9, 2008.
FIELD OF THE INVENTION
The invention relates to the field of manufacturing beverage production machines, particularly machines which are designed to produce a beverage using a pre-portioned beverage or liquid comestible (soup etc.) ingredient such as e.g. capsules or pods containing ground roasted coffee.
For the purpose of the present description, a “beverage” is meant to include any liquid food, such as tea, coffee, hot or cold chocolate, milk, soup, baby food, etc. . . . .
BACKGROUND ART
The development and manufacturing of a range of beverage producing machines, in particular those using portioned ingredients such as capsules or pods, offering different functions and/or different beverage delivery capacities, is complex and costly.
There is a need for rationalizing the development and the manufacturing of the beverage machines while still providing a large range of machines with different functions and options for the consumer.
In particular, it would be an advantage to propose a range of highly versatile beverage producing machines using capsules or pods which can be upgraded, i.e. provided with additional beverage-related functions, at low production costs.
FR 2 554 185 teaches a series of modular elements which can be combined together so as to constitute an espresso coffee beverage system. The modular elements are associated side by side. One element is a coffee producing module. Another element is a steam producing module. Each element comprises an electrical connection.
WO 2007/141334 discloses a modular beverage production system with a docking station and a beverage production module having inter-connected control circuitries. The control circuitry of the module can be disconnected from the circuitry of the docking station for an autonomous control of the module when the module is disconnected from the station.
US 2005/0015263 discloses a network of various food services equipment items that can be controlled from a central computer.
OBJECT OF THE INVENTION
It is an object of the invention to rationalize the production of beverage production machines by offering a range of differing beverage production machines.
“Differing beverage production machines” relates to the beverage-relevant functions of the machines, i.e. different beverage production machines differ as to their hardware or software as how they are able to physically or chemically alter characteristics of the beverage. As the beverage is made based on ingredients and one or more liquids, the beverage-related functions relate to any kind of handling a liquid (water, milk, . . . ) or an ingredient. The “handling” relates to the chemical, physical and/or mechanical processing of the liquid(s) or ingredient.
Non-limiting examples for the physical processing are: heating, changing the texture (e.g. frothing), and mixing. An example for the mechanical processing is dosing. A non-limiting example for the chemical processing is: changing the ingredient/liquid interaction.
This object is achieved by means of the features of the independent claims. The dependent claims develop further the central idea of the invention.
SUMMARY OF THE INVENTION
A first aspect of the invention relates to a method of manufacturing a set of beverage production machines with different beverage-related functions. The beverage production machines are designed for producing a beverage on the basis of pre-portioned ingredient batches, in particular contained in packages. The method comprises the steps of:
providing a plurality of identical core units, the core units being provided with control circuitry and a beverage production module designed for housing an ingredient batch and feeding a liquid to the interior of the ingredient batch, providing a plurality of different base platforms, the base platforms differing as to beverage production functions, and manufacturing a set of different beverage production machines by mounting the core units on the top surface of the differing base platforms and by mounting in particular water reservoirs on the base platforms.
The pre-proportioned ingredient batches may be supplied within packages, typically capsules, to the production machine or may be formed in the machine by supplying a pre-determined amount of ingredient from an ingredient reservoir of the machine. Optionally, the ingredient supplied from the reservoir may be transformed before liquid is fed thereto. For example, the ingredient is ground coffee that is supplied to the production machine within packages or from a reservoir of the machine containing a stock of ground coffee. Alternatively, the ingredient is in the form of coffee beans stored in a reservoir that are supplied in batches and ground before the liquid is fed.
Each base platform may be provided with a seat for receiving a core unit and a connection for receiving a water tank and the electrical supply means. Thus, when mounting a core unit on a base platform, in one step, an electrical connection and a fluid connection between core unit and the base platform may be produced.
Another aspect of the invention relates to a set of differing beverage production machines, manufactured by such a method.
According to a still further aspect of the invention, a set of differing beverage production machines is proposed. Each beverage production machine of the set comprises:
a core unit that is provided with control circuitry and a beverage production module that is arranged for housing an ingredient batch and feeding a liquid to the interior of the ingredient batch, the at least one core unit being mounted on one out of a plurality of different base platforms, the base platforms differing as to beverage production functions.
Each base platform may be provided with a seat for receiving a core unit and a connection for receiving a water tank and the electrical supply means.
The base platforms may be provided with water guiding means for supplying water from the water tank to a connected core unit.
The beverage production module can be designed for ingredient batches provided in capsules or pods.
At least one base platform may be designed to accommodate at least two core units and to supply them with water, preferably from a common water tank. The control circuitries of such core units are preferably inter-connected as discussed in below in greater details.
A still further aspect of the invention relates to a beverage production machine. The machine comprises:
one or more units provided with control circuitry and a beverage production module designed for housing a sealed capsule or a pod and for feeding a liquid to the interior of the ingredient batch,
the at least one core unit being mounted on a base platform providing the core unit with electrical power and water from a water tank also mounted to the base platform.
The capsule or pod contains one or more ingredients for producing a beverage or liquid comestible (soup etc,) when interacting with a supplied liquid (water etc.). The interaction can be e.g. mixing, extracting, brewing or diluting.
Yet another aspect of the invention relates to a beverage production machine comprising a plurality of core units, each unit being provided with a beverage production module designed for housing a beverage ingredient batch, in particular an ingredient contained in a package such as a capsule or a pod, and for feeding a liquid to the beverage ingredient batch, wherein at least two of the core units have a common user power switch (or main switch), such as a toggle-switch or rotatable wheel or knob switch.
In one embodiment, the power switch has only two selection positions for switching on and off said at least two of the core units, in particular the entire plurality of core units, simultaneously.
In another embodiment, the machine has a total number of core units and the power switch has one or more selection positions for switching on a number of core units that is smaller than this total number, the remaining core unit(s) remaining switched off.
For instance, the selection position(s) for switching on a number of core units that is smaller than the total number of core units, is/are permanently associated with one or more corresponding core units.
The machine may comprise a control unit, the selection position(s) for switching on a number of core units that is smaller than the total number, designate(s) a number of core units to be switched on simultaneously, the control unit being arranged to select which core unit(s) to switch on based on an individual history of use of the core units. This latter embodiment is particularly advantageous to avoid uneven wear of the core units. Typically, the history that may be taken into account can include the total number of hours of past activity of each core unit and/or the total number of beverage preparation cycles that have been carried out by each core unit.
To simplify the electronic conception and reduce the number of components, such a control unit may incorporate the control circuitry of one or more core units.
A further aspect of the invention relates to a beverage production machine, in particular a machine as described above. This machine comprises a plurality of core units, each unit being provided with a control circuitry and a beverage production module designed for housing a beverage ingredient batch, in particular an ingredient contained in a package such as a capsule, and for feeding a liquid to the beverage ingredient batch. At least two of the core units have their control circuitries connected together via communication means for exchanging data whenever needed.
The presence of communication means between different core units that are part of the same beverage production machine permits the coordination of the operation of these core units. This is of particular importance when the core units share common resources during use, e.g. a froth milk device, material and/or power sources. Communication between the core units can lead to an optimal sharing of the resources and smooth use of the production machine. Such resources may include fluid resources, electrical power resources, ingredient resources, user interface resources, etc.
The communication means are advantageously arranged to allow a bidirectional communication between two inter-connected control circuitries.
Various communication interfaces and connections can be used to inter-connect the control circuitries, such as SPI, I 2 C, USART, USB systems, wire-bound or even wireless systems. However, it has been found that the communication means between two inter-connected control circuitries can advantageously be made of a simple level shifter, which is inexpensive and allows fast communication and can easily be fitted on the existing type of control circuitry for machines with a single core unit.
Advantageously, the communication means between a pair of inter-connected control circuitries comprise: two transmission cables and a neutral cable extending between a pair of inter-connected control circuitries; and a pair of transistors. A less preferred communication means can involve the use of optocouplers. However, these are slower, more expensive and more energy consuming than a transistor-based configuration.
Usually, one of the connected control circuitry has a master status, the remaining inter-connected control circuitry(ies) having a slave status. Such a slave/master configuration of the control circuitries is particularly advantageous to avoid the need of an additional central control unit for controlling and coordinating the control circuitries of the different core units.
Each inter-connected control circuitry can be arranged to periodically communicate its current master or slave status to the remaining control circuitry(ies) using a master/slave signal. Hence, when for some reason, a control circuitry does not send any master/slave signal, for instance when one core unit becomes inactive, e.g. when it is individually switched off or has a failure, the remaining control circuitries can adapt the operation of their respective core unit to the new configuration. A master/slave signal can be sent from an inter-connected control circuitry every few milliseconds, typically at regular intervals that are in the range of 1 to 20 ms, in particular at about 8.33 or 10 ms.
Preferably, each inter-connected control circuitry is so configured to change its status from slave to master and vice versa, whenever needed. This is particularly useful in case a core unit that is in a master status becomes inactive, and whose master function needs to be replaced by another core unit that acquires a master status.
Typically, each inter-connected control circuitry is configured to be in a slave status as a default status. A master determination process is used to change the status of one of the inter-connected control circuitry to a master status when none of the inter-connected control circuitry has a master status.
In practise, when all the inter-connected control circuitries find themselves in a slave status, for instance at start-up or when the master control circuitry has been deactivated, the slaves will wait for a given period of time, e.g. a few tens of milliseconds such as to 250 ms in particular 100 to 200 ms, before initiating a master designation process. A master designation process can involve a random function, for instance a time-based function that runs simultaneously on all slaves and is terminated when the first slave, after a random period of time determined by this function, is assigned the task to carry out the master function and announces itself as new master vis-à-vis the remaining slaves that then remain slaves in the system.
Conversely, a core unit that has a slave status and that is used more intensively than the core unit with the master status, may take over the master status, the former master becoming a slave. This is particularly advantageous when a master status, compared to slave status, is associated with a prioritised access to shared resources while the slaves only have a subsidiary access.
The inter-connected control circuitries can be arranged to communicate between themselves using a synchronisation signal for allocating between the core units one or more shared resources, such as supply sources of material and/or power having a limited availability and/or limited accessibility, so as to provide a synchronised and enhanced allocation of the supply source(s) between the core units over time.
As mentioned above, a control circuitry having a master status can be arranged to allocate the limited supply sources of material and/or power or other resources as needed for its core unit. In such as case, the control circuitry(ies) having a slave status are arranged to allocate to their respective core unit, the residual allocation capacity of the limited supply sources, within the limits of their own needs of material and/or power or other resources.
When the control circuitries of the core units are arranged to send master/slave signals to each other, such signals are optionally superimposed with the synchronisation signal on a same communication channel but separated through time windows.
In one embodiment, each core unit comprises a thermo-block for heating the liquid prior to feeding to an ingredient batch. In such a case, the inter-connected control circuitries can be arranged to synchronise access by the core units of a common power source with overall limited accessibility per time unit and/or a limited availability, to optimise heating in the thermo-blocks within such overall access and/or power limit. Furthermore, to optimise the operation of the thermo-blocks and their heating and therefore the required allocation of electrical power, the temperature of each thermo-block and/or of the liquid heated thereby is preferably monitored by at least one temperature sensor, optionally combined with a flow meter, connected to the control circuitry of the corresponding core unit.
Typically, the beverage production machine will be connected to an electric network with limited power supply. Such limit may be comprised within a range of 10 to 16 A in a European 220 V network. When the power consumption exceeds this limit the network is disconnected from the central power supply, for example by means of a fuse. Typically, the energy consumption of a core unit with a thermo-block is of the order of 1 to 1.5 kW. Operating several core units simultaneously can thus quickly reach the network's power limit and lead to disconnection. To avoid such a disconnection, the inter-connected control circuitries are so configured that the power used at a given time by the beverage production machine does not reach the network limit, if necessary for example by prioritising the access by the different core units to the power supply over time.
Another problem arises from the perturbation caused in the electric network by any access thereto. Only a limited amount of perturbations, voltage changes, caused by the connection or disconnection of electric appliances to the network, are tolerated. Such norms are called the flicker standards (e.g. EN 61000-3-3) whose limits should not be exceeded by such appliances.
In the context of the beverage production machine of the invention, the temperature of the fluid that is then fed to the ingredient batch should be adjusted to ensure the quality of the final beverage. For instance, for a coffee extraction, the temperature of the fluid, i.e. water, should be maintained within a narrow range, usually from 80 to 90° C., preferably around 86° C.±3° C. When thermo-blocks use a two-state resistor type heater, i.e. an “on or off” type heater with no intermediate level, the temperature adjustment of the heater can only be achieved by adjusting the respective lengths of successive connections and disconnections of the heater to the electric power supply. However, each connection or disconnection induces a perturbation of the network relevant for the flicker standard. It is therefore up to the different inter-connected control circuitries to adapt the connections and disconnections of the thermo-blocks in such a manner that the flicker limits are not exceeded. In particular, to reduce the number of connections/disconnections, the inter-connected control circuitries can be arranged, not only to limit to control the frequency of connections/disconnections of the different thermo-blocks but also to arrange the disconnection of one thermo-block simultaneously with the connection of another thermo-block, i.e. to switch the power supply from one thermo-block to another so that the overall power intake of the beverage production machine remains at a constant level, despite the machine's internal connections/disconnections, and does thus not cause any disturbances in the external electric network to which the beverage production machine is connected.
Therefore, the inter-connected control circuitry of each core unit can be arranged to send a synchronisation signal to the other inter-connected control circuitries for each individual access to the power source with limited accessibility per time unit, so that the overall access limit of the power source per time unit is not exceeded by the total accesses by the different core units during the corresponding time unit. In particular, the inter-connected control circuitries may be so arranged that all the core units enter a pause mode when the overall access limit during a time unit is reached or close to be reached, no liquid heated by the thermo-blocks being fed to an ingredient batch during the pause mode until the corresponding time unit has ended and a new a time unit has started.
For instance, the inter-connected control circuitries are so arranged to count during a time unit all accesses to the power source for heating batches of the liquid passed through the thermo-blocks and then fed to the ingredient batch, and arranged to enter a pause mode when during said time unit the heating by a thermo-block of a further batch of liquid would necessitate a number of accesses to the power source that would lead to exceeding the overall access limit.
It follows that the greater the control of the temperature of the fluid passing through the thermo-block, the greater is the number of accesses (connections and disconnections) of the thermo-block to follow closely a desired temperature profile. It may therefore be necessary, when a close control of the temperature is desired, to reduce the number of heated batches of fluid that are passed through the ingredient batches. In other words, the higher the temperature-related quality of the beverages, the lower the frequency at which the beverages may be produced with the beverage production machine.
For example, in the case of a beverage production machine having two core units for extracting coffee batches, in particular in the form of packages, such as capsule, it will be possible to configure the control circuitry so as to have a pause period/extraction time ratio in the range of 0.25 to 0.5. In other words, in a time period of 10 min., it will be possible to extract coffee (and heat water in the thermo-blocks) between 3 to 8 min which correspond to 3 to 8 cups of coffee, and allow the machine to pause during 2 to 7 min. Typically, or 6 high quality coffee can be extracted during a period of time of 10 min. and leave the machine inactive for about 4 min. during this 10 min. period of time.
Should the user have exhausted the maximum number of beverages that can be prepared during a specific period of time, a cycle, he will have to wait, during a pause period, until a new cycle has begun.
In comparison, in the case of a beverage production machine with two core units that are configured to extract a coffee at 86° C. with a deviation of no more than 3° C. and that are not coordinated as described above, i.e. which can be operated independently and freely from one another, without any consideration for connections and disconnections of the thermo-blocks, the flicker limit may be exceeded by about 50%. If the core units are coordinated but no pause mechanism is provided, the flicker limit may still be exceeded by about 10%.
Further details, objects and advantages of the invention will become evident for the skilled person when reading the following detailed explanations of embodiments of the invention when taken in conjunction with the Figures of the enclosed drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described with reference to the schematic drawings, wherein:
FIGS. 1 to 3 show three different examples of a system of the invention; each example comprising a common core unit 2 , 2 A, 2 B and different base platforms 1 , 3 , 4 onto which the core unit (or units) is (are) attached. FIG. 3 a shows a front view of the system shown in FIG. 3 , FIGS. 3 b and 3 c showing an enlarged top view of two power toggle-switch suitable for such a system.
FIG. 4 shows a flow chart of the modular manufacturing method of the invention.
FIG. 5 shows the interior of a core unit according to the invention.
FIG. 6 shows the rear side of a core unit according to the present invention.
FIG. 7 shows side panels of a core unit.
FIG. 8 shows a core unit in a state ready for being mounted on a base platform.
FIG. 9 shows the base plate of a core unit, which base plate is the interfacing surface to a base platform.
FIG. 10 shows a detail of FIG. 9 in order to illustrate a water (fluid) connector.
FIG. 10 b shows the electrical connection of the core unit with the base platform.
FIG. 11 shows the screwing of the base platform to the core unit to achieve a final secured connection.
FIG. 12 shows a core unit mounted on a first base platform.
FIG. 13 shows a frame (chassis) of a core unit according to the present invention.
FIG. 14 shows a modified core unit according to the present invention.
FIG. 15 is a schematic drawing of the electronic circuit of a level shifter that connects two control circuitries according to the present invention.
DETAILED DESCRIPTION
In FIG. 1 , one example for a configuration comprising a core unit 2 and a base platform 1 is illustrated. The base platform has the minimal functions as to the fluid management, which is supplying the core unit 2 with electrical power and with water from a water tank 7 attached to the base platform. To this regard the base platform 1 according to this example is provided with integrated electrical circuitry to be connected to the mains. Additionally, the shown base platform is provided with water feed lines connecting the water tank 7 with a fluid connector arranged at the top surface of the base platform 1 , on which top surface the core unit 2 is fixedly mounted.
“Fixedly mounted” indicates that the core unit is mounted on the base platform 1 at the manufacturing site. Thus, the mounting is “fixed” in the sense that a consumer can not easily detach the core unit from the base platform 1 . Preferably the core unit 2 is screwed or bolted to the base platform 1 .
Alternatively the core unit 2 can be mounted on the base platform 1 such that a user can detach it, e.g. in order to transport it easily or in order to replace the platform (e.g. by a different one having differing functionalities). This releasable mounting can be achieved e.g. via locking means which can be manually released e.g. via a push-button.
In the shown example, the base platform comprises a base support 5 with a seat 50 to receive the core unit assembly 2 , a drip tray 6 and a removable water tank assembly 7 . Drip tray 6 is covered with a grid member or perforated plate for supporting a receptacle to be filled with beverage via an outlet nozzle in delivery cover 28 .
In FIG. 2 , a more sophisticated configuration of the system is shown in which the base platform 3 comprises a master switch 9 , a base support 5 , a drip tray assembly 6 , a removable water tank assembly 7 and a milk frothing assembly 8 . The milk frothing assembly 8 is one example for a fluid management device able to alter the chemical or physical characteristics of a liquid.
FIG. 3 is a rear view and FIG. 3 a is a front view of another configuration in which two core units 2 A, 2 B are connected to a single base platform 4 with a master switch 9 . One trip tray assembly 6 is provided. Alternatively, two drip trays assemblies may be provided for each of the core units 2 A, 2 B.
A retractable cup support member 6 A is provided above drip tray assembly 6 for supporting small size cups under the beverage outlet in outlet cover 28 . Larger cups or mugs can be placed directly on drip tray assembly 6 when support member 6 A is in its retracted position. On the left-hand side of FIG. 3 a , support member 6 A is shown in its retracted or rest position, pivoted upwards against core unit 2 A. On the right-hand side of FIG. 3 a , support member 6 A is shown in its deployed horizontal position for supporting small cups.
Switch 9 of the system illustrated in FIGS. 3 and 3 a is shown in greater detail in FIG. 3 b . FIG. 3 c illustrates a variation of such a switch.
Switches and interfaces and their constructional features are well known in the art, as for instance disclosed in AT 410 377, CH 682 798, DE 44 29 353, DE 20 2006 019 039, EP 1 448 084, EP 1 676 509, EP 1 707 088, EP 08 155 851.2, FR 2 624 844, GB 2 397 510, U.S. Pat. No. 4,253,385, U.S. Pat. No. 4,377,049, U.S. Pat. No. 4,458,735, U.S. Pat. No. 4,554,419, U.S. Pat. No. 4,767,632, U.S. Pat. No. 4,954,697, U.S. Pat. No. 5,312,020, U.S. Pat. No. 5,335,705, U.S. Pat. No. 5,372,061, U.S. Pat. No. 5,375,508, U.S. Pat. No. 5,645,230, U.S. Pat. No. 5,731,981, U.S. Pat. No. 5,836,236, U.S. Pat. No. 5,927,553, U.S. Pat. No. 5,959,869, U.S. Pat. No. 6,182,555, U.S. Pat. No. 6,354,341, U.S. Pat. No. 6,759,072, U.S. Pat. No. 7,028,603, U.S. Pat. No. 7,270,050, U.S. Pat. No. 7,279,660, U.S. Pat. No. 7,350,455, US 2007/0157820, WO 97/25634, WO 99/50172, WO 03/039309, WO 2004/030435, WO 2004/030438, WO 2006/063645, WO 2006/082064, WO 2006/090183, WO 2007/003062, WO 2007/003990, WO 2008/104751, WO 2008/138710 and WO 2008/138820.
Switch 9 is of the toggle-type with a lever 91 movable along a selection path 92 into various selection positions 93 to 98 .
Toggle-switch of FIG. 3 b has three selection positions and allows a user to:
switch on left core unit 2 A or right core unit 2 B, as indicated by position 94 and corresponding visual sign “L/R” for “Left” or “Right”, switch on left core unit 2 A and right core unit 2 B simultaneously, as indicated by position 95 and corresponding visual sign “L+R” for “Left” and “Right”, or switch off both core units 2 A, 2 B, as indicated by position 93 and corresponding visual sign “OFF”.
When a user does not need both units to be operational at the same time, for example because he or she only wants one cup of beverage to be prepared, the user will move toggle-switch member 91 into selection position 94 . In this position, the system will determine itself which unit 2 A or unit 2 B should be activated, for instance in view of the history of use of units 2 A and 2 B so as to allow even wear of the two core units, used separately over time. In this case, the system includes a control unit that stores, typically in an electronic memory device, the history of use of the core units 2 A and 2 B. Alternatively, if one core unit is in no condition to be operated, for instance because it requires servicing, the control unit may be arranged to active the other core unit.
FIG. 3 c shows another toggle switch that has a selection lever 91 movable along a selection path 92 into various positions to: switch off the system as indicated by selection position 93 ; switch on the left-hand unit 2 A as indicated by selection position 96 ; switch on the right-hand unit 2 B as indicated by selection position 97 ; and switch on both units 2 A, 2 B as indicated by selection position 98 .
The machine may also be provided with an automatic shut-off mode, such as a timer-based mode. In this case, the power-switch may be automatically returned into its “OFF” selection position 93 when the automatic shut-off mode runs an automatic shut-down process on the machine.
In a variation, it is also possible to provide a different multi-position switch such as a rotatable knob or wheel or cursor with a selection scale.
In FIGS. 1 to 3 a , power switch 9 is shown on base platform 1 , 3 , 4 . However, it is also possible to locate such power switches elsewhere, in particular on a core unit.
In a further variation, it is also possible to provide only two operative modes, e.g. via a two-position button, namely: all core units 2 A, 2 B switch on or all core units 2 A, 2 B switched off.
Furthermore, a common water tank 7 is provided. Thus the shown base platform 4 does not only accommodate a plurality of core units 1 , but has the fluid management functionality of having means for distributing water from a common water tank 7 to a plurality of core units.
Note that different fluid management functions can be achieved via hardware and/or software.
As has been shown with reference to FIGS. 1 to 3 a , different platforms are provided which distinguish from each other by their respective fluid management equipment. The core units according to the invention, however, do all have common fluid management equipment. This leads to a modular manufacturing of beverage production machines which will now be explained in the following.
FIG. 4 shows a flow chart representing the modular concept of the invention. A common core unit A or B can be connected respectively to different platforms 1 , 3 or 4 to produce specific machines 1 , 3 or 4 . It can be noted that a limited number of core units can be selected that fits a higher number of base platforms offering different functions. Therefore, a base machine 1 can be easily upgraded (preferably at the manufacturing site and not by the consumer) by exchanging the platform 1 by a second platform 3 which has different fluid management functions than platform 1 . Also, the platform 4 may receive two core unit A, B or A and B, thus offering a larger choice of machines.
The difference in core units A and B may comprise slight variations. However, the core units A and B should be essentially of the same size for fitting in each of the platforms 1 , 3 or 4 .
In FIG. 5 is illustrated an inside view of a core unit of the system. It comprises a frame 10 . See FIG. 13 for the frame 10 alone. On the frame is assembled a brewing module 11 . The brewing module comprises means for holding a substance containing capsule, e.g., a coffee capsule, and beverage delivery means such as a beverage duct.
The holding means typically comprises a capsule holder and brewing cage, a fluid injection system for injecting water in the capsule and a closure device such as a lever and a knee joint mechanism. Suitable extraction modules are described in EP 1 859 713. Since the system is modular, other brewing units of different designs could be associated to the frame for upgrading mechanical functions or receiving other capsule formats or types (e.g., filter pods).
A water heater such as a thermo-block 12 or similar thermal bloc inertia-type heaters is provided in the frame and connected to it. The water heater is associated to the brewing module via a priming valve 13 and soft tubular lines 14 , 15 . For ease of connection, clipping means may be used to connect the tubular lines to the different elements.
A pressure pump 17 is provided to supply water to the water heater at a high pressure. Therefore, the pressure pump is associated to the water heater by means of a soft tubular line 16 . The pump can be a piston pump. A flow meter 18 is also provided upstream the pump to count the volume of water sucked by the pump and distributed to the water heater and therefore to enable a precise beverage volume management. Water line 19 represents the cold water entering the water connection entry 21 and leading to the flow meter 18 . Water line 20 represents the cold water line exiting the water connection exit 22 coming from the priming valve 13 . This line 20 is to balance the pressure in the fluid circuit by purging air and/or water during the priming operation of the system. The valve is described in more detail in EP 1 798 457.
An electronic circuitry 23 is also disposed in the frame to control the different elements of the core unit, in particular, the water heater, the pump and the flow meter.
One or two button prints 24 are also placed on the side of the module which are electronically connected to the electronic circuitry 23 . These are known per se and typically soft pads enabling to open/close the electronic circuit for running the pump. Each print 24 may serve for a programmed volume of water to be pumped corresponding to a beverage size, e.g., a short espresso coffee of 40 mL or a long coffee cup of 110 mL.
In FIG. 10 b one can see, at the rear of the core unit, a possible embodiment of an electrical connector 37 and the water connectors 21 , 22 representing the essential connections to be connected to matching connecting means of the selected base platform.
The different elements are typically connected to the frame by screws, rivets or equivalent connecting means.
As illustrated in FIG. 6 , a cover 25 is connected to the frame to at least partially mask the components of the frame. Then on FIG. 7 , two side panels 26 , 27 are hooked and fixed to the cover on each side of the core unit to finalize the masking of the components.
FIG. 8 represents the core unit 1 as available for being associated to different base platforms. A front beverage delivery cover 28 can be snap fitted to the side panels for masking the front of the brewing unit.
At the front of core unit is provided in the frame a cavity 29 for lodging a capsule collecting basket 29 a which can freely slide in the cavity. The basket is placed below the brewing module for collecting the waste capsules that fall by gravity after brewing and opening of the module by the lever. A recipient 29 b under the basket 29 a is provided to separate waste water from the waste capsules. Thus, the cleaning and the handling of the core unit are enhanced.
In FIG. 9 , a base platform 5 (seen upside down in this Figure) is selected and associated to the core unit 2 of FIG. 8 . The base platform comprises a base support made of injected plastic. FIG. 12 shows the upper side of the base platform with a central seat 50 forming a hollow recess sufficient to receive the core unit. As illustrated in FIG. 8 , the core unit 1 can comprise a lower front engaging portion 31 that can fit in a front connecting recess of the base platform (not shown) to ensure a better connection.
The final secured connection can be done by screwing of the base platform to the core unit as shown in FIG. 11 .
FIGS. 9 and 10 show a recess 36 at the rear and bottom end of the base platform for connecting the water connectors 21 , 22 of the core unit to the water connector 32 of the base platform in the water tank connecting zone. In FIG. 12 , one can see the water tank 7 which is removably mounted on the connecting zone of the base platform. A recessed and/or protruding structure 33 can be provided for a better fitting of the tank on the platform.
On FIG. 10B , one can also see the recess 36 of the platform being equipped with the electrical connection 37 of the core unit 2 for connecting it to the base platform. The connection can be made by flying cables as known per se.
FIG. 14 shows another system with a similar core unit 2 B and a different base platform 6 C. The core unit 2 B is technically identical to the core unit described in relation to the previous Figures but may have aesthetic variants such as a different finish surface, e.g., a metallised or chrome-plated surfaces.
The base platform 6 C has new fluid management functions compared to the base platform of FIG. 12 . It may have a cordless milk frothing assembly 8 . Therefore, the base platform comprises a dedicated area 34 forming support with a cordless electrical connection able to receive in a removable manner a milk frothing jug 80 . The milk jug has mechanical whipping elements for whipping liquid milk. A description of a cordless milk frothing assembly itself is described in detail in WO 2006/050900.
The base platform may also comprise a cup support area 35 . This support area can comprise heating elements, e.g., a resistive heating surface for maintaining the cups at a warm temperature. The heating elements can be switched on as soon as the platform is supplied in current of the main.
It can be noted that the base platforms provide the water and electrical supplies to the core unit. Peripheral functions can be provided such as milk frothing function, cup heating function, a hot water delivery (e.g., by a heating water kettle) additional brewing capacity, etc. The base platform does not need to receive an electronic circuitry although such circuitry is not to be excluded if complex functions would require a specific control, e.g., independent from the control of the core unit. In case, the platform would require a control circuitry, the core unit can work as a master unit and the base platform as a slave unit or vice versa.
In any case, if two or more core units are provided each having control circuitry, a protocol for coordinating the control is provided. E.g. the protocol can coordinate the control such that one of the core units has a higher priority control than the respectively other one.
As illustrated in FIGS. 3 and 3 a , more than one core unit can be connected to a selected platform adapted for this purpose. Each control circuitry of the units can work independently or in a master/slave relationship to ensure a proper energy management control. In particular, compliance with particular flickering norms (e.g., EN61000-3-3) requires the coordination of the empowering of the water heaters and eventually enforcement of current breaks in the extraction frequencies or limitation of simultaneous or overlapping extraction cycles.
FIG. 15 is a schematic drawing of the electronic circuit of a level shifter 60 that connects two control circuitries illustrated in doted lines 60 A and 60 B, each having a micro controller associated with the level shifter 60 . The level shifter 60 comprises two transmission lines 61 , 62 and a neutral line 63 to equalise the electric potentials of the control circuitries 60 A, 60 B. Each line 61 , 62 connects the control circuitries through a transistor 64 .
Such a level shifter 60 permits a fast bidirectional communication between control circuitries 60 A and 60 B at a low price.
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A modular method of manufacturing a set of beverage production machines with different beverage-related functions. The machines are designed for producing a beverage on the basis of pre-portioned ingredient packages. The method includes providing a plurality of identical core units having control circuitry and a beverage production module for housing an ingredient package and feeding a liquid to the interior of the ingredient package, providing a plurality of different base platforms that differ as to beverage production functions, and manufacturing a set of different beverage production machines by mounting respectively at least one of the core units on a top surface of one of the differing base platforms while also mounting water reservoirs on the base platforms.
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This application is a division of U.S. patent application Ser. No. 07/479,889, filed on Feb. 14, 1990, now U.S. Pat. No. 5,081,437, entitled A PRESSURE SENSOR OF THE SEMICONDUCTOR-ON-INSULATOR TYPE, AND A PIEZORESISTIVE ELEMENT SUITABLE THEREFOR."
BACKGROUND OF THE INVENTION
The present invention concerns a pressure sensor of the semiconductor-on-insulator type, and a piezoresistive element suitable for incorporation in such a sensor.
Pressure sensors of the diffused gauge type are well known. European Patent Application No. 109992 describes such a sensor. A very thin deformable diaphragm is formed by machining in a semiconductor wafer, for example of silicon, and a border is left in existence around the diaphragm for mounting the diaphragm in the body of the sensor. To measure the pressure or the pressure difference applied to the diaphragm, piezoresistive gauges are formed on the diaphragm by localized doping of the semiconductor material. In general, there are four diffused gauges mounted in a Wheatstone bridge. One possible solution for implanting the gauges is the following: two of the gauges are disposed in zones of the diaphragm where the stresses due to the pressure are positive, the other two being disposed in zones where the stresses due to the pressure are negative.
One of the problems raised by diffused gauge sensors resides in the fact that it is very difficult to achieve a thorough electrical isolation between the gauges, since they are formed by P-type implantation or diffusion in a substrate of N-type silicon and the insulation between each gauge and the substrate is formed by a PN junction. This insulation problem is further increased when the temperature to which this sensor is subjected increases. Typically, these sensors are limited to a temperature of 130° C.
The technology of silicon-on-insulator (SOI) permits the problem of insulation between the substrate and the gauges to be resolved. The article by E. Obermeier published in IEEE Transactions 1985, pages 430 to 433, describes such a pressure sensor. The silicon substrate is covered with an insulating layer, for example silicon oxide, and the piezoresistive gauges are individually formed on the insulating layer. As in the case of diffused gauges, the sensor comprises four gauges: two central gauges and two peripheral gauges. At the center of the diaphragm, the curve of stresses is "flat", that is to say that the zone of maximum stress is relatively "long". The two gauges disposed in this region are the I-shaped type, that is to say that they have a single part which has a substantial length. At the periphery of the diaphragm, on the contrary, the curve of stresses is very "pointed", that is to say that the zone of maximum stresses has a reduced length. This is why the gauges are placed in U-shapes which are each constituted by two half-gauges of reduced length (forming the limbs of the U) connected at one of their extremities by a conductive connection.
One of the problems in the implementation of these sensors resides in the fact that U- and I- shaped gauges have very different forms. Further, U- shaped gauges comprise two supplementary ohmic contact zones which introduce additional series resistance. It is therefore very difficult to give the four gauges identical resistances. Additionally, the resistance of the gauges themselves and the resistance of the metal-semiconductor contact (zone of ohmic contact) does not vary in the same way with temperature, which makes it impossible to balance the bridge at zero pressure for all temperatures in a given range of temperatures (offset effect). It should be added that if the electrical conductors which connect the gauges together do not all have the same electrical resistance, the effect of temperature variations on these conductors can also introduce drifts in the offset of the bridge. Offset compensation is generally achieved by external compensation elements, for example resistances, which do not have the same temperature coefficient as the gauges of the bridge. It is therefore more difficult to correct the offset in a satisfactory manner in a given range of temperatures as the initial offset to be compensated becomes larger.
Another difficulty resides in the fact that, to obtain an accurate measurement, it is necessary to protect the gauges with respect to electrostatic charges which can be produced on the surface of gauges of semiconductor material, or more precisely on the surface of the protective layer of the gauges. These charges have the effect, directly or indirectly, of modifying in a variable and random manner the cross section of the effective path for the current flowing in each gauge. In the case where the gauge is formed from doped polycrystalline silicon, the electrostatic charges can affect the carrier density in the gauge to a depth of up to 100 A. To eliminate this effect, there is formed on each gauge an electrostatic screen which thus avoids the formation of electrostatic charges. The formation of these screens and their connection to the rest of the circuit are delicate operations, and risk in their turn introducing into the measurement bridge formed by the four gauges asymmetries leading to an unbalance of the bridge and inducing drifts with temperature.
An object of the invention to provide a pressure sensor on an insulating support capable of operating at high temperature (for example 200° C.), which has a bridge of piezoresistive semiconductor gauges having a more symmetrical geometry than bridges of the prior art, which permits the voltage unbalance of the bridge at zero pressure to be eliminated or at least very substantially reduced, so considerably simplifying the implementation of the compensation elements.
According to a first aspect of the invention disclosed herein and claimed in our parent application Ser. No. 07/479 889 now U.S. Pat. No. 5,081,437, the pressure sensor comprises an insulating support, four piezoresistive gauges formed on the insulating support in a semiconductor material, two gauges being U-shaped and two others being I-shaped, and is characterized in that each of the four gauges comprises two half-gauges, each half-gauge comprising an elongate sensing zone of semiconductor material and of reduced width in the plane of the support, two ohmic contact zones disposed at the ends of the half-gauge, and two connection zones in semiconductor material and of greater width disposed between said sensing zone and said ohmic contact zones, the form of the two connection zones being the same for the eight half gauges.
As a result of these characteristics, the global structure of the sensing element constituted by the four piezoresistive gauges is more symmetrical than in the embodiments of the prior art. Additionally, the particular disposition of the gauges permits the surface of the conducting parts serving to connect the gauges together and to the rest of the measurement bridge to be reduced.
Preferably, said sensor also comprises eight screen electrodes in conductive material, each screen electrode covering one of said half-gauges, one end of each screen electrode being electrically connected to a contact zone of the corresponding half-gauge.
A problem which can be encountered with semiconductor on insulator gauge sensors resides in the form of the piezoresistive gauges formed on the insulating support.
Thus, a component formed on an insulator typically comprises a flat insulating support, for example in silicon oxide, on which is disposed the component itself, which is of suitably doped semiconductor material. The component is defined by etching away an initial layer of the semiconductor material so as to leave in existence only the part of the layer necessary to make the component. The component therefore has the form of a "mesa" which stands proud of the upper surface of the insulating support.
In the case where the component is a piezoresistive element, the component ought to have the shape of an elongate bar of constant width. Often, however, the piezoresistive element is provided at each end of the bar with a rectangular electrical connection zone of which the width is greater than that of the bar, to minimize the dispersion of the resistivity characteristics in the manufacturing process.
To define the piezoresistive element and to connect it to the rest of the circuit of which it forms part, it is necessary to deposit on the element successive layers of various kinds, for example a passivation layer followed by a metallization layer followed by an insulation layer, etc. These different layers necessarily overflow or overlap the semiconductor layer defining the piezoresistive element. In a cross-sectional view, these overlapping layers may cause increased stress concentrations in a narrow region around the lateral corner edges of the piezoresistive layer. These stresses concentrations may cause in time a relaxation of the structure and result in some changes of resistivity of the piezoresistive material in that narrow region with corresponding uncontrolled offset variations.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to alleviate this problem.
According to this invention, there is provided a method of forming a piezoresistive element on an insulating support, the element comprising a useful zone of predetermined width and at each end of the useful zone, a connection zone, the method comprising the steps of depositing on said insulating support a layer of semiconductor material, and selectively etching away said layer so as to form a zone wider than said useful zone between said connection zones, said method further including locally doping a zone of said layer with a dopant conferring on said doped semiconductor material piezoresistive properties, said doped zone having the form of said useful zone and said connection zones.
Preferably, said connection zones are equal in width to said wider zone.
Another problem with SOI piezoresistive gauge sensors lies in the rather unexpected vulnerability of the gauges to damage by electrostatic discharge (ESD), particularly when they are made of doped polysilicon. This vulnerability is somewhat surprising, since diffused gauge sensors are not especially vulnerable to ESD, so that SOI piezoresistive gauge sensors might have been expected to be similar in this respect.
However, we have found that in diffused gauge sensors, the aforementioned PN junctions which serve to isolate each gauge from the substrate also operate as diode to limit the voltage which can be applied to the gauges, so providing them with intrinsic protection against ESD. This intrinsic protection is absent in SOI piezoresistive gauges, by virtue of the extremely good insulation provided by the insulating support.
This ESD problem can be overcome by providing a pressure sensor comprising an insulating support and at least one piezoresistive gauge formed in a semiconductor material on the insulating support, the sensor further including a zener diode, arranged to be reverse-biassed in normal operation of the sensor, connected in parallel with the gauge so as to protect it from damage by electrostatic discharge.
Because the diode is reverse biassed and normally operated well below its zener voltage, it does not affect the normal operation of the gauge.
BRIEF DESCRIPTION OF THE DRAWING
In the Drawing:
FIG. 1 is a vertical sectional view of a silicon element prepared for making a sensor according to the invention;
FIG. 2 is a plan view of the silicon element, illustrating the first etching step of the polycrystalline silicon;
FIG. 3 is a plan view showing the second step of deposition and etching of a passivation layer;
FIG. 4 is a plan view showing the third step of deposition and etching of a first metallization layer;
FIG. 4a is a vertical sectional view along the line AA of FIG. 4;
FIG. 5a is a plan view showing the steps of deposition and etching of a thick insulating layer and a second layer of metallization;
FIG. 5b is a vertical sectional view along the line BB of FIG. 5a;
FIG. 6a and 6b are plan views showing a variant of the steps shown by FIGS. 2 to 4;
FIG. 7 shows another variant of the step shown in FIG. 5b;
FIG. 8 shows a variant of the step of FIG. 2 according to the present invention, as that step is used in connection with the steps shown in FIGS. 6a and 6b; and
FIG. 9 is a simplified circuit diagram showing how the piezoresistive gauge of the embodiment of FIG. 6a and 6b is connected in a Wheatstone bridge and provided with ESD protection.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIGS. 1 to 5, a preferred embodiment of a pressure sensor of the silicon-on-insulator type according to the invention will be described.
As FIG. 1 shows, the starting point is a silicon substrate 10 of which the rear face 12 is subsequently etched to form a cavity 14. The monocrystalline silicon preferably has the orientation [100] and the substrate has a thickness of the order of 500 micrometers. On the front face 16 of the substrate 10, a layer 18 of silicon oxide SiO 2 is formed, for example by oxidation of the silicon. The layer 18 preferably has a thickness of the order of 5000 A. On the layer 18 of SiO 2 , a layer 20 of polycrystalline silicon is formed. The layer 20 has a thickness of between 2000 A and 5000 A. The polycrystalline silicon is doped with boron with concentrations of boron of 10 19 to 10 20 atoms cm -3 . Several techniques can be used to form the polycrystalline silicon layer 20. In particular, the technology called LPCVD (Low Pressure Chemical Vapor Deposition) is cited.
In the following step illustrated in FIG. 2, the doped polysilicon layer 20 is etched away throughout its entire thickness so as to leave only the shape indicated globally by reference 22. The remaining part 22 has the general shape of a rectangle having two large sides A and B disposed along two parallel directions XX' and YY'. The large sides A and B are connected by small sides C and D perpendicular to the sides A and B. The small sides C and D have a constant width a. The large sides A and B are identical.
The remaining etched part 22 of polysilicon is formed of four elements 24, 26, 28, 30 respectively corresponding to U-shaped gauges U 1 and U 2 and to I-shaped gauges I 1 and I 2 . The elements 24 and 26 are identical and the elements 28 and 30 are also identical. As has already been indicated, according to the invention each gauge is formed by two half- gauges. The gauges U 1 and U 2 are respectively formed by the half-gauges J 1 , G 1 and J 4 , G 4 , and the gauges I 1 and 2 are respectively formed by the half-gauges J 2 , J 3 and G 2 , G 3 . As FIG. 2 shows, the polysilicon elements forming the half-gauges J 1 to J 4 are disposed along the axis XX', while the half-gauges G 1 to G 4 are disposed along the axis YY'. Each half-gauge is constituted by a sensing or useful zone, two connection zones and two ohmic contact zones. At the level of the polysilicon, the sensing zone takes the form of an elongate bar of length l and width c. The connection zones of the half-gauges are defined by portions of width b of the elements 24 to 30 of polysilicon. The gauge I 1 , as far as the polysilicon is concerned, comprises the sensing zones 32 and 34 and the end portions 36, 38 and 40, the portion 38 being common to the half-gauges J 2 and J 3 . The gauge I 2 has exactly the same form. The gauge U 1 also comprises two sensing zones 42 and 44 of width c and length l, and three end portions 46, 46 and 50. The intermediate end portion has a special shape, since it is formed by the combination of the small side C and two portions 52 and 54 respectively disposed along the directions XX' and YY'. The gauge U 2 has exactly the same form as the gauge U 1 .
In the following step, illustrated by FIG. 3, a passivation layer 56, typically of silicon nitride (Si 3 N 4 ), is deposited over the whole piece to a thickness of about 1000 A. The layer 56 covers the remaining parts 24 to 30 of polysilicon as well as the insulating layer 18. Then windows are produced in the layer 56. These windows, referenced 60 to 82, are arranged above each portion of polysilicon of width a or b, that is to say above each end portion. For the gauge I 1 , the windows 60, 62 and 64 are arranged above the end portions 36, 38 and 40. For the gauge U 1 , the windows 82, 80 and 78 are arranged above the end portions 46, 48, 50. For the gauges I 2 and U 2 , there are identical dispositions. the windows all have a width d slightly less than the width a or b of the corresponding polysilicon portions. The extremity of each window is positioned exactly at a distance e from the extremity of the corresponding sensing zone. For example, the two edges of the window 62 disposed above the connection portion 38 of the gauge I 1 are respectively disposed at the distance e from the extremities of the sensing portions 32 and 34 of this same gauge. It is the same for the other windows of the other gauges referenced 66 to 82.
In the following step illustrated by FIG. 4, a first metallization consists, for example, of a layer 84 of a combination of titanium and tungsten of a thickness of 1000 A to 1500 A. The first metallization layer is etched away so as to leave only the parts shown in FIG. 4.
FIG. 4 shows that the first metallization layer 84 is constituted in fact by twelve zones Z 1 to Z 12 separated one from the other. Each of the metallization zones Z 1 to Z 4 is disposed above the sensing zones and the intermediate connection portion of a respective gauge. For example, for the gauge I 1 , the metallization zone Z 1 covers the connection portion 38 and the sensing zones 32 and 34. The metallization Z 1 is connected by its central part directly to the polysilicon through the window 62. The rest of the metallization is insulated from the polysilicon by the passivation layer. the metallization zones Z 5 to Z 12 permit the connection of each end of each gauge to other elements of the bridge. They will be called interconnection metallization. One end of each of these metallizations Z 5 to Z 12 is disposed with respect to a window in such a manner that there is an electrical connection between this metallization and the polysilicon. For example, for the gauge I 1 , the metallization Z 5 is partly facing the window 60 while the metallization Z 6 is partly facing the window 64. The metallizations Z 1 to Z 4 constitute "screen" electrodes for the gauges I 1 , I 2 and U 1 , U 2 respectively. The midpoint of a "screen" electrode is thus electrically connected to the midpoint of a gauge, that is to say to the intermediate connection portion which connects the sensing zones of the two half-gauges forming the gauge. It can equally be considered that each metallization Z 1 to Z 4 constitutes two "screen" electrodes covering the two half-gauges of the same gauge. The median part of each of these metallizations then serves to electrically connect each electrode to the midpoint of the gauge under consideration.
Functionally, the sensing element is completed with its two U-shaped gauges (U 1 and U 2 ), its two I-shaped gauges (I 1 and I 2 ) and its screen electrodes Z 1 , Z 2 , Z 3 and Z 4 , and its connections to the bridge Z 5 to Z 12 .
By reference more particularly to FIG. 4a, it will be better understood how the different parts are defined with great precision by virtue of the method of the invention.
If a half-gauge is considered, for example the half-gauge J 3 , it comprises a sensing zone of width c and of length l. These dimensions were defined with precision during the etching of the layer 20 of polysilicon. The half-gauge J 3 also comprises two connection zones of width b, this width also being defined with great precision during the etching of the polysilicon. Each connection zone has a length e, which is also defined with great precision for the following reason: during the creation of the windows 62 and 64 (see FIG. 3), their extremities were created with great precision at the distance e from the extremities of the sensing zone 32. And the polysilicon in the windows 62 and 64 is directly in contact with the metallization layer 80. From the point of view of electric current flow, since the metal has an electrical conductivity very much higher than that of the polysilicon, all the current flows in the metal as if there were no polysilicon underneath it. The zones of polysilicon directly covered by the first metallization form the ohmic contact zone.
In this manner, eight polysilicon half-gauges J 1 to J 4 and G 1 to G 4 are obtained, which have exactly the same form particularly at the transition between the useful zone and the ohmic contact zones (windows 66 and 68). In effect, this transition is made by the connection zone, and the sixteen connection zones are identical. For example, the half-gauge J 2 is connected to the half-gauge J 3 by the portion of the metallization Z 1 bounded by the window 62; the half-gauge G 2 is connected to the half-gauge G 3 by the portion of the metallization Z 3 which is bounded by the window 74; and the half-gauge J 1 is connected to the half-gauge G 1 by the portion of the metallization Z 4 bounded by the window 80. According to the exemplary embodiment, the dimensions a and b are equal to 100 microns; l is equal to 100 microns; c is equal to 10 microns and e is of the order of 20 microns. The length of the large sides is equal to 1400 microns, and the length of the small sides is equal to 300 microns.
The way in which the screen electrodes are formed will now be described. The metallization Z 1 constitutes the screen electrode for the half-gauges J 2 and J 3 . In effect, the metallization Z 1 covers these two half-gauges while being separated from them by the passivation layer 56. This screen electrode is connected to the rest of the circuit by the contact between the metallization layer 84 and the polysilicon through the window 62. Thus from the electrical point of view, the midpoint of this screen electrode is connected to the midpoint of the gauge I 2 formed by the half-gauges J 2 and J 3 . It will be understood that the part of the metallization Z 1 which penetrates into the window 62 plays a triple role: it constitutes one of the ohmic contact zones for the half-gauges J 2 and J 3 ; it forms the electrical connection between these two half-gauges; and it connects to the bridge the screen electrodes covering the half-gauges J 2 and J 3 .
If the U-shaped gauge U 1 is now considered, a similar disposition is found. The metallization Z 4 , which covers the half-gauges J 1 and G 1 , forms the screen electrode for this gauge. The electrical connection between the screen electrode and the rest of the electrical circuit is made through the window 80. The electrical connection between the half-gauges J 1 and G 1 is made by the portion of the metallization Z 4 bounded by the window 60. This portion of the metallization Z 1 therefore plays the dual role already explained in the preceding description of the gauge I 1 .
In the following step, illustrated by FIG. 5a, a thick insulating deposition 100 is made. It can be, for example, a deposition of silicon oxide of a thickness of about 6000 A. This deposition covers the entire sensing element. It is then etched away to form eight windows 102 to 116 which are disposed facing the portions of metallization 84 referenced Z 5 to Z 12 . In these windows 102 to 116 the first metallization is exposed.
In the last step, a second metallic deposition 120 is formed (for example of aluminum), which penetrates into the windows 102 to 106. This deposition 120 is etched away to leave only the zones L 1 to L 8 . These conductive zones serve to connect the four gauges of the sensing element of the sensor to the rest of the measurement bridge.
It can thus be seen that any desired components can be inserted between any two gauges of the bridge, for example to effect compensation with the help of resistances.
The build-up of the different depositions is best visible in FIG. 5b, which is a section in the zone of the second metallization 120.
The present invention has a number of advantages with respect to the techniques of the prior art. In the first place, thanks to the fact that the I-shaped gauges are formed by two half-gauges which are themselves strictly identical to the half-gauges forming the U-shaped gauges, the four gauges have exactly the same form as far as the piezoresistive portions which they comprise are concerned. In particular, the special features (passage from the useful zone of a half-gauge to the ohmic contact zone) are equal in number (four) in the four gauges, and the form of these special features is always the same.
As a result of this symmetrical and regular disposition, the effects of these special features rigorously compensate for each other when the whole sensing element is considered.
A sensor in accordance with the present invention can operate over a temperature range of -50° C. to 200° C. with an offset voltage of less than 0.3 mV from the Wheatstone bridge.
Another advantage of the disposition of the gauges according to the invention is that the length of the interconnections between the gauges is significantly reduced with respect to the solutions of the prior art. As a result, differential thermal effects are also significantly reduced.
The preferred way of forming the screen electrodes also has a number of advantages. Each screen electrode has its midpoint electrically connected to the midpoint of each gauge (at the connection between the two half-gauges forming the gauge). However, it will be understood that the screen electrodes could be formed differently: each screen electrode covers a half-gauge (in all, eight screen electrodes). The electrode is then connected by one of its ends to the ohmic contact zone of the half-gauge which is not also the zone of contact for the gauge in question.
In the preceding description, each gauge has two ends which are terminated by an electrical connection, permitting the insertion in the bridge between two gauges of any desired components. However, as has been indicated, thanks to the particular structure of the gauges, the offset voltage is significantly reduced. It is therefore possible for certain applications to introduce no compensation elements for the unbalance voltage.
In this case, the implementation of the sensor can be slightly modified. This is what is shown in FIGS. 6a and 6b.
The essential difference resides in the way in which the electrical connection between the gauges is formed. As FIG. 6a shows, there is no separation, at the level of the polysilicon, between the different gauges. For example, between the sensing zones 32 and 34 of the half-gauges J 1 and J 2 (of FIG. 2), there is a single connection portion referenced 36'. Similarly, between the sensing zones of the half-gauges J 3 and J 4 there is a single connection portion 40'. As far as the windows opened in the passivation layer are concerned, one is found above each connecting portion. For example, the window 130 is found above the connection portion 36' and the window 132 above the connection portion 40'.
During the first metallization step (FIG. 6b), eight metallization zones Z' 1 to Z' 8 are formed. These metallizations Z' 1 to Z' 4 which cover the gauges are identical to the metallizations Z 1 to Z 4 of FIG. 4 and play the role of "screen" electrodes. The metallizations Z' 5 to Z' 8 are connection metallizations. They play a double role: on the one hand they connect together the ends of neighboring gauges; on the other hand, they permit the connection of the gauges to the rest of the bridge. For example, the metallization Z' 5 connects the gauge I 1 to the gauge U 1 .
FIGS. 1 to 5 show a first embodiment of the sensor in which the gauges of the sensor are not initially connected to each other. In contrast, FIGS. 6a and 6b show a second embodiment in which the four gauges of the sensor are all interconnected. It is clear that between these two extreme solutions, several intermediate solutions can be adopted. For example, only the connection between the gauges U 1 and I 2 may be open.
The interconnection between two gauges can be made as in the case of FIGS. 6a and 6b. It can equally be arranging the metallization layer 84 to bridge the gaps between gauges etched as shown in FIG. 2: that is what FIG. 7 shows.
In the embodiments described above, the layer of doped polycrystalline silicon was etched away to the insulating support to define the alternating zones of width b and of width c. As indicated hereinbefore, the rather sharp steps defined at the lateral edges of the zone of width c can cause a problem, so FIG. 8 illustrates, in accordance with the present invention a modification of the step of FIG. 2, as that step is used in conjunction with the steps of FIGS. 6a and 6b, for overcoming this problem. Thus the layer 20 of polysilicon is etched away to leave only the part 222'. The remaining part 222' is a hollow rectangle having two longer sides A' and B' and two shorter sides C' and D', the width of the sides being b throughout their entire length. The alternating zones of width b and of width c are obtained during the doping of the silicon, which is preferably carried out by ion implantation (which is very accurately controllable) prior to the etching step. The doped region is indicated by cross-hatching within dotted lines. This doped region has exactly the same shape as the portion left after the etching step of FIG. 2. The following steps of the method of fabrication are identical to those described above with reference to FIGS. 3 to 5b.
Clearly the modified doping technique described in relation to FIG. 8 can also be used in making the embodiment of the sensor described with reference to FIGS. 1 to 5.
FIG. 9 shows how the gauges I , I 2 , U 1 and U 2 of the embodiment of the invention described with reference to FIGS. 6a and 6b are connected to form a Wheatstone bridge. A stabilized bridge voltage V b is applied between pins 310, 312 of the sensor, the pin 310 serving as a positive pin and being connected internally of the sensor to the metallization Z' 5 of FIG. 6 b and the pin 312 serving as a negative pin and being internally connected to the metallization Z' 7 . The output of the sensor appears between pins 314, 316, which are connected internally of the sensor to the metallization Z' 6 and Z' 8 respectively.
As already mentioned hereinbefore, we have found that the polysilicon gauges I 1 , I 2 are vulnerable to damage caused by ESD. This damage takes two mains forms, depending upon the magnitude of the ESD. For relatively small discharge currents, the structure of the polysilicon can be changed only slightly, but sufficiently to permanently change the resistance of the gauge affected and so introduce an offset into the Wheatstone bridge. For larger discharge currents, the polysilicon of the affected gauge can be completely ruptured (as if it were a fuse), and so render the gauge open circuit.
In order to protect the gauges I 1 , I 2 , U 1 , and U 2 against ESD, respective zener diodes ZD 1 to ZD 4 are connected in parallel with each gauge. As can be seen in FIG. 9, the diodes ZD 1 to ZD 4 are all connected to be reverse-biassed in normal use: the respective cathodes of the diodes ZD 1 , and ZD 2 are connected to the positive pin 310, while their respective anodes are connected to the pins 314 and 316 respectively; and the respective anodes of the diodes ZD 3 and ZD 4 are connected to the negative pin 312, while their respective cathodes are connected to the pins 314 and 316 respectively. Suitable zener diodes for use as the diodes ZD 1 to ZD 4 are those available under the designation JEDEC BZX 55 C 10, which have a sufficiently high resistance when reverse-biassed not to affect the normal operation of the sensor, and are capable of operating satisfactorily at temperatures in excess of 200° C.
Clearly, the embodiment of the invention described with reference to FIGS. 1 to 5 can be protected from the effects of ESD by four zener diodes in an exactly analogous manner.
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The method of making a pressure sensor formed of semiconductor material on an insulating support, i.e., as a semiconductor-on-silicon, is described. The sensor is comprised of four piezoresistive gauges formed in the semiconductor material. Two of the gauges, each have a pair of limbs joined by a base, such that they are U-shaped, and two others are I-shaped. Each of the four gauges comprise two half-gauges, and each half-gauge comprises an elongated sensing zone in semiconductor material and having a reduced width in the plane of the insulating support. Two ohmic contact zones are disposed at the ends of each of the half-gauges, and two connection zones in semiconductor material and of greater width are disposed between the sensing zones and the ohmic contact zones, the form of the two connection zones are the same for each of the eight half-gauges.
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The invention concerns a bending machine for processing thermoplastic workpieces and comprises (a) a bending jaw to bend the workpiece, (b) a stop for the front end of the workpiece when inserted into the bending machine, (c) a heater movable within the machine frame toward and away from the workpiece to plasticize bending lines at the workpiece, (d) a clamp stationary at least during operation and adjacent to the bending jaw to tighten in place the workpiece near the bending line during a bending procedure, (e) a holder to hold the workpiece during the heating phase caused by the heater and movable to-and-fro relative to the clamp.
The applicant manufactures such a machine. This machine comprises a stationary clamp at the middle of the machine frame and followed, as seen in the direction of advance of the workpiece, by a strip-like bending jaw suspended in pivoting manner. A heater and a holder are mounted after the clamp and on a frame moving to-and-for relative to the direction of advance. The heater consists of two superposed, vertically displaceable heating knives behind which there is the holder in the form of a tightening strip. A stop strip is present on the other side of the bending jaw and is movably supported on two side rails.
When proceeding to bending, first the stop strip and the frame with the heater and holder are adjusted to be symmetrical with the front edge of the bending jaw, and then are fastened in place. Next a workpiece, initially in the form of a flat blank, is inserted from the rear in such manner that it comes to rest between the clamping strip of the holder and the two heating knives. The front edge of the workpiece rests against stops in the zone of the bending jaw. Then the heating knives are moved closer so that they rest against the two sides of the workpiece which they heat in such manner, thereby forming a bending line, so that the workpiece is deformable at that bending line. During this procedure the workpiece is held in place both by the clamp and by the holder.
Once the bending line has been sufficiently heated, the clamp and the holder are deactivated, that is, the workpiece is released. Next, it is manually moved forward toward the stop strip until resting against it. Thereupon the clamp is reactivated, that is, the workpiece is supported over its broad surface and tightened in place. Next the bending jaw is pivoted upward in relation to the desired angle of bending, whereby that part of the workpiece which is in front of the clamp is bent upward at the bending line. Simultaneously the next bending line is formed by the heating knives being made to rest again against that part of the workpiece which is located there. After bending has been completed, the clamp and holder are released again and once more the workpiece is advanced to the stop strip, so that the heated bending line comes to rest against the front edge of the bending jaw. A further bending procedure follows. Depending on the angle of bending, a cross-sectionally polygonal, especially square pipe or tube segment can be formed.
The drawbacks of this bending machine are the time-consuming adjustment because the stop strip and the frame must be aligned accurately and symmetrically with the heater and holder each time before bending begins. Again alignment is required if the lengths of the sides must be different. Handling during operation is cumbersome, considering that some of the workpieces are very heavy and must be moved by hand. There is more than trivial danger of accidents.
This bending machine has been developed further for the sake of automatically controlling the entire bending process and hence to lower the danger of accidents. As shown by the German patent 36 37 436, the stationary design of the clamp was abandoned and instead it was made movable in and opposite to the direction of advance of the workpiece. Here the clamp no longer serves only to tighten the workpiece in place when bending with the bending jaw. The clamp now also assumes the function of the holder in the known bending machine, that is, the fastening of the workpiece while the heater is forming the bending line. For that purpose the clamp when open is movable from a position near the bending jaw into a position away from the bending jaw with reference to the bending line, and then is transferred into the tightening position. After the bending line has been formed, the clamp again is moved toward the bending jaw and thereby moves the workpiece with the heated bending line as far as the bending jaw. In this bending machine the holder only tightens the workpiece in place when the clamp is in its deactivated state, that is, in its open state, and is moved back from the bending jaw.
Because of this bending-machine design, handling is required only to insert the workpiece. All the remainder is taken over by the bending machine itself. Manual intervention into the machine, with the attendant danger of accident, no longer is required. It is possible to bend in wholly automatic manner, so that, following workpiece insertion and setting of the spacing between two bending lines, further action is not required.
In a special design, the heater of the bending machine of the German patent 36 37 436 is mounted on the clamp so that it is always moved together with it. The holder may be movable in and opposite the direction of advance of the workpiece and it may comprise a lock to tighten it in position relative to the machine frame.
The above described machine is very complex and hence expensive. Moreover it incurs the significant drawback of long cycles, that is, much time elapses between two bending procedures. This is due to the clamp being forced to remain in the position near the bending jaw during bending and further also some time after bending until the bending line has hardened. Depending on the kind and the thickness of the workpiece material, the time loss so entailed is at least 30 to 40 seconds, frequently however several minutes. Only thereafter will it be possible to move back the clamp and form a new bending line using the heater. The advantage of automation and hence of a single operator therefore is traded off against substantially longer cycles compared to the predecessor machine, especially where thick-wall workpieces are concerned.
Accordingly it is the object of the invention to so design a bending machine that on one hand--in the manner of the German patent 36 37 435--manual advance of the workpiece shall not be required between two bending procedures and on the other hand however short cycles shall be achieved with low design complexity.
SUMMARY OF THE INVENTION
This problem is solved by the invention by a bending machine with the following features:
(f) The holder is freely movable during bending-machine operation,
(g) A motor-driven displacement means is provided for moving the holder,
(h) The bending machine comprises a control such that
(aa) the holder in its closed position together with the tightened workpiece can be moved for open clamp toward the bending jaw,
(bb) following the tightening of the workpiece in the clamp, the holder in its open state can be moved back from said clamp, and
(cc) following the tightening of the workpiece in the clamp, the heater can be activated to form a bending line.
Accordingly the bending machine of the invention departs from the principle of the German patent 36 37 436 wherein the workpiece is moved by means of a displaceable clamp. The invention uses the holder for that purpose and provides a corresponding drive and suitable control.
In the first place, the advantage of design simplicity is achieved. The basis may be the initially described original version of the bending machine with stationary clamp. The design changes relative to this version, when compared with those relative to the German patent 36 37 436, are less pronounced, merely free displacement of the holder being required and the clamp requiring being combined with a displacement drive and a control. The additional control assures that the bending machine shall be so operated that, compared with the case of the bending machine of the German patent 36 37 436, substantially shorter cycles are achieved
This is due to the holder on one hand causing the displacement of the workpiece when the clamp is open, while on the other hand allowing being moved back following tightening the workpiece in the clamp in order to form a new bending line by means of the heater. Accordingly the time required to bend the workpiece and to harden the bending line is used to heat and hence to make, a new bending line. Both procedures essentially require the same time. Following opening of the clamp, that is following the bending and hardening procedure, the workpiece can be moved again by means of the holder toward the bending jaw. Therefore at least 30 to 40 seconds, often several minutes, can be saved per bending procedure.
Accordingly a bending machine is provided which offers semi or fully automatic control by one operator, while at the same time featuring exceedingly short cycles and high processing rates. The inventiveness is emphasized by the fact that these advantages are achieved by the comparatively simple design of the bending machine.
In the embodiment of the invention, the heater is mounted on the holder, that is, the heater always shall be displaced together with the holder. In this way no separate control is needed to match the motion of the heater to that of the holder. Appropriately, the heater also can be activated during the motion of the workpiece. In this way the time interval for displacing therefor the workpiece as far as the bending jaw can be used to heat the bending line. Actuation must be construed as the effect of the heater on the workpiece to achieve heating along a line.
In manner known per se the holder may consist of at least two mutually displaceable clamping strips.
The invention is shown in further detail in an embodiment in the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a topview of the bending machine,
FIG. 2 is a front view of the bending machine of FIG. 1 as seen from the bending jaw,
FIG. 3 is a sideview of the bending machine of FIGS. 1 and 2 with partial sections.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The bending machine 1 shown in the Figures comprises a machine frame 2, essentially consisting of a front frame segment 3, two side frame segments 4, 5 and a rear frame segment 6. The frame segments 3,4,5,6 enclose a rectangle 7 essentially clear on the inside.
As shown in particular by FIGS. 2 and 3, the side frame segment 5 rises higher and serves as a frame for an acrylic glass pane 8. An operating desk 9 is set sideways against this lateral frame segment 5.
Guide bars 10, 11 extend each near and parallel to the side frame segments 5, 6 and between the front frame segment 3 and the rear frame segment 6. A holder 12 is supported in displaceable manner in the direction of the double arrow A on these guide bars 10, 11. The holder 12 consists of two superposed clamping strips 13, 14 of which the upper strip 13 can be raised relative to the lower strip 14 or be lowered toward said lower strip in order to tighten a plastic pane by means of a pneumatic actuator not shown herein in further detail. The lower clamping strip 14 is connected to a positioning cylinder 15 lacking a piston rod and mounted parallel and centrally to the guide bars 10, 11 and on a brace 16 extending between the front frame segment 3 and the rear frame segment 6. The positioning cylinder 15 is operated with compressed air. When the lower clamping strip 14 is displaced, the upper clamping strip 13 also is carried along, that is, it retains its relative position to the lower clamping strip 14 to this extent.
A heater 17 is connected to the lower clamping strip 14 of the holder 12. This heater comprises two heating knives 18, 19 which are parallel to the clamping strips 13, 14 and which are superposed but apart; these knives are guided in vertically displaceable manner along side guide bars 20, 21. Pneumatic cylinders not shown in further detail are provided for that purpose. In this manner the heating knives 18, 19 can be moved from above and below toward a plastic plate tightened between the clamping strips 13, 14 in the holder 12. The heating knives 18, 19 are heated with electrical energy.
As shown in particular by FIG. 3., the guide bars 20, 21 are mounted at the lower side to a horizontal crossbeam 22 which is connected by a vertical beam 23 and a horizontal beam 24 to the lower side of the lower clamping strip 14. Accordingly the heater 17 is carried along when the holder 12 is displaced, that is, the position of the heating knives 18, 19 remains the same relative to the clamping strips 13, 14 except for their heights.
A clamp 25 is mounted to the front frame segment 3. The clamp 25 essentially is designed the same way as the holder 12, that is, it also comprises an upper clamping strip 26 and a lower clamping strip 27. The lower clamping strip 27 is stationary. Its top side is the same height as the top side of the lower clamping strip 14 of the holder 12. The upper clamping strip 26 of the clamp 25 is driven into vertical motion by means of pneumatic cylinders not shown in further detail. When the position is open, a plastic plate can be inserted between the clamping strips 26, 27 and be tightened in place by the lowering of the upper clamping strip 26.
A bending jaw 28 is present in front of the clamp 25, namely in front of the lower clamping strip 27. This jaw extends essentially across the width of the machine frame 2 and is pivotable about a horizontal axis, by means of pivot bearings 29, 30, from the horizontal position shown in FIG. 3 to a vertical position. An electric motor 31 is used for that purpose, of which the torque is transmitted by a bevel gear system 32 to the bending jaw 28. In the horizontal position, the top side of the bending jaw 28 is flush with the top sides of the lower clamping strips 14 and 27 of the holder 12 and clamp 25 resp. In addition, a support frame 33 is mounted to the bending jaw 28 to additionally support the plastic part to be bent.
Bending takes place as follows with the bending machine 1 shown above:
First the holder 12 is moved from the operating desk 9 into the shown front end position in order to define a control null position. The clamping strips 13, 14 of the holder 12 and the clamping strips 26, 27 of the clamp 25 are raised into the open position. Also the bending jaw 28 is pivoted upward by 90 relative to the position shown in FIG. 3 in order to form a stop. Now a plastic plate can be inserted from the rear, first between the clamping strips 13, 14 of the holder 12, and then forward between the clamping strips 26, 27 of the clamp 25, until it comes to rest by its front edge against the bending jaw 28.
Next the desired distance of the bending line from the free end of the plastic plate abutting the bending jaw 28 is fed into the control. The ensuing procedure is carried out either manually, that is, semi-automatically, or, if the control has been appropriately programmed, fully automatically.
First the clamp 25 is closed by lowering the upper clamping strip 26 and thereby the plastic plate has been tightened in its place. Thereupon the holder 12 in its open state is displaced to the rear, that is away from the clamp 25, by a suitable control of the positioning cylinder 15, and this by such a magnitude that the heating knives 18, 19 following the stopping of the holder 12 come to a stop above the desired bending line. The plastic plate then is tightened in place in the holder 12 by lowering the upper clamping strip 13. At the same time the two heating knives 18, 19 are moved toward each other until they come to rest against the upper and lower sides resp. of the plastic plate. Then they heat so much of the plastic in the range of the desired bending line that it plasticises and becomes flexible.
Once the bending line has been sufficiently heated, the clamp 25 is opened by lifting the upper clamping strip 26. Thereupon the holder 12 is displaced again toward the bending jaw 28 by suitably controlling the positioning cylinder 15. At the same time the heating knives 18, 19 are detached from the plastic plate upward and downward so much that, upon further advance of the holder 12, they no longer may collide with the clamp 25 or the bending jaw 28. The horizontal spacing between the heating knives 18, 19 and the clamping strips 13, 14 of the holder 12 is designed to be such that the heated bending line shall come to rest somewhat above the rear edge of the bending jaw 28 when reaching the front end position of the holder 12.
Thereupon the clamp 25 is closed by lowering the upper clamping strip 26 and thereby the plastic panel has been tightened in place. Next the electric motor 31 is driven in such a way that the bending jaw, together with the support structure 33, is pivoted upward. As a result that part of the plastic plate that was slipped onto the bending jaw 28 is correspondingly bent upward, an arbitrary angle being settable by suitable input into the control.
Immediately after the plastic plate has been tightened in place in the clamp 25, that is, still during the bending procedure, the tightening of the plastic plate in the holder 12 is released by moving the upper clamping strip 13 upward, and the holder 12 is displaced to the rear by means of the positioning cylinder 15 until the heating knives 18, 19 again are flush with the nearest provided bending line. The distance to the first bending line can be set by a corresponding input to the control, that is, this distance may be the same as in the first bending procedure, or a different distance may be fed in. Upon stopping the holder 12, the plastic plate is tightened in place by lowering the upper clamping strip 13 and the heating knives 18, 19 are moved downward and upward resp. to rest against the surfaces of the plastic plate.
A further bending line is formed therefore during the bending and hardening process at the previous bending line, Once this process is complete and the new bending line has been sufficiently heated, the previously described procedure is repeated, that is, the holder 12 is closed while the plastic plate is tightened in place and following opening of the clamp 25 it is displaced toward the bending jaw 28 where the heating knives 18, 19 are moved away from the plastic plate. When the front end position of the holder 12 is reached, another bending procedure ensues in the previously described manner.
If desired, a hollow body may be formed in this way, of which the sole open site is a slit which later can be closed by a suitable welding system.
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A bending machine for thermoplastic workpieces includes a first clamp assembly having first and second clamping jaws. A second clamp assembly is disposed along a first side of the first clamp assembly and includes third and fourth clamping jaws. The second clamp assembly is displaceable relative to the first clamp assembly, and the fourth clamping jaw is in planar alignment with the second clamping jaw. A heater assembly includes at least a first heating knife disposed along the first side of the first clamp assembly, and is displaceable relative to the first clamp assembly. A bending jaw is disposed along an opposite second side of the first clamp assembly and is pivotal between a first position in planar alignment with the second and fourth clamping jaws and a second position angularly disposed relative thereto.
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RELATED APPLICATIONS
This is a continuation of U.S. patent application Ser. No. 11/431,833 filed on May 11, 2006 now U.S. Pat. No. 7,765,770, which is a continuation of International Patent Application No. PCT/CA2004/001586 filed Aug. 31, 2004, which claims benefit of Canadian Patent Application No. 2,449,194 filed on Nov. 12, 2003.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to a service line distribution base suited for supporting utility poles of the type used to support overhead lines in power transmission and in external lighting, such as street, highway and traffic lighting.
2. Description of the Prior Art
Utility poles, such as traffic lights, street lights and those used to support power transmission lines are typically mounted on a concrete base or foundation partly buried in the soil. Threaded rods extend vertically upwardly from the exposed top surface of the concrete base for engagement in corresponding holes or slots defined in a mounting flange provided at the bottom end of the utility pole. Nuts are threadably engaged on the threaded rods for securing the pole on the concrete base.
A wire conduit is typically embedded in the concrete base for allowing buried wires to be connected to above-ground equipment, such as lighting fixtures mounted at the top of the utility pole. The number of wire conduits that can be embedded in the concrete base is significantly limited by the structural weakening of the concrete base each time a new conduit is added. Heretofore, the number of wire conduits extending upwardly through a concrete base of a utility pole has been generally limited to four conduits at most. It would be possible to incorporate more wire conduits in the concrete base by increasing the size thereof but this solution is not suitable in that it would result in oversized mass of concrete about the base of each pole. In addition of being unaesthetic, it would significantly increase the cost associated with the installation of the poles.
With the ever increasing complexity of the power transmission and telecommunication network, there is a need for a new service line distribution base that could accommodate a greater number of wire conduits in a confine space while still offering proper support for utility poles and the like.
SUMMARY OF THE INVENTION
It is therefore an aim of the present invention to provide a new base adapted to accommodate a greater number of wire conduits while still providing proper support for anchoring a utility pole in the ground.
It is also an aim of the present invention to provide an underground base comprising a ground anchoring member having an upstanding cruciform portion.
Therefore, in accordance with a general aspect of the present invention, there is provided a utility pole base comprising a ground anchor having an upstanding cruciform portion adapted to extend into the ground, an above-ground portion defining an internal chamber adapted to house electric wires, said above-ground portion being adapted to support a utility pole.
In accordance with a further general aspect of the present invention, there is provided a utility pole comprising an underground anchor, said underground anchor having an upstaging portion of cruciform cross-section, a cabinet extending axially from said underground anchor and defining an internal chamber for housing distribution equipment, said internal chamber having a bottom opening for receiving wires projecting upwardly from the underground anchor, and a pole segment extending axially upwardly from said cabinet.
In accordance with a still further general aspect of the present invention, there is provided an underground base for supporting a service line receiving member, comprising an anchor member having an upstanding portion of cruciform cross-section adapted to be buried into the ground, said anchor member having a top end portion adapted to project out of the ground, said top end portion being provided with mounting points for allowing a service line receiving member to be mounted on top of said anchor member, said mounting points being distributed on an imaginary perimeter bounding an axially open space for allowing buried wire conduits to extend into the service line receiving member once mounted onto the anchor member.
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 side elevation view of a utility pole mounted to a service line distribution base in accordance with a preferred embodiment of the present invention; and
FIG. 2 is a side elevation view of the service line distribution base;
FIG. 3 is a partly exploded isometric view of the service line distribution base;
FIG. 4 is a side elevation view of a ground anchoring portion of the service line distribution base shown in FIG. 3 once installed in the ground with the wire conduits extending upwardly through the anchoring portion;
FIG. 5 is a top plan view of the anchoring portion installed in the ground;
FIG. 6 is a partially exploded perspective view of the ground anchoring portion of the service distribution base;
FIG. 7 is a partially exploded perspective view of a distribution cabinet forming part of the service line distribution base; and
FIG. 8 is an exploded perspective view of the core components of the distribution cabinet shown in FIG. 7 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows one possible utilization of a preferred embodiment of a service line distribution base 10 anchored in the ground for supporting a utility pole 12 . In the illustrated example, the utility pole 12 is provided in the form of a lamp post including a hollow pole member 14 having a lighting fixture 16 attached at an upper end thereof. It is understood that other type of structures or equipment could be mounted on the service line distribution base 10 . For instance, a medium voltage network pole, a traffic light, a bollard fixture or even a decorative cap.
As will be seen hereafter, the service line distribution base 10 advantageously provides for partial or complete burial of service lines 28 , including power transmission lines and telecommunication lines, such as telephone lines and cable television lines. The base 10 also advantageously provides for the integration of a distribution system at the bottom of a utility pole, which distribution system can be used by power and telecommunication utilities to connect subscribers to the utility lines concealed in the pole and in the ground.
As shown in FIGS. 2 and 3 , the base 10 generally comprises a ground anchoring member 18 and a distribution cabinet 20 . The anchoring member 18 is buried in the ground and the distribution cabinet 20 is bolted on top on the anchoring member 18 at ground level. Alternatively, the cabinet 20 could be an integral extension of the anchoring member 18 .
As shown in FIG. 6 , the ground anchoring member 18 is cruciform and includes a main metal plate 22 on opposed sides of which are symmetrically arranged a pair of identical metal plates 24 . The metal plates 24 are welded to opposed sides of the main plate 22 and extend in a same central normal plane relative to the main plate 22 . Each plate 24 corresponds to a half-plate section of the main plate 22 . Notches or cutouts 26 are defined in the distal side edges of the plates 22 and 24 . The cutouts 26 provides for easy placement of the wire conduits 28 , as shown in FIGS. 4 and 5 . The cutouts 26 also greatly contribute to increase the number of wire conduits that can be incorporated into the base 10 by allowing the same to have a smaller angle of insertion. A central oblong slot 30 is also defined in the main plate 22 for allowing wire conduits 28 to pass from one side of the cruciform anchoring member 18 to the other, as shown in FIGS. 4 and 5 . Likewise, half-slot sections are defined in the confronting side edges of the plates 24 to form a second central oblong slots 32 ( FIG. 6 ) intersecting the first oblong slot 30 centrally in a plane perpendicular to the main plate 22 . Holes 34 are defined in the upper half portion of the plates for allowing the wire conduits to be attached to the ground anchoring member with attachment straps (not shown), such as wires, cables, filaments and the like.
As shown in FIG. 6 , a flat horizontal strengthening member 36 preferably extends diagonally between the bottom ends of each pair of adjacent segment of the cruciform anchoring member 18 .
Mounting plates 38 are welded on the top end edges of each plate 22 , 24 at respective terminal distal ends thereof. Each plate 38 defines a central hole 40 for allowing the cabinet 20 to be secured in position on top of the anchoring member 18 by means of bolts and nuts, as shown in FIG. 3 .
A collar 42 is provided at the top end of the cruciform anchor 18 about the plates 22 and 24 . The collar 42 provides additional strength at the top end of the anchoring member 18 where the external forces exerted on the anchoring member 18 are the more important. Also, it confines the space through which the wire conduits project upwardly out of the ground. The collar 42 is preferably provided in the form of two half segments 42 a and 42 b welded to the distal side edges of the plates 22 and 24 .
As shown in FIG. 6 , small notches 46 are defined along the proximal longitudinal side edges of the plates 24 in order to reduce the amount of welding that need to be made. Welding full height without notches is also contemplated.
Longitudinally extending flat plates (not shown) could be welded centrally all along the distal longitudinal side edges of the plates 22 and 24 to further increase the strength of the anchoring member 18 . Each wall segment of the cruciform anchoring member 18 would then have a T-shape.
Now referring to FIGS. 7 and 8 , the construction of the cabinet 20 will be described. As shown in FIG. 8 , the core of the cabinet 20 comprises a central metal plate 48 having opposed central longitudinally extending top and bottom slits 50 and 52 . Top and bottom cross plates 54 and 56 ( FIG. 7 ) are respectively mounted in the top and bottom slits 50 and 52 . A hook or handle 58 is provided on the top edge of the top cross plate 54 for allowing the cabinet 20 to be lift once assembled. A generally circular top cover 60 is welded on top of the central plate 48 and the top cross plate 54 . The cover 60 defines a central circular hole 62 through which the handle 58 extends. The central hole 62 provides for electric wiring in the utility pole 12 ( FIG. 1 ) to extend into cabinet 20 . Four indentations 64 are uniformly distributed in the circumference of the cover 60 for receiving the top end of four corresponding longitudinally extending legs 66 , 68 , 70 and 72 . The legs 66 , 68 , 70 and 72 are substantially coextensive with the central plate 48 . Legs 66 and 68 are welded to oppose longitudinal side edges of the central plate 48 and in respective indentation in the cover 60 . Legs 70 and 72 are welded to the end edges of the top and bottom cross plates 54 and 56 and in respective indentations 64 in the cover 60 . Each leg 66 , 68 , 70 and 72 has a horizontally extending foot portion 74 defining a hole 76 for allowing the cabinet 20 to be bolted to the mounting plates 38 of the anchoring member 18 (see FIG. 3 ).
Indentations 78 are preferably defined in the side edges of the central plate 48 to minimize the amount of welding that has to be done to secure the legs 66 and 68 to the plate 48 .
The opposed faces of the mounting plate 48 are used to mount distribution equipment, such as power bars, electrical connections, junction boxes, etc.
According to a further embodiment of the cabinet, the central plate 48 can be omitted. Only form reinforced legs would be used.
Radial slots 80 are defined in the cover 60 to provide for the bolting of various structures on top of the cabinet 20 .
As shown in FIGS. 3 and 7 , two half-cover shields 82 are securely mounted on top of the cover 60 . Cutouts 84 are provided in the half-cover shields 82 to provide access to the central hole 62 and the radial slots 80 . Leg covering members 86 are provided for covering the legs 66 and 68 . Four access doors 88 are hingedly mounted between the legs 66 , 68 , 70 and 72 . Each door 88 is provided with its respective locking mechanism 90 so that only authorized person can have access to the interior of the cabinet 20 . Semi circular bandings 92 are mounted to the bottom of portion of the legs 66 , 68 , 70 and 80 below the doors 88 in order to completely close the cabinet 20 .
As shown in FIG. 3 , the assembly of the cabinet 20 is completed by installing semi-circular bumpers 94 at the base of the cabinet 20 once the same has been bolted to the anchoring member 18 .
As shown in FIG. 4 , the service line distribution base 10 is installed by first lowering the anchor member 18 in an excavated hole of about 1.8 m (6 ft) deep and 1.8 m (6 ft) in diameter with a compacted aggregate bottom 98 (90% MP) to 1.68 m (66 in.) below the predicted finished grade level. The top of the anchoring member 18 exceeds the finished grade predicted level by about 65 mm (2.5 in.). The next step consists of backfilling the hole using successive layers of compacted aggregate 100 from bottom, up to the beginning of the notches 26 at 500 mm (18 in.). It is recommended to verify that the anchoring member 18 is plumb (straight) while compacting. It is also recommended to backfill with well distributed aggregates of crushed stones 0-20 mm (0-¾ in.) compacted at 90%. A grounding rod (not shown) with a grounding cable (not shown) is then installed. Thereafter, the wire conduits 28 are installed for the various networks to be incorporated. The wire conduits 28 are preferably attached to the anchor member 18 with attachment straps (not shown) extending through the holes 34 in the anchor member 18 . Thereafter, the excavated hole is full with flowable concrete 102 up to between 125 to 150 mm (5 to 6 in.) below the finished grade. If the quantity of wire conduits exceeds 12 , it is recommended to reduce the size of aggregate in concrete to from 20 mm (¾ in.) to 12 mm (½ in.) to ensure a good penetration of the flowable concrete in the middle of the structure. Once the flowable concrete has solidified, finish landscaping to grade level. The distribution cabinet 20 is then bolted on top of the ground anchoring member 18 . Finally, the utility pole 12 is bolted on top of the cabinet 20 . The resulting structure is then ready for cabling and installation of distribution equipment by utilities.
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A service line distribution base ( 10 ) comprises a ground anchor ( 18 ) having an upstanding cruciform portion adapted to extend into the ground. A cabinet ( 20 ) suited to support a utility pole ( 14 ) extends upwardly from the ground anchor ( 18 ). The cabinet ( 20 ) defines and internal space for receiving buried wire conduits ( 28 ) incorporated to the cruciform ground anchor ( 18 ). The cruciform shape of the ground anchor ( 18 ) advantageously permits to incorporate a greater number of wire conduits ( 28 ) into the base of a utility pole as compared to conventional concrete bases.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This is a continuation-in-part of and claims priority to U.S. non-provisional patent application No. 09/764,150 (the '150 application), filed Jan. 19, 2001, now U.S. Pat. No. 6,673,513 which is incorporated herein by reference for all purposes. In addition, a claim of priority is made to Korean patent application No. 2002-34998, filed on Jun. 21, 2002, which is incorporated herein by reference for all purposes.
The '150 application is a continuation-in-part of U.S. non-provisional application No. 09/576,053, filed May 23, 2000, now U.S. Pat. No. 6,517,990. In addition, the '150 application makes a claim of priority to U.S. provisional application No. 60/198,761, filed Apr. 21, 2000; Korean patent application No. 00-2489, filed Jan. 19, 2000; and Korean patent application No. 00-20603, filed Apr. 19, 2000.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to photosensitive polymers and to chemically amplified resist compositions. More particularly, the present invention relates to photosensitive polymers which includes a copolymer containing adamantylalkyl vinyl ether, and to resist compositions which include the photosensitive polymer.
2. Description of the Related Art
As semiconductor devices become highly integrated, photolithography processes used in the manufacture of such devices must be capable of forming fine patterns. For example, 0.2 μm or smaller sized patterns are needed for semiconductor memory devices having capacities exceeding 1 Gbit. Accordingly, conventional resist materials have limited applicability since they are utilized in conjunction with krypton flouride (KrF) excimer lasers having wavelengths (248 nm) which are too large for use in the formation of ultra-fine patterns. Thus, new resist materials have been proposed for use in conjunction with an argon flouride (ArF) excimer laser. This is because the ArF excimer laser has a wavelength (193 nm) which is smaller than that of the KrF excimer laser.
Present resist materials designed for use with ArF excimer lasers suffer several drawbacks as compared with conventional resist materials. The most common of these problems are low transmittance and poor resistance to dry etching.
Acryl- or methacryl-based polymers are generally used and known as ArF resist materials. Representative examples of such polymers include poly(methacrylate)-based polymer materials. However, such polymers exhibit, amount other potential drawbacks, a poor resistance to dry etching. The selectivity of these materials is generally too low to perform a dry etching process using a plasma gas.
Accordingly, in an effort to enhance dry etching resistance, alicyclic compounds having a strong resistance to dry etching, for example, an isobornyl, adamantyl or tricyclodecanyl group, may be introduced into the backbone of a polymer. However, since only a small portion of the polymer is occupied by the alicyclic compound, resistance to dry etching is still weak. Also, since the alicyclic compounds are hydrophobic, if such an alicyclic compound is contained in a polymer, adhesion to materials underlying a resist layer obtained from the polymer may deteriorate.
As another conventional polymer, a cycloolefin-maleic anhydride (COMA) alternating polymer has been suggested. While the fabrication cost associated with raw materials needed to prepare a copolymer such as the COMA system is low, the yield of the polymer is noticeably reduced. Also, the transmittance of the polymer at short wavelengths, for example, 193 nm, is very low. Further, since such polymers have an alicyclic group in their backbone which is strongly hydrophobic, they have poor adhesion characteristics.
Also, due to the structural characteristics of the backbone, these polymers have a high glass transition temperature of about 200° C. or higher. As a result, it is difficult to carry out an annealing process to remove a free volume present in a resist layer obtained from such polymers. Thus, the resist layer is susceptible to an ambient environment. For example, the resist pattern may suffer a T-top profile. Also, in post-exposure delay (PED), the resist layer exhibits a decrease in stability to an ambient atmosphere, which entails many problems in a variety of processes using the resist layer.
SUMMARY OF THE INVENTION
The present invention provides a photosensitive polymer which exhibits favorable adhesion to underlying layer materials and favorable resistance to dry etching, and which is relatively inexpensive to fabricate.
The present invention also provides a resist composition which exhibits favorable lithographic characteristics when conducting a photolithography process using a light exposure source at a short-wavelength region, e.g., 193 nm, as well as a deep UV region, e.g., 248 nm.
According to an aspect of the present invention, there is provided a photosensitive polymer comprising a copolymer having a formula 1:
wherein x is an integer between 1 and 4 inclusive, R 1 is a hydrogen atom or a methyl group, R 2 is an acid-labile C 4 to C 20 hydrocarbon group, p/(p+q+r)=0.1 to 0.4, q/(p+q+r)=0.1 to 0.5, and r/(p+q+r)=0.1 to 0.4. The photosensitive polymer has a weight average molecular weight of 3,000 to 50,000.
Preferably, R 2 is a t-butyl, tetrahydropyranyl or 1-ethoxyethyl group. Also, R 2 may be an alicyclic hydrocarbon group, exemplified by a 2-methyl-2-norbornyl, 2-ethyl-2-norbonyl, 2-methyl-2-isobornyl, 2-ethyl-2-isobornyl, 8-methyl-8-tricyclo[5.2.1.0 2,6 ]decanyl, 8-ethyl-8-tricyclo[5.2.1.0 2,6 ]decanyl, 2-methyl-2-adamantyl, 2-ethyl-2-adamantyl, 2-propyl-2-adamantyl, 2-methyl-2-fenchyl or 2-ethyl-2-fenchyl group.
According to another aspect of the present invention, there is provided a photosensitive polymer comprising a copolymer having a formula 2:
wherein x is an integer between 1 and 4 inclusive, R 3 is a hydrogen atom, or a hydroxy, carboxyl, halide, nitrile, alkyl, alkoxy, sulfonate or acid-labile C 4 to C 20 ester group, p/(p+q+s)=0.1 to 0.4, q/(p+q+s)=0.3 to 0.5, and s/(p+q+s)=0.2 to 0.5. The photosensitive polymer has a weight average molecular weight of 3,000 to 30,000.
Preferably, R 3 is a t-butyl ester, tetrahydropyranyl ester or 1-ethoxyethyl ester group. Also, R 3 may be an 2-methyl-2-norbornyl ester, 2-ethyl-2-norbonyl ester, 2-methyl-2-isobornyl ester, 2-ethyl-2-isobornyl ester, 8-methyl-8-tricyclo[5.2.1.0 2,6 ]decanyl ester, 8-ethyl-8-tricyclo[5.2.1.0 2,6 ]decanyl ester, 2-methyl-2-adamantyl ester, 2-ethyl-2-adamantyl ester, 2-propyl-2-adamantyl ester, 2-methyl-2-fenchyl ester or 2-ethyl-2-fenchyl ester group.
According to yet another aspect of the present invention, there is provided a photosensitive polymer comprising a copolymer having a formula 3:
wherein x is an integer between 1 and 4 inclusive, R 1 is a hydrogen atom or a methyl group, R 2 is a C 4 to C 20 hydrocarbon group, R 3 is a hydrogen atom, or a hydroxy, carboxyl, halide, nitrile, alkyl, alkoxy, sulfonate or C 4 to C 20 ester group, at least one of R 2 and R 3 is an acid-labile group, p/(p+q+r+s)=0.1 to 0.3, q/(p+q+r+s)=0.2 to 0.5, r/(p+q+r+s)=0.1 to 0.4, and s/(p+q+r+s)=0.1 to 0.3. The photosensitive polymer has a weight average molecular weight of 3,000 to 30,000.
According to still another aspect of the present invention, there is provided a resist composition comprising a photosensitive polymer having the above formula 1, 2 or 3, and a photoacid generator (PAG).
The PAG is preferably contained in an amount of about 1.0-15 wt % based on the total weight of the photosensitive polymer. Preferably, the PAG comprises triarylsulfonium salts, diaryliodonium salts, sulfonates or a mixture of at least two of these compounds.
The resist composition according to embodiments of the present invention may further include an organic base. The organic base may be contained in an amount of about 0.01-2.0 wt % based on the amount of the PAG. Examples of the organic base include triethylamine, triisobutylamine, triisooctylamine, triisodecylamine, triethanolamine, and mixtures of at least two of these compounds.
The photosensitive polymer according to embodiments of the present invention is obtained from a copolymer of an adamantylalkyl vinyl ether monomer and maleic anhydride, providing good adhesion to underlying layer materials and high resistance to dry etching. Also, the backbone of the photosensitive polymer is more flexible than a conventional backbone, contributing to a lowering of a glass transition temperature of the photosensitive polymer. Therefore, the resist composition obtained therefrom exhibits favorable lithographic characteristics when used in photolithography processes.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Non-limiting exemplary embodiments of the present invention are described in detail below.
EXAMPLE 1
Synthesis of 1-adamantylethyl Vinyl Ether
36 g (0.2 mol) of 1-admantaneethanol and 72 g (1.0 mol) ethyl vinyl ether were put into a round bottom flask to be dissolved in 100 mL tetrahydrofuran (THF), followed by adding 5 mol % of mercury acetate. Thereafter, the reaction product was reacted for approximately 12 hours under a reflux condition.
After the reaction was completed, the resulting product was subjected to vacuum distillation to give a desired monomer with a yield of 50%.
EXAMPLE 2
Synthesis of 1-adamantylmethyl vinyl ether
The same procedure as in Example 1 was carried out except that 1-admantanemethanol was used instead of 1-adamantaneethanol, to give a desired monomer with a yield of 40%.
EXAMPLE 3
Synthesis of Photosensitive Polymer
2.0 g (10 mmol) of the monomer synthesized in Example 1, 1.0 g (10 mmol) of maleic anhydride, 2.4 g (10 mmol) of 2-methyl-2-adamantyl methacrylate and 0.15 g (3 mol %) azobisisobutyronitrile (AIBN) were dissolved in 10 g of THF, and purged using a nitrogen gas. Thereafter, the resulting product was polymerized at approximately 65° C. for about 20 hours.
After the polymerization reaction was completed, the reaction product was slowly precipitated in excess isopropyl alcohol (IPA) and filtered. The filtered precipitate was dissolved again in an appropriate amount of THF to then be reprecipitated in n-hexane. The obtained filtrate was dried in a vacuum oven maintained at 50° C. for about 24 hours to give a terpolymer having the above formula with a yield of 70%.
The resultant product had a weight average molecular weight (Mw) of 9,700 and a polydispersity (Mw/Mn) of 1.7.
EXAMPLE 4
Synthesis of Photosensitive Polymer
2.0 g (10 mmol) of the monomer synthesized in Example 1, 1.0 g (10 mmol) of maleic anhydride, 2.2 g (10 mmol) of 2-methyl-2-adamantyl acrylate and 0.15 g (3 mol %) AIBN were dissolved in 10 g of THF, and polymerized in the same manner as in Example 3, to give a terpolymer having the above formula with a yield of 68%.
The resultant product had a weight average molecular weight (Mw) of 10,700 and a polydispersity (Mw/Mn) of 1.9.
EXAMPLE 5
Synthesis of Photosensitive Polymer
2.0 g (10 mmol) of the monomer synthesized in Example 1, 2.0 g (20 mmol) of maleic anhydride, 2.0 g (10 mmol) of 5-norbornene-2-carboxylate and 3 mol % AIBN were dissolved in 12 g of THF, and polymerized in the same manner as in Example 3, to give a terpolymer having the above formula with a yield of 55%.
The resultant product had a weight average molecular weight (Mw) of 8,600 and a polydispersity (Mw/Mn) of 1.9.
EXAMPLE 6
Synthesis of Photosensitive Polymer
2.0 g (10 mmol) of the monomer synthesized in Example 1, 1.5 g (15 mmol) of maleic anhydride, 0.5 g (5 mmol) of norbornene, 3.5 g (15 mmol) of 2-methyl-2-adamantyl methacrylate and 3 mol % AIBN were dissolved in 15 g of THF, and polymerized in the same manner as in Example 3, to give a tetrapolymer having the above formula with a yield of 70%.
The resultant product had a weight average molecular weight (Mw) of 9,800 and a polydispersity (Mw/Mn) of 1.8.
EXAMPLE 7
Preparation of Resist Composition and Lithographic Performance
A method of preparing a resist composition according to embodiments of the present invention will now be described.
First, the photosensitive polymers synthesized in Examples 3 through 6 were dissolved in various types of solvents such as propylene glycol monomethyl ether acetate (PGMEA), ethyl lactate or cyclohexanone with a photoacid generator (PAG) to prepare a resist solution. If necessary, an organic base comprising amines may be added in an amount of approximately 0.01 to 2.0 wt % based on the amount of the PAG. Also, to adjust the overall dissolution speed of the resist, the resist composition may further include 5 to 25 wt % of a dissolution inhibitor, based on the weight of the photosensitive polymer.
The PAG is preferably contained in an amount of 1 to 15% by weight based on the weight of the photosensitive polymer. As the PAG, inorganic onium salts or organic onium salts may be used each alone or in combinations of two or more thereof. Examples of the PAG include triarylsulfonium triflate, diaryliodonium triflate, triarylsulfonium nonaflate, diaryliodonium nonaflate, succinimidyl triflate, 2,6-dinitrobenzyl sulfonate, and the like.
For a lithography process, the resist solution is first filtered twice using a 0.2 μm membrane filter to thus obtain a resist composition.
The obtained resist composition is subjected to the following processes to obtain a pattern.
A bare silicon wafer or a silicon wafer having an underlying layer, such as a silicon oxide layer, silicon nitride layer or silicon oxynitride layer, to be patterned thereon is prepared and treated with hexamethyldisilazane (HMDS). Thereafter, the silicon wafer layer is coated with the resist composition to a thickness of approximately 0.3 μm to form a resist layer.
The silicon wafer having the resist layer is pre-baked at a temperature in the range of 120 to 140° C., for approximately 60 to 90 seconds to remove a solvent, followed by exposure using various types of exposure light sources, e.g., deep UV (KrF or ArF), extreme UV (EUV), E-beam or X-ray. Next, in order to induce a chemical reaction at an exposed portion of the resist layer, post-exposure baking (PEB) is performed at a temperature in the range of 110 to 140° C. for approximately 60 to 90 seconds.
As a result, the exposed portion exhibits very high solubility to a developing solution including 2.38 wt % tetramethylammonium hydroxide (TMAH). Thus, during development, the exposed portion is dissolved well for removal. In the case where an ArF excimer laser is used, a 120 to 140 nm line and space pattern can be formed at an exposure dose of approximately 8 to 25 mJ/cm 2 .
The underlying layer, such as a silicon oxide film, to be patterned is etched by a special etching gas, such as plasma, e.g., a halogen or C x F y gas, using the resultant resist pattern as a mask. Subsequently, the resist pattern remaining on the wafer is removed by ashing and a wet process using a stripper, thereby forming a desired silicon oxide pattern.
Table 1 illustrates the results of a lithographic performance evaluation of the resist compositions according to embodiments of the present invention.
For the evaluation shown in Table 1, 1 g of each of the photosensitive polymers synthesized in Examples 3 through 6, and triphenyisulfonium(TPS) triflate, TPS nonaflate or a mixture thereof as a PAG were dissolved in 8 g of cyclohexane, and 2 mg of triisooctylamine as an organic base or triisobutylamine was added thereto for complete dissolution. Thereafter, a resist solution was filtered using a 0.2 μm membrane filter to give a resist composition.
A silicon (Si) wafer treated with an anti-reflective coating was coated with the obtained resist composition to a thickness of approximately 0.3 μm.
Thereafter, the coated wafer was subjected to soft baking (SB) under temperature and time conditions listed in Table 1, and exposed using an ArF excimer laser stepper (NA=0.6, σ=0.75), followed by performing post-exposure baking (PEB) under temperature and time conditions listed in Table 1. Next, development was performed using 2.38% by weight of a tetramethylammonium hydroxide (TMAH) solution for approximately 60 seconds to form a resist pattern. Resolution characteristics of the resist patterns are shown in Table 1.
Referring to Table 1, triisooctylamine was used as the organic base in Example 7-1, while triisobutylamine was used as the organic base in Examples 7-2 through 7-8.
TABLE 1
Dose
Resolution
Examples
Polymer
PAG
SB
PEB
(mJ/cm 2 )
(nm)
EX. 7-1
EX. 3 (1 g)
TPS triflate (5 mg)
120° C./
120° C./
15
140
TPS nonaflate (10 mg)
90 sec
60 sec
EX. 7-2
EX. 3 (1 g)
TPS triflate (5 mg)
120° C./
120° C./
17
120
TPS nonaflate (10 mg)
90 sec
60 sec
EX. 7-3
EX. 3 (1 g)
TPS triflate (5 mg)
120° C./
130° C./
16
120
TPS nonaflate (10 mg)
90 sec
60 sec
EX. 7-4
EX. 3 (1 g)
TPS nonaflate (20 mg)
120° C./
120° C./
17
120
90 sec
90 sec
EX. 7-5
EX. 3 (1 g)
TPS trifiate (5 mg)
120° C./
120° C./
11
130
TPS nonaflate (10 mg)
90 sec
90 sec
EX. 7-6
EX. 4 (1 g)
TPS triflate (5 mg)
120° C./
130° C./
13
140
TPS nonaflate (10 mg)
90 sec
90 sec
EX. 7-7
EX. 5 (1 g)
TPS nonaflate (15 mg)
120° C./
130° C./
18
140
90 sec
90 sec
EX. 7-8
EX. 6 (1 g)
TPS triflate (5 mg)
120° C./
120° C./
16
120
TPS nonaflate (10 mg)
90 sec
90 sec
As shown in Table 1, in each Example, a 120 to 140 nm, clean line and space pattern was obtained at a dose of 11 to 17 mJ/cm 2 .
The photosensitive polymers according to embodiments of the present invention are obtained from a vinyl ether compound capable of easily forming an alternating copolymer in polymerization with an electron withdrawing monomer, e.g., maleic anhydride. In particular, the photosensitive polymers include an adamantylalkyl vinyl ether as a main component of its backbone. The adamantylalkyl vinyl ether monomer is a compound having a C 1 -C 4 linear methylene group. The resist compositions obtained from the photosensitive polymers exhibit improved resistance to dry etching when compared to conventional resist materials, and provide good adhesion to underlying layer materials.
Also, an alkyl chain in the adamantylalkyl vinyl ether monomer included in the photosensitive polymer according to the present invention provides flexibility to the photosensitive polymer. Thus, the backbone of the photosensitive polymer is flexible, thereby having a relatively low glass transition temperature. Thus, it is possible to achieve a sufficient annealing effect for eliminating a free volume from the resist layer formed of the photosensitive polymer during baking. Accordingly, the resist layer has enhanced environmental resistance even at post-exposure delay (PED). Therefore, the resist compositions according to the embodiments of the present invention exhibit excellent lithographic performance characteristics when used in a photolithography process, which is advantageous in manufacturing next-generation semiconductor devices.
While this invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims.
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A photosensitive polymer includes a copolymer containing adamantylalkyl vinyl ether, and a resist composition includes the photosensitive polymer. For example, the photosensitive polymer may include a copolymer having a formula:
wherein x is an integer between 1 and 4 inclusive, R 1 is a hydrogen atom or a methyl group, R 2 is an acid-labile C 4 to C 20 hydrocarbon group, p/(p+q+r)=0.1 to 0.4, q/(p+q+r)=0.1 to 0.5, and r/(p+q+r)=0.1 to 0.4.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The problem which the invention proposes to solve is to provide a textile backing having a decorative effect or effects.
2. Description of the Prior Art
Generally, in known processes, a backing is used which is usually woven on a Jacquard loom, or a meshed backing made on a crochet loom. Such processes make it necessary to use heavy components and complex motion.
In the case of a Jacquard loom shuttles are used, the capacities of which are limited. In addition, in a Jacquard technique speed is limited having regard to the very high mechanical stresses that occur, especially in regard to the sley, which is of the "swivel shuttle attachment" type.
In knitting loom technology, the loom generally employs a beam and a bar guide which constitute a mechanical assembly that necessitates a long setting-up time and reduced production rate.
In both cases, the reserve yarn capacity is very limited, so that it is difficult to make use of yarns of large cross section. Finally and above all, these techniques are poor from the economic point of view and as regards speed.
A process is known from Patent FR 2 339 011 that combines the techniques of a weaving loom with those of a crochet loom. That document essentially describes the formation of a basic textile backing on a loom, with the simultaneous formation of any kind of decorative effect whatsoever. The decorative effect is anchored on to the textile backing by means of locking meshes which are made simultaneously with said backing. However, the solution for achieving these objects is unsatisfactory, since the means for achieving it are so complicated that the results obtained are not satisfactory.
SUMMARY OF THE INVENTION
An object of the invention is to provide a remedy for these drawbacks in a simple, sure, effective and rational way.
The problem that the invention proposes to solve is to obtain a textile backing with decorative effects by using fast looms, including shuttleless looms, in order to obtain very high production rates, by combining the techniques of weaving and stitching.
According to a basic feature of the invention, a process has been conceived and applied, for the automatic manufacture of a textile backing with decorative effects, in which:
a textile backing comprising weft yarns and warp yarns is made on an automatic loom,
simultaneously with the formation of the backing, at least one decorative effect is formed and anchored on the textile backing by means of meshes made simultaneously with the basic backing,
the bonding needles used in forming the locking mesh are raised across the warp yarn lap of the basic backing,
the bonding needles for forming the locking mesh are retracted under the basic textile backing,
the decorative weft is inserted at right angles to the warp yarns of the basic textile backing,
the bonding needles for forming the locking mesh are shifted and raised again, and simultaneously, the locking mesh yarn is shifted according to a circle arc movement and using binding guides, so as to twill the path of said needles, thereby forming the decorative weft's locking mesh and flattening it against the needles,
at the dead center, the binding guides for forming the locking mesh are displaced in translation at right angles to the warp,
the needles and the binding guides for forming the locking mesh are simultaneously lowered, drawing the mesh-forming yarns by creation of a loop of meshes enclosing the decorative weft,
the decorative weft or wefts are held by the meshes of the warp so as to define portions of the floating decorative weft parallel to the warp, thereby constituting loops of decorative weft which are variable in amplitude and length, in accordance with a predetermined program.
For the application of the process, and for carrying out each of its characteristic steps on any type of high speed loom, the device comprises:
means for distributing the decorative weft or wefts,
means for moving the bonding needles for forming the locking mesh in back-and-forth motion so as to subject them to vertical motion in a straight line, respectively on and under the warp and parallel to this latter, constituting a "square" cycle,
means for applying motion in an arc of a circle which crosses the path of the needles, to a support or supports that receive the locking mesh yarn,
means, or a programmed electronic control unit, for displacing in rectangular motion members adapted to detain temporarily the weft or wefts of the decorative effect,
programmable control means adapted to act on the distribution means for the decorative weft so that its displacements can be modified at will.
In order to solve the problem of obtaining decorative effects, the distribution means for the decorative weft or wefts comprise at least one yarn guide supporting said weft, said yarn guide being coupled to a transfer carriage displaceable in straight line motion, control of which is provided by a programmable central unit.
In order to solve the problem of modifying the decorative effect, the yarn guide or guides are fixed on guide bars for the displacement of the carriage in a straight line, at right angles to the warp yarns of the basic textile backing, with the carriage cooperating with a drive system coupled to a programmable motor.
In order to solve the problem of anchoring the decorative effect or effects by means of the locking meshes, the control means for the bonding needles for forming the locking mesh comprise an oscillating support receiving said needles which are mounted in a needle rod, said support cooperating with members for driving and for transforming motion, so as to submit all of said needles to vertical straight line to-and-fro movement through and under the basic textile backing.
With regard to the problem of arranging the decorative effect or effects on the basic backing, the means for applying motion in an arc of a circle to the locking mesh yarn or yarns comprise a system of crank arms and cranks under the control of the support that receives the bonding needles for forming the locking mesh, with said system working through a crank on a shaft, on which the supports that receive the locking mesh yarns are mounted.
The means for displacing, in rectangular motion, the members that are adapted for the temporary retention of the weft or wefts of the decorative effect comprise a deformable parallelogram system.
In order to overcome the problem of distributing the decorative weft on the top of the textile backing, by modifying at will the decorative effects which are obtained, the programmable control means adapted to act on the means for distributing the decorative weft so as to modify its displacement at will, comprise a stepping motor controlled electronically by integrating two parameters, namely an amplitude of the decorative weft in a direction at right angles to the warp yarns and in displacement to right or left, and a frequency of movements, or not, at each revolution of the loom.
BRIEF DESCRIPTION OF THE DRAWING
The invention is described below in greater detail with reference to the accompanying drawings, in which:
FIG. 1 is a large scale top view showing the principle of the manufacturing process in accordance with the invention.
FIG. 2 is a view in transverse cross section taken on the line 2.2 in FIG. 1.
FIG. 3 is a view similar to FIG. 2 for a modified embodiment, in relation to the textile backing in particular.
FIG. 4 is a top view showing one example of the manufacture of the article as a function of the selected program.
FIG. 5 is a front view of a machine equipped with the device in accordance with the invention.
FIG. 6 is a top plan view corresponding to FIG. 5.
FIG. 7 is a side view corresponding to FIG. 5.
FIG. 8 is a front view showing the means for displacing the bonding needles for forming the locking mesh.
FIG. 9 is a front view showing, in particular, the control means for the members adapted for the temporary detention of the weft or wefts of the decorative effect.
FIG. 10 is a top view showing one embodiment of an article made by the process of the invention.
FIG. 11 is a schematic diagram of one example of a programme for the motor controlling the yarn guide for the decorative weft, as a function of the decorative effect obtained.
FIGS. 12, 13 and 14 are pictorial views the gripping of the decorative weft between the back of the needles and the locking yarn on the textile backing.
FIG. 15 is a top view showing, by way of example, one embodiment of loops having different amplitudes, as a function of the selected program.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As is shown in FIG. 1, a textile backing is made on an automatic loom of any known and suitable type, and comprises weft yarns (1) and warp yarns (2). Simultaneously with the formation of the backing, at least one decorative effect (3) is formed and is anchored on the textile backing by means of meshes (4) made simultaneously with the basic backing.
As will be explained in the remainder of the description, the meshes (4) are made by means of needles (5) which are moved in a predetermined way. The decorative effect (3) is obtained by means of a decorative weft (6). Formation of the basic backing, by means of the warp and weft system, is carried out in an entirely conventional way in combination with a comb or reed (P), but it is not described in detail, because firstly this technique is perfectly well known to a person skilled in the art and secondly, it is not part of the specific object of the invention.
The bonding needles (5) for forming the locking mesh (4) are disposed very substantially at right angles to the warp lap or shed (2), and are fixed to a base block (15) or needle bed which is moved in vertical alternating motion.
In accordance with the process of the invention, when the comb (P) is drawn away from the beat-up position, the needles (5) advance parallel to the warp and rise perpendicularly, across the warp yarn lap (2) of the basic backing. When the needles (5) descend and disappear below the warp yarn lap (2) of the basic backing, they are retracted below the latter at the level of insertion of the last pick. This withdrawal of the needles (5) is necessary in order to prevent them from coming into contact with the comb (P), which occupies their position on reaching the beat-up position.
For this purpose, the needle rod (7) slides in two bearings of an oscillating support (8) which is pivoted on an axis (O1). The needle rod (7) is coupled through a crank pin (9) to an assembly comprising a crank arm (10) and crank (11). This assembly (10) (11) is balanced, and receives its motion from a shaft (O2) so as to apply alternating vertical motion to the needle rod (7).
Having regard to the oscillating mounting of the support (8), the needles (5) can be retracted below the base fabric as described.
As far as the oscillating mounting of the support (8) is concerned, this latter is obtained by a system in which a cam (12) is mounted on a shaft (13) and arranged to act on a roller (14), which is secured to said support and offset angularly with respect to the pivot axis (O1). A resilient member of the spring type ensures the return of the support (8).
The needles (5), by withdrawing, tend to block the base weft (1) by means of the mesh. When the needles (5) are below the basic textile backing (1) (2), with the sley of the loom being in the beat-up position, the decorative weft (6) is transferred and laid at right angles to the warp yarns (2). The decorative weft (6) is supported by yarn guides (15) fixed to a carriage (16). For example, according to the decorative effect to be obtained, the arrangement may have four yarn guides (15), each of which is fixed to one carriage (16).
Each of the carriages is mounted for free sliding movement on a bar (17), and on a parallel bar which serves as a guide (18), and the bars (17) and (18) together enable the carriage to move in a straight line at right angles to the warp (2). Each carriage (16) is driven by means of a toothed drive belt (19) mounted on a toothed idle wheel (20) and a toothed drive wheel (21) which is fitted on the shaft of a motor (22). This arrangement is repeated for each of the transfer carriages (16).
According to a major feature of the invention, each of the motors (22) is controlled electronically by being connected to a central programming unit. For example, each motor comprises a stepping motor, used in automatic switching, being of the ESCAP PP 520 type, or a direct current motor. Two Hall effect cells incorporated in the motor permit this type of control.
The program integrates two parameters:
a weft amplitude in the direction at right angles to the warp yarns, following a displacement to right or left,
a frequency of movement, or not, at each revolution of the loom.
FIG. 4 shows one example of a decorative effect obtained by the weft (6) in accordance with a predetermined programme for the motors (22).
An arbitrary choice is made of one possibility for movement or rest, for example over 50 revolutions or cycles of the weaving loom, which constitutes the "programme step". An amplitude of movement, which is called the "motor travel", is fixed for each cycle. In the example of the article to be produced shown in FIG. 4, in accordance with the chosen program, the decorative weft (6) is distributed so as to form a small loop at steps 0 to 2, 13 and 15, 15 and 18. This decorative weft (6) forms a large loop between the second and thirteenth steps of the program, and therefore over eighteen loom cycles. On return to 0, the transfer carriage (16) which displaces the decorative weft (6) comes below an electronic position sensor (C), which is adjusted mechanically as may be convenient for the job. The value of the travel of the carriage is fixed so as to put it to the left of the textile backing at the beginning of the work, in position 0, after a number of pulses have been communicated to the motor. Various stations are programmed in accordance with the decorative motif to be obtained.
At step No. 0 of the program, which corresponds to the first cycle of the loom, the carriage is returned to the left, at the value 0. At step No. 1 of the program, this value is maintained in such a way that the carriage remains stationary. At step No. 2 of the program, it starts towards the value 200 pulses, corresponding to the formation of the large loop of the decorative effect, and it maintains this value until the program step No. 13 at which the value reverts to 0, and then, at programme step No. 15, it goes to the value 130 and returns the carriage to the value 0 at step 18, this step being coincident with the step 0 in the programme for the first cycle.
Reference is made to FIG. 11, which shows one example of programming the motor for controlling the yarn guides for the decorative weft in accordance with the decorative effect to be obtained.
After transfer and laying of the decorative weft (6) on the basic backing, it is convenient to anchor this decorative weft on to said backing by means of the locking mesh yarn (4).
FIGS. 12-14 are sequential pictorial views showing the relative positions of the binding guide s(23) and the needles (5) during a cycle.
To this end, the needles (5) advance and ascend vertically, the comb (P) retracts, and simultaneously, binding guides (23) which receive the yarn from the needles (5) that are arranged to form the locking mesh, are raised in a movement in an arc of a circle which crosses the path of said needles (5). As is shown in FIGS. 12, 13 and 14, these arrangements have the effect of gripping the decorative weft (6). This gripping is effected between the back of the needles (5) and the locking mesh yarns (4) which pass through the yarn guides (40).
As is shown in FIG. 5 in particular, the binding guides (23) are fixed to a shaft (O3), coupled to a crank (26) so as to be given the oscillating motion through a system comprising a crank arm (25) and crank (26) (FIG. 8). This crank arm and crank assembly is controlled by a system of toothed wheels which is responsive to the movements of the needles from the shaft (O2).
It should be noted that the shaft (O3) is always in abutment, in particular by means of a spring (27), on the anvil of a return lever (28). This lever (28) is coupled to a coupling rod (29) which receives its motion through a cam (30), via a follower roller (31) carried by the coupling rod. These various movements are provided by the motor of the loom, in particular through a toothed belt (32) and a toothed wheel (33) mounted on the shaft (02) (FIG. 7).
The needles (5) being at the top dead center, the binding guides (23) are displaced through one step of the straight line movement of the needles (5), the effect of which is to cause the locking mesh yarn (4) to be laid by causing it to penetrate into an arrangement of the needles (5), for example below the point of this needle (FIG. 2). At that instant, the needles (5) begin their descent, as do the binding guides, carrying in their movement the yarn (4) which forms a loop that passes into the previously formed mesh so as to create a new mesh.
When the needles reach the bottom dead center, they are displaced as described above in order to avoid the sley and to complete the anchoring of the decorative weft (6).
In accordance with another feature of the invention, the device includes picot hooks (34) arranged at the level of the end of the needles (5) and yarn guides (15) that receive the decorative weft. These picot hooks (34) are controlled by any known and suitable system for giving them a rectangular motion. The effect of these picot hooks is to detain the yarns (6) of the decorative effect temporarily during the travel of the yarn guides (15), for example at the instant when the loop is formed. It should be noted that the device has two picot hooks (34) working alternately (FIG. 5). The motion of the picot hooks is linked with that of the yarn guides (15), and it controls the width of the loop.
In the example shown, the picot hooks (34) are mounted in a support (35) and are actuated by a system of deformable parallelograms consisting of cranks (36) (37) (38) (39) (FIG. 9).
It should be noted that this mechanical system may replace an electronic control unit which acts either on a motor having angular motion, or on an electromagnet acting on the back-and-forth travel of the picot hook. Such a system is controlled by the programme described above. A similar electronic control unit displaces the picot hook, or not, at right angles to the warp yarn, moving further away from or closer to the latter so as to form loops of different amplitudes in accordance with the chosen programme, as is for example shown in FIG. 15. Quite clearly, this Figure should not be regarded as limiting.
The advantages will appear clearly from the description, but the following in particular will be emphasized and recapitulated:
the possibility of using a shuttleless loom, thus giving a very high weaving speed;
flexibility of weaving;
the possibility of modifying at will the decorative effect or effects, according to the program;
the quality of the product obtained; and
the possibility of adapting the device for any type of loom.
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A textile backing with a decorative weft is manufactured by raising at least one bonding needle across the warp yarn lap of the textile backing, the bonding needle being used to form a locking mesh having a number of loops; retracting the needles under the textile backing; inserting a decorative weft at right angles to the warp yarns; simultaneously raising and shifting the needles and shifting the locking mesh yam in a circular arc movement using binding guides in order to twill the path of the bonding needle, thereby forming a locking mesh for retaining the decorative weft; displacing the binding guides in translation at a top dead center position for flattening the decorative weft yam against the needle; lowering the bonding needles, drawing the mesh-forming yarn, and creating a loop of locking mesh yarn which encloses the decorative weft; and re-shifting the guides in translation at bottom dead center position in preparation for a new cycle.
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BACKGROUND OF THE INVENTION
Several methods and devices are in current use for measuring the density of drilling fluids used to drill oil and gas wells. All of these devices and methods measure only the density of fluids in surface facilities and none incorporates the capability of vertical height measurement of a fluid column in a riser.
In the method of the invention measurements of the drilling fluid density may be made with the drilling fluid in either a static or dynamic condition. Also, the height of the fluid column in the riser above a known reference level is measurable when the density of the fluid is known.
The invention has several advantages over existing methods and devices used to measure drilling fluid densities. The drilling fluid density measurements are made using a length of well bore annular drilling fluid column in either a static or dynamic state and prior to separation of any drilled solids or gas. In this manner a more realistic measurement of the density of the drilling fluid returns is provided. With the measured density of the drilling fluid, the height of the drilling fluid column above a reference point is continuously measured. Such capability can be used to locate the level of the drilling fluid column in the event of complete loss of circulation and to measure the volume of fluid needed to fill the hole when "pulling" the drill string (trip out). Marine drilling may in the future require airlift of the returns drilling fluid to prevent loss of circulation. When airlift is required, monitoring of the total hydrostatic head in the marine riser will be essential for well control. The present invention provides such capability. Any appreciable column of formation gas entering the well bore and rising to a point above the reference point in the riser will result in a reduction in the average density of the measured fluid column and therefore can be detected by the method of the present invention.
SUMMARY OF THE INVENTION
A method for measuring the density, and with that known measured density determining the vertical height, of a drilling fluid column formed in a marine riser used in offshore drilling operations in which the riser extends from a submerged wellhead to the surface of the water which comprises the steps of measuring the hydrostatic pressure of the drilling fluid column in the riser at a selected point along the length of the riser, the point being a known distance below the fluid returns outlet of the riser such that said pressure measurement at that point provides an indication of variations in drilling fluid weight and drilling fluid level in the riser. The apparatus comprises a small tube extending from above the water's surface and connected at its lower end to the riser at the point it is desired to measure the pressure of the drilling fluid column.
In one embodiment of the apparatus the tube contains a check valve, which permits flow of fluid into the riser but prevents flow of fluid from the riser into the tube, and a pressure regulator valve. Fluid in the tube at the check valve is at a pressure at or just above the pressure of the drilling fluid in the riser at the point or level of the connection of the tube to the riser. The pressure of the fluid in the tube measured at the surface provides a measurement of the fluid weight and fluid level within the riser. In another embodiment of the invention, instead of a check valve and pressure regulator valve, the tube contains a hydraulic pressure cell and is filled with fluid. The pressure of the fluid in the tube measured at the surface provides a measurement of the drilling fluid weight and fluid level within the riser.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of a marine riser with a small tube connected between the riser and a source of fluid pressure, as in one embodiment of the invention;
FIG. 2 is a schematic view of a marine riser with a small tube connected thereto containing a hydraulic pressure cell, as in another embodiment of the invention; and
FIG. 3 is a recorded log of pressure versus time measured during actual drilling operations in accordance with the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1 there is shown a marine riser 10, which includes at its submerged lower end a standard ball joint 11, connected to a blowout preventer assembly 12 arranged near or on the ocean floor. A drill pipe 13 extends through riser 10 and ball joint 11 and blowout preventer 12 during drilling of a subsea well. Riser 10 is suitably suspended from the drilling vessel, not shown, and is provided with a drilling fluid returns outlet 14 above the water level 16. Although not shown the riser may also contain, as is customary, one or more flexible and/or telescopic joints to compensate for minor vertical and horizontal movements of the vessel. A small tube 20 extends from above the water's surface to the lower end of riser 10 where it is connected thereto just above blowout preventer 12 at 21. A check valve 22 is arranged in tube 20 adjacent connection 21 and prevents flow of fluids from riser 10 into tube 20 but allows fluids to flow from the tube 20 into the riser 10. Above water surface 16 tube 20 is connected to a pressure source, indicated at 23. A pressure regulator valve 24 and a pressure gauge 25 are located in tube 20 near a pressure measuring device 26, which device is, in turn, connected to a pressure recorder 27.
In a drilling operation, as indicated by the arrows, drilling fluid is circulated down drill pipe 13 and upwardly through the annulus formed by the borehole wall and drill pipe 13 and the annulus formed by riser 10 and drill pipe 13. Thus, the riser and the drill pipe form an annular flow path 30 for drilling fluid returns from the well bore to the surface drilling fluid system located on the drilling vessel.
A small quantity of air, gas or other fluid of known density is introduced into tube 20 from the source 23. Pressure regulator valve 24 controls the pressure of the fluid in tube 20 which is set at or slightly above the pressure of the drilling fluid at connection point 21. Variations in fluid pressure in tube 20 is measured by pressure measuring device 26 and recorded, as indicated in FIG. 3.
It is known from the laws of physics that a column of fluid (liquid or gas) exerts a pressure in all directions which is a function of density of the fluid and height of the fluid column. Published data on pure water (H 2 O) density (1.0) establishes a pressure of 0.433 pounds per square inch (psi) per foot of fluid column. Using such relationship and a known (measured) height of fluid column "H," the average density of any fluid in the riser can be determined by measuring the hydrostatic pressure at point 21. The fluid column of unknown density in riser 10 exerts a pressure (P) at that point.
At level 21 the fluid column of known density in tube 20 exerts a pressure of: ρ(H) × 0.433 psi where ρ = density or specific gravity of fluid in tube 20.
As an example, to determine density assume ρ = 1.0 (pure water) and H = 1000 ft. then the pressure P exerted by a water column in tube 20 equals 1.0 × 1000 × 0.433 = 433 psi.
When the pressure exerted by the column of unknown density in the riser exceeds 433 psi fluid cannot flow from the surface injection point 21 into the riser 10 for the check valve 22 prevents flow from the riser (unknown fluid column) to the known fluid column in tube 20 but permits flow of fluid in the other direction.
When the pressure at the point of injection 21 is mechanically increased sufficiently to initiate movement of fluid from the tube (known fluid column) into the riser (unknown fluid column) the applied surface pressure plus 433 psi is equal to P. Assume a pressure of 87 psi is required at the surface injection point 23 to initiate movement of fluid from the tubing into the riser. Therefore, 87 psi plus 433 psi equals 520 psi at point 21.
ρ (unknown) = 520 psi/1000 ft. (0.433)
ρ (unknown) = 1.20; which equated to pounds per gallon equals water (H 2 O) at 1.0 density equals 8.34 pounds per gallon.
Therefore, 8.34 × 1.20 = 10 pounds per gallon for the unknown fluid column.
The calculation would be similar if air (or other gas) is used instead of water (or other liquid) as the injected fluid.
The applied pressure at the surface (P) + ρ (H) = P (subsurface); and using published density and compressibility factors for air, or other gas used, and measured applied pressure at the surface, the subsurface pressure of 520 psi and the unknown density of 1.20 or 10 pounds per gallon can be determined.
To determine the height (h) of the fluid column in the event of lost returns, assume that the riser fluid column is being monitored and is known to be 10 pounds per gallon when the returns are lost and the fluid level in the riser falls below the known height H, and water is being used as the injected fluid and the surface injection pressure is measured at 10 psi, then:
P = (H) (0.433) + 10 psi
P = (1000) (0.433) + 10 psi = 443 psi.
With a known density of 1.20 in the marine riser:
433 = 1.20 (0.433) (h) or
h = 443/(1.20) (0.433) = 443/0.52 = 833 ft. or
1000 ft. - 833 ft. = 167 ft.
below the outlet level.
The measured pressure plus the hydrostatic pressure of the column of fluid in tube 20, as explained, is equal to the hydrostatic pressure of the drilling fluid column inside riser 10.
An alternative apparatus is illustrated in FIG. 2 in which riser 10a has connected to it a tube 20a which at the surface of the water is closed as at 35 after being filled with fluid. The fluid pressure is measured by the the pressure measuring device 26a which is connected to a recorder, not shown. A pressure gauge 25a is connected into tube 20a and a hydraulic pressure cell 36 is arranged on tube 20a adjacent its connection 21a to marine riser 10a adjacent ball joint 11a above blowout preventer 12a. The determination of density of the drilling fluid and the height of the fluid column in the riser in the embodiment of FIG. 2 is the same as described with respect to the embodiment of FIG. 1.
Referring to FIG. 3 a log of pressure is measured and recorded versus time (hours) in accordance with the embodiment of FIG. 1 for a typical drilling operation.
Referring to the lower end curve 40, during the period indicated at 41 the steady hydrostatic pressure of about 59 reflects drilling operations with 13 pounds per gallon mud. The slight movements of the line indicates rapid opening and closing of the check valve 22. At the interval indicated at 42 (immediately above interval 41) the drill string has been raised and fluid is being circulated through the drill pipe and drill bit and up the annulus and out the riser discharge. During this circulation operation some gas from the subsurface formations enters the drilling fluid as evidenced by reduction in the hydrostatic pressure of the drilling fluid. During the interval "trip out", indicated at 43, the drill pipe is being pulled. A greater reduction in hydrostatic pressure of the drilling mud is shown during that operation. Similarly, during the "trip in" period indicated at 44, (in which the drill pipe is being run back into the borehole) the hydrostatic pressure of the drilling mud is reduced but not quite to the extent shown for the trip-out operation. During the period indicated at 45 the drilling mud is being circulated out prior to drilling and again a greater reduction in hydrostatic pressure is shown. During the period indicated at 46 the drilling operation is resumed at the same hydrostatic pressure, 59, and mud weight as the drilling operation shown for the drilling period 41. The interval designated 47 shows a reduction in the hydrostatic pressure and indicates that the drill bit has cut into a gas formation during drilling and the hydrostatic pressure of the drilling fluid in the riser is reduced by gas entering the drilling fluid from that formation.
In operation on a floating drilling the small tube is generally available from a spare pilot tube in the blowout preventer hydraulic control hose bundle. High pressure air (up to 3000 psi) is also available on many floating drilling vessels from the riser tensioning system. Thus, the invention is readily installed on many floating rigs at nominal cost. The equipment described above for making and practicing the invention, including the check valve, pressure regulator, pressure measuring device, pressure cell and recorder, is conventional, commercially available equipment.
The term drilling fluid as used herein includes any drilling mud system useful in drilling wells and particularly oil and/or gas wells.
Changes and modifications may be made in the illustrative embodiments of the invention shown and/or described herein without departing from the scope of the invention as defined in the appended claims.
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A method is disclosed for remotely measuring the vertical height and/or density of a drilling fluid column in a marine riser. The hydrostatic pressure of the drilling fluid is measured at any point below the surface outlet of the drilling fluid in the marine riser. The distance between the surface outlet or discharge level of the drilling fluid (normally the top of the fluid column) in the riser and the level in the riser at which the presure measurement is made (bottom of the fluid column) is known because of the physical arrangement of the riser permitting conversion of the pressure measurement to density. The height of the fluid column in the riser from the bottom to the top thereof when the top of the fluid column falls below the surface outlet is determinable by using the measured fluid density just prior to the drop in the height of the fluid column.
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BACKGROUND OF THE PRESENT INVENTION
1. Field of Invention
The present invention relates generally to an engine fuel injection system, and more particularly to an electronic control common rail DME injection system.
2. Description of Related Arts
DME is known as a “green substitution fuel for diesel in 21st century”, but the DME is a gas at normal temperature and pressure, and has low viscosity, and poor sealing. The above characters cause sealing and abrasion problem in the plunger matching portions in the injection system, which is the difficult problem in application. Besides DME, the other low-viscosity fuels, such as liquefied petroleum gas (LPG), also have same low viscosity to cause the sealing and abrasion problem in the plunger matching portions in the injection system. The US006119664A patent of AVL company disclosed a common rail electronic control injection system using a low-viscosity fuel. The system comprises a high-pressure pump, a common rail tube, an electronic control injector, an electronic control unit, wherein the fuel is pressed to 200-350 bar by the high-pressure pump and is sent into the common rail tube, a two-position three-way solenoid valve is disposed between the common rail tube and the electronic control injector, the electronic control injector begins to inject when the common rail tube is connected with the electronic control injector via the two-position three-way solenoid valve, and the electronic control injector stops injecting when the two-position three-way solenoid valve is connected with a returning tube. The disadvantage of this design is that the sealing and abrasion problem in the plunger matching portions is inevitable because DME is directly pressed by the high-pressure pump.
SUMMARY OF THE PRESENT INVENTION
An object of the present invention is to provide a common rail electronic control injection system, which is capable of avoiding the sealing and abrasion problem in the plunger matching portions of oil pump so as to greatly improve the lifetime and durability of system.
Another object of the present invention is to provide a common rail electronic control injection system, wherein the high-pressure pump is universal in the hydraumatic industry so as to reduce the manufacture cost.
Accordingly, in order to accomplish the above objects, the present invention provides a common rail electronic control injection system, comprising:
a fuel container containing a fuel of DME or other low-viscosity fuel, a common rail tube, a high-pressure tube, an electronic control injector, an electronic control unit, a high-pressure pump, a working medium case containing a working medium, a reversing component for reversing the transport direction of the working medium, and a pressure convertor transferring working medium pressure to the fuel;
wherein the electronic control injector is connected with the common rail tube through the high-pressure tube;
the working medium case, the high-pressure pump, the reversing component and the pressure convertor connect in turn by pipeline;
an inlet of the pressure convertor is communicated with the fuel in the fuel container, an outlet of the pressure convertor is connected with the common rail tube;
the pressure convertor comprises at least two parallel working components, wherein each working component is divided into a fuel chamber and a working medium chamber by a dividing element. The dividing element can freely deform or move between the fuel chamber and the working medium chamber by pressure effect, The number of the working components is preferably two;
the fuel chamber is connected in parallel with an input one-way valve and an output one-way valve, the input one-way valve is connected with an inlet of the fuel chamber, the output one-way valve is connected with an outlet of the fuel chamber;
the working medium chamber is connected with an outlet of the reversing component through a gangway of the working medium chamber and a working medium tube.
As a preferred embodiment, the working medium is diesel oil, engine lubricant or hydraulic oil.
The dividing element is preferably a flexible film. A periphery of flexible film is hermetically fixed on an inner wall of the working component. Further, the flexible film is made of fluorine rubber.
The reversing component is a two-position four-way solenoid valve controlled by the electronic control unit, wherein a pressure inlet of the two-position four-way solenoid valve is connected with an outlet of the high-pressure pump, a liquid returning vent of the two-position four-way solenoid valve is connected with the working medium case.
An relief valve is disposed between the outlet of the high-pressure pump and the pressure inlet of the two-position four-way solenoid valve, wherein the relief valve is controlled by the electronic control unit, a liquid returning vent of the relief valve is connected with the working medium case. In order to further improve control precision of common rail pressure, a pressure sensor is disposed on the common rail tube for measuring fuel pressure within the common rail tube, wherein a signal output of the pressure sensor is connected with the electronic control unit.
In order to reduce the leakage, an electronic control one-way valve is connected between the common rail tube and the output main tube, and is controlled by the electronic control unit, when the electronic control one-way valve is power-on, the electronic control one-way valve is two-way through; when the electronic control one-way valve is power-off, the electronic control one-way valve is one-way through, namely, the liquid or gas in common rail tube can pass through the electronic control one-way valve, while the opposite way is blocked.
With the above project, the pump does not press the low-viscosity fuel directly, so as to avoid leakage and abrasion of the plunger, so as to extend service life of the system. The high-pressure pump is universal in the hydraumatic industry so as to reduce the manufacture cost. Long-time test proves that the common rail electronic control injection system has no irregular abrasion in the plunger matching portions.
These and other objectives, features, and advantages of the present invention will become apparent from the following detailed description, the accompanying drawings, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of a common rail electronic control injection system according to a preferred embodiment of the present invention.
FIG. 2 to FIG. 5 are measure graph and photo according to the injection experiment of the present invention.
FIG. 2 is a graph of injection rule under different common rail pressure.
FIG. 3 is a graph of injection quantity under different common rail pressure and different drive impulse duration.
FIG. 4 is a graph of preinjection rule by adjusting drive pulse signal, both the preinjection quantity and the space between the mail pulse injections are easily controlled by adjusting the drive impulse duration of the preinjection drive pulse and the space between the main pulses.
FIG. 5 is a photo of spraying according to different injection time in preinjection process.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1 of the drawings, a common rail electronic control injection system according to a preferred embodiment of the present invention is illustrated, which comprises a fuel container 1 containing a fuel A which is DME or a low-viscosity fuel similar with DME, a common rail tube 2 , a high-pressure tube 3 , an electronic control injector 4 , an electronic control unit 5 , a high-pressure pump 6 , a working medium case 7 containing a working medium B, a reversing component 8 for reversing the transport direction of the working medium B, and a pressure convertor 9 transferring working medium B pressure to the fuel A, wherein the electronic control injector 4 is connected with the common rail tube 2 via the high-pressure tube 3 ; the working medium case 7 , the high-pressure pump 6 , the reversing component 8 and the pressure convertor 9 connect in turn by pipeline.
The pressure convertor 9 consists of two working components 91 , wherein each working component 91 is divided into a fuel chamber 9101 containing the fuel A and a working medium chamber 9102 containing the working medium B by an dividing element 911 , the dividing element 911 can freely deform or move between the fuel chamber 9101 and the working medium chamber 9102 by pressure effect so as to transfer pressure from the working medium chamber 9102 to the fuel chamber 9101 . It is worth mentioning that the number of working component 91 can also be an even number which is larger than two.
The fuel chamber 9101 is connected in parallel with an input one-way valve 10 and an output one-way valve 11 , wherein the input one-way valve 10 is connected with an inlet of the fuel chamber 91011 , the output one-way valve 11 is connected with an outlet of the fuel chamber 91012 . The working medium chamber 9102 is connected with an outlet of the reversing component 81 via a gangway of the working medium chamber 91021 and a working medium tube 12 .
According to the preferred embodiment of the present invention, the dividing element 911 is a flexible film. A periphery of the flexible film is hermetically fixed on an inner wall of the working component 91 , the flexible film is made of fluorine rubber in order to improve the anti-corrosion ability and anti-swelling ability. The dividing element 911 can also be other embodiments, such as a dividing piston, the dividing piston freely moves between the fuel chamber 9101 and the working medium chamber 9102 so as to transfer pressure.
The working medium B is a liquid at normal temperature and pressure, the liquid can be hydraulic oil, engine oil or diesel. According to the preferred embodiment of the present invention, the working medium B is engine oil, the working medium case 7 is an oil sump tank of engine.
The reversing component 8 is a two-position four-way solenoid valve controlled by the electronic control unit 5 , wherein a pressure inlet of the two-position four-way solenoid valve 82 is connected with an outlet of the high-pressure pump 61 , a liquid returning vent of the two-position four-way solenoid valve 83 is connected with the working medium case 7 . One two-position four-way solenoid valve can control two working components 91 , the number of the two-position four-way solenoid valve increases in proportion when the number of working component is more than two. The two-position four-way solenoid valve can also be replaced by other component, such as one combination of four electromagnetic on-off valves substitutes for one two-position four-way solenoid valve.
According to the preferred embodiment of the present invention, an relief valve 13 is connected between the outlet of the high-pressure pump 61 and the pressure inlet of the reversing component 82 , wherein the relief valve 13 is controlled by the electronic control unit 5 , a liquid returning vent of the relief valve 131 is connected with the working medium case 7 .
In order to further improve control precision of common rail pressure, a pressure sensor 14 is disposed on the common rail tube 2 for measuring fuel pressure within the common rail tube 2 , wherein a signal output of the pressure sensor 14 is connected with the electronic control unit 5 . The pressure sensor 14 can also be disposed on the pipeline between the high-pressure pump 6 and the two-position four-way solenoid valve because an output pressure of the high-pressure pump 6 and the fuel pressure within the common rail tube 2 are essentially equal. When the system demand is not high, the relief valve 13 can be replaced by a constant-pressure valve, and the pressure sensor 14 is cancelled, such that the output pressure of the high-pressure pump 6 is constant.
The fuel chamber 9101 is connected in parallel with an input one-way valve 10 and an output one-way valve 11 . The input one-way valve 10 is connected with the fuel container 1 through an input main tube 15 . On the input main tube 15 , a manual shutoff valve 16 is in turn with a first electronic control shutoff valve 17 controlled by the electronic control unit 5 , the manual shutoff valve 16 is closed when the engine does not work for a long time, the first electronic control shutoff valve 17 is closed when the engine meets emergency, such as leakage. The output one-way valve 11 is connected with the common rail tube 2 through an output main tube 18 .
An electronic control one-way valve 19 is disposed between the common rail tube 2 and the output main tube 18 , and is controlled by the electronic control unit 5 . When the electronic control one-way valve 19 is power-on, the electronic control one-way valve 19 is two-way through; when the electronic control one-way valve 19 is power-off, the electronic control one-way valve 19 is one-way through, namely, the liquid or gas in common rail tube 2 can pass through the electronic control one-way valve 19 , while the opposite way is blocked.
A second electronic control shutoff valve 20 is disposed between an input tube of DME and an output tube of DME, and is controlled by the electronic control unit 5 , wherein one end of the second electronic control shutoff valve is disposed on the output main tube 18 located between the pressure convertor 9 and the electronic control one-way valve 19 , another end of the second electronic control shutoff valve is disposed on the input main tube 15 located between the pressure convertor 9 and the fuel container 1 . When the engine stops, the second electronic control shutoff valve 20 is open, the DME pressure within the common rail tube 2 is released and reduced to close to the pressure within the fuel container 1 so as to reduce the leakage between the electronic control injector 4 and the engine, and improve the system security.
The common rail electronic control injection system works as follows.
The generation and control of fuel pressure: the engine drives the high-pressure pump 6 to rotate when the engine works, the engine lubricant is inhaled into the high-pressure pump 6 from the working medium case 7 , and comes out of the outlet of the high-pressure pump 61 after being pressed, the electronic control unit 5 uses the relief valve 13 to adjust the output pressure of the high-pressure pump 6 , and the engine lubricant comes into the pressure inlet of the two-position four-way solenoid valve 82 ; the two-position four-way solenoid valve has two outlets, one outlet of the two-position four-way solenoid valve is communicated with the pressure inlet 82 so as to output the high-pressure lubricant into the working medium chamber 9102 , and another outlet of two-position four-way solenoid valve is communicated with the liquid returning vent 83 so as to recycle the lubricant from the working medium chamber 9102 ; the high-pressure lubricant within the working medium chamber 9102 presses the fuel A within the fuel chamber 9101 spaced by the dividing element 911 , here, the input one-way valve 10 is closed and the output one-way valve 11 is open, the fuel A is transferred into the common rail tube 2 by pipeline after being pressed, at the same time, in another working component 91 , the low-pressure fuel A from the fuel container 1 comes into the fuel chamber 9101 and drives the lubricant to come out of the working medium chamber 9102 spaced by the dividing element 911 , the lubricant returns into the working medium case 7 through the two-position four-way solenoid valve, then the inhaling process of the fuel A and the ejecting process of the working medium B have finished; the two-position four-way solenoid valve is controlled by the electronic control unit 5 , periodically switches the working medium flow of the two outputs, such that two working components 91 alternately finish the ejecting and inhaling process of the fuel A.
In the above process, the pressure control of the fuel A within the common rail tube 2 depends on controlling the lubricant pressure, the pressure sensor 14 disposed on the common rail tube 2 sends the common rail pressure signal to the electronic control unit 5 so as to realize closed loop control of common rail pressure. In this process, the electronic control one-way valve 19 is in a two-way through condition, the first electronic control shutoff valve 17 is open, and the second electronic control shutoff valve 20 is closed.
The injection of the DME: the electronic control unit 5 judges the operation condition of the engine according to all input signals of the engine, gets different injection phase and injection amount, and controls the electronic control injector 4 to inject or not by the drive signal.
Stopping: after the engine stops, the first electronic control shutoff valve 17 is closed, the second electronic control shutoff valve 20 is open, the electronic control one-way valve 19 is in a one-way through condition, the high-pressure fuel A within the common rail tube 2 returns into the fuel container 1 through the electronic control one-way valve 19 and the second electronic control shutoff valve 20 , the common rail pressure quickly depresses to be close to the pressure of the fuel container 1 , here, because the temperature around the engine is high, the DME within the electronic control injector 4 and common rail tube 2 gasifies, the DME continually drains through the electronic control one-way valve 19 until there in no liquid fuel between the common rail tube 2 and the electronic control injector 4 ; the electronic control one-way valve 19 automatically closes to avoid the fuel regorging.
Emergency: in normal condition, the first electronic control shutoff valve 17 is open, the first electronic control shutoff valve 17 can be closed by the electronic control unit 5 or the driver when the system is found abnormal condition.
It is worth mentioning that the invention can be extended to other low-viscosity fuel similar with DME, such as injection system of liquefied petroleum gas.
One skilled in the art will understand that the embodiment of the present invention as shown in the drawings and described above is exemplary only and not intended to be limiting.
It will thus be seen that the objects of the present invention have been fully and effectively accomplished. It embodiments have been shown and described for the purposes of illustrating the functional and structural principles of the present invention and is subject to change without departure from such principles. Therefore, this invention includes all modifications encompassed within the spirit and scope of the following claims.
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A common rail electronic control injection system which uses a DME or a low-viscosity fuel similar with DME to inject into a combustion engine, includes a fuel container, a common rail tube, a high-pressure tube, an electronic control injector, an electronic control unit, a high-pressure pump, a working medium case, a reversing component, and a pressure convertor, wherein the pressure convertor includes at least two working components, each working component is divided into a fuel chamber and a working medium chamber by an dividing element, the dividing element can freely deform or move between the fuel chamber and the working medium chamber by pressure effect. The invention avoids the sealing and abrasion problem in the plunger matching portions which is caused by the low-viscosity fuel so as to greatly improve the lifetime and reliability of system.
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CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This Application claims the benefit of priority and is a Continuation application of the prior International Patent Application No. PCT/JP2013/082339, with an international filing date of Dec. 2, 2013, which designated the United States, the entire disclosures of all applications are expressly incorporated by reference in their entirety herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a display tool and fixture.
[0004] 2. Description of Related Art
[0005] Patent Article 1 describes a merchandise display tool. This merchandise display tool has an engaging member that is detachable from a bar member of a merchandise display shelf and a merchandise display bar whose rear end is detachably connected with the engaging member. The engaging member of the display tool is made of resin and the merchandise display bar is made of metal.
[0006] Patent Article 1: Official Gazette for Unexamined Japanese Patent Application No. 1999(H11)-076011.
BRIEF SUMMARY OF THE INVENTION
[0007] As shown in FIG. 7 , in a fixture 1 of the prior art, a retaining member 6 used for hanging to hold commercial goods is welded to a support member 4 at a welding component 8 . In order to reinforce the structural weakness, each member including the support member 4 is made to be thicker and longer (in the longitudinal direction of the frame) or needs a reinforcing member. The present invention has a purpose of providing a display tool and fixture that are stronger than the prior art.
[0008] A fixture of a first invention for achieving the aforementioned purpose of the present invention is composed of a member to be fixed, a support member attached to the member to be fixed, and a retaining member extending in a nearly horizontal direction to intersect with a direction along which the member to be fixed extends so that one end thereof is supported by the support member while being positioned at the lower side of the member to be fixed to hang and hold commercial goods in position.
[0009] In the fixture of the first invention, the support member is composed of a first support component that supports the retaining member at a first position, a second support component that supports the retaining member at a second position, and a coupling component that connects the first support component and the second support component.
[0010] In the fixture of the first invention, the coupling component is mounted on the member to be fixed.
[0011] In the fixture of the first invention, there are a first and a second hole formed in the first and the second support members for passing through the retaining member, respectively.
[0012] In the fixture of the first invention, the first support component or the second support component, or the first support component and the second support component have means for fixing the retaining member in position.
[0013] In the fixture of the first invention, the second support component has a positioning component that determines the position of the retaining member in the longitudinal direction.
[0014] In the fixture of the first invention, the base end of the retaining member is tapered or chamfered.
[0015] In the fixture of the first invention, the retaining member is detachably attached to the support member.
[0016] In the fixture of the first invention, the tip of the retaining member preferably has a means for preventing commercial goods from being dropped.
[0017] In the fixture of the first invention, the retaining member is preferably straight, and the means for preventing commercial goods from being dropped is preferably a groove formed along the entire circumference of the tip of the retaining member, or the retaining member has a diameter larger than that of the retaining member.
[0018] In the fixture of the first invention, the fixing means has preferably the direction of extending the center axis of the first hole which is not aligned with the direction of extending the center axis of the second hole.
[0019] In the fixture of the first invention, the means for positioning the retaining member in the longitudinal direction may be a cuff formed on the second support component.
[0020] The display tool of the second invention for achieving the aforementioned purpose is composed of a support member attached to a member to be fixed, and a retaining member which extends in a direction intersecting with a direction along which the member to be fixed extends so that one end thereof is supported by the support member while being positioned at the lower side of the member to be fixed to hang and hold commercial goods in position.
[0021] The present invention may improve the structural strength of the fixture compared with the prior art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is a right side views of a frame, a support member, and a retaining member of the fixture of a first embodiment of the present invention.
[0023] FIGS. 2A and 2B are a right side view and the front view of the support member of the fixture of the present invention.
[0024] FIG. 3 is a right side of a modified example of the fixture of the present invention.
[0025] FIGS. 4A and 4B are a front view and a right side view of a modified example of the support member of the fixture of the present invention.
[0026] FIG. 5 is a right side views of a frame, a support member, and a retaining member of the fixture of a second embodiment of the present invention.
[0027] FIGS. 6A and 6B are a right side view and the front view of the support member of the fixture of a second embodiment of the present invention.
[0028] FIG. 7 is a right side view of a frame, a support member, and a retaining member of the fixture of the prior art.
DETAILED DESCRIPTION OF THE INVENTION
[0029] Referring to figures attached herein, embodiments of the present invention are described for understanding the present invention in detail. In each figure, the parts irrelevant to the description may be omitted.
First Embodiment
[0030] The fixture of the first embodiment of the present invention may be installed in a convenience store for hanging to display commercial goods.
[0031] As shown in FIG. 1 , the fixture 10 has a frame (part of a fixture member to be fixed) 12 , a support member 14 , and a retaining member 16 . The support member 14 and the retaining member 16 constitute an example of a display tool.
[0032] The frame 12 , for example, has a rectangular cross section, and extends in an essentially horizontal direction. Here, the “horizontal direction” does not mean exactly the level line. In other words, the “horizontal direction” means an “essentially level line” within a tolerance allowed by design and production (and the same hereinafter). For instance, the direction in which the frame 12 extends may be slanted within the range of −10 degrees to +10 degrees from the level line. The frame 12 is, for example, a cross bar (a bar member). The material of the frame 12 may be metal, resin, and paper such as cardboard, and the like. Another example of the fixing member to be fixed is a lattice structured member and a board like member.
[0033] The support member 14 is attached to the frame 12 to support the retaining member 16 . Namely, the support member 14 may couple the frame 12 with the retaining member 16 . As shown FIGS. 2A and 2B , the support member 14 has the first support component 14 a and the second support component 14 b and the coupling component 14 c.
[0034] The support component 14 a is located in front of the frame 12 (which is the side of displaying commercial goods), extending vertically. As shown in FIG. 2B , at the midpoint of the frame 12 in the vertical direction, there is a cuff part 22 whose lower part is bent to the front side. In the cuff part 22 , there is a hole H 1 through which the retaining member 16 passes. In other words, the first support component 14 a may support the retaining member 16 at the first position.
[0035] The support component 14 b is located at the back of the frame 12 (which is the opposite side of displaying merchandise), extending vertically. In the second support component 14 b, there is a second hole H 2 , which is essentially the same size as the first hole H 1 , through which the retaining member 16 passes. In other words, the second support component 14 b may support the retaining member 16 at the second position which is behind the first position of the retaining member 16 . At the lower end of the second support component 14 b, a cuff part 20 is formed folding its tip upward. The retaining member 16 contacts with the cuff part 20 so that the position of the retaining member 16 in the longitudinal direction may be determined when the retaining member 16 is attached to the support member 14 .
[0036] Because of the cuff part 22 formed in the first support component 14 a, the direction of extending the center axis AX 1 of the first hole H 1 formed in the first support component 14 a and the direction of extending the center axis AX 2 of the second hole H 2 formed in the second support component 14 b are different. In other words, viewing from the side, the center axis AX 1 of the first hole H 1 intersects with the center axis AX 2 of the second hole H 2 .
[0037] The coupling component 14 c is connected to the upper end of the first support component 14 a and to the upper end of the second support component 14 b to couple the first support component 14 a with the second support component 14 b. The coupling component 14 c is mounted on the upper surface of the frame 12 (refer to FIG. 1 ).
[0038] The material of the support member 14 is for example metal and plastics. However, if the support member 14 attains pre-determined strength, its material is not particularly limited, and rubber, wood, cloth, and paper such as cardboard and the like may be used as well.
[0039] The retaining member 16 is, for example, a rod like member whose cross section is a circle or an ellipse. The retaining member 16 extends to the direction with which the frame 12 intersects. The retaining member 16 may hang commercial goods by inserting its one end into a hole of a package of the commercial goods.
[0040] As described above, the base end of the retaining member 16 is attached to the support member 14 , passing through the first hole H 1 formed in the first support component 14 a and the second hole H 2 formed on the second support component 14 b , and contacting with the lower surface of the frame 12 .
[0041] In order to attach the retaining member 16 to the support member 14 , appropriate force is applied to the cuff part 22 (refer to FIGS. 2A and 2B ) under the first support component 14 a of the support member 14 to push the part backward so that the support member 14 is bent to align the center axes of the first hole H 1 and the second hole H 2 so that the retaining member 16 may be inserted into the aligned holes. If the backward-pushing force from the cuff part 22 under the support component 14 a of the support member 14 is released, the support member 14 restores its straight shape, which exerts force on the retaining member 16 in the radial direction, holding it to the support member 14 in position.
[0042] In order to detach the retaining member 16 from the support member 14 , appropriate force is applied to the cuff part 22 (refer to FIGS. 2A and 2B ) under the first support component 14 a of the support member 14 to push it backward so that the support member 14 is bent to align the center axes of the first hole H 1 and the second hole H 2 so that the retaining member 16 may be pulled out from the aligned holes. In this way, the retaining member 16 is detachable whereby a retaining member of appropriate length may be used for various applications.
[0043] Under the first support component 14 a, there was the cuff part 22 which is bent toward the front side for opening itself. Instead of the cuff part 22 , the other cuff part 24 which is bent toward the front side for opening itself may be also formed under the second support component 14 b as shown in FIG. 3 , and FIGS. 4A and 4B . For example, if commercial goods are not filled from the backside of the retaining member 16 , the parts under the first support component 14 a and the second support component 14 b may be bent together.
[0044] Furthermore, the parts under the first support component 14 a and the second support component 14 b may not be bent either but the center axis AX 1 of the first hole H 1 and the center axis AX 2 of the second hole H 2 may be misaligned. In other words, the direction of the center axis AX 1 of the first hole H 1 and the direction of the center axis AX 2 of the second hole H 2 may be different.
[0045] The degree of misalignment between the center axis AX 1 of the first hole H 1 and the center axis AX 2 of the second hole H 2 or easiness of bending the support member 14 determines the force that is applied to fix the retaining member 16 to the support member 14 in position. By enlarging the degree of misalignment, it is possible to design the fixture of the present invention un-detachably without tools.
[0046] The tip of the retaining member 16 is preferably tapered where the diameter decreases gradually toward the tip end. By tapering the tip, it is easier to insert the retaining member 16 into the first hole H 1 and the second hole H 2 . Instead of tapering, it is also possible to chamfer the edge for this purpose.
[0047] As shown in FIG. 1 , at the tip of the retaining member 16 , there is a groove 30 formed on the entire circumference. Forming the groove 30 may prevent commercial goods from being dropped. In addition, since the groove 30 is formed along the entire circumference, the retaining member 16 may be installed without concern about the rotational direction of the center axis of the retaining member 16 .
[0048] Instead of forming the groove 30 at the tip of the retaining member 16 , a cap (not shown in the figure) may be attached to the tip. Making the outer diameter of the cap larger than that of the retaining member 16 may also prevent commercial goods from being dropped. The cross-sectional shape of the retaining member 16 may be arbitrary.
[0049] Next, the operation of the fixture 10 is described hereinafter. In the fixture of the prior art shown in FIG. 7 , the first most possible location that would be broken due to excessive weights of hanging commercial goods and the retaining member is the welded part 5 that welded the support member 3 to the retaining member 2 , and second most possible part is the peripheral area of the upper front surface 6 of the support member 3 .
[0050] The reason why the welded part 8 welding the support member 4 to the retaining member 6 is the most possibly breakable part is the lever action to the welded part 8 ; for example, if the width of the upper surface of the support member 4 is 20 mm and the length of the retaining member 6 is 220 mm, then the magnitude of force acting on the welded part 8 will be approximately 5 to 10 times the total weight of hanging commercial goods and the retaining member 6 .
[0051] The reason why the part around the upper front surface 4 a of the support member 4 is the second most breakable part is that the support member 6 of the prior art has a structure which receives the aforementioned force in the bending direction for the part of the upper surface 4 a of the support member 4 with certain thickness and width.
[0052] As for the operation of the display tool 10 of the embodiment, it may significantly reduce the thickness and width of the support member 14 compared with the prior art because no welding is required for manufacturing the member and the rear part of the lower surface 12 a of the frame 12 (referring to FIG. 1 ) receives the total weight of hanging commercial goods and the retaining member 16 a. Because the rear part of the lower surface 12 a of the frame 12 receives the most weight of hanging commercial goods and the retaining member 16 , it is possible to install a retaining member 16 with a diameter larger than the prior art.
[0053] The total weight of hanging commercial goods and the retaining member 16 is also supported by the lower rim of the first hole H 1 and the upper rim of the second hole H 2 . As a result, the total weight of commercial goods and the retaining member acts as the stretching force in the direction perpendicular to the thickness direction of the first support component 14 a and the thickness direction of the second support component 14 b respectively (refer to the arrow Al shown in FIG. 1 ) and as the compression force (refer to the arrow A 2 shown in FIG. 1 ), and hence the support member is stronger than the prior art.
[0054] The retaining member 16 does not necessarily contact with the lower surface of the member 12 to be fixed.
[0055] Next, the manufacturing method of the fixture is described. In particular, the manufacturing process of a metal support member 14 is described. The support member 14 is manufactured by bending a rectangular plate material. A detailed description of the manufacturing step is given hereinafter.
[0056] (First Step)
[0057] The first step is to cut a metal plate of an appropriate length.
[0058] (Second Step)
[0059] The second step is to form the first hole H 1 and the second hole H 2 at the predetermined positions of the first support component 14 a and the second support component 14 b as shown in FIG. 2A and FIG. 2B , respectively.
[0060] (Third Step)
[0061] The third step is to bend the plate material at two different mid positions in the longitudinal direction of the plate material to form the first support component 14 a, the second support component 14 b, and the coupling component 14 c.
[0062] (Fourth Step)
[0063] The fourth step is to form a cuff part 20 by folding the tip of the second support component 14 b at two different positions. The folding positions are not limited to two. For forming the cuff parts, folding is carried out at least one or more different positions at the tip of the second support component 14 and formed cuffs that determine the position of the retaining member 16 in the longitudinal direction. Furthermore, if the position of the retaining member 16 in the long direction may be determined, the cuff parts are not necessarily formed by folding.
[0064] (Fifth Step)
[0065] A cuff part 22 is formed by bending the mid position of the first support component 14 a so that the tip of the first support component 14 a is opened outward. With this step, the center axis AX 1 of the first hole H 1 and the center axis AX 2 of the second hole H 2 become unaligned.
[0066] As described above, the support member 14 may be easily manufactured by applying the bending and the drilling steps on the plate material. The aforementioned second and fifth steps may be interchanged if possible, and the forth and the fifth steps may be carried out as required and not always carried out.
[0067] As explained above, the fixture 10 may maintain a stronger structure that the prior art. As shown in FIG. 7 , in a fixture of the prior art, because the base end of the retaining member 16 is welded, it is impossible to add commercial goods from behind, whereby the idea of first in, first out, i.e., selling goods in stock first is not implemented. However, the fixture 10 of the embodiment of the present invention may implement the first in, first out by adding goods to the retaining member 16 from behind because the retaining member 16 is detachable.
[0068] For adding commercial goods to a retaining member 6 of the prior art where a support member 4 and a retaining member 6 are welded together, there should be some room between a hole of a commercial goods package for hanging it and its content. In other words, a package is made to be somewhat longer for this purpose. By making the package longer, a shop clerk may hold the upper parts of the packages and add them all to the retaining member. However, due to the package thickness and other reasons, commercial goods that cannot be hung are placed on a shelf and the like.
[0069] The fixture 10 of the embodiment of the present invention does not require the aforementioned package modification but may hang thick commercial goods to implement the first in, first out sales easily.
[0070] Furthermore, the fixture 10 has another advantage in facing up commercial goods and pushing them forward.
[0071] On a shelf of displaying commercial goods, a periodic facing up is required to line them up otherwise the shelf display becomes noticeably disorganized. The fixture 10 may line up commercial goods to be less disorganized than a conventional shelf and hence an organized display may be maintained.
[0072] The fixture 10 basically does not require pushing the displayed commercial goods forward. A shop clerk may add commercial goods by lowering the tip of the retaining member 16 which is detached from the support member 14 , and then attach it to the support member 14 to push the commercial goods forward.
Second Embodiment
[0073] A fixture 50 as a second embodiment of the present invention is described hereinafter. The configurational elements which are the same as those in the fixture of the first embodiment have the identical reference numerals and are omitted from the description.
[0074] As shown in FIG. 5 and FIGS. 6A and 6B , the directions of the center axis AX 11 of the first hole H 11 formed in a first support component 54 a and the center axis AX 12 of the hole H 12 of a second support component 54 b are essentially the same. There is a ring 60 made of flexible material such as silicon and rubber is fitted to the rim of the second hole H 12 of the second support component 54 b. The inner diameter of the ring 60 is smaller than the outer diameter of the retaining member 16 whereby the ring 60 may hold the retaining member 16 that is inserted (press-fitted) into the ring.
Third Embodiment
[0075] Next, a fixture of a third embodiment of the present invention is described hereinafter. The configurational elements which are the same as those in the fixture of the first embodiment have the identical reference numerals and are omitted from the description.
[0076] It is possible to fix the retaining member in position using the magnetic force of a magnet attached to the rear end or the cuff member of the retaining member. It is also possible to make a locking mechanism at the cuff for fixing the retaining member in position. Furthermore, using a material such as plastic to increase the thickness of the support member and fix it with a wedge and the like may eliminate the cuff of the support member.
[0077] The present invention is not limited to the embodiments described above, and may be modified without changing the technological scope of the present invention. For example, all of the aforementioned embodiments or part of them combined may be considered within the scope of the present invention.
[0078] The fixture of the aforementioned embodiments may be also used to hang cookware in a kitchen. The retaining member of the fixture may be also used for holding documents by poking them. In other words, the fixture of the present invention includes storage cabinets for hanging cookware and office cabinets to hold documents.
[0079] In general, if a commercially available fixture utilizes the fixture of the present invention, it needs a display tool for displaying commercial goods' prices. The support member of the fixture of the aforementioned embodiments of the present invention may also be integrated with a display tool.
[0080] Note that, this invention is not limited to the above-mentioned embodiments. Although it is to those skilled in the art, the following are disclosed as the one embodiment of this invention.
Mutually substitutable members, configurations, etc. disclosed in the embodiment can be used with their combination altered appropriately. Although not disclosed in the embodiment, members, configurations, etc. that belong to the known technology and can be substituted with the members, the configurations, etc. disclosed in the embodiment can be appropriately substituted or are used by altering their combination. Although not disclosed in the embodiment, members, configurations, etc. that those skilled in the art can consider as substitutions of the members, the configurations, etc. disclosed in the embodiment are substituted with the above mentioned appropriately or are used by altering its combination.
[0084] While the invention has been particularly shown and described with respect to preferred embodiments thereof, it should be understood by those skilled in the art that the foregoing and other changes in form and detail may be made therein without departing from the sprit and scope of the invention as defined in the appended claims.
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To provide a display tool and fixture having above-average strength. A fixture ( 10 ) having: a member ( 12 ) to be fixed; a support member ( 14 ) mounted to the member ( 12 ) to be fixed; and a holding member ( 16 ) which extends in a direction intersecting with the member ( 12 ) to be fixed, which is positioned so that one end thereof is supported by the support member ( 14 ) and so as to make contact with the undersurface of the member ( 12 ) to be fixed or so as to be below the member ( 12 ) to be fixed, and from which an article is hung and held.
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BACKGROUND
Process pressure transmitters are used to monitor pressure of process fluids used in industrial processes. Process pressure transmitters include a pressure sensor that typically provides an electrical output in response to a change in process fluid pressure. Each process pressure transmitter includes transmitter electronics for receiving and processing the electrical output of the pressure sensor. The transmitter electronics are also typically configured to transmit a signal, digital, analog, or a combination thereof, over a control loop or network to a central monitoring location such as a control room.
Pressure sensors used in pressure transmitters generally include a flexible sensor element, such as an electrode plate or a piezo-resistor that deflects in response to a pressure change. The sensor element is fluidically coupled to the process fluid typically through an isolation system. The isolation system includes a metal diaphragm that is configured to contact the process fluid. The isolation system also includes a sealed passageway that extends from the isolator diaphragm to the pressure sensor. The sealed passageway is typically filled with a substantially incompressible fill fluid such as silicone oil. As the pressure of the process fluid changes, the position of the isolator diaphragm changes thereby transferring a pressure change through the isolation fluid to the pressure sensor element. When the pressure sensor element moves in response to the pressure change, a corresponding change in an electrical characteristic of the pressure sensor, such as capacitance or resistance, changes as well. The electrical characteristic of the pressure sensor element is measured by the pressure transmitter electronics and is used to compute the pressure of the process fluid.
Differential pressure transmitters are used in a variety of applications where a difference between two pressures must be measured. Examples of such applications include level measurement in a container and flow measurement across a differential pressure producer such as an orifice plate or venturi. Differential pressure sensors typically require two isolation systems to convey separate process pressures to opposite sides of a single differential pressure sensor element. Typically, a differential pressure transmitter is installed with an integral manifold/valve body that enables both zero calibration of the transmitter and removal/replacement of the transmitter without having to shut off pressure to the transmitter/manifold assembly. The interface between the transmitter and the manifold is defined by International Standard IEC 61518, entitled “Mating dimensions between differential pressure (type) measuring instruments and flanged-on shut-off devices up to 413 BAR (41.3 MPa).”
FIG. 1 is a diagrammatic view of a process fluid differential pressure transmitter coupled to a manifold assembly in accordance with the International Standard set forth above. Transmitter 10 is coupled to manifold 12 by four bolts (not shown) that extend from surface 16 of manifold 12 into transmitter 10 . By using the four bolts, no fittings or additional hardware are used or required to hold the assembly together. This arrangement provides for simple assembly by the end user.
It is sometimes desirable to connect differential pressure transmitters to processes having extremely high static pressures. For example, deeply penetrating oil wells require large line pressures to transport the oil to surface levels. In applications above 413 bar, the manifolds tend to be spaced from the differential pressure transmitter with impulse piping or lines coupling the manifold to the differential pressure transmitter. This is due, at least on part, to the stresses that would be placed on the four clamping bolts if the differential pressure transmitter were bolted directly to the manifold. Given that known isolator diaphragms can exceed 0.8 inches in diameter and that two such isolators are required for differential pressure measurement, a static pressure of 10,000 psi can generate a pressure on the bolts in excess of 5,000 pounds.
FIG. 2 is a diagrammatic view of a differential pressure transmitter coupled to a manifold that is suitable for applications that exceed line pressures of 413 bar. Differential pressure transmitter 20 is coupled to manifold 22 via a pair of impulse lines 24 , 26 . The fluidic couplings between manifold 22 and impulse lines 24 , 26 and between the impulse lines 24 , 26 and differential pressure transmitter 20 are generally configured to support high line pressure. For example, such couplings sometimes use tapered fittings of the type disclosed in U.S. Pat. No. 3,362,731. However, current high pressure coupling systems require the user to route the impulse piping between the manifold and the differential pressure transmitter and to employ fittings on each end of each impulse line. Providing a high-pressure fluidic coupling system that could better accommodate coupling short runs of impulse piping would facilitate installation of differential pressure transmitters in high line pressure applications.
SUMMARY
A process fluid pressure sensing system includes a process fluid pressure transmitter and a process manifold. The process fluid pressure transmitter has first and second pressure inlets and is configured to obtain a measurement relative to pressures applied at the first and second pressure inlets and provide a process variable output based on the measurement. The process manifold is operably coupled to a process fluid and has first and second pressure outlets. A first high-pressure coupling joins the first pressure outlet of the process manifold to the first pressure inlet of the process fluid pressure transmitter. A second high-pressure coupling joins the second pressure outlet of the process manifold to the second pressure inlet of the process fluid pressure transmitter. The first and second high-pressure fluid couplings are configured to accommodate misalignment between the respective pressure outlets and inlets.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic view of a differential pressure transmitter coupled to a manifold assembly.
FIG. 2 is a diagrammatic view of a differential pressure transmitter coupled to a manifold that is suitable for applications that exceed line pressures of 413 bar.
FIG. 3 is a diagrammatic view of a known high pressure fluidic coupling that uses coned and threaded fittings.
FIG. 4 is a diagrammatic view of portions of two devices being coupled together with known cone and threaded connections.
FIG. 5 is a diagrammatic view of a high pressure fluidic coupling in accordance with an embodiment of the present invention.
FIG. 6 is a diagrammatic view of portions of two devices being coupled together in accordance with an embodiment of the present invention.
FIG. 7 is a diagrammatic cross-sectional view of a differential pressure transmitter coupled to a process manifold in accordance with an embodiment of the present invention.
FIG. 8 is an enlarged view of a high-pressure fluidic coupling in accordance with an embodiment of the present invention.
FIG. 9 is a diagrammatic view of a high pressure fluidic coupling in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION
While embodiments of the present invention will generally be described with respect to a differential pressure transmitter, those skilled in the art will appreciate that embodiments of the present invention are practicable with any high-pressure fluid coupling application where precise axial alignment of the fluid couplings is impossible, difficult, or simply time-consuming.
FIG. 3 is a diagrammatic view of a high pressure fluidic coupling that uses coned and threaded fittings such as are known and commercially available from such manufacturers as Parker Autoclave Engineers of Erie, Pa., and BuTech, of Burbank Calif. Typically, the high-pressure fluidic coupling consists of three components: a tube 32 with a thrust collar 34 and a gland 36 to hold tube 32 into female fitting 38 . The sealing mechanism is a metal-to-metal seal 39 between cone 40 machined on the end of tube 32 and a cone 42 machined into female fitting 38 . This metal-to-metal seal 39 is essentially a line contact formed by the intersection of cone 40 on the end of tube 32 and cone 42 in the female fitting 38 . Collar 34 and gland 36 not only hold tube 32 into female fitting 38 , but also ensure that tube 32 enters female fitting 38 at the correct angle. Precise axial alignment is required between male and female couplings in order to ensure a leak-free connection. If the collar and gland did not maintain the proper angle of the tube in the female fitting, the line contact would become two points and a gap could be caused that would allow leaks. For example, if a conical end tube is inclined 5 degrees to the axis of the coned portion of the female fitting, the seal area will consist of two points and two gaps of approximately 0.002 inches wide (for a 0.250 inch OD tube) will result. Thus, if there is any misalignment between devices that are to be coupled with coned and threaded couplings, a bend in the tubing must be provided to compensate for such misalignment. In instances where the two devices are closely-spaced, it can be difficult or even impossible to create the appropriate bends.
FIG. 4 is a diagrammatic view of portions of two devices being coupled together with known cone and threaded connections. Device 44 is separated from device 46 by approximately 1.74 inches. The two devices 44 , 46 are to be coupled with a known cone and threaded coupling for a 0.250″ outside diameter tube. As shown in FIG. 4 , even a relatively small misalignment of 0.090″ over a 1.74″ span requires that a bend 48 be introduced into tube 32 in order to ensure that tubing 48 approaches each device 44 , 46 at precisely 90 degrees. The bending step itself can be time-consuming. Moreover, since the bend results is a permanent deformation of the tubing, it is possible that improper bending operations could damage the tubing. For reference, the coupling shown at reference numeral 50 is that described above with respect to FIG. 3 .
In accordance with embodiments of the present invention, a high-pressure fluidic coupling is provided that can accommodate some misalignment without requiring tubing to be bent. Embodiments of the present invention still provide the robust seal of metal-to-metal contact, but can allow the tubing to enter fitting even when not completely axially aligned with the fitting.
FIG. 5 is a diagrammatic view of a high pressure fluidic coupling in accordance with an embodiment of the present invention. Coupling 100 includes tube 102 having spherical end 104 that is received by conical recess 142 of female fitting 138 . While conical recess 142 is illustrated in FIG. 5 , other geometries such as a straight bore, ellipse, or sphere can be used for the internal recess structure of female fitting 138 as long as a suitable line contact can be formed with spherical end 104 . In the embodiment shown, tube 102 has an externally threaded portion 160 that receives internally threaded thrust collar 162 . However, in order to accommodate slight axial misalignment, some inside dimensions of gland nut 136 have been enlarged. Specifically, internal surface 164 has a diameter that sized to provide a gap 166 between surface 164 and outside diameter 168 of tube 102 . Thus, tube 102 is allowed to move within gap 166 . Similarly internally threaded thrust collar 162 has an outer surface 167 with a diameter that provides a gap 170 between surface 167 and internal surface 172 of gland nut 136 . Another adaptation of the gland nut/thrust collar interaction is a curved surface 174 that defines the gland nut/thrust collar interface. As, different axial misalignments are accommodated, thrust collar 162 may be slid off-center. The gaps illustrated in FIG. 5 are exaggerated for the purposes of illustration and clarity. Those skilled in the art will recognize that any suitable dimensions for the outer diameter of the thrust collar; inner diameters of the gland nut; and radius of curvature for interface 174 can be changed and adjusted as long as a robust interface 174 can be maintained to reliably cause spherical end 104 to sealingly bear against conical recess 142 at all possible misalignments.
FIG. 6 is a diagrammatic view of portions of two devices being coupled together in accordance with an embodiment of the present invention. Device 200 is coupled to device 202 through a high-pressure fluidic coupling. For contrast, the dimensions of separation and axial misalignment for FIG. 6 are identical to those of FIG. 4 . FIG. 6 includes a tube 204 having spherical ends 206 , 208 , which are received in respective conical recesses 210 , 212 . Thus, each of the two fluidic connections illustrated in FIG. 6 can be in accordance with that shown with respect to FIG. 5 . However, the two degree misalignment can be accommodated by the fluidic coupling without requiring a bend to be introduced into tube 204 . Thus, the overall fluidic connection may require less time and effort to complete than that shown in FIG. 4 .
As set forth above, embodiments of the present invention can be advantageously used to provide high-pressure fluidic couplings in a variety of applications where strict axial alignment is difficult or impossible. However, embodiments of the present invention are particularly applicable to coupling differential pressure transmitters to process fluid manifolds. While embodiments of the present invention can be used for impulse line connections, embodiments of the present invention can also enable direct coupling of a differential pressure transmitter to a process manifold for pressures exceeding 413 bar.
FIG. 7 is a diagrammatic cross-sectional view of a process fluid pressure transmitter coupled to a process manifold in accordance with an embodiment of the present invention. Differential pressure transmitter 250 has a plurality of high-pressure fluidic couplings 252 , 254 with process manifold 256 . For clarity, the internal details of transmitter 250 and manifold 256 are not shown. Each coupling can include a female interface that can be in accordance with known high-pressure couplings, such as the known Autoclave FC-250 interface that provides an internal cone recess. Typically, such internal cone recess would couple to a corresponding male cone surface. However, the male portion of the coupling includes a spherical surface (shown in FIG. 8 ) that seals against internal cone recess of the female fitting. The arrangement still provides a robust metal-to-metal seal, but can accommodate less stringent manufacturing tolerances and surface finishes. Advantageously, the entire assembly can still be bolted together with four bolts (similar to the IEC 61518 interface). However, the bolted assembly may be rated to pressures that significantly exceed 413 bar.
FIG. 8 is an enlarged depiction of rectangle 258 shown in FIG. 7 . Each of female connector portions 260 can be in accordance with known designs, such as those having an internal cone recess 262 . Each portion 260 may also include a threaded portion 264 of female fitting 260 that is intended to mate with the male threads on a gland used in typical coned-and-threaded fittings. Alignment feature 267 uses threads 264 to center tube 266 in fitting 260 as it is brought into contact with a respective internal cone recess 262 . As can be appreciated, when two or three such high-pressure fluidic couplings are required, ensuring the precise alignment of each fitting becomes very difficult. However, using seal tubes having spherical ends 268 enables seal tube 266 to enter the female fitting at a slight angle, and thus allows for manufacturing with relaxed tolerances for individual fittings on both the differential pressure transmitter and the process manifold. Another advantage provided by embodiments of the present invention is due, at least in part, to the small surface area on the ends of the tubes and the rigid nature of the tubes. Specifically, similar bolts and torques used for flanged IEC 61518 connections can be used to affix the differential pressure transmitter to the process manifold at much higher pressures. Moreover, the entire transmitter/manifold assembly can still be bolted together with as little as four bolts. This provides simple assembly for end users, but still allows the completed assembly to perform at higher pressures.
FIG. 9 is a diagrammatic view of a high pressure fluidic coupling in accordance with an embodiment of the present invention. FIG. 9 bears some similarities to FIG. 5 , and like components are numbered similarly. High pressure coupling 300 includes a tube 302 having a conically-recessed end 304 that contacts spherical surface 306 of female fitting 308 in device 310 . Coupling 300 includes thrust collar 162 and gland nut 136 , much like the coupling illustrated with respect to FIG. 5 . So arranged, tube 302 is allowed to be slightly axially misaligned with female fitting 308 , but can still maintain a high-pressure seal. Spherical surface 306 can be manufactured or otherwise provided in any suitable manner. For example, surface 306 can be cast as part of device 310 or surface 306 can be provided by a ball having a passageway therethrough that is welded to device 310 . Alternately, spherical surface 306 can be part of a metal-injection molded (MIM) insert that is welded within a bore in device 310 .
Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention.
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A process fluid pressure sensing system includes a process fluid pressure transmitter and a process manifold. The process fluid pressure transmitter has first and second pressure inlets and is configured to obtain a measurement relative to pressures applied at the first and second pressure inlets and provide a process variable output based on the measurement. The process manifold is operably coupled to a process fluid and has first and second pressure outlets. A first high-pressure coupling joins the first pressure outlet of the process manifold to the first pressure inlet of the process fluid pressure transmitter. A second high-pressure coupling joins the second pressure outlet of the process manifold to the second pressure inlet of the process fluid pressure transmitter. The first and second high-pressure fluid couplings are configured to accommodate misalignment between the respective pressure outlets and inlets.
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RELATED APPLICATION
This application claims priority to U.S. Provisional Patent Application No. 61/050,387, which was filed May 5, 2008.
This application is a United States National Phase application of PCT application Ser. No. PCT/US2009/040313 filed Apr. 13, 2009.
BACKGROUND OF THE INVENTION
This invention relates generally to a microchannel heat exchanger including multiple fluid circuits.
A microchannel heat exchanger (MCHX) exchanges heat between a refrigerant and a fluid, such as air. The microchannel heat exchanger includes a plurality of microchannel tubes. The refrigerant flows through the plurality of microchannel tubes, and the air flows over the plurality of microchannel tubes.
The microchannel heat exchanger utilizes a single refrigerant circuit. The refrigerant enters the circuit through an inlet and can make multiple passes through the microchannel heat exchanger. The refrigerant then exits the circuit through an outlet. This results in a high refrigerant side pressure drop for a given amount of refrigerant side heat transfer. This adverse relationship affects the overall system performance, particularly at high outdoor ambient conditions, which causes the discharge pressure to be higher than a comparable round tube plate fin (RTPF) heat exchanger.
SUMMARY OF THE INVENTION
A microchannel heat exchanger includes a plurality of microchannel tubes including a first set of microchannel tubes and a second set of microchannel tubes. A first circuit of the microchannel heat exchanger includes the first set of microchannel tubes, and a portion of a first fluid flows through the first set of microchannel tubes and exchanges heat with a second fluid. A second circuit of the microchannel heat exchanger includes the second set of microchannel tubes, and a reminder of the first fluid flows through the second set of microchannel tubes and exchanges heat with the second fluid. The first fluid from the first circuit and the first fluid from the second circuit combine into a common flow.
In another example, a refrigeration system includes a compressor for compressing a refrigerant, a condenser for cooling the refrigerant, an expansion device for expanding the refrigerant, and an evaporator for heating the refrigerant. One of the condenser and the evaporator is a microchannel heat exchanger. The microchannel heat exchanger includes a plurality of microchannel tubes including a first set of microchannel tubes and a second set of microchannel tubes. A first circuit of the microchannel heat exchanger includes the first set of microchannel tubes, and a portion of the refrigerant flows through the first set of microchannel tubes and exchanges heat with air. A second circuit of the microchannel heat exchanger includes the second set of microchannel tubes, and a reminder of the refrigerant flows through the second set of microchannel tubes and exchanges heat with the air. The refrigerant from the first circuit and the refrigerant from the second circuit combine into a common flow.
These and other features of the present invention will be best understood from the following specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The various features and advantages of the invention will become apparent to those skilled in the art from the following detailed description of the currently preferred embodiment. The drawings that accompany the detailed description can be briefly described as follows:
FIG. 1 illustrates a prior art refrigeration system;
FIG. 2 illustrates a multiple circuit microchannel heat exchanger; and
FIG. 3 illustrates a multiple circuit microchannel heat exchanger including a subcooler.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a refrigeration system 20 including a compressor 22 , a first heat exchanger 24 , an expansion device 26 , and a second heat exchanger 28 . Refrigerant circulates through the closed circuit refrigeration system 20 .
When the refrigeration system 20 is operating in a cooling mode, the refrigerant exits the compressor 22 at a high pressure and a high enthalpy and flows through the first heat exchanger 24 , which acts as a condenser. In the first heat exchanger 24 , the refrigerant rejects heat to air and is condensed into a liquid that exits the first heat exchanger 24 at a low enthalpy and a high pressure. A fan 30 directs the air through the first heat exchanger 24 . The cooled refrigerant then passes through the expansion device 26 , expanding the refrigerant to a low pressure. After expansion, the refrigerant flows through the second heat exchanger 28 , which acts as an evaporator. In the second heat exchanger 28 , the refrigerant accepts heat from air, exiting the second heat exchanger 28 at a high enthalpy and a low pressure. A fan 32 blows air through the second heat exchanger 28 . The refrigerant then flows to the compressor 22 , completing the cycle.
When the refrigeration system 20 is operating in a heating mode, the flow of the refrigerant is reversed with a four-way valve 34 . The first heat exchanger 24 accepts heat from the air and functions as an evaporator, and the second heat exchanger 28 rejects heat to the air and functions as a condenser. For ease of reference, the microchannel heat exchanger can be referred to as a microchannel heat exchanger 38 and is shown in further detail in FIG. 2 .
Either or both of the heat exchangers 24 and 28 can be the microchannel heat exchanger 38 . The microchannel heat exchanger 38 can be part of a refrigeration system 20 used with a microdevice, an automobile air conditioner or a residential system.
FIG. 2 illustrates a first example microchannel heat exchanger 38 . The microchannel heat exchanger 38 includes an entry/exit header 40 , a return header 42 , and microchannel tubes 44 that extend between the headers 40 and 42 . The microchannel tubes 44 are substantially parallel. Each microchannel tube 44 is a flat multi-port tube, and each port has a hydraulic diameter of less than 1 mm.
The microchannel heat exchanger 38 includes multiple independent and separate refrigerant sections or circuits. In one example, the microchannel heat exchanger 38 includes a first circuit 46 and a second circuit 48 that are separate from each other. In the below described example, the refrigerant makes two passes through each refrigerant circuit 46 and 48 . However, the refrigerant can make any number of passes through each refrigerant circuit 46 and 48 . For example, the refrigerant can make only one pass or can make more than two passes through the microchannel heat exchanger 38 . A pass is defined as one trip through the microchannel tubes 44 between the headers 40 and 42 . Therefore, the refrigerant makes two passes through the microchannel tubes 44 to complete a circuit.
In one example, the microchannel heat exchanger 38 is a condenser, and a distributor 112 splits the refrigerant from the compressor 22 into two paths. One path of the refrigerant flows through a coil of the first circuit 46 , and one path of refrigerant flows through a coil of the second circuit 48 . In one example, the refrigerant is split equally between the two circuits 46 and 48 .
A divider wall 56 splits the entry/exit header 40 into a first entry/exit section 52 and a second entry/exit section 54 , preventing refrigerant flow between the sections 52 and 54 . A divider wall 100 separates the first entry/exit section 52 into a first entry section 104 and a first exit section 102 . A divider wall 106 separates the second entry/exit section 54 into a second entry section 108 and a second exit section 110 . A divider wall 62 splits the return header 42 into a first return section 58 and a second return section 60 , preventing refrigerant flow between the sections 58 and 60 .
The refrigerant enters the first circuit 46 through an inlet 64 . In one example, the refrigerant in the first entry section 104 of the first entry/exit section 52 of the entry/exit header 40 flows through a group 114 of microchannel tubes 44 in a direction A, rejecting heat to the air flowing over the microchannel tubes 44 . The refrigerant then flows into the first return section 58 of the return header 42 . The refrigerant flow then turns 180° in the first return section 58 and flows back into another group 116 of microchannel tubes 44 in an opposing second direction B, rejecting additional heat to the air flowing over the microchannel tubes 44 . This pattern is repeated for additional passes. The refrigerant then enters the first exit section 102 of the first entry/exit section 52 of the entry/exit header 40 and exits the first circuit 46 through an outlet 68 . The groups 114 and 116 of microchannel tubes 44 are exclusive to the first circuit 46 .
In another example, the refrigerant enters the first circuit 46 through the first exit section 102 and exits the first circuit 46 through the first entry section 104 .
The refrigerant enters the second circuit 48 through an inlet 70 . The refrigerant in the second entry section 108 of the second entry/exit section 54 of the entry/exit header 40 flows through a group 118 of microchannel tubes 44 in a direction A, rejecting heat to the air flowing over the microchannel tubes 44 . The refrigerant then flows into the second return section 60 of the return header 42 . The refrigerant flow then turns 180° in the second return section 60 and flows back into another group 120 of microchannel tubes 44 in an opposing second direction B, rejecting additional heat to the air flowing over the microchannel tubes 44 . This pattern is repeated for additional passes. The refrigerant then enters the second exit section 110 of the second entry/exit section 54 of the entry/exit header 40 and exits the second circuit 48 through an outlet 74 . The groups 118 and 120 of microchannel tubes 44 are exclusive to the second circuit 48 .
In another example, the refrigerant enters the second circuit 48 through the second exit section 110 and exits the second circuit 48 through the second entry section 108 .
The refrigerant from the outlets 68 and 74 are combined into a single flow path and then directed to the expansion device 26 .
Although two refrigerant circuits 46 and 48 each including two passes through the microchannel tubes 44 are illustrated and described, it is to be understood that the microchannel heat exchanger 38 can include any number of circuits, and the refrigerant in each circuit can make any number of passes through the microchannel heat exchanger 38 .
Additionally, the microchannel heat exchanger 38 can be an evaporator, and the refrigerant from the expansion device 26 is split into multiple circuits and accepts heat from the air passing over the microchannel tubes 44 before flowing to the compressor 22
By employing multiple refrigerant circuits in the microchannel heat exchanger 38 , the mass flow of the refrigerant is divided equally between the multiple circuits, decreasing the refrigerant side pressure drop of the refrigerant and improving refrigerant side heat transfer. The refrigerant side heat transfer can be further raised by optimally selecting the number of passes and the number of microchannel tubes 44 for each pass within each circuit. This helps to reduce the refrigerant side pressure drop, as well as reduce the charge sensitivity of the microchannel heat exchanger 38 .
FIG. 3 illustrates a second example microchannel heat exchanger 76 . The microchannel heat exchanger 76 includes the features of the microchannel heat exchanger 38 of FIG. 2 and a subcooler 78 (a third circuit). In the example illustrated and described, the microchannel heat exchanger 76 is a condenser. However, the microchannel heat exchanger 76 can be an evaporator.
The subcooler 78 is formed by a subcooler entry/exit section 80 of the entry/exit header 40 , a return subcooler section 82 of the return header 42 , and groups 122 and 124 of microchannel tubes 44 . A divider wall 86 separates the subcooler entry/exit section 80 from the sections 52 and 54 of the entry/exit header 40 to prevent refrigerant flow between the sections 52 , 54 and 80 , and a divider wall 88 separates the return subcooler section 82 from the sections 58 and 60 of the return header 42 to prevent refrigerant flow between the sections 58 , 60 and 82 . The subcooler entry/exit section 80 is further divided by a divider wall 126 that separates the subcooler entry/exit section 80 into a subcooler entry section 128 and a subcooler exit section 130 to enable the flow to enter and leave on the same side of the microchannel heat exchanger 76 .
The refrigerant exchanges heat with the air as described above with reference to FIG. 2 . Refrigerant from the outlets 68 and 74 merges into a single path, and the refrigerant enters an inlet 90 of a subcooler circuit 96 . Refrigerant in the subcooler entry section 128 of the subcooler entry/exit section 80 of the entry/exit header 40 flows through the group 122 of microchannel tubes 44 in a direction A, rejecting heat to the air flowing over the microchannel tubes 44 . The refrigerant then enters the return subcooler section 82 of the return header 42 . The refrigerant flow then turns 180° in the return subcooler section 82 and flows back into another group 124 of microchannel tubes 44 in the opposing second direction B, rejecting additional heat to the air flowing over the microchannel tubes 44 . The refrigerant then enters the subcooler exit section 130 of the subcooler entry/exit section 80 of the entry/exit header 40 and exits the subcooler circuit 96 through an outlet 94 . The refrigerant is then directed to the expansion device 26 . The subcooler groups 122 and 124 of microchannel tubes 44 are exclusive the subcooler circuit 96 .
Although the subcooler circuit 96 includes two passes in the example illustrated and described, any number of passes can be employed. For example, the refrigerant can make a single pass through the subcooler 78 or make more than two passes through the subcooler 78 . By employing a subcooler 78 , the heat transfer and refrigerant side pressure drop can be further optimized.
The foregoing description is only exemplary of the principles of the invention. Many modifications and variations of the present invention are possible in light of the above teachings. The preferred embodiments of this invention have been disclosed, however, so that one of ordinary skill in the art would recognize that certain modifications would come within the scope of this invention. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described. For that reason the following claims should be studied to determine the true scope and content of this invention.
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A microchannel heat exchanger includes a plurality of microchannel tubes including a first set of microchannel tubes and a second set of microchannel tubes. A first circuit of the microchannel heat exchanger includes the first set of microchannel tubes, and a portion of a first fluid flows through the first set of microchannel tubes and exchanges heat with a second fluid. A second circuit of the microchannel heat exchanger includes the second set of microchannel tubes, and a reminder of the first fluid flows through the second set of microchannel tubes and exchanges heat with the second fluid. The first fluid from the first circuit and the first fluid from the second circuit combine into a common flow.
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BACKGROUND OF THE INVENTION
This invention relates to a noise generator for use in telephones and other communication devices wherein it is desired to avoid complete silence during a communication.
As used herein, “telephone” is a generic term for a communication device that utilizes, directly or indirectly, a dial tone from a licensed service provider. As such, “telephone” includes desk telephones, cordless telephones, speaker phones (see FIG. 1 ), hands free kits (see FIG. 2 ), and cellular telephones (see FIG. 3 ), among others. For the sake of simplicity, the invention is described in the context of telephones but has utility in any communication device that silences a channel temporarily.
Anyone who has used a speaker phone, for example, is well aware of the cut off speech and the silent periods during a conversation caused by echo canceling circuitry within the speaker phone. Such phones generally operate in what is known as half-duplex mode, which means that only one person can speak at a time. While such silent periods assure that sound from the speaker phone is not coupled directly into the microphone within the speaker phone, the quality of the call is poor.
Telephones of the prior art often impose a silence in an attempt to eliminate acoustic and electronic echoes. When speech is gated off by a center clipper, attenuated by a residual echo suppresser, or canceled by a noise cancellation system, the resulting output is unnaturally quiet. The silence has been interpreted by consumers as a broken connection and a party to a call might mistakenly hang up. This problem has been solved by providing so-called “comfort noise” in which a low level noise signal is applied to a line rather than silence. U.S. Pat. No. 6,122,611 (Su et al.) describes a system that not only adds noise during periods of silence but also adds a little noise during conversation to avoid changes in the apparent loudness of the speech.
While one might think that all noise is the same, such is not the case. An automobile produces quite a different background noise from an office or a living room full of people. Adding “white” (spectrally flat random) noise produces yet another background sound. U.S. Pat. No. 5,657,422 (Janiszewski et al.) discloses filtering the noise in a low pass filter to make it sound more natural. While better than white noise, it remains a problem to provide a comfort noise that resembles the actual noise in each individual telephone call.
In view of the foregoing, it is therefore an object of the invention to provide an improved generator of comfort noise.
Another object of the invention is to provide comfort noise that more closely matches the spectral content of actual noise during a call.
A further object of the invention is to provide a comfort noise that matches actual background noise as closely as possible by shaping white noise using a quadrature mirror filter bank.
SUMMARY OF THE INVENTION
The foregoing objects are achieved in this invention in which comfort noise is derived from a white noise signal by filtering the white noise signal in a quadrature mirror filter (QMF) bank that uses a polyphase filter structure to produce a comfort noise signal that is selectively coupled to at least one channel in a telephone. Preferably, an M (M>2) channel quadrature mirror filter bank with a plurality of polyphase filters is used and the magnitude of the white noise into each filter is controlled in accordance with the magnitude of the signal in a corresponding sub-band in a channel. In accordance with another aspect of the invention, the signals from higher frequency sub-bands are combined and control a single input to a QMF bank, thereby increasing the low frequency content of the comfort noise. In accordance with another aspect of the invention, the QMF banks are cascaded upwardly (the output of one bank is coupled to the low pass input of the next bank), which provides finer spectral resolution at low frequencies.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete understanding of the invention can be obtained by considering the following detailed description in conjunction with the accompanying drawings, in which:
FIG. 1 is a perspective view of a conference phone or a speaker phone;
FIG. 2 is a perspective view of a hands free kit;
FIG. 3 is a perspective view of a cellular telephone;
FIG. 4 is a generic block diagram of audio processing circuitry in a telephone;
FIG. 5 is a more detailed block diagram of audio processing circuitry in a telephone;
FIG. 6 is a simplified block diagram illustrating the operation of a comfort noise generator constructed in accordance with the invention;
FIG. 7 is a block diagram of a polyphase filter used in implementing the invention; and
FIG. 8 is a block diagram of a comfort noise generator constructed in accordance with a preferred embodiment of the invention.
Those of skill in the art recognize that, once an analog signal is converted to digital form, all subsequent operations can take place in one or more suitably programmed microprocessors. Reference to “signal”, for example, does not necessarily mean a hardware implementation or an analog signal. Data in memory, even a single bit, can be a signal. In other words, a block diagram herein can be interpreted as hardware, software, e.g. a flow chart, or a mixture of hardware and software. Programming a microprocessor is well within the ability of those of ordinary skill in the art, either individually or in groups.
DETAILED DESCRIPTION OF THE INVENTION
This invention finds use in many applications where the electronics is essentially the same but the external appearance of the device may vary. FIG. 1 illustrates a conference phone or speaker phone such as found in business offices. Telephone 10 includes microphone 11 and speaker 12 in a sculptured case. Telephone 10 may include several microphones, such as microphones 14 and 15 to improve voice reception or to provide several inputs for echo rejection or noise rejection, as disclosed in U.S. Pat. No. 5,138,651 (Sudo). Acoustic echo can occur when sound from speaker 12 is coupled to one of the microphones. Background noise can be considerable in a speaker phone because the user is typically a meter or more away from a microphone.
FIG. 2 illustrates what is known as a hands free kit for providing audio coupling to a cellular telephone, illustrated in FIG. 3 . Hands free kits come in a variety of implementations but generally include powered speaker 16 attached to plug 17 , which fits an accessory outlet or a cigarette lighter socket in a vehicle. A hands free kit also includes cable 18 terminating in plug 19 . Plug 19 fits the headset socket on a cellular telephone, such as socket 21 ( FIG. 3 ) in cellular telephone 22 . Some kits use RF signals, like a cordless phone, to couple to a telephone. A hands free kit also typically includes a volume control and some control switches, e.g. for going “off hook” to answer a call. A hands free kit also typically includes a visor microphone (not shown) that plugs into the kit. Background noise in a vehicle can also be considerable but distinctly different from the background noise in a speaker phone.
The various forms of telephone can all benefit from the invention. FIG. 4 is a block diagram of the major components of a cellular telephone. Typically, the blocks correspond to integrated circuits implementing the indicated function. Microphone 31 , speaker 32 , and keypad 33 are coupled to signal processing circuit 34 . Circuit 34 performs a plurality of functions and is known by several names in the art, differing by manufacturer. For example, Infineon calls circuit 34 a “single chip baseband IC.” QualComm calls circuit 34 a “mobile station modem.” The circuits from different manufacturers obviously differ in detail but, in general, the indicated functions are included.
A cellular telephone includes both audio frequency and radio frequency circuits. Duplexer 35 couples antenna 36 to receive processor 37 . Duplexer 35 couples antenna 36 to power amplifier 38 and isolates receive processor 37 from the power amplifier during transmission. Transmit processor 39 modulates a radio frequency signal with an audio signal from circuit 34 . In non-cellular applications, such as speakerphones, there are no radio frequency circuits and signal processor 34 may be simplified somewhat. Problems of echo cancellation and noise remain and are handled in audio processor 40 . It is audio processor 40 that is modified to include the invention. How that modification takes place is more easily understood by considering an audio processor in more detail.
FIG. 5 is a detailed block diagram of an audio processing circuit, including a noise reduction circuit and an echo canceling circuit, loosely based on chapter 6 of Digital Signal Processing in Telecommunications by Shenoi, Prentice-Hall, 1995. Sub-band filter bank 54 is not shown in the text. The following describes signal flow through the transmit channel, from microphone input 42 to line output 44 . The receive channel, from line input 46 to speaker output 48 , works in the same way.
Sound is converted into an electrical signal by a microphone (not shown in FIG. 5 ) and the electrical signal is coupled to microphone input 42 . The sound may or may not include sound from a speaker (not shown in FIG. 5 ) driven by the signal at speaker output 48 . The signal at input 42 is digitized in A/D converter 51 and coupled to summation network 52 . There is, as yet, no signal from echo canceling circuit 53 and the signal proceeds to sub-band filter block 54 , which is initially set to minimum attenuation. In sub-band filter block 54 , the transmit channel is divided by frequency into a plurality of sub-bands. In a preferred embodiment of the invention, ten sub-bands are used. As few as two sub-bands can be used.
The signals from at least some the sub-bands are combined and coupled through non-linear processor 55 to summation circuit 56 , where comfort noise from generator 57 can be added to the signal. Non-linear processor 55 includes, for example, a center clipper, as noted above. A center clipper fully attenuates low level signals producing the silence described above. The output signal from summation circuit 56 is converted into analog form by D/A converter 58 , amplified in amplifier 59 , and coupled to line output 44 .
Control circuit 60 , which includes signal inputs (not shown) from several points in the audio processing circuit, controls sub-band selection and attenuation, non-linear processing, comfort noise insertion, and echo cancellation. Echo canceller 53 reduces acoustic echo between speaker output 48 to microphone input 42 . Echo canceller 61 reduces line echo between line output 44 and line input 46 .
In the prior art, comfort noise is simply generated and added, as in the Su et al. patent, or white noise is filtered (in a low pass filter) as in the Janiszewski et al. patent. Unlike the prior art, the comfort noise generated in accordance with the invention mimics the power distribution of actual noise during a call, thereby producing a much more realistic background noise. FIG. 6 illustrates the basic operation of the invention.
In FIG. 6 , comfort noise generator 70 includes white noise generator 71 coupled through multiplier 72 to the high pass input of quadrature mirror filter bank 77 . White noise generator 74 is coupled through multiplier 73 to the low pass input of QMF bank 77 . The gain of each channel is controlled in accordance with the amplitude of the signals in the sub-bands defined by sub-band filter 75 and sub-band filter 76 . Filters 75 and 76 are preferably band pass filters, in which the center frequency of filter 75 is higher than the center frequency of filter 76 . By controlling gain in accordance with the amplitude, or power, in the sub-bands, one obtains a better representation of the actual noise. That is, the amplitude of each white noise signal is adjusted in accordance with the power in each sub-band.
White noise generators 71 and 74 are each preferably a sixteen bit white noise generator synthesizing uniformly distributed random data in the interval (−1, 1). In accordance with another aspect of the invention, a different seed (starting value) is used in each white noise generator to provide a higher degree of randomness in the channels.
Filter 77 uses a polyphase filter structure to implement the QMF bank. FIG. 7 is a block diagram of a preferred embodiment of the polyphase filter structure 80 for use in the invention.
Filter 80 includes a low pass input coupled to summation circuit 81 and to subtractor 82 . A high pass input is also coupled to summation circuit 81 and to subtractor 82 . The input signals are added in summation circuit 81 and coupled to all pass filter 83 . The input signals are subtracted in subtractor 82 and coupled to all pass filter 84 . The output from filter 83 is up-sampled in block 85 and delayed one sample time in block 87 . The output from filter 84 is up-sampled in block 86 and added to the delayed signal in summation circuit 88 .
The derivation of filters 83 and 84 is described as follows. A low pass, third order elliptical filter was designed to have 1 dB ripple in the pass band, 40 dB ripple in the stop band, and a stop band frequency of 0.25 cycles per sample. These specification yielded the following low pass filter.
H 0 ( z ) = 0.15894 + 0.40296 z - 1 + 0.40296 z - 2 + 0.15984 z - 3 1 - 0.30823 z - 1 + 0.62909 z - 2 - 0.19706 z - 3
The following equations are used to derive the polyphase components.
a 0 ( z 2 )= H 0 ( z )+ H 1 ( z ) [1] and a 1 ( z 2 )= H 0 ( z )− H 1 ( z ) [2] where H 1 ( z )= H 0 (− z )
and H 1 (z) is a high pass filter. Solving these equations for a 0 (z 2 ) and a 1 (z 2 ) yields the following polyphase filters.
a 0 ( z 2 ) = 0.15894 + 0.62715 z - 2 + 0.38190 z - 4 + 0.03132 z - 6 1 + 1.16320 z - 2 + 0.27422 z - 4 - 0.03883 z - 6 a 1 ( z 2 ) = 0.45195 + 0.56796 z - 2 + 0.17939 z - 4 1 + 1.16320 z - 2 + 0.27422 z - 4 - 0.03883 z - 6
Equations [1] and [2] correspond to equation 3.6.14 in P. P. Vaidyananthan, Multirate Systems and Filter Banks , p. 87, Prentice-Hall, Upper Saddle River, N.J., 1993. FIG. 7 implements the function represented by equations [1] and [2].
Each of the filters represented by a 0 (z) and a 1 (z) are further divided into second order sections and implemented using the Direct Form I method. Direct Form I minimizes the effect of coefficient quantization noise by allowing both numerator and denominator coefficients to be multiplied and accumulated before rounding is performed. This method is more robust to quantization problems in typical fixed point implications.
FIG. 8 illustrates a comfort noise generator constructed in accordance with a preferred embodiment of the invention. In the embodiment of FIG. 8 , the outputs from ten analysis sub-band filters are used for generating scaling factors for sub-band comfort noise. The sub-band filters are in existing audio processing circuitry; see FIG. 5 . A separate set of sub-band filters is not used for the invention to reduce cost and complexity. More or fewer sub-band filters could be used instead. Obviously, if existing circuitry does not include an analysis filter bank, then one must be provided.
As illustrated in FIG. 8 , there are ten sub-band filters, 90 - 99 , of progressively higher center frequency; i.e. sub-band filter 90 has the lowest center frequency and sub-band filter 99 has the highest center frequency. Although the particular frequency are not critical, the following example is representative of an effective frequency allocation. Many others could be used instead. Obviously, the range of frequencies is determined by application. In the example below, the range of frequencies is determined by the bandwidth of a telephone network.
Analysis
Analysis
QMF
QMF
Band
Bandwidth (Hz)
Band
Bandwidth (Hz)
0
102-242.5
0
0-250
1
283.6-352.1
1
250-500
2
370.3-456.9
3
480.4-594.6
4
625.3-773.1
2
500-1000
5
812.9-1005.9
6
1057.7-1309.5
7
1377-1706.2
3
1000-2000
8
1796.2-2233.9
9
2451-3395
4
2000-4000
The output from sub-band filter 90 is coupled to the square root circuitry 100 . The outputs from sub-band filter 91 and sub-band filter 92 are added and coupled to the square root circuitry 101 . The outputs from sub-band filter 93 , sub-band filter 94 , and sub-band filter 95 are added and coupled to square root circuitry 102 . The outputs from sub-band filter 96 , sub-band filter 97 , and sub-band filter 98 are added and coupled to square root circuitry 103 . The output from sub-band filter 99 is coupled to square root circuitry 104 . While, in theory, one could use (n−1) polyphase filters with (n) sub-band filters, where n≧2, it is preferred to combine the outputs from several filters to reduce the number of polyphase filters and to bias comfort noise generation in favor of lower frequencies.
Square root circuit 100 feeds into amplifier 110 , square root circuit 101 feeds 111 , square root circuit 102 feeds amplifier 112 , square root circuit 103 feeds amplifier 113 , and square root circuit feeds amplifier 114 . The incoming signals (data) represent power or, more accurately, mean squared values. The square root circuits provide the RMS (root mean squared) value of the signal for adjusting the gain of the white noise signal.
The output of amplifier 110 multiplies the output of white noise generator 130 through multiplier 120 ; the output of amplifier 111 multiplies the output of white noise generator 131 through multiplier 121 ; the output of amplifier 112 multiplies the output of white noise generator 132 through multiplier 122 , the output of amplifier 113 multiplies the output of white noise generator 134 through multiplier 124 .
The output of multiplier 120 is coupled to the low pass input QMF bank 140 . The output of multiplier 121 is coupled to the high pass input of QMF bank 140 . The output of QMF bank 140 is coupled to the low pass input of QMF bank 141 . The output of multiplier 122 is coupled to the high pass input of QMF bank 141 . The output of QMF bank 141 is coupled to the low pass input QMF bank 142 . The output of multiplier 123 is coupled to the high pass input of QMF bank 142 . The output of QMF bank 142 is coupled to the low pass input QMF bank 143 . The output of multiplier 124 is coupled to the high pass input of QMF bank 143 . The output of QMF bank 143 is the generated comfort noise.
The invention thus provides an improved generator of comfort noise in which the comfort noise more closely matches the spectral content of actual noise during a call. This is achieved by shaping white noise in a M channel quadrature mirror filter bank in accordance with the amplitude of the actual noise.
Having thus described the invention, it is understood by those of skill in the art that various modifications can be made within the scope of the invention. For example, as noted above, other forms of filter bank architectures can be used. In analog form, the blocks shown as multipliers are programmable gain amplifiers. In software, the operation is a multiplication of the two input digital values. Fewer separate white noise generators could be used, with a consequent decrease in randomness of the signals.
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Comfort noise is derived from a white noise signal by filtering the white noise signal in a QMF bank to produce comfort noise signal that is selectively coupled to at least one channel in a telephone. Preferably, a plurality of QMF banks are used and the magnitude of the white noise into each filter is controlled in accordance with the magnitude of the signal in a corresponding analysis sub-band in a channel. In accordance with another aspect of the invention, the signals from higher frequency analysis sub-bands are combined and control a single input to a QMF bank, thereby increasing the low frequency resolution of the comfort noise. In accordance with another aspect of the invention, the QMF banks are cascaded upwardly (the output of one bank is coupled to the low pass input of the next bank), which also enhances the low frequency resolution of the comfort noise.
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CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application is a division of U.S. application Ser. No. 12/353,203, filed Jan. 13, 2009, which is a continuation-in-part of U.S. application Ser. No. 11/038,780, filed Jan. 18, 2005, which claims the benefit of U.S. Provisional Application No. 60/537,153, filed Jan. 16, 2004, the disclosures of which are hereby expressly incorporated by reference in their entirety.
BACKGROUND
[0002] Blasting technologies have expedited mining operations, such as surface mining and subterranean mining, by allowing the strategic and methodic placement of charges within the blasting site. Despite this, blasting technologies still carry safety risks that should be minimized. Effective blasting requires not only well-placed detonators, but also timed detonation of the charges, preferably in a predetermined sequence. Accordingly, accurate and precise control and firing of the detonators is important for effective and efficient blasting. The more precise and accurate control of the detonators also leads to an increase in safety of the system overall. Thus, it is desirable to have a blasting system that effectively and efficiently controls the detonation of various types of charges while simultaneously increasing the overall safety of the system.
SUMMARY
[0003] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
[0004] In accordance with the disclosed subject matter, a remote firing system, a controller device, a remote device, and a method for remotely detonating explosives is provided. The system form of the disclosed subject matter includes a remote firing system that comprises a set of remote devices. Each remote device is capable of communicating a safety data structure that contains a system identifier for identifying the remote firing system from other remote firing systems and a device identifier for identifying a remote device from other remote devices. The remote firing system further includes a controller device for causing the set of remote devices to trigger detonators. The controller device is capable of selecting a subset of the set of remote devices for triggering detonators and further being capable of communicating the safety data structure that contains a system identifier for identifying the remote firing system from other remote firing systems and device identifiers for identifying the subset of remote devices to control.
[0005] In accordance with further aspects of the disclosed subject matter, a device form of the disclosed subject matter includes a controller device that includes a set of selection and information panels that correspond with a set of remote devices. A subset of selection and information panels is selectable to cause a corresponding subset of remote devices to be selected for detonating explosives. The controller device further includes a communication module for transmitting and receiving safety communication. The communication module is capable of communicating with the subset of remote devices to indicate their selection for detonating explosives by the controller device.
[0006] In accordance with further aspects of the disclosed subject matter, a remote device that includes a communication module for transmitting and receiving a safety data structure that contains a system identifier for identifying a remote firing system that comprises the remote device and a device identifier for identifying the remote device. The remote device also includes a memory for recording state changes of the remote device. The remote device further includes a switch for selecting either shock-tube detonator initiation or electric detonator initiation.
[0007] In accordance with further aspects of the disclosed subject matter, a method for remotely detonating explosives. The method includes selecting a subset of a set of selection and information panels on a controller device to cause a corresponding subset of remote devices to be selected for detonating explosives. The method further includes issuing an arming command by the controller device to the subset of remote devices to cause the subset of remote devices to prepare for detonation. The method yet further includes issuing a firing command by the controller device to the subset of remote devices by simultaneously selecting dual fire switches together on the controller device to cause the subset of remote devices to detonate explosives.
DESCRIPTION OF THE DRAWINGS
[0008] The foregoing aspects and many of the attendant advantages of the disclosed subject matter will become more readily appreciated as the same become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
[0009] FIG. 1 is a pictorial diagram showing a plan view of an open pit surface mine, wherein conventional blasting techniques are employed;
[0010] FIG. 2 is a pictorial diagram showing a cross-sectional illustration of a subterranean mining operation;
[0011] FIG. 3 is a pictorial diagram illustrating a remote firing system using safety communication according to one embodiment;
[0012] FIG. 4 is a pictorial diagram of a controller device user interface, in accordance with one embodiment;
[0013] FIG. 5 is a pictorial diagram illustrating a remote device user interface, in accordance with one embodiment;
[0014] FIG. 6 is a block diagram showing various inputs, outputs, and internal control modules for a controller device, in accordance with one embodiment;
[0015] FIG. 7 is a block diagram showing various inputs, outputs, and internal control modules for a remote device, in accordance with one embodiment;
[0016] FIG. 8 is a block diagram showing various inputs, outputs, and internal modules for a blasting machine, in accordance with one embodiment;
[0017] FIG. 9 is a process diagram illustrating a method for communicating by a controller device using secure communication, in accordance with one embodiment; and
[0018] FIG. 10 is a process diagram illustrating a method for receiving and processing by a remote device messages containing security protocol information, in accordance with one embodiment.
DETAILED DESCRIPTION
[0019] FIG. 1 depicts a plan view of surface mining in an open pit mine 100 . By way of example, there may exist one or more groups of explosives 102 , known as shots. Although not shown, other shots may be situated in various locations throughout the mine depending on where the blasting will occur. The shot 102 (and all of the detonators within the shot) may be tethered to a blasting machine 104 , or it may be tethered directly to a remote device 106 . The blasting machine 104 is further tethered to the remote device 106 , which is in communication with a controller 108 . The blasting system is controlled by an operator 110 at the controller 108 . The operator 110 may initiate a blasting sequence by transmitting one or more signals using the controller 108 to the remote device 106 , which may command the blasting machine 104 to initiate the detonators in the shot 102 depending on the type of detonators. While FIG. 1 shows the blasting machine 104 , the remote device 106 , and the controller 108 in communication wirelessly or by wire, one of skill in the art will appreciate that any type of communication link may also be used between the varying devices.
[0020] In the open pit mine 100 , a danger area 112 is associated with loose rock, known as fly rock, which can be thrown great distances by the explosive force released upon detonation of the shot 102 . To ensure safety, the blasting machine 104 , the remote device 106 , the controller 108 , and the operator 110 is suitably be located outside the perimeter of the danger area 112 . Similarly, vehicles and other mine employees (not shown) are suitably also be located outside the perimeter of the danger area 112 . Although mine personnel (not shown), known as spotters, guard areas of ingress to the mine that cannot be observed by the operator 110 , there still exists a danger that someone or something will enter the danger area 112 . There also exists a risk of third-party access to any of the communication links between the devices. Accordingly, various embodiments of the disclosed subject matter, as discussed in more detail below, provide for additional safety features within the controller 108 and the remote device 106 to mitigate the safety risks.
[0021] FIG. 2 depicts a cross-sectional view of blasting carried out in a subterranean mine 200 . As in surface mining (as seen in FIG. 1 ), a blasting machine 204 and a lead line 203 are used to detonate explosives in headings 202 A-D. As with surface mining, shots containing the explosive charges are placed in the headings 202 A-D of working shafts 214 A-B. The working shafts 214 A-B connect to a main shaft 212 . The main shaft 212 leads to the surface and carries the lead line 203 from the blasting machine 204 located at the surface, to the headings 202 A-D. Due to the dangers of cave-ins for subterranean mining, entire mines are generally shut down and evacuated prior to detonation of explosives. This requires evacuation of both an operator 210 and other mine personnel (not shown) to the surface. As in surfacing mining, the safety features of the various embodiments of the disclosed subject matter decrease the risk associated with blasting operations.
[0022] FIG. 3 depicts a generalized view of a blasting system 300 as used in surface mining ( FIG. 1 ), subterranean mining ( FIG. 2 ), or the like. A group of explosives 302 include various detonators. Depending on the type of detonator in the group of explosives 302 , it may be coupled directly to a remote device 306 , or it may be coupled to a blasting machine 304 , which in turn is coupled to the remote device 306 . The remote device 306 is in communication with a controller 308 , which receives inputs 310 from an operator, such as the operator 110 in FIG. 1 , or from some other input source. As noted above, while FIG. 3 depicts various communication links between devices as either wired or wireless, one of skill in the art will appreciate that any type of communication link may be used as long as the information transmitted is accurate.
[0023] According to various embodiments of the disclosed subject matter, the detonators in the group of explosives 302 are detonated by the blasting machine 304 or the remote device 306 when an ARM (enables the initiator or charging mechanism in the detonator) and/or a FIRE (releases the initiator or charging mechanism in the detonator) command is sent. The blasting machine 304 or the remote device 306 may also discharge the initiator or charging mechanism in the detonator upon receiving a DISARM command from the remote device 306 . The DISARM command may initiate in the controller 308 or in the remote device 306 , as discussed in more detail below. If the blasting machine 304 receives a STATUS command from the remote device 306 , information relating to the status of a detonator in the group of explosives 302 will be sent to the remote device 306 . Status information includes, for example, arming/disarming of the detonator, or a status error in firing of the detonator.
[0024] The remote device 306 sends messages to the blasting machine 304 as previously noted, but also sends and receives messages by way of the controller 308 . According to various embodiments of the disclosed subject matter, and as will be discussed in more detail below, the remote device 306 and controller 308 communicate using a security protocol, such as a code word embedded in the transmitted signal, to ensure authenticity of the message communicated and so that third-parties cannot interfere with messages received or sent. Additionally, the controller 308 receives the inputs 310 to manage the blasting operation by configuring to send arming, disarming, and firing commands from the controller 308 to the remote device 306 , which may in turn send the commands to the blasting machine 304 for firing or disarming of the detonators in the group of explosives 302 .
[0025] FIG. 4 illustrates an exemplary front panel for a controller device user interface 400 in accordance with one embodiment of the disclosed subject matter. Any suitable number of remote devices (not shown) are controllable from the controller device user interface 400 . The left portion of the controller device user interface 400 includes selection and remote device panels 402 A-H for eight remote devices. Each remote device panel 402 A-H includes membrane switches 404 A-H that allows selection or deselection of an associated remote device. Further, each remote device panel 402 A-H includes labeling and light indicators, such as LEDs or the like, for a READY state 406 , ARMED state 407 , battery condition 408 , and selected state 409 of the associated remote device.
[0026] The right portion of the controller device user interface 400 includes a controller device interface, an informational interface, and a user input section interface. The controller device interface includes an external antenna connection port 410 , an electronic key interface 412 , and a programming port 414 . The informational interface includes a controller device battery status panel 420 , including labeling and light indicators, such as LEDs or the like, for a slow charge 421 , a fast charge 422 , a 20% remaining battery capacity 423 , a 40% remaining battery capacity 424 , a 60% remaining battery capacity 425 , a 80% remaining battery capacity 426 , and a 100% remaining battery capacity 427 . These percentages of remaining battery capacity are arbitrarily selected and other percentages, or different styles of display, can be substituted in other embodiments without departing materially from the scope of the disclosed subject matter.
[0027] The informational interface includes a panel 430 containing labeling and indicator lights, such as LEDs or the like, for a device power 432 , an electronic key status 434 , a device transmitting 436 , and a device receiving 438 . Additionally, the user input selection interface comprises panels 440 , 444 , 450 , 453 , 460 , 463 , 470 , and 473 . The panel 440 is used for placing a controller device in the ON state with the membrane switch 442 . The panel 444 is used for placing a controller device in the OFF state with the membrane switch 446 . The panel 450 is used for selecting a status query operation with the membrane switch 452 . The panel 453 is used for placing the controller device battery status panel 420 in an ON or OFF state by cycling the membrane switch 455 . The panel 460 is used for selecting an ARM command operation with the membrane switch 462 . The panel 463 is used for selecting a DISARM command operation with the membrane switch 465 . The dual panels 470 and 473 are used for selecting a FIRE command operation with the dual membrane switches 472 and 475 .
[0028] The panels 450 , 453 , 460 , 463 , 470 , and 473 further include labeling and indicator lights 451 , 454 , 461 , 464 , 471 , and 474 , respectively, such as LEDs or the like. Combinations of the aforementioned light indicators can be used to indicate device conditions. One example is flashing of all light indicators when the device is placed in the ON state, which also indicates the initiation of a self-testing operation. Other suitable combinations are possible as well.
[0029] FIG. 5 illustrates an exemplary front panel 500 for a remote device user interface 502 . The remote device user interface 502 includes an external antenna port 504 and a programming port 506 . The remote device user interface 502 further includes an electronic initiator port (not shown) connected to the blasting machine, as well as a lead line connection port 508 for connecting lead lines directly to the detonators. The electronic initiator port may be located on the side of the remote device 306 or other suitable location. One of ordinary skill will also appreciate that the electronic port may be a serial port or other suitable port, and it may use a suitable communication protocol when communicating with the blasting machine. For example, the blasting machine and the electronic initiator port may communicate using protocol RS232, or the like.
[0030] As further seen in FIG. 5 , the lead line connection port 508 is shown on the face of the remote device user interface 502 , but may be located on the left sidewall of the remote device or other suitable location on the remote device. An output select switch 509 selects an initiation method associated with panels 510 , 520 , or 530 . In accordance with one embodiment, the output select switch 509 may be a mechanical toggle switch. In other embodiments, the output select switch 509 may be a pushbutton switch, or other switch capable of selecting one initiation method at a time. The panels 510 , 520 , or 530 each correspond to different types of detonators. The panel 530 is used for electronic detonators connected to the blasting machine 304 through the electronic initiator port. The panel 510 is used for electric detonator initiation, and the panel 520 is used for shock tube detonator initiation. Both types of detonators are connected to the remote device 306 through the lead line connection port 508 .
[0031] The electric detonator panel 510 , the shock tube initiator panel 520 , and the electronic initiator panel 530 all include labeling and light indicators 512 , 514 , 522 , 524 , 532 , and 534 , respectively, such as LEDs or the like, for READY and ARMED status. The remote device user interface 502 further includes an electronic key panel 540 and a battery charger panel 550 . The electronic key panel 540 includes a connection port 548 to couple to an electronic key; three light indicators 542 , 544 , and 546 , such as LEDs or the like, which indicate remote device transmission, electronic key status, and remote device receiving in accordance with safety communication ability of various embodiments of the disclosed subject matter. A battery charger panel 550 includes a labeling and light indicator 552 , such as an LED or the like, for indicating connectivity to a battery charger. Two additional light indicators 554 and 556 with labeling, indicate slow and fast charging rates.
[0032] A power panel 560 on the remote device user interface 502 is used for placing the remote device in an ON or OFF state, and includes a labeling and light indicator 562 , such as an LED or the like, and a remote device power switch 564 . A remote device battery status panel 570 includes a switch 574 for activating a battery status display 572 , such as a digital voltmeter, for example. In accordance with one embodiment, switches 564 and 574 may be mechanical momentary push button switches, or other suitable switches.
[0033] In one embodiment of the disclosed subject matter, combinations of the aforementioned light indicators on the remote device user interface 502 are used to indicate various device conditions. One such example is the slow charge light indicator 554 being lit and the fast charge light indicator 556 being dark to indicate a fully charged battery. Given that there is not an exhaustive list of all combinations of light indications for various other conditions experienced while operating a blasting operation in accordance with the disclosed subject matter, other combinations of light indicators are possible.
[0034] FIG. 6 is a block diagram of internal functional modules, inputs, and outputs for a controller device 600 . Inputs to the controller device 600 can be received as information stored on an electronic key 602 , information from an interlock device 604 , information from user inputs 606 , and information from an antenna 608 . The internal functional modules are coupled to the electronic key 602 , interlock device 604 , and user inputs 606 , and include an electronic key module 610 , programming port module 612 , self-test module 614 , battery status module 616 , controller device user interface module 618 , timer module 620 , remote device selection module 622 , controller device mode module 624 , controller device command module 626 , and communications module 628 for transmitting and receiving safety communication. Safety communication is preferably achieved by transmitting and receiving safety data through the external antenna 608 coupled to the communications module 628 . Other devices, including but not limited to radio repeaters and leaky feeder systems, can be connected in place, or in addition to, the external antenna 608 without departing materially from the scope of the disclosed subject matter.
[0035] The electronic key module 610 serves as a coupling interface between the controller device 600 and external electronic key 602 . Information stored on the electronic key 602 is read into the internal memory (not shown) of the controller device 600 for processing. The controller device 600 may also write information onto the electronic key 602 through the electronic key module 610 .
[0036] The programming port module 612 serves as a coupling interface between the controller device 600 and an external programming device, such as a digital computer or the interlock device 604 . The external programming device may allow, for example, information stored in certain memory locations (not shown) to be read out of the controller device 600 , information to be written into certain memory locations (not shown) in the controller device 600 , or modification of settings for the controller device 600 , among others. Many operations can be conducted through the programming port module 612 , and it may be implemented using a 14-pin DIN type connector or other suitable connectors, designating various conductors for functionality such as battery charger contacts, the interlock device 604 input contacts, programming function contacts, and contacts for additional future functionality, among others.
[0037] The self-test module 614 tests the internal circuitry and functionality of the controller device 600 for faults. The self-test module 614 indicates component failures by flashing indicator lights, such as LEDs or the like, on the controller device 600 , as discussed previously. Other suitable methods of indicating self-test results can be used without departing from the scope of the disclosed subject matter.
[0038] The battery status module 616 displays the status and condition of a battery (not shown) in the controller device 600 . The battery status module 616 may include a battery capacity display, such as a gas-gauge style digital display, battery condition indicators, such as the previously discussed flashing indicator light 454 on the controller device user interface panel 400 , and recharge rate indicator lights, such as LEDs, on the panel 420 , among others. Other suitable displays and indicators can be used without departing from the scope of the disclosed subject matter.
[0039] The controller device user interface module 618 handles all user input for the controller device 600 not handled by the remote device selection module 622 , controller device mode module 624 , or controller device command module 626 . Functions carried out by the controller device user interface module 618 include functions such as turning a battery meter ON or OFF, among others.
[0040] The timer module 620 can be implemented mechanically, with discrete electronics, with software, or by some combinations thereof. Preferably, the timer module 620 is used for the controller device 600 features requiring elapsed time information. For example, the timer module 620 may have a countdown timer that triggers the execution of a DISARM command as an automatic safety feature. When the controller device 308 , as seen in FIG. 3 , transmits an ARM command to the remote device 306 , the timer module 620 may begin a countdown sequence in which the controller 308 must initiate a FIRE command to the remote device 306 . If there is no fire command initiated before the timer module 620 ends the countdown sequence, a DISARM command will be sent to the remote device 306 , and the detonators will be disarmed.
[0041] The remote device selection module 622 serves as an interface for the operator 110 allowing specific remote devices to be either selected or deselected. Preferably, multiple remote devices can be contemporaneously selected and operated from a single controller device. Additionally, it is preferable that the controller device command module 626 serve as the operator interface to selectively initiate command signals. The available commands may include ARM, FIRE, DISARM, and STATUS (querying the status of remote devices), among others. Other suitable commands can be used without materially departing from the scope of the disclosed subject matter.
[0042] The controller device mode module 624 serves as the operator interface for selecting the operating mode of the controller device 600 . The controller device mode module 624 may include NORMAL (signifying normal operation mode), PROGRAMMING (signifying programming mode), and QUERY (signifying safety communication query mode, such as the SAFETY POLL™ query facility offered by Rothenbuhler Engineering Co.), among others. The NORMAL mode is preferably the default mode and is used for detonating explosives. The PROGRAMMING mode preferably allows the controller device 600 to function as a programming device for programming electronic keys, or other programmable options. The QUERY mode is preferably used to automatically test safety communication between the controller device 600 and selected remote devices (not shown). Additional suitable modes or suitable modifications of the listed modes can be included in the controller device mode module 624 without departing from the scope of the presently disclosed subject matter.
[0043] The communications module 628 serves to enable safety communication between the controller 308 and other system devices through a transmission medium. Preferably, the communications module 628 includes a 5-watt maximum power radio transceiver for transmission and reception of radio frequency signals in the kHz to MHz range. Any suitable power or frequency range can be used for the transceiver without departing materially from the scope of the disclosed subject matter, and other suitable methods of communication besides wireless communication may also be used.
[0044] FIG. 7 is a block diagram of the internal functional modules, inputs, and outputs for a remote device 700 . Inputs to the remote device 700 include information contained on an electronic key 702 , information received from user inputs 704 , safety communications can be received or transmitted by an external antenna 706 , and signals initiating a shot are output to a blasting machine (not shown) by a lead line interface 708 . The internal functional modules include modules such as an electronic key module 710 , remote device user interface module 712 , self-test module 714 , programming port module 716 , battery status module 718 , memory module 720 , timer module 722 , communications module 724 , remote device output mode module 726 , and remote device operating mode module 728 , among others.
[0045] The electronic key module 710 serves as a coupling interface between the remote device 700 and electronic key 702 . Further, information stored on the electronic key 702 can be read into the memory module 720 for processing by the remote device 700 through the electronic key module 710 . Additionally, it is preferable that the remote device user interface module 712 handle all user input received by the remote device 700 not handled in the remote device operating mode module 728 , or remote device output mode module 726 . The remote device user interface module 712 further includes functions such as turning a battery meter ON by depressing a momentary switch, among others.
[0046] The self-test module 714 tests the internal circuitry and functionality of the remote device 700 for faults. The self-test module 714 indicates component failures by flashing indicator lights, such as LEDs or the like, on the remote device user interface 502 as previously discussed. Other suitable methods to indicate self-test results can be used.
[0047] The programming port module 716 serves as a coupling interface between the remote device 700 and an external programming device (not shown), for example a digital computer. The external programming device may allow, for example, information stored in certain memory locations to be read out of the remote device 700 , information to be written into certain memory locations on the remote device 700 , or modification of internal remote device settings, among others. Many other suitable operations can be conducted through the programming port module 716 , and the programming port module 538 may also be implemented using a 14-pin DIN type connector or other suitable connectors, designating various conductors for functionality such as battery charger contacts, programming function contacts, and contacts for additional future functionality, among others.
[0048] The battery status module 718 displays the status and condition of a battery (not shown) in the remote device 700 . The battery status module 718 may include a battery capacity display, such as a digital display, battery condition indicators, such as the previously discussed flashing indicator lights on the remote device user interface 502 , and recharging rate indicator lights, such as LEDs or the like, among others. Other suitable displays or indicators can be used.
[0049] The memory module 720 may be implemented in the remote device 700 as an internal memory. In addition to the information that may be read from and written to the memory module 720 as discussed above, the memory module 720 stores a history log (not shown) of each remote device 700 . The history log of each remote device 700 records state changes in the remote device 700 and the time those changes occur. For example, if the remote device 700 is in an ARMED state and subsequently issues a FIRE command to initiate detonation, a state change from ARMED to FIRE will be recorded, with the time of the change, in the history log. By recording each change in state for each remote device 700 , better and more accurate diagnostics may be performed to evaluate timing problems or other errors during operation. The history log of each remote device 700 may also be password protected so as to prevent unauthorized access.
[0050] The timer module 722 can be implemented mechanically, with discrete electronics, with software, or by some combination thereof. Preferably, the timer module 722 is used for remote device features requiring elapsed time information. For example, as with the timer module 620 of the controller device 600 as above, the timer module 722 may initiate a countdown timer that, when finished, will trigger a DISARM command to disarm the remote device 700 if the remote device 700 has been ARMED and not FIRED within a specified time period. Preferably, the timer module 722 serves as a backup to the timed disarm sequence in the timer module 620 in the controller device 600 as previously discussed.
[0051] The communications module 724 serves to enable safety communication between the remote device 700 and other system devices via a transmission medium. Preferably, the communications module 724 includes a 1-watt maximum power radio transceiver for transmission and reception of radio frequency signals in the kHz to MHz range. Any suitable power or frequency range may be used for the transceiver without departing materially from the scope of the presently disclosed subject matter. Further, other suitable methods of communication may be used.
[0052] The remote device output module 726 serves as an interface for the operator 110 that allows method selection for initiating a remote detonation (such as electric detonators, shock tube initiators, or electronic initiators, among others). Additionally, it is preferable that the remote device operating mode module 728 serve as an interface to select the operating mode of the remote device 700 . The remote device operating mode module 728 may include NORMAL (signifying normal operation mode) and PROGRAMMING (signifying programming mode), among others. The NORMAL mode is preferably the default mode and is used for detonating explosives. The PROGRAMMING mode preferably allows the remote device 452 to be programmed with a semi-permanently assigned device identifier. Additional suitable modes or suitable modifications of the listed modes can be included in the remote device operating mode module 728 .
[0053] FIG. 8 is a block diagram of various components in a blasting machine 800 in accordance with aspects of the presently disclosed subject matter. A remote device interface 802 is coupled to the remote device 306 , for example, for communication between the blasting machine 800 and remote device 306 . A central processing unit 804 carries out processing functions of the blasting machine 800 , including communication with the remote device 306 and sending commands to detonators. A memory 810 of the blasting machine 800 may be used in conjunction with the central processing unit 804 , but may also store data on attached detonators for further communication. A self-test module 806 tests the internal circuitry and functionality of the blasting machine 800 for faults. If the self-test module 806 detects failures, the blasting machine 800 will communicate the fault information to the remote device 306 , which will in turn communicate the fault information to the controller 308 . Depending on the fault detected by the self-test module 806 of the blasting machine 800 , indicator lights, such as LEDs or the like, on the controller device user interface 502 , as previously discussed, may indicate an error. Other suitable methods to indicate self-test results may also be used.
[0054] A battery status module 808 monitors and communicates the status and condition of the battery (not shown) in the blasting machine 800 . The battery status module 808 may include a battery capacity display, such as a digital display, battery condition indicators, such as the previously discussed flashing indicator lights on the remote device user interface 502 , and recharging rate indicator lights, such as LEDs or the like, among others. Other suitable displays or indicators may be used.
[0055] A lead line interface 812 of the blasting machine 800 connects to each detonator in the group of explosives 302 , and communicates with each detonator in the group of explosives 302 . This includes sending initiation commands when the blasting machine 800 receives a FIRE command from the remote device 306 , and also includes receiving status information about each detonator in the group of explosives 302 . As discussed above, status information about each detonator in the group of explosives 302 may, in turn, be communicated to the remote device 306 and stored in the history log in the memory module 720 .
[0056] FIG. 9 is a flow chart describing a preferred method 900 for the controller 308 to securely communicate with the remote device 306 . Since the remote device 306 is the only point of entry for commands to the blasting machine 304 and to the group of explosives 302 , it is important that there be established a way of ensuring the commands received at the remote device 306 are from the controller 308 . According to a preferred method in accordance with the presently disclosed subject matter, at a block 902 , the controller 308 initializes a code word to be sent with every data packet message communicated to the remote device 306 . The code word preferably consists of 32 bits, but may have more or less bits depending on the communication protocol between the controller 308 and remote device 306 , and the level of security desired for communications from the controller 308 .
[0057] At a block 904 , the initialized code word from block 902 is inserted into the outgoing data packet message and sent to the remote device 306 . After the controller 308 has sent the data packet message with the initialized code word, the code word is incremented at a block 906 by the controller 308 . This newly incremented code word will be inserted into the next data packet message sent to the remote device 306 from the controller 308 . One of skill in the art will recognize that any type of incrementing will work, and need not be expressly communicated to the remote device 306 , as long as the code word is incremented in some way from the initialized code word.
[0058] FIG. 10 is a flow chart describing a preferred method 1000 of receiving a message at the remote device 306 and validating the source of that message. The remote device 306 receives a data packet message at a block 1002 . The entire data packet message may be checked for accuracy using error correcting techniques, such as CRC error checking or the like. In a block 1004 , the remote device 306 must check to see if the received data packet message is the first received message from the controller 308 . One of skill in the art will appreciate there may be a number of ways to do this. By way of example, the remote device 306 may have a data packet message counter that counts the number of valid messages received. Initially such a counter would be at zero, but after receiving the data packet message with the initialized code word from the controller 308 , the remote device 306 would recognize the data packet message as a first message, increase the message count, and store the code word in the remote device 306 , as in a block 1006 . Any other suitable method for determining if a data packet message is a first message may be used, however, without departing from the scope of the presently disclosed subject matter.
[0059] If the data packet message received is not a first message, then the code word from the received message is compared against the stored code word in the remote device 306 , as in a block 1008 . If the received code word is incremented compared to the stored code word, then in a block 1012 the data packet message is accepted as valid from the controller 308 and executed. The new code word received from the valid data packet message is then stored in the remote device 306 as the new code word as in a block 1006 . If the code word received is not incremented compared to the stored code word, then the data packet message is ignored, as in a block 1010 . By comparing received code word and stored code word in a block 1008 to see if the code word has been incremented, the blasting system introduces a level of safety that works to prevent third-party access to the remote device 306 and thus to the explosives.
[0060] While illustrative embodiments have been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the disclosed subject matter.
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A remote firing system for remotely detonating explosive charges includes features that provide safety and efficiency improvements. These features include safety communication among multiple remote devices and multiple controller devices, a polling functionality permitting rapid deployment of system devices, electronic key systems, programmable remote devices for easy replacement of failing remote devices, and an event history log for the remote devices for efficient diagnostic evaluation.
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CROSS-REFERENCE TO RELATED APPLICATION
The present application claims the benefit of priority of German Patent Application No. 102007057285.0, filed Nov. 28, 2007. The entire text of the priority application is incorporated herein by reference in its entirety.
FIELD OF THE DISCLOSURE
The present disclosure relates to a method for filling containers with such as in beverage bottling operations.
BACKGROUND
Such a method is known from DE-AS 1 114 719. This publication refers to a method for hot filling carbonated beverages, particularly beer. The beverage is here filled via a device comprising a valve-controlled filling element with an outlet opening through which the liquid passes into the container. There is also provided a return gas path in the form of a return gas tube that extends through the valve up into the container and through which the air displaced by the liquid can escape out of the container. Such return gas tubes also define the filling level in the container. Here liquid and possibly formed foam cannot be prevented from wetting the return gas tube on the outside and inside and from possibly getting stuck there. In a renewed filling process for a further container the foam stuck in the interior of the return gas tube and evolving from the preceding filling operation may for instance interfere with the new filling operation, i.e. for instance it may prolong the filling time, reduce the filling level or create an excessive amount of foam due to interference with the pressure relief in a clogged return gas tube. In the known method, the return gas tube is therefore spray-washed or blown out as a precautionary measure after each filling operation, so that liquid residues possibly contained in the return gas tube pass to the outside.
Blowing or spray-washing, however, constitutes an additional operation that needs time, whereby the filling operation is prolonged. Moreover, the cleaning agent is consumed. If water is used as the cleaning agent, it must be collected and discharged in addition. The return gas tube is blown out with inert gas, i.e. for instance CO 2 , which passes into the atmosphere after blowing and is lost. Although the individual blow-off process requires a very small amount of gas, gas consumption will add up considerably due to the many blow-off processes.
SUMMARY OF THE DISCLOSURE
It is thus the object of the present disclosure to make the known method more economic.
Owing to the design according to the disclosure it is also possible to save a considerable amount of cleaning agent, i.e. particularly gas, because cleaning is only carried out in case of need.
Although the question whether a cleaning operation should be carried out can also be answered by directly determining the contamination in the return gas path, this is preferably determined indirectly.
The finding whether cleaning is needed can be made, for example, by determining process parameters and/or quality assurance criteria that must be determined at any rate in the course of the filling operation or thereafter and the deviation thereof from the set desired value could be ascribed to contamination of the return gas path.
Such criteria or parameters are e.g. the filling level reached in the container, the filling time by determining the filling end, excessive foaming, or the like.
Preferably cleaning is only carried out via a defined number of filling operations and is then terminated automatically until deviation from desired values is again determined.
Cleaning is preferably carried out by blowing off.
An embodiment of the method according to the disclosure shall now be explained in more detail with reference to the single FIGURE, which shows a filling head in a very schematized illustration.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration showing a filling device of a filling machine for containers.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In the illustrated embodiment the filling device 1 is part of a rotation counter-pressure filling machine (not shown in more detail) for filling containers 2 , such as bottles, with a CO 2 -containing beverage. The filling device 1 includes a housing 3 on the lower end of which a filling pipe 4 is formed. This pipe is upwardly followed by a valve seat 5 which cooperates with a valve body 6 supported in a vertically movable way in housing 3 . Due to the liquid valve formed in this way the outlet of the liquid into the container 2 is controlled. The control operation is here carried out via a control device (not shown) in such a way that the valve body 6 is lifted from the valve seat 5 for such a long time until the liquid in the container 2 has reached a predetermined filling level. This can be determined either via a desired value for a filling time that after a preceding test run should be adequate for filling the container 2 with the predetermined filling amount, with the valve being subsequently closed again, or the flow rate is measured, or the reached filling level is measured, or the like, while the parameters defining the filling level are monitored.
The filling device 1 further includes a centering bell 7 which is supported in a vertically movable way and is provided with a sealing ring 8 . The centering bell 7 ensures an exact centering of the bottle mouth for the filling process. Furthermore, the sealing ring 8 effects a tight sealing between the bottle 2 pressed against the filling device 1 and the filling pipe 4 .
The filling device 1 has further formed therein a return gas path which in the illustrated embodiment, as is in general use in filling machines, is configured as a return gas tube 9 that is arranged such that it extends into the container 2 when the container 2 is pressed against the centering bell 7 and the centering bell 7 is pressed against the housing 3 in the filling position. The return gas pipe 9 extends in the illustrated embodiment through an opening in the valve body 6 .
For filling a container 2 the container is pressed against the centering bell 7 and the centering bell 7 against the housing 3 . Depending on the type of liquid to be filled, pressure gas may e.g. be introduced via the return gas path into the container 2 before the liquid is filled in. This pressure gas or the air present in the container 2 is displaced during filling by the liquid and evacuated via the return gas path. After the predetermined filling level has been reached, at which the immersion depth of the return gas tube 9 into the container 2 can define the filling level, the filling operation is terminated and the container 2 is separated from the filling device 1 . After the first container has been removed, the filling device 1 is prepared for filling a second container.
Before or after the closing operation the container 2 passes through various quality control stations in which it is e.g. determined whether the desired value of the filling level has been reached, whether excessive foam formation has taken place, or the like.
However, if deviations in the predetermined process sequence, e.g. variations in the filling processes or filling mistakes, are detected during the filling operation of the first container or during the quality control of the first container, for instance because any one of the operating parameters, such as the filling end (filling level), the filling duration (measure of the liquid throughput), or the like, and/or specific quality assurance criteria, such as the filling level detected in the container, the formation of foam, which hints at an uncontrolled relief, or the like, does not comply with the predetermined desired values (possibly within certain tolerance limits), one reason for this may be that the return gas path is soiled or clogged by liquid or foam. To eliminate the possible cause for failing to achieve the desired values, which cause is the easiest one to eliminate, i.e. contamination of the return gas path, a cleaning operation for the return gas path is started. In the illustrated embodiment the return gas path is cleaned by blowing off with the help of a gas jet, preferably an inert gas such as CO 2 , or air, from the side oriented away from the container 2 . Cleaning may be carried out by way of one or several air blasts through the same return gas path from the side oriented away from the container 2 .
In case the contamination of the return gas path is not of an incidental nature, but is caused by the kind of liquid, or if it is detected that the contamination of the return gas path has accumulated due to a series of successive filling operations until an extent has been reached that brings the desired value of the parameters or quality criteria out of the range of tolerances, the cleaning operation can be carried out through a predetermined number of filling operations through the same filling device 1 , or each time according to a predetermined number of filling operations. Adjacent filling devices can also be cleaned at the same time for a predetermined number of filling operations. The interposition of a cleaning step of the return gas path between two filling operations can also be limited in time. Furthermore, precautions can be taken where a cleaning process for the return gas path can be started by the operating personnel independently of the overall control during transition to a different product.
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A method for filling containers with liquid, where a gas displaced by the liquid out of the container escapes via a return gas path, and the return gas path is cleaned. To make such a method more economic and to save cleaning agents, the return gas path is only cleaned in case of need.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to provisional U.S. Application Ser. No. 60/496,007, filed on Aug. 18, 2003, which is herein incorporated by reference in its entirety.
FIELD OF THE INVENTION
The present invention relates to novel liver X receptors (LXR) and nucleic acid sequences encoding such receptors.
BACKGROUND OF THE INVENTION
Gene expression is regulated in eukaryotic cells by the interplay of transcription factors. Steroid hormones (e.g., glucocorticoids, mineralocorticoids, estrogens, progestins, androgens and vitamin D) were found to bind to their nuclear receptors which are transcription factors and by this means regulate expression of gene coding for specific proteins and control critical cellular activities such as differentiation, proliferation and apoptosis (Meier, Recept. Signal Transduct. Res. 1997, 17, 319-335). The liver X receptors (LXRs) are a family of transcription factors that were first identified as orphan members of the nuclear receptor superfamily. The identification of a specific class of oxidized derivatives of cholesterol as ligands for the LXRs has been crucial to helping understand the function of these receptors in vivo and first suggested their role in the regulation of lipid metabolism. LXRs, members of the nuclear receptor super-family, include LXRα (also termed RLD-1) and ubiquitous receptor (UR, also called LXRβ). LXR-dependent pathways include but are not limited to cholesterol-7alpha-hydroxylase to increase the consumption of cholesterol via the bile acid route, expression of ABC proteins with the potential to stimulate reverse cholesterol transport and increase plasma HDL-C levels (Venkateswaran et al., J. Biol. Chem. 275, 2000, 14700-14707; Costet et al., J. Biol. Chem. 2000 275(36):28240-28245; Ordovas, Nutr. Rev. 58, 2000, 76-79, Schmitz and Kaminsky, Front. Biosci. 6, 2001, D505-D514), and/or inhibit intestinal cholesterol absorption (Mangelsdorf, XIIth International Symposium on Atherosclerosis, Stockholm, June 2000). In addition, possible cross talk between fatty acid and cholesterol metabolism mediated by liver LXR have been hypothesized (Tobin et al., Mol. Endocrinol. 14, 2000, 741-752).
In summary, ongoing research suggests that there exists complexity in LXR-dependent pathways and LXR variants may contribute to these pathways differently.
In order to understand the LXR-dependent pathways and mechanism of LXR action, it is important to isolate and characterize novel subtypes, variants, and/or isoforms of the LXR. Identification of the underlying LXR subtype, variant, or isoform responsible for a particular disease state or pathological condition can permit a more accurate means of prognosticating the LXR-related disease outcomes. Furthermore, the presence or amount of expression of such polynucleotides and/or the polypeptides encoded by such polynucleotides can be used for diagnosing associated pathological conditions, diagnosing a susceptibility to an associated pathological condition; develop gene-specific and isoform-specific therapies for diseases or disorders influenced by LXR, follow the progress of a therapy for an LXR-related disease or disorder, and/or develop new pharmaceutical drug targets.
With the recognition that these variants can be as critical to metabolic and physiologic function as proteins that are separately encoded, there is a need to identify and to characterize additional variants of the LXRα proteins. The present invention satisfies this need and provides related advantages as well.
SUMMARY OF THE INVENTION
The invention relates to the identification of nucleic acid sequences encoding novel LXRα variants (e.g., LXRα-64, LXRα-42e + , and LXRα-42e − ) and certain activities and features of those variants. Accordingly, the invention relates to an isolated nucleic acid molecule encoding a human liver X receptor alpha (LXRα) variant polypeptide such as an isolated nucleic acid molecule encoding SEQ ID NO:4, 6, 8, 17, or 19, an isolated nucleic acid molecule encoding an amino acid sequence having at least 90% (e.g., 90%, 95%, or 99%) identity with the SEQ ID NO:4, 6, 8, 17, or 19, an isolated nucleic acid molecule that hybridizes with the isolated nucleic acid molecule of described above under hybridization conditions of 6×SSC (1 M NaCl), 50% formamide, 1% SDS at 42° C., and a wash in 1×SSC at 42° C., and a wash at 68° C., in 0.2×SSC, and 0.1% SDS; and an isolated nucleic acid molecule that is complementary to any of the LXRα variant sequences described herein. The LXRα variant nucleic acid molecule can also be a fragment of a full length LXRα variant mRNA or cDNA. In general, at least a portion of the fragment is sequence that is not found in a wild type LXRα mRNA or cDNA. In some embodiments, the isolated nucleic acid molecule consists of SEQ ID NO:3, 5, 7, 16, or 18.
In certain embodiments, the isolated nucleic acid molecule is a DNA molecule. The isolated nucleic acid molecule can be an RNA molecule, or can contain synthetic nucleotides and naturally occurring nucleotides. In some cases, the isolated nucleic acid molecule includes the nucleic acid sequence of SEQ ID NO:3, 5, 7, 16, or 18 or a fragment thereof, or can consist of the nucleic acid sequence of SEQ ID NO:3, 5, 7, 16, or 18. In certain embodiments, a nucleic acid molecule of the invention can encode a polypeptide that has LXR-responsive pathway activity, e.g., can form a dimer with a wild-type LXRα, can form a heterodimer with a retinoid X receptor (RXR) (e.g., an RXRα, RXRβ, or RXRγ), or can affect the expression or activity of an LXR-responsive pathway molecule such as expression of ABCA1 or SREBP-1C.
In another embodiment, the invention relates to a polypeptide (an LXRα variant polypeptide, e.g., an LXRα-64 polypeptide, an LXRα-42e + polypeptide, an LXRα-42e − polypeptide, or a fragment thereof) encoded by an isolated LXRα variant nucleic acid molecule described herein. In some cases, the polypeptide can form a dimer with a wild-type LXRα. In some cases, the polypeptide can form a heterodimer with an RXR (e.g., an RXRα, RXRβ or RXRγ). Formation of the heterodimer can, in certain embodiments, inhibit formation of a heterodimer between the RXR and a nuclear receptor with which the RXR naturally heterodimerizes. In this case, the formation of the heterodimer can result in modulation (e.g., a decrease or increase) of an activity associated with dimerization of the RXR and the nuclear receptor with which it naturally heterodimerizes. In another embodiment, an LXRα variant polypeptide can form a heterodimer that inhibits formation of an RXR homodimer. In some cases, the inhibition results in modulation (e.g., an increase or decrease) of an activity induced by the RXR homodimer. In certain embodiments, an LXRα variant polypeptide or fragment thereof can exhibit dominant negative activity with respect to an LXR (e.g., a wild type LXRα). In certain embodiments, the polypeptide described herein is a fragment of an LXRα variant and can exhibit at least one function of an LXRα variant, e.g., binding to an antibody that specifically binds to the LXRα variant.
Also included in the invention is a construct (e.g., a plasmid, including without limitation, pCMV/myc, pcDNA 3.1, or a derivative thereof) that includes an isolated nucleic acid molecule of an LXRα variant or a fragment thereof. The isolated nucleic acid molecule can be operatively linked to a regulatory sequence.
In another embodiment, the invention relates to a host cell comprising an isolated nucleic acid molecule as described herein (e.g., an LXRα variant or a derivative thereof) or a descendent of the cell. Also included is host cell comprising a construct described supra. The host cell can be a prokaryotic cell (e.g., an E. coli cell), or an eukaryotic cell such as a mammalian cell, e.g., a mouse cell, rat cell, monkey cell, or human cell (such as a human embryonic cell or other type of stem cell). Examples of host cells, without limitation include a human hepatoma cell (HepG2), a Chinese hamster ovary cell (CHO), a monkey COS-1 cell, and a human embryonic kidney cell (HEK 293). Other examples of host cells include, without limitation, a Saccharomyces cerevisiae cell, a Schizosaccharomyces pombe cell, and a Pichia pastoris cell.
In one aspect the invention is an isolated LXRα variant polypeptide that includes the amino acid sequence of an LXRα-64, LXRα-42e + , or and LXRα-42e − , e.g., the isolated polypeptide includes the amino acid sequence of SEQ ID NO:4, 6, 8, 17, 19, a naturally occurring allelic variant thereof, or a fragment thereof. The isolated polypeptide can consist of the amino acid sequence of SEQ ID NO:4, 6, 8, 17, 19, or a fragment thereof. In general, a fragment does not share homology with more than 25 contiguous amino acids of SEQ ID NO:2 (e.g., 20, 15, 10, or 5 contiguous amino acids). In certain embodiments, the isolated LXRα variant polypeptide includes heterologous amino acid sequences.
In another aspect, the invention relates to a method for detecting the presence of an LXRα variant polypeptide (e.g., an LXRα-64, LXRα-42e+, or LXRα-42e−) in a sample. The method includes contacting the sample with a compound (e.g., an antibody such as a monoclonal antibody) that selectively binds to an LXRα variant polypeptide (or a fragment thereof) and determining whether the compound binds to the polypeptide in the sample. The invention also includes a kit that includes a compound that selectively binds to an LXRα variant polypeptide (e.g., an LXRα-64, LXRα-42e+, or LXRα-42e−) and instructions for use.
An embodiment of the invention includes an antibody that specifically binds to an isolated LXRα variant polypeptide described herein (e.g., an LXRα-64, LXRα-42e+, or LXRα-42e−), or a fragment thereof. In some cases, the antibody does not bind significantly to wild type LXRα. The antibody is, in certain embodiments, a polyclonal antibody. In other embodiments, the antibody is a monoclonal antibody. The antibody can include a detectable label. Also included is a fragment of an antibody such as a Fab fragment of an antibody that specifically binds to an LXRα variant. The invention also relates to a composition that includes an antibody described herein or a fragment thereof and a pharmaceutically acceptable carrier.
An aspect of the invention includes a method of identifying a new LXRα variant nucleic acid molecule (e.g., an LXRα-64, LXRα-42e + , or LXRαe−). The method includes hybridizing a sample comprising one or more nucleic acid molecules with an LXRα variant nucleic acid molecule or a fragment thereof under stringent hybridization conditions, identifying a nucleic acid molecule in the sample that hybridizes with the LXRα variant nucleic acid molecule, thereby identifying a putative LXRα variant nucleic acid molecule, and determining the sequence of the putative LXRα variant nucleic acid molecule, wherein a putative LXRα variant nucleic acid molecule having a sequence that is not identical to the sequence of an LXRα variant is a new LXRα variant nucleic acid. In some cases, the new LXRα variant nucleic acid molecule encodes a known LXRα variant polypeptide. In some cases the new LXRα variant nucleic acid molecule encodes an LXRα polypeptide that is not identical to a known LXRα variant (e.g., an LXRα-64, LXRα-42e + , or LXRαe−). A new LXRα variant polypeptide can include one or more conservative substitutions compared to a known LXRα variant polypeptide.
In one aspect, the invention relates to a method of detecting expression of an LXRα variant (e.g., an LXRα-64, LXRα-42e + , or LXRα-42e − ) in a biological sample. The method includes hybridizing the biological sample with an LXRα variant nucleic acid molecule or fragment thereof (as described herein) and determining whether the nucleic acid molecule hybridizes to a nucleic acid molecule in the sample, wherein hybridization indicates that the LXRα variant is expressed. In some embodiments, the amount of hybridization is determined (e.g., an absolute amount or a relative amount compared to a control or reference amount).
Another aspect of the invention relates to a method of decreasing RXR dimer formation in a cell. The method includes contacting the cell with an LXRα variant polypeptide (e.g., an LXRα-64, LXRα-42e + , or LXRα-42e − ) or fragment thereof, thereby inhibiting RXR dimer formation (e.g., RXR heterodimerization is inhibited or RXR homodimerization is inhibited).
In yet another aspect the invention relates to a method of identifying an LXRα variant (e.g., an LXRα-64, LXRα-42e + , or LXRα-42e − ) ligand. The method includes providing a sample comprising an LXRα variant polypeptide, contacting the sample with a test compound, determining whether the test compound can bind to the LXRα variant, such that a compound that can bind to the LXRα variant is an LXRα variant ligand. In some embodiments, the Kd of the ligand is less than 1×10 6 , less than 1×10 9 , between 1×10 6 and 1×10 12 , between 1×10 9 and 1×10 12 . In some cases, an RXR is present in the sample. The method can include determining whether the LXRα variant ligand can bind a wild type LXRα, e.g., determining that the LXRα variant ligand does not bind to a wild type LXRα. In some cases, the identified LXRα variant ligand has a higher affinity for an LXRα variant compared to a wild type LXRα.
An aspect of the invention relates to modulating (e.g., increasing or decreasing) the expression of an LXRα-regulated gene. The method includes modulating expression or activity of an LXRα variant (e.g., an LXRα-64, LXRα-42e + , or LXRα-42e − ). Examples of the LXRα-regulated gene include, without limitation, an SREBP-1C (sterol regulatory binding element 1c), FAS, CYP7A1 (cholesterol 7-alpha hydroxylase), ApoE, CETP (cholesterol ester transfer protein), LPL (lipoprotein lipase), ABCA1 (ATP-binding cassette transporter-1), ABCG1, ABCG5, ABCG8, ABCG4, and PLTP (phospholipid transfer protein).
In yet another aspect, the invention relates to a method of modulating LXRα variant (e.g., an LXRα-64, LXRα-42e + , or LXRα-42e − ) expression or activity in a subject. The method includes introducing into a subject an LXRα variant nucleic acid molecule or a fragment thereof in an amount and for a time sufficient for the LXRα variant to be expressed and modulate LXRα expression or activity. In some embodiments the LXRα variant inhibits expression or activity (e.g., induction of expression of an LXRα-dependent pathway gene) of a wild-type LXRα. In some cases, the activity is LXRα heterodimerization, e.g., ligand-stimulated heterodimerization.
In another aspect, the invention includes a method of modulating expression or activity of an RXR in a subject. The method includes introducing into a subject an LXRα variant (e.g., an LXRα-64, LXRα-42e + , or LXRα-42e − ) nucleic acid molecule or a fragment thereof in an amount and for a time sufficient for the LXRα variant to be expressed and modulate expression or activity of the RXR. In some embodiments, heterodimerization of the RXR (e.g., heterodimerization of RXR with a PPARα, PPARγ, PPARδ, RAR, XR, or PXR) is modulated (e.g., inhibited) or homodimerization of the RXR is modulated (e.g., inhibited). The RXR can be, e.g., an RXRα, RXRβ, or RXRγ.
In yet another aspect, the invention includes a method for treating an individual having an RXR-related disease or disorder, the method comprising administering to the individual a pharmaceutically effective amount of an LXRα variant (e.g., an LXRα-64, LXRα-42e + , or LXRαe−) or a fragment thereof.
The invention also relates to a pharmaceutical, composition that includes a cell that can express an LXRα variant (e.g., an LXRα-64, LXRα-42e + , or LXRαe − ) or fragment thereof, and optionally, includes a pharmaceutically acceptable carrier; an isolated LXRα variant nucleic acid molecule or fragment thereof as described herein and a pharmaceutically acceptable carrier; or an LXRα variant (e.g., an LXRα-64, LXRα-42e + , or LXRαe−) polypeptide as described herein and a pharmaceutically acceptable carrier.
Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, suitable methods and materials are described below. All publications, patent applications, patents, and other references mentioned herein are incorporated by reference in their entirety. In addition, the materials, methods, and examples are illustrative only and not intended to be limiting.
Other features and advantages of the invention will be apparent from the detailed description, drawings, and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS AND SEQUENCE DESCRIPTIONS
The invention can be more fully understood from the following detailed description, the drawings, and sequences, which form a part of this application.
FIG. 1A depicts a sequence comparison of wild type LXRα (native) cDNA with a portion of the variant LXRα-64 cDNA (referred to in Example 2). The top line illustrates a portion of the wild type LXRα sequence and the bottom line depicts portions of the LXRα-64 sequence. The numbers represent the nucleotide position from the start codon of each cDNA sequence.
FIG. 1B depicts a sequence comparison of the predicted amino acid sequences of human LXRα (native) with LXRα-64 corresponding to the sequences in FIG. 1A . The top line depicts a portion of the native LXRα amino acid sequence and the bottom line is a portion of the LXRα-64 amino acid sequence. The numbers represent the amino acid positions in the predicted sequences. The additional sequence that is specific for the LXRα-64 variant is underlined.
FIG. 2A depicts a sequence comparison of a portion of wild type LXRα cDNA with a portion of the novel variant LXRα-42e + cDNA (referred to in Example 2). The top line depicts portions of the native LXRα sequence and the bottom line is a portion of the LXRα-42e + sequence. The numbers represent the nucleotide positions from the start codon of the cDNAs.
FIG. 2B depicts a sequence comparison of the predicted amino acid sequences of a human LXRα (wild type) with LXRα-42e + . The top line is a portion of the native LXRα sequence and the bottom line is a portion of the new variant. The numbers represent the amino acid positions. Sequence that is specific for the LXRα-42e + variant is underlined.
FIG. 3A depicts a sequence comparison of a portion of a wild type LXRα cDNA with a portion of the novel variant LXRα-42e − cDNA (referred to in Example 2). The top line depicts portions of the wild type LXRα sequence and the bottom line is a portion of the LXRα-42e − sequence. The numbers represent the nucleotide positions from the start codon of the cDNAs.
FIG. 3B depicts a sequence comparison of the predicted amino acid sequences of a wild type human LXRα with LXRα-42e − . The top line is a portion of the wild type LXRα sequence and the bottom line is a portion of the new variant. The numbers represent the amino acid positions. Sequence that is specific for the LXRα-42e − variant is underlined.
FIG. 4 is a diagrammatic representation of LXRα-64 mRNA.
FIG. 5 is a diagrammatic representation of LXRα-42e + mRNA.
FIG. 6 is a diagrammatic representation of LXRα-42e − mRNA.
FIG. 7A is a bar graph depicting the results of experiments assaying the relative RNA expression of LXRα-64 in various tissues.
FIG. 7B is a bar graph depicting the results of experiments assaying the relative RNA expression of LXRα-42 (LXRα-42e + and LXRα-42e − combined) in various tissues.
FIG. 8A is a bar graph depicting the results of experiments assaying gene regulation of RNA expression of LXRα-64 in THP-1 cells.
FIG. 8B is a bar graph depicting the results of experiments assaying gene regulation of RNA expression of LXRα-42 in THP-1 cells.
FIG. 9 is a bar graph depicting the results of experiments assaying LXRα-64 and LXRα-42 inhibition of LXR ligand-dependent activation of a reporter gene.
FIG. 10 is a bar graph depicting the results of experiments assaying the inhibition of LXR ligand-dependent activation of a reporter gene by LXRα-64 and LXRα-42. The difference between this experiment and the experiment whose results are shown in FIG. 9 is that 293 cells were cotransfected with the wild type LXRα and each of the new variants simultaneously.
FIG. 11 is a bar graph depicting the results of experiments assaying SREBP-1C expression in HEK293 cells transfected with expression vectors encoding RXRα (RXRa), wild type LXRα (LXRa) and RXRα, or LXRα-64 (L64) and RXRα in the presence or absence of an LXRα agonist (TO901317), an RXRα agonist (9RA), or both agonists. Samples are RXRα+pCMV (control vector), RXRa+L64, RXRa+LXRa. Expression is displayed as a fold change compared to control.
FIG. 12 is a bar graph depicting the results of experiments assaying ABCA1 expression in HEK 293 cells transfected with expression vectors encoding RXRα (RXRa), wild type LXRα (LXRa) and RXRα, or LXRα-64 (L64) and RXRα in the presence or absence of an LXRα agonist (TO901317), an RXRα agonist (9RA), or both agonists. Samples are RXRα+pCMV (control vector), RXRa+L64, RXRa+LXRa. Expression is displayed as a fold change compared to control.
A brief list of sequence descriptions is provided below and sequences are provided after the Examples and in the figures.
SEQ ID NO:1 is the nucleotide sequence that codes for the wild type LXRα. SEQ ID NO:2 is the deduced amino acid sequence of wild type LXRα. SEQ ID NO:3 is the nucleotide sequence that codes for the variant, LXRα-64. SEQ ID NO:4 is the deduced amino acid sequence of variant, LXRα-64. SEQ ID NO:5 is the nucleotide sequence that codes for the variant, LXRα-42e + . SEQ ID NO:6 is the deduced amino acid sequence of variant, LXRα-42e + . SEQ ID NO:7 is the nucleotide sequence that codes for the variant, LXRα-42e − . SEQ ID NO:8 is the deduced amino acid sequence of variant, LXRα-42e − . SEQ ID NO:9 is the nucleotide sequence of the forward primer LXRα-For. SEQ ID NO:10 is the nucleotide sequence of the reverse primer LXRα-rev. SEQ ID NO:11 is the nucleotide sequence of the forward primer L64-for. SEQ ID NO:12 is the nucleotide sequence of the reverse primer L64-rev. SEQ ID NO:13 is the nucleotide sequence of the L64 TaqMan probe. SEQ ID NO:14 is part of LXRα promoter sequence used for the luciferase assay (referred to in Example 6) SEQ ID NO:15 is the nucleotide sequence of the LXR response element (LXRE). SEQ ID NO:16 is the unique nucleotide sequence of LXRα-64 variant which contains additional sequence compared to the wild type that connects exons 6 and 7 of wild type LXRα, creating a longer exon 6 in LXRα-64 variant. The new exon 6 includes all of exon 6 as described for wild-type LXRα in addition to extra sequence that is derived from sequence in intron 6 of wild type LXRα that is located between exon 6 and exon 7. SEQ ID NO:17 is the deduced amino acid sequence encoded by SEQ ID NO:16. SEQ ID NO:18 is the unique nucleotide sequence of LXRα-42e that combines with exon 8 of wild type LXRα to create a longer exon 8 in the LXRα-42 variant. This sequence is 234 nucleotides in length and contains a stop codon (TAG) at position 126, thus the following 108 nucleotides are untranslated. It is found in both LXRα-42e − and LXRα-42e + . SEQ ID NO:19 is the deduced amino acid sequence encoded by SEQ ID NO:18. SEQ ID NO:20 is the nucleotide sequence of the LXRα response element (LXRE) used in the present invention. SEQ ID NO:21 is the nucleotide sequence of the primer L42-For. SEQ ID NO:22 is the nucleotide sequence of the primer L42-Rev. SEQ ID NO:23 is the nucleotide sequence of an L42 probe. SEQ ID NO:24 is a portion of the nucleotide sequence of a wild type (native) LXRα cDNA. SEQ ID NO:25 is a portion of the nucleotide sequence of an LXRα-64 cDNA. SEQ ID NO:26 is a portion of the nucleotide sequence of an LXRα-64 cDNA. SEQ ID NO:27 is a portion of the amino acid sequence of a wild type LXRα cDNA. SEQ ID NO:28 is a portion of the amino acid sequence of an LXRα-64 cDNA. SEQ ID NO:29 is a portion of the nucleotide sequence of a wild type LXRα cDNA. SEQ ID NO:30 is a portion of the nucleotide sequence of an LXRα-42e+ cDNA. SEQ ID NO:31 is a portion of the nucleotide sequence of an LXRα-42e+ cDNA. SEQ ID NO:32 is a portion of the amino acid sequence of a wild type LXRα. SEQ ID NO:33 is a portion of the amino acid sequence of an LXRα-42e+ cDNA. SEQ ID NO:34 is a portion of the nucleotide sequence a wild type LXRα cDNA. SEQ ID NO:35 is a portion of the nucleotide sequence an LXRα-42e− cDNA. SEQ ID NO:36 is a portion of the nucleotide sequence LXRα-42e− cDNA. SEQ ID NO:37 is a portion of the nucleotide sequence a wild type LXRα cDNA. SEQ ID NO:38 is a portion of the nucleotide sequence LXRα-42e− cDNA. SEQ ID NO:39 is a portion of the amino acid sequence of a wild type LXRα. SEQ ID NO:40 is a portion of the amino acid sequence of an LXRα-43e−. SEQ ID NO:41 is a portion of the nucleotide sequence of a wild type LXRα cDNA.
DETAILED DESCRIPTION OF THE INVENTION
Applicants have succeeded in identifying and characterizing new splice variants of an LXRα gene that encode novel LXRα variants referred to herein as LXRα-64, LXRα-42e + and LXRα-42e − , respectively. The newly identified sequences produce variants that differ structurally and functionally from known LXRα proteins. LXRα-64, LXRα-42e + and LXRα-42e − variants are encoded by the polynucleotide sequences of SEQ ID NO:3, SEQ ID NO:5, and SEQ ID NO:7, respectively, and represent alternative variants of the full-length LXRα cDNA.
Genomic organization analysis showed that the newly isolated variants; LXRα-64, LXRα-42e + , and LXRα-42e − share certain protein domains and structural organization with wild type LXRα ( FIGS. 4 , 5 , and 6 ). RT-PCR analysis revealed that the variant mRNA transcripts of the present invention are most abundant in liver ( FIGS. 7A and 7B ). More particularly, LXRα-64 is most highly expressed in liver, small intestine, and pancreas. LXRα-42e + and LXRα-42e − are most highly expressed in liver. There is significantly less expression in other tissues. The N-terminal, DNA binding, and hinge domains of the three LXRα subtypes are identical to the corresponding regions of wild type LXRα, whereas the C-terminal domain and the ligand binding domain (LBD) exhibit some variability. In contrast with wild type LXRα, LXRα-64 variant has an extra 64 amino acids in its ligand binding domain, LXRα-42e + has an alternative 42 amino acids starting at residue 367 of the wild type LXRα sequence and the C terminal from residue 368 to the end of the wild type LXRα (80 amino acids) is not present in this variant, and therefore lacks a portion of the ligand binding domain that is present in the wild type LXRα. LXRα-42e − contains 349 amino acids and lacks 60 amino acids that are encoded by exon 6 of wild type LXRα. Starting at amino acid 237 of LXRα-42 − , there is 100% identity for 71 amino acids with the wild type LXRα. This is followed by 42 amino acids that are completely different from wild type. Like LXRα-42+, the C-terminal of wild type LXRα is not present in LXRα-42e−.
It is also demonstrated herein that the novel LXRα variants are functional in that they can act as dominant negative modulators of wild-type LXRα activity. In addition, LXRα-64 and LXRα-42e + and LXRα-42e − variants have been found to be upregulated by LXR or RXR agonists in human monocyte/macrophage THP-1 cells ( FIG. 8 ). Furthermore, LXR ligand-dependent activation was found to be sharply decreased when the novel LXRα-64, LXRα-42e + , and LXRα-42e − variants were co-transfected with a reporter gene ( FIGS. 9 and 10 ). Ligand-dependent induction of LXR-dependent pathway genes was also decreased in the presence of LXRα-64 in the presence of an LXRα agonist ( FIGS. 11 and 12 ), and in some cases, even in the absence of an LXRα agonist ( FIG. 11 ).
The three novel LXRα variants have also been shown to antagonize the biological/biochemical activity of a naturally occurring (wild type) LXRα protein by acting as dominant negative genes. A portion of an LXRα protein, e.g., a DNA binding domain (DBD), can also activate, somewhat less efficiently than a wild type LXRα, the biological/biochemical activities of a wild type LXRα protein.
Increasing the expression or activity of an LXRα variant (e.g., LXRα-64) is useful for treating disorders associated with the expression of SREBP-C1. For example, disrupting the activity of an LXRα, e.g., by overexpressing an LXRα-64 or increasing the activity of an LXRα-64 that is expressed in a cell (e.g., by administering a compound that differentially binds to LXRα-64 compared to wild type LXRα) can provide a method of inhibiting the insulin induction of SREBP-C1, and therefore provides a method of inhibiting undesirable induction of fatty acid synthesis by insulin. In another example, overexpressing an LXRα variant (e.g., LXRα-64) or selectively activating an LXRα variant (for example, with a compound that differentially binds to the LXRα-variant) can result in inhibition of SREBP-C1, and therefore provides a method of treating hypertriglyceridemia, which is a condition that is a strong predictor of heart disease. In another example, lowered SREBP-C1 expression (by increased expression or activity of an LXRα variant such as LXRα-64) can result in lower expression of VLDL-TGs (very low density lipoprotein triglycerides), a desirable effect in certain disorders such as diabetes and certain types of hyperlipoproteinemia. Wild type LXR has the effect of upregulating ABCA1, which is involved in reverse cholesterol transport and it has been found that an LXRα variant can inhibit basal expression of SREBP-1C, which is involved in triglyceride synthesis.
Nuclear receptors that heterodimerize with RXR and activation of these heterodimers results in increased expression of specific genes. In the case of undesirable expression of one or more of these genes (e.g., LXR-mediated upregulation of SREBP1c), then overexpression of an LXRα-64 is beneficial to a subject if expression of the LXRα variant binds to the RXR, thereby decreasing the availability of the RXR for heterodimerization and therefore reducing induction undesirable gene expression.
As more fully described below, the present invention provides isolated nucleic acids that encode each of the novel variants of LXRα homologues and fragments thereof. The invention further provides vectors for propagation and expression of the nucleic acids of the present invention, host cells comprising the nucleic acids and vectors of the present invention, proteins, protein fragments, and protein fusions of the present invention, and antibodies specific for all of any one of the variants. The invention provides pharmaceutical or physiologically acceptable compositions comprising, the polypeptides, polynucleotides and/or antibodies of the present invention, as well as, typically, a physiologically acceptable carrier. The present invention additionally provides diagnostic, investigational, and therapeutic methods based on the LXRα-64, LXRα-42e + and LXRα-42e − nucleic acid fragments, polypeptides and antibodies of the present invention.
Definitions
The following definitions and abbreviations are provided for the full understanding of terms and abbreviations used in this specification.
As used herein and in the appended claims, the singular forms “a”, “an”, and “the” include the plural reference unless the context clearly indicates otherwise. Thus, for example, a reference to “a host cell” includes a plurality of such host cells, and a reference to “an antibody” is a reference to one or more antibodies and equivalents thereof known to those skilled in the art, and so forth.
The abbreviations in the specification correspond to units of measure, techniques, properties or compounds as follows: “min” means minutes, “h” means hour(s), “μL” means microliter(s), “mL” means milliliter(s), “mM” means millimolar, “M” means molar, “mmole” means millimole(s), “kb” means kilobase, “bp” means base pair(s), and “IU” means International Units.
“Dulbecco's-modified Eagle Medium” is abbreviated DMEM. “High performance liquid chromatography” is abbreviated HPLC. “High throughput screening” is abbreviated HTS. “Open reading frame” is abbreviated ORF. “Polyacrylamide gel electrophoresis” is abbreviated PAGE. “Sodium dodecyl sulfate-polyacrylamide gel electrophoresis” is abbreviated SDS-PAGE. “Polymerase chain reaction” is abbreviated PCR. “Reverse transcriptase polymerase chain reaction” is abbreviated RT-PCR. “Liver X receptor alpha” is abbreviated LXRα. “Retinoid X receptor” is abbreviated RXR. RXR refers to all RXRs including RXRα, RXRβ, RXRγ, and combinations thereof. “DNA binding domain” is abbreviated DBD. “Ligand binding domain” is abbreviated LBD. “Untranslated region” is abbreviated UTR. “Sodium dodecyl sulfate” is abbreviated SDS.
In the context of this disclosure, a number of terms shall be utilized. As used herein, the term “nucleic acid molecule” refers to the phosphate ester form of ribonucleotides (RNA molecules) or deoxyribonucleotides (DNA molecules), or any phosphoester analogs, in either single-stranded form, or a double-stranded helix. Double-stranded DNA-DNA, DNA-RNA and RNA-RNA helices are possible. The term nucleic acid molecule, and in particular DNA or RNA molecule, refers only to the primary and secondary structure of the molecule, and does not limit it to any particular tertiary forms. Thus, this term includes double-stranded DNA found, inter alia, in linear (e.g., restriction fragments) or circular DNA molecules, plasmids, and chromosomes. In discussing the structure of particular double-stranded DNA molecules, sequences may be described according to the normal convention of giving only the sequence in the 5′ to 3′ direction along the nontranscribed strand of DNA (i.e., the strand having a sequence corresponding to the mRNA).
A “recombinant nucleic acid molecule” is a nucleic acid molecule that has undergone a molecular biological manipulation, or is derived from a molecule that has undergone biological manipulation, i.e., non-naturally occurring nucleic acid molecule. Furthermore, the term “recombinant DNA molecule” refers to a nucleic acid sequence that is not naturally occurring, or can be made by the artificial combination of two otherwise separated segments of sequence, i.e., by ligating together pieces of DNA that are not normally continuous. By “recombinantly produced” is meant production of a non-naturally occurring combination, often accomplished by either chemical synthesis means, or by the artificial manipulation of isolated segments of nucleic acids, e.g., by genetic engineering techniques using restriction enzymes, ligases, and similar recombinant techniques as described by, for example, Sambrook et al., Molecular Cloning , second edition, Cold Spring Harbor Laboratory, Plainview, N.Y.; (1989), or Ausubel et al., Current Protocols in Molecular Biology , John Wiley & Sons, New York, N.Y. (1989), and DNA Cloning: A Practical Approach , Volumes I and II (ed. D. N. Glover) IREL Press, Oxford, (1985).
In some cases, a recombinant nucleic acid molecule is constructed to replace a codon with a redundant codon encoding the same or a conservative amino acid, while typically introducing or removing a sequence recognition site. Alternatively, a recombinant nucleic acid molecule is designed to join together nucleic acid segments of desired functions to generate a single genetic entity comprising a desired combination of functions not found in the common naturally occurring forms of a manipulated sequence. Restriction enzyme recognition sites can be the target of such artificial manipulations, but other site-specific targets, e.g., promoters, DNA replication sites, regulation sequences, control sequences, or other useful features may be incorporated by design. Examples of recombinant nucleic acid molecules include recombinant vectors, such as cloning or expression vectors that contain DNA sequences, which are in a 5′ to 3′ (sense) orientation or in a 3′ to 5′ (antisense) orientation. Vectors suitable for making recombinant vectors (e.g., expression vectors) that include LXRα variant sequences and fragments thereof are known in the art.
The terms “polynucleotide,” “nucleotide sequence,” “nucleic acid,” “nucleic acid molecule,” “nucleic acid sequence,” “nucleic acid fragment,” “oligonucleotide,” “gene,” “mRNA encoded by a gene” refer to a series of nucleotide bases (also called “nucleotides”) in DNA and RNA, and include any chain of two or more nucleotides, RNA or DNA (either single or double stranded, coding, complementary or antisense), or RNA/DNA hybrid sequences of more than one nucleotide in either single chain or duplex form (although each of the above species may be particularly specified).
The polynucleotides can be chimeric mixtures or derivatives, or modified versions thereof, and can be single-stranded or double-stranded. A polynucleotide can be modified at a base moiety, sugar moiety, or phosphate backbone, for example, to improve stability of the molecule or alter its hybridization parameters. An antisense polynucleotide may comprise a modified base moiety which is selected from the group including, but not limited to, 5-fluorouracil, 5-bromouracil, 5-chlorouracil, 5-iodouracil, hypoxanthine, xanthine, 4-acetylcytosine, 5-(carboxyhydroxylmethyl)uracil, 5-carboxymethylaminomethyl-2-thiouridine, 5-carboxymethylamino methyluracil, dihydrouracil, beta-D-galactosylqueosine, inosine, N6-isopentenyladenine, 1-methylguanine, 1-methylinosine, 2,2-dimethylguanine, 2-methyladenine, 2-methylguanine, 3-methylcytosine, 5-methylcytosine, N6-adenine, 7-methylguanine, 5-methylaminomethyluracil, 5-methoxyaminomethyl-2-thiouracil, beta-D-mannosylqueosine, 5′-methoxycarboxymethyluracil, 5-methoxyuracil, 2-methylthio-N6-isopentenyladenine, wybutoxosine, pseudouracil, queosine, 2-thiocytosine, 5-methyl-2-thiouracil, 2-thiouracil, 4-thiouracil, 5-methyluracil, uracil-5-oxyacetic acid methylester, uracil-5-oxyacetic acid, 5-methyl-2-thiouracil, 3-(3-amino-3-N-2-carboxypropyl)uracil, and 2,6-diaminopurine. A nucleotide sequence typically carries genetic information, including the information used by cellular machinery to make proteins and enzymes. These terms include double- or single-stranded genomic and cDNA, RNA, any synthetic polynucleotide, genetically manipulated polynucleotide, and both sense and antisense polynucleotides. This includes single- and double-stranded molecules, i.e., DNA-DNA, DNA-RNA and RNA-RNA hybrids, as well as “protein nucleic acids” (PNAs) formed by conjugating bases to an amino acid backbone. This also includes nucleic acids containing modified bases, for example thio-uracil, thio-guanine, and fluoro-uracil, or containing carbohydrate, or lipids.
A “genomic DNA” is a DNA strand that has a nucleotide sequence homologous with a gene. By way of example, a fragment of chromosomal DNA is a genomic DNA.
In the context of the present invention, the following abbreviations for the commonly occurring nucleic acid bases are used. “A” refers to adenosine, “C” refers to cytidine, “G” refers to guanosine, “T” refers to thymidine, and “U” refers to uridine.
Polynucleotides of the invention can be synthesized using methods known in the art, e.g., by use of an automated DNA synthesizer (such as those that are commercially available from Biosearch, Applied Biosystems). As examples, phosphorothioate oligonucleotides can be synthesized by the method of Stein et al., Nucl. Acids Res., 16, 3209, (1988), methylphosphonate oligonucleotides can be prepared by use of controlled pore glass polymer supports (Sarin et al., Proc. Natl. Acad. Sci. U.S.A. 85, 7448-7451, (1988).
A number of methods have been developed for delivering antisense DNA or RNA to cells, e.g., antisense molecules can be injected directly into a tissue site. Modified antisense molecules that are designed to target specific cells (e.g., an antisense nucleic acid linked to a peptide or antibody that can specifically bind to a receptor or antigen expressed on the target cell surface) can be administered systemically. An antisense RNA molecule can be generated by in vitro or in vivo transcription of a DNA sequences encoding the antisense RNA molecule. Such DNA sequences can be incorporated into a wide variety of vectors that incorporate suitable RNA polymerase promoters such as the T7 or SP6 polymerase promoters. Alternatively, antisense constructs that synthesize antisense RNA constitutively or inducibly, depending on the promoter used, can be introduced stably into cell lines. To improve intracellular concentrations of the antisense to a level sufficient to suppress translation of targeted endogenous mRNAs, one may utilize a recombinant DNA construct in which the antisense oligonucleotide is placed under the control of a strong promoter. The use of such a construct to transfect target cells will result in the transcription of sufficient amounts of single-stranded RNAs that will form complementary base pairs with the endogenous target gene transcripts and thereby prevent translation of the target gene mRNA. For example, a vector can be introduced in vivo such that it is taken up by a cell and directs the transcription of an antisense RNA in the cell. Such a vector can remain episomal or become chromosomally integrated, as long as it can be transcribed to produce the desired antisense RNA. Such vectors can be constructed by recombinant DNA technology methods known in the art. Vectors can be plasmid, viral, or others known in the art that are suitable for replication and expression in mammalian cells. Expression of a sequence encoding an antisense RNA can be facilitated using any promoter known in the art to act in mammalian, e.g., human cells. Such promoters can be inducible or constitutive. Such promoters include, but are not limited to, the SV40 early promoter region (Bernoist and Chambon, Nature, 290, 304-310, (1981)), the promoter contained in the 3′ long terminal repeat of Rous sarcoma virus (Yamamoto et al., Cell, 22, 787-797, (1980)), the herpes thymidine kinase promoter (Wagner et al., Proc. Natl. Acad. Sci. U.S.A. 78, 1441-1445, (1981)), and the regulatory sequences of the metallothionein gene (Brinster et al., Nature 296, 39-42, (1982)). Any type of plasmid, cosmid, yeast artificial chromosome, or viral vector can be used to prepare the recombinant DNA construct that can be introduced directly into a tissue site. Alternatively, viral vectors can be used that selectively infect the desired tissue, in which case administration may be accomplished by another route (e.g., systemically).
Ribozymes are RNA molecules possessing the ability to specifically cleave single-stranded RNA in a manner analogous to DNA restriction endonucleases. Through the modification of nucleotide sequences that encode a ribozyme, it is possible to engineer molecules that recognize specific nucleotide sequences in an RNA molecule and cleave it (Cech, JAMA, 260, 3030, (1988)). A major advantage of this approach is that, because they are sequence-specific, only mRNAs with specific sequences are inactivated.
The polynucleotides described herein may be flanked by natural regulatory (expression control) sequences, or may be associated with heterologous sequences, including promoters, internal ribosome entry sites (IRES) and other ribosome binding site sequences, enhancers, response elements, suppressors, signal sequences, polyadenylation sequences, introns, 5′- and 3′-non-coding regions, and the like. The nucleic acids can also be modified by other means known in the art. Non-limiting examples of such modifications include methylation, “caps”, substitution of one or more of the naturally occurring nucleotides with an analog, and internucleotide modifications such as, for example, those with uncharged linkages (e.g., methyl phosphonates, phosphotriesters, phosphoroamidates, or carbamates) and with charged linkages (e.g., phosphorothioates or phosphorodithioates). Polynucleotides may contain one or more additional covalently linked moieties, such as, for example, proteins (e.g., nucleases, toxins, antibodies, signal peptides, or poly-L-lysine), intercalators (e.g., acridine or psoralen), chelators (e.g., metals, radioactive metals, iron, or oxidative metals), and alkylators. The polynucleotides may be derivatized by formation of a methyl or ethyl phosphotriester or an alkyl phosphoramidate linkage. Furthermore, the polynucleotides herein can also be modified with a label capable of providing a detectable signal, either directly or indirectly. Exemplary labels include radioisotopes, fluorescent molecules, biotin, and the like.
The term “upstream” refers to a location that is toward the 5′ end of the polynucleotide from a specific reference point.
The terms “base paired” and “Watson and Crick base paired” are used interchangeably herein to refer to nucleotides that can be hydrogen bonded to one another by virtue of their sequence identities in a manner like that found in double-helical DNA with thymine or uracil residues linked to adenine residues by two hydrogen bonds and cytosine and guanine residues linked by three hydrogen bonds (see Stryer, (1995) Biochemistry, 4th edition, which disclosure is hereby incorporated by reference in its entirety).
The term “exon” refers to a nucleic acid sequence found in genomic DNA that is predicted (e.g., using bioinformatics) and/or experimentally confirmed to contribute contiguous sequence to a mature mRNA transcript.
The terms “branch site” and “3′ acceptor sites” refer to consensus sequences of 3-splice junctions in eukaryotic mRNAs. Almost all introns begin with GU and end with AG. From the analysis of many exon-intron boundaries, extended consensus sequences of preferred nucleotides at the 5 and 3 ends have been established. In addition to AG, other nucleotides just upstream of the 3′ splice junction also are important for precise splicing (i.e., branch site consensus, YNYURAY and 3′ acceptor site, (Y)nNAG G).
The term “nucleic acid fragment encoding polypeptide” encompasses a polynucleotide that includes only the coding sequence as well as a polynucleotide that includes coding sequence and additional coding or non-coding sequence.
A nucleic acid molecule is “hybridizable” to another nucleic acid molecule, such as a cDNA, genomic DNA, or RNA, when a single stranded form of the nucleic acid molecule can anneal to the other nucleic acid molecule under the appropriate conditions of temperature and solution ionic strength (Sambrook, J. et al. eds., Molecular Cloning: A Laboratory Manual (2d Ed. 1989) Cold Spring Harbor Laboratory Press, NY. Vols. 1-3 (ISBN 0-87969-309-6). The conditions of temperature and ionic strength determine the “stringency” of the hybridization. For preliminary screening for homologous nucleic acids, low stringency hybridization conditions, corresponding to a T m of 55°, can be used, e.g., 5×SSC, 0.1% SDS, 0.25% milk, and no formamide; or 30% formamide, 5×SSC, 0.5% SDS). Moderate stringency hybridization conditions correspond to a higher T m , e.g., 40% formamide, with 5× or 6×SCC. High stringency hybridization conditions correspond to a higher T m , e.g., 50% formamide, 5× or 6×SSC. In general, high stringency conditions are hybridization conditions hybridization in 6×SSC (1 M NaCl), 50% formamide, 1% SDS at 42° C., followed by washing for 20 minutes in 1×SSC, 0.1% SDS at 42° C., and then washing three times for 20 minutes each at 68° C. in 0.2×SSC, 0.1% SDS. Hybridization requires that the two nucleic acids contain complementary sequences although, depending on the stringency of the hybridization, mismatches between bases are possible. The appropriate stringency for hybridizing nucleic acids depends on the length of the nucleic acids and the degree of complementation, variables well known in the art. The greater the degree of similarity or homology between two nucleotide sequences, the greater the value of T m for hybrids of nucleic acids having those sequences. The relative stability (corresponding to higher T m ) of nucleic acid hybridizations decreases in the following order: RNA:RNA, DNA:RNA, DNA:DNA. For hybrids of greater than 100 nucleotides in length, equations for calculating T m have been derived (Sambrook et al. eds., Molecular Cloning: A Laboratory Manual (2d Ed. 1989) Cold Spring Harbor Laboratory Press, NY. Vols. 1-3. (ISBN 0-87969-309-6), 9.50-9.51). For hybridization with shorter nucleic acids, i.e., oligonucleotides, the position of mismatches becomes more important, and the length of the oligonucleotide determines its specificity (Sambrook et al. eds., Molecular Cloning: A Laboratory Manual (2d Ed. 1989) Cold Spring Harbor Laboratory Press, NY. Vols. 1-3. (ISBN 0-87969-309-6), 11.7-11.8). The T m of such sequences can also be calculated and appropriate hybridization conditions determined.
Nucleic acid molecules described herein include nucleic acid sequences that hybridize under stringent conditions to the LXRα variant coding sequences described herein and complementary sequences thereof. For the purposes of this invention, the term “stringent conditions” means hybridization will occur only if there is at least 90%, e.g., at least 95% identity between the nucleic acid sequences. Accordingly, the present invention also includes isolated nucleic fragments that are complementary to the complete sequences as reported in the accompanying Sequence Listing as well as those that are at least 95% identical to such sequences, and polynucleotides having sequences that are complementary to the aforementioned polynucleotides. The polynucleotides of the present invention that hybridize to the complement of LXRα variant coding sequences described herein generally encode polypeptides that retain substantially the same biological function or activity as the mature LXRα polypeptide encoded by the cDNA of SEQ ID NO:3, SEQ ID NO:5 or SEQ ID NO:7.
A “substantial portion” of an amino acid or nucleotide sequence is a sufficient amount of the amino acid sequence of a polypeptide or the nucleotide sequence of a gene to putatively identify that polypeptide or gene, either by direct evaluation of the sequence by one skilled in the art, or by computer automated sequence comparison and identification using an algorithm such as BLAST (Basic Local Alignment Search Tool; Altschul, S. F., et al., (1993) J. Mol. Biol. 215:403-410; see also ncbi.nlm.nih.gov/BLAST. In general, a sequence of at least ten, e.g., at least 15, at least 20, at least 25, or at least 30 or more contiguous nucleotides is necessary to putatively identify a polypeptide or nucleic acid sequence as homologous to a known protein or gene. Moreover, with respect to nucleotide sequences, gene specific oligonucleotide probes comprising 15-30 (e.g., 20-30) contiguous nucleotides may be used in sequence-dependent methods of gene identification (e.g., Southern hybridization) and isolation (e.g., in situ hybridization of bacterial colonies or bacteriophage plaques). In addition, short oligonucleotides of 12-25 bases (e.g., 12-20 bases, 15-20 bases) can be used as amplification primers in PCR in order to obtain a particular nucleic acid fragment comprising the primers. Accordingly, a “substantial portion” of a nucleotide sequence comprises enough of the sequence to specifically identify and/or isolate a nucleic acid fragment comprising the sequence. The present specification teaches partial or complete amino acid and nucleotide sequences encoding one or more particular LXR variants. The skilled artisan, having the benefit of the sequences as reported herein, can use all or a substantial portion of the disclosed sequences for purposes known to those skilled in this art. Accordingly, the present invention comprises the complete sequences as reported in the accompanying Sequence Listing, as well as substantial portions of those sequences as defined above.
The term “complementary” is used to describe the relationship between nucleotide bases that are capable to hybridizing to one another. For example, with respect to DNA, adenosine is complementary to thymine and cytosine is complementary to guanine.
“Identity” or “similarity”, as known in the art, refers to relationships between two or more polypeptide sequences or two or more polynucleotide sequences, as determined by comparing the sequences. In the art, identity also means the degree of sequence relatedness between polypeptide or polynucleotide sequences, as the case may be, as determined by the match between strings of such sequences. Both identity and similarity can be readily calculated by known methods such as those described in: Computational Molecular Biology , Lesk, A. M., ed., Oxford University Press, New York, 1988; Biocomputing: Informatics and Genome Projects , Smith, D. W., ed., Academic Press, New York, 1993; Sequence Analysis in Molecular Biology , von Heinje, G., Academic Press, 1987; Computer Analysis of Sequence Data , Part I, Griffin, A. M., and Griffin, H. G., eds., Humana Press, New Jersey, 1994; and Sequence Analysis Primer , Gribskov, M. and Devereux, J., eds., M Stockton Press, New York, 1991. Methods commonly employed to determine identity or similarity between sequences include, but are not limited to those disclosed in Carillo, H. and Lipman, D., SIAM J. Applied Math. 48:1073 (1988). Methods to determine identity and similarity are codified in publicly available computer programs. Computer program methods to determine identity and similarity between two or more sequences include, but are not limited to, GCG program package (Devereux, J., et al., Nucleic Acids Res. 12(1): 387 (1984)), BLASTP, BLASTN, and FASTA (Paschal, S. F. et al., J. Molec. Biol. 215: 403 (1990)).
The term “homologous” refers to the degree of sequence similarity between two polymers (i.e., polypeptide molecules or nucleic acid molecules). The homology percentage figures referred to herein reflect the maximal homology possible between the two polymers, i.e., the percent homology when the two polymers are so aligned as to have the greatest number of matched (homologous) positions.
The term “percent homology” refers to the extent of amino acid sequence identity between polypeptides. The homology between any two polypeptides is a direct function of the total number of matching amino acids at a given position in either sequence, e.g., if half of the total number of amino acids in either of the sequences are the same then the two sequences are said to exhibit 50% homology.
The term “ortholog” refers to genes or proteins that are homologs via speciation, e.g., closely related and assumed to have common descent based on structural and functional considerations. Orthologous proteins generally have the same function and the same activity in different species. The term “paralog” refers to genes or proteins that are homologs via gene duplication, e.g., duplicated variants of a gene within a genome. See also, Fritch, W M (1970) Syst. Zool. 19:99-113. The term “ortholog” may refer to a polypeptide from another species that corresponds to LXRα variant-like polypeptide amino acid sequence as set forth in SEQ ID NOS:4, 6, 8, 17, or 19. For example, mouse and human LXRα-like polypeptides are considered to be orthologs of each other.
The term “fragment”, “analog”, and “derivative” when referring to the polypeptide of the present invention (e.g., SEQ ID NOS:4, 6, 8, 17, and 19), can refer to a polypeptide that retains essentially at least one biological function or activity as the reference polypeptide. Thus, an analog includes a precursor protein that can be activated by cleavage of the precursor protein portion to produce an active mature polypeptide. The fragment, analog, or derivative of the polypeptide described herein (e.g., SEQ ID NOS:4, 6, 8, 17, and 19) may be one having conservative or non-conservative amino acid substitution. The substituted amino acid residues may or may not be encoded by the genetic code, or the substitution may be such that one or more of the substituted amino acid residues includes a substituent group, is one in which the polypeptide is fused with a compound such as polyethylene glycol to increase the half-life of the polypeptide, or one in which additional amino acids are fused to the polypeptide such as a signal peptide or a sequence such as polyhistidine tag which is employed for the purification of the polypeptide or the precursor protein. Such fragments, analogs, or derivatives are deemed to be within the scope of the present invention.
“Conserved” residues of a polynucleotide sequence are those residues that occur unaltered in the same position of two or more related sequences being compared. Residues that are relatively conserved are those that are conserved amongst more related sequences than residues appearing elsewhere in the sequences.
Related polynucleotides are polynucleotides that share a significant proportion of identical residues.
Different polynucleotides “correspond” to each other if one is ultimately derived from another. For example, messenger RNA corresponds to the gene from which it is transcribed. cDNA corresponds to the RNA from which it has been produced, such as by a reverse transcription reaction, or by chemical synthesis of a DNA based upon knowledge of the RNA sequence. cDNA also corresponds to the gene that encodes the RNA. Polynucleotides also “correspond” to each other if they serve a similar function, such as encoding a related polypeptide in different species, strains or variants that are being compared.
An “analog” of a DNA, RNA or a polynucleotide, refers to a molecule resembling a naturally occurring polynucleotide in form and/or function (e.g., in the ability to engage in sequence-specific hydrogen bonding to base pairs on a complementary polynucleotide sequence) but which differs from DNA or RNA in, for example, the possession of an unusual or non-natural base or an altered backbone. See for example, Uhlmann et al., Chemical Reviews 90, 543-584, (1990).
The term “naturally occurring”, as applied to an object, refers to the fact that an object may be found in nature. For example, a polypeptide or polynucleotide sequence that is present in an organism (including bacteria) that may be isolated from a source in nature and which has not been intentionally modified by man in the laboratory is naturally occurring. As used herein, the term “naturally occurring” is used to refer to a known LXRα, which is also referred to as “wild type” LXRα. This use of the term should not be construed to mean that the LXRα variants described herein are not naturally occurring.
A “coding sequence” or a sequence “encoding” an expression product, such as a RNA, polypeptide, protein, or enzyme, is a nucleotide sequence that, when expressed, results in the production of that RNA, polypeptide, protein, or enzyme, i.e., a nucleotide sequence can encode an amino acid sequence for a polypeptide or protein, e.g., enzyme.
The term “codon degeneracy” refers to divergence in the genetic code permitting variation of the polynucleotide sequence without affecting the amino acid sequence of an encoded polypeptide. Accordingly, the present invention relates to any nucleic acid fragment or the complement thereof that encodes all or a substantial portion of the amino acid sequence encoding an LXRα-64, LXRα-42e + , or LXRα-42e − protein as set forth in SEQ ID NOS:4, 6, and 8. The skilled artisan is well aware of the “codon-bias” exhibited by a specific host cell to use nucleotide codons to specify a given amino acid. Therefore, when synthesizing a gene for improved expression in a host cell, it is desirable to design the gene such that its frequency of codon usage approaches the frequency of preferred codon usage of the host cell.
The term “encoding” refers to the inherent property of specific sequences of nucleotides in a polynucleotide, such as a gene, a cDNA, or an mRNA, to serve as templates for synthesis of other polymers and macromolecules in biological processes having either a defined sequence of nucleotides (i.e., rRNA, tRNA, and mRNA) or a defined sequence of amino acids and the biological properties resulting therefrom. Thus, a gene encodes a protein if transcription and translation of mRNA corresponding to that gene produces the protein in a cell or other biological system. Both the coding strand, the nucleotide sequence of which is identical to the mRNA sequence is (usually provided in sequence listings), and the non-coding strand, used as the template for transcription of a gene or cDNA, can be referred to as encoding the protein or other product of that gene or cDNA.
The polynucleotide of the present invention, can be in the form of RNA or in the form of DNA, which DNA includes cDNA and synthetic DNA. The DNA may be single-stranded or double-stranded. If it is single-stranded, it can be the coding strand or non-coding (antisense) strand. The coding sequence can be identical to the coding sequence of any one of SEQ ID NOS:3, 5, 7, 16, 18 or a fragment thereof or may be a different coding sequence which, as a result of degeneracy or redundancy of the genetic code, encodes for the same polypeptide as the reference coding sequence, e.g., one of SEQ ID NOS:3, 5, 7, 16, 18, or a fragment thereof.
The present invention includes variants of the herein-above described polynucleotides described herein that encode fragments, analogs, and derivatives of the polynucleotides characterized by the deduced amino acid sequence of SEQ ID NOS:4, 6, 8, 17, or 19. The variant of the polynucleotide can be a naturally occurring allelic variant of the polynucleotide or a non-naturally occurring variant of the polynucleotide.
A polynucleotide of the present invention may have a coding sequence that is a naturally occurring allelic variant of the coding sequence characterized by the DNA sequence of the SEQ ID NOS:4, 6 or 8, 17 and 19.
The polynucleotide that encodes the mature polypeptide, i.e., an LXRα, may include only the coding sequence for the mature polypeptide or the coding sequence for the mature polypeptide and additional sequence such as gene control sequence, regulatory sequence, or secretory sequence.
The present invention therefore includes polynucleotides such that the coding sequence for the mature polypeptide may be operatively linked in the same reading frame to a polynucleotide sequence that aids in expression and secretion of a polypeptide from a host cell (e.g., a signal peptide). The polynucleotide may also encode a precursor protein.
A polynucleotide of the present invention may also have coding sequence fused in-frame to a marker sequence, such as hexa-histidine tag (Qiagen Inc.), at either 3′ or 5′ terminus of the gene, e.g., to allow purification of the polypeptide.
“Synthetic genes” can be assembled from oligonucleotide building blocks that are chemically synthesized using procedures known to those skilled in the art. These building blocks are ligated and annealed to form gene segments that are then enzymatically assembled to construct the entire gene. “Chemically synthesized”, as related to a sequence of DNA, means that the component nucleotides were assembled in vitro. Manual chemical synthesis of DNA may be accomplished using well-known procedures, or automated chemical synthesis can be performed using one of a number of commercially available machines. Accordingly, the genes can be tailored for optimal gene expression based on optimization of nucleotide sequence to reflect the codon bias of the host cell. The skilled artisan appreciates the likelihood of successful gene expression if codon usage is biased towards those codons favored by the host. Determining preferred codons can be based on a survey of genes derived from the host cell where sequence information is available.
The term “gene” refers to a nucleic acid fragment that expresses a specific protein, including regulatory sequences preceding (5′ noncoding sequences) and following (3′ non-coding sequences) the coding sequence. “Native gene” refers to a gene as found in nature with its own regulatory sequences. “Chimeric gene” or “chimeric construct” refers to any gene or a construct, not a native gene, comprising regulatory and coding sequences that are not found together in nature. Accordingly, a chimeric gene or chimeric construct may comprise regulatory sequences and coding sequences that are derived from different sources, or regulatory sequences and coding sequences derived from the same source, but arranged in a manner different than that found in nature. “Endogenous gene” refers to a native gene in its natural location in the genome of an organism. A “foreign” gene refers to a gene not normally found in the host organism, but which is introduced into the host organism by gene transfer. Foreign genes can comprise native genes inserted into a non-native organism, or chimeric genes. A “transgene” is a gene that has been introduced into the genome by a transformation procedure.
“Target gene,” “target gene sequence,” “target DNA sequence,” or “target sequence” refers to a gene where the gene, its RNA transcript, or its protein product is modulated by a transcription factor. The target sequence may include an intact gene, an exon, an intron, a regulatory sequence or any region between genes. The target gene may comprise a portion of a particular gene or genetic locus in the subject's genomic DNA. “Target gene,” as used herein, refers to a differentially expressed gene involved in LXR responsive pathways. “Differential expression”, refers to both quantitative as well as qualitative differences in a gene's temporal and/or tissue expression patterns. Examples of LXR target genes are SREBP-1c (sterol regulatory binding element 1c), FAS, CYP7A1 (cholesterol 7-alpha hydroxylase), ApoE, CETP (cholesterol ester transfer protein), LPL (lipoprotein lipase), ABCA1 (ATP-binding cassette transporter-1), ABCG1, ABCG5, ABCG8, ABCG4, and PLTP (phospholipid transfer protein) (Edwards et al. Vasc. Pharmacol. 38, (2002) 249-256). The term “regulatory sequences” refer to nucleotide sequences located upstream (5′ non-coding sequences), within, or downstream (3′ non-coding sequences) of a coding sequence, and which influence), e.g., transcription, RNA processing, RNA stability, or translation of the associated coding sequence. Regulatory sequences may include promoters, translation leader sequences, introns, and polyadenylation recognition sequences.
The term “gene control sequence” refers to the DNA sequences required to initiate gene transcription plus those required to regulate the rate at which initiation occurs. Thus a gene control sequence may consist of the promoter, where the general transcription factors and the polymerase assemble, plus all the regulatory sequences to which gene regulatory proteins bind to control the rate of these assembly processes at the promoter. For example, the control sequences that are suitable for prokaryotes may include a promoter, optionally an operator sequence, and a ribosome binding site. Eukaryotic cells are known to utilize promoters, enhancers, and/or polyadenylation signals.
The term “promoter” refers to a nucleotide sequence capable of controlling the expression of a coding sequence or functional RNA. In general, a coding sequence is located 3′ to a promoter sequence. The promoter sequence consists of proximal and more distal upstream elements, the latter elements often referred to as enhancers. Accordingly, an “enhancer” is a nucleotide sequence that can stimulate promoter activity and may be an innate element of the promoter or a heterologous element inserted to enhance the level or tissue-specificity of a promoter. Promoters may be derived in their entirety from a native gene, or be composed of different elements derived from different promoters found in nature, or even comprise synthetic nucleotide segments. It is understood by those skilled in the art that different promoters may direct the expression of a gene in different tissues or cell types, or at different stages of development, or in response to different environmental conditions.
The term “3′ non-coding sequences” refer to nucleotide sequences located downstream of a coding sequence and include polyadenylation recognition sequences and other sequences encoding regulatory signals capable of affecting mRNA processing or gene expression. The polyadenylation signal is usually characterized by affecting the addition of polyadenylic acid tracts to the 3′ end of the mRNA precursor.
The term “translation leader sequence” refers to a nucleotide sequence located between the promoter sequence of a gene and the coding sequence. The translation leader sequence is present in the fully processed mRNA upstream of the translation start sequence. The translation leader sequence may affect processing of the primary transcript to mRNA, mRNA stability or translation efficiency.
The term “operatively linked” refers to the association of two or more nucleic acid fragments on a single nucleic acid fragment so that the function of one is affected by the other. For example, a promoter is operatively linked with a coding sequence when it is capable of affecting the expression of that coding sequence (i.e., that the coding sequence is under the transcriptional control of the promoter). Coding sequences can be operatively linked to regulatory sequences in sense or antisense orientation.
The term “domain” refers to an amino acid fragment with specific biological properties. This term encompasses all known structural and linear biological motifs. Examples of such motifs include but are not limited to helix-turn-helix motifs, leucine zippers, glycosylation sites, ubiquitination sites, alpha helices, and beta sheets, signal peptides which direct the secretion of proteins, sites for post-translational modification, enzymatic active sites, substrate binding sites, and enzymatic cleavage sites.
“DNA-binding domain” refers to the portion of any DNA binding protein that specifically interacts with desoxyribonucleotide strands. A sequence-specific DNA binding protein binds to a specific sequence or family of specific sequences showing a high degree of sequence identity with each other.
The term “LBD” or “ligand-binding domain” refers to the protein domain of a nuclear receptor, such as a steroid superfamily receptor or other suitable nuclear receptor as discussed herein, which binds a ligand (e.g., a steroid hormone).
The term “reporter gene” means any gene that encodes a product whose expression is detectable and/or quantifiable by physical, immunological, chemical, biochemical, or biological assays. A reporter gene product may, for example, have one of the following attributes, without restrictions: a specific nucleic acid chip hybridization pattern, fluorescence (e.g., green fluorescent protein), enzymatic activity, toxicity, or an ability to be specifically bound by a second molecule, labeled or unlabeled.
The term “RNA transcript” refers to the product resulting from RNA polymerase-catalyzed transcription of a DNA sequence. When the RNA transcript is a complementary copy of the DNA sequence, it is referred to as the primary transcript or it may be an RNA sequence derived from post-transcriptional processing of the primary transcript and is referred to as the mature RNA. “Messenger RNA (mRNA)” refers to the RNA that is without introns and can be translated into polypeptides by the cell. “cDNA” refers to DNA that is complementary to and derived from an mRNA template. The cDNA can be single-stranded or converted to double-stranded form using, for example, the Klenow fragment of DNA polymerase I.
A sequence “complementary” to a portion of an RNA, refers to a sequence having sufficient complementarity to be able to hybridize with the RNA, forming a stable duplex; in the case of double-stranded antisense nucleic acids, a single strand of the duplex DNA may thus be tested, or triplex formation may be assayed. The ability to hybridize will depend on both the degree of complementarity and the length of the antisense nucleic acid. The complementarity of an antisense RNA may be with any part of the specific nucleotide sequence, i.e., at the 5′ non-coding sequence, 3′ non-coding sequence, introns, or the coding sequence. Generally, the longer the hybridizing nucleic acid, the more base mismatches with an RNA it may contain and still form a stable duplex (or triplex, as the case may be). One skilled in the art can ascertain a tolerable degree of mismatch by use of standard procedures to determine the melting point of the hybridized complex.
“Functional RNA” refers to sense RNA, antisense RNA, ribozyme RNA, or other RNA that may not be translated but yet has an effect on cellular processes.
An “anti-sense” copy of a particular polynucleotide refers to a complementary sequence that is capable of hydrogen bonding to the polynucleotide and can therefor be capable of modulating expression of the polynucleotide. These are DNA, RNA or analogs thereof, including analogs having altered backbones, as described above. The polynucleotide to which the anti-sense copy binds may be in single-stranded form or in double-stranded form. A DNA sequence linked to a promoter in an “anti-sense orientation” may be linked to the promoter such that an RNA molecule complementary to the coding mRNA of the target gene is produced.
The antisense polynucleotide may comprise at least one modified sugar moiety selected from the group including but not limited to arabinose, 2-fluoroarabinose, xylulose, and hexose. In one embodiment, the antisense oligonucleotide may comprise at least one modified phosphate backbone selected from the group consisting of a phosphorothioate, a phosphorodithioate, a phosphoramidothioate, a phosphoramidate, a phosphordiamidate, a methylphosphonate, an alkyl phosphotriester, and a formacetal or analog thereof.
The term “sense” refers to sequences of nucleic acids that are in the same orientation as the coding mRNA nucleic acid sequence. A DNA sequence linked to a promoter in a “sense orientation” is linked such that an RNA molecule that contains sequences identical to an mRNA is transcribed. The produced RNA molecule, however, need not be transcribed into a functional protein.
A “sense” strand and an “anti-sense” strand when used in the same context refer to single-stranded polynucleotides that are complementary to each other. They may be opposing strands of a double-stranded polynucleotide, or one strand may be predicted from the other according to generally accepted base-pairing rules. Unless otherwise specified or implied, the assignment of one or the other strand as “sense” or “antisense” is arbitrary.
The term “polynucleotide encoding polypeptide” encompasses a polynucleotide that may include only the coding sequence as well as a polynucleotide that may include additional coding or non-coding sequence.
The term “siRNA” or “RNAi” refers to small interfering RNAs and the process by which they function. siRNAs are capable of causing RNA interference and can cause post-transcriptional silencing of specific genes in cells, for example, in mammalian cells (including human cells) and in the body, for example, mammalian bodies (including humans). The phenomenon of RNA interference is described and discussed in Bass, Nature, 411, 428-29, (2001); Elbahir et al., Nature, 411, 494-98, (2001); and Fire et al., Nature, 391, 806-11, (1998), where methods of making interfering RNA also are discussed. The siRNAs based upon the sequence disclosed herein can be made by approaches known in the art, including the use of complementary DNA strands or synthetic approaches. Exemplary siRNAs could have up to 29 bps, 25 bps, 22 bps, 21 bps, 20 bps, 15 bps, 10 bps, 5 bps or any integer thereabout or therebetween.
The term “expression”, as used herein, refers to the transcription and stable accumulation of sense (mRNA) or antisense RNA derived from the nucleic acid fragment of the invention. Expression may also refer to translation of mRNA into a polypeptide. “Antisense inhibition” refers to the production of antisense RNA transcripts capable of suppressing the expression of the target protein.
The term “overexpression” refers to the production of a gene product in transgenic organisms that exceeds levels of production in normal or non-transformed organisms. “Co-suppression” refers to the production of sense RNA transcripts capable of suppressing the expression of identical or substantially similar foreign or endogenous genes (U.S. Pat. No. 5,231,020, incorporated herein by reference).
The term “altered levels” refers to the production of gene product(s) in transgenic organisms in amounts or proportions that differ from that of normal or non-transformed organisms. Over expression of the polypeptide of the present invention may be accomplished by first constructing a chimeric gene or chimeric construct in which the coding region is operatively linked to a promoter capable of directing expression of a gene or construct in the desired tissues at the desired stage of development. For reasons of convenience, the chimeric gene or chimeric construct may comprise promoter sequences and translation leader sequences derived from the same genes. 3′ Non-coding sequences encoding transcription termination signals may also be provided. The instant chimeric gene or chimeric construct may also comprise one or more introns in order to facilitate gene expression. Plasmid vectors comprising the instant chimeric gene or chimeric construct can then be constructed. The choice of plasmid vector is dependent upon the method that will be used to transform host cells. The skilled artisan is well aware of the genetic elements that must be present on the plasmid vector in order to successfully transform, select and propagate host cells containing the chimeric gene or chimeric construct. The skilled artisan will also recognize that different independent transformation events will result in different levels and patterns of expression (Jones et al., 1985, EMBO J. 4:2411-2418; De Almeida et al., 1989, Mol. Gen. Genetics 218:78-86), and thus that multiple events must be screened in order to obtain lines displaying the desired expression level and pattern. Such screening may be accomplished by Southern analysis of DNA, Northern analysis of mRNA expression, Western analysis of protein expression, or phenotypic analysis.
The terms “cassette” or “expression cassette” refer to a DNA coding sequence or segment of DNA that codes for an expression product that can be inserted into a vector at defined restriction sites. The cassette restriction sites are designed to ensure insertion of the cassette in the proper reading frame. Generally, foreign DNA is inserted at one or more restriction sites of the vector DNA, and then is carried by the vector into a host cell along with the transmissible vector DNA. A segment or sequence of DNA having inserted or added DNA, such as an expression vector, can also be called a “DNA construct.”
The term “expression system” means a host cell and compatible vector under suitable conditions, e.g., for the expression of a protein coded for by foreign DNA carried by the vector and introduced to the host cell. Common expression systems include E. coli host cells and plasmid vectors, insect host cells and Baculovirus vectors, and mammalian host cells and vectors.
The term “transfection” refers to the insertion of an exogenous polynucleotide into a host cell, irrespective of the method used for the insertion, or the molecular form of the polynucleotide that is inserted. The insertion of a polynucleotide per se and the insertion of a vector or plasmid comprised of the exogenous polynucleotide are included. The exogenous polynucleotide may be transcribed and translated by the cell, maintained as a nonintegrated vector, for example, a plasmid, or may be stably integrated into the host genome.
The term “transformed” refers to any known method for the insertion of a nucleic acid fragment into a host prokaryotic cell. The term “transfected” refers to any known method for the insertion of a nucleic acid fragment into a host eukaryotic cell. Such transformed or transfected cells include stably transformed or transfected cells in which the inserted DNA is rendered capable of replication in the host cell. They also include transiently expressing cells that express the inserted DNA or RNA for limited periods of time. The transformation or transfection procedure depends on the host cell being transformed. It can include packaging the nucleic acid fragment in a virus as well as direct uptake of the nucleic acid fragment, such as, for example, electroporation, lipofection, or microinjection. Transformation and transfection can result in incorporation of the inserted DNA into the genome of the host cell or the maintenance of the inserted DNA within the host cell in plasmid form. Methods of transformation are well known in the art and include, but are not limited to, lipofection, electroporation, viral infection, and calcium phosphate mediated direct uptake. Transfection methods are known to those in the art including calcium phosphate DNA co-precipitation (Methods in Molecular Biology, Vol. 7, Gene Transfer and Expression Protocols, Ed. E. J. Murray, Humana Press (1991)); DEAE-dextran; electroporation; cationic liposome-mediated transfection; and tungsten particle-facilitated microparticle bombardment (Johnston, Nature 346:776-777 (1990)). Strontium phosphate DNA co-precipitation (Brash et al., Molec. Cell. Biol. 7:2031-2034 (1987) is an alternative transfection method.
“Cells,” “host cells,” or “recombinant host cells” are terms used interchangeably herein. It is understood that such terms refer not only to the particular subject cell but also to the progeny or potential progeny of such a cell. Because certain modifications may occur in succeeding generations due to either mutation or environmental influences, such progeny may not, be identical to the parent cell, but are still included within the scope of the term as used herein. The term “recombinant cell” refers to a cell that contains heterologous nucleic acid, and the term “naturally occurring cell” refers to a cell that does not contain heterologous nucleic acid introduced by the hand of man.
The cell may be a prokaryotic or a eukaryotic cell. Typical prokaryotic host cells include various strains of E. coli . Typical eukaryotic host cells are mammalian, such as Chinese hamster ovary cells or human embryonic kidney 293 cells (HEK 293 cells). The introduced DNA is usually in the form of a vector containing an inserted piece of DNA. The introduced DNA sequence may be from the same species as the host cell or a different species from the host cell, or it may be a hybrid DNA sequence, containing some foreign and some homologous DNA. It is further understood that such terms refer not only to the particular subject cell but also to the progeny or potential progeny of such a cell. Because certain modifications may occur in succeeding generations due to either mutation or environmental influences, such progeny may not, in fact, be identical to the parent cell, but are still included within the scope of the term as used herein.
The term “clone” refers to a population of cells derived from a single cell or common ancestor by mitosis. A “cell line” refers to a clone of a primary cell that is capable of stable growth in vitro for several generations.
The term “cell growth” refers to an increase in the size of a population of cells.
The term “cell division” refers to mitosis, i.e., the process of cell reproduction.
The term “proliferation” refers to growth and division of cells. “Actively proliferating” means cells that are actively growing and dividing.
The term “differentiate” refers to having a different character or function from the original type of tissues or cells. Thus, “differentiation” is the process or act of differentiating.
The term “gene-inducible system” refers to the use of ligands to regulate gene expression. Several regulatory systems have been developed that utilize small molecules to induce gene expression (reviewed in Clackson, Curr. Opin. Chem. Biol., 1, 210-218, (1997); Lewandoski, Nat Rev Genet. 2, 743-755, (2001). A gene-inducible system is a molecular tool which allows for low to undetectable basal expression of a target gene when the system is not activated and increased expression levels of the target gene when the system is activated.
The term “inhibiting cellular proliferation” refers to slowing and/or preventing the growth and division of cells. Cells may further be specified as being arrested in a particular cell cycle stage: G1 (Gap 1), S phase (DNA synthesis), G2 (Gap 2) or M phase (mitosis).
The term “preferentially inhibiting cellular proliferation” refers to slowing and/or preventing the growth and division of cells as compared to normal cells.
The term “apoptosis” refers to programmed cell death as signaled by the nuclei in normally functioning human and animal cells when age or state of cell health and condition dictates. “Apoptosis” is an active process requiring metabolic activity by the dying cell, often characterized by cleavage of the DNA into fragments that give a so called laddering pattern on gels. Cells that die by apoptosis do not usually elicit the inflammatory responses that are associated with necrosis, though the reasons are not clear. Cancerous cells, however, are unable to experience, or have a reduction in, the normal cell transduction or apoptosis-driven natural cell death process. Morphologically, apoptosis is characterized by loss of contact with neighboring cells, concentration of cytoplasm, endonuclease activity-associated chromatin condensation and pyknosis, and segmentation of the nucleus, among others.
The term “polypeptide” refers to a polymer of amino acids without regard to the length of the polymer; thus, “peptides,” “oligopeptides”, and “proteins” are included within the definition of polypeptide and used interchangeably herein. The term refers to a naturally occurring or synthetic polymer of amino acid monomers (residues), irrespective of length, where amino acid monomer here includes naturally occurring amino acids, naturally occurring amino acid structural variants, or synthetic non-naturally occurring analogs that are capable of participating in peptide bonds. This term also does not specify or exclude chemical or post-expression modifications of the polypeptides of the invention, although chemical or post-expression modifications of these polypeptides may be included or excluded as specific embodiments. Therefore, for example, modifications to polypeptides that include the covalent attachment of glycosyl groups, acetyl groups, phosphate groups, lipid groups and the like are expressly encompassed by the term polypeptide. Further, polypeptides with these modifications may be specified as individual species to be included or excluded from the present invention. The natural or other chemical modifications, such as those listed in examples above can occur anywhere in a polypeptide, including the peptide backbone, the amino acid side-chains and the amino or carboxyl termini. It will be appreciated that the same type of modification may be present in the same or varying degrees at several sites in a given polypeptide. Also, a given polypeptide may contain many types of modifications. Polypeptides may be branched, for example, as a result of ubiquitination, and they may be cyclic, with or without branching. Modifications include acetylation, acylation, ADP-ribosylation, amidation, covalent attachment of flavin, covalent attachment of a heme moiety, covalent attachment of a nucleotide or nucleotide derivative, covalent attachment of a lipid or lipid derivative, covalent attachment of phosphotidylinositol, cross-linking, cyclization, disulfide bond formation, demethylation, formation of covalent cross-links, formation of cysteine, formation of pyroglutamate, formylation, gamma-carboxylation, glycosylation, GPI anchor formation, hydroxylation, iodination, methylation, myristoylation, oxidation, pegylation, proteolytic processing, phosphorylation, prenylation, racemization, selenoylation, sulfation, transfer-RNA mediated addition of amino acids to proteins such as arginylation, and ubiquitination. (See, for instance, proteins—structure and molecular properties, 2nd Ed., T. E. Creighton, W. H. Freeman and Company, New York (1993); posttranslational covalent modification of proteins, b. c. Johnson, Ed., Academic Press, New York, pgs. 1-12, 1983; Seifter et al., Meth. Enzymol. 182:626-646, 1990; Rattan et al., Ann. NY Acad. Sci. 663:48-62, 1992). Also included within the definition are polypeptides which contain one or more analogs of an amino acid (including, for example, non-naturally occurring amino acids, amino acids which only occur naturally in an unrelated biological system, or modified amino acids from mammalian systems), polypeptides with substituted linkages, as well as other modifications known in the art, both naturally occurring and non-naturally occurring. The term “polypeptide” may also be used interchangeably with the term “protein” or “peptide”.
The term “peptide” refers to any polymer of two or more amino acids, wherein each amino acid is linked to one or two other amino acids via a peptide bond (—CONH—) formed between the NH.sub.2 and the COOH groups of adjacent amino acids. Preferably, the amino acids are naturally occurring amino acids, particularly alpha-amino acids of the L-enantiomeric form. However, other amino acids, enantiomeric forms, and amino acid derivatives may be included in a peptide. Peptides include “polypeptides,” which, upon hydrolysis, yield more than two amino acids. Polypeptides may include proteins, which typically comprise 50 or more amino acids. The term “oligopeptide” herein denotes a protein, polypeptide, or peptide having 25 or fewer monomeric subunits.
“Variant” refers to a polynucleotide or polypeptide that differs from a reference polynucleotide or polypeptide, but retains the essential properties thereof. A typical variant of a polynucleotide differs in nucleotide sequence from the reference polynucleotide. Changes in the nucleotide sequence of the variant may or may not alter the amino acid sequence of a polypeptide encoded by the reference polynucleotide. Nucleotide changes may result in amino acid substitutions, additions, deletions, fusions and truncations in the polypeptide encoded by the reference sequence, as discussed below.
The term “variant(s)” refers to a polypeptide plurality of polypeptides that differ from a reference polypeptide respectively. Generally, the differences between the polypeptide that differs in amino acid sequence from reference polypeptide, and the reference polypeptide are limited so that the amino acid sequences of the reference and the variant are closely similar overall and, in some regions, may be identical. A variant and reference polypeptide may differ in amino acid sequence by one or more substitutions, deletions, additions, fusions and truncations, which may be present in any combination. A substituted or inserted amino acid residue may or may not be one encoded by the genetic code. Typical conservative substitutions include Gly, Ala; Val, Ile, Leu; Asp, Glu; Asn, Gln; Ser, Thr; Lys, Arg; and Phe and Tyr. Additionally, a variant may be a fragment of a polypeptide of the invention that differs from a reference polypeptide sequence by being shorter than the reference sequence, such as by a terminal or internal deletion. A variant of a polypeptide of the invention also includes a polypeptide that retains essentially the same biological function or activity as such polypeptide e.g., precursor proteins that can be activated by cleavage of the precursor portion to produce an active mature polypeptide. Moreover, a variant may be (i) one in which one or more of the amino acid residues are substituted with a conserved or non-conserved amino acid residue (preferably a conserved amino acid residue) and such substituted amino acid residue may or may not be one encoded by the genetic code, or (ii) one in which one or more of the amino acid residues includes a substituent group, or (iii) one in which the mature polypeptide is fused with another compound, such as a compound to increase the half-life of the polypeptide (for example, polyethylene glycol), or (iv) one in which the additional amino acids are fused to the mature polypeptide such as a leader or secretory sequence or a sequence which is employed for purification of the mature polypeptide or a precursor protein sequence. A variant of the polypeptide may also be a naturally occurring variant such as a naturally occurring allelic variant, or it may be a variant that is not known to occur naturally. Non-naturally occurring variants of polynucleotides and polypeptides may be made by mutagenesis techniques or by direct synthesis. Also included as variants are polypeptides having one or more post-translational modifications, for instance glycosylation, phosphorylation, methylation, ADP ribosylation and the like. Embodiments include methylation of the N-terminal amino acid, phosphorylations of serines and threonines and modification of C-terminal glycines. Among polypeptide variants in this regard are variants that differ from the aforementioned polypeptides by amino acid substitutions, deletions or additions. The substitutions, deletions or additions may involve one or more amino acids. Alterations in the sequence of the amino acids may be conservative or non-conservative amino acid substitutions, deletions or additions. All such variants defined above are deemed to be within the scope of those skilled in the art from the teachings herein and from the art.
The LXRα variant described herein that is designated LXRα-64 (SEQ ID NO:4), is homologous to the previously known LXRα in that it contains a DNA binding domain and a ligand binding domain; however, different from the known LXRα in its middle part of the sequence in that it contains 64 new amino acids. By virtue of the partial identity, and partial divergence of their amino acid sequences, the variant and the known homologues may have some functionality in common but may differ in other functions. For example, wild-type LXRα is known to be a sensor for cellular oxysterols and, when activated by its agonists, increase the expression of genes that control sterol and fatty acid metabolism/homeostasis where as LXRα-L64, LXRα-42e + and LXRα-42e − function as dominant negative modulators of the wild type LXRα.
The term “dominant negative polypeptide” means an inactive variant of a protein, which, by interacting with the cellular machinery, displaces an active protein from its interaction with the cellular machinery or competes with the active protein, thereby reducing the effect of the active protein. For example, a dominant negative receptor that binds a ligand but does not transmit a signal in response to binding of the ligand can reduce the biological effect of expression of the ligand. Likewise, a dominant negative catalytically inactive kinase that interacts normally with target proteins but does not phosphorylate the target proteins can reduce phosphorylation of the target proteins in response to a cellular signal. Similarly, a dominant negative transcription factor that binds to a promoter site in the control region of a gene but does not increase gene transcription can reduce the effect of a normal transcription factor by occupying promoter binding sites without increasing transcription.
The term “splice variant” refers to cDNA molecules produced from RNA molecules initially transcribed from the same genomic DNA sequence but which have undergone alternative RNA splicing. Alternative RNA splicing occurs when a primary RNA transcript undergoes splicing, generally for the removal of introns, which results in the production of more than one mRNA molecule each of them may encode different amino acid sequences. The term splice variant may also refer to the proteins encoded by the above cDNA molecules. The splice variant may be partially identical in sequence to the known homologous gene product. “Splice variants” refer to a plurality of proteins having non-identical primary amino acid sequence but that share amino acid sequence encoded by at least one common exon.
As used herein, the phrase “alternative splicing” and its linguistic equivalents includes all types of RNA processing that lead to expression of plural protein isoforms from a single gene; accordingly, the phrase “splice variant(s)” and its linguistic equivalents embraces mRNAs transcribed from a given gene that, however processed, collectively encode plural protein isoforms. For example, and by way of illustration only, splice variants can include exon insertions, exon extensions, exon truncations, exon deletions, alternatives in the 5′ untranslated region (“5′ UT”) and alternatives in the 3′ untranslated region (“3′ UT”). Such 3′ alternatives include, for example, differences in the site of RNA transcript cleavage and site of poly(A) addition (e.g., Gautheret et al., Genome Res. 8:524-530 (1998)).
The term “isolated” means that the material is removed from its original or native environment (e.g., the natural environment if it is naturally occurring). Therefore, a naturally occurring polynucleotide or polypeptide present in a living animal is not isolated, but the same polynucleotide or polypeptide, separated by human intervention from some or all of the coexisting materials in the natural system, is isolated. For example, an “isolated nucleic acid fragment” is a polymer of RNA or DNA that is single- or double-stranded, optionally containing synthetic, non-natural or altered nucleotide bases. An isolated nucleic acid fragment in the form of a polymer of DNA may be comprised of one or more segments of cDNA, genomic DNA or synthetic DNA. Such polynucleotides could be part of a vector, integrated into a host cell chromosome at a heterologous site, and/or such polynucleotides or polypeptides could be part of a composition, and still be isolated in that such vector or composition is not part of the environment in which it is found in nature.
The term “purified” does not require absolute purity; rather, it is intended as a relative definition. Purification of starting material or natural material to at least one order of magnitude, preferably two or three orders, and more preferably four or five orders of magnitude is expressly contemplated. Similarly, the term “substantially purified” refers to a substance, which has been separated or otherwise removed, through human intervention, from the immediate chemical environment in which it occurs in Nature. Substantially purified polypeptides or nucleic acids may be obtained or produced by any of a number of techniques and procedures generally known in the field.
The term “purified” is further used herein to describe a polypeptide or polynucleotide of the present invention that has been separated from other compounds including, but not limited to, polypeptides, polynucleotides, carbohydrates, or lipids. The term “purified” may be used to specify the separation of monomeric polypeptides of the invention from oligomeric forms such as homodimers, heterodimers, or trimers. The term “purified” may also be used to specify the separation of covalently closed (i.e., circular) polynucleotides from linear polynucleotides. A substantially pure polypeptide or polynucleotide typically comprises about 50%, preferably 60 to 90% weight/weight of a polypeptide or polynucleotide sample, respectively, more usually about 95%, and preferably is over about 99% pure but, may be specified as any integer of percent between 50 and 100. Polypeptide and polynucleotide purity, or homogeneity, is indicated by a number of means well known in the art, such as agarose or polyacrylamide gel electrophoresis of a sample, followed by visualizing a single band upon staining the gel. For certain purposes, higher resolution can be provided by using HPLC or other means that are known in the art. As an alternative embodiment, purification of the polypeptides and polynucleotides of the present invention may be expressed as “at least” a percent purity relative to heterologous polypeptides and polynucleotides (DNA, RNA or both). In one embodiment, the polypeptides and polynucleotides of the present invention are at least; 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, 95%, 96%, 96%, 98%, 99%, or 100% pure relative to heterologous polypeptides and polynucleotides, respectively. In another embodiment the polypeptides and polynucleotides have a purity ranging from any number, to the thousandth position, between 90% and 100% (e.g., a polypeptide or polynucleotide at least 99.995% pure) relative to either heterologous polypeptides or polynucleotides, respectively, or as a weight/weight ratio relative to all compounds and molecules other than those existing in the carrier. Each number representing a percent purity, to the thousandth position, may be claimed as individual species of purity.
A protein may be said to be “isolated” when it exists at a purity not found in nature where purity may be adjudged with respect to the presence of proteins of other sequence, with respect to the presence of non-protein compounds, such as nucleic acids, lipids, or other components of a biological cell, or when it exists in a composition not found in nature, such as in a host cell that does not naturally express that protein.
The polypeptide and the polynucleotides of the present invention are preferably provided in an isolated form, and preferably are purified to homogeneity.
The term “Mature” protein refers to a post-translationally processed polypeptide; i.e., one from which any pre- or propeptides present in the primary translation product have been removed. “Precursor” protein refers to the primary product of translation of mRNA; i.e., with pre- and propeptides still present. Pre- and propeptides include but are not limited to intracellular localization signals.
The term “antibody” refers to a polypeptide, at least a portion of which is encoded by at least one immunoglobulin gene, or fragment thereof, and that can bind specifically to a desired target molecule. The term includes naturally occurring forms, as well as fragments and derivatives.
Fragments may include those produced by digestion with various proteases, those produced by chemical cleavage and/or chemical dissociation, and those produced recombinantly, so long as the fragment remains capable of specific binding to a target molecule. Among such fragments are Fab, Fab′, Fv, F(ab)′ 2 , and single chain Fv (scFv) fragments. Derivatives within the scope of the term include antibodies (or fragments thereof) that have been modified in sequence, but remain capable of specific binding to a target molecule, including: interspecies chimeric and humanized antibodies; antibody fusions; heteromeric antibody complexes and antibody fusions, such as diabodies (bispecific antibodies), single-chain diabodies, and intrabodies (see, e.g., Marasco (ed.), Intracellular Antibodies: Research and Disease Applications , Springer-Verlag New York, Inc. (1998) (ISBN: 3540641513), the disclosure of which is incorporated herein by reference in its entirety).
The term “immunoreactive” refers to a polypeptide when it is “immunologically reactive” with an antibody, i.e., when it binds to an antibody due to antibody recognition of a specific epitope contained within the polypeptide. Immunological reactivity may be determined by antibody binding, more particularly by the kinetics of antibody binding, and/or by competition in binding using as competitor(s) a known polypeptide(s) containing an epitope against which the antibody is directed. The techniques for determining whether a polypeptide is immunologically reactive with an antibody are known in the art. An “immunoreactive” polypeptide may also be “immunogenic.”
Antibodies can be produced by any known technique, including harvest from cell culture of native B lymphocytes, harvest from culture of hybridomas, recombinant expression systems, and phage display.
A molecule is “antigenic” when it is capable of specifically interacting with an antigen recognition molecule of the immune system, such as an immunoglobulin (antibody) or T cell antigen receptor. An antigenic polypeptide contains at least about 5, and preferably at least about 10, amino acids. An antigenic portion of a molecule can be that portion that is immunodominant for antibody or T cell receptor recognition, or it can be a portion used to generate an antibody to the molecule by conjugating the antigenic portion to a carrier molecule for immunization. A molecule that is antigenic need not be itself immunogenic, i.e., capable of eliciting an immune response without a carrier. The portions of the antigen that make contact with the antibody are denominated “epitopes”.
The term “molecular binding partners”—and equivalently, “specific binding partners”—refer to pairs of molecules, typically pairs of biomolecules, which exhibit specific binding. Non-limiting examples are receptor and ligand, antibody and antigen, and biotin to any of avidin, streptavidin, NeutrAvidin™ and CaptAvidin™.
The term “binding partner” or “interacting proteins” refers to a molecule or molecular complex which is capable of specifically recognizing or being recognized by a particular molecule or molecular complex, as for example, an antigen and an antigen-specific antibody or an enzyme and its inhibitor. Binding partners may include, for example, biotin and avidin or streptavidin, IgG, and protein A, receptor-ligand couples, protein-protein interaction, and complementary polynucleotide strands. The term “binding partner” may also refer to polypeptides, lipids, small molecules, or nucleic acids that bind to polypeptides in cells. A change in the interaction between a protein and a binding partner can manifest itself as an increased or decreased probability that the interaction forms, or an increased or decreased concentration of protein-binding partner complex. For example, LXRα-64 or LXRα-42 protein may bind with another protein or polypeptide and form a complex that may result in modulating LXR or RXR activity.
“Specific binding” refers to the ability of two molecular species concurrently present in a heterogeneous (inhomogeneous) sample to bind to one another in preference to binding to other molecular species in the sample. Typically, a specific binding interaction will discriminate over adventitious binding interactions in the reaction by at least two-fold, more typically by at least 10-fold, often at least 100-fold; when used to detect analyte, specific binding is sufficiently discriminatory when determinative of the presence of the analyte in a heterogeneous (inhomogeneous) sample.
The term “dimeric” refers to a specific multimeric molecule where two protein polypeptides are associated through covalent or non-covalent interactions. “Dimeric molecule” can be receptors that are comprised of two identical (homodimeric) or different (heterodimeric) protein molecule subunits.
The term “homodimer” refers to a dimeric molecule wherein the two subunit constituents are essentially identical, for example RXR and RXR. The “homodimeric complex” refers to a protein complex between two identical receptors (e.g., RXR/RXR). The “homodimeric complex” may include dimeric proteins with minor microheterogeneities that occasionally arise on production or processing of recombinant proteins. The term “homodimerization” refers to the process by which two identical subunits (e.g., RXR and RXR) dimerize.
The term “heterodimer” refers to a dimeric molecule wherein the two subunit constituents are different, for example RXR and LXR. The term “heterodimeric complex” refers to a protein complex between any one of the nuclear receptors (e.g., RXR and any one of the variants of the present invention, or, RXR and LXRα, LXRβ, PPARα, PPARγ, PPARδ, RAR, XR, or PXR). The term “heterodimerization” refers to a process by which two different subunits (e.g., RXR and LXRα-64) dimerize.
The term “naturally heterodimerizes” refers to a process by which a molecule (e.g., polypeptide) normally heterodimerizes with different molecules in nature. For example, polypeptides that naturally heterodimerize with RXR are the nuclear receptors that normally heterodimerize with RXR in nature such as LXRα, LXRβ, PPARα, PPARγ, PPARδ, RAR, XR, and PXR.
The term “LXR responsive pathway” refers to any one of the pathways known in the art which involve activation or deactivation of a nuclear receptor (e.g., LXR or RXR), and which are at least partially mediated by the LXR.
The term “signal transduction pathway” refers to the molecules that propagate an extracellular signal through the cell membrane to become an intracellular signal. This signal can then stimulate a cellular response. The polypeptide molecules involved in signal transduction processes may be receptor and non-receptor proteins.
The term “receptor” refers to a molecular structure within a cell or on the surface of the cell that is generally characterized by the selective binding of a specific substance. Exemplary receptors include cell-surface receptors for peptide hormones, neurotransmitters, antigens, complement fragments and immunoglobulins as well as cytoplasmic receptors for steroid hormones.
The term “modulation” refers to the capacity to either enhance or inhibit a functional property of a biological activity or process, for example, receptor binding or signaling activity. Such enhancement or inhibition may be contingent on the occurrence of a specific event, such as activation of a signal transduction pathway and/or may be manifest only in particular cell types. A “modulator” of a protein refers to a wide range of molecules (e.g., antibody, nucleic acid fragment, small molecule, peptide, oligopeptide, polypeptide, or protein) and/or conditions which can, either directly or indirectly, exert an influence on the activation and/or repression of the protein (e.g., receptor of interest), including physical binding to the protein, alterations of the quantity or quality of expression of the protein, altering any measurable or detectable activity, property, or behavior of the protein, or in any way interacts with the protein or compound.
The term “inhibit” refers to the act of diminishing, suppressing, alleviating, preventing, reducing or eliminating, whether partial or whole, a function or an activity. For example, inhibition of gene transcription or expression refers to any level of downregulation of these functions, including complete elimination of these functions. The term “inhibit” can be applied to both in vitro as well as in vivo systems. As used herein, the term “inhibitor” or “repressor” refer to any agent that inhibits.
The term “small molecule” refers to a synthetic or naturally occurring chemical compound, for instance a peptide or oligonucleotide that may optionally be derivatized, natural product or any other low molecular weight (typically less than about 5 KD) organic, bioinorganic or inorganic compound, of either natural or synthetic origin. Such small molecules may be a therapeutically deliverable substance or may be further derivatized to facilitate delivery.
The term “inducer” refers to any agent that induces, enhances, promotes or increases a specific activity, such as lipid metabolism, or LXR molecule expression.
The term “agent” or “test agent” or “test sample” refers to any molecule or combination of more than one molecule that is to be tested.
Examples of agents of the present invention include but are not limited to peptides, proteins, small molecules, and antibodies. Nucleotide fragments and portions, as well as antisense embodiments described, above may also serve as agents, if desired. Agents can be randomly selected or rationally selected or designed. As used herein, an agent is said to be “randomly selected” when the agent is chosen randomly without considering the specific interaction between the agent and the target compound or site. As used herein, an agent is said to be “rationally selected or designed,” when the agent is chosen on a non-random basis that takes into account the specific interaction between the agent and the target compound or site and/or the conformation in connection with the agent's action.
The term “biological sample” is broadly defined to include any cell, tissue, biological fluid, organ, multi-cellular organism, and the like. A biological sample may be derived, for example, from cells or tissue cultures in vitro. Alternatively, a biological sample may be derived from a living organism or from a population of single-cell organisms. A biological sample may be a live tissue such as liver. The term “biological sample” is also intended to include samples such as cells, tissues or biological fluids isolated from a subject, as well as samples present within a subject. That is, the detection method of the invention can be used to detect LXR variant mRNA, protein, genomic DNA, or activity in a biological sample in vitro as well as in vivo. For example, in vitro techniques for detection of LXR variant mRNA include TaqMan analysis, northern hybridization, and in situ hybridization. In vitro techniques for detection of LXRα protein include enzyme-linked immunosorbent assays (ELISAs), western blots, immunoprecipitations and immunofluorescence. In vitro techniques for detection of LXR variant genomic DNA include southern hybridizations.
The term “test sample” refers to a biological sample from a subject of interest. For example, a test sample can be a cell sample or tissue sample. A “test sample” and “biological sample” are used interchangeably herein.
The term “body fluid” refers to any body fluid including, without limitation, serum, plasma, lymph fluid, synovial fluid, follicular fluid, seminal fluid, amniotic fluid, milk, whole blood, sweat, urine, cerebro-spinal fluid, saliva, sputum, tears, perspiration, mucus, tissue culture medium, tissue extracts, and cellular extracts. It may also apply to fractions and dilutions of body fluids. The source of a body fluid can be a human body, an animal body, an experimental animal, a plant, or other organism.
The terms “treatment”, “treating”, and “therapy” to any process, action, application, therapy, or the like, wherein a subject, including a human being, is provided medical aid with the object of improving the subject's condition, directly or indirectly, or slowing the progression of a condition or disorder in the subject.
Furthermore, the term “treatment” is defined as the application or administration of an agent (e.g., therapeutic agent or a therapeutic composition) to a subject, or an isolated tissue or cell line from a subject, who may have a disease, a symptom of disease or a predisposition toward a disease, with the purpose to cure, heal, alleviate, relieve, alter, remedy, ameliorate, improve or affect the disease, the symptoms of disease or the predisposition toward disease. As used herein, a “therapeutic agent” refers to any substance or combination of substances that assists in the treatment of a disease. Accordingly, a therapeutic agent includes, but is not limited to, small molecules, peptides, antibodies, ribozymes and antisense oligonucleotides.
Therapeutic agent or therapeutic compositions may also include a compound in a pharmaceutically acceptable form that prevents and/or reduces the symptoms of a particular disease. For example a therapeutic composition may be a pharmaceutical composition that prevents and/or reduces the symptoms of a lipid metabolism disorder. It is contemplated that the therapeutic composition of the present invention will be provided in any suitable form. The form of the therapeutic composition will depend on a number of factors, including the mode of administration. The therapeutic composition may contain diluents, adjuvants and excipients, among other ingredients.
The term “therapeutically effective amount” refers to the amount of a compound or composition of compounds that, when administered to a subject for treating a disease, is sufficient to effect such treatment for the disease. The “therapeutically effective amount” will vary, according to parameters known to those in the art, for example, depending on the compound, the disease, the severity of the disease, and the age, weight, or sex of the mammal to be treated.
The term “subject” refers to any mammal, including a human, or non-human subject. Non-human subjects can include experimental, test, agricultural, entertainment or companion animals.
The present invention incorporates by reference methods and techniques known in the field of molecular and cellular biology. These techniques include, but are not limited to techniques described in the following publications: Old, R. W. & S. B. Primrose, Principles of Gene Manipulation: An Introduction To Genetic Engineering (3d Ed. 1985) Blackwell Scientific Publications, Boston. Studies in Microbiology; V.2:409 pp. (ISBN 0-632-01318-4), Sambrook, J. et al. eds., Molecular Cloning: A Laboratory Manual (2d Ed. 1989) Cold Spring Harbor Laboratory Press, NY. Vols. 1-3. (ISBN 0-87969-309-6); Miller, J. H. & M. P. Calos eds., Gene Transfer Vectors For Mammalian Cells (1987) Cold Spring Harbor Laboratory Press, NY (ISBN 0-87969-198-0). The DNA coding for the protein of the present invention may be any one provided that it comprises the nucleotide sequence coding for the above-mentioned protein of the present invention.
Nucleic Acid Molecules
The present invention relates to isolated nucleic acid molecules that encode three novel LXRα variant proteins (i.e., LXRα-64, LXRα-42e + , and LXRα-42e − ). Also included are nucleic acid molecules having at least 90% sequence identity to an LXRα variant protein or a fragment thereof, degenerate variants of an LXRα variant, variants that encode an LXRα-64, LXRα-42e + , and LXRα-42e − protein having conservative or moderately conservative substitutions, cross-hybridizing nucleic acids (e.g., that hybridize under conditions of high stringency), and fragments thereof.
The sequences of the present invention are presented, respectively, in SEQ ID NO:3 (full length nucleotide sequence of LXRα-64, cDNA), SEQ ID NO:4 (full length amino acid sequence of LXRα-64), SEQ ID NO:5 (nucleotide sequence encoding the entirety of LXRα-42e + ), SEQ ID NO:6 (full length amino acid sequence of LXRα-42e + ), SEQ ID NO:7 (nucleotide sequence encoding the entirety of LXRα-42e − ), SEQ ID NO:8 (full length amino acid sequence of LXRα-42e − ), SEQ ID NO:16 (unique nucleotide sequence of LXRα-64 variant that connects exon 6 and 7 of wild type LXRα and creates a bigger exon 6 in LXRα-64 variant compared to exon 6 of the wild type LXRα), SEQ ID NO:17 (deduced amino acid sequence encoded by SEQ ID NO:16), SEQ ID NO:18 (unique nucleotide sequence of LXRα-42e that combines with exon 8 of wild type LXRα to create a longer exon 8 in LXRα-42e variants compared the exon 8 of wild type LXRα), and SEQ ID NO:19 (the deduced amino acid sequence encoded by SEQ ID NO:18).
The nucleic acids of the present invention can be produced by polymerase chain reaction (PCR). Such reactions are known to one of skill in the art, e.g., U.S. Pat. Nos. 4,754,065; 4,800,159; 4,683,195, and 4,683,202 provide PCR techniques and methods. These U.S. patents are hereby incorporated by reference in their entirety.
In another embodiment of the present invention, an LXRα-64, LXRα-42e + or LXRα-42e − nucleic acid molecule is a synthetic nucleic acid or a mimetic of a nucleic acid that may have increased bioavailability, stability, potency, or decreased toxicity compared to a naturally occurring LXRα variant. Such synthetic nucleic acids may have alterations of the basic A, T, C, G, or U bases or sugars that make up the nucleotide polymer to as to alter the effect of the nucleic acid.
LXRα variant and nucleic acid fragments derived from LXRα variants described herein can be used as reagents in isolation procedures, diagnostic assays, and forensic procedures. For example, sequences from an LXRα-64, LXRα-42e + or LXRα-42e − polynucleotide described herein to which they can hybridize (e.g., under stringent hybridization conditions) can be detectably labeled and used as a probe to isolate other sequences. In addition, sequences from an LXRα-64, LXRα-42e + , or LXRα-42e − polynucleotide can be used to design PCR primers for use in isolation, diagnostic, or forensic procedures.
The LXRα-64, LXRα-42e + , and LXRα-42e − nucleic acid molecules described herein can also be used to clone sequences located upstream of the LXRα variant sequences on corresponding genomic DNA. Such upstream sequences may be capable of regulating gene expression, and may include, e.g., promoter sequences, enhancer sequences, or other upstream sequences that influence transcription or translation levels. Once identified and cloned, these upstream regulatory sequences can be used in expression vectors designed to direct the expression of an inserted gene in a desired spatial, temporal, developmental, or quantitative fashion.
Sequences derived from polynucleotides described herein can be used to isolate the promoters of the corresponding genes using chromosome walking techniques. Chromosome walking techniques are known in the art, e.g., the GenomeWalker® kit available from BD Biosciences Clontech (Palo Alto, Calif.), which may be used according to the manufacturer's instructions.
Once the upstream genomic sequences have been cloned and sequenced, prospective promoters and transcription start sites within the upstream sequences may be identified by comparing the sequences upstream of the polynucleotides of the inventions with databases containing known transcription start sites, transcription factor binding sites, or promoter sequences.
In addition, promoters in the upstream sequences may be identified using promoter reporter vectors as follows: The expression of a reporter gene is detected when placed under the control of regulatory active polynucleotide fragment or variant of the LXRα-64, LXRα-42e + and LXRα-42e − promoter region located upstream of the first exon of the LXRα-64, LXRα-42e + , or LXRα-42e − genes. Suitable promoter reporter vectors, into which the LXRα-64, LXRα-42e + , or LXRα-42e − promoter sequences may be cloned include pSEAP-Basic, pSEAP-Enhancer, pβgal-Basic, pβgal-Enhancer, or pEGFP-1 Promoter Reporter vectors available from Clontech, or pGL2-basic or pGL3-basic promoterless luciferase reporter gene vector from Promega. Briefly, each of these promoter reporter vectors include multiple cloning sites positioned upstream of a reporter gene encoding a readily assayable protein such as secreted alkaline phosphatase, luciferase, beta-galactosidase, or green fluorescent protein. The sequences upstream an LXRα-64, LXRα-42e + , or LXRα-42e − coding region are inserted into the cloning sites upstream of the reporter gene in both orientations and introduced into an appropriate host cell. The level of reporter protein is assayed and compared to the level obtained from a vector that lacks an insert in the cloning site. The presence of an elevated expression level by the vector containing the insert with respect to the control vector indicates the presence of a promoter in the insert. In some cases, the upstream sequences are cloned into vectors that contain an enhancer for increasing transcription levels from weak promoter sequences. A significant level of expression by the insert-containing vector above that observed for the vector lacking an insert indicates that a promoter sequence is present in the inserted upstream sequence. Promoter sequence within the upstream genomic DNA may be further defined by site directed mutagenesis, linker scanning analysis, or other techniques familiar to those in the art.
The strength and the specificity of the promoter of each LXRα-64, LXRα-42e + and LXRα-42e − gene can be assessed through the expression levels of a detectable polynucleotide operatively linked to the LXRα-64, LXRα-42e + , or LXRα-42e − promoters in different types of cells and tissues. The detectable polynucleotide may be either a polynucleotide that specifically hybridizes with a predefined oligonucleotide probe, or a polynucleotide encoding a detectable protein, including LXRα-64, LXRα-42e + and LXRα-42e − polypeptides or fragments or variants thereof. This type of assay is well known to those skilled in the art. Some of the methods are discussed in more detail elsewhere in the application.
The promoters and other regulatory sequences located upstream of the polynucleotides of the inventions may be used to design expression vectors capable of directing the expression of an inserted gene in a desired spatial, temporal, developmental, or quantitative manner. A promoter capable of directing the desired spatial, temporal, developmental, and quantitative patterns may be selected using the results of the expression analysis described herein. For example, if a promoter that confers a high level of expression in muscle is desired, the promoter sequence upstream of a polynucleotide of the invention derived from an mRNA that is expressed at a high level in muscle may be used in the expression vector.
Furthermore, nucleic acid fragments of the invention may be used to isolate and/or purify nucleic acids similar thereto using any methods well known to those skilled in the art including the techniques based on hybridization or on amplification described in this section. These methods may be used to obtain the genomic DNAs which encode the mRNAs from which the LXRα-64, LXRα-42e + and LXRα-42e − cDNAs are derived, mRNAs corresponding to LXRα-64, LXRα-42e + and LXRα-42e − cDNAs, or nucleic acids which are homologous to LXRα-64, LXRα-42e + and LXRα-42e − cDNAs or fragments thereof, such as variants, species homologues or orthologs.
Alternatively the nucleic acid fragments and genes of the present invention can be used as a reference to identify subjects (e.g., mammals, humans, patients) expressing decreases of functions associated with these receptors.
Vectors and Host Cells
The present invention relates to the vectors that include polynucleotides of the present invention, host cells that genetically engineered with vectors of the present invention such as cloning vector or expression vector and to the production of polypeptides of the present invention by recombinant techniques. For example, LXRα-64, LXRα-42e + and LXRα-42e − nucleic acid molecule could be linked to a vector. The vector may be a self-replicating vector or a replicative incompetent vector. The vector may be a pharmaceutically acceptable vector for methods of gene therapy.
The present invention further relates to a method of production of the polypeptides of the present invention by expressing polynucleotides encoding the polypeptides of the present invention in a suitable host and recovering the expressed products employing known recombinant techniques. The polypeptides of the present invention can also be synthesized using peptide synthesizers. Host cells can be engineered with the vectors of the present invention. The host organism (recombinant host cell) may be any eukaryotic or prokaryotic cell, or multicellular organism. Alternative embodiments can employ mammalian or human cells, especially embryonic mammalian and human cells. Suitable host cells include but are not limited to mammalian cells such as Human Embryonic Kidney cells (HEK 293), Human hepatoma cells (HepG2), Chinese hamster ovary cells (CHO), the monkey COS-1 cell line, the mammalian cell CV-1), amphibian cells (e.g., Xenopus egg cell). Yeast cells ( Saccharomyces cerevisiae, Schizosaccharomyces pombe, Pichia pastoris ), and insect cells. Furthermore, various strains of E. coli (e.g., DH5□ HB101, MC1061) may be used as host cells in particular for molecular biological manipulation.
The vectors may be cloning vectors or expression vectors such as in the form of a plasmid, a cosmid, or a phage or any other vector that is replicable and viable in the host cell. The engineered host cells can be cultured in conventional nutrient media modified as appropriate for activating promoters, selecting transformants or amplifying a polynucleotide of the present invention. The culture conditions such as pH, temperature, and the like, are those suitable for use with the host cell selected for expression of the polynucleotide are known to the ordinarily skilled in the art.
Plasmids generally are designated herein by a lower case “p” preceded and/or followed by capital letters and/or numbers, in accordance with standard naming conventions that are familiar to those of skill in the art. The plasmids herein are either commercially available, publicly available on unrestricted bases, or can be constructed from available plasmids by routine application of well-known, published procedures. Additionally, many plasmids and other cloning and expression vectors that can be used in accordance with the present invention are well known and readily available to those of skill in the art. Moreover, those of skill readily may construct any number of other plasmids suitable for use in the invention. The properties, construction and use of such plasmids, as well as other vectors, in the present invention will be readily apparent to those of skill from the present disclosure.
The appropriate DNA sequence may be inserted into the vector by a variety of the procedures known in the art.
The DNA sequence in the expression vector may be operatively linked to an appropriate expression control sequence(s) (promoter) to direct mRNA synthesis. Such promoters include but are not limited to SV40, human cytomegalovirus (CMV) promoters (e.g., pCMV/myc vectors, pcDNA 3.1 vector or any form of the pcDNA series), SP6, T7, and T3 RNA polymerase promoters. The expression vector may also include a ribosome binding site for translation initiation, a transcription terminator, and an appropriate sequence for amplifying the expression. The expression vector may also include one or more selectable marker genes to provide a specific phenotype for the selection of transformed host cells such as neomycin resistance for eukaryotic cells or ampicillin resistance for E. coli.
The expression vectors may include at least one selectable marker. Such markers include but are not limited to dihydrofolate reductase or neomycin resistance for eukaryotic cell culture and tetracycline or ampicillin resistance genes for culturing in E. coli and other bacteria. Representative examples of appropriate hosts include, but are not limited to, bacterial cells, such as E. coli, Streptomyces , and Salmonella typhimurium cells; fungal cells, such as yeast cells; insect cells such as Drosophila S2 and Spodoptera Sf9 cells; animal cells such as CHO, Cos, and Bowes melanoma cells; and plant cells. Appropriate culture media and conditions for the above-described host cells are known in the art.
Illustrative examples of vectors for use in bacteria include, but are not limited to, pA2, pQE70, pQE60 and pQE-9, available from Qiagen (Valencia, Calif.); pBS vectors, Phagescript vectors, Bluescript™ vectors, pNH8A, pNH16a, pNH18A, pNH46A, available from Stratagene (Cedar Creek, Tex.); and pGEMEX®-1, pGEMEX®-2, PinPoint™ X series, pET-5 series, available from Promega (Madison, Wis.). Eukaryotic vectors include, but are not limited to, pWLNEO, pSV2CAT, pOG44, pXT1, and pSG, available from Stratagene; and pSVK3, pBPV, pMSG, and pSVL available from Pharmacia. Other suitable vectors will be apparent to the skilled artisan.
The gene can be placed under the control of a promoter, ribosome binding site (for bacterial expression), suitable gene control sequence, or regulatory sequences so that the DNA sequence encoding the protein is transcribed into RNA in the host cell transformed by a vector containing the expression construct. Such promoters include but are not limited to SV40, human cytomegalovirus (CMV) promoters (e.g., pCMV/myc vectors, pcDNA 3.1 vector or any form of the pcDNA series), SP6, T7, and T3 RNA polymerase promoters. In some cases it may be desirable to add sequences that cause the secretion of the polypeptide from the host cell, with subsequent cleavage of the secretory signal.
For some applications, it is desirable to reduce or eliminate expression of genes encoding a polypeptide of the present invention. To accomplish this, a chimeric gene or a chimeric construct designed for co-suppression of the instant polypeptide can be constructed by linking a gene or gene fragment encoding that polypeptide to a promoter sequences. Alternatively, a chimeric gene or chimeric construct designed to express antisense RNA for all or part of the instant nucleic acid fragment can be constructed by linking the gene or gene fragment in reverse orientation to a promoter sequences. Either the co-suppression or antisense chimeric genes can be introduced into desired host cell via transformation wherein expression of the corresponding endogenous genes are reduced or eliminated.
Polypeptides
LXRα variant polypeptides are useful for a variety of applications, including but not limited to producing antibodies (e.g., that specifically bind to an LXRα variant), modulating LXR wild type activity, and altering fatty acid and cholesterol metabolism (e.g., by modulating gene expression of enzymes that regulate fatty acid and cholesterol metabolism in a cell in which the LXRα variant is expressed). LXRα variant polypeptides are also useful for identifying compounds that differentially bind to LXRα wild type polypeptides and LXRα variant polypeptides. Such compounds are candidate compounds for differentially regulating metabolic activities associated with LXRα.
The polypeptides of the present invention can be produced by growing suitable host cells transformed by an expression vector described above under conditions whereby the polypeptide of interest is expressed. The polypeptides can then be isolated and purified. Methods purifying proteins from cell cultures are known in the art and include, but not limited to, ammonium sulfate precipitation, anion or cation exchange chromatography, and affinity chromatography.
Cell-free translation systems can also be employed to produce the polypeptides of the present invention using the RNAs derived from the polynucleotides of the present invention.
The polypeptides of the present invention can be produced by growing suitable host cells transformed by an expression vector (e.g., as described herein) under conditions whereby the polypeptide of the interest is expressed. The polypeptide may then be isolated and purified. Methods of the purification of proteins from cell cultures are known in the art and include but are not limited to ammonium sulfate precipitation, anion or cation exchange chromatography, and affinity chromatography.
Cell-free translation systems may also be employed to produce the polypeptides of the present invention using the RNAs derived from the polynucleotides of the present invention.
Large-scale production of cloned LXRα-64, LXRα-42e + , and LXRα-42e − can enable the screening of large numbers of LXRα-64, LXRα-42e + , and LXRα-42e − analogs, and can facilitate the development of new or improved agonists and antagonists for the treatment of lipid metabolism disorders. More specifically, the screening of large numbers of analogs for LXRα-64, LXRα-42e + , and LXRα-42e − activity could lead to development of improved drugs affecting lipid metabolism. Lipid metabolism disorders and conditions include but are not limited to atherosclerosis, diabetes, obesity, Alzheimer's disease, inflammatory disorders, and hypercholesterolemia.
For some applications it is useful to direct a polypeptide described herein to different cellular compartments, or to facilitate secretion of a polypeptide from the cell. It is thus envisioned that the chimeric gene described above may be further supplemented by altering the coding sequence to encode the instant polypeptides with appropriate intracellular targeting sequences such as transit sequences added and/or with targeting sequences that are already present removed.
Furthermore, the polypeptides of the present invention or cells expressing them can be used as immunogen to prepare antibodies using methods known to those skilled in the art. For example, a polypeptide encoded by SEQ ID NOS:3, 5, or 7 or a fragment thereof and/or a polypeptide encoded by SEQ ID NO:16 or 18, or cells expressing any of the aforementioned polypeptides can be used as immunogens. Of particular use are antibodies directed against the novel 64 amino acids of LXRα-64, which are not present in wild type LXRα. The antibodies can be polyclonal or monoclonal, and may include chimeric, single chain, and Fab fragments or the products of a Fab expression library. The antibodies are useful for detecting the polypeptide of the present invention in situ in cells or in vitro in cell extracts.
In addition, a polypeptide of the present invention can be used as a target to facilitate design and/or identification of compounds that may be useful as drugs (e.g., candidate compounds). In particular, these compounds may be used to treat diseases resulting from alterations in pathways such as bile acid synthesis, control of plasma lipoprotein composition, the transport of cholesterol from peripheral tissues to the liver, regulation of cell proliferation, differentiation, and apoptosis. In addition, the polypeptides of the present invention can be used to identify additional targets (e.g., co-activator or co-repressor proteins) that may influence LXRα. Various uses of the LXRα variants of the present invention include but are not limited to therapeutic modulation of pathophysiologic isoprenoid synthetic pathway, cholesterol metabolism, cholesterol catabolism, bile acid synthesis, and cell differentiation (e.g., gene delivery approaches, gene silencing approaches, protein therapeutics, antibody therapeutics), diagnostic utility, pharmaceutical drug targets, identification of receptor-based agonists or antagonists, and study of the molecular mechanisms of LXRα action.
Moreover, in cells with low LXRα activity due to phenotypic expression of endogenous dominant negative LXRα variants of the present invention, gene-silencing approaches such as antisense, siRNA (small interfering RNA), can be employed as strategies to induce or stimulate LXRα activity. Additionally, the novel variants of the present invention may be used to make fusion LXRα variants that may be employed toward the development of receptor-based agonists and antagonists.
Furthermore, the novel sequences of the present invention, e.g., SEQ ID NO:16, and SEQ ID NO:18, can be used to generate a dominant negative regulator of wild type LXRα. Nucleic acid molecules of SEQ ID NO:16 or 18 or fragments thereof can be incorporated into any one of the existing variants such as LXRα, and/or other nuclear receptors. The resulting new polypeptides comprising the amino acid sequence encoded by SEQ ID NO:16 and 18 or fragments thereof (e.g., the sequences set forth in SEQ ID NO:17 and 19) can generate a dominant negative regulator of wild type LXRα.
The importance of LXRs, and particularly LXRα to the delicate balance of cholesterol metabolism and fatty acid biosynthesis has led to the development of modulators of LXRs that are useful as therapeutic agents or diagnostic agents for the treatment of disorders associated with bile acid and cholesterol metabolism. The novel dominant negative LXRα variants of the present invention can be utilized to develop such therapeutic agents or diagnostic agents. Accordingly, an embodiment of the present invention is a method of treating a condition characterized by an aberrant or unwanted level of LXR (e.g., LXRα) expression, in a subject. The method includes providing the subject with a therapeutically effective amount of an LXRα-64, LXRα-42e + , or LXRα-42e − protein, homologous proteins, or fragments of an LXRα variant protein having a desirable activity such as the ability to inhabit an LXRα variant activity, or any combination thereof that can modulate an LXRα activity. The proteins may be provided by introducing into LXRα-bearing cells of the subject, a nucleic acid sequence encoding an LXRα-64, LXRα-42e + , or LXRα-42e − protein, homologous protein, or fragment, or any combinations thereof under conditions such that the cells express an LXRα-64, LXRα-42e + , or LXRα-42e − protein, homologous protein, or fragment thereof resulting in modulation of wild type LXRα receptor and/or other nuclear receptors that heterodimerize with RXR. Examples of these receptors include but are not limited to LXRα, LXRβ, PPARα, PPARγ, PPARδ, RAR, XR, and PXR.
Introduction of an LXRα variant nucleic acid into cells of a subject may comprise a) treating cells of the subject or a cultured cell or tissue suitable for transplantation into the subject (e.g., a cultured stem cell line, bone marrow cells, umbilical cord blood cells) ex vivo to insert the nucleic acid sequence into the cells; and b) introducing the cells from step a) into the subject (e.g., U.S. Pat. Nos. 6,068,836 and 5,506,674).
The subject may be an animal such as a mammal (e.g., mouse, rat, non-human primate, dog, goat, or sheep). The mammalian subject can be a human.
LXRs function as heterodimers with the retinoid X receptors (RXRs). Moreover, RXRs are unique in their ability to function as both homodimeric receptors and as heterodimeric partners (e.g., LXRα, LXRβ, PPARα, PPARγ, PPARδ, RAR, XR, and PXR (Miyata et al., J. Biol. Chem., 271 9189-9192, 1996)) in multiple hormone responsive pathways. LXR variants of the present invention, LXR64, LXRα-42e + , and LXRα-42e − can heterodimerize with RXR. Thus, for example, where LXR64, LXRα-42e + , and/or LXRα-42e − variants are translated, RXR will heterodimerize with these variants rather than heterodimerizing with LXRα, LXRβ, PPARα, PPARγ, PPARδ, RAR, XR, and/or PXR, or homodimerizing with itself (RXR). This reduces the pool of RXR available for heterodimerization with specific nuclear receptors, and/or homodimerizing.
Therefore, as dominant negative variants, the novel LXRα-64, LXRα-42e + , and LXRα-42e − of the present invention may be used for targeting specific receptors such as LXRα, LXRβ, PPARα, PPARγ, PPARδ, RAR, XR, or PXR. Accordingly, dominant negative LXRα variants of the present invention offer utility for therapeutic modulation of pathophysiologic conditions, diagnosis, risk for developing a disease, or treatment of a wide variety of disease states in which RXR, LXR, or other nuclear receptor (e.g., LXRα, LXRβ, PPARα, PPARγ, PPARδ, RAR, PXR, XR) mediate processes associated with the pathophysiologic condition or disease. Examples of such diseases are atherosclerosis, diabetes, obesity, cancer, and drug metabolism disorders.
Furthermore, LXRα variants of the present invention can modulate target gene expression or target gene product activity by interacting with wild-type LXRα binding partners such as RXR. LXR or RXR activity, as used herein, refers to modulation of LXR (e.g., LXRα) or RXR target gene expression or activity, respectively.
In one embodiment, target gene specificity of RXR-containing cells can be altered by contacting the cells with at least one of the novel LXRα variants of the present invention. In one specific embodiment, the RXR-containing cell, target genes operatively associated with response element(s) having the sequence 5′-AGGTTAnnnnTGGTCA-3′ (SEQ ID NO:15), wherein each “n” is independently selected from A, G, T or C, can be activated by contacting the cells with at least one of the novel LXRα variants of the present invention.
The effect of LXRα variants of the present invention on homodimerization or heterodimerization processes can be determined using various methods known in the art. Examples of these methods are described in Terrillon et al. Molecular Endocrinology 2003, 17: 677-691, Germain-Desprez et al., J. Biol. Chem., 2003, 278 (25) 22367-22373, and Mercier et al., J. Biol. chem. 2002, 277 (47) 44925-44931. For example, the activity of RXR can be determined by quantitative assessment of RXR homodimerization or heterodimerization using any of the techniques in the above references. For example, nuclear receptor homo- and heterodimerization can be quantitated by fusing one of the nuclear receptors (e.g., an RXR) cDNA to the energy donor Rluc ( Renilla luciferase) at the carboxyl terminus and fusing the second nuclear receptor (e.g., an LXRα) cDNA to the energy acceptor GFP (green fluorescent protein). Using BRET technology (Biosignal Packard), which allows separation between the Renilla luciferase and the green fluorescent protein emission spectra, the homo- and heterodimerization of the nuclear receptors can be quantitated.
Furthermore, the present invention relates to methods of reducing the expression of mammalian SREBP-1 genes. The invention is based on the discovery that LXRα variants, as dominant negatives, inhibit wild-type LXRα and correspondingly can inhibit SREBP-1 expression in mammalian cells. The latter conclusion can readily be confirmed by assessing SREBP-1 gene expression in the presence and absence of the variants of the present invention. Abnormal expression of SREBP-1 gene is involved in conditions such as lipodystrophy, hyperglyceremia, hypertriglyceridemia and diabetes. The variants of the present invention are useful not only for therapeutic and prophylactic treatment of conditions that are mediated by SREBP-1 over-expression, but are also useful for investigation of the mechanisms of fatty acid homeostasis, and the causes and mechanisms of lipodystrophy.
Antibodies
The invention also provides an isolated and purified antibody, e.g., a monoclonal antibody or polyclonal antibody, including an idiotypic or anti-idiotypic antibody, which is specific for a novel LXRα variant. The polypeptides of the present invention or cells expressing them may be used as immunogen to prepare antibodies by methods known to those skilled in the art. For example, these polypeptides encoded by SEQ ID NOS:3, 5, 7, 16, or 18 or any portion of SEQ ID NOS:3, 5, 7, 16, or 18 and/or encoded by SEQ ID NO:3, 5, 7, 16, or 18 or cells expressing any of the aforementioned polypeptides may be used as immunogens. These antibodies can be polyclonal or monoclonal and may include chimeric, single chain, and Fab fragments or the products of the Fab expression library. The antibodies are useful for detecting the polypeptide of the present invention in situ in cells or in vitro in cell extracts. In general, an antibody specifically binds to a specific peptide or molecule. By “specifically binds” or “selectively binds” is meant a molecule that binds to a particular entity, e.g., an LXRα variant polypeptide in a sample, but which does not substantially recognize or bind to other molecules in the sample, e.g., a biological sample, which includes the particular entity.
For example, the antibody may specifically recognize the novel 64 amino acids of the novel variant. Rabbits are immunized with a peptide comprising SEQ ID NO:4 or an immunogenic portion thereof, or a fusion peptide comprising SEQ ID NO:4, and polyclonal antisera specific for the novel variants isolated. Alternatively, spleen cells from immunized animals are fused to myeloma cells to produce hybridomas. The hybridomas are then screened to identify ones secreting a monoclonal antibody specific for a polypeptide or peptide comprising the 64 amino acid sequences of the novel LXRα-64 variant. These antibodies are useful to detect the novel LXRα-64 variants in biological samples, e.g., clinical samples, to detect the relative amount of the novel variant to other variant.
Screening Assays
In general, the new methods described herein include methods of identifying compounds that can modulate the expression or activity of an LXRα variant. In some cases, the compounds are identified that modulate the expression or activity of an LXRα variant and either do not affect, or affect to a lesser extent, the expression or activity of a wild type LXRα.
Also included are methods of producing LXRα (e.g., large-scale production) of cloned LXRα would enable the screening of relatively large numbers of LXRα analogs, and would facilitate the development of new or improved agonists and antagonists in the clinical therapy of -scale production of cloned LXRα would enable the screening of large numbers of LXRα related disorders such as lipid metabolism disorders. More specifically, the screening of large numbers of analogs for scale production of cloned LXRα would enable the screening of large numbers of LXRα activity could lead to development of improved tools and drugs for use in diagnosis and clinical therapy of, e.g., lipodystrophy, hypertriglyceridemia, hyperglyceremia, diabetes, or hypercholesterolemia.
In one embodiment, the polypeptides of the present invention are used as targets to facilitate design and/or identification of compounds that modulate the expression or activity of the polypeptides, e.g., by binding to a polypeptide. Such compounds are candidate compounds for treating disorders associated with LXRα-mediated pathways, e.g., can be used as drugs to regulate one or more aspects of an LXRα pathway. In particular, such compounds can be used to treat diseases resulting from alterations in hormone responsive pathways such as diabetes and drug metabolism disorders. In addition, the polypeptides of the present invention can be used to identify additional targets (e.g., co-activator or co-repressor proteins) that may influence hormone signaling. Various uses of the LXRα variants of the present invention include but are not limited to therapeutic modulation of pathophysiologic conditions involving aberrant lipid metabolism (e.g., gene delivery approaches, gene silencing approaches, protein therapeutics antibody therapeutics), diagnostic utility, pharmaceutical drug targets, identification of receptor-based agonists or antagonists, and study of the molecular mechanisms of LXRα action.
The systematic study of LXRα variants will make it possible to deduce structure-activity relationships for the proteins in question. Knowledge of these variants with respect to the disease studied is fundamental, since it makes it possible to understand the molecular cause of the pathology. Furthermore, the novel LXRα variants may be used for targeting of specific receptor interactions as a distinct approach in identification of tissue selective nuclear receptor modulators such as LXRα, LXRβ, PPARα, PPARγ, PPARδ, RAR, XR, and PXR.
Accordingly, the invention provides methods (also referred to herein as “screening assays”) for identifying modulators, i.e., candidate compounds or agents (e.g., proteins, peptides, peptidomimetics, peptoids, small molecules, or other drugs) that bind to LXRα variant proteins, have a stimulatory or inhibitory effect on, for example, LXRα variant expression or activity, or have a stimulatory or inhibitory effect on, for example, the expression or activity of an LXRα variant substrate. Compounds thus identified can be used to modulate the activity of target gene products (e.g., LXRα variant genes) in a therapeutic protocol, to elaborate the biological function of the target gene product, or to identify compounds that disrupt normal target gene interactions.
In one embodiment, the invention provides assays for screening candidate or test compounds that are substrates of an LXRα variant protein or polypeptide or a biologically active portion thereof. In another embodiment, the invention provides assays for screening candidate or test compounds that bind to or modulate the activity of an LXRα variant protein or polypeptide or a biologically active portion thereof.
The test compounds of the present invention can be obtained, for example, using any of the numerous approaches in combinatorial library methods known in the art, including biological libraries; peptoid libraries (libraries of molecules having the functionalities of peptides, but with a novel, non-peptide backbone that are resistant to enzymatic degradation but that nevertheless remain bioactive; see, e.g., Zuckermann et al. (1994) J. Med. Chem. 37:2678-85); spatially addressable parallel solid phase or solution phase libraries; synthetic library methods requiring deconvolution; the ‘one-bead one-compound’ library method; and synthetic library methods using affinity chromatography selection. The biological library and peptoid library approaches are limited to peptide libraries, while the other four approaches are applicable to peptide, non-peptide oligomer or small molecule libraries of compounds (Lam (1997) Anticancer Drug Des. 12:145).
Examples of methods for the synthesis of molecular libraries can be found in the art, for example in: DeWitt et al. (1993) Proc. Natl. Acad. Sci. U.S.A. 90:6909; Erb et al. (1994) Proc. Natl. Acad. Sci. USA 91:11422; Zuckermann et al. (1994) J. Med. Chem. 37:2678; Cho et al. (1993) Science 261:1303; Carrell et al. (1994) Angew. Chem. Int. Ed. Engl. 33:2059; Carell et al. (1994) Angew. Chem. Int. Ed. Engl. 33:2061; and in Gallop et al. (1994) J. Med. Chem. 37:1233.
Libraries of compounds may be presented in solution (e.g., Houghten (1992) Biotechniques 13:412-421), or on beads (Lam (1991) Nature 354:82-84), chips (Fodor (1993) Nature 364:555-556), bacteria (Ladner, U.S. Pat. No. 5,223,409), spores (Ladner, supra), plasmids (Cull et al. (1992) Proc. Natl. Acad. Sci. USA 89:1865-1869) or on phage (Scott and Smith (1990) Science 249:386-390; Devlin (1990) Science 249:404-406; Cwirla et al. (1990) Proc. Natl. Acad. Sci. 87:6378-6382; Felici (1991) J. Mol. Biol. 222:301-310; Ladner supra.).
In one embodiment, an assay is a cell-based assay in which a cell that expresses an LXRα variant protein or biologically active portion thereof is contacted with a test compound, and the ability of the test compound to modulate a LXRα variant activity is determined. Determining the ability of the test compound to modulate LXRα variant activity can be accomplished by monitoring, for example, dominant negative activity of the LXRα variant in a cell expressing a wild type LXRα, e.g., by monitoring the expression of an LXRα-inducible gene or gene product. The cell, for example, can be of mammalian origin, e.g., human.
The ability of the test compound to modulate LXRα variant binding to a compound, e.g., a naturally occurring LXRα variant ligand, or to bind to an LXRα variant can also be evaluated. This can be accomplished, for example, by coupling the compound with a radioisotope or enzymatic label such that binding of the compound to the LXRα variant can be determined by detecting the labeled compound in a complex. Alternatively, an LXRα variant can be coupled with a radioisotope, enzymatic label, or engineered to include a peptide label to monitor the ability of a test compound to modulate LXRα variant binding to, e.g., an LXRα variant, wild type LXRα, or heterodimerize with another member of the steroid receptor superfamily in a complex. For example, compounds can be labeled with 125 I, 35 S, 14 C, or 3 H, either directly or indirectly, and the radioisotope detected by direct counting of radioemmission or by scintillation counting. Alternatively, compounds can be enzymatically labeled with, for example, horseradish peroxidase, alkaline phosphatase, or luciferase, and the enzymatic label detected by determination of conversion of an appropriate substrate to product.
The ability of a compound to interact with an LXRα variant, with or without the labeling of any of the interactants, can be evaluated. For example, a microphysiometer can be used to detect the interaction of a compound with an LXRα variant without the labeling of either the compound or the LXRα variant (e.g., McConnell et al. (1992) Science 257:1906-1912). As used herein, a “microphysiometer” (e.g., Cytosensor) is an analytical instrument that measures the rate at which a cell acidifies its environment using a light-addressable potentiometric sensor (LAPS). Changes in this acidification rate can be used as an indicator of the interaction between a compound and an LXRα variant.
In yet another method, a cell-free assay is provided in which an LXRα variant protein or biologically active portion thereof is contacted with a test compound and the ability of the test compound to bind to the LXRα variant protein or biologically active portion thereof is evaluated. Preferred biologically active portions of the LXRα variant proteins to be used in assays include fragments that participate in interactions with LXRα variant molecules, non-LXRα variant molecules (e.g., fragments with high surface probability scores), and predicted ligand binding domains of an LXRα variant.
Soluble and/or membrane-bound forms of isolated proteins (e.g., LXRα variant proteins or biologically active portions thereof) can be used in the cell-free assays of the invention.
Cell-free assays involve preparing a reaction mixture of the target gene protein and the test compound under conditions and for a time sufficient to allow the two components to interact and bind, thus forming a complex that can be removed and/or detected using methods known in the art.
The interaction between two molecules can also be detected, e.g., using fluorescence energy transfer (FET) (see, for example, Lakowicz et al., U.S. Pat. No. 5,631,169; Stavrianopoulos, et al., U.S. Pat. No. 4,868,103). A fluorophore label on the first, ‘donor’ molecule is selected such that its emitted fluorescent energy will be absorbed by a fluorescent label on a second, ‘acceptor’ molecule, which in turn is able to fluoresce due to the absorbed energy. Alternately, the ‘donor’ protein molecule may simply utilize the natural fluorescent energy of tryptophan residues. Labels are chosen that emit different wavelengths of light, such that the ‘acceptor’ molecule label may be differentiated from that of the ‘donor’. Since the efficiency of energy transfer between the labels is related to the distance separating the molecules, the spatial relationship between the molecules can be assessed. In a situation in which binding occurs between the molecules, the fluorescent emission of the ‘acceptor’ molecule label in the assay should be maximal. An FET binding event can be conveniently measured through standard fluorometric detection means well known in the art (e.g., using a fluorimeter).
In another embodiment, determining the ability of the LXRα variant protein to bind to a target molecule can be accomplished using real-time Biomolecular Interaction Analysis (BIA) (e.g., Sjolander and Urbaniczky (1991) Anal. Chem. 63:2338-2345 and Szabo et al. (1995) Curr. Opin. Struct. Biol. 5:699-705). “Surface plasmon resonance” or “BIA” detects biospecific interactions in real time, without labeling any of the interactants (e.g., BIAcore). Changes in the mass at the binding surface (indicative of a binding event) result in alterations of the refractive index of light near the surface (the optical phenomenon of surface plasmon resonance (SPR)), resulting in a detectable signal that can be used as an indication of real-time reactions between biological molecules.
In one embodiment, the target gene product (e.g., an LXRα variant protein or fragment thereof) or the test substance is anchored onto a solid phase. The target gene product/test compound complexes anchored on the solid phase can be detected at the end of the reaction. In general, the target gene product can be anchored onto a solid surface, and the test compound (which is not anchored) can be labeled, either directly or indirectly, with detectable labels discussed herein.
It may be desirable to immobilize an LXR(X variant, an anti-LXRα variant antibody, or its target molecule to facilitate separation of complexed from uncomplexed forms of one or both of the proteins, as well as to accommodate automation of the assay. Binding of a test compound to an LXRα variant protein, or interaction of an LXRα variant protein with a target molecule in the presence and absence of a candidate compound, can be accomplished in any vessel suitable for containing the reactants. Examples of such vessels include microtiter plates, test tubes, and micro-centrifuge tubes. In one embodiment, a fusion protein can be provided that adds a domain that allows one or both of the proteins to be bound to a matrix. For example, glutathione-S-transferase/LXRα variant fusion proteins or glutathione-S-transferase/target fusion proteins can be adsorbed onto glutathione Sepharose™ beads (Sigma Chemical, St. Louis, Mo.) or glutathione derivatized microtiter plates, which are then combined with the test compound or the test compound and either the non-adsorbed target protein or LXRα variant protein, and the mixture incubated under conditions conducive to complex formation (e.g., at physiological conditions for salt and pH). Following incubation, the beads or microtiter plate wells are washed to remove any unbound components, the matrix immobilized in the case of beads, complex determined either directly or indirectly, for example, as described above. Alternatively, the complexes can be dissociated from the matrix, and the level of LXRα variant binding or activity determined using standard techniques.
Other techniques for immobilizing either a LXRα variant protein or a target molecule on matrices include using conjugation of biotin and streptavidin. Biotinylated LXRα variant protein or target molecules can be prepared from biotin-NHS (N-hydroxy-succinimide) using techniques known in the art (e.g., biotinylation kit, Pierce Chemicals, Rockford, Ill.), and immobilized in the wells of streptavidin-coated 96 well plates (Pierce Chemical).
To conduct the assay, the non-immobilized component is added to the coated surface containing the anchored component. After the reaction is complete, unreacted components are removed (e.g., by washing) under conditions such that any complexes formed will remain immobilized on the solid surface. The detection of complexes anchored on the solid surface can be accomplished in a number of ways. Where the previously non-immobilized component is pre-labeled, the detection of label immobilized on the surface indicates that complexes were formed. Where the previously non-immobilized component is not pre-labeled, an indirect label can be used to detect complexes anchored on the surface; e.g., using a labeled antibody specific for the immobilized component (the antibody, in turn, can be directly labeled or indirectly labeled with, e.g., a labeled anti-Ig antibody).
In one embodiment, this assay is performed utilizing antibodies reactive with an LXRα variant protein or target molecules but which do not interfere with binding of the LXRα variant protein to its target molecule. Such antibodies can be derivatized to the wells of the plate, and unbound target or LXRα variant protein trapped in the wells by antibody conjugation. Methods for detecting such complexes, in addition to those described above for the GST-immobilized complexes, include immunodetection of complexes using antibodies reactive with the LXRα variant protein or target molecule, as well as enzyme-linked assays that rely on detecting an enzymatic activity associated with the LXRα variant protein or target molecule.
Alternatively, cell free assays can be conducted in a liquid phase. In such an assay, the reaction products can be separated from unreacted components by any of a number of techniques known in the art, including but not limited to differential centrifugation (for example, Rivas and Minton, (1993) Trends Biochem Sci 18:284-7); chromatography (gel filtration chromatography, ion-exchange chromatography); electrophoresis (e.g., Ausubel et al., eds. Current Protocols in Molecular Biology 1999, J. Wiley: New York.); and immunoprecipitation (for example, Ausubel et al., eds. (1999) Current Protocols in Molecular Biology , J. Wiley: New York). Such resins and chromatographic techniques are known to one skilled in the art (e.g., Heegaard, (1998) J. Mol. Recognit. 11:141-8; Hage and Tweed, (1997) J. Chromatogr. B. Biomed. Sci. Appl. 699:499-525). Further, fluorescence energy transfer may also be conveniently utilized, as described herein, to detect binding without further purification of the complex from solution.
In some cases, the assay includes contacting the LXRα variant protein or biologically active portion thereof with a known compound that binds the LXRα variant (e.g., an LXRα, LXRα variant, or other member of the steroid receptor superfamily) to form an assay mixture, contacting the assay mixture with a test compound, and determining the ability of the test compound to interact with an LXRα variant protein, wherein determining the ability of the test compound to interact with an LXRα variant protein includes determining the ability of the test compound to preferentially bind to the LXRα variant or biologically active portion thereof, to disrupt the interaction between the LXRα variant and the known compound, or to modulate the activity of a target molecule, as compared to the known compound (e.g., by monitoring dominant negative activity of the LXRα variant).
The target gene products of the invention can, in vivo, interact with one or more cellular or extracellular macromolecules, such as proteins. For the purposes of this discussion, such cellular and extracellular macromolecules are referred to herein as “binding partners.” Compounds that disrupt such interactions can be useful in regulating the activity of the target gene product. Such compounds can include, but are not limited to molecules such as antibodies, peptides, and small molecules. The target genes/products for use in this embodiment are generally the LXRα variant genes identified herein. In an alternative embodiment, the invention provides methods for determining the ability of the test compound to modulate the activity of an LXRα variant protein through modulation of the activity of a downstream effector of a LXRα variant target molecule. For example, the activity of the effector molecule on an appropriate target can be determined, or the binding of the effector to an appropriate target can be determined, as previously described.
To identify compounds that interfere with the interaction between the target gene product and its cellular or extracellular binding partner(s), a reaction mixture containing the target gene product and the binding partner is prepared, under conditions and for a time sufficient, to allow the two products to form complex. In order to test an inhibitory agent, the reaction mixture is provided in the presence and absence of the test compound. The test compound can be initially included in the reaction mixture, or can be added at a time subsequent to the addition of the target gene and its cellular or extracellular binding partner. Control reaction mixtures are incubated without the test compound or with a placebo. The formation of any complexes between the target gene product and the cellular or extracellular binding partner is then detected. The formation of a complex in the control reaction, but not in the reaction mixture containing the test compound, indicates that the compound interferes with the interaction of the target gene product and the interactive binding partner. Additionally, complex formation within reaction mixtures containing the test compound and normal target gene product can also be compared to complex formation within reaction mixtures containing the test compound and mutant target gene product. This comparison can be important in those cases wherein it is desirable to identify compounds that disrupt interactions of mutant but not normal target gene products.
These assays can be conducted in a heterogeneous or homogeneous format. Heterogeneous assays involve anchoring either the target gene product or the binding partner onto a solid phase, and detecting complexes anchored on the solid phase at the end of the reaction. In homogeneous assays, the entire reaction is carried out in a liquid phase. In either approach, the order of addition of reactants can be varied to obtain different information about the compounds being tested. For example, test compounds that interfere with the interaction between the target gene products and the binding partners, e.g., by competition, can be identified by conducting the reaction in the presence of the test substance. Alternatively, test compounds that disrupt preformed complexes, e.g., compounds with higher binding constants that displace one of the components from the complex, can be tested by adding the test compound to the reaction mixture after complexes have been formed. The various formats are briefly described below.
In a heterogeneous assay system, either the target gene product or the interactive cellular or extracellular binding partner is anchored onto a solid surface (e.g., a microtiter plate), while the non-anchored species is labeled, either directly or indirectly. The anchored species can be immobilized by non-covalent or covalent attachments. Alternatively, an immobilized antibody specific for the species to be anchored can be used to anchor the species to the solid surface.
In order to conduct the assay, the partner of the immobilized species is exposed to the coated surface with or without the test compound. After the reaction is complete, unreacted components are removed (e.g., by washing) and any complexes formed will remain immobilized on the solid surface. Where the non-immobilized species is pre-labeled, the detection of label immobilized on the surface indicates that complexes were formed. Where the non-immobilized species is not pre-labeled, an indirect label can be used to detect complexes anchored on the surface; e.g., using a labeled antibody specific for the initially non-immobilized species (the antibody, in turn, can be directly labeled or indirectly labeled with, e.g., a labeled anti-Ig antibody). Depending upon the order of addition of reaction components, test compounds that inhibit complex formation or that disrupt preformed complexes can be detected.
Alternatively, the reaction can be conducted in a liquid phase in the presence or absence of the test compound, the reaction products separated from unreacted components, and complexes detected; e.g., using an immobilized antibody specific for one of the binding components to anchor any complexes formed in solution, and a labeled antibody specific for the other partner to detect anchored complexes. Again, depending upon the order of addition of reactants to the liquid phase, test compounds that inhibit complex or that disrupt preformed complexes can be identified.
In some methods, a homogeneous assay can be used. For example, a preformed complex of the target gene product and the interactive cellular or extracellular binding partner product is prepared in that either the target gene products or their binding partners are labeled, but the signal generated by the label is quenched due to complex formation (see, e.g., U.S. Pat. No. 4,109,496 that utilizes this approach for immunoassays). The addition of a test substance that competes with and displaces one of the species from the preformed complex will result in the generation of a signal above background. In this way, test substances that disrupt target gene product-binding partner interaction can be identified.
In yet another aspect, the LXRα variant proteins can be used as “bait proteins” in a two-hybrid assay or three-hybrid assay (see, e.g., U.S. Pat. No. 5,283,317; Zervos et al. (1993) Cell 72:223-232; Madura et al. (1993) J. Biol. Chem. 268:12046-12054; Bartel et al. (1993) Biotechniques 14:920-924; Iwabuchi et al. (1993) Oncogene 8:1693-1696; and Brent WO94/10300), to identify other proteins, that bind to or interact with an LXRα variant (“LXRα variant -binding proteins” or “LXRα variant-bp”) and are involved in LXRα variant activity. Such LXRα variant-bps can be activators or inhibitors of signals (e.g., ligands) by the LXRα variant proteins or LXRα variant targets as, for example, downstream elements of a LXRα variant-mediated signaling pathway. Kits for performing such assays are commercially available (e.g., Stratagene, La Jolla, Calif.; BD Biosciences Clontech, Palo Alto, Calif.).
In another embodiment, modulators of LXRα variant expression are identified. For example, a cell or cell free mixture is contacted with a candidate compound and the expression of an LXRα variant mRNA or protein evaluated relative to the level of expression of the LXRα variant mRNA or protein in the absence of the candidate compound. When expression of the LXRα variant mRNA or protein is greater in the presence of the candidate compound than in its absence, the candidate compound is identified as a stimulator of LXRα variant mRNA or protein expression. Alternatively, when expression of the LXRα variant mRNA or protein is less (statistically significantly less) in the presence of the candidate compound than in its absence, the candidate compound is identified as an inhibitor of the LXRα variant mRNA or protein expression. The level of the LXRα variant mRNA or protein expression can be determined by methods described herein for detecting the LXRα variant mRNA or protein.
In another aspect, the invention pertains to a combination of two or more of the assays described herein. For example, a modulating agent can be identified using a cell-based or a cell free assay, and the ability of the agent to modulate the activity of an LXRα variant protein can be confirmed in vivo, e.g., in an animal such as an animal model for hypercholesterolemia, or other disorder related to fatty acid metabolism.
This invention further pertains to novel agents identified by the above-described screening assays. Accordingly, it is within the scope of this invention to further use an agent identified as described herein (e.g., an LXRα variant modulating agent, an antisense LXRα variant nucleic acid molecule, an LXRα variant-specific antibody, or an LXRα variant-binding partner) in an appropriate animal model to determine the efficacy, toxicity, side effects, or mechanism of action, of treatment with such an agent. Furthermore, novel agents identified by the above-described screening assays can be used for treatments as described herein.
Transgenic Animals
The invention also relates to non-human transgenic animals. Such animals are useful for studying the function and/or activity of an LXRα variant protein and for identifying and/or evaluating modulators of LXRα variant expression or activity. As used herein, a “transgenic animal” is a non-human animal, such as a mammal, e.g., a rodent such as a rat or mouse, in which one or more of the cells of the animal includes a transgene. Other examples of transgenic animals include non-human primates, sheep, dogs, cows, goats, chickens, amphibians, and the like. A transgene is exogenous DNA or a rearrangement, e.g., a deletion of endogenous chromosomal DNA, which generally is integrated into or occurs in the genome of the cells of a transgenic animal. A transgene can direct the expression of an encoded gene product in one or more cell types or tissues of the transgenic animal, other transgenes, e.g., a knockout, reduce expression. Thus, a transgenic animal can be one in which an endogenous LXRα variant gene has been altered by, e.g., by homologous recombination between the endogenous gene and an exogenous DNA molecule introduced into a cell of the animal, e.g., an embryonic cell of the animal, prior to development of the animal. In some cases the ortholog of the LXRα variant is identified in the animal and ortholog sequence is used to generate the transgenic animal. When homology is sufficient between the known (e.g., human) and LXRα variant gene of interest, the human sequence can be used.
Intronic sequences and polyadenylation signals can also be included in the transgene to increase the efficiency of expression of the transgene. A tissue-specific regulatory sequence(s) can be operably linked to a transgene of the invention to direct expression of an LXRα variant protein to particular cells. A transgenic founder animal can be identified based upon the presence of an LXRα variant transgene in its genome and/or expression of the LXRα variant mRNA in tissues or cells of the animals. Transgenic animals can also be identified by other characteristics associated with the transgene. For example, a transgenic animal expressing an LXRα-64 transgene will have a decreased amount of SREBP-1C expression, which is particularly notable in the presence of an LXRα agonist compared to a control animal. A transgenic founder animal can then be used to breed additional animals carrying the transgene. Moreover, transgenic animals carrying a transgene encoding an LXRα variant protein can further be bred to other transgenic animals carrying other transgenes.
LXRα variant proteins or polypeptides can be expressed in transgenic animals, e.g., a nucleic acid encoding the protein or polypeptide can be introduced into the genome of an animal. In general, the nucleic acid is placed under the control of a tissue specific promoter, e.g., a milk or egg specific promoter, and recovered from the milk or eggs produced by the animal. Suitable animals for this application include mice, pigs, cows, goats, and sheep.
The invention also includes a population of cells from a transgenic animal. Methods of isolating and propagating such cells are known in the art and include the development and propagation of primary, secondary, and immortalized cells.
EXAMPLES
The present invention is further defined in the following Examples, in which all parts and percentages are by weight and degrees are Celsius, unless otherwise stated. It should be understood that these Examples, while indicating examples of embodiments of the invention, are given by way of illustration only. From the above discussion and these Examples, one skilled in the art can ascertain the essential characteristics of this invention, and without departing from the spirit and scope thereof, can make various changes and modifications of the invention to adapt it to various usages and conditions. The Examples are not to be construed as limiting the scope or content of the invention in any way.
Example 1
Cloning of Human LXR Variants
Total RNA was isolated from THP-1 cells (human monocyte-macrophage cell line using a QIAGEN Kit (QIAGEN, Valencia, Calif.). The first-strand cDNA was synthesized from 0.1 μg of total THP-1 RNA in a 20 μL reaction mixture containing 4 μL of 5XRT reaction buffer, 10 units of Rnasin, 200 μM dNTP, 20 μM random primer, and 20 units of reverse transcriptase. The mixture was incubated at 42° C. for 1 hour and then at 53° C. for 30 minutes. The unhybridized RNA was then digested with 10 units of RNase H at 37° C. for 10 minutes. Two μL of the reverse transcriptase products were subjected to PCR amplification using human LXRα-specific primers. The primer sequences were LXRα-For: 5′-CG GTCGAC ATGTCCTTGTGGCTGGGG (SEQ ID NO:9); and LXRα-Rev: 5′-CA GCGGCCGC TTCGTGCACATCCCAGATCTC (SEQ ID NO:10) (restriction sites are underlined). Thirty-five cycles of amplification were performed in a thermocycler at 94° C. (30 seconds), 58° C. (30 seconds), and 72° C. (2 minutes). The RT-PCR products were analyzed on a 1.2% agarose gel. The same amount of total RNA was used as a template in the PCR to verify that the band was amplified from cDNA. The RT-PCR products were sub-cloned into the Sal I/Nit I sites of pCMV expression vector for sequencing. The result of sequencing the subclones was the identification of a number of novel sequences, including those termed herein LXRα-64, LXRα-42e + , AND LXRα-42e − .
Example 2
Sequencing and Preliminary Analysis of the Clone
Using the LXRα-For and LXRα-Rev primers of Example 1 (supra), three alternative variants of human LXRα were identified and cloned from human monocyte/macrophage THP-1 cells. The variants-were LXRα-64, which was found to be 64 amino acids longer than the native (wild-type) LXRα; LXRα-42e + , which has,42 amino acids different from native LXRα; and LXRα-42e − , which has 42 amino acids different from native LXRα and the sequence corresponding to exon 6 of native LXRα is missing. The comparison of nucleotide sequences and predicted amino acid sequences of the new LXRα variants with wild-type human LXRα are shown in FIGS. 1B , 2 B, and 3 B.
FIG. 1A illustrates the novel nucleotide sequence that is present in LXRα-64 that is not present in wild type LXRα (nucleotides 1121-1154). FIG. 1B illustrates the novel amino acid sequence that is present in LXRα-64 that is not present in wild type LXRα (amino acids 368-409).
FIG. 2A illustrates the novel nucleotide sequence that is present in LXRα-42e + . The missing sequence in LXRα-42e + that is present in wild type LXRα (nucleotides 1121-1154) introduces a frame shift. This results in a novel amino acid sequence in LXRα-42e + (amino acids 368-409 of LXRα-42e + ). LXRα-42e + lacks the amino acid sequence corresponding to amino acids 368-447 of wild type LXRα-42e + .
FIG. 3A depicts the complete sequence for LXRα-42e − from nucleotides 651-1220. This figure does not depict the entire sequence of wild type LXRα from the corresponding region (nucleotides 651-1166). The sequence corresponding to nucleotides 708-887 of wild type LXRα are not present in LXRα-42e − . The sequence corresponding to nucleotides 1101-1134 of LXR-42e − is not present in wild type LXRα. FIG. 3B shows sequences that are present in wild type LXRα and not in LXRα42e − (amino acids 237-296 and 368-447 of wild type LXRα) and sequences that are present only in LXRα-42e − (amino acids 308-349 of LXRα-42e − ).
The entire cDNA coding region and the predicted amino acid sequence of the new variants are shown in SEQ ID NO:3 (nucleotide sequence coding for LXRα-64), SEQ ID NO:4 (deduced amino acid sequence of LXRα-64), SEQ ID NO:5 (nucleotide sequence coding for LXRα-42e + cDNA), SEQ ID NO:6 (deduced amino acid sequence of LXRα-42e + ), SEQ ID NO:7 (nucleotide sequence coding for LXRα-42e − ), SEQ ID NO:8 (deduced amino acid sequence of LXRα-42e − ), SEQ ID NO:16 (unique nucleotide sequence of LXRα-64 that connects exons 6 and 7 of wild type LXRα, derived from intron 6, creating a larger exon 6), SEQ ID NO:17 (unique amino acid sequence in LXRα-64 and encoded by SEQ ID NO:16), SEQ ID NO:18 (the novel portion of exon 8 in LXRα-42e mRNAs that is not present in exon 8 of wild-type LXRα, and SEQ ID NO:19 (deduced amino acid sequence encoded by the additional sequence identified in LXRα-42 cDNAs).
Example 3
Gene Characterization
The genomic organization of the novel variants of the present invention, LXRα-64, LXRα-42 + and LXRα-42 − , was determined. Transcription start sites, genomic structure, alternative splicing, and functional domains of the LXRα-64, LXRα-42 + and LXRα-42 − and their comparison with wild type LXRα are described in FIGS. 4 , 5 , and 6 respectively.
FIG. 4 diagrams the structure of LXRα-64 mRNA, showing that novel sequence is incorporated into sequence corresponding to exon 6 of wild type LXRα. Therefore, a probe having the novel sequence is useful for, e.g., identifying the expression of an LXRα-64 or identifying LXRα-64 variants. The amino acid sequence encoded by the novel sequence can be used as an antigen to generate an antibody that specifically binds to LXRα-64 variants. It is a characteristic of LXRα-64 variants that their mRNAs contain the novel sequence nucleic acid sequence and encode the novel amino acid sequence. Such variants may contain conservative substitutions.
FIG. 5 diagrams the structure of LXRα-42e + mRNA, showing that novel sequence is incorporated into sequence corresponding to exon 8 of wild type LXRα, the sequence introducing a stop signal into the sequence preceding exon 9. The new LXRα-42e + sequence also lacks exon 10 of wild type LXRα. A probe having the novel sequence is useful for, e.g., identifying the expression of an LXRα-42e + or identifying LXRα-42e + variants. It is a characteristic of LXRα-42e + variants that their mRNAs contain the novel nucleic acid sequence and encode the novel amino acid sequence. Such variants may contain conservative substitutions. Certain LXRα-42e + variants lack exon 10. In some cases an LXRα-42e + variant contains both the novel sequence and lacks exon 10.
FIG. 6 diagrams the structure of LXRα-42e − mRNA, showing that exon 6 of wild type LXRα is absent in LXRα-42e − . (Some reports of wild type LXRα designate exon 1 as exon 1 A and exon 2 as exon 1 B. Under this terminology, exon 5 of the wild type LXRα corresponds to the missing exon 6 sequence.) A probe that includes the contiguous exon 5 and exon 7 sequence of LXRα-42e − is therefore useful, e.g., for specifically detecting expression of this sequence or for identifying novel variants of LXRα-42e − . Accordingly, a characteristic of an LXRα-42e − variant is the lack of wild type exon 6. An amino acid sequence that is encoded by the sequence bridging exons 5 and 7 is also useful for generating an antibody that specifically binds to an LXRα-42e − .
Example 4
Tissue Distribution
Tissue distribution studies were performed using real-time PCR and Multiple Tissue cDNA panels (MTC, human cDNA) from BD Biosciences Clontech (Palo Alto, Calif.). Real-time quantitative PCR assays were performed on the panels using an Applied Biosystems 7700 sequence detector (Foster City, Calif.). Each amplification mixture (50 μL) contained 50 ng of cDNA, 400 nM forward primer (SEQ ID NO:11), 400 nM reverse primer (SEQ ID NO:12), 200 nM dual-labeled fluorogenic probe (SEQ ID NO:13) (Applied Biosystems), 5.5 mM MgCl 2 , and 1.25 units Gold Taq (Applied Biosystems). The primers amplify a portion of the LXRα sequences that is about 80 nucleotides in length. The PCR thermocycling parameters were 95° C. for 10 minutes, and 40 cycles at 95° C. for 15 seconds, and 60° C. for 1 minute. Together with the samples and no-template controls, a serially diluted cDNA standard was analyzed in parallel. All samples were analyzed for human glyceraldehyde-3-phosphate dehydrogenase (GAPDH) expression in parallel in the same run using probe and primers from predeveloped assays for GAPDH (Applied Biosystems). All of the target gene expression was normalized to the expression of GAPDH. Quantitative analysis was performed using the threshold procedure, following the manufacturer's protocol (Perkin-Elmer), and relative amounts were calculated from the standard curve.
The primers and probe used to detect LXRα variant LXRα-64 in these studies were as follows: L64-For (5′-TGGGAAGCAGGGATGAGG-3′; SEQ ID NO:11), L64-Rev (5′-GAGGGCTGGTCTTGGAGCA-3′; SEQ ID NO:12), and L64 TaqMan probe (FAM-TCGGCCTCCCTGGAAGAGGCC-TAMRA; SEQ ID NO:13). The L64 primers and probe are localized to the 64 nucleotides that are found in the LXRα-64 cDNA.
LXRα-64 mRNA was found to be most abundantly expressed in liver ( FIG. 7A ). Transcripts were also detected at a relatively high level in small intestine, placenta, pancreas, ovary, and colon. Very little expression was observed in the other tester tissues. The primers and probe used to detect LXRα variant LXRα-42 in these studies were as follows: L42-For (5′-GGTGGAGGCATTTGCTGTGT-3′; SEQ ID NO:21), L42-Rev (5′-CCCAAATTGCAACCAAAATATAGA-3′; SEQ ID NO:22) and L42 probe (FAM-TTTAGGATGAGAGAGCTTGGCTGGAGCAT-TAMRA; SEQ ID NO:23). FAM/TAMRA fluorogenic probes are available from BioSearch Technologies (Novato, Calif.).
The expression of LXRα-42 had different pattern compared to LXRα-64. While the most abundant expression was observed in liver, the LXRα-42 sequences were detected only at low levels or were absent in the other tissues tested.
Wild type LXRα as well as LXRα variants are highly expressed in liver. Next to liver, wild type LXRα is present in the greatest abundance in pancreas followed by testis, small intestine, and spleen, which share similar levels of mRNA. Prostate, thymus, kidney, ovary, placenta, lung, and colon express less than testis, while leukocyte, heart, brain, and skeletal muscle contain negligible amounts of wild type LXRα mRNA. LXRα-64 is also expressed at the highest level in liver followed by small intestine. Placenta, pancreas, ovary, colon, and lung express less LXRα-64 than small intestine. Expression was observed to be even lower in kidney and leukocyte, while heart, brain, skeletal muscle, spleen, thymus, prostate, and testis contained negligible amounts of expression. LXRα-42 expression (LXRα-42e − plus LXRα-42e + ) in lung was lower than in liver. The remaining tissues (discussed supra) had significantly lower levels of expression compared to liver.
Example 5
Upregulation of LXRα-L64 by LXR Agonists in dTHP-1 Cells
Experiments were performed to determine whether agonists of wild type LXRα could also regulate the expression of LXRα variants. In these experiments, THP-1 cells were obtained from the American Type Culture Collection (ATCC) and cultured in RPMI medium containing 10% fetal bovine serum (FBS). For gene expression analysis in differentiated THP-1 cells, the THP1 cells were incubated in RPMI medium supplemented with 10% lipoprotein-deficient serum (LPDS) (Intracel Corp, Rockville, Md.) and treated with 150 nM phorbol ester for 3 days followed by treatment with LXR, RXR, or Peroxisome Proliferator-activated Receptor γ (PPARγ) agonist compounds, specifically with vehicle only (control), 10 μM T0901317, 10 μM GW 3965, 10 μM Ciglitazone, or 1 μM 9RA. The primers and TaqMan probe for the real-time RT-PCR was described as in Example 4. The data showed that expression of LXRα-64 and LXRα-42 mRNAs was increased in THP-1 cells incubated with either of the two synthetic LXR agonists T0901317 ([N-(2,2,2,-trifluoro-ethyl)-n-[4-(2,2,2,-trifluoro-1-hydroxy-1-trifluoromethyl-ethyl)-phenyl]-benzenesulfonamide]) (Repa et al., Science 2000 289(5484):1524-9, and Schultz et al., Genes Dev. 2000 14(22):2831-8), GW3965 [3-(3-(2-chloro-3-trifluoromethylbenzyl-2,2-diphenylethylamino)propoxy)phenylacetic acid] (Collins et al., J. Med. Chem., 2002 45: 1963-1966 and Laffitte et al., Mol. Cell. Biol. 2001, 21: 7558-7568), PPARγ ligand (10 μM of citglitazone), and RXR ligand (9-cis retinoic acid) ( FIGS. 8A and 8B ).
These data demonstrate that expression of LXRα variants can be induced using known LXRα agonists.
Example 6
Functional Characterization of LXRα Variants
Human LXRα promoter (SEQ ID NO:14) was amplified by PCR using information from the published LXRα genomic structure and sequence (GenBank accession no. AC090589. A fragment spanning from −2660 to −2363 (relative to the transcription start site from exon 1) of LXRα promoter which contains the LXR response element (5′-TGACCAgcagTAACCT-3′, SEQ ID NO:20) (Laffitte et al. 2001, Mol. Cell. Biol. 21, 7558-7568 and Whitney et al., 2001, J. Biol. Chem. 276, 43509-43515) of LXRα was subcloned into pGL3 basic plasmid to create pGL-3-LXRα-Luc. The GenBank accession number of the LXRα “native” sequence used as a reference for the experiments and analysis disclosed herein is Genbank accession number for human LXRα is BC008819. Coding regions of human LXRα, and RXRα (GenBank accession number BC007925) were amplified by RT-PCR according to the sequences in GenBank and subcloned into pCMV/myc/nuc expression vectors (Invitrogen, Carlsbad, Calif.). The new LXRα-L64 coding region was subcloned into pCMV/myc/nuc expression vectors.
HEK 293 cells were grown in Dulbecco's modified Eagle's medium (DMEM) containing 10% FBS. Transfections were performed in triplicate in 24 well plates using Lipofectamine 2000 (Invitrogen). Each well was transfected with 400 ng of reporter plasmid, 100 ng of receptor expression vector, and 200 ng of pCMV-βgal reference plasmid containing a bacterial β-galactosidase gene. Additions to each well were adjusted to contain constant amounts of DNA and of pCMV (Invitrogen, Carlsbad, Calif.) expression vector. After six to eight hours following transfection, the cells were washed once with phosphate-buffered saline (PBS), and then incubated with fresh medium containing 10% lipoprotein-deficient serum (LPDS) (Intracel Corp, Rockville, Md.) and an LXR agonist, RXR agonist, or vehicle control for 24 hours. The cells were harvested, analyzed, and the extracts were assayed for luciferase and β-galactosidase activity in a microplate luminometer/photometer reader (Lucy-1; Anthos, Salzburg, Austria). Luciferase activity was normalized to β-galactosidase activity.
In more detail, HEK 293 cells were contransfected with either control pGL3-basic vector (Promega Madison, Wis. 53711) or pGL3-LXRα-Luc (part of LXRα promoter containing the LXRE sequence of LXRα promoter (TGACCAgcagTAACCT; SEQ ID NO:20) was subcloned into Kpn I/Xho I sites of pGL3-basic vector) reporters with pCMV-h LXRα/pCMV-hRXRα, pCMV-LXRα-64/pCMV-hRXRα, pCMV-LXRα-42e + /pCMV-hRXRα, pCMV-LXRα-42e − /pCMV-hRXRα respectively. Following transfection, cells were incubated for 24 hours in DMEM supplemented with 10% lipoprotein-deficient serum (LPDS) and 10 μM T0901317 or vehicle control then luciferase activity assayed and normalized.
As shown in FIG. 9 , when the new LXRα variants were co-transfected with the reporter gene, the LXR ligand-dependent activation was sharply decreased as compared with the co-transfected native LXRα. Furthermore, as shown in FIG. 10 , when the variants and LXRα were simultaneously co-transfected with the reporter gene, the activation of exogenous LXRα was inhibited as compared with LXRα co-transfected along. These data indicated that the newly cloned LXRα variants can function as dominant negative regulators of native LXRα expression.
Example 7
Regulation of LXR Target Genes by LXR Variant
An important feature of LXRα is its involvement in multiple physiologic effects, some of which are advantageous to an organism and some of which are, at least in certain cases, deleterious to the organism. Thus, the discovery described herein of new LXRα variants provides targets to permit the differential regulation of different aspects of LXRα activity in a cell. To determine the function of the variants, the expression of LXR target genes in the presence of an expressed LXRα variant was examined.
In these experiments, coding regions of human LXRα, RXRα, and the LXRα variant (LXRα-64) were amplified by RT-PCR. The PCR products were subcloned into pCMV/myc/nuc expression vectors (Invitrogen, Carlsbad, Calif.) and used in the experiments described infra.
Expression experiments were conducted in HEK 293 cells that were propagated in Dulbecco's modified Eagle's medium (DMEM) containing 10% FBS. The cultured cells were transfected with either the expression vector containing a sequence encoding LXRα (wild type) or an expression vector encoding LXRα-64. All samples were co-transfected with an expression vector encoding an RXRα sequence. Transfections were performed in triplicate in 24 well plates using the Lipofectamine 2000 (Invitrogen, Carlsbad, Calif.). Each well was transfected with 200 ng of the LXRα expression vector (LXRα), the LXRα-64 expression vector (L64), or control plasmid (pCMV) along with 200 ng of human RXRα expression vector (RXRα). Additions to each well were adjusted to contain constant amounts of DNA and of pCMV expression vector. Six to eight hours following transfection, the cells were washed once with phosphate-buffered saline (PBS), then incubated with fresh medium containing 10% lipoprotein-deficient serum (LPDS) (Intracel Corp, Rockville, Md.) and a synthetic LXR agonist (TO901317) and/or RXR agonist (9-cis-retinoic acid, 9RA), or vehicle only (control) for 48 hours. The cells were then harvested and total RNA was isolated from the cells using a QIAGEN kit. The levels of gene expression were determined with Real-time quantitative PCR assays using an Applied Biosystems 7700 sequence detector.
When a sequence encoding the new variant, LXRα-64, was cotransfected with human RXRα-encoding sequence and expressed in HEK 293 cells, basal, LXR ligand-dependent, and LXR+RXR ligand-dependent induction of SREBP-c1 (an LXR target gene) expression was sharply decreased compared to expression of SREBP-c1 in cells transfected with either wild type LXRα with RXRα or empty expression vector with RXR α ( FIG. 11 ). The basal expression of another LXR target gene, ABCA1 was not affected by the introduction of the variant L64 with RXRα into the cells. However, LXR as well as LXR+RXR-ligand dependent induction of ABCA1 expression was less in cells expressing LXRα-64 and RXRα compared to expression in cells transfected with native LXRa and RXRa or empty expression vector with RXRa. ( FIG. 12 ).
These data demonstrate that the LXRα variants can differentially regulate the expression of LXR target genes in HEK 293 cells, serving as dominant negative modulators of LXRα-induced gene expression. Thus, regulating expression or activity of an LXRα variant provides a method of differentially regulating LXRα-associated effects in cells.
These data also demonstrate that over expressing an LXRα variant can inhibit SREBP-C1 expression. Also, induction of expression of SREBP-1C by an LXR agonist is significantly decreased in a cell expressing an LXRα variant (e.g., LXRα-64. Therefore, increasing the expression or activity of an LXRα variant (e.g., LXRα-64) is useful for treating disorders associated with the expression of SREBP-1C. For example, disrupting the activity of an LXRα, e.g., by over expressing an LXRα-64 or increasing the activity of an LXRα-64 that is expressed in a cell (e.g., by administering a compound that differentially binds to LXRα-64 compared to wild type LXRα) can provide a method of inhibiting the insulin induction of SREBP-1C, and therefore provides a method of inhibiting undesirable induction of fatty acid synthesis by insulin. In another example, over expressing an LXRα variant (e.g., LXRα-64) or selectively activating an LXRα variant (for example, with a compound that differentially binds to the LXRα-variant) can result in inhibition of SREBP-1C, and therefore provides a method of treating hypertriglyceridemia, which is a condition that is a strong predictor of heart disease. In another example, lowered SREBP-1C expression (by increased expression or activity of an LXRα variant such as LXRα-64) can result in lower expression of VLDL-TGs (very low density lipoprotein triglycerides), a desirable effect in certain disorders such as diabetes and certain types of hyperlipoproteinemia.
Wild type LXR expression in the presence of an LXR agonist has the effect of upregulating ABCA1, which is involved in reverse cholesterol transport. Expression of an LXRα variant (e.g., LXRα-64) has little apparent effect on cellular processes. Therefore, overexpression of an LXRα variant can be beneficial in that it decreases expression of a particular LXRα target gene (e.g., SREBP-1C) but does not affect another LXRα target gene whose expression may be desirable (e.g., ABCA1).
Nuclear receptors that heterodimerize with RXR and activation of these heterodimers results in increased expression of specific genes. In the case of undesirable expression of one or more of these genes (e.g., LXR-mediated upregulation of SREBP1c), then overexpression of an LXRα-64 can be beneficial to a subject if expression of the LXRα variant binds to the RXR, thereby decreasing the availability of the RXR for heterodimerization and therefore reducing induction undesirable gene expression.
Sequences
SEQ ID NO:1
cDNA of the Entire Coding Region of Wild Type LXRα
1 atgtccttgt ggctgggggc ccctgtgcct gacattcctc ctgactctgc 51 ggtggagctg tggaagccag gcgcacagga tgcaagcagc caggcccagg 101 gaggcagcag ctgcatcctc agagaggaag ccaggatgcc ccactctgct 151 gggggtactg caggggtggg gctggaggct gcagagccca cagccctgct 201 caccagggca gagccccctt cagaacccac agagatccgt ccacaaaagc 251 ggaaaaaggg gccagccccc aaaatgctgg ggaacgagct atgcagcgtg 301 tgtggggaca aggcctcggg cttccactac aatgttctga gctgcgaggg 351 ctgcaaggga ttcttccgcc gcagcgtcat caagggagcg cactacatct 401 gccacagtgg cggccactgc cccatggaca cctacatgcg tcgcaagtgc 451 caggagtgtc ggcttcgcaa atgccgtcag gctggcatgc gggaggagtg 501 tgtcctgtca gaagaacaga tccgcctgaa gaaactgaag cggcaagagg 551 aggaacaggc tcatgccaca tccttgcccc ccaggcgttc ctcacccccc 601 caaatcctgc cccagctcag cccggaacaa ctgggcatga tcgagaagct 651 cgtcgctgcc cagcaacagt gtaaccggcg ctccttttct gaccggcttc 701 gagtcacgcc ttggcccatg gcaccagatc cccatagccg ggaggcccgt 751 cagcagcgct ttgcccactt cactgagctg gccatcgtct ctgtgcagga 801 gatagttgac tttgctaaac agctacccgg cttcctgcag ctcagccggg 851 aggaccagat tgccctgctg aagacctctg cgatcgaggt gatgcttctg 901 gagacatctc ggaggtacaa ccctgggagt gagagtatca ccttcctcaa 951 ggatttcagt tataaccggg aagactttgc caaagcaggg ctgcaagtgg 1001 aattcatcaa ccccatcttc gagttctcca gggccatgaa tgagctgcaa 1051 ctcaatgatg ccgagtttgc cttgctcatt gctatcagca tcttctctgc 1101 agaccggccc aacgtgcagg accagctcca ggtggagagg ctgcagcaca 1151 catatgtgga agccctgcat gcctacgtct ccatccacca tccccatgac 1201 cgactgatgt tcccacggat gctaatgaaa ctggtgagcc tccggaccct 1251 gagcagcgtc cactcagagc aagtgtttgc actgcgtctg caggacaaaa 1301 agctcccacc gctgctctct gagatctggg atgtgcacga atga
SEQ ID NO:2
The Deduced Amino Acid Sequence of Wild Type LXRα
1 MSLWLGAPVP DIPPDSAVEL WKPGAQDASS QAQGGSSCIL REEARMPHSA 51 GGTAGVGLEA AEPTALLTRA EPPSEPTEIR PQKRKKGPAP KMLGNELCSV 101 CGDKASGFHY NVLSCEGCKG FFRRSVIKGA HYICHSGGHC PMDTYMRRKC 151 QECRLRKCRQ AGMREECVLS EEQIRLKKLK RQEEEQAHAT SLPPRRSSPP 201 QILPQLSPEQ LGMIEKLVAA QQQCNRRSFS DRLRVTPWPM APDPHSREAR 251 QQRFAHFTEL AIVSVQEIVD FAKQLPGFLQ LSREDQIALL KTSAIEVMLL 301 ETSRRYNPGS ESITFLKDFS YNREDFAKAG LQVEFINPIF EFSRAMNELQ 351 LNDAEFALLI AISIFSADRP NVQDQLQVER LQHTYVEALH AYVSIHHPHD 401 RLMFPRMLMK LVSLRTLSSV HSEQVFALRL QDKKLPPLLS EIWDVHE*
SEQ ID NO:3
The cDNA Sequence that Codes for LXRα-64
1 atgtccttgt ggctgggggc ccctgtgcct gacattcctc ctgactctgc 51 ggtggagctg tggaagccag gcgcacagga tgcaagcagc caggcccagg 101 gaggcagcag ctgcatcctc agagaggaag ccaggatgcc ccactctgct 151 gggggtactg caggggtggg gctggaggct gcagagccca cagccctgct 201 caccagggca gagccccctt cagaacccac agagatccgt ccacaaaagc 251 ggaaaaaggg gccagccccc aaaatgctgg ggaacgagct atgcagcgtg 301 tgtggggaca aggcctcggg cttccactac aatgttctga gctgcgaggg 351 ctgcaaggga ttcttccgcc gcagcgtcat caagggagcg cactacatct 401 gccacagtgg cggccactgc cccatggaca cctacatgcg tcgcaagtgc 451 caggagtgtc ggcttcgcaa atgccgtcag gctggcatgc gggaggagtg 501 tgtcctgtca gaagaacaga tccgcctgaa gaaactgaag cggcaagagg 551 aggaacaggc tcatgccaca tccttgcccc ccaggcgttc ctcacccccc 601 caaatcctgc cccagctcag cccggaacaa ctgggcatga tcgagaagct 651 cgtcgctgcc cagcaacagt gtaaccggcg ctccttttct gaccggcttc 701 gagtcacgcc ttggcccatg gcaccagatc cccatagccg ggaggcccgt 751 cagcagcgct ttgcccactt cactgagctg gccatcgtct ctgtgcagga 801 gatagttgac tttgctaaac agctacccgg cttcctgcag ctcagccggg 851 aggaccagat tgccctgctg aagacctctg cgatcgaggt ggctggagaa 901 gggcaaggga tgaagggaga agcagagtgg gattatctgt gggaggggcc 951 tccagacatc gagctgggag agccaaatct gctgggaagc agggatgagg 1001 agaatcggcc tccctggaag aggccatgct ccaagaccag ccctcctagt 1051 ccccgtttga ggtttgctgc ttgtgtgcag gtgatgcttc tggagacatc 1101 tcggaggtac aaccctggga gtgagagtat caccttcctc aaggatttca 1151 gttataaccg ggaagacttt gccaaagcag ggctgcaagt ggaattcatc 1201 aaccccatct tcgagttctc cagggccatg aatgagctgc aactcaatga 1251 tgccgagttt gccttgctca ttgctatcag catcttctct gcagaccggc 1301 ccaacgtgca ggaccagctc caggtggaga ggctgcagca cacatatgtg 1351 gaagccctgc atgcctacgt ctccatccac catccccatg accgactgat 1401 gttcccacgg atgctaatga aactggtgag cctccggacc ctgagcagcg 1451 tccactcaga gcaagtgttt gcactgcgtc tgcaggacaa aaagctccca 1501 ccgctgctct ctgagatctg ggatgtgcac gaatga
SEQ ID NO:4
The Deduced Amino Acid Sequence of LXRα-64
1 MSLWLGAPVP DIPPDSAVEL WKPGAQDASS QAQGGSSCIL REEARMPHSA 51 GGTAGVGLEA AEPTALLTRA EPPSEPTEIR PQKRKKGPAP KMLGNELCSV 101 CGDKASGFHY NVLSCEGCKG FFRRSVIKGA HYICHSGGHC PMDTYMRRKC 151 QECRLRKCRQ AGMREECVLS EEQIRLKKLK RQEEEQAHAT SLPPRRSSPP 201 QILPQLSPEQ LGMIEKLVAA QQQCNRRSFS DRLRVTPWPM APDPHSREAR 251 QQRFAHFTEL AIVSVQEIVD FAKQLPGFLQ LSREDQIALL KTSAIEVAGE 301 GQGMKGEAEW DYLWEGPPDI ELGEPNLLGS RDEENRPPWK RPCSKTSPPS 351 PRLRFAACVQ VMLLETSRRY NPGSESITFL KDFSYNREDF AKAGLQVEFI 401 NPIFEFSRAM NELQLNDAEF ALLIAISIFS ADRPNVQDQL QVERLQHTYV 451 EALHAYVSIH HPHDRLMFPR MLMKLVSLRT LSSVHSEQVF ALRLQDKKLP 501 PLLSEIWDVH E*
SEQ ID NO:5
The cDNA Sequence of the Coding Region of LXRα-42e +
1 atgtccttgt ggctgggggc ccctgtgcct gacattcctc ctgactctgc 51 ggtggagctg tggaagccag gcgcacagga tgcaagcagc caggcccagg 101 gaggcagcag ctgcatcctc agagaggaag ccaggatgcc ccactctgct 151 gggggtactg caggggtggg gctggaggct gcagagccca cagccctgct 201 caccagggca gagccccctt cagaacccac agagatccgt ccacaaaagc 251 ggaaaaaggg gccagccccc aaaatgctgg ggaacgagct atgcagcgtg 301 tgtggggaca aggcctcggg cttccactac aatgttctga gctgcgaggg 351 ctgcaaggga ttcttccgcc gcagcgtcat caagggagcg cactacatct 401 gccacagtgg cggccactgc cccatggaca cctacatgcg tcgcaagtgc 451 caggagtgtc ggcttcgcaa atgccgtcag gctggcatgc gggaggagtg 501 tgtcctgtca gaagaacaga tccgcctgaa gaaactgaag cggcaagagg 551 aggaacaggc tcatgccaca tccttgcccc ccaggcgttc ctcacccccc 601 caaatcctgc cccagctcag cccggaacaa ctgggcatga tcgagaagct 651 cgtcgctgcc cagcaacagt gtaaccggcg ctccttttct gaccggcttc 701 gagtcacgcc ttggcccatg gcaccagatc cccatagccg ggaggcccgt 751 cagcagcgct ttgcccactt cactgagctg gccatcgtct ctgtgcagga 801 gatagttgac tttgctaaac agctacccgg cttcctgcag ctcagccggg 851 aggaccagat tgccctgctg aagacctctg cgatcgaggt gatgcttctg 901 gagacatctc ggaggtacaa ccctgggagt gagagtatca ccttcctcaa 951 ggatttcagt tataaccggg aagactttgc caaagcaggg ctgcaagtgg 1001 aattcatcaa ccccatcttc gagttctcca gggccatgaa tgagctgcaa 1051 ctcaatgatg ccgagtttgc cttgctcatt gctatcagca tcttctctgc 1101 aggtgtggag gaggggcaat gggaaacagc aagagactta caccaaggag 1151 ggctgcaggt cccacaggaa tcggtggggg gaggggggtg gtggcttggg 1201 agggtggagg catttgctgt gttattttag
SEQ ID NO:6
The Deduced Amino Acid Sequence of LXRα-42e +
1 MSLWLGAPVP DIPPDSAVEL WKPGAQDASS QAQGGSSCIL REEARMPHSA 51 GGTAGVGLEA AEPTALLTRA EPPSEPTEIR PQKRKKGPAP KMLGNELCSV 101 CGDKASGFHY NVLSCEGCKG FFRRSVIKGA HYICHSGGHC PMDTYMRRKC 151 QECRLRKCRQ AGMREECVLS EEQIRLKKLK RQEEEQAHAT SLPPRRSSPP 201 QILPQLSPEQ LGMIEKLVAA QQQCNRRSFS DRLRVTPWPM APDPHSREAR 251 QQRFAHFTEL AIVSVQEIVD FAKQLPGFLQ LSREDQIALL KTSAIEVMLL 301 ETSRRYNPGS ESITFLKDFS YNREDFAKAG LQVEFINPIF EFSRAMNELQ 351 LNDAEFALLI AISIFSAGVE EGQWETARDL HQGGLQVPQE SVGGGGWWLG 401 RVEAFAVLF*
SEQ ID NO:7
cDNA Sequence that Codes for LXRα-42e −
1 atgtccttgt ggctgggggc ccctgtgcct gacattcctc ctgactctgc 51 ggtggagctg tggaagccag gcgcacagga tgcaagcagc caggcccagg 101 gaggcagcag ctgcatcctc agagaggaag ccaggatgcc ccactctgct 151 gggggtactg caggggtggg gctggaggct gcagagccca cagccctgct 201 caccagggca gagccccctt cagaacccac agagatccgt ccacaaaagc 251 ggaaaaaggg gccagccccc aaaatgctgg ggaacgagct atgcagcgtg 301 tgtggggaca aggcctcggg cttccactac aatgttctga gctgcgaggg 351 ctgcaaggga ttcttccgcc gcagcgtcat caagggagcg cactacatct 401 gccacagtgg cggccactgc cccatggaca cctacatgcg tcgcaagtgc 451 caggagtgtc ggcttcgcaa atgccgtcag gctggcatgc gggaggagtg 501 tgtcctgtca gaagaacaga tccgcctgaa gaaactgaag cggcaagagg 551 aggaacaggc tcatgccaca tccttgcccc ccaggcgttc ctcacccccc 601 caaatcctgc cccagctcag cccggaacaa ctgggcatga tcgagaagct 651 cgtcgctgcc cagcaacagt gtaaccggcg ctccttttct gaccggcttc 701 gagtcacggt gatgcttctg gagacatctc ggaggtacaa ccctgggagt 751 gagagtatca ccttcctcaa ggatttcagt tataaccggg aagactttgc 801 caaagcaggg ctgcaagtgg aattcatcaa ccccatcttc gagttctcca 851 gggccatgaa tgagctgcaa ctcaatgatg ccgagtttgc cttgctcatt 901 gctatcagca tcttctctgc aggtgtggag gaggggcaat gggaaacagc 951 aagagactta caccaaggag ggctgcaggt cccacaggaa tcggtggggg 1001 gaggggggtg gtggcttggg agggtggagg catttgctgt gttattttag
SEQ ID NO:8
Deduced Amino Acid Sequence of LXRα-42e −
1 MSLWLGAPVP DIPPDSAVEL WKPGAQDASS QAQGGSSCIL REEARMPHSA 51 GGTAGVGLEA AEPTALLTRA EPPSEPTEIR PQKRKKGPAP KMLGNELCSV 101 CGDKASGFHY NVLSCEGCKG FFRRSVIKGA HYICHSGGHC PMDTYMRRKC 151 QECRLRKCRQ AGMREECVLS EEQIRLKKLK RQEEEQAHAT SLPPRRSSPP 201 QILPQLSPEQ LGMIEKLVAA QQQCNRRSFS DRLRVTVMLL ETSRRYNPGS 251 ESITFLKDFS YNREDFAKAG LQVEFINPIF EFSRAMNELQ LNDAEFALLI 301 AISIFSAGVE EGQWETARDL HQGGLQVPQE SVGGGGWWLG RVEAFAVLF*
SEQ ID NO:9
The Nucleotide Sequence of the Forward Primer, LXRα-For
5′-CGGTCGACATGTCCTTGTGGCTGGGG
SEQ ID NO:10
The Nucleotide Sequence of the Reverse Primer, LXRα-Rev
5′-CAGCGGCCGCTTCGTGCACATCCCAGATCTC
SEQ ID NO:11
The Nucleotide Sequence of the Forward Primer, L64-For
5′-TGGGAAGCAGGGATGAGG-3′
SEQ ID NO:12
The Nucleotide Sequence of the Reverse Primer, L64-Rev
5′-GAGGGCTGGTCTTGGAGCA-3′
SEQ ID NO:13
The Nucleotide Sequence of the L64 TaqMan Probe
FAM-TCGGCCTCCCTGGAAGAGGCC-TAMRA
SEQ ID NO:14
Part of LXRα Promoter Sequence; Used for the Luciferase Assay Referred to in Example 6
1 tgggaactgg agttcatagc aaaacaggaa gagccggtga gcaggaaact 51 gggaatgggg cagggggtga atgaccagca gtaacctcag cagcttgcct 101 cccacatctg gactggagca tctgcagggt tctcagcctc tcccctgtag 151 cccaccagcc ctggctgctt ccattacagc acttcactgg cccaagacgc 201 aacaagacaa gattgtcctg gactctgaca cagcaaaggg actggagtga 251 ggacatctgg gttctgatcc cagcccagcc actaactgtg tggtcttgga
SEQ ID NO:15
The Nucleotide Sequence of the LXR Response Element (LXRE)
5′-AGGTCAnnnnAGGTCA-3′
SEQ ID NO:16
The Unique Nucleotide Sequence of the LXRα-64 Variant that Forms a New, Larger Exon 6 and Connects Exons 6 and 7 of Wild Type LXRα
GCTGGAGAAG GGCAAGGGAT GAAGGGAGAA GCAGAGTGGG ATTATCTGTG GGAGGGGCCT CCAGACATCG AGCTGGGAGA GCCAAATCTG CTGGGAAGCA GGGATGAGGA GAATCGGCCT CCCTGGAAGA GGCCATGCTC CAAGACCAGC CCTCCTAGTC CCCGTTTGAG GTTTGCTGCT TGTGTGCAGG TG
SEQ ID NO:17
The Deduced Amino Acid Sequence Encoded by SEQ ID NO:16
VAGEGQGMKGEAEWDYLWEGPPDIELGEPNLLGS RDEENRPPWKRPCSKTSPPSPRLRFAACVQ
SEQ ID NO:18
The Unique Nucleotide Sequence of LXRα-42e that Forms a New Exon 8 that Includes Exon 8 of Wild Type LXRα and Creates a Longer Exon 8 LXRα-42 Variant.
GTGTGGAGGA GGGGCAATGG GAAACAGCAA GAGACTTACA CCAAGGAGGG CTGCAGGTCC CACAGGAATC GGTGGGGGGA GGGGGGTGGT GGCTTGGGAG GGTGGAGGCA TTTGCTGTGT TATTTTAGGA TGAGAGAGCT TGGCTGGAGC ATGTCTCTAT ATTTTGGTTG CAATTTGGGG TATGGAACTG GACCCTGGCC AGACCTGCTC CTCAACTCTC TTGGTGACCT ATAG
SEQ ID NO:19
The Deduced Amino Acid Sequence Encoded by SEQ ID NO:18
GVEEGQWETARDLHQGGLQVPQESVGGGGWWLGRVEAFAVLF
SEQ ID NO:20
The Nucleotide Sequence of the LXR Response Element (LXRE) in LXRα Promoters
5′-TGACCAgcagTAACCT-3′
SEQ ID NO:21
The Nucleotide Sequence of L42-For
5′-GGTGGAGGCATTTGCTGTGT-3′
SEQ ID NO:22
The Nucleotide Sequence of L42-Rev
5′-CCCAAATTGCAACCAAAATATAGA-3′
SEQ ID NO:23
The Nucleotide Sequence of L42 Probe
FAM-TTTAGGATGAGAGAGCTTGGCTGGAGCAT-TAMRA
Other Embodiments
It is to be understood that while the invention has been described in conjunction with the detailed description thereof, the foregoing description is intended to illustrate and not limit the scope of the invention, which is defined by the scope of the appended claims. Other aspects, advantages, and modifications are within the scope of the following claims.
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This invention provides novel human LXRα variant polypeptides and nucleic acids encoding such polypeptides. This invention also provides the therapeutic, diagnostic, and research utilities as well as the production of such polynucleotides and polypeptides. It is emphasized that this abstract is provided to comply with the rules requiring an abstract that 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 meaning of the claims. 37 CFR 1.72(b).
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RELATED APPLICATION
This application is a division of my copending application Ser. No. 340,595 filed Mar. 12, 1973, now U.S. Pat. No. 3,861,102 for "BUILDING STRUCTURE".
BACKGROUND OF THE INVENTION
Presently there is a need for what may be termed low cost housing and buildings. The building and construction industry has attempted to solve such problems by deliberately reducing the overall quality of such structures to the absolute minimum acceptable standards. However, in so doing whatever savings in money are realized are those which are primarily attributable to the cost of materials employed and the elimination of certain features which, although desirable, are not considered essential to the utility of the overall structure.
The reason that savings are limited to such areas is because the employment of skilled tradesmen, at the construction site, for the cutting and fitting of the various components requires the payment of the same hourly rate of pay even though the resulting structure may be considered "low cost."
There have been other attempts to reduce costs as by the construction of prefabricated structures within a factory and then transporting such prefabricated structure to its intended site. However, this method requires the expense of moving such prefabricated structures (with attendant possibilities of damage thereto) and is further limited to the construction of prefabricated structures which can be physically accommodated within the factory.
Further, prior art attempts at mass production of building structures, as by prefabrication of component portions thereof, have generally followed the basic building practices heretofore established for many years. That is, the conventional wall plates, wall studs, sheeting, exterior siding and interior wall finishing is employed for constructing the prefabricated component portions. Except for a few basic departures, most of which employ the geodesic principle, resulting in dome-like configurations, the prior art has not made any significant attempts to combine the advantages of easily and quickly erectable structures with the concept of minimizing the required material for building such structures as by developing component configurations which will maximize the stress carrying capabilities of such components.
Accordingly, the invention as herein disclosed and described is primarily directed to the solution of the above and other attendant problems.
SUMMARY OF THE INVENTION
According to the invention, a building structure comprises a plurality of spaced vertically extending support columns, a plurality of separate wall panels respectively situated between said spaced support columns, and means operatively interconnecting said plurality of columns as to thereby result in structural integrity of said columns and said wall panels.
Various general and specific objects and advantages of the invention, among which is the ability to manufacture standardized type of components in a factory and then without assembly ship such components to the building site, will become apparent when reference is made to the following detailed description considered in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings, wherein for purposes of clarity certain elements or details may be omitted from one or more views;
FIG. 1 is a side elevational view of a building structure embodying the teachings of the invention;
FIG. 2 is a perspective view of the structure of FIG. 1;
FIG. 3 is an enlarged exploded view of certain of the elements shown in each of FIGS. 1 and 2;
FIG. 4 is an enlarged cross-sectional view taken generally on the plane of line 4--4 of FIG. 2 and looking in the direction of the arrows;
FIG. 5 is an enlarged top plan view of the column of FIG. 4 taken generally on the plane of line 5--5 of FIG. 4 and looking in the direction of the arrows;
FIG. 6 is an enlarged fragmentary cross-sectional view taken generally on the plane of line 6--6 of FIG. 3 and looking in the direction of the arrows;
FIG. 7 is an enlarged cross-sectional view taken generally on the plane of line 7--7 of FIG. 3 and looking in the direction of the arrows;
FIG. 8 is an enlarged fragmentary cross-sectional view taken generally on the plane of line 8--8 of FIG. 4 and looking in the direction of the arrows;
FIG. 9 is an enlarged fragmentary cross-sectional view as if taken on line 9--9 of FIG. 3 illustrating a possible configuration thereof;
FIG. 10 is a fragmentary exploded view, somewhat similar to FIG. 3, illustrating another form of the invention;
FIG. 11 is an enlarged fragmentary cross-sectional view taken generally on the plane of line 11--11 of FIG. 10 illustrating the related elements in assembled form;
FIG. 12 is a view similar to FIG. 10 but illustrating a further embodiment of the invention;
FIG. 13 is a fragmentary side elevational view illustrating the elements of FIG. 12 in assembled relationship;
FIG. 14 is an enlarged fragmentary cross-sectional view taken generally on the plane of line 14--14 of FIG. 13 and looking in the direction of the arrows;
FIG. 15 is a view similar to FIG. 12 but illustrating another embodiment of the invention;
FIG. 16 is an enlarged fragmentary cross-sectional view taken generally on the plane of line 16--16 of FIG. 15 and looking in the direction of the arrows;
FIG. 17 is an elevational perspective view of another form of one of the elements embodying the teachings of the invention;
FIG. 18 is an enlarged top plan view of the column of FIG. 17 taken generally on the plane of line 18--18 and looking in the direction of the arrows;
FIGS. 19, 22, 23, 24 and 25 are side elevational views of some typical wall panel constructions;
FIGS. 20 and 21 are each cross-sectional views taken generally on the plane of line 20--20 of FIG. 19;
FIGS. 26 and 27 correspond to FIGS. 1 and 2 but illustrate a multi-floor type of structure embodying the teachings of the invention;
FIG. 28 is a view similar to FIG. 3 but illustrating various elements of the structure of FIGS. 26 and 27 in exploded perspective;
FIG. 29 is an enlarged fragmentary cross-sectional view taken generally on the plane of line 29--29 of FIG. 27 and looking in the direction of the arrows;
FIG. 30 is a fragmentary view, partly in cross-section and partly in elevation illustrating the inverted employment of one of the elements of the invention;
FIG. 31 is a cross-sectional view taken generally on the plane of line 31--31 of FIG. 30 and looking in the direction of the arrows;
FIG. 32 is simplified illustration of a pair of columns and cooperating wall panel member illustrating typical tension stress patterns therein;
FIG. 33 is a view similar to FIG. 32 but illustrating a slight modification thereof; and
FIG. 34 is a cross-sectional view of one of the elements shown in FIG. 32, taken generally on the plane of line 34--34 and looking in the direction of the arrows.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now in greater detail to the drawings, FIG. 1 illustrates, in side elevational view or building or structure 10 embodying the teachings of the invention with FIG. 2 being a perspective view of such structure with the addition thereto of, for example, a suitable roof over the entry to such building.
Generally, the structure 10 is illustrated as being comprised of a roof 12 supported as by vertically extending wall assemblies 14 which, in turn are comprised of cooperating alternating wall panels 16 and columns or posts 18 and 20 with columns 18 being employed within the run of the wall assembly while columns 20 are employed as corner columns or posts.
FIG. 3 illustrates in exploded perspective view the general manner of assembly and inter-relationship of the elements shown in FIGS. 1 and 2. As can be seen, in the preferred embodiment columns 18 are comprised of a main vertically extending body portion 22 having axially aligned legs 24, 26, 28 and 30 formed integrally therwith and angularly spaced thereabout as, for example, at 90° intervals. Legs 24, 26, 28 and 30 respectively terminate in aligned foot-like portions 32, 34, 36 and 38. Further, grooves or recesses 40, 42, 44 and 46 are respectively formed in legs 24, 26, 28 and 30 in a manner as to extend downwardly into the respective aligned foot portions 32, 34, 36 and 38. As typically illustrated in FIG. 4, such grooves preferably terminate in a vertical slot 48 formed in each of the foot portions.
Wall panels 16 are preferably of a generally trapezoidal configuration having opposed slanting side wall edges 50 and 52 terminating at their lower ends in arcuate corners 54 and 56 each blending into a lower edge 58. At the upper end of each panel 16, oppositely sloping edges 60 and 62 extending generally upwardly as to meet generally vertically extending wall edges 64 and 66 which, in turn, terminate in an upper panel edge 68. As illustrated, in the preferred embodiment, each upper edge 68 has a groove 70 formed therein and coextensive therewith.
The top of each column 18 is preferably truncated, as at 72, and provided with an upwardly extending locating member 74 which is received through an aperture 76 formed in a seal 78 as well as received within a cooperating aperture 80 formed in a capping or filler plate member 82.
As shown, the plate member 82 may be comprised of a generally triangular panel-like body portion 84 provided with upwardly extending and outwardly directed boundary like edge portions 86 and 88 which, at their respective lower ends, terminate in what may be referred to as an extension 90 of column 18. The extension 90 has opposed grooves 92 and 94 formed therein which respectively align with grooves or recesses 46 and 42 of column 18 and a second set of opposed grooves or recesses 96 and 98 which not only respectively align with grooves 44 and 40 of column 18 but also respectively continue upwardly coextensively with edge portions 86 and 88. Further, the top edge 100 of plate member 82 preferably has a groove 102 formed therein and coextensively therealong.
As also shown in FIG. 3, lower connecting or base members 104 are preferably provided so as to both receive therein a portion of the cooperating wall panel 16 and to join succeeding columns 18 to each other. As typically illustrated, such base members 104 may be comprised of a main body 106 having a longitudinally extending slot or groove 108 formed therein with elongated slots or apertures 110 and 112 formed therethrough and opening into such groove 108. Further tongue-like extensions 114 and 116 are provided at opposite ends of the body 106 as to be aligned with slot 108. With reference also to FIG. 4, extensions 114 and 116 are of a length as to be receivable within slots 48 formed in the foot portions of columns 18 while the inner-most longitudinal surface of groove 108 is at an elevation substantially equal to the elevation of such cooperating grooves within the same foot portions. As best seen in FIG. 3, each of the column foot portions is provided with a through aperture 118 while extension 114 has an aperture 120 formed therethrough and extension 116 has an aperture 122 formed therethrough.
Generally, in assembling a building embodying the invention, base columns 18 and base members 104 may be first assembled, atop any suitable support means, as by having the extensions 114 and 116 received by the slots of the foot portions. For example, still referring to FIG. 3, one of the bases 104 would have extension 116 received in slot 48 of foot 36 thereby placing its groove 108 in line with groove 44 so as to form a continuation thereof while the other shown base 104 would have its extension 114 received in slot 48 of foot 32 thereby placing its groove 108 in registry with groove 40 so as to form a continuation thereof. When bases 104 are thusly assembled to foot portions 36 and 32, suitable pins, bolts or any other effective retaining means, such as at 124, are inserted respectively through then aligned holes 118, 122 and 118, 120 thereby securing the bases 104 to the intermediately located column 18 and making such components into a unitary structure. Of course, succeeding columns and bases are similarly interconnected as to form the continuous wall 14.
As the columns 18 and bases 104 are connected to each other some relative movement may be necessary as between coacting column and base. Since in the preferred embodiment bases 104 are secured to a lower support surface, as by fastening means 126 extending through slots 110, such slots 110 are elongated to enable the movement of such bases 104 relative to the said lower support surface and whatever anchoring means may be provided therein for coaction with said fastening means 126.
In the preferred sequence of operations, the various components are assembled as follows. That is, for example, a base 104 is secured to a column 18, then the filler or capping plate member 82 is affixed atop the column 18, then a wall panel 16 is placed within the groove 108 of such base member 104 and slid therealong until the edges are cooperatingly received within the grooves or recesses of column 18 and extension 90 of plate member 82.
For example, if it is assumed that the base 104 shown on the right side of FIG. 3 has been secured to column 18 and that capping or filler member 90 has also been affixed atop column 18, then the wall panel 16, also shown on the right side of FIG. 3, would be placed as to have its lower edge 58 received within groove 108 after which the panel 16, while still remaining in groove 108, would be moved therealong until edge 50 was received within aligned grooves 40 and 98 of column 18 and extension 90, respectively. Simultaneously, edges 60 and 64 of panel 16 are cooperatingly received within that portion of groove 98 which extends upwardly from extension 90. It should be observed that preferably the place of juncture between extension 90 and column 18 is at an elevation lower than the elevation of corner 51 (defined by edges 50 and 60) and corner 53 (defined by edges 52 and 62). Consequently, the strength of the panel 16 thusly received enhances the rigidity of the assembly composed of column 18 and capping member 82. When the elements are assembled as described, the upper groove 102 of member 82 and upper groove 70 of wall panel 16 are placed in functional alignment with each other.
After the above operations are completed, the next succeeding column 18 and filler or capping member 82, situated thereatop, can be moved into position against the opposite side edges of wall panel 16 and secured to the base 104 as previously described, after which the previously described operations are cyclically repeated until the wall assembly 14 is completed.
It should be apparent that in order to prevent water seepage (as might occur during a rain storm) and to prevent or at least minimize air leakage through such a wall assembly, it is preferred to have the various grooves and cooperating edges of the various components of respective dimensions resulting in tight engagement therebetween.
FIG. 4, a cross-sectional view taken generally on the plane of line 4--4 of FIG. 2, illustrates, on the left side, a column 18 and filler plate 82 in axial cross-section while on the right side, the plane of cross-section is taken along the vertical median of a wall panel 16. If the columns 18, as in one contemplated embodiment of the invention, are constructed of concrete, it becomes highly desirable to reduce the weight thereof as much as possible and consistent with structural strength and integrity. This may be done, for example, by having a hollow core 129 (preferably tapered) formed as by an axially extending paper-like tube 130 the upper end of which may be of a dimension as to closely or tightly receive the locating pin 74 therein. As typically illustrated, each of the longitudinal grooves in the column 18 is preferably provided with a radiused portion 132 blending with the continuation of such recess or groove within the respective foot portion. The primary purpose of such curvelinear portions 132 is to closely conform to the rounded corners 54 and 56 of wall panels 16 when such are assembled to the columns 18.
As generally illustrated in FIG. 4, the columns 18 and bases 104 may be situated atop a concrete slab 134. However, the practice of the invention is not limited merely to its use in combination with such a slab. That is, for example, suitable foundation type footings may be formed for the placement thereatop of such columns and bases while a floor as generally in phantom line at 136 may be poured between such columns and bases.
As best seen in FIG. 6, the recess or aperture 80 may have a second opening or passageway 138 communicating therewith. The purpose of such passageway 138 is to provide access means for the introduction therethrough of a suitable adhesive, welding or cementing agent, after the filler plate 82 is placed atop the column 18, as depicted generally by either FIGS. 2, 4 or 8, in order to bond the various coacting components and form a more unitary structure which is for all practical purposes free of any seams which might permit water or moisture passage therethrough.
FIG. 7, an enlarged fragmentary cross-sectional view taken generally on the plane of line 7--7 of FIG. 3, illustrates, in cross-section, the fact that addition stress reinforcing members, such as steel rods 140, may be included within the body of the column 18.
FIG. 9, an enlarged fragmentary cross-sectional view taken generally on the plane of line 9--9 of FIG. 3, illustrates that in the preferred embodiment, the wall panel 16 is preferably formed of opposed sheet-like wall surfaces 146 and 144 between which is situated suitable core means 142. The periphery of the entire panel 16 may, in turn, be defined as by a suitable edging member 148 which may be secured to the wall sheets 144 and 146 by any suitable means as, for example, by cementing. Further, in the preferred embodiment, sheets 144 and 146 as well as edge 148 are formed of plastic material having a relatively low rate of thermal conductivity. Although not absolutely essential, nevertheless, it is contemplated that because of manufacturing tolerances as well as the selection of relative dimensions for ease of assembly, the various coacting elements may not, in and of themselves, achieve a tight interfit. Therefore, in order to enhance such interfits and prevent air and moisture leakage, suitable sealing means such as a functionally continuous resilient deflectable seal 150 may be affixed to the edge of panel 16 as to extend, for example, along edges 64, 60, 50, 58, 52, 62 and 66.
FIG. 10 illustrates a modification of the invention employing a wall panel 16a which, for purposes of discussion, is identical to wall panel 16 except that edges 60a and 62a (respectively corresponding to edges 60 and 62) now terminate in an upper edge 152 instead of vertical edges 64 and 66 as in FIG. 3. In order to accommodate the slightly varied configuration of wall panel 16a, a different form of capping or filler member 154 is employed.
As can be seen, member 154 has an upper edge 156, with a recess or groove 158 formed therein and coextensively therewith, terminating in opposed end edges or surfaces 160 and 162. A lower disposed edge 164, generally parallel to edge 156, terminates in two edges 166 and 168 extending downwardly and sloping away from each other. Similar but oppositely directed openings or recesses 170 are respectively formed in end surfaces 160 and 162 as to accommodate therein upwardly extending pins or rods 74 in each of the support columns 18 when such capping or extension members 154 are placed atop such cooperating support columns 18. The under surfaces of edges 166, 164 and 168 have a continuous groove or recess 172 formed therein as to respectively receive therein edges 60a, 152 and 62a of panel 16a during assembly thereof. Body 174 of extension member 154, at the outward surface thereof, is preferably provided with tapered protrusions 176 and 178 as to provide a general blending appearance with the column 18 when placed thereatop. When the extension members 154 are assembled atop columns or posts 18, respective end edges or surfaces 162 and 160 of succeeding extension members 154 are in justaposed relationship, with pin 74 received within the cavity conjointly defined by the respective recesses 170. If desired, such juxtaposed surfaces 160 and 162 may be suitably sealed or even cemented to each other, if desired.
Additionally, as also seen in enlarged cross-sectional view in FIG. 11, the extension 154 is preferably provided with a ledge or flange surface 180, extending the full length of the capping member 154, for supporting a cooperating roof structure 12, as generally depicted in phantom line.
FIG. 12 illustrates another modification of the invention similar to that illustrated by FIG. 10 with the main exception being that the single piece extension or capping member 154 of FIG. 10 is now made into two separate pieces which are respectively the left half and right half of original one-piece member 154. Accordingly, all elements which are like or similar to those of FIG. 10 are identified with like reference numerals while the respective capping members are identified with like reference numbers provided with a suffix R or L depending upon whether such corresponds with the right hand half of extension member 154 or the left hand half of such extension member 154. As should be apparent, sections 154R and 154L are respectively provided with end surfaces 182 and 184 which, when assembled as illustrated in FIG. 13, become juxtaposed to each other. As with relationship to surfaces 160 and 162 discussed relative to FIG. 10, surfaces 182 and 184 may be sealed or cemented, if desired.
FIG. 15 illustrates another modification of the invention similar to that illustrated by FIG. 12 with the main exception being that the two extension pieces 154R and 154L are now made into a one piece configuration just as if the two pieces 154R and 154L shown in FIG. 12 were brought together. All elements in FIG. 15 which are like or similar to those of FIG. 12 are identified with like reference numerals with the exception that the resulting single piece capping or extension members of FIG. 15 is identified as 154C, the resulting single continuous upper edge is identified as 156C, the resulting single upper groove is identified as 158C and the single continuous flange is identified as 180C. Just as with regard to the previous embodiments described, aperture or clearance 80C is adapted for the reception therein of locating member 74.
At this point it should be made clear that the columns identified at 20 of FIGS. 1 and 2 may be identical to the columns 18 and for the purposes of FIGS. 1 and 2 they are identical. However, such corner or juncture columns may in fact assume different configurations to the extent that such configurations will accommodate a peripheral configuration of the building structure other than square or rectangular. One of such columns is illustrated by FIGS. 17 and 18.
Column 20b of FIGS. 17 and 18 is illustrated as being comprised of a main vertically extending body portion 190 having axially extending legs 192, 194 and 196 preferably formed integrally therewith and angularly spaced thereabout as, for example, at 120° intervals. Legs 192, 194 and 196 respectively terminate in aligned foot-like portions 198, 200 and 202. Further, grooves or recesses 204, 206 and 208 are respectively formed in legs 192, 194 and 196 in a manner as to extend downwardly into the respective aligned foot portions 198, 200 and 202. Similarly too, as best shown in FIG. 4, each of the foot portions 198, 200 and 202 has a vertically extending slot 210 formed therein into which the grooves 204, 206 and 208 respectively terminate.
The top of column 20b is preferably truncated, as at 212, and provided with an upwardly extending locating member 214 received as within an axially extending tube 216 and which functions in the same manner as locating member 74. As with reference to core 129 of FIG. 4, a column 20b is also similarly provided with an axially extending core 218.
As should be evident from FIGS. 17 and 18, it is possible to form columns functionally equivalent to columns 18 of FIGS. 1 and 2 but having less or greater number of legs as well as having such legs spaced from each other by different angular degrees.
The various columns contemplated by the invention may assume other varied or modified forms depending, especially, on their particular intended use. For example, it is conceivable that because of certain considerations only three of the four legs and foot portions illustrated in, for example, FIG. 5 would be desired. In such event the column could be fabricated to exclude possibly leg 30 and foot portion 38 while retaining the remaining legs and foot portions as shown. In other instances, especially in the interior of buildings, it may be desirable to eliminate the interior foot portion. This could be achieved, for example, by forming the related leg portion to have a continuous downwardly extending contour as illustratively depicted by phantom line 220 in FIG. 17. Further, even though the various columns 18, 20 and 20b have been described as being formed of concrete, it is specifically contemplated that such can be and will also be formed of plastic material as by, for example, molding. By so doing the overall weight of such columns can be kept at an absolute minimum while at the same time providing all of the necessary structural strength.
In forming such columns of either concrete, plastic or some other suitable material, it should be made clear that the exterior surfaces thereof can be enhanced and tailored to the exact aesthetic requirements of the overall structure as well as to the surrounding environment. That is, it is possible to create a surface-like layer of any texture, configuration or design as well as the selection of the color thereof.
Although it has been stated that in the preferred embodiment of the invention the wall panels 16, 16a are preferably formed of a laminated construction employing plastic material as panel sheets, such wall panels may, nevertheless, be formed of any sutiable material and may be of solid cross-sectional configuration.
For example, FIG. 19 illustrates a typical wall panel 16a in elevation with such panel being of any suitable material and either of hollow core or solid in cross-section. (For ease of illustration in FIGS. 20 and 21 such are shown as if the panel 16a was solid in cross-section.) FIG. 20, a cross-sectional view taken generally on the plane of line 20--20 merely illustrates that the opposed exposed surfaces 222 and 224 may in fact be planar and free of any interruptions therein, while FIG. 21, also a view taken generally on the plane of line 20--20, illustrates that the surfaces 224 and 226 may be provided with projecting portions 228 (shown in phantom line on FIG. 19) selected and located in positions for desired aesthetic effect.
FIGS. 22, 23 and 24 typically illustrate, in 256, 258 other possible constructions of wall panels 16b, 16c and 16d. For example, wall panel 16b could be formed from separate sheet portions 230, 232, 234 and 236 or, in the alternative, could be so contoured as to have the appearance of such separate sheet portions but, in reality be a single integrally formed panel sheet. As generally depicted in FIG. 23, the panel sheet may also be formed with inclined strength reinforcing means as generally indicated by intersecting lines 238, 240, 242, 244, 246, 248, 250, 252, 254, 258 and 260 and that, if desired windows may be provided as at 262. The same generally applies to wall panel 16d of FIG. 24 wherein the intersecting strength reinforcing means are depicted by horizontal lines 264, 266, 268 and 270 and vertical lines 272, 274, 276 and 278, while portions 280 and 282 may represent window means.
FIG. 25 is intended only to illustrate the fact that such wall panels 16e may, in fact be formed with a suitable opening as at 284 in order to define a passageway therethrough. Such opening 284 may, of course, be fitted with a door frame assembly and door if such be desired.
Although it is believed obvious, nevertheless it might be best to specifically point out that, as shown in FIGS. 1 and 2, the corner columns 20 support a capping or filler member 79 functionally equivalent to members 82 except that the body of member 79 is formed as to have body portions 81 and 83 which are at an angle to each other as to thereby conform to the angle formed by the wall assemblies at that particular corner.
FIGS. 26 and 27 are similar respectively to FIGS. 1 and 2 in that they also illustrate a building structure constructed in accordance with the teachings of the invention with the exception that the building 300 is of a multi-story construction. All elements which are like or similar to those of the preceding Figures are identified with like reference numerals. The various members which are identified with a reference number provided with a suffix, T, correspond to those members having the same reference number appearing at the lower part of FIG. 28. The only purpose for designating the "T" is for ease of reference since such "T" designation is intended to connote that member's relative position, namely, top.
Referring in greater detail to FIG. 28, it can be seen that wall panels 310 and 310T are again preferably of trapezoidal configuration having inclined side edges 312 and 314 which terminate at one end in an edge 318 and at the other end in an edge 316. Edge 318 of panel 310 is adapted to be received within groove 108 of base 104 while edge 318 of panel 310T is similarly adapted to be received within groove 108 of member 104T. Side edges 312 and 314 of panel 310 are adapted to be received as within grooves 40 and 44, respectively, of succeeding columns 18 while edges 312 and 314 of panel 310T are respectively received within grooves 44 and 40 of succeeding columns 18T respectively juxtaposed to the columns 18.
A connecting piece or member 320 is shown as comprising a longitudinally extending body 322 with an upwardly directed groove 324 formed therein and extending generally coextensively with the body 322. A second lower disposed downwardly directed groove 326 is also formed in body 322 and extends generally coextensively therewith. Body 322 is also provided with preferably integrally formed longitudinally extending flange portions 328 and 330 which, as best seen in FIG. 29, provide means for the support of the upper floor assembly 332. Laterally extending anchoring portions or tabs 334 and 336 are provided with apertures 338 for the respective reception therethrough of locating or assembly pins 74. Additionally, preferably, vertically extending projecting portions 340 and 342 are provided which are preferably at least partially received within the axially extending grooves of the columns 18 and 18T.
In assembled relationship, the base member 104 would be connected to spaced succeeding columns 18 and wall panel 310 would be received within groove 108 of base 104 as well as the longitudinal grooves of the spaced cooperating columns 18 as previously described. Next, the connecting member 320 is placed over edge 316 of panel 310 and pins 74 of columns 18. At this point it should be noted that in the preferred form of the invention, tab 336 is at an elevation slightly higher than opposite tab 334 thereby allowing for the placement, about a single pin 74, of tab 334 of one connecting member 320 and thereatop the tab 336 of the next succeeding connecting member. Of course, as previously described, suitable seals such as that disclosed at 78 and as generally indicated at 344 of FIG. 29 may be employed.
Subsequently, panel 310T is placed as to have its edge 316 received in upper slot 324 of connecting member 320 and columns 18T are placed respectively atop the tab portions of connecting members 320 in a manner preferably whereby pins 74 are received within the hollow portions of columns 18T as generally depicted in FIG. 29. Edges 312 and 314 are also received within cooperating grooves of columns 18T. Finally, upper disposed member 104T is connected via extensions 114 and 116 to foot portions 36 and 32 of columns 18T and, in so doing, receives edge 318 of wall panel 310T within its groove 108.
The invention also provides means for the ready attachment of facia members 350. That is, as illustrated in both FIGS. 28 and 29, facia means 350 is provided with opposed cut-out portions 352 and 354 as to enable the mounting thereof as by placing cut-out portion 352 over foot 34 and cut-out portion 354 over foot 34 of the next succeeding column 18T. The width of such cut-out portions is such as to extend approximately half the width of cooperating supporting foot portions. The facia means may, of course, be secured in any suitable manner as, for example, by either mechanical fastening means or suitable cementing means.
In addition to other anchoring means discussed, further anchoring means such as depicted at 360, 362, 364 and 366 may be employed to further assure adequate securing of cooperating components.
Any suitable roof assembly or structure may be employed. However, it should be evident that the invention provides a basic structure wherein such a roof assembly 12, if desired, may be layed across the supporting wall assemblies. In some situations where the roof is actually placed atop the wall assemblies, grooves, as disclosed for example at 70, 102 and 158 are employed to receive suitable sealing means, as depicted at 368 of FIG. 4, for forming a sealing barrier as between the roof assembly and the supporting walls.
FIG. 30 illustrates the use of what might be considered an inverted column 18 which, for purposes of discussion is depicted as being an interior support column. That is the foot portions are located upper-most as to provide comparatively large support surfaces for supporting beams 372 and other structural members passing thereover. Further, the reduced size of the lower end of the inverted column 18 also provides for greater useful floor space. It should be brought out that the grooves 40, 42, 44 and 46 (all or any of them) may be employed as passage means for enabling, for example, the drawing therethrough of telephone or electrical cable, as from above a drop-type ceiling 374, to any selected location in proximity to such related inverted column 18. Further after such cables are drawn through the grooves, suitable facing-like cover means (not shown) may be placed in the grooves as to cover such cables.
Although the preferred form of the invention employs trapezoidal wall panels, it should be clear that wall panels of other configurations may be employed without departing from the spirit of the invention. However, it has been discovered that panels having inclined side edges, such as at 16, provide the best means for dissipating loading stresses, imposed on such panels from atop thereof, to the spaced cooperating columns or posts.
FIG. 32 is a somewhat simplified illustration of two columns 400, 402 and cooperating wall panel member 412. (This is a typical type of illustration and such reference numbers as are employed are used merely for ease of specific reference.) Assuming that the columns 400 and 402 are operatively connected to each other as by a base member 415 and a wall panel member 412 is situated therein, let it further be assumed that there is a generally equal loading at the top of the wall member 412 as depicted by the arrows 416. With such an assumption, it can be seen that, because of the inclined coacting side edges, resultant forces as indicated generally by arrows 418 will act against columns 400 and 402 as well as the base member 415. As a consequence of such resultant forces, the entire system is placed in tension as generally indicated by the heavy dash line 420 which passes through columns 400, 402 and base 415. If the columns 400 and 402 are not anchored to each other through the agency of a base member 415 but instead operatively connected to each other as by being individually anchored as through a related floor or foundation 422, the tension stress line (shown in heavy dash line-work) would pass through such support 422 also placing it in tension. Obviously, depending on how the columns 400 and 402 are operatively connected to each other, such tension stress lines could pass through both a base member such as at 415 and the support 422.
By placing such materials in tension, maximum utilization of the strengths of such materials is achieved. That is, the columns 400 and 402 need not have cross-sectional thicknesses as is necessary by the prior art to carry the full loads in compression. Further, in view of the fact that succeeding wall panel members actually have vectors of the resultant forces 418 generally horizontally disposed and oppositely directed against the column between such panels, such column thereby has its inherent rigidity increased further enabling the carrying of any load placed directly thereatop as depicted by either of arrows 424.
FIG. 33 is a view similar to FIG. 32 but illustrating the fact that the panel member may actually have other configurations including, for example, an arcuate or circular edge configuration 426. All elements which are like or similar to those typically illustrated in FIG. 32 are identified with like reference numbers provided with a suffix "a".
In view of the above, it can be seen that columns such as 400 and 402 (or other corresponding columns as hereinbefore disclosed) are not necessarily columns in the usual sense of the word in that they do not (and in the preferred embodiment will not be) necessarily carry the full roof or upper floor loads in compression as do the "columns" referred to by the prior art. That is, regardless of the actual use, that is, interior or exterior wall systems, the invention provides modular stress or load bearing means which has the appearance of spaced conventional columns and intermediate non-load bearing wall panels.
Further, as generally typically depicted by FIG. 34, a wall panel member or means 412 may actually be comprised of a series of abutting wall portions 411, 413 and 417 which, if desired, may also include suitable interlocking means 419. It should also be mentioned that the term, building structure, is herein employed not only to designate an entire building but any sub-component thereof as well as any wall-type section or portion thereof.
Although only a select number of preferred embodiments of the invention have been disclosed and described, it is apparent that other embodiments and modifications of the invention are possible within the scope of the appended claims.
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A building structure of either single or multi-story construction employs wall panels and columns each of which may be fabricated as at a factory and transported to the building site and there erected in a generally modular mode of operation.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to and the benefit of U.S. Provisional Patent Application Ser. No. 60/934,104 entitled “Inserter for intervertebral spacer” filed on Jun. 11, 2007 which is incorporated herein by reference in its entirety. This application also claims priority to and is a continuation-in-part of U.S. patent application Ser. No. 12/156,857 entitled “Inserter for a spinal implant” filed on Jun. 4, 2008 which claims priority to and the benefit of U.S. Provisional Patent Application Ser. No. 60/933,538 filed on Jun. 7, 2007, all of which are hereby incorporated by reference in their entireties.
FIELD
[0002] The present invention generally relates to medical devices, and in particular, the present invention relates to a surgical instrument for introducing spinal implants such as an intervertebral spacer into a disc space between adjacent vertebral bodies.
BACKGROUND
[0003] Deterioration or dislocation of a spinal disc located between two adjacent vertebral bodies often results in the two adjacent vertebral bodies coming closer together. The reduced disc space height typically results in instability of the spine, decreased mobility and pain and discomfort for the patient. A common treatment is to surgically restore the proper disc space height to thereby alleviate the neurologic impact of the collapsed disc space. Typically, most surgical corrections of a disc space include at least a partial discectomy which is followed by restoration of normal disc space height and, in some instances, fusion of the adjacent vertebral bodies. Restoration of normal disc space height generally involves the implantation of a spacer and fusion typically involves inclusion of bone graft or bone graft substitute material into the intervertebral disc space to create bony fusion. Fusion rods may also be employed. Some implants further provide artificial dynamics to the spine. Such techniques for achieving interbody fusion or for providing artificial disc functions are well-known in the art.
[0004] One problem, among others, with inserting an implant, for example, is associated with patient anatomy. Inserting and positioning the implant in the space between adjacent vertebrae can be difficult or time consuming if the bony portions are spaced too close together, or if the adjacent tissue, nerves or vasculature impedes access to or placement of the implant in the space between the bony portions. Furthermore, maintenance of distraction of the space during insertion of the implant requires additional instruments in the operative space which can make the procedure more invasive and impede access and visibility during implant insertion and thereby make the procedure more difficult.
[0005] Another difficulty of implant insertion is related to the point of access to the damaged disc space which may be accomplished from several approaches to the spine with each approach having different associated difficulties. One approach is to gain access to the anterior portion of the spine through a patient's abdomen. For an anterior approach, extensive vessel retraction is often required and many vertebral levels are not readily accessible from this approach. Another approach is a posterior approach. This approach typically requires that both sides of the disc space on either side of the spinal cord be surgically exposed, which may require a substantial incision or multiple access locations, as well as extensive retraction of the spinal cord. Yet another approach is a postero-lateral approach to the disc space. The posterior-lateral approach is employed in a posterior lumbar interbody fusion (PLIF) or transforaminal lumber interbody fusion (TLIF) procedure which may be performed as an open technique which requires making a larger incision along the middle of the back. Through this incision, the surgeon then cuts away, or retracts, spinal muscles and tissue to access the vertebrae and disc space. The TLIF procedure may also be performed as a minimally invasive or as an extreme lateral interbody fusion (XLIF) procedure that involves a retroperitoneal transpoas approach to the lumbar spine as an alternative to “open” fusion surgery. In the minimally invasive procedure, the surgeon employs much smaller incisions, avoids disrupting major muscles and tissues in the back and reduces the amount of muscle and tissue that is cut or retracted. As a result, blood loss is dramatically reduced and these minimally invasive benefits also lead to shorter hospital stays and quicker patient recovery times. The aforementioned and various other difficulties associated with the point of access to the damaged disc space and the need to navigate an implant insertion instrument through the point of access further place demands on insertion instrument design. Therefore, there remains a need for improved insertion instruments, implants and techniques for use in any one or more types of approaches to the disc space that facilitate and provide for effective insertion while saving time, minimizing the degree of invasiveness for the patient and complementing surgeon skill demands.
SUMMARY
[0006] According to one aspect of the invention, an inserter for implanting a spinal implant is disclosed. The instrument includes a shaft assembly connected to a jaw assembly at one end and to a handle assembly at the other end. The shaft assembly has an angled portion and includes an inner shaft and an outer shaft. The handle assembly is connected to the shaft assembly such that the handle assembly is operable to open and close the jaw assembly to thereby connect to and release the spinal implant.
[0007] According to another aspect of the invention, an inserter for a spinal implant is provided. The instrument includes a jaw assembly, a shaft assembly and a handle assembly. The shaft assembly is connected to the jaw assembly. The shaft assembly includes an inner shaft and a distal shaft. The inner shaft has a distal end configured to engage the jaw assembly. The inner shaft is located in the outer shaft such that the inner shaft is movable with respect to the outer shaft. The distal end of the outer shaft is connected to the jaw assembly such that the jaw assembly is movable with respect to the outer shaft. The handle assembly is connected to the shaft assembly. The handle assembly includes a first portion connected to the second portion such that the second portion is movable with respect to the first portion. The first portion is connected to the proximal end of the outer shaft and the second portion is connected to the proximal end of the inner shaft. The inner shaft is operable via the second portion to open and close the jaw assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The invention is best understood from the following detailed description when read in conjunction with the accompanying drawings. It is emphasized that, according to common practice, the various features of the drawings are not to-scale.
[0009] On the contrary, the dimensions of the various features are arbitrarily expanded or reduced for clarity.
[0010] FIG. 1 a illustrates a top view of an inserter according to the present invention.
[0011] FIG. 1 b illustrates a cross-sectional view of the inserter of FIG. 1 according to the present invention.
[0012] FIG. 2 a illustrates a perspective view of a jaw piece of a jaw assembly of an inserter according to the present invention.
[0013] FIG. 2 b illustrates a top cross-sectional view of the jaw piece of FIG. 2 a of an inserter according to the present invention.
[0014] FIG. 3 a illustrates a perspective view of an outer shaft of a shaft assembly of an inserter according to the present invention.
[0015] FIG. 3 b illustrates a top view of the outer shaft of FIG. 3 a according to the present invention.
[0016] FIG. 3 c illustrates a side view of the outer shaft of FIG. 3 a according to the present invention.
[0017] FIG. 4 illustrates a top view of an inner shaft of a shaft assembly of an inserter according to the present invention.
[0018] FIG. 5 illustrates a cross-sectional view of a handle of a handle assembly of an inserter according to the present invention.
[0019] FIG. 6 illustrates a cross-sectional view of a knob of a handle assembly according to the present invention.
[0020] FIG. 7 a illustrates a top and cross-sectional view of a spacer in juxtaposition with an inserter according to the present invention.
[0021] FIG. 7 b illustrates a top cross-sectional view of a spacer connected to an inserter according to the present invention.
DETAILED DESCRIPTION
[0022] Before the subject devices, systems and methods are described, it is to be understood that this invention is not limited to particular embodiments described, as such may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting, since the scope of the present invention will be limited only by the appended claims.
[0023] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs.
[0024] It must be noted that as used herein and in the appended claims, the singular forms “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a spinal segment” may include a plurality of such spinal segments and reference to “the screw” includes reference to one or more screws and equivalents thereof known to those skilled in the art, and so forth.
[0025] All publications mentioned herein are incorporated herein by reference to disclose and describe the methods and/or materials in connection with which the publications are cited. The publications discussed herein are provided solely for their disclosure prior to the filing date of the present application. Nothing herein is to be construed as an admission that the present invention is not entitled to antedate such publication by virtue of prior invention. Further, the dates of publication provided may be different from the actual publication dates which may need to be independently confirmed.
[0026] The present invention is described in the accompanying figures and text as understood by a person having ordinary skill in the field of spinal implants and related instrumentation.
[0027] Referring now to FIGS. 1 a and 1 b , there are shown top and cross-sectional views, respectively, of an inserter 10 for inserting an intervertebral spacer into a disc space between two adjacent vertebral bodies. The inserter 10 includes a jaw assembly 12 , a shaft assembly 14 and a handle assembly 16 . The shaft assembly 14 is connected to the jaw assembly 12 and the handle assembly 16 . Turning now to FIGS. 2 a and 2 b , there are shown perspective and cross-sectional views, respectively, of the jaw assembly 12 according to the present invention. The jaw assembly 12 includes a two jaw pieces 18 (one jaw piece is shown in FIGS. 2 a and 2 b ), and two fasteners 20 (shown in FIG. 1 b ). Each jaw piece 18 includes a jaw pin receiving portion 22 , a bore 24 for receiving a fastener 20 and spacer engaging features 26 . The spacer engaging features 26 are extending features configured to engage the interbody spacer (not shown). In one variation, the features 26 are projections configured to be inserted into complementary shaped apertures in the interbody spacer. The jaw pin receiving portion 22 includes a first receiving portion 28 and a scalloped portion 30 .
[0028] Referring back to FIG. 1 b , the shaft assembly 14 includes an outer shaft 32 and an inner shaft 34 . The inner shaft 34 is disposed inside the outer shaft 32 . The outer shaft 32 will now be discussed in reference to FIGS. 3 a , 3 b and 3 c.
[0029] Turning now to FIGS. 3 a , 3 b and 3 c , there are shown perspective, top and side views, respectively, of the outer shaft 32 according to the present invention. The outer shaft 32 includes a distal end 36 and a proximal end 38 . The outer shaft 32 is configured as a tube having a central bore 40 opening at and extending between the distal and proximal ends 36 , 38 . In one variation, the outer shaft 32 includes an angled portion 42 imparting the outer shaft 32 with a curve, bend or bayonet-like appearance. The bayonet shape permits the working distal end 36 to be displaced from the proximal handling end 38 . The displacement of the working distal end 36 from the proximal handling end 38 by a distance eases installation of the implant and helps keep the working distal end 36 substantially unobstructed by the instrument's proximal end when viewed from the proximal end 38 along the longitudinal axis of the distal end 36 . In another variation, the outer shaft 32 is not angled and is a substantially straight tube. In one variation, the outer shaft 32 includes an open portion 44 that opens to and extends from the proximal end 38 towards the distal end 36 . The open portion 44 comprises a section of the outer shaft 32 in which the at least a portion of the wall is removed.
[0030] Still referencing FIGS. 3 a , 3 b and 3 c , the distal end 36 of the outer shaft 32 includes a jaw assembly receiving portion 46 configured to receive and connect to the jaw assembly 12 . The jaw assembly receiving portion 46 includes a slot 48 and two substantially flattened portions 50 in substantial parallel orientation with respect to one another. Each flattened portion 50 includes two aligned bores 52 for receiving fasteners 20 .
[0031] Turning now to FIG. 4 , there is shown an inner shaft 34 according to the present invention. The inner shaft 34 includes a distal end 54 and a proximal end 56 .
[0032] The inner shaft 34 is configured to be substantially cylindrical in shape. In one variation, the inner shaft 34 includes an angled portion 58 imparting the inner shaft 34 with a curve, bend or bayonet-like appearance. The angled portion 58 of the inner shaft 34 is configured to conform to the shape of an angled outer shaft 32 such that the angled inner shaft 34 fits inside an angled outer shaft 32 . In another variation, the inner shaft 34 is not angled and is substantially straight and configured to fit within an outer shaft 32 that is also substantially straight. The inner shaft 34 includes a pin 60 at the distal end 54 configured to engage the jaw assembly 12 and to be received in the pin receiving portions 22 of each jaw piece 18 . The pin 60 has a bulbous head or spherically-shaped head connected to a neck portion as shown in FIG. 4 . Other suitable and functional shapes for the pin 60 are within the scope of the present invention and include any polyhedron or partial polyhedron, cube or partial cube, sphere or partial sphere, cylinder or partial cylinder, a prism or partial prism, cylinder or partial cylinder, and any shape with an angled surface or any shape having a surface angled with respect to the inner shaft. The proximal end 56 of the inner shaft 34 includes a threaded portion 62 configured for threaded engagement with the handle assembly 16 . The shaft assembly 14 is assembled by inserted the inner shaft 34 into the outer shaft 32 .
[0033] Turning briefly back to FIG. 1 b , the handle assembly 16 includes a handle 64 and a knob 66 . The handle 64 will now be discussed in reference to FIG. 5 .
[0034] Referring now to FIG. 5 , there is shown a cross-sectional view of the handle 64 of the handle assembly 16 . The handle 64 includes a proximal end 68 and a distal end 70 . The handle 64 has an outer gripping surface and is substantially cylindrical in shape. The handle 64 includes a shaft assembly receiving portion 74 at the distal end 70 configured to connect with at least a portion of the shaft assembly 14 . The handle also includes a knob receiving portion 76 at the proximal end 68 configured to connect to the knob 66 . In one variation, the shaft assembly receiving portion 74 and the knob receiving portion 76 form a central bore 72 of varied diameter opening to and extending between the proximal and distal ends 68 , 70 as shown in FIG. 5 . The handle 64 also includes at least one pin slot 77 for the insertion of pins (not shown) to securely connect the handle 64 to the outer shaft 32 .
[0035] Referring now to FIG. 6 , there is shown a cross-sectional view of the knob 66 of the handle assembly 16 . The knob 66 has a distal end 78 and a proximal end 80 .
[0036] The distal end 78 includes an engaging portion 82 configured to connect with the handle 64 and with the inner shaft 34 . The engaging portion 82 includes a male member having an interior threaded bore 84 for connecting with the threaded portion 62 of the inner shaft 34 . The interior threaded bore 84 opens at the distal end 84 and extends inwardly towards the proximal end 80 . The outer surface of the male member engaging portion 82 is sized to be received in the knob receiving portion 76 of the handle 64 and includes recesses 88 for receiving locking pins for connecting the knob 66 to the handle 64 . The proximal end 80 of the knob 66 has a larger cross-section and includes an interior threaded bore 86 opening at the proximal end 80 and extending inwardly towards the distal end 78 . The threaded bore 86 serves as a connection point for a slap hammer attachment (not shown) permitting use of a slap hammer to aid in removing the inserter 10 from tight intervertebral spaces.
[0037] The assembly of the inserter 10 will now be discussed. The inner shaft 34 is inserted into the outer shaft 32 . Pins 60 of the inner shaft 34 are located in the pin receiving portions 22 of each jaw piece 18 . Fasteners 20 are inserted into the aligned bores 52 of the outer shaft and bores 24 of the jaw pieces 18 and swaged thereto to secure the jaw pieces 18 to the outer shaft 32 capturing the pin 60 of the inner shaft 34 in between the jaw pieces 18 such that the jaw pieces 18 are capable of movement with respect to the outer shaft 32 and about fasteners 20 . At the proximal end, the threaded portion 62 of the inner shaft 34 is threadingly engaged inside bore 84 . The outer and inner shafts 32 , 34 are passed into the central bore 72 of the handle 64 . Pins are passed into apertures 77 of the handle 64 to secure the handle 64 and outer shaft 32 together such that the inner shaft 34 is permitted to move with respect to the outer shaft 32 . Other pins are passed into apertures 77 to engage recesses 88 to prevent the knob 66 from falling out yet permitting it to rotate with respect to the handle 64 .
[0038] Operation of the inserter instrument 10 will now be discussed with initial reference to FIGS. 7 a and 7 b . Referring firstly to FIG. 7 a , an interbody spacer 90 having engaging apertures 92 is shown in juxtaposition with the inserter 10 with the jaw assembly 12 in an open position in which the jaw pieces 18 are spread apart, pivoted about their respective connecting fasteners 20 . The typical spacer 90 includes a body formed by a wall extending about a central cavity. The cavity extends between and opens at an upper bearing surface and a lower bearing surface. The upper and lower bearing surfaces contact the adjacent vertebral endplates to support the adjacent vertebrae when the spacer is implanted into the spinal disc space. The bearing surfaces include grooves formed to facilitate engagement with the vertebral endplates and resist the spacer from migrating within the disc space. The spacer includes a convexly curved anterior wall and an opposite concavely curved posterior wall. These wall portions are connected by a convexly curved leading end wall and a convexly curved trailing end. The overall shape provides a banana or kidney type shape for the spacer.
[0039] The spacer 90 includes spacer engaging apertures 92 that are shown in FIG. 7 a to be aligned with the spacer engaging features 26 of the jaw assembly 12 . The handle knob 66 is rotated such that the threaded engagement with the inner shaft 34 draws the inner shaft 34 proximally with respect to the handle 64 and outer shaft 32 moving the integral jaw pin 60 along with it, thereby angulating the jaws 18 about fasteners 20 into a closed position as shown in FIG. 7 b . In the closed position, the spacer engaging features 26 are clamped to the spacer 90 as shown in FIG. 7 b . Turning the knob 66 in reverse releases the spacer 90 . Hence, the spacer 90 is released and recaptured as desired. The open portion 44 of the outer shaft 32 allows the inner shaft 34 to pass therethrough as it moves proximally and distally with respect to the outer shaft 32 as the knob 66 is turned.
[0040] The preceding merely illustrates the principles of the invention. It will be appreciated that those skilled in the art will be able to devise various arrangements which, although not explicitly described or shown herein, embody the principles of the invention and are included within its spirit and scope. Furthermore, all examples and conditional language recited herein are principally intended to aid the reader in understanding the principles of the invention and the concepts contributed by the inventors to furthering the art, and are to be construed as being without limitation to such specifically recited examples and conditions. Moreover, all statements herein reciting principles, aspects, and embodiments of the invention as well as specific examples thereof, are intended to encompass both structural and functional equivalents thereof. Additionally, it is intended that such equivalents include both currently known equivalents and equivalents developed in the future, i.e., any elements developed that perform the same function, regardless of structure. The scope of the present invention, therefore, is not intended to be limited to the exemplary embodiments shown and described herein. Rather, the scope and spirit of present invention is embodied by the appended claims.
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An inserter for implanting a spinal implant such as an intervertebral spacer into a spinal disc space is disclosed. The inserter comprises a jaw assembly connected to a shaft assembly that is connected to a handle assembly. The shaft assembly includes an angled portion in which the distal end of the instrument is displaced from the proximal end of the instrument affording the clinician a more unobstructed view of the operative site. The user operates the handle assembly at the proximal end to open and close the jaw assembly to thereby connect to and release from the intervertebral spacer.
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This application is a divisional of U.S. patent application Ser. No. 09/026,357, filed Feb. 19, 1998 now U.S. Pat. No. 6,190,332.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to surgical device design and fabrication and, more particularly, to core wires for use in catheters and the like.
2. Description of the Related Art
Medical catheters, such as guidewires and balloon catheters, have been proven efficacious in treating a wide variety of blood vessel disorders. Moreover, these types of catheters have permitted clinicians to treat disorders with minimally invasive procedures that, in the past, would have required complex and perhaps life threatening surgeries. For example, balloon angioplasty is now a common procedure to alleviate stenotic lesions (i.e., clogged arteries) in blood vessels, thereby reducing the need for heart bypass operations.
Because medical catheters must be passed through a tortuous blood vessel network to reach the intended treatment site, it is desirable that the catheters be fairly flexible, especially at the distal end. However, the distal end must not be so flexible that it tends to bend back upon itself when the clinician advances the catheter distal end through the patient.
One method of imparting desired flexibility characteristics to a catheter has been to incorporate a “core wire” into the distal end of the catheter. A core wire is a wire that extends from the distal end of a catheter body, providing structural support to the distal end to prevent bend backs or kinks during catheter advancement. Furthermore, the core wire is also flexible, such that the catheter distal end may navigate tortuous blood vessel networks or other body cavities.
Previously known catheter core wires may not be sufficiently rigid at the very distal tip of the wire. In particular, catheter core wires are commonly formed of superelastic materials such as NiTi alloys which exhibit an elastic response when subject to stress. Superelasticity refers to the ability of a material to undergo deformation and to return to its original configuration without being permanently or “plastically” deformed. This superelasticity, often referred to as transformational superelasticity, exhibits itself as the parent crystal structure of the material as it transforms into a different crystal structure. In superelastic materials the parent crystal structure is known as the austenitic phase and the product crystal structure is known as the martensitic phase. Such formed martensite is termed stress-induced martensite.
While superelasticity may be desirable for the majority of the core wire, superelasticity at the very distal tip of the core wire creates the problem that the tip will not be shapeable. Shapeability is desirable so that a doctor or other person inserting the catheter into the body can shape the tip into a form advantageous for insertion and navigation through the body. If the tip of the core wire is superelastic, the material cannot be shaped.
An additional problem with previously known core wires is that they may not be securely attached to the distal end of the catheter. What is needed is a method to make the connection between the catheter and the core wire secure so that these stress of vascular navigation will not cause breakages.
SUMMARY OF THE INVENTION
The present invention addresses the needs raised above by providing an improved core wire for use in a medical catheter. In one aspect of the invention, there is provided a core wire with a shapeable tip and method of manufacturing the same. A core wire previously made superelastic is subject to additional processing to remove superelasticity from a distal tip, thereby allowing the material at the distal tip to be shapeable to aid in advancing the core wire through a blood vessel or other body cavities.
In one embodiment, the core wire is manufactured by first providing an elongate body of NiTi alloy or similar material. This elongate body is subject to a first cold working in the range of about 20 to 40%. A heat treatment in the range of about 300° to 600° C. for 10 seconds to 60 minutes is performed to impart superelasticity to the body. Following heat treatment, the distal end of the core wire is cold worked from about 10 to 50%, removing superelasticity from this end and producing a shapeable tip at the end of the core wire. The core wire that results is a flexible, superelastic body having a shapeable distal tip with no superelasticity.
Alternatively, once the NiTi is imparted with superelasticity, the distal end of the core wire can be removed of its superelasticity by an additional heat treatment. Heat treatments at temperatures of about 400-800° C. for extended periods of time will cause the material to lose its superelasticity at the distal end. Additionally, superelasticity can be imparted to the core wire by a solution treatment followed by aging process.
In another embodiment of the present invention, a method is provided for securing the core wire to the distal end of an elongated catheter tubular body. Conventional means for attaching a core wire to a catheter body is by soldering, which uses flux of hydrogen. NiTi alloys are susceptible to hydrogen embrittlement, which will in turn diminish the tensile strength of the material. Because of the stresses involved in advancing the catheter through a vessel network, it has been discovered that a core wire soldered to a catheter may break off during catheter advancement. In one aspect of the present method, the tubular body is mechanically crimped onto the core wire to secure the core wire in place. This crimping method has been found to increase the strength of the bond between the core wire and the catheter tube so that greater pull force is required to break the core wire off from the catheter.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a catheter incorporating the core wire of one embodiment of the present invention.
FIG. 2 is a longitudinal partial sectional view of a distal portion of the catheter implementing the preferred core wire before balloon mounting.
FIG. 3A is a schematic view of a first process step for producing the core wire.
FIG. 3B is a schematic view of a second process step for producing the core wire.
FIG. 3C is a schematic view of a third process step for producing the core wire.
FIG. 3D is a schematic view of a fourth process step for producing the core wire.
FIG. 4A is a side view of the core wire manufactured in accordance with the preferred method of the present invention.
FIG. 4B is a cross-sectional view along line 4 B— 4 B of the core wire of FIG. 4 A.
FIG. 5 is a graph comparing the elastic characteristics at the proximal end and at the distal tip of the core wire.
FIG. 6 is a longitudinal cross-sectional view of a distal portion of the catheter implementing the preferred core wire after balloon mounting.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, there is depicted a catheter 10 incorporating the core wire in accordance with the preferred embodiment of the present invention. Although the core wire is depicted and discussed in the context of being part of a simple occlusive device having a single lumen, it should be appreciated that the principles and aspects of the present invention are applicable to more complex occlusive devices having structures and functionalities not discussed herein. For example, the present inventors contemplate that the core wire of the present invention may be used in occlusive devices functioning as anchorable guide wires or filters. In addition, the core wire of the present invention is also applicable to catheters having other types of balloons, such as latex or silicone, or to catheters used for dilatation balloons, made of materials such as polyethylene terephthalate. Moreover, the core wire of the present invention may also be adapted to other types of non-balloon catheters, such as irrigation catheters used in drug delivery or radiation therapy. The tip design of the core wire can also be applicable to ordinary guidewires. In this case the guidewire may be hollow or solid. The manner of adapting the core wire of the present invention to these various structures and functionalities will become readily apparent to those of skill in the art in view of the description which follows.
Guidewires and Catheters
FIGS. 1 and 2 illustrate a guidewire or similar catheter incorporating a preferred embodiment of the core wire of the present invention. The manufacture and construction of the core wire is described in more detail below in connection with FIGS. 3 and 4, respectively. Referring to FIG. 1, catheter 10 generally comprises an elongate flexible tubular body 12 extending between a proximal control end 14 , corresponding to a proximal section of the tubular body 12 , and a distal functional end 16 , corresponding to a distal section of tubular body 12 . Tubular body 12 has a central lumen 18 which extends between ends 14 and 16 . An inflation port 20 is provided on tubular body 12 near the proximal end 14 . Inflation port 20 is in fluid communication with lumen 18 , such that fluid passing through inflation port 20 into or out of lumen 18 may be used to inflate or deflate inflatable balloons in communication with lumen 18 . Lumen 18 is sealed fluid tight at distal end 16 . Inflation port 20 may be similar to existing female luer lock adapters or would be a removable valve at the end, as disclosed in assignee's co-pending application entitled LOW PROFILE CATHETER VALVE AND INFLATION ADAPTER, application Ser. No. 08/975,723, filed Nov. 20, 1997, now U.S. Pat. No. 6,050,972, the entirety of which is incorporated by reference.
The length of tubular body 12 may be varied considerably depending upon the desired application. For example, where catheter 10 serves as a guidewire for other catheters in a conventional percutaneous transluminal coronary angioplasty procedure involving femoral artery access, tubular body 12 is comprised of a hollow hypotube having a length in the range of from about 160 to about 320 centimeters with a length of about 180 centimeters being optimal for a single operator device and 300 centimeters for over the wire applications. Alternately, for a different treatment procedure, not requiring as long a length of tubular body 12 , shorter lengths of tubular body 12 may be provided. Moreover, the catheter 10 may comprise a solid body rather than a hollow hypotube.
Tubular body 12 generally has a circular cross-sectional configuration with an outer diameter within the range of from about 0.008 inches to 0.14 inches. In many applications where catheter 10 is to be used as a guidewire for other catheters, the outer diameter of tubular body 12 ranges from 0.010 inches to 0.038 inches, and preferably is 0.014 to 0.018 inches in outer diameter or smaller. Non-circular cross-sectional configurations of lumen 18 can also be adapted for use with the present invention. For example, triangular, rectangular, oval, and other non-circular cross-sectional configurations are also easily incorporated for use with the present invention, as will be appreciated by those of skill in the art.
Tubular body 12 has sufficient structural integrity, or “pushability,” to permit catheter 10 to be advanced through vasculature to distal arterial locations without buckling or undesirable kinking of tubular body 12 . It is also desirable for tubular body 12 to have the ability to transmit torque, such as in those embodiments where it may be desirable to rotate tubular body 12 after insertion into a patient. A variety of biocompatible materials, known by those of skill in the art to possess these properties and to be suitable for catheter manufacture, may be used to produce tubular body 12 . For example, tubular body 12 may be made of a stainless steel material such as Elgiloy™, or may be made of polymeric materials such as nylon, polyimide, polyamides, polyethylene or combinations thereof. In one preferred embodiment, the desired properties of structural integrity and torque transmission are achieved by forming tubular body 12 out of an alloy of titanium and nickel, commonly referred to as nitinol. In a more preferred embodiment, the nitinol alloy used to form tubular body 12 is comprised of about 50.8% nickel and the balance titanium, which is sold under the trade name Tinel™ by Memry Corporation. It has been found that a catheter tubular body having this composition of nickel and titanium exhibits an improved combination of flexibility and kink resistance in comparison to other materials. Further details are disclosed in assignee's co-pending applications entitled HOLLOW MEDICAL WIRES AND METHODS OF CONSTRUCTING SAME, application Ser. No. 08/812,876, filed Mar. 6, 1997, now U.S. Pat. No. 6,068,623, and SHAFT FOR MEDICAL CATHETERS, application Ser. No. 09/026,105, filed Feb. 19, 1998, now U.S. Pat. No. 6,288,072, both of which are hereby incorporated by reference.
As illustrated in FIG. 1, an expandable member such as an inflatable balloon 22 is mounted on tubular body 12 . Balloon 22 may be secured to tubular body 12 by any means known to those skilled in the art, such as adhesives or heat bonding. In one preferred embodiment, balloon 22 is a compliant balloon formed out of a material comprising a block polymer of styrene-ethylene-butylene-styrene, as disclosed in assignee's co-pending application entitled BALLOON CATHETER AND METHOD OF MANUFACTURE, application Ser. No. 09/026,225, filed Feb. 19, 1998 of which is incorporated by reference.
Referring to FIG. 2, a distal portion of tubular body 12 is shown before mounting of the balloon 22 . A notch 24 is provided in the tubular body 12 to allow fluid communication between the inner lumen 18 and the balloon 22 (not shown) attached to the tubular body 12 . An elongate body or core wire 26 is provided at the distal end 36 of the tubular body 12 , and extends within the inner lumen 18 of the tubular body 12 to a position visible through the notch 24 . Adhesive stops 56 , 58 are provided on tubular body 12 to prevent adhesive bonding of the balloon 22 past the location of the stops, as disclosed in the above-referenced application BALLOON CATHETER AND METHOD OF MANUFACTURE, application Ser. No. 09/026,225, filed Feb. 19, 1998.
Core wire 26 is preferably formed of a shape memory alloy, such as nitinol, but may also be formed of other materials, such as stainless steel. The core wire 26 extends from a proximal end 48 , corresponding to a proximal section of the core wire, to a distal end 30 , corresponding to a distal section of the core wire. The core wire 26 has a flattened tip 28 at its distal end 30 , as described in more detail below in connection with FIGS. 3 and 4. Core wire 26 may range in length from about 20 mm to 100 mm, or more preferably from about 25 mm to 50 mm, and for most occlusive device applications, is typically about 40 mm. In one preferred embodiment, the length of the core wire is about 37 mm. Flattened tip 28 extends from the distal end 30 for a length between about 5 and 10 mm, and more preferably about 7.5 mm.
As shown in FIG. 2, coil 32 is provided around the core wire 26 and extends substantially along the entire length of core wire 26 , from the distal end 30 of core wire 26 to the distal end 36 of tubular body 12 . Coil 32 is soldered at the distal tip 30 of the core wire 26 forming a ball 34 . Coil 32 is secured to the distal end 36 of tubular body 12 by suitable means such as soldering, brazing, or by an adhesive, as described in more detail below. One preferred adhesive type for connecting coil 32 to tubular body 12 is a cyanoacrylate such as LOCTITE 4011, although, as will be appreciated by those of skill in the art, other similar adhesives adopted to form metal to metal bonds may also be used. Coil 32 is formed of a suitable radiopaque material such as gold, platinum or a platinum alloy. Coil 32 can have a suitable outside diameter which corresponds to the outer diameter of tubular body 12 , and can have a suitable length ranging from about 10 to about 50 mm. For example, where tubular body 12 has an outer diameter of 0.014 inches, and core wire 26 has a length of 37 mm, coil 32 may have a length of about 35 mm.
As described in more detail below, the core wire 26 and the coil 32 are formed into a subassembly prior to attachment to tubular body 12 . Once the coil 32 is attached to the core wire, the proximal end 48 of core wire 26 is inserted into tubular body 12 at distal end 36 . Two crimps 38 and 40 are provided near the distal end 36 of the tubular body 12 to secure the core wire 26 to the tubular body. The crimps are preferably located in a location between the notch 24 and the distal tip 36 of the tubular body 12 . The crimps are preferably located a distance 0.5 to 1.5 mm apart, and more preferably, about 1.0 mm apart. The more distal crimp 40 preferably is located about 0.5 mm from the distal tip 36 of tubular body 12 .
Manufacture of the Core Wire
Referring to FIGS. 3A, 3 B, 3 C and 3 D, the core wire 26 can be manufactured by facilitating various thermal and/or mechanical treatments. The alloy comprising the core wire is preferably a NiTi or other superelastic alloy with a length preferably from about 20 to 50 mm, and more preferably with a length of about 37 mm. The alloy can be made superelastic by cold working the material and then heat treating the alloy. In the first step, a cold work can be performed to reduce the core wire diameter. Various facilitating instruments such as swager, metal extrusion and drawing equipment can be utilized to provide cold work. In a preferred embodiment, the core wire 26 is shaped by wire drawing the material at a preferred cold work range of about 20-40%, as shown in FIG. 3 A.
In step two of the process shown in FIG. 3B, following the cold work the core wire is preferably heat treated at a temperature range between about 300 and 600° C. This heat treatment can preferably be done in a salt bath, such as potassium nitrate, or in a protective atmosphere, such as Argon gas, for about 10 seconds to 60 minutes. In this embodiment, the heat treated core wire 26 may not be quenched but preferably cooled down to room temperature in a protective atmosphere. This heat treatment imparts superelastic characteristics to the core wire. Heat treatments below 750° C. do not result in heavy oxidation and therefore may be performed in air.
Step three in the process shown in FIG. 3C provides the core wire 26 with a tapered configuration toward its distal end. The tapering of the wire may be produced by a centerless grinding technique or similar method as would be known to one skilled in the art. In one preferred embodiment, for a core wire with a length of about 37 mm, the wire 26 may be tapered over a distance of about 30 mm.
The fourth step of the process shown in FIG. 3D is to remove the superelasticity from the distal end of the core wire by providing an additional cold work at the distal end 30 . This cold work is preferably performed by rollers to produce a flattened tip 28 at a length about 5-10 mm from the distal end 30 , and more preferably for a length of about 7.5 mm. The preferred cold work range is between about 10 and 50%, and more preferably about 40%. Alternate means for cold working the distal end of the core wire may be used, such as wire drawing or neutron radiation, or other means that would be known to those skilled in the art. As a result of the cold working, the nitinol core wire deforms to a cold worked martensite phase.
As shown in FIG. 4A, the core wire that results from the above described manufacturing has a constant cross-section from proximal end 48 to a boundary 42 , and then tapers in an extending portion 46 from a greater diameter at boundary 42 to a smaller diameter at second boundary 44 towards the distal end 30 of the wire 26 . The cross-sectional area of extending portion 46 decreases by at least about 20%, preferably by at least about 60%, more preferably by about 70%, and optimally by about 80% or more. In one embodiment, the core wire has a diameter of about 0.075 inches at boundary 42 and a diameter of about 0.003 inches at boundary 44 . Beyond boundary 44 , a region of constant cross-section 28 is provided where the core wire has a planar configuration, as shown in FIG. 4 B. This flattened, constant cross-sectional area preferably has a length of between about 5 and 10 mm, and more preferably a length of about 7.5 mm. The thickness of the tip is preferably in the range of about 0.001 to 0.004 inches, and more preferably, about 0.002 inches.
As shown in FIG. 4A, the core wire 26 has a proximal section extending from proximal end 48 to the boundary 44 between the tapered section 46 and the flattened tip region 28 which is superelastic. The core wire 26 has a distal section with a flattened tip portion 28 exhibiting no superelasticity. Elastic characteristics of the nitinol alloys can be best viewed by the stress strain diagrams obtained from various mechanical testing methods such as tensile tests, torsion tests, bending tests or compression tests. Among these methods, the tensile test emerges as the most common mechanical testing method. In particular, tensile tests provide very useful information about both the type of deformation and the amount of deformation that a test sample undergoes under an applies stress. In this respect, FIG. 5, which shows the stress-strain relationship of the proximal and distal sections of core wire 26 , provides very valuable information about the deformation characteristics of the nitinol alloy under tensile test conditions.
As shown in FIG. 5, the core wire 26 in general exhibits two different types of elastic deformation characteristics. The first deformation characteristics is shown by the solid curve 60 , corresponding to the stress-strain behavior of the distal tip 28 . Under the applied stress the curve 60 follows a substantially linear path 62 , wherein the material elastically deforms up to a point 64 , and upon unloading follows a substantially linear unloading curve 66 . There is a slight non-linearity in loading and unloading which causes a hysteresis in strain. The material at the tip 28 can thus be deformed to about 4% with less than about 0.3% permanent set.
FIG. 5 also shows a stress-strain curve 68 of the proximal section of the core wire 26 . Under the applied stress the curve 68 follows a substantially linear path 70 where the austenitic phase elastically deforms. The austenitic phase elastically deforms with increasing stress up to a critical yielding stress value 72 where martensitic transformation begins. After this critical stress point 72 , the material continues to transform into martensite. Throughout the transformation, despite a constant increase in deformation rate of the material, the applied stress remains about the same critical stress value 72 thereby revealing the superelastic property of the material. This superelastic behavior forms a loading plateau 74 on the curve 68 until the entire austenite phase transforms into the martensite phase.
Still referring to FIG. 5, at the end of transformation, the curve 68 no longer follows a straight path but a linearly increasing path 76 where the martensitic material elastically deforms up to a point 78 where unloading begins. During the unloading, the martensite structure transforms into austenite structure. Due to internal friction, there is not an overlap of loading and unloading, and the unloading curve moves down to lower stress values. During the course of unloading, the martensitic phase is first unloaded along the substantially linear portion 80 of curve 68 . At a critical stress value 82 , martensite to austenite transformation begins and continues along the unloading plateau 84 . Upon completion of austenitic transformation, the elastic deformation on austenitic material is unloaded along the linear portion 86 .
Thus, the core wire that results is substantially flexible in a proximal section and has less flexibility, and thus, greater shapeability, at a distal tip. In one preferred embodiment, the flexibility in the proximal section results from the material being processed to exhibit transformational superelasticity, i.e., having an austenite phase which will transform to a martensite phase upon the application of stress. The shapeability of the distal section results from the fact that the distal tip 28 , because of processing as described above, is in a martensitic phase, and thus exhibits only substantially linear elasticity.
Other processing than the steps described above may be used to impart flexibility and shapeability to the different portions of core wire 26 . For instance, instead of cold working and heat treating the wire as shown in FIGS. 3A and 3B, the core wire can be made superelastic by a solution treatment followed by aging process. Solution treatment temperatures are preferably above about 500° C., more preferably above about 700° C., and in one preferred embodiment, about 750° C. Following solution treatment, the core wire is quenched followed by aging. Aging temperatures are preferably in the range of about 300° to 500° C., and more preferably about 350° C.
In addition, superelasticity can be removed from the distal end of core wire 26 by providing an additional heat treatment on the distal end. The heat treatment can be performed with or without need for the second cold work step described in FIG. 3 D. The heat treatment preferably occurs at a temperature between about 400° and 800° C. For a temperature of 400° C., a heat treatment for about an hour or more is necessary to remove superelasticity from the core wire. For a temperature of 800° C., a heat treatment for about ten minutes or more will remove superelasticity. Other combinations of temperature and time of heat treatment to remove superelasticity from the wire as would be known to those skilled in the art. The resulting material at the distal end is in a martensite phase having substantially linear elasticity.
Securing the Core Wire to the Tubular Body
Referring again to FIG. 2, and also to FIG. 6 showing a cross-section of the assembled distal end of catheter 10 , there is depicted tubular body 12 incorporating a core wire manufactured by the present invention. The catheter 10 shown in FIG. 6, in addition to showing the tubular body 12 , core wire 26 and coil 32 as shown in FIG. 2, also depicts the balloon 22 mounted on the tubular body 12 . A distal marker 54 is located on tubular body 12 under an adhesive taper 50 adjacent the proximal end 92 of balloon 22 . A distal adhesive taper 52 is provided adjacent the distal end 94 of balloon 22 . Further details are provided in the above-referenced application SHAFT FOR MEDICAL CATHETERS application Ser. No. 09/026,105, filed Feb. 19, 1998, now U.S. Pat. No. 6,288,072.
In order to attach the core wire 26 to the tubular body 12 , the coil 32 is first attached to the core wire 26 in a subassembly. The core wire 26 is processed as described above and cut to the desired length. In the embodiment shown in FIGS. 2 and 6, the length of the core wire is about 37 mm. The coil 32 is then cut to a desired length which is shorter than the length of the core wire. As shown in FIGS. 2 and 6, the coil length is about 35 mm. The coil 32 is then slid over the core wire into a position leaving a proximal end 48 of the core wire exposed. In the embodiment shown in FIGS. 2 and 6, the proximal end 48 of the core wire 26 is exposed about 2 mm. The coil 32 is then soldered to the core wire 26 , preferably at two positions on the core wire 26 . FIG. 2 shows a proximal solder 88 at an intermediate position on the core wire, and a distal solder which forms the ball 34 at distal end 30 . Other locations for soldering the coil 32 to the core wire 26 are also contemplated by the invention.
This core wire-coil subassembly is then ready for insertion into tubular body 12 . Proximal end 48 of core wire 26 is inserted into a lumen 18 of tubular body 12 until the coil 32 butts against tubular body 12 , and core wire 26 is visible through notch 24 . Core wire 26 is secured within lumen 18 by crimping tubular body 12 such that the interior surface of tubular body 12 defining lumen 18 contacts proximal end 48 and firmly secures it within lumen 18 . Preferably, tubular body 12 is crimped at at least two points to secure proximal end 48 within lumen 18 . As shown in FIG. 2, two crimps 38 and 40 secure the tubular body 12 to the core wire 26 . In those embodiments where tubular body 12 is made of nitinol, sufficient crimping pressure must be exerted upon tubular body 12 to overcome the elastic response of nitinol. Generally, this requires exertion of sufficient pressure to deform the nitinol tubular body 12 by about 9% or more. For a nitinol tubular body 12 having an outer diameter of 0.014 inches, and an inner diameter of about 0.0095 inches, to be crimped over a nitinol core wire end 48 having an outer diameter of about 0.009 inches, it has been found that a pressure of about 120 ksi is sufficient. Other pressures may also be used provided that they are sufficient to cause tubular body 12 to securely contact core wire 26 , but not so great as to unduly deform tubular body 12 .
End 48 may be further sealed by use of adhesives 90 which are used to seal the balloon 22 to tubular body 12 . As shown in FIG. 2, balloon 22 is sealed at a proximal end 92 to the tubular body 12 , and at a distal end 94 to the coil 32 and tubular body 12 . The balloon 22 is bonded to tubular body 12 and the coil 32 by the adhesive 90 , preferably a cyanoacrylate such as LOCTITE 4011, although other types of adhesives may be used. The adhesive 90 is applied to the proximal and distal ends 92 and 94 of the balloon 22 and wicks into the balloon 22 up to the position of the adhesive stops 56 and 58 . Further details of balloon bonding are given in the above referenced application BALLOON CATHETER AND METHOD OF MANUFACTURE, application Ser. No. 09/026,225, filed Feb. 19, 1998. This adhesive 90 acts not only to seal the balloon to the catheter, but also to aid in sealing the coil 32 to the distal end 36 of tubular body 12 .
It will be appreciated that certain variations in the method of manufacture of the core wire of the present invention may suggest themselves to those skilled in the art. The foregoing detailed description is to be clearly understood as given by way of illustration, the spirit and scope of this invention being limited solely by the appended claims.
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The present invention provides an improved core wire for use in a medical catheter. In one aspect, the invention provides a core wire with a shapeable tip and method of manufacturing the same. A core wire previously made superelastic is subject to additional processing to remove its superelasticity thereby allowing the material to be shapeable to aid in advancing the core wire through a blood vessel or other body cavities. In another aspect of the present invention, a method is provided for securing the core wire to the distal end of an elongated catheter tubular body. The tubular body is mechanically crimped onto the core wire to secure the core wire in place. This crimping method has been found to increase the strength of the bond between the core wire and the catheter tube so that greater pull force is required to break the core wire off from the catheter.
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FIELD OF THE INVENTION
[0001] This invention relates to the field of detecting conception and/or implantation in animals, including humans, and apparati therefor.
BACKGROUND OF THE INVENTION
[0002] It has been a long-sought goal of physicians and veterinarians to have reliable diagnostic markers for conception, implantation and viable pregnancies, to help manage treatment of infertility and early pregnancy treatment. In humans, early pregnancy diagnosis based on placental protein markers is only routinely relied upon at 4 weeks after conception, and ultrasonic analysis is only reliably positive at 7-8 weeks gestation.
[0003] In the livestock industry, it is important to be able to identify animals that have not successfully conceived following breeding. For example, in the cattle industry at the present time, there is no way to identify such animals before 35-40 days after breeding, and the identification must be made by a veterinarian using palpation. Alternatively, ultrasound analysis can detect a developing embryo at 21 days. Veterinarian palpation is by far the most commonly used method, costing approximately $4 to $10 per test. The cost for an ultrasound analysis is prohibitive for routine farm management. In addition to the costs of these tests, the farmer suffers an additional and significant financial loss in having cows that have been bred but have not conceived, also referred to as “open” cows. The “open” cow costs the farmer an additional $4 to $10 dollars per day. The better milk producers are the hardest cows to breed, so while they are “open” the loss is even greater. Less than 50% of cows conceive on the first breeding. Due to this fact, the usual breeding program allows for 2½ semen straws per cow. If the time interval during which a cow is “open” can be shortened to days instead of months, this would substantially increase the overall calving rates.
[0004] A factor, named early pregnancy factor (EPF) or more recently immunosuppressive early pregnancy factor (ISEPF), has been detected in animals using a bioassay, and it is thought to be responsible for suppressing the maternal immune response against the embryo/fetus. Despite the demonstration of the activity through a bioassay, the literature presents several different MW forms for ISEPF. In mice, Clarke et al. (Clin Exp. Immunol. 32:318, 1978) reported an EPF of approximately 180,000 kD. In sheep, Clarke et al (J. Reprod. Immunol. 1980 Vol. 2:151) described the existence of multiple forms of EPF, including 20 kD, 50 kD, and 250-350 kD forms. In a 1987 paper from the same laboratory, Clarke et al describe the purification of a 12 kD EPF from the placenta of 12 weeks pregnant sheep (J. Reprod. Immunol. 1987 10:133-156). Cavanaugh described the purification of a 21 kD EPF from cultured ovaries and oviducts of mice, which is composed of three subunits, 10.5, 7.2 and 3.4 kD in size (J. Reprod. Fertil. 71:581, 1984). The factor has most recently been described as a glycoprotein of high molecular weight (Threlfall, 1993), but prior to this invention, a functionally pure preparation was not known.
[0005] An indirect bioassay for the ISEPF utilizes an in vitro, rosette inhibition assay described by Bach and Antoine (Nature 217:658 1968), which measures the ability of ISEPF to enhance the inhibition of rosette formation between T cells and heterologous erythrocytes induced by anti-lymphocyte serum (ALS). Both molecular weight components must be present to detect ISEPF in the rosette assay. It has been postulated that the ALS sterically hinders the binding of the erythrocytes in the assay; ISEPF enhances the inhibition by saturating some binding sites on the lymphocytes (Smart, Y C et al., Fertil. & Steril. 35: 397, 1981). ISEPF has been found in the mouse (Morton et al., Nature 249:459 1974), rat (Heywood, L H et al. Australian Soc. for Reprod. Biol. 1979), human Morton, H. et al., Lancet 394 1977), sheep (Morton, H. et al. Res. in Vet. Sci. 26:261 1979), pig (Grewal, A S et al. Australian Soc. for Reprod. Biol. 1981), and cattle (Nancarrow et al. J. Reprod. & Fert. 57:385 1979). Noonan et al (Nature 278:629 and 649 1979) have described ISEPF as species non-specific.
[0006] Given the appearance of ISEPF very soon after mating, it is possible that ISEPF could be an excellent early marker for conception in animals. However, the rosette inhibition assay is technically difficult to perform, time-consuming, cumbersome and subject to numerous false-positive readings (Sinosich et al., 1985). To develop an ISEPF assay that is reproducible and not subject to a large number of false-positive signals, a substantially pure preparation of ISEPF is required. Prior to this invention, no protocols for the complete purification of a high molecular weight ISEPF have been reported.
[0007] There remains a need for a reliable assay to detect pregnancy as early as possible after conception and further to detect spontaneous abortion.
[0008] There is a need to be able to breed animals and determine, within 12-48 hours, whether the breeding has resulted in conception. In cattle, as an example, such non-conceiving cows could be recycled with injections of prostaglandin and inseminated again without the loss of thirty days. There is further a need to be able to enhance the ability of elite cows to implant at a higher rate.
SUMMARY OF THE INVENTION
[0009] The present invention provides a purified factor, herein referred to as the “early conception factor” or ECF, antibodies specific for ECF, and kits and apparatuses for detecting the presence or absence of ECF in fluid or tissue samples taken from animals. Methods for detecting conception within 12-48 hours of breeding/mating are described. Methods for detecting fetal death following conception and implantation are also provided. Means for enhancing embryonic implantation utilizing the ISEPF and the anti-ISEPF antibodies of this invention are also provided.
BRIEF DESCRIPTION OF FIGURES
[0010] [0010]FIG. 1 is a schematic of the support of the present invention, showing 1) a support on which a sample containing ECF has been analyzed (“ECF-positive”) and 2) a support on which a sample not containing ECF has been analyzed (“ECF-negative”); “T”marks the location of a band of test, or anti-ECF, antibodies; “C” marks the location of a band of control antibodies.
[0011] [0011]FIG. 2 is a schematic of a body in contact with a support of the present invention, shown in both the open and closed positions.
DETAILED DESCRIPTION OF THE INVENTION
Definitions
[0012] As used herein, “conception” can be used interchangeably with “fertilization”.
[0013] As used herein, “a” can mean one or more than one.
[0014] As used herein, “purified” refers to a protein (polypeptide, peptide, etc.) that is sufficiently free of contaminants or cell components with which it normally occurs to distinguish it from the contaminants or other components of its natural environment. The purified protein can be homogenous, but need not be homogeneous. It must be sufficiently free of contaminants to be useful in a clinical or research setting, for example, in an assay for detecting antibodies to the protein.
Detailed Description
[0015] The present invention provides antibodies that specifically bind to purified ECF. The antibodies can be specifically reactive with a unique epitope of the antigen or they can also react with epitopes of other organisms. The term “bind” means capable of reacting or otherwise associating nonrandomly with an antigen. “Specifically bind”, “specifically react with” or “specifically against” describe an antibody or other ligand that does not cross react substantially with any antigen other than the one specified, in this case, the purified ECF.
[0016] Preferably, the purified ECF has a molecular weight between 190,000 and 205,000 as measured by denaturing gel electrophoresis in a 4-15% gradient polyacrylamide gel, with appropriate MW standards including 20,000, 144,000 and 208,000 [Amersham Polyacryl® standards]. The glycoprotein ECF is obtained through an initial purification step that removes all non-glycoproteins. This step can be perchloric acid extraction. The resulting glycoprotein fraction can be used as described herein to produce antibodies and to treat animals, including humans. The ECF may be further purified by ion exchange chromatography, and further again by column chromatography, resulting in Fractions A1, A2, and B, as described in Example 1. These fractions are combined to produce a further purified ECF. ECF purified by one or more of the steps described in Example 1, and Fractions A1, A2 and B thereof, can be obtained from cows, cats, dogs, humans, horses, sheep and pigs.
[0017] The present invention provides antibodies that can recognize and bind ECF from cows, cats, dogs, humans, horses, sheep and pigs. The present antibodies can be of any isotype, e.g. IgG, IgM, or IgA types, from any animal, and they can be polyclonal, monoclonal, humanized, fully human or chimeric. The antibodies can be monovalent or divalent single chain antibodies. As contemplated herein, the antibody includes any ligand which binds the ECF, for example, an intact antibody, a fragment of an antibody or another reagent that has reactivity with the antigen. Antibodies raised against ECF from one species can be used to recognize and bind ECF from other species. Optimization of interspecies antigen-antibody reactions is performed according to protocols known in the art, including optimization of the ratio of antibody-antigen and the blocking proteins used to enhance specificity. Preferably, antibodies raised to the ECF from a given species are used to recognize and bind ECF from the same species.
[0018] The present invention provides a method of detecting the glycoprotein ECF using antibodies, by contacting a fluid or tissue sample from the subject with an amount of anti-ECF antibody specifically reactive with ECF, and detecting the reaction. It is contemplated that ECF can be detected in an intact form in the sample, or as fragments. The fluid sample of this method can comprise any body fluid which would contain ECF or a cell containing ECF, such as blood, plasma, serum, saliva and urine. Other possible examples of body fluids include sputum, mucus, gastric juice and the like. One method effective for the detection of ECF can, for example, be as follows: (1) bind the anti-ECF antibody to a support; (2) contact the bound antibody with a fluid or tissue sample containing ECF; (3) contact the above with a secondary antibody bound to a detectable moiety (e.g., horseradish peroxidase enzyme or alkaline phosphatase enzyme); (4) contact the above with the substrate for the enzyme; (5) contact the above with a color reagent; (6) observe color change. In a specific embodiment, washing steps are included between one or more of the steps listed above. The detectable moiety will allow visual detection of a precipitate or a color change, visual detection by microscopy, or automated detection by spectrometry, radiometric measurement or the like. Examples of detectable moieties include fluorescein and rhodamine (for fluorescence microscopy), horseradish peroxidase (for either light or electron microscopy and biochemical detection), biotin-streptavidin (for light or electron microscopy), colloidal gold (for precipitate formation) and alkaline phosphatase (for biochemical detection by color change). The detection methods and moieties used can be selected, for example, from the list above or other suitable examples by the standard criteria applied to such selections (James W. Goding, Monoclonal Antibodies: Principles and Practice, Academic Press, 1983; and Harlow and Lane, Antibodies; A Laboratory Manual, Cold Spring Harbor Laboratory, Cold Spring Harbor, New York, 1988).
[0019] A specific embodiment of this invention for detecting ECF involves the use of a “dipstick” assay in which a strip (the “dipstick”) is prepared with anti-ECF antibodies immobilized on the strip in a sharp band at a location spacially separated from the location for loading sample. At the sample loading location, anti-ECF antibodies labeled with a detectable moiety are deposited. Then, a) a test fluid is added to the sample loading pad; b) the ECF in the test fluid binds to the anti-ECF antibodies, and this complex is wicked along the strip by capillary flow until it contacts the immobilized anti-ISEPF antibody band; and c) ECF:anti-ECF antibody complexes are concentrated at the band, allowing visualization of the detectable moiety, by any of the methods described above. In a further embodiment of this invention, a second band of antibodies can be immobilized on the strip, on the side distal to the sample loading band. The antibodies of this second band are chosen to recognize the immunoglobulin of the animal in which the anti-ECF antibodies were produced, e.g. anti-goat IgG. This second band serves as an internal, positive control for the dipstick assay to demonstrate that the dipstick is working properly. The amount of anti-ISEPF antibodies immobilized at the first band is controlled so that enough ECF:anti-ECF antibody complex will move through the first band location to contact the anti-goat IgG antibodies.
[0020] The present invention provides a method of detecting conception or implantation in an animal comprising detecting the presence of ECF in samples taken from a mated female animal. The type of sample taken will depend on the species of animal being tested, but serum, urine or milk samples are preferred. Saliva and vaginal secretions can also be used. The sample can be used without further processing or it can be processed by dilution in a fluid, such as a blocking solution to limit non-specific binding. Examples of blocking solutions include SeaBlock (East Coast Biologicals, New Brerwich, Me.) mixed with 1% newborn calf serum and 10 mM Tris with 2% Tween-20.
[0021] The present invention further provides a method for detecting the absence of conception in an animal within 12-48 hours of mating comprising determining the presence or absence of ECF, the absence of ECF indicating the absence of conception.
[0022] The present invention provides methods for detecting spontaneous abortions in pregnant animals by monitoring the level of ECF after mating, e.g. from less than one day to 48 days. Preferably, the levels of ECF are monitored periodically following conception and/or implantation. In humans, such monitoring can also be used to minimize the use of abortion-inducing drugs, e.g. RU-486, by indicating whether conception and implantation have occurred following mating.
[0023] The present invention can be used to enhance the likelihood of implantation or conception in animals, including humans, and to minimize the chances for abortion. Low levels of ECF are correlated with a lower likelihood of conception or implantation, while higher ECF levels are a good predictor of a high likelihood of conception, implantation and maintained pregancy. Thus, animals could be provided with additional ECF, most likely through intravenous administration, to bring their levels of ECF into the appropriate ranges for conception, implantation and pregnancy maintenance.
[0024] The present invention provides apparati for use in detecting the presence of ECF comprising a support on which antibodies to ECF are present. In one embodiment (FIG. 1), the support ( 1 ) comprises a strip made of material along which fluid can flow. At one end of the strip, sample fluid is introduced, and the fluid flows along the support and contacts antibodies to ECF. In a specific embodiment, a wicking aid ( 2 ), such as Whatman CHO-17, is attached to the non-sample end of the strip to enhance fluid flow. In a specific embodiment, the location for sample introduction includes an absorbent pad ( 3 ), which can be made of a glass fiber material, Whatman FO-75, or any other suitable material.
[0025] The present invention provides apparati for use in detecting the presence of ECF comprising a body in contact with a support on which antibodies to ECF are present. The body can be made from different types of materials, e.g plastic, metal, or cardboard, and it can be of any shape that will accomodate the support. A specific embodiment (FIG. 2) of the body ( 4 ) is a football-shaped compact, 4 to 10 cm long, hinged at one end, with guides ( 5 ) to secure the support and one opening ( 6 ) for introduction of the sample and another opening ( 7 ) for viewing the antibody-antigen reaction. Another specific embodiment is a rectangularly shaped box with a bottom and top, (2-3)×(4-10) cm. The support can be any material to which antibodies can be bound. Different types of antibodies may bind better to one support than another, as is well understood in the art. As an example, IgA monoclonal antibodies do not bind well to most membranes. Nevertheless, having determined a method for accomplishing this, the present invention can utilize IgA antibodies.
[0026] In one embodiment of the apparatus, the antibodies to ECF are monoclonal IgAs, and the sample pad is a glass fiber material. In a specific embodiment, the absorbent sample pad is made from Whatman FO-75. In a specific embodiment of the apparatus, the antibodies to ECF are polyclonal, and the support is a 5 micron nitrocellulose membrane. In a specific embodiment, the nitrocellulose membrane is Whatman 5 μM. Other membranes, currently available or later developed, can also be used. The absorbent sample pad and any wicking aid can be disposed atop the support material, for example the nitrocellulose membrane. Alternatively, the absorbent sample pad and a wicking aid can be placed so that their ends abut the ends of the support, such as the nitrocellulose membrane.
[0027] In one embodiment of the apparatus, the support will have anti-ECF antibodies placed at two, spacially separated locations. A fluid containing the test sample from an animal is introduced to the support, and the support wicks the fluid so that it first contacts the location on the support where labeled antibodies have been deposited, and then continues to wick along the support to contact the second location wherein antibodies are bound. Anti-ECF polyclonal antibodies can be used at both locations, or any combination of anti-ECF monoclonal and polyclonal antibodies at the two locations can be used. For example, labeled anti-ECF monoclonal antibodies are placed at one location on the support, anti-ECF polyclonal antibodies are bound to another location, and the test sample is introduced at the location wherein the monoclonal antibodies have been placed. In another embodiment, labeled anti-ECF polyclonal antibodies are placed at the location where the sample is introduced, and anti-ECF monoclonal antibodies are immobilized at the second location. Anti-ECF monoclonal antibodies recognizing different epitopes can be used at both locations.
[0028] The apparatus can further include means for directing the sample-containing fluid to the chosen location on the support. In a further embodiment, a blocking solution, as described herein, can be added after the sample is placed on the support.
[0029] Throughout this application, various publications are referenced. The disclosures of these publications in their entireties are hereby incorporated by reference into this application in order to more fully dsecribe the state of the art to which this invention pertains.
EXAMPLES
Example 1
Purification of ECF
[0030] Serum was collected from cows at 12-48 hours after breeding in volumes greater than 250 ml and frozen until pregnancy was confirmed in 45 days. When serum was approved for ECF extraction, through confirmation of pregnancy by other means, it was thawed at room temperature. Equal volumes of a dilute perchloric acid solution (70% perchloric acid diluted in a ratio of 1 ml per 50 ml distilled water) and serum were mixed using a magnetic stirrer. The mixture was kept in an ice bath with constant stirring for 1 hour. The mixture was then centrifuged for 30 minutes at 2000 g using a refrigerated centrifuge. The resulting supernatant was dialyzed for 72 hours against distilled water, then checked for the presence of ECF by immunological documentation.
[0031] Dialyzed supernatant, buffered to pH 7.4 with sodium phosphates, containing ECF was further purified using a highly purified cellulose powder containing diethylaminoethyl (DEAE) exchange groups equilibrated in 0.025M sodium phosphate buffer pH 7.4. The non-absorbed fraction from the DEAE powder was collected as Fraction A. The material in the supernatant that bound to the DEAE column was eluted using 0.05M Sodium Phosphate, 0.9% sodium chloride pH 7.4 and collected as Fraction B. Fractions A and B were each dialyzed against distilled water.
[0032] Fraction A was then further purified by passing it over a Sepharose 4B with 0.05M Tris HCL buffer pH 7.4, and collecting two peaks, labeled Fraction A1 and Fraction A2, which were then recombined to reconstitute Fraction A.
[0033] The two ECF fractions, A (reconstituted as above) and B, and a combination of equal milligrams of Fractions A and B, were each diluted to 1 milligram per ml in normal saline. These three preparations were used to immunize three separate graded goats for the production of antibodies. The three goats' antiserum were tested against each of the three immunizing preparations. For example, Goat No. 20, which was immunized with the combination of Fraction A and Fraction B, showed strong immunological reactivity against all three of the immunizing antigens.
Example 2
Production of Anti-ECF Polyclonal Antibodies
[0034] Graded goats were immunized with the purified ECF fractions A and B from Example 1, which were combined and diluted to 1 mg/ml.
[0035] Eight primary injections of antigen using Freund's complete adjuvant were given to each goat. A typical immunizing antigen preparation contained 20 ml of reconstituted Fraction A and Fraction B (both prepared as described in Example 1) at 1 mg/ml and 20 milliters of Freund's Complete Adjuvant. Two (2) milliters of this preparation were removed and homogenized to less than 1 milliter which was then injected into the muscle of the goat. Injections were given twice a week, three days apart. Eight days following the eighth injection, the goats were bled and the antibodies harvested from the blood. The antibodies were tested for activity against purified ECF. Those animals that tested positive were subsequently given monthly booster injections, and were bled eight days after each booster injection to provide a steady supply of antiserum.
[0036] To increase the specificity of the antiserum so produced, each serum collection was absorbed with pooled normal human serum and serum from non-immunized cows until no lines were visible in Ouchterlony Gel Diffusion studies. This pre-absorbed antiserum was further purified using sodium sulfate fractionation. The resulting antibody preparations were then used for the development of a hemagglutination-inhibition assay and an enzyme immunoassay. The antibodies were also further purified using a Procept A (Bioprocessing Ltd., Durham, United Kingdom) chromatographic column, eluted with phosphate buffered saline at pH 7.4, and these antibodies were used in the dip-stick assay.
Example 3
Production of Anti-ECF Monoclonal Antibodies
[0037] Balb C mice were used for immunization using the immunizing preparations described in Example 2. The same immunization schedule as used for the goats was followed for the mice, except that two days following the last injection, the fusion of the mouse spleen cells with SP2/0-Ag melanoma cells (available from American Type Culture Collection) using 30% polyethyleneglycol in RPMI 1640 medium was performed. Standard maintenance of hybridoma cells in hypoxanthine, aminopterin, and thymidine (HAT)-containing medium was followed (Goding, 1983; and Harlow and Lane, 1988). The antibody producing cells with the strongest titer were identified using hemagglutination procedures with red blood cells that were coated with ECF, prepared following standard procedures known in the art.
[0038] Selected hybridoma cells were propagated for the production of monoclonal antibodies. Cloning of a specific hybridoma cell line was done by limiting dilution in fluid phase and semisolid agarose techniques. The anti-ECF antibody producing clones were maintained and grown in volume using HAT-containing DMEM (Dulbecco's modified Eagle's medium), using protocols known in the art (Harlow and Lane, 1988).
[0039] An anti-ECF monoclonal antibody selected by these procedures was isotyped and documented to be an IgA. It was shown to react with various preparations of ECF antigens by Western blot analyses. This monoclonal antibody was coupled to colloidal gold using procedures known in the art (e.g. Julian Beesley, Colloidal Gold, Oxford Press, 1989)
Example 4
Construction of an Assay Kit for Determining Conception Status
[0040] A kit was constructed using anti-ECF polyclonal antibodies described in Example 2 bound to a 4.5×0.5 centimeter (cm) strip of Whatman's 5 micron nitrocellulose membrane. Anti-ECF monoclonal antibodies, as described in Example 3, were coupled to colloidal gold to form a conjugate and deposited on a 2.5 cm×0.5 pad of Whatman's OF-75 material.
[0041] The kit was assembled as a lateral flow device by placing the two antibody-containing strips end-to-end as a 7 cm strip, with the animal test sample to be introduced to the FO75 pad, i.e. the “sample end”. A second pad, made from CHO-17 glass fiber material, was placed at the other end (i.e. the non-sample end) to aid in the wicking of fluid from the sample end through the nitrocellulose membrane strip. The anti-ECF polyclonal antibodies were bound to the membrane in a “Test” band (approximately 0.1 cm in width) located approximately 3.4 cm from the sample end of the strip. A control goat IgG antibody (Sigma, St. Louis, Mo.) was bound in a similarly sized “Control” band located approximately 0.5 cm from the anti-ECF polyclonal antibodies, on the side of this band distal from the sample end.
Example 5
Performing the ECF Assay for “Open” Cows
[0042] A serum sample from a cow being tested was introduced as a drop to the strip kit of Example 4 at the sample end of the strip, approximately 1 cm from the end of the strip. Approximately 2-8 drops of blocking buffer is added directly on top of the serum sample, and the liquid is allowed to wick along the strip to the two areas bound with antibodies. The presence of a single line on the strip (which would be located at the control band) indicates that the cow is “open”, i.e. the cow has not conceived. The presence of two lines on the strip, located at each of the control and test bands, indicates a cow that has conceived.
[0043] The assay was performed on 153 cows that had been artificially inseminated, and the results of the ECF assay were compared to the results from veterinary palpation. Of 65 animals shown to be pregnant by veterinary palpation, 53 were positive in the ECF assay. Of 89 animals determined not to be pregnant by palpation, 45 were negative in the ECF assay.
Example 6
Assay for ECF in Humans
[0044] Samples were collected from patients who were artificially inseminated. Samples were assayed for the presence of ECF using a urease-anti-ECF conjugate. The following data was collected:
Sampling Time after insemination (in days) Patient No. 0.25 2.0 6.0 12.0 Pregnant? 1 .358 .120 .100 .100 no 2 .114 .095 .094 .091 no 3 .103 .099 .093 .098 no 4 .103 .096 .100 .095 no 5 .070 .079 .052 .088 no 6 .104 .096 .081 .108 no 7 .301 .159 .105 .111 no 8 .104 .106 .094 .101 no 9 .102 .098 .092 .058 no 10 .075 .085 .091 .050 no 11 .075 .082 .078 .087 no 12 .073 .076 .081 .096 no 13 .079 .081 .078 .078 no 14 1.657 1.691 1.674 1.557 yes 15 1.660 1.690 1.708 1.577 yes 16 .087 .070 .087 .088 no 17 .074 .078 .075 .077 no 18 .085 .077 .074 .074 no 19 .087 .081 .075 .030 no 20 .082 .077 .079 .096 no 21 .084 .079 .074 .075 no 22 .083 .078 .078 .077 yes* 23 .087 .088 .090 .078 no 24 .077 .074 .078 .080 no
[0045] Although the present invention has been described with reference to specific details of certain embodiments thereof, it is not intended that such details should be regarded as limitations upon the scope of the invention except as and to the extent that they are included in the accompanying claims.
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The present invention provides antibodies which specifically bind early conception factor, which can be found in body fluids of animals including but not limited to the cow, cat, dog, horse, human, sheep, and pig. The invention provides methods for detecting conception or the absence of conception in an animal, the latter being recognized by the absence of early conception factor in a suitable body fluid collected from the animal. Apparati for detecting early conception factor in a body fluid from an animal comprising the antibodies which specifically bind early conception factor are also provided.
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BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to a rotary heat exchanger and more specifically to a rotary heat exchanger which exhibits good heat exchange characteristics and an improved leakproof seal construction.
DESCRIPTION OF THE PRIOR ART
JP-B-59-41111 and JP-B-60-23277 disclose rotatary heat exchangers of nature shown in FIGS. 1 and 2. This type of device includes an inlet port 1 via which fluid F is supplied into a supply chamber 2. A seal arrangement 3 supports a supply conduit 4 in a manner wherein the upstream end thereof is placed in fluid communication with the supply chamber 2. The downstream end of the supply conduit communicates with an essentially annular rotatable header 5. A plurality of hollow blower blades are arranged to establish fluid communication between the outer peripheral portion of the supply header and the corresponding portion of a rotatable exhaust header 7. An exhaust conduit 8 is arranged to communicate at its upstream end with exhaust header and to be rotatably supported by way of seal arrangements 9 and 10 in a exhaust chamber 11. The portion of the exhaust conduit defined between the two seal arrangements 9 and 10 is apertured in a manner wherein the fluid which is supplied into the exhaust header can be discharged into the exhaust chamber 11 and subsequently drained therefrom via an outlet conduit 12.
The hollow blower blades 6 are provided with a plurality fins 13 which improve the heat exchange efficiency of the arrangement. A motor 14 is operatively connected to an end portion of the exhaust conduit 8. When this motor is energized the rotatary headers and interconnecting hollow blower blades are induced to rotate in a manner to define a rotary type blower arrangement.
However, this arrangement suffers from the drawback that both the fins 13 which are formed either in the form of circular or annular plates and the shaped hollow blower blades must be very carefully formed and assembled in order to achieve a good fit and the required balance of the rotating parts.
This of course renders the manufacture and assembly of the same both difficult and time consuming and increases the cost of the device undesirably.
In addition to this, the seal arrangements 3, 9 and 10 which are provided in order to prevent leakage of the fluid which is circulated through the device and subject to cooling, are subject to vibration and radial forces due to the inevitable slight imbalance in the rotating parts of the device and tend to readily readily deteriorate to the point of permitting leakage to occur.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a rotary heat exchanger which can be readily and economically manufactured and which has a durable bearing/seal construction which ensures smooth rotation and protects the seals from vibrational forces and the like in a manner which ensures the longevity of the same.
In brief, the above object is achieved by an arrangement which features plurality of hollow disc shaped members which are arranged along a distribution conduit and arranged to be rotatable about an axis which is concentric with the axis of the distribution conduit. A plurality of exhaust conduits are arranged to fluidly interconnect the disc members at locations proximate their peripheries. Structures which define inlet and outlet chambers include bearings and seals which are arranged in parallel so that the bearings protect the seals from damage during rotation of the device.
More specifically, a first aspect of the present invention is deemed to comprise a rotary heat exchanger which features: a distribution conduit, said distribution pipe being arranged to be coaxial with an axis of rotation of said rotary heat exchanger, said distribution conduit having a open end and a closed end, said open end being arranged to be supplied with fluid; a plurality of hollow annular disc members, said hollow disc members being arranged to communicate at their inner peripery with said distribution pipe in a manner wherein the fluid which is supplied into said distribution pipe flows radially outward therethrough; and a plurality of exhaust conduits, said exhaust conduits being arranged to fluidly interconnect said annular disc members at locations proximate the outer peripheries thereof.
A second aspect of the invention is deemed to comprise a rotary heat exchanger which features: a distribution conduit, said distribution pipe being arranged to be coaxial with an axis of rotation of said rotary heat exchanger, said distribution conduit having a open end and a closed end; a plurality of hollow annular disc members, said hollow disc members being arranged to communicate at their inner peripery with said distribution pipe; a plurality of exhaust conduits, said exhaust conduits being arranged to fluidly interconnect said annular disc members at locations proximate the outer peripheries thereof; first and second end plates, said first and second end plates each having a dished configuration, said first end plate having an opening in which said open end of distribution pipe is received, said second end plate having a plurality of openings in which said plurality of exhaust conduits are received; first and second covers, said first and second covers being arranged with said first and second end plates to define first and second enclosed spaces therebetween; first and second plates, said first and second plates being arranged to partition said first and second enclosed spaces and to define an inlet chamber in said first space and an outlet chamber in said second space, said first and second plates being formed with first and second bores, respectively, said first bore being arranged to receive a portion of said inlet pipe arrangement and said second bore being arranged to receive a portion of said outlet pipe arrangement, said inlet chamber fluidly communicating with both of said distribution conduit and said inlet pipe so that fluid introduced thereinto from said inlet pipe can be transferred into said distribution pipe, said outlet chamber being arranged to fluidly communicate with said exhaust conduits and said outlet pipe in manner that the fluid discharged thereinto from said exhaust conduits can transferred into said outlet pipe arrangement; first and second bearings, said first bearing being disposed beween and operatively interconnecting said first cover and said inlet pipe arrangement in a manner wherein said cover is rotatably supported on said inlet pipe arrangement so as to be rotatable about said axis, said second bearing being disposed between and opertively interconnecting said second cover and said outlet pipe arrangement in a manner wherein said second cover is rotatably supported on said outlet pipe arrangement so as to be rotatable about said axis; and first and second seal arrangements, said first and second seal arrangements being disposed on said inlet and outlet pipe arrangements respectively, said first and second seal arrangements being arranged to prevent leakage of fluid from said inlet and outlet chambers via said first and second bores.
A third aspect of the present invention is deemed to comprise an automotive vehicle which comprises: an engine compartment; an engine disposed in said engine room; a rotary heat exchanger disposed in said engine room; a duct disposed about said rotary heat exchanger, said duct having an inlet which is arranged to be exposed to a source of ram pressure which induces air to flow therethrough when said vehicle is moving, said duct and an outlet, which discharges the air which passes through the duct in a manner wherein it does not contact the engine.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cut-away perspective view showing the prior art arrangement discussed in the opening paragraphs of the instant disclosure;
FIG. 2 is a schematic elevation of the arrangement shown in FIG. 1;
FIG. 3 is a sectional elevation showing the construction and arrangement of a first embodiment of the present invention;
FIG. 4 is a sectional side elevation taken along section line IV--IV of FIG. 3;
FIG. 5 is plan view showing a the first embodiment of the present invention enclosed in a housing equipped with two cooling fans;
FIG. 6 is a schematic side elevation showing a ducting arrangement in which the embodiments of the invention can be utilized; and
FIGS. 7 and 8 show a second embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 3 and 4 shows a first embodiment of the present invention. In this arrangement a plurality of hollow disc-shaped members 21 are mounted concentrically on a distribution pipe or conduit 22 and arranged to each fluidly communicate therewith.
The outer peripheral sections of the disc members 21 are in fluid communication with one another by way of exhaust conduits 23 and 24. As will be appreciated from FIG. 4, the exhaust conduits extend essentially parallel to the distribution conduit 22 and are located diametrically opposite to and equidistant therefrom.
In this arrangement, a plurality of small, convex, essentially hemispherical projections 21a are formed on each of the lateral surfaces of the disc members 21 in the manner shown in FIG. 4. A plurality of louver-like members 25a are formed on a radially acting fin 25 which extends from the outer periphery of each of the disc members. These louver members 25a are designed to act as air agitation means which promote the flow of air over the surfaces of the hollow disc members 21 and interconnecting conduits and to simultaneously release to the air heat which is conducted to the disc members and conduits.
A first dished annular end plate 26 is fixedly connected to the upstream end of distribution conduit 22 cooperate with a cover 27 which is secured thereto to define an enclosed space. A circular plate 28 having a central boss portion in which a coaxial through bore is formed is disposed in the enclosed space and secured to the inboard face of the cover 27 via by suitable means such as screws. A suitable sealing gasket is interposed between the cover 27 and the plate 28 in a manner to provide a fluid tight seal and thus define a supply or inlet chamber within the end plate 26.
A bearing 29 such as a roller bearing is operatively disposed between the cover 27 and an annular flange portion formed on an inlet pipe arrangement 30. This arrangement is fixedly supported on a stationary member such as a vehicle chassis or the like.
The downstream end of the inlet pipe arrangement 30 is received in a bore formed in the circular plate 28 in the manner shown in FIG. 4. This portion of the inlet pipe 30 is formed with a plurality of diameter radial bores 30a. The boss portion is also formed with a plurality of radial bores 28a which are offset from those formed in the inlet pipe 30.
The radial bores 28a and 30a to ensure the maintenance of a layer of liquid between the surfaces of the inlet pipe and the bore which are in bearing contact with one. The layer other and thus provides a kind of lubrication.
The cover 27 is further formed with a V-shaped groove 27a about the outer periphery thereof which receives a V-belt which is drivingly connected with the crankshaft of the engine or similar source of rotational energy.
A mechanical seal 31 is disposed on the section of the inlet pipe arrangement located between the plate and the inboard surface of the annular flange on which the bearing 29 is supported. This seal includes a floating seal member 31a, a carbon seal 31b, a spring 31c and a shaft seal 31d. The annular floating seal member 31a is disposed in an annular recess formed in the outboard face of the plate 25. The carbon seal 31b is arranged about the outboard edge of the floating seal member shaft seal 31d at the other end.
A second dished end plate 32 communicates with the downstream ends of the exhaust conduits 23 and 24. A cover 33 and circular plate 34 which are essentially the same as elements 27 and 28, cooperate with an outlet pipe arrangement 36 to define an exhaust chamber.
A roller bearing 35, and a seal arrangement are disposed with respect to the cover 33 and circular plate 34 in a manner essentially the same as that described in connection with the inlet pipe end of the arrangement.
FIGS. 5 and 6 show the above arrangement as applied to an automotive cooling system. FIG. 6 shows the system schematically. In these figures, the numeral 41 denotes a engine hood, 42 a duct in which the rotatary heat exchanger according to the first embodiment of the present invention is disposed, 43 is an engine which in is transversely mounted in an engine compartment 49, 44 denotes a V-belt which provides a drive connection between the cover 27 and a source of rotational energy such as the crankshaft of the engine, an electric motor, or the like, 45 denotes a radiator grill or similar apertured arrangement via which air can flow into the engine compartment and duct 42, 46 denote fans which are arranged at the downstream end of the duct 42, 47 denotes an air outlet cover which cooperate with the two fans 46, and 48 denotes a bumper.
Although not shown, the ends of the inlet and outlet pipes are connected by hoses to the engine coolant jacket and/or other devices included in the cooling system.
The operation of the system is such that the hot coolant from the engine is pumped to the inlet pipe arrangement 30 from where it flows into the inlet chamber and into the distribution conduit 22. From the distribution conduit the hot coolant flows radially outward through the hollow disc members 21 and into the two exhaust conduits 23, 24. The effluent from the exhaust conduits 23, 24 is subsequently discharged into the exhaust chamber and therefrom into the exhaust pipe arrangement 36. During this time the hollow disc members are being rotated in a manner which promotes the release of heat to the air flowing over the surfaces thereof. It will be appreciated that the portions of the distribution conduit 22 and the exhaust conduits which extend between the disc members 21 are also exposed to the flow of air and also release heat thereto. To a lesser degree, heat is also lost from the end plates and covers which are also rotating and therefore act as heat exchanging members. The hemispherical projections 21a also add to the amount of heat which is released from the surfaces of the disc members.
It will be noted that with the instant embodiment the amount of surface area avaiable for heat exchange is much greater than in the case of the prior art arrangement shown in FIG. 1.
With the arrangement shown in FIGS. 5 and 6, the problem wherein there is a limit to the number of fins which can provided on the device in order to avoid a loss of blowing action is overcome via the provision of the two fans 46. These devices are driven by selectively energizable electric motors and thus enable selective control of the amount of air which is caused to flow over the heat exchanging surfaces of the rotating elements. Accordingly, during cold weather and the like, the fans can be de-energized to obviate uncessary power usage and noise generation.
The combination of the fans 46, the louvers 25a and the hemispherical projections 21a provide sufficient air flow and air agitation between the disc members to disturb the layer of air which tends to form between the air and metal surface interface, and therefore promote and increase in the heat exchanging efficiency of the device. In addition, the ramming effect with which air from radiator grill 45 enters the duct 42 adds to the flow over the heat exchanging surfaces and reduces the load on the fans 46.
A further advantage derived with the arrangement illustrated in FIGS. 5 and 6 is that the heat which is released from the rotary heat exchanger according to the present invention is exhausted directly from the engine room and. This avoids the problem of conventional heat exchanges in which the flow of hot air tends to flow from the heat exchanger onto the engine and impedes the the cooling of the engine, whereby the purpose of the heat exchanger or radiator is defeated. Accordingly, the air which in this arrangement actually flows over the engine and associated components is essentially at ambient temperatures and therefore is able to much more readily remove heat from elements such as drive belts, rubber hoses and the like which are susceptible to high temperatures.
It should be noted that the locations of the heat exchanger and the arrangement of the duct 42 is not limited to the illustrated arrangements. By way of example, it is possible to place the heat exchanger behind the engine at a relatively low level and arrange the duct to extend from the air box located immediately in front of the windshield down around the heat exchanger. With this arrangement, the high pressure which develops in front of the windshield can be use to ram air down over the heat exchanger and thus avoid the undesirable flow of heated air from heat exchanger over the engine.
As a further alternative the duct can be arranged to induct air from below the vehicle, pass it over the heat exchanger and discharge the hot effluent back under the vehicle at a location downstream of the induction area.
Various modifications and changes to the location and arrangement of duct can be easily made by those skilled in the automotive art and description of further alternative arrangements will be omitted for the sake of brevity.
As a heat exchanger according to the present invention is in the form of an elongate cylinder, it is possible to lower the hood at the front of the vehicle to a much greater extent than in the case of conventional stationary, upright radiators which must be disposed at the front of the vehicle engine. Accordingly, improvements in front end design and reduced air resistance and drag characteristics are rendered possible.
FIGS. 7 and 8 show a second embodiment of the present invention. In this arrangement the annular fin and louver arrangement of the first embodiment (see FIG. 4) is replaced by an arrangement wherein fins 50 are each formed with a plurality of L-shaped cuts and bent to form fan blades 50a. As the surface area of these blades 50a is slightly larger than that of the louvers 25a, an increased amount of air movement is induced.
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A rotary heat exchanger comprises a plurality of hollow disc shaped members which are arranged along a distribution conduit and are rotatable about an axis which is concentric with the axis of the distribution circuit. Two diametrically opposed exhaust conduits fluidly interconnect the disc members at locations proximate their peripheries. Bearings and seals are arranged next to one another along inlet and exhaust pipes so that the bearings protect the seals from damage during rotation of the heat exchanger.
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BACKGROUND OF THE INVENTION
The present invention relates to breathing apparatus for protecting crew members, in particular the technical flight crew, of an airplane against the risks associated with depressurization at high altitude and/or the occurence of smoke in the cockpit.
A major, although non-exclusive application lies in passenger airliners that can reach high altitudes, and above all so-called “jumbo” or “super-jumbo” aircraft of very large capacity.
At present, each airliner pilot has breathing apparatus comprising a mask fitted with a demand regulator connected to a source of breathing gas. Aviation regulations require that the mask can be put into place and supply oxygen to its wearer in less than 5 seconds. At present, this result is generally achieved by using a mask with a pneumatic harness that can be inflated and deflated, such as one of those described in documents FR-A-1 506 342 (or GB 1175080), FR-A-2 784 900, and U.S. Pat. No. 5,623,923, the content of which is incorporated herein by way of reference. The source of gas under pressure must be capable of instantly delivering oxygen or air greatly enriched in oxygen at a pressure which is sufficient for inflating the harness and feeding the regulator of the mask. In general, the source is a cylinder of oxygen under pressure.
On airliners, another installation is provided to supply passengers with breathing gas in the event of depressurization and to ensure survival until the airplane has come down to an altitude where normal breathing is possible at ambient atmospheric pressure.
On passenger “jumbos”, the necessary supply of oxygen requires a very large weight.
In order to reduce this mass, the oxygen supply can be replaced by an on board oxygen generator, such as a battery of on-board oxygen generator systems (OBOGS) fed with air derived from the compressor of one or more of the engines. However, such generators supply air that is highly enriched in oxygen only after a delay has elapsed from the command to supply oxygen. In addition, the output pressure of an OBOGS depends on the rotational speed of the engine and the air supplied is enriched in oxygen to a degree that is variable. The pressure initially available can be too low to inflate the fast-donning harness. The initial degree of enrichment can also be insufficient. A common buffer tank for acting as a supply of very enriched air is placed at the outlet of the OBOGS, but that solution is far from perfect, particularly since the available pressure can be insufficient for inflating a harness and since the presence of an oxygen transfer pipe causes a further delay. Other types of on-board generator and even common oxygen supplies present similar drawbacks.
SUMMARY OF THE INVENTION
An object of the present invention is to provide an improved breathing apparatus of the type having an oxygen supply and a mask with an inflatable pneumatic harness apparatuses. It is a more specific object to provide apparatus adapted to large capacity airliners having a common supply for the crew and passegers. It is a more particular object to provide apparatus which guarantees that breathing gas at a pressure which is sufficient to make rapid donning possible and guarantees that the oxygen content of the gas breathed in is sufficient from the very first breaths of the user, before the airplane reaches an altitude at which oxygen availability becomes essential, possibly even prior to takeoff.
To this end, there is provided a breathing apparatus having a line for feeding the regulator of a mask, said line including an individual plenum specific to the mask (or to a small number of masks) and of sufficient volume to provide for at least two typical breaths in succession, the plenum being being provided with an inlet check valve for connection to a generator of oxygen or more frequently oxygen-enriched air. The pressure inside said plenum is thus the maximum pressure supplied by the generator during a preceding period.
When using an OBOGS, which deliversgas whose oxygen content varies, in particular depending on the instant in its oxygen-delivery cycle, it is preferable to provide the feed line with a control valve that enables the plenum to be filled initially only when oxygen content is greater than a predetermined threshold, e.g. 94%. The valve can also be kept closed whenever the admission pressure is too low.
Once the first breaths have been breathed and the generator is operating under steady conditions, or in the event of the plenum being emptied while the generator is still not fully satisfying the conditions specified above, means are typically provided to enable gas from the generator to flow freely to the regulator of the mask.
In practice, a plenum for storing 3 to 5 liters of expanded gas suffices. Present mask harnesses generally require a pressure of about 2 bars and a volume of about 1 liter for inflation purposes. As a general rule, an OBOGS delivers pressure that can vary over a ratio of 1 to 6 depending on engine speed. For an OBOGS delivering pressure that varies over the range 0.5 bars to 3 bars, the maximum pressure reached when the engines are at full power for climbing greatly exceeds the pressure required in the plenum.
The invention makes it possible to use a common on-board generator both for the crew and for passengers, and to avoid carrying oxygen cylinders which are heavy and require frequent verification, except cylinders that might be required for possible therapeutic reasons.
The plenum can often be incorporated in a mask storage box which causes oxygen to flow to the regulator on being opened. The plenum is then directly connected to a hose feeding both the regulator and the harness of the mask. This configuration only requires a small increase in the size of a box such as that described in document U.S. Pat. No. 6,039,045, for example.
The above features and others, will be better understood on reading the following description of particular embodiments, given as non-limiting examples. The description refers to the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simplified view of apparatus constituting a particular embodiment of the invention, having a full face mask, and shown with the mask out of the storage box; and
FIG. 2 shows a modified embodiment.
DETAILED DESCRIPTION
The apparatus shown in FIG. 1 comprises a breathing mask 10 with a regulator 12 enabling dilution with ambient air and with a pneumatic harness 14 which can be constituted, in particular, by any one of the various types described in the above-mentioned patent applications. When not in use, the mask and the harness are stored in a box 16 provided with a two-flap door 18 , 20 . A valve 22 carried by the case of the box is interposed between a flexible hose 26 connected to the regulator of the mask and a feed pipe 24 . The valve 22 is so placed and arranged to communicate the hose with the pipe 24 when the user of the mask 10 pulls the mask out from the box and the flap 18 opens. Sometimes, the box also carries a switch for selecting between operation of the regulator with dilution (providing protection against hypoxia only) and without dilution (for providing protection against smoke or at very high altitude).
In steady conditions of operation, the pipe 24 receives air highly enriched in oxygen from a generator 30 , generally constituted by an OBOGS battery with alternate absorption and delivery cycles. Two OBOGS are shown in FIG. 1. A same single generator feeds a large number of masks. By way of example each OBOGS includes a molecular sieve. Such OBOGS are commercially available, e.g. making use of the dispositions described in U.S. Pat. No. 4,561,865, and the prior art cited therein.
In the embodiment of the invention shown in FIG. 1 , a feed line provides a connection between the storage box and an outlet manifold 32 of the generator 30 . There is found in succession, from the downstream end to the upstream end of the line: a plenum 34 , a non-return check valve 36 and a control valve (typically a solenoid valve) 38 . The check valve guarantees that a volume of air that is highly enriched in oxygen under a pressure sufficient to inflate the harness is maintained in the plenum even during periods when the generator 30 is delivering air at a pressure that is lower than the pressure required inside the plenum 34 . As illustrated, a three-port control valve 38 is associated with a control module 40 which ensures that, so long as the mask is stored, the plenum is fed with gas coming from the generator 30 only when that gas has an oxygen content in excess of a threshold, e.g. 94 ±2%. For this purpose, a gas analyzer 42 is connected to the feed line to the plenum 34 and supplies a signal to the module 40 . The module 40 can also have a pressure takeoff 44 and be arranged or programmed to cut off communication of the manifold 32 with the plenum 34 unless the pressure supplied by the generator exceeds a predetermined value, higher than the value needed to ensure that the harness 14 can be fully inflated.
In a simplified embodiment, the solenoid valve 38 is controlled to put the manifold 32 into communication with the check valve 36 as long as the oxygen content of the breathing gas exceeds the threshold.
In another variant, suitable for use when the source of oxygen-enriched gas initially and immediately provides an oxygen content that is sufficiently high, the valve 38 can be omitted.
In another variant, the module 40 is designed to control the solenoid valve so as to put the manifold 32 into communication with the check valve 36 on receiving a signal indicating that the flap 18 of the box has been opened. This ensures that the mask is fed continuously while it is being worn.
In the modified embodiment shown in FIG. 2 , the mask 10 is designed to be stored other than in a mask box. It is connected by the flexible hose 26 to a separate plenum. The connection between the plenum 34 and a solenoid valve 38 includes a non-return check valve 36 . In the example shown, the solenoid valve 38 is connected to a control module 40 which puts the manifold 32 into communication with the check valve 36 :
when the oxygen content as measured by a gas analyzer 42 exceeds a determined value; and when the pressure in the plenum 34 as measured by a sensor 44 is below a determined value, so as to provide breathing gas directly from the source.
Other embodiments are also possible, optionally using solenoid valves, in particular depending on the nature of generator 30 .
The bank of OBOGS is typically for supplying boxes containing emergency passenger masks, as well as the masks of the crew members, with oxygen enriched air.
When using OBOGS generators, an exemplary method of operating the complete installation is as follows.
During initial climbing of the airplane after takeoff, at least one of the generators 30 is put into operation to extract oxygen selectively. Since the jet engines are then operating at full power the air which passes through the molecular sieve of the generator is at high pressure.
Once the molecular sieve becomes saturated, atmospheric air feed is transferred to another OBOGS. A set of valves provided on the first OBOGS is controlled so as to communicate the outlet of the OBOGS with the manifold 32 and the OBOGS is heated to deliver oxygen. Since the pressure is high, and since the gas has a high oxygen content, the individual buffer plenums 34 are filled to a pressure that is sufficient for inflating harnesses. Means can be provided to deplete the buffer plenum of the air it might have been contained prior to being filled with oxygen enriched air under pressure. One or more common storage tanks 46 can also be filled at this stage in addition to the individual plenums.
Once these operations have been performed and the second OBOGS has also become saturated in oxygen, the first OBOGS can be refilled so as to ensure that a maximum supply of oxygen enriched air is available.
In a variant, at least one of the generators is controlled to implement an absorption/delivery cycle prior to take-off so that the pilots have oxygen-rich gas under pressure available and suitable for enabling them to don their masks, e.g. in the event of smoke.
Under all circumstances, the pilots are able to don the breathing mask in a few seconds whatever the altitude and very highly enriched breathing gas is immediately avalable for breathing.
One or more common tanks give the passengers access to oxygen as well, but with a delay that can be somewhat longer. Since the generators are initially saturated in oxygen and under pressure, they enable the feed to be maintained under high pressure during the time needed to descend to an end-of-cruising altitude, in the range 5000 meters to 8000 meters, where a lower pressure suffices for breathing requirements, and where pressure is indeed lower because the engines are operating at reduced speed.
Numerous possible modifications will immediately appear to those familiar with the relevant art. For instance a same plenum of increased capacity can be shared between two pilots.
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A breathing apparatus for an aircraft crew member has a breathing mask provided with a demand regulator and connected to a source of breathing gas, such as a pressurized oxygen cylinder or preferably an OBOGS. The apparatus includes an individual buffer plenum specific to the mask on a line for feeding the regulator of the mask from the source. The volume of the plenum is sufficient to provide for at least two typical breaths of the mask wearer in succession. A non-return check valve is located between the plenum and the source.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the rotogravure printing of an uncoated paper web with printing inks which contain water-immiscible solvents.
2. Description of the Prior Art
Uncoated, highly supercalendered and highly filled papers are produced on a large scale and are used as the print carrier in magazine and illustration rotogravure. These papers are referred to hereinafter as natural rotogravure papers. They are printed with printing inks, which contain a considerable proportion of water-immiscible solvents. Such solvents are, for example, toluene, xylene and benzene.
Constantly increasing quality of the natural rotogravure paper is being demanded because of changes in the paper making and rotogravure processes. Specifically, this is due to the increasing speed of the paper machines and the consequently accelerated dewatering on the Fourdrinier, since with twin wires, a less homogeneous paper sheet would be produced as well as the increasing speeds of the rotogravure printing machines.
One of the major problems resulting from the higher machine speeds is that a lower printing ink viscosity is required which, in turn, affects the "migration" of the printing ink into the paper.
The migratory properties of a printing ink are regarded as good if the ink, in the brief period between application and drying, does not migrate away from the point of application so that the contours of the ink on the printed and dried paper are the same as they were when the ink was applied to the paper, i.e., the image is sharp. In the case of poor migration properties, the printing ink penetrates into the paper and spreads out, which leads to a nonuniform and blurred printing image. In black areas, for example, insufficient blackening occurs and the printed image has inferior gloss. At the same time, the uneven distribution of fibers and filler material in the microregion of the surface can be observed in the printed image.
Various attempts have been made to improve the printability of papers. German Pat. No. 828,478 proposes that various minerals, such as, zeolite, be added to the fibrous material or that these minerals, in combination with starch or different binders be applied to the surface of the paper in a preparation step. At the same time, the penetration of oily molecules or of other printing fluids is promoted by the channels which traverse the interior of these minerals.
German Pat. No. 844,402 discloses the addition and distribution of discrete clay particles as a filler in the structure of the paper to prevent a running of the printing ink because of their adsorption effect. The use of oil-absorbing substances for improving the printing properties is also described in British Pat. No. 1,093,041. These substances are synthetically produced pigments having an amorphous structure and are used as fillers in a conventional manner.
The use of extruded minerals, such as, kaolin or attapulgite has been suggested in U.S. Pat. No. 3,433,704 for the production of newsprint. The oils used in newsprint ink tend to migrate through the paper and give rise to the formation of translucent areas in the printed paper. The use of the extruded minerals is intended to prevent the printed image which is applied to one side of the paper from showing through on the side by limiting the reduction in opacity caused by the oils.
These proposals are based on utilizing the adsorption properties of the different minerals for printing inks or on increasing the printing opacity. This approach, which is also adhered to in the reference "Physical Chemistry of Pigments in Paper Coating", page 422, has not been practiced in rotogravure printing with solvent-containing printing inks, i.e, printing inks containing toluene. This may primarily be attributed to the fact that the construction of rotogravure inks is completely different from that of newsprint inks. The latter having a significantly higher viscosity of about 50 Pascal seconds, while rotogravure inks have an average viscosity of 10 and a maximum viscosity of 20 Pascal seconds. In actual practice, however, viscosities of 4 Pascal seconds are also used in rotogravure printing. The already mentioned oils, predominantly mineral oils, are used as color carriers in printing newsprint, while more volatile solvents, especially toluene and benzene, in which natural or synthetic resins are dissolved, are used in rotogravure printing. The color carriers of newsprint inks remain in the paper while the toluene used as a solvent for the resins, evaporates immediately.
However, newsprint paper also has a generally different construction than the natural rotogravure papers addressed in the present application. Specifically, natural rotogravure papers have the maximum possible amount of fillers added. Additionally, they have a higher chemical pulp content and differ in their physical properties, e.g., they have a much higher density and higher smoothness which is obtained by a supercalandering process.
Newsprint paper, on the other hand, is only machine-calandered, is run with the addition of only insignificant amounts of filler and has a density of about 0.6 g/cc.
The enveloping of fibrous materials with hydratable colloidal, film-forming clays is disclosed in German Pat. Nos. 2,451,216 and 2,608,239. German Pat. No. 2,451,216 deals with a acceptor paper, in which hydratable, colloidal clays or fibrous materials coated with such clays are contained as color acceptors for suitable color precursors. On the other hand, German Pat. No. 2,608,239 describes an image receiving material for electrophotographic processes, in which hydratable, film-forming, colloidal clays become effective to fix the water-extractable harmful substances of the type released by the thermofixation of toner particles.
These patents disclose the use of such enveloped fibers which have a high adsorptive power for that particular function.
SUMMARY OF THE INVENTION
We have discovered an uncoated paper for rotogravure printing which possesses significantly superior migration properties as compared to conventional natural gravure papers. The paper of the present invention can be printed very satisfactorily with inks which contain water-immiscible solvents.
More particularly, the paper of the present invention is composed of a fibrous web, the fibers of which are partially or totally enveloped with a clay hydrogel which clay is hydratable, is colloidal, and is film-forming, said web having an area weight of from about 45 to 100 g/m 2 , a density of from about 0.95 to 1.2 g/cc and a smoothness of from about 600 to 1500 Bekk seconds.
It is particularly surprising that the high adsorptive power of these materials has no effect relative to the printing inks as it would have to be expected in accordance with the above-mentioned prior art, but that, rather, a repelling effect occurs relative to the printing ink.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The outstanding effect obtained with the present invention, in comparison to conventional natural gravure papers, which contain no hydratable, film-forming colloidal clays enveloping the fibers, is probably attributable to the fact that the extensive homogenization of the paper surface is achieved by the envelopment of the fibers. As a result, the printing ink comes into contact with a surface which consists of a uniform material, because the different fibrous materials used have the same surface due to their film-like envelope. The conventional fillers, which are added to the fibrous material as a pigment during the manufacturing process cannot envelop the fiber itself but are merely filtered off during the sheet formation on the Fourdrinier and cannot produce this homogeneity. Rather, demixing takes place to a varying extent during the dewatering of the paper sheet, whereby the fillers accumulate on the upper side of the paper sheet.
The essential reason for the decreased migration may well be the fact that the hydratable, film-forming, colloidal clays contain a considerable amount of bound water which is not the case with conventional fillers. This higher water content is attributable to the property of film-forming, hydratable, colloidal clays of swelling in water and thereby retaining large quantities of water in the films which are formed.
At the drying temperatures, conventionally used in a paper machine, this water cannot evaporate and, because it is not miscible with the solvent of the gravure ink, it exerts a repelling effect in the printing ink.
This is a short-term effect, which is however completely adequate because, at the high machine speeds of the printing machine in the drying section, only fractions of a second elapse between the application of the printed image and the evaporation of the highly volatile solvent.
The use of additional and conventional inorganic fillers, which are added in the usual manner to the pulp before sheet formation, produces sufficient opacity and whiteness in the paper sheet. In the case of a combined batch, of, for example, kaolin, as additional inorganic filler together with hydratable, colloidal, film-forming clays, in a common mixing vat and subsequent mixing with the fibrous paper material, not only the fibers are enveloped which can easily be detected by suitable staining methods but also a partial film-like enveloping of the kaolin particles takes place. Consequently, there is an even better homogenization, because the printing ink is then printed on fiber and filler material which is coated with the same material to the greatest extent possible.
In the production of paper, the drying process of the paper web is followed by a supercalendering treatment in which the paper web is compressed to a density of about 0.95 to 1.2 g/cc. In doing, so the Bekk gloss is advantageously adjusted to about 600 to 1,500 seconds. By the use of natural rotogravure papers, whose fibers are enveloped at least partially in the inventive manner with clays, substantial improvements in the printing results are obtained from the point of view of migration. The range of area weight preferably is between about 45 and 100 g/m 2 . Excellent improvements over the previously known natural rotogravure papers are obtained with an area weight of from about 55 to 70 g/m 2 .
Especially advantageous results are obtained from the use of such papers in which the amount of fiber-enveloping, film-forming, colloidal clays are about 1.2 to 8 weight percent of the total material. If lesser amounts are added, the decrease in migration is insufficient while, if higher amounts are added, the dewatering speed of the paper web is adversely affected because of the particularly high water absorptive capacity or water retention capacity of the special types of clay.
Particularly suitable papers in accordance with the present invention for use in rotogravure processes are those whose fibrous material is enveloped with montmorillonite clays selected from the group of bentonites, with an attapulgite or a sepiolite. Not sufficiently swelling clay materials from these groups have, however, proven to be unsuitable because they do not have the ability to envelop the fibers in the manner of a gel or a film. Thus, the film-forming property is important to achieve the desired results. Such clay minerals, when added to the pulp, do not possess a significant amount of bound water after the paper web is dried and, in their mode of action, merely correspond to the conventional pigment fillers.
A particular advantage resides in the use of natural rotogravure papers whose fibers are enveloped by a naturally occuring bentonite clay whose montmorillonite mineral has a ratio of sodium and calcium ions of between 40:60 to 60:40. The strength and elasticity of the film enveloping the fibers is in this case significantly improved over a clay which contains as the mineral a 100% sodium montmorillonite. If a clay with this ion ratio is not available, a natural rotogravure paper whose fibers are enveloped by a colloidal, film-forming clay in which an ion exchange in the above-mentioned ratio has taken place by a treatment with soda or soda lye can be advantageously used. The initial product for such a clay may be a 100% calcium bentonite.
An especially advantageous embodiment of the invention can be obtained through the use of a natural rotogravure paper, the fibers of which are enveloped by a colloidal, film-forming clay whose montmorillonite mineral contains up to 40% magnesium ions and whose residual ion portion consists of sodium ions.
Clay of this type is obtained from a 100% calcium bentonite by initially converting it to a 100% sodium bentonite using a soda lye or soda treatment and, subsequently, exchanging a portion of the sodium ions for magnesium ions by adding a magnesium salt, for example, magnesium sulfate, or magnesium hydroxide. Excellent results were obtained with an ion ratio of 25:75 magnesium to sodium ions.
A further improvement of the migratory property can be achieved by using a natural rotogravure paper in which organic water-soluble macromolecules are connected to the highly swellable and film-forming clays which envelope the fibers. In this connection, polyethylene oxides with a molecular weight of between 5,000 to 100,000 are preferred as the macromolecules. These substances, which are called polyglycols can be added to the clay suspension after the ion exchange has been performed in amounts of from about 10% by weight polyglycol from a solution having a maximum concentration of about 10%. The quality of the film is not impaired by this addition.
Another advantageous embodiment provides for the use of a natural rotogravure paper whose fibers are enveloped by highly swellable and film-forming clays and in which an aqueous solution of a polyglycol is sprayed onto the web of material prior to rolling up the paper.
When natural rotogravure papers with clay-enveloped fibers are used, the most significant improvement lies in achieving less migration. However, because the amounts of hydratable, film-forming, colloidal clays used are at most 8 weight percent, based on the total furnish, they do not have a detrimental effect on other important properties, such as, opacity, brightness, smoothness and gloss. In order to obtain these properties, the addition of conventional, inorganic fillers is therefore unavoidable and an ash content of greater than 15% by weight has proven to be advantageous. The amount to be added to the pulp suspension before the formation of the sheet may be up to about 20 weight percent higher than the amount which is actually to be retained in the paper. Thus, the difference between the amount added and the amount retained in the paper may be attributed to losses, which usually occur in the manufacture of paper, even when retention aids are used.
Suitable fillers for use include kaolin, calcium carbonate, talc, titanium dioxide, barium sulfate and calcium sulfate. Kaolin, calcium carbonate and talc have proven to be particularly suitable.
For economic reasons, efforts are made to keep the portion of the cost attributable to the fibrous material as small as possible. Newsprint is therefore frequently manufactured without the addition of any chemical woodpulp. In the case of natural rotogravure papers, which are higher grade material, the use of a certain amount of chemical woodpulp cannot be avoided. For the purposes of the present invention, a paper is particularly suitable for use in rotogravure printing if it contains more than about 10 weight percent of chemical woodpulp, based on the total amount of fibrous material.
A further improvement can be achieved by using paper, whose fiber portion consists of about 20 to 25 weight percent of chemical woodpulp and about 75 to 80 weight percent of mechanical woodpulp. Preferably, kaolin and hydratable, colloidal, film-forming clays are added to such a fibrous material in an amount so that, based on the total weight, there is about 18 to 26 weight percent of kaolin and about 1.6 to 3.5 weight percent of these colloidal clays in the finished paper. In the preferred range of area weights of 55 to 70 g/m 2 and at a density of 1.0 to 1.15 g/cc, such a paper has a Bekk smoothness of 900 to 1,200 seconds after calendering.
The excellent printing results, which can be achieved with such a paper, may be attributed, inter alia, to the fact that the paper has a homogeneous surface as already mentioned. It is at the same time a particular advantage that the clays, which envelop the fibers do not require a binder of a different auxiliary for their fixation. These clays also have the advantageous capability to firmly combine with the fibers by means of hydrogen bonding.
The following examples illustrate the present invention.
EXAMPLE 1
A semi-bleached softwood sulfate pulp is dispersed in a pulper at a consistency of 4.8% and a pH of 7 and beaten to a freeness of 23° SR (Schopper Riegler). In a central stock preparation unit, the chemical pulp is mixed with a chip-free mechanical pulp of 76° SR in a ratio of 24:76.
A 42% kaolin slurry is prepared in a separate vessel and adjusted to a pH of 8.4. To this slurry, a 3.5% solution of a sodium/calcium bentonite, with a Na:Ca ion ratio of 40:60 is added. The mixing of the kaolin slurry with the colloidal solution of the bentonite is carried out in such a manner that there are 8.6 parts by weight of kaolin to 1 part by weight of bentonite, the weight proportions referring to the absolutely dry substance.
To 71 parts by weight of the pulp mixture described, 29 parts by weight of the kaolin/bentonite mixture, calculated as solids, are now added. The total furnish is now adjusted with aluminum sulfate to a pH of 5.2 and, after a further dilution, is supplied to a head box of paper machine, from where it is formed into a paper with an area weight of 60 g/m 2 . After drying, the paper web is treated on a supercalender to produce a density of 1.12. The finished paper has a Bekk smoothness of 1,100 seconds and has the following fiber composition:
75 weight percent of mechanical woodpulp
25 weight percent of chemical woodpulp
Based on the total furnish, the finished paper contains
22 weight percent of kaolin and
2.5 weight percent of film-forming clays.
EXAMPLE 2
A pulp from a semi-bleached softwood sulfate pulp having a pH of 7.2 and a freeness of 20° to 22° SR, is added at a consistency of 3.5 weight percent to a 7 weight percent colloidal solution of a well swollen sodium attapulgite. If both are calculated on the basis of their solids content, there are 100 parts by weight of pulp to 8.3 parts of weight of attapulgite.
The mixture of attapulgite solution and pulp fiber is mixed in a known manner with mechanical woodpulp so that there are (without attapulgite) 76 parts by weight of mechanical woodpulp to 24 parts by weight of chemical woodpulp.
A 40% by weight kaolin slurry, adjusted to a pH of 8.3, is added to the mixture of mechanical woodpulp, chemical woodpulp and attapulgite solution so that there are 100 parts by weight of the mixture of mechanical woodpulp, chemical woodpulp and attapulgite to 19.6 weight percent of kaolin. This mixture is adjusted with alum to a pH of 4.6 and, after dilution in the usual manner, formed into a paper web. The dried and calendered paper has an area weight of 62 g/m 2 and a density of 1.1 g/cc, as well as a Bekk smoothness of 1150 seconds. The fibrous material consists of 75.5 parts by weight of mechanical woodpulp and 24.5 parts by weight of chemical woodpulp. There are 1.8 parts by weight of attapulgite and 18 parts by weight of kaolin, calculated on the basis of the total furnish of the paper.
EXAMPLE 3
A paper is prepared as described in Example 2. However, the attapulgite used in Example 2, is replaced by sepiolite. A paper of 67 g/m 2 is obtained. It has a density of 1.14 g/cc, a Bekk smoothness of 1000 seconds and a fiber stuff composition of 24 weight percent of chemical woodpulp and 76 weight percent of mechanical woodpulp. Based on the furnish, there are 18.5 parts by weight of kaolin and 1.7 parts by weight of sepiolite in the paper.
EXAMPLE 4
A paper is prepared in accordance with Example 1, with the exception that the sodium/calcium bentonite in Example 1 is replaced with a sodium/magnesium bentonite with an ion ratio of Na:Mg of 75:25.
EXAMPLE 5
A semi-bleached softwood sulfate pulp is dissolved in the pulper at a consistency of 4.8% and a pH of 7 and is beaten to 23° SR. After beating, 1.5% by weight of a mixture of Na/Mg bentonite and polyglycol which had been prepared as follows are added to the pulp:
1.5% by weight NaOH and 7% by weight MgSO 4 are added to a previously dispersed 8% calcium bentonite suspension. A high viscosity is obtained which is considered a good sign for activation. From a 6% solution, a polyglycol with a molecular weight of 20,000 is added in an amount of 18% by weight relative to the bentonite.
In a mixing unit, the treated chemical woodpulp is mixed with a chip-free mechanical woodpulp of 76° SR in a ratio of 25:75% by weight and with a separately prepared slurry of kaolin and calcium carbonate. The kaolin/calcium carbonate slurry consists to 70 parts by weight of kaolin and 30 parts by weight of calcium carbonate. The suspension has a ratio of pulp to filler of 71:29.
At a pH value of 7.4, this mixture is diluted to 0.8% and a paper web is formed in the conventional manner. The dried and supercalendered paper has a weight per unit area of 60 g/m 2 , a density of 1.1 and a smoothness according to Bekk of 1,100 seconds. The ash content is 25%.
COMPARISON EXAMPLE
A paper is prepared as described in Example 1. However, no hydratable, film-forming, colloidal clay is employed. The proportion of kaolin is increased so that the finished paper contains 24.5 parts by weight of kaolin and, in other respects, has the same fiber stuff composition as the paper of Example 1. The finished paper has an area weight of 60 g/m 2 , a density of 1.13 and a Bekk smoothness of 1120 seconds.
The paper webs described in Examples 1 to 5 and in the Comparison Example are printed with a toluene-containing printing ink on a rotogravure machine. In the case of the paper webs, prepared according to the inventive examples, there is a significantly higher degree of blackening and a better color intensity in the areas printed black. The printed image has a more brilliant even solid and has a better color gloss. In contrast, the paper web prepared according to the Comparison Example and corresponding in other respects to the mechanical values and the composition of the inventive example, but whose fibers have no enveloping of hydratable, film-forming, colloidal clays, has a noticeably inferior and less brilliant even solid.
The better printing results in the case of the paper webs prepared according to Examples 1 to 5, may be explained by the increased toluene holdout, which leads to less migration.
The improved effect relative to toluene-containing printing inks is illustrated once more by carrying out the laboratory experiment, which is described in the following and which is also known under the name of Patra test.
An experimental appratus is used which consists of an inclined plane and a roller, which rolls down the plane. Both are constructed of polished steel. Samples of paper web, prepared according to Examples 1 to 5 and the Comparison Example are attached to the inclined plane. A defined drop of colored toluene is then placed on the roller, which immediately is allowed to roll down the inclined plane. In so doing, the paper samples are mounted on the inclined plane so that the roller, prior to rolling over the paper sample, rolls out the solvent drop on the inclined plane. The ink spot, rolled out on the roller, is then transferred to the paper sample. The size of the colored mark depends on the toluene holdout of the paper. The size of the mark is evaluated and it turns out that the paper webs, prepared according to the inventive examples, produce a significantly larger area than the paper web which had been prepared according to the Comparison Example.
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An uncoated paper web suitable for rotogravure printing with water-immiscible solvent-containing inks, the fibers of the web being partially or totally enveloped with a clay hydrogel, the clay being hydratable, colloidal and film-forming. The web provides superior printing results in rotogravure printing. A method for printing the web is disclosed.
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CROSS REFERENCE TO RELATED APPLICATIONS
This is a divisional of application Ser. No. 09/158,630, filed Sep. 22, 1998, now U.S. Pat. No. 5,919,951 which is a divisional of application Ser. No. 09/039,599, now U.S. Pat. No. 6,124,475 filed Mar. 16, 1998.
FIELD OF THE INVENTION
The invention relates to a method of preparing a thiophene-containing or furan-containing conjugated compound, whereby a soluble precursor compound, comprising a precursor unit having thermally separable substituents, is heated such that said thermally separable substituents are eliminated from said precursor compound while converting said precursor compound into said thiophene-containing or furan-containing conjugated compound. The invention also relates to precursor compounds suitable for use in such a method. The invention further relates to a semiconductor device in which use is made of a conjugated compound obtainable by using such a method.
BACKGROUND OF THE INVENTION
Conjugated compounds, or more in particular, thiophene-containing or furan-containing conjugated compounds are used in various industrial applications. For example, they can be used as dyes or pigments, as (semi)conductors, (electro)luminescent material or in electr(on)ical, optical and electro-optical devices such as light emitting diodes, field-effect transistors, solar cells, polarizing optical elements and batteries. In the context of the invention a compound is considered to be conjugated if, upon electronic excitation, it absorbs ultraviolet light or radiation of lower frequencies.
However, due to the inherent rigidity of the conjugated system, many potentially interesting conjugated compounds are insoluble. For many industrial applications processability from solution and therefore solubility is an essential requirement if an economically viable process is to be obtained.
To enhance the solubility of a conjugated compound it has been proposed to include solubilizing substituents such as large alkyl or alkoxy groups. However, this has the undesired side-effect that properties other than the solubility, such as the charge-carrier mobility, are adversely affected as well.
In order to enhance the processability from solution, it has also been proposed to use a method of the type mentioned in the opening paragraph. In such a method, referred to as a precursor method for short, the processing, such as, for example, the formation of a layer by spincoating, is done using the precursor compound. As a final step, the precursor compound is (thermally) converted by separating the separable substituents from the remainder of the compound thus forming the conjugated compound. Only a few conjugated compounds have been prepared by a method which uses such precursor compounds. One example is poly(2,5-thienylenevinylene) as disclosed in a publication by Kwan-Yue Jen et al. in J. Chem. Soc., Chem. Comm., 1987, p309. Since the precursor method is a very attractive method of rendering conjugated compounds processable from solution, there still exists a need for methods of preparing a conjugated compound using precursor compounds.
SUMMARY OF THE INVENTION
It is an object of the invention to provide, inter alia, a method of preparing a thiophene-containing or furan-containing conjugated compound from a precursor compound which is processable from solution and thermally convertible to said thiophene-containing or furan-containing conjugated compound.
The object of the invention is achieved by a method of the type mentioned in the opening paragraph which, according to the invention, is characterized in that the precursor unit used is a tetrahydrothiophene or tetrahydrofuran unit having thermally separable substituents —SR 1 and —SR 2 , wherein R 1 and R 2 are independently selected as an all or aryl group. In the method according to the invention use is made of thermally convertible precursor compounds having precursor units which, after elimination of the thermally separable substituents by heating to an adequate temperature of, typically 200° C., are converted into thiophene or furan heterocycles. The presence of the precursor units enhances the solubility of the precursor compound of which they are part relative to the conjugated compound which contains the corresponding thiophene or furan units. The precursor units can be suitably used in any method of preparing a thiophene or furan-containing compound but preferably they are used to prepare conjugated compounds. Precursor units which can be converted into thiophene or furan units were hitherto unavailable and allow conjugated compounds which are known to be rather intractable, such as unsubstituted polythiophene, to be processed as though they are soluble.
The improved processability is most advantageously exploited in conjunction with a substrate. A preferred embodiment of the method according the invention is therefore characterized in that, before the precursor compound is heated, a solution comprising the precursor compound is prepared and provided onto a substrate. Suitably, the substrate is made, for example, of glass, quartz, silicon or a synthetic resin. The conjugated compound can be processed in the form of a layer by any conventional method which uses a solvent, for example, by spincoating a solution of the precursor compound onto the substrate.
Heating is suitably performed by conventional means such as an oven or a hot plate. Though not essential, heating may be performed under reduced pressure or under an inert atmosphere.
The precursor compound used in the method according to the invention contains precursor units derived from the heterocycles tetrahydrothiophene or tetrahydrofuran. Since in most thiophene-containing or furan-containing compounds the thiophene or furan ring is substituted at both the 2 and 5 position, use is made in particular of precursor units which are substituted correspondingly by non-separable substituents.
In addition to said substituents, the precursor unit has thermally separable substituents. By heating or, depending on the type of separable substituent, any other suitable method such as irradiation, these substituents are separated from the precursor unit. The separation takes place by way of a β elimination reaction which involves two groups on adjacent atoms, one group of which is the thermally separable group. The reaction produces a double bond on the heterocycle, thus converting the tetrahydrothiophene or tetrahydrofuran into the corresponding dihydro heterocycle. Two thermally separable substituents suffice to convert a tetrahydrothiophene (tetrahydrofuran) into its thiophene (furan) analog. The first of said two thermally separable substituents can be located at the 2 position, but from a synthetic point of view the 3 position is preferred. Analogously, the second thermally separable substituent is located at the 4 position.
Examples of-thermally separable substituents are sulfone, sulfoxide, alkoxy, aryloxy, such as phenoxy, amino, —NR 3 + , or —SR 2 + groups. Suitable precursor units are tetrahydrothiophene or tetrahydrofuran units having thermally separable substituents —SR 1 and —SR 2 , wherein R 1 and R 2 are independently selected as an alkyl or aryl group.
Preferably, a precursor unit is used according to the formula (I)
wherein X is equal to O or S, and R 1 and R 2 independently selected as an alkyl or aryl group. By heating to a temperature of, typically, 200° C. or higher, the thermally separable groups —SR 1 and —SR 2 are eliminated thus forming the sulfides R 5 SR 1 and R 6 SR 2 and a conjugated unit in the form of a thiophene (X=S) or furan (X=O) unit having substituents R 3 and R 4 located at the positions 3 and 4 respectively. The substituents R 3 and R 4 can be varied so as to obtain a range of conjugated compounds which can be rendered processable from solution. Since the tetrahydro unit itself is not conjugated, which has a solubility enhancing effect, and the substituents R 1 , R 2 , R 5 , and R 6 enhance the solubility as well, the choice of substituents R 3 and R 4 is not limited by solubility considerations. Suitable choices are for example methyl, ethyl, (m)ethoxy, nitro or hydrogen.
The substituents R 1 , R 2 , R 5 , and R 6 are not part of the conjugated compound which is obtained after thermal conversion and can, for example, be used to influence the temperature at which the thermal conversion occurs or can be chosen so as to obtain a convenient processing or synthetic route. Preferably, they are chosen such that the sulfide to be eliminated vaporizes at the temperature at which the thermal conversion is carried out.
A suitable choice of R 5 and R 6 is hydrogen. Substituents R 1 and R 2 are preferably selected from the group consisting of phenyl, 4-methylphenyl, 4-chlorophenyl, 4-nitrophenyl, 4-pyridyl, ethyl and tert-butyl. Surprisingly, the rate and temperature of conversion is almost the same throughout this group. Also, the thermal conversion proceeds faster if the substituents —SR 1 and R 5 (or —SR 2 and R 6 ) are in a trans conformation with respect to each other.
The thermally separable substituent can also be eliminated from the precursor compound by using a base as a catalyst, preferably in solution.
In order to reduce the number of isomers of the precursor compounds which will be formed during synthesis, R 1 is preferably chosen equal to R 2 . Reducing the number of isomers makes the synthetic procedure and in particular the purification of crude products much simpler.
A preferred method according to the invention is characterized in that use is made of a 2,5-dithienyltetrahydrothiophene or 2,5-dithienyltetrahydrofuran unit as the precursor unit. Said precursor units are convenient building blocks in the synthesis of precursor compounds of which use is made in methods according to the invention. For example, the thiophene rings can be selectively brominated at the (unsubstituted) 2 and 5 positions. The (di)bromo compounds thus obtained can be suitably used in a large variety of well known coupling reactions, such as the palladium catalyzed reaction between a bromo compound and an aromatic stannane (see for instance, J. K. Stille, Angew. Chem., Int. Ed. Engl. 1986, 25, p508), or the coupling of two bromo compounds using a nickel-based catalyst (see for instance, K. Chmil et al in Makromol. Chem. Rapid Commun. 1993, 14, p217)
Another preferred embodiment of the method according to the invention is characterized in that the thiophene-containing or furan-containing conjugated compound being prepared is a polymer having a substantially conjugated backbone. In the context of the invention, the term polymer includes oligomer. Processability from solution is a property which many a polymer having a substantially conjugated backbone does not possess. Due to the presence of an extensive conjugated system, in many cases a potentially interesting conjugated polymer compound cannot be synthesized at all or only if it has a low molar mass. The method according to the invention can therefore be applied with particular advantage to such conjugated polymers.
An example of a conjugated polymer which can be rendered soluble by the method according to the invention is a polythiophene. Polythiophenes are semiconductors, can be easily doped and are quite stable. However, the availability of these compounds is hampered by solubility problems. For example, a polythiophene without any substituents is only soluble up to the hexamer. Polythiophene of higher molecular weight can be prepared by electrochemical polymerization but this leads to intractable films as well as to a polythiophene having a backbone which has many topological defects. Using the method according to the invention an unsubstituted polythiophene can be prepared which is substantially free of topological defects and of relatively high molecular weight. A suitable precursor compound uses tetrahydrothiophene precursor units having arylthio or alkylthio groups as the thermally separable substituents. A ratio of one precursor unit to two thiophene units is already sufficient to render the precursor compound soluble in many common organic solvents thus allowing polythiophene films of high quality to be obtained on a variety of substrates.
The polythiophene samples prepared using the method according to the invention are of high molecular weight. Gel permeation chromatographic analysis indicates that a number-average molecular weight of at least 3500 can be routinely obtained. The optical absorption spectrum shows a broad peak between 350 and 750 nm which is characteristic of polythiophene. However, unlike polythiophene samples which are not according to the invention, the broad peak shows various shoulders. This is considered to be due to the absence of topological defects.
The invention further relates to precursor compounds which can be suitably used in a method according to the invention.
A suitable precursor compound is a soluble precursor compound comprising a precursor unit consisting of a tetrahydrothiophene or tetrahydrofuran unit having thermally separable substituents —SR 1 and —SR 2 , wherein R 1 and R 2 are independently selected as an alkyl or aryl group.
Examples of such suitable precursor compounds have already been described hereinabove. Also suitable are of course intermediate precursor compounds comprising as a precursor unit a dihydrothiophene or dihydrofuran unit which can be obtained from the precursor compounds described hereinabove by heating such that some, but not all, of the thermally separable substituents are eliminated from the precursor compounds thus forming the intermediate precursor compounds.
The intermediate compounds need not be obtained by partial thermal conversion of the tetrahydro heterocycle. For example, treatment of 3,4-bis(phenylthio)-2,5-di(2-thienyl)-tetrahydrothiophene with 2-thienyllithium at −20° C. results in the corresponding dihydro compound, 3-phenylthio-2,5-di(2-thienyl)-2,3-dihydrohydrothiophene. The dihydro compounds have lower conversion temperatures than the corresponding tetrahydro compounds.
The invention also relates to a semiconductor device having a semiconducting layer comprising a polythiophene which is obtainable by using a method according to the invention.
In a preferred embodiment, the semiconductor device is a field-effect transistor in which the semiconducting field-effect active layer comprises unsubstituted polythiophene, where the term polythiophene is understood to include oligothiophene. By determining current voltage characteristics at various gate voltages a pronounced field-effect is observed. A typical value of the field-effect charge-carrier mobility is approximately 10 −6 cm 2 /(Vs) at a bulk conductivity of 8×10 −9 S/cm. These-values-are typical of amorphous semiconducting polymers processed from solution. A good field-effect transistor combines a high mobility with a low bulk conductivity.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be further elucidated with the aid of the following examples.
In the drawings:
FIG. 1 shows the absorbance A (in arbitrary units au) as a function of wavelength λ (in nm) of a conjugated compound (curve A) prepared by the method according to the invention using a precursor compound (curve B) according to the invention, and
FIG. 2 shows the drain current I d (in A) as a function of the gate voltage V g (in V) at a drain voltage of −20 V (curve A) and −2 V (curve B) of a field-effect transistor according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Example 1
Synthesis of 3,4-bis(phenylthio)-2,5-di(2-thienyl)-tetrahydrofuran
2-phenylthioacetic acid
Thiophenol (521 g, 4.736 mol) in 800 ml THF is added to a cold mixture of sodium hydroxide (400 g, 10 mol) and 2 kg ice. Sodium bromide (50 g) and triethylbenzylammonium chloride (8 g) are added to the 20° C. mixture which is stirred mechanically in a large beaker. Chloroacetic acid (500 g, 5.29 mol) is added portionwise at a temperature of 30-40° C. and at the same time ice is being added in order to moderate the exothermal reaction. At the end of the chloroacetic acid addition another 80 g sodium hydroxide is added to make the mixture basic. The thick paste is diluted with so much water that a stirrable paste is obtained (the total volume being about 7 l). After stirring for 2 hours and standing overnight, the paste is acidified with concentrated hydrochloric acid. Air is bubbled through the mixture in order to remove the THF and allow the product to crystallize. It is collected by filtration-and washed with water. After air-drying there is obtained 762 g (4.536 mol, 96%) of 2-phenylthioacetic acid.
2-phenylthioacetyl chloride
A quantity of 762 g (4.536 mol) of 2-phenylthioacetic acid is stirred at room temperature for 3 hours with thionyl chloride (375 ml, 5.14 mol), then stirred at 40° C. for 3 hours. Rotary evaporation followed by bulb-to-bulb distillation gives 777 g (4.166 mol, 92%) of 2-phenylthioacetyl chloride.
2-phenylthio-1-(2-thienyl)-ethanone
To a cooled mixture of 2-phenylthioacetyl chloride (593 g, 3.18 mol), thiophene (286 g, 3.40 mol), and 1500 ml toluene, tin(IV)chloride (875 g, 3.36 mol) is added over a period of 2 to 3 hours at temperatures between 0 and 7° C. The mixture is then stirred for 3 hours whereby the temperature of the reaction mixture rises gradually to room temperature. Some ice is added carefully to the mixture followed by 100 ml concentrated hydrochloric acid in 1500 ml water. The layers are separated and the organic layer is washed with 2×500 ml water. The aqueous layers are extracted with 1 l toluene. The organic layers are dried and rotary evaporated. The residue is stirred with 1500 ml methanol, then filtered, the solid being washed with 1 l methanol. A quantity of 421 g of 2-phenylthio-1-(2-thienyl)-ethanone is obtained. The filtrate is rotary evaporated and the residue is purified by bulb-to-bulb distillation. The product, which distils at about 140° C. and 1 mm Hg, is stirred with methanol to give a pure product. The filtrate of this crystallization is rotary evaporated and the residue is allowed to stand with some seed crystals. The supernatant liquid is poured off and the residue is stirred with methanol to give an additional amount of product. The total yield is 627 g (2.68 mol, 84%).
1 H NMR (CCl 4 ): δ4.0 (s, 2H), 6.9-7.6 (m, 8H).
2,3-bis(phenylthio)-1,4-di(2-thienyl)-1,4-butanedione
2-phenylthio-1-(2-thienyl)-ethanone (231.4 g, 0.989 mol) is added at −3 to 3° C. in portions over a period of 1.5 hours to a mixture of sodium hydride (37.5 g, 55-65% dispersion in oil, 1.016 mol maximum) and 950 ml THF. After stirring for 30 min at −5° C., the solution is cooled and cupric chloride (120 g, 0.893 mol) is added at −72° C. The mixture is allowed to warm up slowly with mechanical stirring (after 3 hours the internal temperature is −10° C. and after 5 hours 5° C.). It is subsequently stirred for 4 hours at 10 to 20° C. before it is heated at. 43° C. for 11 hours. After rotary evaporation (the THF can be reused) 500 ml 2 N hydrochloric acid and 1500 ml toluene are added to the residue. The mixture is stirred, then filtered under vacuum and the layers are separated. The organic layer is washed with 2×150 ml water, then dried and evaporated to leave about 120 g residue. The solid is stirred at 50° C. with 1500 ml toluene and the first aqueous layer. Filtration, separation, washing with the other water layers, drying and evaporation gives another 30 g. These combined product fractions contain some starting material. The solid is boiled with 750 ml chloroform, the mixture is filtered while hot over a big plug of cotton wool and the filtrate is rotary evaporated. The undissolved material is boiled once more with 500 ml chloroform, the mixture is filtered while hot over a plug of cotton wool and the filtrate is rotary evaporated. To the combined filtrates, which contain both the meso and dl isomer of 2,3-bis(phenylthio)-1,4-di(2-thienyl)-1,4-butanedione, 600 ml toluene and 3.6 g diethylamine are added and the mixture is stirred for 20 hours at room temperature. Filtration and washing with toluene gives 137 g of the pure meso isomer(0.294 mol. 59%). The filtrate is rotary evaporated and the residue is purified by bulb-to-bulb distillation. The distillate fraction, which boils at 140° C. and 1 mm Hg is stirred with methanol. This gives 24 g of the starting compound.
1 H NMR of the dl-isomer (CDCl 3 ): δ4.65 (s, 2H), 7.0-7.6 (m, 16H).
1 H NMR of the meso-isomer (CDCl 3 ): δ4.85 (s, 2H), 7.1-7.8 (m, 16H).
2,3-bis(phenylthio)-1,4-di(2-thienyl)-1,4-butanediol
A mixture of lithium aluminum hydride (30.8 g, 0.789 mol) and 1 l THF is cooled with liquid nitrogen to about −10° C. Meso 2,3-bis(phenylthio)-1,4-di-(2-thienyl)-1,4-butanedione (288.88 g, 0.620 mol) is added in portions over a period of 30 minutes at temperatures between 0 and −10° C. After the addition the mixture is stirred mechanically for 20 minutes at the same temperature. Ethylacetate (200 ml) is added dropwise while cooling well at temperatures below 7° C., followed by 200 ml acetic acid at the same temperatures. The mixture is stirred for 5 minutes, then poured in 800 ml 4 N hydrochloric acid. The layers are separated and the organic layer is washed with 2×250 ml brine, then dried and rotary evaporated. The aqueous layers are extracted with 1 l ethylacetate, which is dried and combined with the partially evaporated THF-layer. Rotary evaporation is continued until about 500 g residue is left. About 300 ml methanol is added to this suspension, stirring, filtration and washing with methanol gives 248.72 g of 2,3-bis(phenylthio)-1,4-di(2-thienyl)-1,4-butanediol. The filtrate is rotary evaporated and the residue is stirred with some methanol to give another 8.50 g of the same compound, resulting in a total yield of 257.22 g (0.547 mol. 88%).
1 H NMR (CDCl 3 ): δ2.7 (bs, 2H, exchange with D 2 O), 3.6 (bs, 2H), 5.7 (bs, 2H), 6.8-7.2 (m, 16H).
3,4-bis(phenylthio)-2,5-di(2-thienyl)-tetrahydrofuran
To a suspension of 2,3-bis(phenylthio)-1,4-di(2-thienyl)-1,4-butanediol (54.0 g, 114.9 mmol) in 350 ml dioxane there is added 8.70 g conc. sulfuric acid in 4 almost equal portions with a 45 minutes interval between each addition. The rather thick suspension is stirred mechanically for 4 days at room temperature whereby a clear solution is obtained. The solution is poured into 500 ml water and the product is extracted with 2×300 ml toluene. The organic layer is washed with 2×250 ml water, then dried and rotary evaporated. A quantity of 50 ml ether, followed by 200 ml methanol as well as some seed crystals are stirred into the residue. The crystallized product is filtered off and washed with methanol. It weighs 21.83 g. The filtrate is rotary evaporated and the residue is chromatographed on an aluminum oxide column (16×3 cm) using a 1/1 mixture of toluene and hexane as the eluent, thus obtaining a fraction with an additional amount of the product. This fraction is rotary evaporated and the residue is dissolved in some ether. Methanol is added while stirring, whereupon 3,4-bis(phenylthio)-2,5-di(2-thienyl)-tetrahydrofuran crystallizes. It is isolated in the usual way and weighs 7.04 g. The total yield is 28.87 g (63.9 mmol, 56%).
1 H NMR (CDCl 3 ): δ4.2-4.4 (m, 2H), 5.5 (d, 1H), 5.9 (d, 1H), 6.9-7.4 (m, 16H).
The product, 3,4-bis(phenylthio)-2,5-di(2-thienyl)-tetrahydrofuran, is a precursor compound having a precursor according to the formula (I) wherein X=O, R 1 =R 2 =Ph, R 3 =R 4 =R 5 =R 6 =H, which can be suitably used in a method according to the invention. Heating the compound to approximately 250° C. for 30 minutes yields the conjugated compound 2,5-di(2-thienyl)-furan.
Example 2
Synthesis of 3,4-bisphenylthio)-2,5-di(2-thienyl)-tetrahydrothiophene
Lawesson's reagent (151.6 g, 0.375 mol) is stirred with 1 l pyridine at 50° C. for 1 hours, resulting in a solution, and 2,3-bis(phenylthio)-1,4-di(2-thienyl)-1,4-butanediol as obtained in Example 1 (129.52 g, 0.276 mol) is added and the mixture is stirred for 1 hours at 50-60° C., resulting in a rather thick suspension. The suspension is warmed up to 90° C. over a period of 2 hours and then kept at 90±3° C. for 3 days (becoming a clear solution after 2 days). The solution is rotary evaporated (the solvent is used for similar reactions) and the residue is stirred for 30 minute with 1 l toluene and 750 ml 2 N sodium hydroxide solution. The layers are separated and the organic layer is washed with 2×300 ml water. The aqueous layers are extracted with 500 ml toluene. The organic layers are dried and rotary evaporated. The residue is stirred with hexane to which so much toluene is added that the oil is converted into a crystalline solid. Filtration and washing gives the crude unsymmetrical isomer which is combined with 15.0 g of a similar crude product and then purified over a short aluminum oxide column using hexane/toluene (1/1) as the eluent. The eluent is rotary evaporated and the residue is recrystallized from toluene/hexane to yield 55.46 g of the unsymmetrical isomer of 3,4-bis(phenylthio)-2,5-di(2-thienyl)-tetrahydrothiophene. The filtrates from both crystallizations are combined and filtered over an aluminum oxide column (together with some other filtrates from two similar reactions). The elution is carried out using hexane containing increasing amounts of toluene. Several fractions are obtained. The first fractions contain an impurity, which probably results from dehydration of the diol. The next fractions with mainly the symmetrical isomer are combined, rotary evaporated and the residue is recrystallized from hexane/toluene. The next column fractions are a mixture of the symmetrical and unsymmetrical isomer. The next column fractions, which are enriched in the unsymmetrical isomer, are combined and rotary evaporated, and the residue is recrystallized from hexane/toluene to give the unsymmetrical isomer. The filtrates of the crystallizations and the mixed fractions are combined and again purified over an aluminum oxide column. Further purification then gives an additional amount of the symmetrical and unsymmetrical isomer. A total amount of 108.01 g of the symmetrical and unsymmetrical isomer is thus obtained from 3 reactions starting from a total of 248.02 g of 2,3-bis(phenylthio)-1,4-di(2-thienyl)-1,4-butanediol (0.231 mol, 44%).
1 H NMR (CDCl 3 ) of the unsymmetrical isomer: δ4.0-4.2 (m, 2H), 5.1 (d, J=10 Hz, 1H), 5.55 (d, J=4 Hz, 1H), 6.8-7.3 (m, 16H).
1 H NMR (CDCl 3 ) of the symmetrical isomer: δ4.2 (d, J=5 Hz, 2H), 5.0 (d, J=5 Hz, 2H), 6.8-7.4 (m, 16H).
The product, 3,4-bisphenylthio)-2,5-di(2-thienyl)-tetrahydrothiophene, is a precursor compound having a precursor unit according to the formula (I) wherein X=S, R 1 =R 2 =Ph, R 3 =R 4 =R 5 =R 6 =H, which can be suitably used in a method according to the invention. When heated at 175° C. for 30 min, thiophenol is quantitatively eliminated and the conjugated compound terthiophene is obtained.
Example 3
Synthesis of 3,4-bis((4-chloro)phenylthio)-2,5-di(2-thienyl)-tetrahydrothiophene
Starting from 4-chlorothiophenol, the synthesis of this compound is analogous to that of the tetrahydrothiophene synthesized in Example 2.
1 H NMR (CDCl 3 ): δ3.9-4.1 (m, 2H), 5.05 (d, J=10 Hz, 1H), 5.55 (d, J=4 Hz, 1H), 6.8-7.3 (m, 14H).
The product, 3,4-bis[(4-chloro)phenylthio]-2,5-di(2-thienyl)-tetrahydrothiophene, is a precursor compound having a precursor unit according to the formula (I), wherein X=S, R 1 =R 2 =4-chlorophenyl, R 3 =R 4 =R 5 =R 6 =H, which can be suitably used in a method according to the invention. When heated at 175° C. for 30 minutes, 4-chlorothiophenol is quantitatively eliminated and the conjugated compound terthiophene is obtained.
Example 4
Synthesis of 3,4-bis((4-methyl)phenylthio)-2,5-di(2-thienyl)-tetrahydrothiophene
Starting from thiocresol, the synthesis of this compound is analogous to that of the tetrahydrothiophene synthesized in Example 2.
1 H NMR (CDCl 3 ): δ2.25 (ss, 6H), 3.9-4.1 (m, 2H), 5.05 (d, J=10 Hz, 1H), 5.5 (d, J=4 Hz, 1H), 6.9-7.3 (m ,14H).
The product, 3,4-bis(4-methyl)phenylthio-2,5-di(2-thienyl)-tetrahydrothiophene, is a precursor compound having a precursor unit according to the formula (I), wherein X=S, R 1 =R 2 =4-methylphenyl, R 3 =R 4 =R 5 =R 6 =H, which can be suitably used in a method according to the invention. When heated at 175° C. for 30 minutes, 4-methylthiophenol is eliminated and the conjugated compound terthiophene is obtained.
Further precursor compounds which have been prepared in an analogous manner are 3,4-diethyl-2,5-di(2-thienyl)-tetrahydrothiophene and 3,4-di(tert-butyl)-2,5-di(2-thienyl)-tetrahydrothiophene. Thermal conversion proceeds under substantially identical conditions as mentioned above.
Further precursor compounds which can be prepared analogously are 3,4-bis((4-nitro)phenylthio)-2,5-di(2-thienyl)-tetrahydrothiophene and 3,4-bis(4-pyridyl)-2,5-di(2-thienyl)-tetrahydrothiophene.
Example 5
Synthesis of the dimer of 3,4-bis(phenylthio)-2,5-di(2-thienyl)-tetrahydrothiophene
3,4-bis(phenylthio)-2,5-di(5-bromo-2-thienyl)-tetrahydrothiophene To an ice-cooled solution of the unsymmetrical isomer of 3,4-bisuphenylthio)-2,5-di(2-thienyl)-tetrahydrothiophene as obtained in Example 2 (20.0 g, 42.8 mmol) in 80 ml DMF there is added in portions in about 5 minutes 20.5 g (115.2 mmol) N-bromosuccinimide (NBS). After part of the NBS had been added the temperature rose to 11° C. The addition of the remainder of the NBS was performed at 5-7° C. The mixture was stirred for 30 minutes, allowing the temperature to rise to 12° C. The solution is cooled and 4.0 g sodium dithionite is added. The mixture is stirred for 30 minutes at 5° C., then 30 minutes at 5 to 15° C. The mixture is cooled with ice and 50 ml water is added, followed by 50 ml toluene. After stirring for 5 minutes the mixture is poured in 300 ml water and 300 ml toluene. The layers are separated, the aqueous layer is extracted with 300 ml toluene, and the organic layers are washed with 2×100 ml water, then dried and rotary evaporated. The residue is filtered over a short aluminum oxide column using hexant/toluene (1/1) as the eluent. Rotary evaporation of the eluate, followed by crystallization of the residue from hexane/toluene affords 17.17 g of the unsymmetrical isomer of 3,4-bis(phenylthio)-2,5-di(5-bromo-2-thienyl)-tetrahydrothiophene (27.4 mmol, 64%).
1 H NMR (CDCl 3 ): δ3.9-4.2 (m, 2H), 4.95 (d, J=10 Hz, 1H), 5.4 (d, J=4 Hz, 1H), 6.8-6.9 (m, 4H), 7.0-7.3 (m, 10H).
3,4-bis(phenylthio)-2(5-bromo-2-thienyl)-5(5-tributylstannyl-2-thienyl)-tetrahydrothiophene
A solution of 3,4-bis(phenylthio)-2,5-di(5-bromo-2-thienyl)-tetrahydrothiophene (6.26 g, 10.0 mmol) in 80 ml THF is cooled to at least −70° C. n-Butyllithium (5.0 ml, 12.5 mmol) in hexane is added in 2 minutes at these temperatures. The mixture is then stirred for 5 min at −80° C., after which tributyltin chloride (90%, 4.78 g, 14.7 mmol) in 5 ml THF is added over a 1 minutes period at −70° C. or less. The mixture is stirred for 30 min at −60 to −80° C., then allowed to warm up to −10° C. Water and hexane are added and the mixture is worked up in the usual way by pouring the mixture in water, extracting with hexane, washing with water, drying and rotary evaporating. The crude product is chromatographed over an aluminum oxide column (25×2 cm), using hexane containing increasing amounts of toluene as the eluent. Hexane elutes some impurities and the bistin compound, hexane containing some toluene elutes the product, hexane/toluene. (1/1) elutes some starting dibromide. The monotin compound weighs 6.05 g (7.24 mmol, 72%), it still contains some minor impurities.
dimer of 3,4-bis(phenylthio)-2,5-di(2-thienyl)-tetrahydrothiophene
A quantity of 6.05 g (7.24 mmol) of 3,4-bis(phenylthio)-2(5-bromo-2-thienyl)-5(5-tributylstannyl-2-thienyl)-tetrahydrothiophene, 5.66 g of 3,4-bis(phenylthio)-2,5-di(5-bromo-2-thienyl)-tetrahydrothiophene (9.04 mmol), dichlorobistriphenylphosphinepalladium (350 mg, 0.50 mmol) and 40 ml N,N-dimethylacetamide are heated for 48 hours at 65-70° C. Zinc powder (4.0 g) is added and the mixture is stirred for another 24 hours at 65-70° C. The solvent is removed under vacuum at 60° C., chloroform is added to the residue and the mixture is filtered over a short aluminum oxide column. The filtrate is rotary evaporated and the residue is chromatographed over an aluminum oxide column (20×3 cm) using hexane containing increasing amounts of toluene as the eluent. This gives several fractions which are rotary evaporated. The residue is dissolved in a small amount of toluene and this solution is then added, while stirring, to an excess of methanol. This causes precipitation of the products, which are subsequently analyzed by HPLC (Nucleosil 5NO 2 column, hexane/dichloromethane, 20/80 as the eluent, flow 0.5 ml/min). The monomer 3,4-bis(phenylthio)-2,5-di(2-thienyl)-tetrahydrothiophene has a retention time of 3.32 minutes, the dimer thereof a retention time of 5.29 minutes and the trimer thereof a retention time of 4.90 minutes. Two major fractions were obtained, 1.00 g dimer of 3,4-bis(phenylthio)-2,5-di(2-thienyl)-tetrahydrothiophene (almost pure) and 4.37 g dimer (containing 5-10% of the trimer).
The dimer and trimer of 3,4-bis(phenylthio)-2,5-di(2-thienyl)-tetrahydrothiophene are both precursor compounds having precursor units according to the formula (I), wherein X=S, R 1 =R 2 =phenyl, R 3 =R 4 =R 5 =R 6 =H, and showing excellent solubility in chloroform, dichloromethane, THF and the like. They can be suitably used in a method according to the invention. When heated at 200-250° C. for 15 minutes, thiophenol is quantitatively eliminated and a thiophene-containing conjugated compound, sexithiophene, is formed from the dimer, whereas from the trimer nonithiophene is formed.
Example 6
Synthesis of the trimer of 3,4-bis(phenylthio)-2,5-di(2-thienyl)-tetrahydrothiophene
3,4-bis(phenylthio)-2,5-di(5-tributylstannyl-2-thienyl)-tetrahydrothiophene
A solution of 3,4-bis(phenylthio)-2,5-di(5-bromo-2-thienyl)-tetrahydrothiophene (7.96 g, 12.71 mmol) as obtained in Example 5, in 100 ml THF is cooled to a temperature below −80° C. n-Butyllithium (10.7 ml, 26.75 mmol) in hexane is added in 2 minutes at these temperatures. The mixture is then stirred for 5 minutes at −80° C. (longer stirring times lead to side-reactions, probably resulting from deprotonation at the 2-position of the tetrahydrothiophene ring), after which tributyltin chloride (90%, 10.7 g, 32.9 mmol) in 10 ml THF is added over a 3 min period at a temperature below −70° C. The mixture is stirred for 30 minutes at −60 to −80° C., then allowed to warm up to −25° C. Water and hexane are added and the mixture is worked up in the usual way. The crude product is chromatographed over an aluminum oxide column (30×4 cm), using hexane containing increasing amounts of toluene as the eluent. Hexane elutes some impurities, hexane containing a trace of toluene elutes the bistin compound, 3,4-bis(phenylthio)-2,5-di(5-tributylstannyl-2-thienyl)-tetrahydrothiophene, which still contains some minor impurities. The yield is 7.13 g (6.82 mmol, 54%).
trimer of 3,4-bis(phenylthio)-2,5-di(2-thienyl)-tetrahydrothiophene
The bistin compound (3.73 g, 3.57 mmol) obtained above, 3,4-bis(phenylthio)-2,5-di(5-bromo-2-thienyl)-tetrahydrothiophene (4.52 g, 7.22 mmol), the catalyst dichlorobistriphenylphosphinepalladium (315 mg, 0.45 mmol) and 25 ml N,N-dimethylacetamide are mixed and heated for 20 hours at 80° C. Another 100 mg catalyst (0.14 mmol) is added and the mixture is heated for 24 hours at 85° C. Zinc powder (2.0 g) is added and the mixture is stirred for 24 hours at 85° C. (Note: a lower temperature is beneficial, because some elimination of thiophenol is observed at 85° C.). The solvent is removed under vacuum, chloroform is added to the residue and the mixture is filtered over a short aluminum oxide column. The filtrate is rotary evaporated and the residue is chromatographed over an aluminum oxide column using hexane containing increasing amounts of toluene as the eluent. This gives several fractions which are rotary evaporated. The residue is dissolved in a small amount of toluene and this solution is then added, while stirring, to an excess of methanol. This causes precipitation of the products, which are subsequently analyzed by HPLC. The fractions consist of the dimer, dimer/trimer mixtures and almost pure trimer of 3,4-bis(phenylthio)-2,5-di(2-thienyl)-tetrahydrothiophene.
Example 7
The synthesis of 3,4-bis(phenylthio)-2,5-di[5-(2,2′-bithienyl)]-tetrahydrothiophene
A 50 ml flask, equipped with condenser, magnetic stirrer and nitrogen inlet was charged with 56.2 mg (0.08 mmol) of di(triphenylphosphine)palladium(II)dichloride in 20 ml dry THF, followed by 500 mg (0.8 mmol) of the dibromo compound as obtained in Example 5 in 5 ml THF. Slowly, 670 mg (1.83 mmol) of 2-tributylstannylthiophene in 5 ml of THF was added under nitrogen. The synthesis of 2-tributylstannylthiophene is described by Kotani et al. in J. Organomet. Chem., 1992, 429, p403. The reaction mixture was stirred for 16 hours at 60° C. After cooling to room temperature, the THF was removed in vacuo, followed by the addition of 40 ml water with a few drops of HCl. The mixture was extracted three times with 20 ml ether. The combined organic phases were washed with water and saturated NaCl solution. The organic layer was dried with magnesium sulfate and removed in vacuo. The product, 3,4-bis(phenylthio)-2,5-di[5-(2,2′-bithienyl)]-tetrahydrothiophene, was purified by column chromatography using pentane: ethyl acetate [9:1] as eluent. Yield 203 mg (39.8%).
1 H NMR: δ=6.9-7.7 (m, 20H), 6.0 (d, 1H), 5.1 (d, 1H), 4.5 (q, 2H) ppm.
The product, 3,4-bis(phenylthio)-2,5-di[5-(2,2′-bithienyl)]-tetrahydrothiophene, is a precursor compound having a precursor unit according to the formula (I), wherein X=S, R 1 =R 2 =phenyl, R 3 =R 4 =R 5 =R 6 =H, which can be suitably used in a method according to the invention. Heating at 200-250° C. for 15 minutes results quantitatively in quinquethiophene.
Example 8
The synthesis of 3,4-bis(phenylthio)-2,5-di[5-(2,2′:5′,2″-terthienyl)]-tetrahydrothiophene
The synthesis of this tetrahydrothiophene is analogous to the synthesis described in Example 7, with this difference that 2-tributylstannylthiophene is replaced by 2-thienyl-5-tributylstannylthiophene, the synthesis of which is described by Hark et al. in Tetrahedron Lett., 1994, 35, p7719. The yield is 28.1%.
1 H NMR: δ=6.9-7.6 (m, 24 H), 6.0 (d, 1H), 5.1 (d, 1H), 4.5 (q, 2H) ppm.
The product, 3,4-bis(phenylthio)-2,5-di[5-(2,2′:5′,2″-terthienyl)]-tetrahydrothiophene, is a precursor compound having a precursor unit according to the formula (I), wherein X=S, R 1 =R 2 =phenyl, R 3 =R 4 =R 5 =R 6 =H, which can be suitably used in a method according to the invention. Heating at 200-250° C. for 15 minutes results quantitatively in septithiophene.
Example 9
The synthesis of the tetrahydrothiophene according to the formula:
The synthesis of this tetrahydrothiophene is analogous to the synthesis described in Example 7, with this difference that 2-tributylstannylthiophene is replaced by 2-(5-tributylstannyl-2-thienyl)-5-(2-thienyl)thiophene, which can be prepared in an analogous manner. The yield is 117 mg (86.3%).
1 H NMR: δ6.9-7.7 (m, 28 H), 6.0 (d, 1H), 5.1 (d, 1H), 4.5 (q, 2H) ppm.
The product is a precursor compound having a precursor unit according to the formula (I), wherein X=S, R 1 =R 2 =phenyl, R 3 =R 4 =R 5 =R 6 =H, which can be suitably used in a method according to the invention. Heating at 200-250° C. for 15 minutes results quantitatively in nonithiophene.
Example 10
Synthesis of poly[3,4-bis(phenylthio)-2,5-di(2-thienyl)-tetrahydrothiophene]
The dibromide 3,4-bis(phenylthio)-2,5-di(5-bromo-2-thienyl)-tetrahydrothiophene (0.5 g, 0.8 mmol), dissolved in 5 ml dimethylformamide, was added to a solution of 2,2′-bipyridyl (315 mg; 2.0 mmol) and Ni(cyclooctadiene) 2 (550 mg, 2.0 mmol) in 20 ml of dimethylformamide. The mixture was stirred for 24 hours at 60° C. under an inert atmosphere and precipitated into methanol (200 ml). The solid material was dissolved again in chloroform, washed with water, reprecipitated in ether and dried in vacuum overnight.
Yield: 245 mg (65.7%).
1 H NMR (DMSO) of the unsymmetrical polymer: δ4.3 (2H), 4.9 (1H), 5.85 (1H), 6.8-7.2 (16H).
The molecular weight of the precursor compound thus obtained is determined by gel permeation chromatography (GPC) as follows:
A solution of the polymer in chloroform (2 mg/ml) kept at a temperature of 40° C. is filtered over a 0.5 micron Millex filter and analysed on a GPC system, comprising a PL gel 5 mm Guard column connected in series to a second PL gel 5 mm Mixed C column and a UV/VIS detector set at 254 nm. The calibration is performed using polystyrene standards (Easical). The polymer elutes between 14 and 18 minutes with a maximum at 16 minutes. From the chromatograms, the number-average molecular weight of the polymer is calculated to be 3500, the weight-average molecular weight amounts to 6400 and the dispersion amounts to 1.8. By comparison, an almost pure sample of the trimer, which corresponds to the polymer with n=1, has a retention time of 19 minutes. From these data, the number-average molecular weight of the trimer is calculated to be 220, the weight-average molecular weight amounts to 230 and the dispersion amounts to 1.1. Theoretically, these numbers should equal 460, 460, and 1 respectively, which demonstrates that, as a person skilled in the art will expect, the GPC analysis of the polymer underestimates the molecular weight. In fact, the molecular weight appears to be underestimated by a factor of 2.
The product, poly[3,4-bis(phenylthio)-2,5-di(2-thienyl)-tetrahydrothiophene], is a precursor compound having precursor units according to the formula (I), wherein X=S, R 1 =R 2 =phenyl, R 3 =R 4 =R 5 =R 6 =H, which can be suitably used in a method according to the invention. It has excellent solubility in common organic solvents like chloroform, THF and dichloromethane. A thermogravimetric analysis (Perkin Elmer 7 Series Thermal Analysis System), whereby 1.538 mg of the polymer is heated at a rate 10° C. per min from 30 to 500° C., shows that phenylthiol is eliminated between approximately 190 and 270° C. thus forming the conjugated compound polythiophene.
FIG. 1 shows the absorbance A (in au) as a function of the wavelength λ (in nm) of a conjugated compound (curve A) prepared by the method according to the invention using a precursor compound (curve B) according to the invention. The spectra are recorded by means of a Perkin Elmer Lambda 9 spectrophotometer. The spectrum represented by curve B corresponds to the precursor compound poly[3,4-bis(phenylthio)-2,5-di(2-thienyl)-tetrahydrothiophene]. After evacuating for 2 hours at 250° C. and 10 −5 Torr, the spectrum in curve A is obtained which shows a broad peak between 350 and 750 nm which is characteristic of polythiophene. However, unlike polythiophene samples which are not according to the invention, the broad peak shows various shoulders. This is considered to be due to the absence of topological defects.
Example 11
Using the polymer obtained in Example 10, a metal-insulator-semiconductor field-effect transistor (MISFET) is manufactured as follows:
A highly doped n ++ -type silicon wafer which acts as the gate contact, is provided with a 200 nm insulating layer of thermally grown silicondioxide. Using standard lithographic techniques, a set of interdigitated source and drain gold contacts is provided on top of the insulator to give channel widths in the range of 3-20 mm and channel lengths in the range of 2-20 microns, thus rendering the MISFIT substrate complete. Source to drain resistances are in excess of 10 12 Ohms. Subsequently, a 1 wt % solution of poly[3,4-bis(phenylthio)-2,5-di(2-thienyl)-tetrahydrothiophene] as prepared in Example 10 in chloroform is spincoated onto the MISFET substrate (3 seconds at 300 rpm followed by 30 s at 1000 rpm) to give a 50-150 nm thick precursor layer. The precise thickness is determined by means of a quartz substrate onto which the polymer is spincoated in an identical manner. The semiconducting layer is formed from the precursor layer by heating at a temperature of 250° C. at 10 −5 Torr for 2 hours. The MISFET—in fact a set of MISFETS is formed—is now complete. A current voltage characteristic of a MISFET whose channel width is 10 mm and channel length is 5 microns is then determined by connecting a current measuring device and both the gate and drain to a voltage source. Starting at a gate bias V g of +20 V, the gate bias is swept to −20 V and back to +20 V. This is done at different drain voltages, the source being grounded at all times. In order to avoid doping of the semiconducting layer, samples are evacuated prior to measurement and the measurement itself is performed under nitrogen or vacuum. The result is shown in FIG. 2 .
FIG. 2 shows the drain current I d (in A) as a function of the gate voltage V g (in V) at a drain voltage of −20 V (curve A) and −2 V (curve B) of a field-effect transistor according to the invention.
Using standard equations which model the current voltage characteristic of the MISFET taken at a drain voltage of −2 V, a voltage at which the MISFET is operating in the linear regime, the conductivity is calculated to be 8×10 −9 S/cm and the charge-carrier mobility is calculated to be 10 −6 cm 2 /(Vs).
Example 12
Example 11 is repeated with this difference that the polymer poly[3,4-bis(phenylthio)-2,5-di(2-thienyl)-tetrahydrothiophene] is (partially) replaced by either the dimer of 3,4-bis(phenylthio)-2,5-di(2-thienyl)-tetrahydrothiophene, which after conversion yields sexithiophene, the trimer of 3,4-bis(phenylthio)-2,5-di(2-thienyl)-tetrahydrothiophene, which after thermal conversion yields nonithiophene, or mixtures thereof. Some typical values of the conductivity ρ and charge-carrier mobility μ are collected in Table 1.
TABLE 1
polymer
(wt %)
dimer (wt %)
trimer (wt %)
ρ (S/cm)
μ(cm 2 /(V S )
0
100
0
2 × 10 −8
1 × 10 −5
0
0
100
5 × 10 −7
6 × 10 −5
50
50
0
6 × 10 −6
5 × 10 −4
25
0
75
9.5 × 10 −7
2.5 × 10 −4
From the results in this table it is apparent that the most favourable electrical properties are obtained, a low conductivity in combination with a high mobility being particularly desirable, if mixtures of polymers and oligomers of thiophene are used.
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The invention relates to a method of preparing thiophene-containing or furan-containing conjugated compounds such as polythiophene. The method uses a precursor compound having tetrahydrothiophene or tetrahydrofuran precursor units having arylthio or alkylthio substituents. The precursor units can be thermally converted into thiophene or furan units. Due to the presence of the precursor units the precursor compound is soluble and can, unlike the corresponding conjugated compound, be processed from solution.
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FIELD OF THE INVENTION
[0001] The present invention relates to a tool for gaining access to a locked motor vehicle, for example engaging the lock button of the vehicle door.
BACKGROUND OF THE INVENTION
[0002] It is not uncommon that the owner or operator of a motor vehicle lock the doors of the motor vehicle for example with the key left in the ignition switch. This leaves the owner or operator with the problem of opening the vehicle without damaging it. Professional motorist assistance services exist and may be brought in to solve the problem, but this may cause an objectionable delay and may incur costs.
[0003] In past years owners have resorted to attempting to manually open doors if a vehicle window has been left slightly open, or by maneuvering a wire tool past the weather gasket of the door. A wire tool may be fashioned from commonly available materials such as coat hangers for example. However, in an effort to dissuade theft, vehicle manufacturers have attempted to make it more difficult to gain access to the vehicle by such measures. One of the steps many manufacturers have adopted is to eliminate or minimize the enlarged head which in past years characterized door lock buttons.
[0004] While access through the window to the door lock button and to the door handle remain among the most practical ways to engage a door lock button, current vehicle manufacturing practice now requires tools more adapted to this purpose than was formerly the case.
SUMMARY OF THE INVENTION
[0005] The present invention provides an access tool which is well suited for the task of engaging a modern door lock button to open a door of a motor vehicle. The novel tool has a long slender shaft which is sufficiently flexible as to yield to obstacles as it is maneuvered into place, yet which is sufficiently rigid as to be guided while being grasped at one end while causing a snaring loop at the opposite end to be maneuvered over the shaft of a vehicle door lock button. The novel access tool may have an internal stranded metallic cable which is capable of resisting significant manual pulling forces to accommodate opening of the vehicle door lock button.
[0006] One aspect of the invention is that it is modular in that it comprises a plurality of mutually attachable and removable components. Connections are unthreaded, for example being friction fit and locked by a detent device which does not require threading. A pin may be inserted through the long, slender body of the tool to lock two body sections together.
[0007] The novel access tool may have a variety of replaceable working heads each adapted for a particular task. For example, the tool may have a flexible loop for engaging a door handle, a rigid hook, a magnet, and a miniature flash light.
[0008] It is an object of the invention to provide a modular access tool for gaining access to locked motor vehicles.
[0009] Another object of the invention is to eliminate tedious threading of modular sections together.
[0010] It is an object of the invention to provide improved elements and arrangements thereof by apparatus for the purposes described which is inexpensive, dependable, and fully effective in accomplishing its intended purposes.
[0011] These and other objects of the present invention will become readily apparent upon further review of the following specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Various objects, features, and attendant advantages of the present invention will become more fully appreciated as the same becomes better understood when considered in conjunction with the accompanying drawings, in which like reference characters designate the same or similar parts throughout the several views, and wherein:
[0013] FIG. 1 is a plan view of a kit of components which may be assembled to form an access tool according to at least one aspect of the invention.
[0014] FIG. 2 is an environmental plan view of an exemplary access tool assembled from the kit of FIG. 1 in a configuration adapted to engage a door lever of a motor vehicle.
[0015] FIG. 3 is a plan view of a component bearing a loop for engaging a door handle of a motor vehicle.
[0016] FIG. 4 is a plan view of an alternative component bearing a loop for engaging a door handle of a motor vehicle.
[0017] FIG. 5 is a side view of the component of FIG. 4 .
[0018] FIG. 6 is a side view, shown partially in cross section, of a working head for holding a magnet.
[0019] FIG. 7 is a cross sectional side view of a connector sleeve.
[0020] FIG. 8 is a side cross sectional view of an alternative working head for holding a magnet.
[0021] FIG. 9 is a side view, shown partially in cross section, of still another holder for a magnet.
[0022] FIG. 10 is a top view of a connector.
[0023] FIG. 11 is a side view of the connector of FIG. 10 .
[0024] FIG. 12 is an end view of the connector of FIG. 10 .
DETAILED DESCRIPTION
[0025] Referring first to FIGS. 1 and 2 , according to at least one aspect of the invention, there is shown a kit 10 of components of the modular access tool of the present invention. The tool is modular in that firstly, it may be assembled by joining selected ones of the components depicted in FIG. 1 to form a tool having characteristics for performing one of several optional ways of engaging the door handle (see FIG. 2 ) or a door lock button (not shown) of a motor vehicle (a portion of which is shown in FIG. 2 ). Secondly, the access tool may include different components so that it takes slightly different forms according to which of the selected ones of the components have been assembled. The access tool may vary in overall length, in the type of working head assembled thereto, or in both ways. Therefore, it must be understood that any one access tool assembled from the components of the kit 10 may leave one or more components unused in any one application.
[0026] FIG. 2 shows an exemplary assembly of an access tool 100 of the present invention. The access tool 100 may comprise a main body section 102 , an extension 104 , and a working head 106 bearing a loop 108 . In FIG. 2 , the loop 108 is depicted snaring a door handle 2 . Pulling by hand on the tool 100 will cause the door handle 2 to swing as indicated by the arrow A, thus opening the door. It will be appreciated that the tool 100 has been slipped into the interior of the vehicle, or the cabin, by pushing it past door and body gaskets (not shown) of the vehicle body. The components of the tool 100 are sufficiently slender as to pass through such a space.
[0027] Some vehicles may have door levers configured so as to be better engaged by a hook such as the hook 110 formed on a component 112 comprising a main arm section 114 which accounts for most of the length of the component 112 , the hook 110 , and an angled section 116 which may be snap fit or otherwise removably connected to the main body section 102 . It will be seen in FIG. 1 that the angled section 116 may form an angle (indicated by an arrow B) of about one hundred thirty-five degrees with the main arm section 114 . The hook 110 may be formed by straight sections 118 , 120 arranged at an included angle (indicated by an arrow C) defined between the straight sections 118 , 120 of about one hundred thirty-five degrees.
[0028] The straight section 118 may be arranged at an included angle (indicated by an arrow D) defined between the straight section 118 and the main arm section 114 of about one hundred thirty-five degrees.
[0029] The main body section 102 may also have an included angle (indicated by an arrow E) defined between a principal section 122 and a relatively short transition section 124 of about one hundred thirty-five degrees.
[0030] The main body section 102 may include a handle 125 having a diameter 127 defined along its length which is greater in magnitude than the diameter 129 of the main body section 102 . It will also be appreciated that the diameter 129 of the main body section 102 is substantially similar to the diameter 131 of the extension 104 . Preferably, comparable diameters of other extensions where provided, are similar to the diameter 129 .
[0031] Other access tools (not shown) may be formed by incorporating additional extensions such as an extension 126 bearing the hook 112 , an extension 128 bearing an illumination lamp 130 , or a working head 132 incorporating a magnet 134 . An illumination lamp may be formed in the dimensions and proportions of a working head such as the working head 132 if desired. Where provided, the illumination lamp may include an electrical power source such as a battery cell (not separately shown) and if desired, an externally accessible switch adapted to switch the illumination lamp on and off.
[0032] FIG. 3 shows details of the working head 106 . The working head 106 may comprise the loop 108 and a base 136 . The loop 108 may comprise metallic strands, which may be retained within flexible sleeves 138 , 140 . The free ends 142 , 144 of the loop 108 may be secured by crimping the base 136 thereover. The base 136 may have a socket 146 formed therein for attachment to an elongated component of the kit 10 , such as the component 112 , or an extension such as the extension 104 .
[0033] FIGS. 4 and 5 show an alternative working head 150 which may comprise a loop 152 and a base 154 which entraps and retains the loop 152 by being crimped thereover for example. The loop 152 may comprise metallic strands retained and organized by sleeves 156 , 158 . The working head 150 may engage another component of the kit 10 other than by a socket such as the socket 146 of FIG. 3 . Instead, the working head 150 may incorporate a mechanical detent device such as a pin 160 . The pin 160 may engage a socket 162 by friction for example.
[0034] Other mechanical detent devices may be provided in place of the pin 160 . For example, a device wherein a projecting member is spring urged to engage and project outwardly from an opening such as the socket 162 , which may be pressed manually out of interference with a sleeve or other member to release engagement may be provided. This is a well known type of detent device and need not be further described herein. It is merely desirable to note that connection of elongated members such as the component 112 to an extension such as the extension 104 is preferably provided by a detent device which does not rely on screw threading, so that elongated members may be rapidly pressed together and separated when desired.
[0035] FIG. 6 shows a light tip extension 164 . The light tip extension may have a socket 166 for connection to an elongated member and a socket 168 for receiving a pin or other mechanical detent device (neither shown).
[0036] FIG. 7 shows a connection arrangement which may be employed to connect elongated members such as the component 112 , extensions such as the extension 104 , and working heads such as the working head 106 if desired. In this arrangement, a sleeve 170 forms a female member into which may be inserted a male member such as an end terminal 172 . The end terminal may have a throughbore 174 which may be aligned with holes 176 , 178 formed in the sleeve 170 to receive a mechanical detent device such as a pin (not shown). The sleeve 170 may have an aditional hole 180 which may receive a complementing end terminal (not shown, but which may be similar to the end terminal 172 ), so that two end terminals may be retained within the sleeve 170 by pins. It will be appreciated that the end terminal 172 has a tongue 182 which occupies half of the open interior space of the sleeve 170 . This accommodates a corresponding tongue of the complementing end terminal in close cooperation therewith. That is, a complementing tongue may occupy that portion of the sleeve 170 which is left unoccupied by the tongue 182 , where the complementing tongues overlap one another for a portion of the length of the sleeve 170 .
[0037] The working head 132 is shown in detail in FIG. 8 . The magnet 134 is seen received within a socket 184 which faces in one direction, with an oppositely opening socket 186 facing an opposite direction. The sockets 184 , 186 may be separated by an internal flange 188 which limits penetration of the magnet 134 into the socket 184 and by an elongated member such as the component 112 or an extension such as the extension 104 into the other socket 186 .
[0038] As seen in FIG. 9 , a magnet (not shown) may be retained within a working head 190 . The working head 190 may comprise a socket 192 which may be crimped over the magnet, and an engagement end 194 comprising a socket 196 and a tongue 198 which is structurally and functionally similar to the tongue 182 of FIG. 7 .
[0039] FIGS. 10 , 11 , and 12 show an adaptor 200 which may be employed to join elongated members such as the component 112 , extensions such as the extension 104 , and working heads such as the working head 106 if desired. The adaptor 200 may comprise a tongue 202 , a socket 204 , and an outwardly projecting low wall 206 which limits penetration of the adaptor 200 into an elongated member or working head by interference fit.
[0040] While the present invention has been described in connection with what is considered the most practical and preferred embodiment, it is to be understood that the present invention is not to be limited to the disclosed arrangements, but is intended to cover various arrangements which are included within the spirit and scope of the broadest possible interpretation of the appended claims so as to encompass all modifications and equivalent arrangements which are possible.
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A modular access tool for operating door handles and door locks of motor vehicles from the exterior of the motor vehicle. The access tool is provided in sections which are removably attachable to one another such that the overall operative length is adjustable in discrete steps. A working head, such as a loop, a hook, or a magnet is attachable at the end of the access tool. Optionally, an illumination light may be attachable at the end of the access tool. Sections join together by threadless interference based detent devices.
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This is a division of U.S. patent application Ser. No. 07/177,903 filed Apr. 1, 1988, now U.S. Pat. No. 4,813,612, issued Mar. 21, 1989, which is a continuation of U.S. patent application Ser. No. 06/866,505 filed May 23, 1986 and now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to a paper feeding device to feed each sheet of image forming paper or document to an image processing apparatus such as copying machines and facsimile units.
Image processing apparatus such as copying machines and facsimile units are hitherto provided with a paper feeding device having a paper cassette and/or a stack bypass enabling to set a number of sheets of image forming paper, and/or a paper feeding device having an automatic document feeder enabling to set a number of sheets of documents.
The paper feeding device having the aforementioned paper feed cassette is advantageous in that the cassette can be changed easily when it is necessary to use a paper of different size. For copying machines, as an example, the document size to be copied recently tends to become larger, and a larger size of paper cassette has been used to accept a larger image forming paper corresponding to larger documents which are to be copied. When a paper feed cassette is mounted onto a copying machine proper, therefore, larger area for installing the copying machine is required than for the copying machine itself, which is causing a problem of lowered efficiency in use of the limited office space.
To solve the problem, a reverse paper feeding device has been proposed in which a direction of paper feeding from the paper cassette by the feed roller is set in opposite to a direction of paper feeding by a resist roller which operates synchronously with the optical system. In this case, the whole copying machine can be made compact even with the paper cassette being mounted by thereon so that the paper cassette may not be projected from the area of a vertical projection, for example, of the optical system which requires the largest plane size.
Such a reversing paper feeding device is composed of a feed roller to send out each sheet of paper from the paper cassette, a delivery roller to carry the paper fed from the feed roller toward a resist roller, and a guide member to reverse a direction of the paper carried by the delivery roller. The driving of feed roller and the resist roller are controlled in timing with a specific paper feeding, and driving of the delivery roller is also controlled in timing with the specific paper feeding by using a clutch or the like.
Accordingly, the feed roller and the delivery roller are driven to rotate enabling the preliminary paper feeding to the point where the front end of paper comes in contact with the resist roller, thereafter the delivery roller and the resist roller are driven to rotate enabling a paper feeding for accomplishing a copying operation.
With a reversing paper feeding device of the above composition, installation area of the copying machine can be made smaller and exact paper feeding can be ensured. It is necessary, however, to control driving of the delivery roller corresponding to driving condition of the feed roller and the resist roller, which makes the electrical control system and mechanical revolution transfer mechanism more intricated as a disadvantage. And further the device is also disadvantageous in that the position of the delivery roller attached is rather limited making it difficult to design the whole paper feeding device, and additional members are necessary to attach the delivery roller.
Besides, in the conventional composition of the paper feeding device to feed each sheet of paper from a paper cassette which has no click to prevent double feeding by means of a feed roller and a friction pad pressed in contact with each other, a pressing mechanism to upwardly turn a document setting board mounted in the paper feed cassette so as to be turned freely is provided in the copying machine, and a pressure releasing lever mechanism to stop upwardturning of the document setting board by a means of pressure mechanism is also attached.
Under the condition where the document setting board is upwardly turned by the pressing mechanism when the paper feed cassette is mounted, therefore, the upper-most paper is pressed to the feed roller to enable paper feeding sheet by sheet. When the upward-turning of the document setting board is stopped by the pressure releasing lever mechanism, on the other hand, the pressing mechanism retreats from the paper cassette and the cassette can be pulled out.
By the paper feeding device of aforementioned mechanism, the document setting board can be upwardly turned simply by mounting a paper feed cassette, but the paper feeding device is disadvantageous in that the operation of pulling out the paper cassette is troublesome because the pressure release lever mechanism must be operated before pulling out the cassette. The need of a pressure release lever mechanism in addition to the pressure mechanism makes the composition of the whole paper feeding device more intricated and the manufacturing cost higher.
When the paper feeding device of the above composition is adopted, the front end of the next paper is positioned between the feed roller and the friction pad by the friction force between adjacent sheets of papers when feeding of one sheet of paper completes. If copying operation is continued as it is, there will be no problem, however, if it is necessary to change the paper size or the like, a new paper cassette must be mounted after pulling out the currently used paper cassette. While the cassette is changed, the paper of which top end is held between the feed roller and the friction pad remains in the copying machine, and a new paper feed cassette is set under this condition. Accordingly, the remaining paper is greatly crumpled or folded, and a jamming is finally resulted if the copying operation is kept going on.
To solve the above problem, a paper feeding device (Refer to the Japanese Patent Laid-Open Publication No. 203629/1982) has been proposed, in which the contact condition of the feed roller with the friction pad is released when the paper cassette is pulled out to prevent the paper from remaining in the copying machine.
By the paper feeding device of the above composition, only the contact condition of the feed roller with the friction pad is released when the paper cassette is pulled out and residual paper is prevented from remaining in the position between the feed roller and the friction pad by being pulled by the friction force between the residual paper and the papers stored in the paper cassette. In such a condition, remaining paper can be prevented from the remaining state rather accurately if the paper size is large, however, if the size is small, the paper carried to the specified position by the feed roller remains in the copying machine even when the paper cassette is pulled out, and jamming is resulted when a new paper feed cassette is set.
The problem is outstanding particularly for the type of copying machine in which almost part of the paper cassette is housed into the copying machine because the remaining paper can't be watched or checked easily from outside.
The aforementioned paper feeding device containing a stack bypass or an automatic document feeder has a preliminary feed roller and a feed roller and the preliminary feed roller is moved in opposite direction to paper pressing direction by a solenoid, a lever, a cam and the like under the condition where transmission of the driving force of the both rollers is cut off so that a number of sheets of paper can be set easily and exactly at the specified position.
At paper feeding operation, the preliminary feed roller is moved in paper pressing direction by the solenoid, the lever, the cam and the like and the both rollers are driven under this condition so that the paper is carried sheet by sheet.
By the composition to move the preliminary feed roller in paper pressing direction simply by applying force and without using any solenoid, lever, cam, or the like, the papers could be set rather easily at the specified position provided that the number of sheets of paper is comparatively small because the tangential direction of the preliminary feed roller at the point where the upper sheet of paper comes in contact is close to horizontal direction and the preliminary feed roller can be upwardly moved against the applied force. When the number of sheets of paper is increased, however, the tangetial direction of the preliminary feed roller at the point where the upper top of paper comes in contact rises sharply and the vertical component of a force to upwardly move the preliminary feed roller against the applied force is quickly reduced, making it difficult to set the papers at the specified position.
If the number of sheets of paper is further increased and the upper surface of the papers goes up to the level approximately equal to the center axis of the preliminary feed roller, it becomes almost impossible to move the preliminary feed roller against the applied force and paper can hardly be set at the specified position. However, by employing the above-mentioned mechanism to move the preliminary feed roller with a solenoid, a lever, a cam, and the like paper setting can be made easily.
Though the paper setting can be exactly made, the paper feeding device of the aforementioned composition requires a mechanism to move the preliminary feed roller and also a means to control the mechanism, which is disadvantageous in that the whole paper feeding mechanism is intricated and the manufacturing cost is raised.
An object of the present invention is to ensure exact preliminary paper feeding and main paper feeding by reversing a paper-feed direction to the opposite without the need of driving a feed roller in a controlled manner.
Another object of the present invention is to enable the document setting board to be automatically rotated by a pressing mechanism, and to have the pressing mechanism automatically retreat from inside the paper cassette following the pulling out of an inserted paper cassette,.
A further object of the invention is to prevent a paper from remaining when the paper feed cassette is pulled out.
A still further object of the invention is to make the whole paper feeding device simple by eliminating the complicated mechanism to move the preliminary feed roller and the means to control that mechanism so as to make the manufacturing cost lower.
It is also another object of the invention to prevent inclined paper feeding by raising the preliminary feed roller equally at the right and left sides in longitudinal direction thereof when paper is inserted.
In accordance with the present invention, in a paper feeding device in which a direction of delivering a document fed from the inside of a paper cassette by a feed roller is reversed so as to be conducted to a resist roller which operates synchronously with a movement of an optical system, there is provided a guide section which is composed of an outer guide plate and an inner guide plate to form a space for permitting the document to pass therethrough, and a delivery roller which is, in use, driven to rotate and is mounted on the guide section near the feed-roller side.
And preferably, the above paper cassette includes therein a document setting board to support a document, and the paper feeding device includes a pressing mechanism for lifting up the document setting board in a state that the paper cassette is set in the image processing apparatus, and a locking mechanism to prevent the pressing mechanism from lifting up the document setting board after removing the paper cassette.
More preferably, the paper feeding device includes a drive-force transmitting mechanism for transmitting to a feed roller a rotary force in the opposite direction to the paper-feeding direction upon the removal of the paper cassette from the image processing apparatus.
Further, in accordance with the present invention, a paper feeding device wherein a feed roller further feeds a document which is fed by a preliminary roller is characterized in that the preliminiary feed roller is in use pushed in a direction to press the document, and there is provided a guide member which turns following an operation of setting the document on a predetermined position so as to move the preliminary feed roller in the opposite direction to the pressing direction on the document.
Preferably, the above guide member has on an end thereof a pushing section hanging at least over an end portion on the driving side of the shaft of the preliminary roller, and on the other end of the guide member a receiving section lying at least below the opposite end portion of the shaft of the preliminary roller.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the outline of the internal mechanism of a copying machine provided with a paper feeding device of the present invention;
FIG. 2 is an enlarged longitudinal section of the paper feeding device of FIG. 1;
FIG. 3 is an exploded perspective side view of the paper feeding device in FIG. 1;
FIG. 4 is a longitudinal section of the principal part showing the condition with no paper feed cassette;
FIG. 5 is a longitudinal section of the principal part showing the condition with a paper feed cassette mounted;
FIG. 6 is a plan view showing the attached condition of an auxiliary roller;
FIG. 7 is a longitudinal section showing the relationship between the feed roller and the friction pad;
FIG. 8 is a plan view showing a mechanism to rotate in opposite direction to paper feeding;
FIG. 9 is a side view showing paper feed condition;
FIG. 10 is a side view showing the condition of pulling out a paper feed cassette;
FIG. 11 is a side view showing another embodiment of the mechanism to rotate the feed roller in opposite direction to paper feeding;
FIG. 12 is a side view showing still other embodiment;
FIG. 13 is a perspective view of the paper feeding device of FIG. 2;
FIG. 14 is a schematic longitudinal section showing the condition of setting a small number of sheets of paper;
FIG. 15 is a schematic longitudinal section showing the condition of setting a large number of sheets of paper;
FIG. 16 is an enlarged and schematic longitudinal section showing a document tray, feed roller, and preliminary feed roller;
FIG. 17 is an enlarged and schematic longitudinal section showing the document tray and feed roller;
FIG. 18 is a schematic view showing another embodiment of the mechanism to transmit revolution to the preliminary feed roller;
FIG. 19 is a plan view to show another embodiment of the paper feeding device of FIG. 1;
FIG. 20 is an exploded perspective view showing the principal part;
FIG. 21 is a side view showing the principal part;
FIG. 22 is a schematic longitudinal section to show the condition of paper feeding from the paper cassette; and.
FIG. 23 is a side view showing the condition of pulling out paper feed cassette.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows the outline of the internal mechanism of a copying machine incorporated with a paper feeding device of the present invention.
Of the whole housing (1) of the copying machine, the part incorporating the optical system (2) comprising a lamp, reflecting mirrors, and a lens is made wider and the other part incorporating the copying section (3) and the paper conveying section (4) is made narrower.
To be more specific, a contact glass (11) to set documents to be copied is provided at the specified position on the housing (1) of the copying machine.
The optical system (2) is composed of a lamp (21) to scan and expose documents while moving at a specified speed, reflecting mirrors (22) (23) (24) to lead the reflected light from the documents to a lens (25) while moving after the lamp (21), and a reflecting mirror (26) to lead the light coming through the lens (25) to the copying section (3).
The copying section (3) comprises a photoreceptor drum (31) which turns in one direction at every copying operation, corona dischargers (32), a developing device (33), a transferring corona discharger (34), a separating belt (35) and a cleaner (36) provided around the photoreceptor drum (31).
The paper conveying section (4) has the first paper feeding device (5) to feed out paper (P) sheet by sheet from the paper feed cassette (12) set on lower position of the copying section (3), a resist roller (41) driven synchronously with transferring of the lamp (21), a delivery roller (42) to carry the paper (P) separated from the photoreceptor drum (31) by the separating belt (35), a heating and fusing device (43), and a discharge roller (44) to discharge the paper (P) onto a discharge tray (15). A preliminary feed roller (103) to carry the paper (P) to the resist roller (41) and the 2nd paper feeding device (10) primarily made of a feed roller (102) are also attached to a specific position of a document tray (101) at a specific position of the copying machine housing (1) to enable selection of paper feed from the paper feed cassette (12) and from the document tray (101).
FIG. 2 to FIG. 5 show detailed composition of the 1st paper feeding device (5), which is primarily composed of a feed roller (51), delivery roller (52), driven roller (53) as a driven member, and a guide (55).
The feed roller (51) rotates while being pressed against the surface of the paper (P) held by a document setting board (13) which is turned upward by the lift-up lever (14) attached to a specific position in the copying machine housing (1) so as to feed out of paper (P) sheet by sheet and the paper is lead between the feed roller (51) and the friction pad (58) so that double paper feeding is prevented exactly.
As shown in FIG. 6, an auxiliary roller (51c) to press the paper (P) on the end thereof is attached, in a manner to slide freely, to a sheet (51a) to which the feed roller (51) is also attached. When the feed roller (51) is mounted together with the shaft (51a), sliding range of the auxiliary roller (51c) is limited by a rib (57a) projected from outer surface of the inner guide member (57) as described later. Accordingly, manufacturing and assembling become easy. The auxiliary roller (51c) may be fixed to the shaft (51a) in advance, but attaching accuracy of the auxiliary roller (51c) must be higher in this case.
As shown in FIG. 7, the friction pad (58) is fixed to a contact member (12a) which regulates setting position of the paper cassette (12) and is formed narrower than the feed roller (51).
An edge parallel to the paper feed direction is formed on the tapered face (58a) and the paper (P) caught between the feed roller (51) and the friction pad (58) is bent along the tapered face (58a) to prevent folding or cutting of the paper, and thus jamming is prevented if the paper (P) is carried as it is.
The paper (P) is allowed to be bent further along the feed roller (51) and the friction pad (58) to provide a space (59) where front end of the paper (P) can be corrected.
After the space (59), the delivery roller (52) normally turned and the driven roller (53) pressed against the delivery roller (52) by a plate spring (54) are attached, and the guide member (55) composed of an outer guide plate (56) and an inner guide member (57) is attached between the normally rotated delivery roller (52) or the driven roller (53) and aforementioned resist roller (41).
To be more specific, the paper cassette (12) has a document setting board (13) which can be turned in an up-and-down direction when the paper cassette is inserted into the copying machine housing (1). The up and down movement of the document is achieved by forcing one end of the document setting board to rotate about the other end of the document setting board which is pivotably secured to the paper cassette. Additionally a rectangular opening (63) is provided along the front end of the bottom plate of the paper feed cassette (12) and to the bottom portion of the front plate of the paper cassette which is first inserted into the housing.
A support (65) is fixed to the inner end of the bottom plate (64) of the copying machine housing (1) and a lift-up lever (14) is turnably attached between a set of brackets (66a) and (66b) provided on the support (65).
One bracket (66a) is fixed onto the support (65) with a set screw (67) and the other bracket (66b) is made in one piece with the support (65) by bending a part of the support (65), and the push lever (14) is held so as to turn upward and downward by projections (14a) (14b) provided at both sides of the bent part in the middle of the lift-up lever (14) and inserted into through holes (66c) (66d) made on the brackets (66a) (66b).
A stopper dent (14c) is also provided on the base of the lift-up lever (14) and another stopper dent (68a) is also provided on a bent part (68) at an inner side of the support (65), and a coil spring (69) to turn the lift-up lever (14) upward (clockwise direction in FIG. 4 and FIG. 5) is provided between the stopper dents (14c) and (68a).
A locking means (70) is provided in addition, which is composed of a locking mechanism (71) to lock the lift-up lever (14) in downward turning condition and of an lock-releasing mechanism (72) to release locking into upward turning condition.
Having an interlocking projection (14d) at a side of the base of the lift-up lever (14) and an interlocked projection (75c) to be locked with the interlocking projection (14d), the locking means (70) is turned to a locked condition (See FIG. 4) when the interlocking projection (14d) and the interlocked projection (75c) are interlocked with each other. The lock-releasing mechanism (72) has a release lever (75) of an arc shape and supports the release lever (75) between a pair of brackets (76a) (76b) provided on the support (65) in a manner that the lever can be turned freely.
That is, one bracket (76a) is made in one piece with the support (65) by bending a part of the support, and the other bracket (76b) is fixed onto the support by a set screw (77) and the release lever (75) is supported so as to turn freely by the projections (75a) (76b) at both sides of the base of the unlocking lever (75) inserted into the through holes (76c) (76d) provided on the brackets (76a) (76b). In addition, the bottom end of a plate spring (78) bent to approximately U-shape is fixed onto the support (65) with a screw (79) and the top end is put in contact with the outer face of the release lever (75) to turn the release lever (75) to the direction of the paper cassette (12) (counter-clockwise direction in FIG. 4 and FIG. 5).
The interlocked projection (75c) is provided on the release lever (75) corresponding to the interlocking projection (14d) provided on the lift-up lever (14). When the interlocking projection (14d) interlocks with the interlocked projection (75c), upward turning of the lift-up lever (14) by the coil spring (69) is prevented as shown in FIG. 4. i.e. locking condition is selected. When the locking projection (14d) is disengaged from the interlocked projection (75c), the lift-up lever (14) is turned upward by the coil spring (69), i.e. unlocking condition is selected.
The release lever (75) has a top end which comes in contact with the front plate of the paper cassette (12) mounted onto the copying machine, and operating pieces (80) extending downward diagonally are provided at the front side of the front plate of the paper feed cassette (12). There are two operating pieces (80) provided with certain spacing in a transversal direction of the paper feed cassete (12). Corresponding to the operating pieces (80), contained pieces (81) are provided at the top side of the lift-up lever (14).
The contacted pieces (81) are made of a contacted member (82) of triangular shape provided at a side of the lift-up lever (14), and a contacted roller (84) supported at the side with a short shaft (83) so as to turn freely, and the surface of the contacted member (82) is inclined upward to the side of the contracted roller (84). It is preferable to provide a guide member (85) of approximately the same shape as the contacted member (82) symetrically to the contacted member (82) around the contacted roller (84).
The contact member (12a) has a contact part (12b) extending substantially vertically upward and an inclined part (12c) extending upward slantwise from the top end of the contact part (12b) in paper carrying direction, and covers the top of the support (65). The top side of the lift-up lever (14) and the top end of the release lever (75) are projected through an opening (12d) formed at approximately the center in transversal direction of the contact member (12b) (width-direction of the paper P). On the bottom plate (64) of the copying machine housing (1), a housing space (64a) is provided to accept the top end of the lift-up lever (14) when the lever (14) turns downward. As shown in FIG. 8 to FIG. 10, a rack (86) is made at the upper front of one side plate of the paper cassette, and a storage space (87) is provided immediately after the back side of the rack (86).
Driving force of the driving power source (not illustrated) is transmitted at a specified timing to one end of the shaft (51a) to which the feed roller (51) is attached through a driving force transmission mechanism comprising a gear (88a) and a clutch (88b). To the other end of the shaft (51a), a gear (89), a gear attaching plate (90) and a lever (91) are attached. At a specified position of the gear attaching plate (90), a gear (92) to be interlocked with the gear (89) and another gear (93) to be interlocked with the gear (92) are attached.
The lever (91) and the gear attaching plate (90) are turned downward around the shaft (51a) by a tension spring (94) provided between the top end of the lever (91) and a fixed point in the copying machine housing (1).
The storage space (87) is provided at a position where the gear (93) can be housed when the paper feed cassette (12) is mounted completely so that the gear (93) following revolution of the feed roller (51) for paper feeding can be turned freely. The feed roller (51) can also be turned in reverse direction to paper feeding by the gear (93) interlocked with the rack (86) following pull-out motion of the paper cassette (12).
As shown in FIG. 6, the inner guide member (57) is totally made of synthetic resin and a plurality of ribs with convex curvature on the side are provided on the outer surface of the guide member. An outer guide plate (56) made of steel or the like is attached with about 1 mm spacing to the top of the ribs and the space between the ribs and the outer guide plate is used for paper transfer.
The delivery roller (52) is supported, in a manner to turn freely, at a position a little off the above mentioned space of the inner guide member (57), and a switch (60) to detect the paper (P) is held immediately before the resist roller (41). The driven roller (53) is attached to an opening and closing member (61) which is held onto the copying machine housing (1) by a plate spring (54) so as to be opened and closed.
When the opening and closing member (61) is opened, the driven roller (53) is kept off the delivery roller (52), and under closed condition of the opening and closing member (61), the driven roller (53) is pressed in contact with the delivery roller (52). The pressure of the plate spring (54), however, is set smaller than the firmness of the paper (P). The magnet (62) is to keep the opening and closing (61) at closed condition.
Operation of the 1st paper feeding device (5) is as shown below. When the paper feed cassette (12) is not set, the lift-up lever (14) turns downward, as shown in FIG. 4, and the interlocking projection (14d) interlocks with the interlocked projection (75c) of the release lever (75) to keep the downward turning operation. When the paper feed cassette (12) is inserted through the opening of the copying machine housing (1) under this condition, lower end of the pair of operating pieces (80) at the front side plate of the paper cassette (2) first comes in contact with the upper face of the corresponding guide member (85). As the cassette is inserted further, it goes over the guide member (85), the contacted roller (84) and the contacted member (82) in the order as mentioned. While going over, the front side of the paper feed cassette (12) is moved up and down to some extent due to the inclined face of the guide member (85) and the contacted member (82).
As the paper cassette (12) is kept inserted further, the front side plate comes in contact with the top end of the release lever (75) just before the end of setting of the paper feed cassette (12) i.e. immediately before the front plate of the paper cassette (12) comes in contact with the contact part (12b) of the contact member (12a), then the release lever (75) turns clockwise against the pressure of the plate spring (78) as the paper feed cassette (12) moves.
At the end of setting of the paper feed cassette (12), the interlocking projection (14d) of the push lever (14) is released from the interlocked projection (75c) of the release lever (75), then the lift-up lever (14) is turned upward by the coil spring (69) to turn the document setting board (13) upward (counter-clockwise direction in FIG. 5) and to put the feed roller (51) in pressed contact with the paper (P) at the top thereof. (See FIG. 5.)
Accordingly, rotary force is transmitted to the shaft (51a) through the driving force transmission mechanism comprising the gear (88a) and the clutch (88b) and the feed roller (51) is rotated in the direction indicated by an arrow (51b) to feed the paper (P) out of the paper feed cassette (12). If two or more sheets of papers (P) are sent out at a time, the friction resistance between the friction pad (58) and the paper (P) functions to feed out the upper-most paper (P).
During the paper feed operation, the gear (93) is also rotated but the rotation is idle as it is housed in the storage spaces (87) and causes no problem.
The sheet of paper (P) sent out between the feed roller (51) and the friction pad (58) is led through the space (59) to the position between the delivery roller (52) and the driven roller (53). Since revolution of the delivery roller (52) is applied as the carrying force of the paper (P), the carrying force is sufficient to carry the paper (P) through the guide (55) and contact with the resist roller (41). Even after the front end of the paper (P) touches the resist roller (41), the paper (P) is carried further for certain time by the delivery roller (52), and the paper (P) fits along the whole surface of the outer guide plate (56) as shown by the continuous line in FIG. 2.
Because of the firmness of the paper (P), the driven roller (53) is moved against the pressure of the spring (54), which serves to keep the paper (P) under the condition of no carrying force applied although the delivery roller (52) is kept turning.
This arrangement exactly prevents the trouble that the paper (P) is carried to the resist roller (41) more than necessary resulting in jamming.
If the paper (P) is not very firm, the driven roller (53) is little moved but the contact pressure to the delivery roller (52) is lessened and the delivery roller slips on the paper (P) thus carrying of the paper (P) is stopped.
The preliminary paper feeding stops under the condition where the paper (P) is slackened from the regular carrying face by about 5 to 10 mm in the space (59) and front end of the paper (P) can be corrected.
For the following paper feeding, the feed roller (51) is kept suspended, and the friction between the friction pad (58) and the paper (P) functions as a resisting force. When carrying of the paper (P) by the resist roller (41) starts, the paper (P) is immediately pulled and fitted along the outer surface of the inner guide member (57), as shown by the broken line in FIG. 2, as firmness of the paper (P) is no longer enough to separate the driven roller (53) from the delivery roller (52).
The driven roller (53) is strongly pressed, therefore, to the delivery roller (52) and revolution of the delivery roller (52) functions for carrying the paper (P) without any slipping. The carrying force applied to the paper (P) by the resist roller (41) and the delivery roller (52) overcomes the resistance to complete the paper feeding to the copying section (3).
Should jamming happen between the feed roller (51) and the delivery roller (52), the blocked paper (P) can be removed easily by opening the opening and closing member (61).
If the paper cassette (12) must be pulled out to replenish paper (P) or to change the size of the paper in use (P), the release lever (75) first turns downward following transfer of the paper feed cassette (12) to the outside (left side in FIG. 2). The paper feed cassette (12) moves outward further to go off the top of the release lever (75), then each one of the operating piece (80) comes in contact with the contacted part (81) to turn the lift-up lever (14) downward. At the end of downward turning of the lift-up lever (14), the interlocking projection (14d) interlocks with arc-shaped inner surface of the release lever (75) to turn the release lever (75) upward, then the interlocking projection (14d) goes over the interlocking projection (75c). Accordingly, downward turning the lift-up lever (14) can be maintained by the interlocking projection (14d) interlocked with the interlocked projection (75c) even if the paper cassette (12) move outward further and downward turning power of the lift-up lever (14) by the operating piece (80) is no longer effective.
In the initial stage of pulling out of the paper feed cassette (12), the gear (93) goes off the storage space (87) and is interlocked with the rack (86) (See FIG. 10.). Accordingly, the gear (93) rotates following outward movement of the paper feed cassette (12) and rotary force in reverse direction to paper feeding is transmitted to the shaft (51a) through the gears (92), (89). In this case, transmission of the driving force is normally shut off by the clutch (88b), and the feed roller (51) is rotated in reverse direction to paper feeding, and the paper (P) of which the top end is caught between the feed roller (51) and the friction pad (58) is carried in reverse direction, i.e. to the paper feed cassette (12) so as to be free. If the paper feed cassette (12) is pulled out while the clutch (88b) is still kept in the condition of driving power transmission, the gear (93) turns upward around the shaft (51a) to be released from the rack (86), and collision of the gear (93) against the rack (86) is prevented.
As is made clear in the above description, upward or downward turning of the lift-up lever (14) is selected automatically following setting and pulling-out of the paper cassette (12) resulting in easy setting and pulling-out of the cassette (12). At pulling out of the paper feed cassette (12), the feed roller (51) turns in reverse direction to paper feeding in the initial stage of pulling, and top end of the paper (P) is not caught between the feed roller (51) and the friction pad (58) and the contact area of the paper with the friction pad (58) is kept less. This serves to pull out the paper (P) completely together with the paper feed cassette (12) and prevents the paper (P) from the remaining in the copying machine housing (1).
Although the delivery roller (52) is kept turned throughout paper feeding operation, carrying force is applied to the paper (P) only while the driven roller (53) is pressed onto the delivery roller (52).
This means that a carrying force is applied to the paper by the feed roller (51) while the paper being fed is between the feed roller and the friction pad (58). Also, a carrying force is applied to the paper by the delivery roller (52) from the time the paper being fed passes between the delivery roller and the driven roller (53) up until the time the leading edge of the paper being fed comes in contact with the suspended resist roller (41) causing the paper to bend to conform to the inner surface of the outer guide plate. While the paper is positioned so as to conform to the inner surface of the outer guide plate (56), the driven roller (53) is moved against the pressure of the spring (54), and, thus, no carrying force is applied to the paper. Subsequently, when resist roller (41) is rotated and the paper is pulled and fitted along the outer surface of the inner guide plate (57), the firmness of the paper is no longer sufficient to separate the delivery roller (52) from the driven roller (53), and, thus, the delivery roller again applies a carrying force to the paper being fed through the feeding device. Under any other condition than above, no or almost no carrying force is applied to the paper (P) and paper feeding is free from any trouble.
It is most preferable to position the feed roller (52) at a point where carrying direction of the paper (P) changes sharply, as illustrated, so that selection and control of the condition where carrying force can be transmitted exactly by firmness of the paper (P) and of the condition where carrying force is little transmitted due to slipping can be practiced exactly with no regard to friction resistance of the delivery roller (52).
As known from the above description, the driven roller (53) is not necessarily required and can be omitted because carrying force transmission condition and slip condition can be selected only if the contact pressure to the delivery roller (52) can be changed according to transfer condition of the paper (P).
If the lift-up lever (14) can be turned by the operating piece (80), the contacted member (82) can also be omitted and it is possible to provide the operating piece (80) and the contacted part (81) at one side only.
When rollers (89') (92') (93') for driving power transmission are used in place of the gears (89) (92) (93) as the mechanism to turn the feed roller (51) in reverse direction to paper feeding, as shown in FIG. 11, and a friction pad (86') is used instead of the rack (86), it is possible to turn the roller (93') following transfer of the paper cassette (12) by the friction force between the friction pad (86') and the roller (93') and to turn the feed roller (51) in reverse direction to paper feeding.
When a rachet gear (93") is attached coaxially to the roller (93'), as shown in FIG. 12, and a rachet pawl (86") is used in place of the friction pad (86'), the feed roller (51) can be rotated in reverse direction to paper feeding by turning the rachet gear (93") only at the pulling-out operation of the paper feed cassette (12).
FIG. 13 to FIG. 17 shows details of the composition of the second paper feeding device (10), which is primarily made of a document tray (101), feed roller (102), preliminary feed roller (103) and a guide member (104).
The preliminary feed roller (103) comprises a plurality of friction rollers attached with certain spacing from each other at specified positions along a shaft (107) to which rotary force is transmited through an idler gear (115) and a driving gear (116).
Both ends of the shaft (107) are interlocked with a long hole (108a) made at a specified position in a side plate (108) to press the preliminary feed roller in paper pressing direction by its own weight. Rotary force to the shaft (107) is transmitted only when the paper (P) is sensed by a limit switch (100).
The guide member (104) is held at a specified position for paper insertion, inside of the side plate (108), so as to turn freely.
The top edges of both ends of the guide member (104) project respectively toward the shaft (107) to form a pushing section (104a) extending over the driving end of the shaft (107) and also a receiving section (104b) extending beneath the opposite end the driving side of the shaft (107) so that the preliminary feed roller (103) can be moved upward without being inclined. The guide member (104) is reinforced by a rib (104c) provided on the upper face of the guide member (104).
The feed roller (102) is attached to the down-stream side of the preliminary feed roller (103). Roller (102) includes a center roller (102a) which prevents double feeding of the paper (P). Paper (P) is being pressed by a friction pad (112), attached at a specific position to the top end side of the document tray (101). Feed roller (102) also includes auxiliary rollers (102b) which are positioned on both sides of the center roller (102a) and are attached to a shaft (102c).
Like the above-mentioned friction pad (58) (See FIG. 7.), the friction pad (112) is narrower than the center roller (102a), and its edge has a tapered face (112a) parallel to feeding direction of the paper (P).
For ordinary paper (P), only the center roller (102a) is used for paper feeding. When paper having a high friction factor, such as thick paper, a second original, or OHP paper is to be fed, the carrying force of the auxiliary rollers (102b) is applied to obtain a higher carrying force than the friction from the friction pad (112) so as to ensure exact paper feeding.
In more detail, the friction pad (112) is pressed upward by the spring (112b) to maintain contact with the center roller (102a). Corresponding to the auxiliary rollers (102b), recesses (102d) are provided on the document tray (101), into which the auxiliary rollers (102b) are positioned to the extent that do not come in contact with the surface of recesses (102d). The paper (P) is fed between the center rollers (102a) and the auxiliary roller (102b), and the document tray (101), being caught by the rollers (102a) (102b) and the document tray (101), as shown by the alternate one-dot chain line in FIG. 17 so as to transmit the carrying force exactly.
Since the auxiliary rollers (102b) are not in contact with the recesses (102d), the carrying force is somewhat lower than in the case where the roller is in direct contact with the recesses, and double feeding of the paper is prevented. The mechanism to transit the rotary force from the driving power source (not shown) to the shaft (102c) is composed of a clutch (113), connected to one end of the shaft (102c), and a drive gear (114), to transmit the rotary force from the driving power source (not shown) to the clutch (113). The shaft (102c) is driven only when the rotary force is tramsmitted to the clutch (113).
A bend control plate (105), having recesses (105a) (105b) at both ends, is supported in such a manner that the recesses (105a) (105b) are interlocked respectively with the shafts (107) (102c), and in this supported condition the lower surface (105c) of the bend control plate (105) comes close to the upper-most paper (P) set on the document tray (101).
Accordingly, the spacing between the upper-most paper (P) and the lower face (105c) of the bend control plate (105) is kept approximately constant. Without regard to the quantity of the paper (P). This prevents the paper (P) from being bent upward too much between the feed roller (102) and the preliminary feed roller (103) when carrying force is applied by the preliminary feed roller (103) only. Only one sheet of the bend control plate (105) may be held at a position close to the center roller (102a). It is also possible to support a plurality of sheets of the bend control plate (105) with certain spacing or to bend the bend control plate (105) in the middle so that the interlocking positions with the shafts (102c) (107) are offset from each other.
The mechanism to tranmit the rotary force from the driving power source (not illustrated) to the shaft (107) is composed of an idler gear (115) attached to the shaft (102c) through a bearing (115a) so as to turn freely, and a driving gear (116) fixed to one end of the shaft (107) and interlocked with the idler gear (115). Idler gear (115) turns in the same direction as does the shaft (102c).
The document tray (101) has a notch (117) approximately at the center and in the direction perpendicular to the paper feeding direction, and a projection (119) on a side control plate (118) is interlocked with the notch (117) and is fastened with a stop ring (120). Accordingly, the side control plate (118) can slide freely along the notch (117).
By fitting a cut mark (118a) suitably to the appropriate paper size indication, one end of the paper (P) can be controlled by a vertical part (118b) rising vertically from the side control plate (118). Paper of a desired size can be fed by fitting the side control plate (118) to the corresponding size indication. To feed paper of A6 size, for example, fit the cut mark (118a) to the A6 position. For feeding A4 size paper, move the side control plate (118) to the position shown by the two-dot chain line to fit the cut mark (118a) to the A4 position. The other side of the paper is controlled by a control part (121) rising vertically from the document tray (101). Since the reference for the second paper feeding device (10) is at the side of the control part (121), i.e. one side reference, the paper (P) is first put in contact with the control part (121), then the side control plate (118) is slid to control the other side of the paper (P). A foldable projection (101a) is provided on the document tray (101), and the projection (101a) can be rotated freely around the shaft (122). For large size paper, therefore, the projection (101a) is opened to support the paper (P) on the rear end. For small size paper, the projection (101a) is folded and the side control plate (118) slides on the projection (101a). The document tray (101) is attached to the side plates (108) (108) so as to turn freely around the fulcrum point (123).
The top end of the document tray (101) is inclined downward toward the down-stream side of paper feed so that the paper (P) can be inserted easily. After passing nearly to the bottom of the preliminary feed roller (103), however, the document tray (101) turns upward, and the inclination is increased gradually toward the downstream side, with a first crest (124), a root (125), a second crest (126) for better transfer of paper. This inclination extends to the point where the feed roller (102) comes into contact with the friction pad (112). As FIG. 16 indicates, the inclination from point A1, right under the preliminary feed roller (103), to the first crest (124) is an easy slope, and the height is not very high. The inclination from the root (125) to the second crest (126) has a sharp slope and is so arranged that the top of the second crest (126) is at a point lying on a line defined by the extension from point A1 beneath the preliminary feed roller (103) to point A2 on the second crest (124). If the number of sheets of paper (P) from the second paper feeding device (10) is small, the paper (P) is fed as the preliminary feed roller (103) rotates, as shown in FIG. 14. Even after passing through Point A2, the paper does not fall down into the root (125) because of the firmness of the paper. The paper goes to the top of the second crest (126), as shown by the one-dot chain line, and then is supported by the first and the second crests (124) (126) to come in contact with a specified position of the feed roller (102), and the transfer stops. If the first crest (124) is not provided, it may possible that the paper (P) falls into the root (125) and does not come in contact with the feed roller (102).
When a large number of sheets of paper (P) is in second paper feeding device (10) to be fed, the paper (P) moves with the preliminary feed roller (103), as shown in FIG. 15, and falls into the root (125) because of its own weight, where the lower-most paper stops.
Upper layers of the paper are inclined toward the feed roller (102). When the upper-most layer comes in contact with the feed roller (102) at a position not so far upward from the position where the feed roller (102) touches the friction pad (112), the paper carrying stops. Smooth paper feeding is ensured because the paper assumes a stand-by condition when coming in contact with approximately the same point on the feed roller (102) without regard to the number of stacked sheets of the paper (P).
According to a test by the inventors of the present invention, for reference, feeding of the paper (P) was most smooth when the angle θ1 from the upstream side of paper feeding of the document tray (101) to point A1 almost directly beneath the preliminary feed roller (103) in FIG. 16 was set at about 10°, the angle θ2 from point A1 to point A2 of the first crest (124) at about 10°, the angle θ3 from point A2 to the lower-most end of the root (125) at about 7°, and the angle θ4 from the lower-most end of the root (125) to the upper-most end of the second crest (126) at 25°.
The second paper feeding device (10) operates as described below. First the side control plate (118) is slid along the notch (117) so that the cut mark (118a) fits the desired paper size indication marked on the document tray (101). Then paper of that size is set on the tray (101).
To set paper of especially large size, the projection (101a) is opened by turning it around the shaft (122) to support the paper on the rear end. The paper touches the limit switch (100) before reaching the guide member (104), the main motor starts turning, and the rotation is transmitted to the idler gear (115) and further to the driving gear (116) to turn the preliminary feed roller (103). Accordingly, the paper in contact with the preliminary feed roller (103) goes through the paper feed channel, formed between the paper guide (104d) of the guide member (104) and the document tray (101), and is carried smoothly to the specified position.
At this time, the driving gear (116) is rotated in the direction of arrow R2 by the rotary force transmitted to the driving gear (116), and lifting force is applied, by which the end at the driving side of the shaft (107) of the preliminary feed roller (103) is pushed upward. However, the upward motion is constrained to some extent by the pressure section (104a) of the guide member (104), while the guide member (104) is rotated around the shaft (104e) by the force acting upon the pressing section (104a). Accordingly, the receiving section (104b) at the other end of the shaft (104e) is lifted. Therefore, the preliminary feed roller (103) is moved upward approximately in a horizontal condition, and the paper (P) can be set at the specified position easily.
When the number of sheets is small, the paper can be placed at a position easily carried by the feed roller (102) while being put in contact with the first and the second creasts (124) (126) of the document tray (101). If the number of sheets of paper is larger, the lower sheets of the paper come in contact with the root (125) and are prevented from advancing further, and only the upper sheet of the paper is advanced. Toward the upper sheet, the paper is inclined, and the main motor stops when the upper-most sheet is put in contact with the specified position for easy carrying by the feed roller (102). Accordingly, the preliminary feed roller (103) is also stopped.
When the copying start button (not illustrated) is then pushed, the main motor starts turning, the driving gear (114) of the feed roller (102) turns in the direction of arrow R3 following the main motor, and the clutch (113) is engaged.
Then the rotary force is transmitted to the center roller (102a) and the auxiliary roller (102b). Following the idle gear (115) turning in the direction of arrow R1, the driving gear (116) of the preliminary feed roller (103) turns in the direction of arrow R2 to assist paper feeding from the document tray (101) into the copying machine. At this time, the center roller (102a) is in contact with the friction pad (112) which is pressed from the bottom by a spring to prevent double paper feeding.
For carrying papers of high friction coefficient, carrying is assisted by the auxiliary rollers (102b).
When the paper (P) is fed further through the paper feed channel (45) composed of the upper and lower guide plates, and at a specified time after the front end of the paper touches the limit switch (60), the clutch (113) is disengaged to cut off transmission of the rotary force of the driving gear (114) to the feed roller (102), and the feed roller (102) comes to a stop. During the operation, the front end of the paper (P) meets the resistance of the resist roller (41), by which diagonal paper feeding is prevented and the timing with exposure is controlled. As soon as the feed roller (102) comes to a stop, the resist roller (41) starts turning to carry the paper (P) toward the transfer section T of the photoreceptor drum (31). Although the guide member (104) is composed of the pressing section (104a) at one end of the shaft (104e) and of the receiving section (104b) at the other end, it is also possible to compose the guide member (104) with a pressing section and a receiving section provided respectively at both ends of the shaft (104e).
The upper-stream side of the first crest (124) can be of any shape provided that the top end of the document tray (101) is formed as described above, i.e. the shape with the first and second crests (124) (126), and a root (125) in-between. A sharp slope from the top of the first crest (124) to the root (125) is also acceptable.
In the above embodiment, the auxiliary roller (102b) to assist paper feeding is provided at both sides of the center roller (102a) which is in contact with the friction pad (112). The invention, however, is not limit thereto, and the rollers to assist paper feeding may be located at any position so long as they are on the center roller (102a).
It may also possible to provide a pair of side control plates (118) so as to be interlocked in reverse directions with respect to each other and so that papers of different sizes are set approximately along the center line of the document tray (101) and to provide the center roller (102a) and the friction pad (112) corresponding to the center line. In this case, the guide member (104) can be of the composition having a plurality of receiving sections (104b) and no pressing section (104a).
FIG. 18 shows an embodiment to transmit rotary force to the shaft (107) of the preliminary feed roller (103) through a chain (109) and a sprocket (106). The sprocket (106) is provided with an interlocking projection (106a) and the shaft (107) is provided with a pin (110) which can be interlocked with the interlocking projection (106a). Accordingly, the shaft (107) can be rotated only when the sprocket (106) rotates and the pin (110) is interlocked with the interlocking projection (106a). When the sprocket (106) is stopped, the preliminary feed roller (103) can be turned freely by almost 360° in the same direction as the turning direction of the sprocket (106). In other words, the paper (P) can be set smoothly onto the document tray (101) because the preliminary feed roller (103) turns following insertion of the paper (P) even when the roller is not driven.
Accordingly, the limit switch (100) for detecting the paper (P) can be positioned between the preliminary feed roller (103) and the feed roller (102), and then the paper (P) can be advanced toward the resist roller (41) by rotating the feed roller (102) after detecting of the paper (P) by the limit switch (100).
It is also possible to insert a one-way bearing instead of the interlocking projection (106a) and the pin (110).
In the above embodiment, the second paper feeding device (10) is applied to the stack by-pass mechanism. Even by applying the second paper feeding device (10) to the automatic document feeder, smooth setting and exact feeding of documents can be practiced in the same manner as in the above embodiment.
FIG. 19 to FIG. 23 are to show another embodiment of the 1st paper feeding device (5). Major differences from the above embodiment are that the feed roller (51) is attached to the shaft (51a) with a one-way bearing (51d) in-between, that a star wheel (51e) is attached to the shaft (51a) at a position far off the feed roller (51), and that a friction pad driving unit (58a) is attached for putting in contact or separating the friction pad (58) and the feed roller (51) to follow the mounting and dismounting operation of the paper feed cassette (12). All the rest of the device is implemented in the same manner as for the above embodiment. Accordingly, the same reference numbers are directed to the same components as in the above embodiment.
The details are as described below.
As shown in FIG. 19 and FIG. 20, the shaft (51a) is held so as to rotate freely through a pair of frames (51f), and a clutch (88b) is attached to the projected end of the shaft (51a).
To the clutch (88b), a gear (88a) is attached to transmit rotary force from the driving power source, not illustrated.
The shaft (51a) and a gear (89) are interlocked so as to rotate together by means of the other projected end of the shaft (51a) and a cylindrical shaft (89a) of the gear (89), held together by an interlocking pin (89c) fixed and passed through the shaft (51a) with a pair of recesses (89b) on the end of the cylindrical shaft (89a).
The lever (91) and a gear attaching plate (90) support the shafts of gears (89) (92) and (93) so as to turn freely. The top end of the lever (91) is bent toward the gear attaching plate (90), and the lower part of the bent end is bent further to the top side to form an interlocking plate (91a) through which a hole (91b) is provided. A shaft (94b) extending up from the upper surface plate (94a) at the upper part of the mounted paper feed cassette (12) is loosely inserted into the hole (91b). A washer (94d) is fixed to the top end of the shaft (94b) with a screw (94e), and the shaft (94b) is inserted loosely into a push spring (94f) which is restrained at both ends by the washer (94d) and the interlocking plate (91a).
Accordingly, the rack (86) and the gear (93) can be interlocked without any shock when the lever (91) and the gear attaching plate (90) are turned downward around the shaft (51a) by the push spring (94f) to mount and dismount the paper feed cassette (12).
The feed roller (51) is attached to approximately the middle of the shaft (51a) through a one-way bearing (51d), and rotary force is transmitted to the feed roller (51) only when the shaft (51a) is rotated in paper feeding direction from the paper feed cassette (12). The feed roller (51) turns freely relative to the shaft (51a) when the shaft (51a) is rotated in reverse direction one pulling out of the paper feed cassette (12) as the gear (93) interlocks with the rack (86) and when rotation of the shaft (51a) is stopped by the clutch (88b).
The star wheel (51e) is rotated together with the shaft (51a) and is attached to the shaft (51a) at a position not far off the feed roller (51) so as to be put in contact with the paper (P) accurately when the size of the paper (P) stored in the paper feed cassette (12) is changed. The star wheel (51e) is made of rubber, at least the edge of the peripery, to reduce the area in contact with the paper (P) and to ensure transmission of sufficient friction force. The friction pad driving unit (58a) is composed as described below.
As shown in FIG. 21, the upper end side of the lever (58c) connected to a friction pad support (58b) is supported by a shaft (58d) so as to rotate freely. The horizontal plate (12e) at the center of a contact member (12a) has the first receiver (12f) extending practically upright and also the second receiver (12g) extending downward diagonally from the top end of the first receiver (12f) to the paper feed cassette (12). In addition, a push spring (58e) is attached between the second receiver (12g) and the friction pad support (58b), and another push spring (58g), of higher strength than the push spring (58e), is attached between the first receiver (12f) and an interlocking member (58f) held on the horizontal plate (12e) so as to interlock the collar (58h) made at the base side of the interlocking member (58f) with the lower end of the lever (58c) at all times.
When the paper cassette (12) is not mounted, the interlocking member (58f) is projected from the contact part (12b) to the paper feed cassette setting side by the urging of the push spring (58g), and the lever (58c) is turned forcefully clockwise around the shaft (58d) by the collar (58h) of the interlocking member (58f). Accordingly, the friction pad (58) is separated from the feed roller (51).
When the paper cassette (12) is mounted, on the other hand, the interlocking member (58f) is pushed in by the front plate of the paper cassette (12) against the urging of the push spring (58g), and the friction pad support (58b) and also the lever (58c) are turned counter-clockwise around the shaft (58d) by the urging of the push spring (58e). Accordingly, the friction pad support (58) is pressed against the feed roller (51), and the feed roller (51) rotates to feed out the paper (P) sheet by sheet.
The lift-up lever (14) has a contacted part (81) composed of a projection of isosceles triangular shape, and the upper edge of the opening (63) made on the paper cassette (12) has an inclined face (63a) which is forwardly slanted down.
In this embodiment, the paper feeding operation proceeds in the following manner.
When the paper cassette (12) is set in the copying machine housing (1), the inclined face (63a) goes over the contacted part (81) of isosceles triangular shape of the lift-up lever (14), and the release lever (75) is turned to unlock the lift-up lever (14), as in the case of the above embodiment. Then the lift-up lever (14) is turned upward by the coil spring (69). Accordingly, the document setting board (13) is turned upward to press the upper-most paper (P) against the feed roller (51). By insertion of the paper cassette (12), the interlocking member (58f) is pushed inwardly against the push spring (58g). By urging of the push spring (58e), therefore, the friction pad support (58b) is turned counter-clockwise around the shaft (58d), and the friction pad (58) is pressed against the surface of the feed roller (51).
When the shaft (51a) is then rotated through the gear (88a) and the clutch (88b) for paper feeding, the rotary force is transmitted to the feed roller (51) through the one-way bearing (51d) making it possible to feed the paper (P) from the paper cassette (12). In the initial stage of paper feeding from the paper cassette (12), the front end of the paper (P) is led between the feed roller (51) and the friction pad (58). Even when two or more sheets of paper (P) are sent out, the paper is sent out sheet by sheet exactly to the down-stream side of the feed roller (51) and the friction pad (58).
The paper (P) sent out sheet by sheet, as shown in FIG. 22, is led through the space (59) to the position between the delivery roller (52) and the driven roller (53), then is lead further to the guide (55) while the carrying force is transmitted by the delivery roller (52). Finally, the front end of the paper (P) comes in contact with the resist roller (41). Then the preliminary paper feeding completes as the carrying force is kept transmitted for a little while thereafter. As the clutch (88b) is so controlled to shut transmission of the rotary force when the preliminary paper feeding completes, the shaft (51a), the star wheel (51e) and the feed roller (51) stop rotating.
After completion of the preliminary paper feeding in this manner, the resist roller (41) is turned in timing with document exposure operation, i.e. the transfer timing of the lamp (21) and the reflecting mirrors (22) (23) (24) to start the main paper feeding.
Since the main paper feeding is made by rotating the resist roller (41) while transmission of the rotary force to the feed roller (51) and the star wheel (51e) is being shut off, slackening of the paper (P) at the guide (55) is removed in the initial stage of the main paper feeding.
When slackening is removed almost completely, carrying force is transmitted to the paper (P) by the delivery roller (52). It is possible, therefore, to feed the paper (P) exactly at the same speed as the speed of revolution of the photoreceptor drum (31) against the friction resistance caused by contact of the paper (P) with each part.
The length of the paper (P), however, is not necessarily constant. Some paper (P) is short to the extent that the rear end is separated from the feed roller (51) when the preliminary paper feeding completes, but other paper (P) may be longer, to the extent that the rear end is caught between the feed roller (51) and the friction pad (58) when the preliminary paper feeding completes.
If the paper (P) is short, and the resist roller (41) is turned, the feed roller (51) does not resist paper feed at all. Throughout the whole period of paper feeding by the resist roller (41), friction resistance is subjected to almost no change and paper feeding is carried out under even transfer condition, which enables transfer of the toner image formed on the surface of the photoreceptor drum (31) onto the paper surface by the transferring corona discharger (34) without any positional deviation.
If the paper (P) is long, the rear end of the paper (P) is caught between the feed roller (51) and the friction pad (58) in the initial stage of rotation of the resist roller (41), and outer end of the star wheel (51e) is kept in contact with the surface of the paper (P). As the resist roller (41) rotates, therefore, slackening of the paper (P) is removed, and then the feed roller (51) and the friction pad (58) function to resist the paper feeding. Being attached to the shaft (51a) through the one-way bearing (51d), the feed roller (51) rotates freely as the paper (P) is transfered and the resistance is smaller than that of the condition where the feed roller (51) is suspended.
Accordingly, the resistance hardly changes even when the rear end of the paper (P) goes through the feed roller (51) and the friction pad (58) and transfer deviation of toner image due to changes in the resistance can be avoided almost completely.
The shaft (51a) and the feed roller (51) are attached with the one-way bearing (51d) in-between as shown in FIGS. 19 and 20. When the paper feed cassette (12) is pulled out and the shaft (51a) is rotated in the reverse direction, therefore, the rotary force in the reverse direction is not transmitted to the feed roller (51).
Consequently, the sheet of paper (P) of which the front end is between the feed roller (51) and the friction pad (58) cannot be transferred to the paper feed cassette (12) by the feed roller (51). When the paper feed cassette (12) is pulled out, however, the interlocking member (58f) is moved by the push spring (58g), the collar (58h) is interlocked with the lever (58c) to turn the friction pad support (58b) in clockwise direction against the push spring (58e), and the friction pad (58) is separated from the feed roller (51). Thus, the front end of the paper is released.
The rack (86) and the gear (93) are interlocked with each other in the middle of the pull-out motion of the paper feed cassette (12), and so turning force in reverse direction is transmitted to the shaft (51a) through the gear (92) (89), and the one-way bearing (51d) prevents the feed roller (51) from turning, but the star wheel (51e) is turned in the reverse direction of paper feeding. Because feed roller (51) and star wheel (51e) have a larger diameter than does gear (89), the paper is moved a greater distance than the distance which paper feed cassette (12) moves. The star wheel (51e) is made of rubber, at least on the edge of the periphery, and keeps a certain extent of friction resistance on the paper (P), which makes it possible to feed the paper (P) released as described above to the side of the paper feed cassette (12) and to keep the friction resistance between the friction pad (58) and the paper (P) at a very low level. This serves to prevent exactly the paper (P) from remaining in the copying machine housing (1) when the paper feed cassette (12) is pulled out. If the paper (P) remains in the copying machine housing (1) when the paper cassette (12) is pulled out with the front end being caught between the feed roller (51) and the friction pad (58), the remaining paper (P) is crumpled when the paper feed cassette (12) is mounted next time, and jamming is very probable. By the above embodiment, however, jamming can be prevented as the paper (P) is not left in the housing (1).
For the type of copying machines where a larger portion of the paper feed cassette (12) is inserted into the housing (1) of the copying machine, the embodiment to prevent residual paper (P) completely is practically very effective, as it is not easy to check for any remaining paper (P) from the outside.
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A paper feeding device for a paper cassette of an image processing apparatus. The paper cassette is mounted at a specific position on the image processing apparatus in a manner permitting the cassette to be pulled out. A preliminary feed roller feeds the paper on the paper cassette toward a feed roller which is normally energized in a paper pressing direction. When the paper cassette is mounted in the image processing apparatus, the document setting board disposed in the paper cassette is upwardly turned by a pressing mechanism. When the paper cassette is pulled out, the feed roller from the paper cassette is turned in reversed direction. A feed channel to guide the paper from the paper cassette is formed in a curved manner, and a normally turned delivery roller is provided inside the curved channel.
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REFERENCE TO PROVISIONAL APPLICATION
[0001] This application claims an invention which was disclosed in Provisional Application No. 60/508,957, filed Oct. 6, 2003, entitled “VCT SENSOR AND ACTUATOR MODULE”. The benefit under 35 USC § 119(e) of the United States provisional application is hereby claimed, and the aforementioned application is hereby incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The invention pertains to the field of variable cam timing (VCT). More particularly, the invention pertains to a variable cam timing (VCT) sensor and actuator module.
BACKGROUND OF THE INVENTION
[0003] U.S. Pat. No. 6,435,154, which is incorporated herein by reference, discloses a front cover for an internal combustion engine that comprises variable cam timing (VCT) controls integrated into the cover. The controls include a variable force solenoid (VFS) and a cam position sensor located in front of, and operably connected to a cam phaser. In an embodiment of the invention, the engine cover, once assembled, comprises a single unit having an electronic interface module (EIM), VFS and position sensor integrated within said cover.
[0004] However, electrical leads of the electrical system involved are generally independently or individually connected inside the engine cover, creating undesirable results such as complicated wiring because of increased numbers of independent wiring and connections. Other undesirable results include increased difficulty in installing and repairing the components the electrical leads terminate, sealing problems or the lack of proper sealing because of the increased number of leads leading out of the engine. It should be noted that inside the engine cover, there is oil or oil splashes. These oil or oil splashes affects the integrity of stranded wire and its connections to terminals within the engine cover in the presence of high levels of oil splash, heat, and vibration. To prevent the above occurrence is a sizeable task. Therefore, it is desirable to incorporate all the suitable electrical leads into a single consolidated member.
[0005] Further, it is well known to use lead frames in the computer chip manufacturing art. A lead frame, in the computer chip manufacturing art, is defined as a member used to make a resin encapsulation package, which encapsulates a semiconductor chip and is mounted on a substrate, such as a printed circuit board, to electrically connect the semiconductor chip to the substrate.
SUMMARY OF THE INVENTION
[0006] A lead frame incorporating all the suitable electrical wiring is provided. The lead frame has only one electrical connector leading out of the engine cover.
[0007] In a VCT system, a single member incorporating all the suitable electrical wiring is provided. The single member has only one electrical connector leading out of the engine cover.
[0008] A leadframe/housing member is provided which retains and accurately positions a number of devices internally within the engine valve/cam/timing area and communicates forces, energy, or electrical signals between components inside the engine cover and other components.
[0009] Accordingly, a lead frame disposed within the confines of an engine cover, having an insulating portion and an electrically conducting portion is provided. The conducting portion has at least one electrically conducting interconnect. Both the insulating portion and the electrically conducting portion form an integral piece for retaining and accurately positioning devices within an internal combustion engine. The lead frame includes a plurality of retaining elements for retaining or positioning of at least some of the devices; and an electrical connector member extending outside the confines of the internal combustion engine, the electrical connector member having a plurality of electrically conducting terminals in electrical communication with at least some of the devices within the internal combustion engine by means of at least one electrically conducting interconnect, whereby at least some of the devices are retained and accurately positioned within the internal combustion engine.
BRIEF DESCRIPTION OF THE DRAWING
[0010] FIG. 1 shows an inside view of elements inside the cam cover of the present invention.
[0011] FIG. 2 shows an outside view of the cam cover of the present invention.
[0012] FIG. 3 shows elements inside the cam cover and engine front cover of the present invention.
[0013] FIG. 4 shows a first view of elements inside the engine front cover of the present invention.
[0014] FIG. 5 shows a second view of elements inside the engine front cover of the present invention.
[0015] FIG. 6 shows a third view of elements inside the engine front cover of the present invention.
[0016] FIG. 7 shows a first view of a lead frame of the present invention electrically connecting, positioning, and securing the elements FIG. 8 shows a second view of the lead frame of the present invention electrically connecting and holding the elements.
[0017] FIG. 8A shows an inside structure of a lead frame of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0018] Refering to FIGS. 1-8 , a one piece leadframe/housing 10 made of materials such as plastic and copper alloys as electrical connecting elements therein is provided. The lead frame 10 has a single integrally sealed electrical connector 12 and a number of “M” slot connections 14 . “M” slot connections 14 are used for connecting variable force solenoid (VFS) actuators 16 , sprocket sensors (not shown), and other sensors (also not shown). The leadframe/housing 10 is designed to have individual actuators and sensors be independently field serviceable.
[0019] An “M” slot has an opening having the shape of the alphabet “M” with flat stamped leads. “M” slot's use includes receiving a solenoid terminal blade, wherein the blade is inserted through the opening.
[0020] Referring specifically to FIG. 1 , elements inside the cam cover 20 of the present invention is depicted. Lead frame/housing 10 retains and accurately positions a pair of solenoids 16 such as variable force solenoids (VFS) for controlling or actuating a pair of spool valves (not shown) for a pair of VCT phasers 18 (see FIGS. 4-6 ). The moving or actuating element is in the center of each of the solenoids 16 . The element comes in contact with a valve such as spool valve preferably in the center of the VCT phaser 18 . A cam cover 20 is provided. The pair of solenoids 16 is mounted onto cam cover 20 by a plurality of fasteners 22 . In other words, fasteners 22 transcend cam cover 20 , variable force solenoid 16 , and lead frame 10 in order to rigidly attach variable force solenoid 16 upon lead frame 10 and cam cover 20 . Further, lead frame 10 also holds in place other elements such as a second solenoid 23 . As described supra, other elements such as sensors may also be held by lead frame 10 in a similar manner.
[0021] Referring to FIG. 2 , an outside view of the cam cover of the present invention is depicted. As can be seen, electric connector 12 extends through an electric connector opening 20 a . Electric connector 12 has a plurality of pin therein for electrically connecting to other devices (not shown) such as an engine control unit (ECU) for sending out and receiving signals. Through openings 20 b (not shown) and 20 c lead frame 10 , variable force solenoid 16 , and second solenoid 23 on the other side of cam cover 20 are partially shown. Openings 20 d and 20 c are used for affixing cam cover 20 to an engine cover 24 (see FIG. 3 ), and the cylinder head (not shown).
[0022] Referring to FIGS. 4-6 , three views from inside engine cover 24 are shown. A pair of camshafts 26 is provided, which are supported by bearing support 28 . A sealing element 30 such as a gasket is disposed between lead frame 10 and cam cover 20 in order to seal the inside of cam cover 20 from outside. VCT phaser 18 has a first portion thereof affixed to camshafts 26 and a second portion angularly adjustable in relation to the first portion. VCT phaser 18 are positioned in such as way that variable force solenoid 16 can act thereon respectively upon a valve (not shown) located in the center of VCT phaser 18 for the angularly adjustable VCT phaser 18 . Note that there is no contact between lead frame 10 and VCT phaser 18 except the location wherein actions upon the valve occur.
[0023] Referring to FIGS. 7 and 8 , two views of lead frame 10 electrically connecting and physically rigidly affixing various elements including second solenoid 23 , variable force solenoid 16 , and other suitable elements are depicted. “M” slots 14 thereon are used to electrically connect and physically rigidly affix some of the other suitable elements. Further, lead heads 32 may be used to electrically connect and/or physically rigidly affix variable force solenoid 16 on lead frame 10 .
[0024] Referring to FIG. 8A , the inside structure of lead frame 10 is shown. Lead frame 10 includes insulating member 10 a and electrically conducting member 10 b . Lead frame 10 b may include more than one independently electrically conducting interconnects.
[0025] As can be appreciated, lead frame 10 electrically connects and physically rigidly affixs various elements inside engine cover 24 or cam cover 20 . Further lead frame 10 saves multiple wire runs inside engine cover 24 or cam cover 20 as well.
[0026] The leadframe design of the present invention includes the following features: Increased reliability of the VCT system due to the reduction of electrical connections which are chronic weak points of any electrical system; decreased likelihood of oil leaks or foreign matter infiltration to the engine because only one electrical connector to the outside may be used; and overall savings in components and labor because the leadframe replaces many components with one, and assembly is simplified. The cost savings in such matters as-reduced warranty should be apparent, as well.
[0027] The shape of lead frame 10 can vary according the usage. Lead frame 10 does not need to be fixed in the shape as shown in FIGS. 1-8 . Different applications may require different shapes.
[0028] It should be noted the lead frame 10 taught in the present invention is different from the lead frames in the computer chip manufacturing art in that the present invention provides a single seal between components inside the engine cover and components outside the engine cover. Further, semiconductor chip encapsulation is not involved in the present invention. Further, lead frame 10 may be installed in any type of engines such as V-type, I-type, L-type, etc.
[0029] The following are terms and concepts relating to the present invention.
[0030] It is noted the hydraulic fluid or fluid referred to supra are actuating fluids. Actuating fluid is the fluid which moves the vanes in a vane phaser. Typically the actuating fluid includes engine oil, but could be separate hydraulic fluid. The VCT system of the present invention may be a Cam Torque Actuated (CTA) VCT system in which a VCT system that uses torque reversals in camshaft caused by the forces of opening and closing engine valves to move the vane. The control valve in a CTA system allows fluid flow from advance chamber to retard chamber, allowing vane to move, or stops flow, locking vane in position. The CTA phaser may also have oil input to make up for losses due to leakage, but does not use engine oil pressure to move phaser. Vane is a radial element actuating fluid acts upon, housed in chamber. A vane phaser is a phaser which is actuated by vanes moving in chambers.
[0031] There may be one or more camshaft per engine. The camshaft may be driven by a belt or chain or gears or another camshaft. Lobes exist on camshaft to push on valves. In a multiple camshaft engine, most often has one shaft for exhaust valves, one shaft for intake valves. A “V” type engine may have one camshaft (Overhead valve or OHV); for overhead cam (OHC) engines, two camshafts (one for each bank), or four (intake and exhaust for each bank).
[0032] Chamber is defined as a space within which vane rotates. Chamber may be divided into advance chamber (makes valves open sooner relative to crankshaft) and retard chamber (makes valves open later relative to crankshaft). Check valve is defined as a valve which permits fluid flow in only one direction. A closed loop is defined as a control system which changes one characteristic in response to another, then checks to see if the change was made correctly and adjusts the action to achieve the desired result (e.g. moves a valve to change phaser position in response to a command from the ECU, then checks the actual phaser position and moves valve again to correct position). Control valve is a valve which controls flow of fluid to phaser. The control valve may exist within the phaser in CTA system. Control valve may be actuated by oil pressure or solenoid. Crankshaft takes power from pistons and drives transmission and camshaft. Spool valve is defined as the control valve of spool type. Typically the spool rides in bore, connects one passage to another. Most often the spool is most often located on center axis of rotor of a phaser.
[0033] Differential Pressure Control System (DPCS) is a system for moving a spool valve, which uses actuating fluid pressure on each end of the spool. One end of the spool is larger than the other, and fluid on that end is controlled (usually by a Pulse Width Modulated (PWM) valve on the oil pressure), full supply pressure is supplied to the other end of the spool (hence differential pressure). Valve Control Unit (VCU) is a control circuitry for controlling the VCT system. Typically the VCU acts in response to commands from ECU.
[0034] Driven shaft is any shaft which receives power (in VCT, most often camshaft). Driving shaft is any shaft which supplies power (in VCT, most often crankshaft, but could drive one camshaft from another camshaft). ECU is Engine Control Unit that is the car's computer. Engine Oil is the oil used to lubricate engine, pressure can be tapped to actuate phaser through control valve.
[0035] Housing is defined as the outer part of phaser with chambers. The outside of housing can be pulley (for timing belt), sprocket (for timing chain) or gear (for timing gear). Hydraulic fluid is any special kind of oil used in hydraulic cylinders, similar to brake fluid or power steering fluid. Hydraulic fluid is not necessarily the same as engine oil. Typically the present invention uses “actuating fluid”. Lock pin is disposed to lock a phaser in position. Usually lock pin is used when oil pressure is too low to hold phaser, as during engine start or shutdown.
[0036] Oil Pressure Actuated (OPA) VCT system uses a conventional phaser, where engine oil pressure is applied to one side of the vane or the other to move the vane.
[0037] Open loop is used in a control system that changes one characteristic in response to another (say, moves a valve in response to a command from the ECU) without feedback to confirm the action.
[0038] Phase is defined as the relative angular position of camshaft and crankshaft (or camshaft and another camshaft, if phaser is driven by another cam). A phaser is defined as the entire part which mounts to cam. The phaser is typically made up of rotor and housing and possibly spool valve and check valves. A piston phaser is a phaser actuated by pistons in cylinders of an internal combustion engine. Rotor is the inner part of the phaser, which is attached to a camshaft.
[0039] Pulse-width Modulation (PWM) provides a varying force or pressure by changing the timing of on/off pulses of current or fluid pressure. Solenoid is an electrical actuator which uses electrical current flowing in coil to move a mechanical arm. Variable force solenoid (VFS) is a solenoid whose actuating force can be varied, usually by PWM of supply current. VFS is opposed to an on/off (all or nothing) solenoid.
[0040] Sprocket is a member used with chains such as engine timing chains. Timing is defined as the relationship between the time a piston reaches a defined position (usually top dead center (TDC)) and the time something else happens. For example, in VCT or VVT systems, timing usually relates to when a valve opens or closes. Ignition timing relates to when the spark plug fires.
[0041] Torsion Assist (TA) or Torque Assisted phaser is a variation on the OPA phaser, which adds a check valve in the oil supply line (i.e. a single check valve embodiment) or a check valve in the supply line to each chamber (i.e. two check valve embodiment). The check valve blocks oil pressure pulses due to torque reversals from propagating back into the oil system, and stop the vane from moving backward due to torque reversals. In the TA system, motion of the vane due to forward torque effects is permitted; hence the expression “torsion assist” is used. Graph of vane movement is step function.
[0042] VCT system includes a phaser, control valve(s), control valve actuator(s) and control circuitry. Variable Cam Timing (VCT) is a process, not a thing, that refers to controlling and/or varying the angular relationship (phase) between one or more camshafts, which drive the engine's intake and/or exhaust valves. The angular relationship also includes phase relationship between cam and the crankshafts, in which the crank shaft is connected to the pistons.
[0043] Variable Valve Timing (VVT) generically refers to any process that dynamically changes the valve opening and closing events. VVT could be associated with VCT, or could be achieved by varying the shape of the cam or the relationship of cam lobes to cam or valve actuators to cam or valves, or by individually controlling the valves themselves using electrical or hydraulic actuators. In other words, all VCT is VVT, but not all VVT is VCT.
[0044] Accordingly, it is to be understood that the embodiments of the invention herein described are merely illustrative of the application of the principles of the invention. Reference herein to details of the illustrated embodiments are not intended to limit the scope of the claims, which themselves recite those features regarded as essential to the invention.
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A lead frame disposed within the confines of an engine cover, having an insulating portion and an electrically conducting portion. The conducting portion has at least one electrically conducting interconnect. Both the insulating portion and the electrically conducting portion form an integral piece for retaining and accurately positioning devices within an internal combustion engine. The lead frame includes a plurality of retaining elements for retaining or positioning of at least some of the devices; and an electrical connector member extending outside the confines of the internal combustion engine, the electrical connector member having a plurality of electrically conducting terminals in electrical communication with at least some of the devices within the internal combustion engine by means of the at least one electrically conducting interconnect, whereby at least some of the devices are retained and accurately positioned within the internal combustion engine.
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[0001] The present application is a 37 C.F.R. §1.53(b) continuation of U.S. patent application Ser. No. 12/985,389 filed on Jan. 6, 2011, which is a 37 C.F.R. §1.53(b) continuation of U.S. patent application Ser. No. 12/639,872 filed on Dec. 16, 2009, now U.S. Pat. No. 7,930,910 B2, which is a 37 C.F.R. §1.53(b) continuation of U.S. patent application Ser. No. 12/267,457 filed Nov. 7, 2008, currently pending, which is a 37 C.F.R. §1.53(b) continuation of U.S. patent application Ser. No. 10/461,451 filed Jun. 16, 2003, now U.S. Pat. No. 7,533,548 B2, which claims priority to Korean Patent Application No. 85521/2002, filed Dec. 27, 2002, the entire contents of which are hereby incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a drum type washing machine, and more particularly, to a drum type washing machine which can maximize a capacity of a drum without changing an entire size of a washing machine.
[0004] 2. Description of the Related Art
[0005] FIG. 1 is a side sectional view showing a drum type washing machine in accordance with the conventional art, FIG. 2 is a front sectional view showing the drum type washing machine in accordance with the conventional art.
[0006] The conventional drum type washing machine comprises: a cabinet 102 for forming an appearance; a tub 104 arranged in the cabinet 102 for storing washing water; a drum 106 rotatably arranged in the tub 104 for washing and dehydrating laundry; and a driving motor 110 positioned at a rear side of the tub 104 and connected to the drum 106 by a driving shaft 108 thus for rotating the drum 106 .
[0007] An inlet 112 for inputting or outputting the laundry is formed at the front side of the cabinet 102 , and a door 114 for opening and closing the inlet 112 is formed at the front side of the inlet 112 . The tub 104 of a cylindrical shape is provided with an opening 116 at the front side thereof thus to be connected to the inlet 112 of the cabinet 102 , and a balance weight 118 for maintaining a balance of the tub 104 and reducing vibration are respectively formed at both sides of the tub 104 .
[0008] Herein, a diameter of the tub 104 is installed to be less than a width of the cabinet 102 by approximately 30-40 mm with consideration of a maximum vibration amount thereof so as to prevent from being contacted to the cabinet 102 at the time of the dehydration.
[0009] The drum 106 is a cylindrical shape of which one side is opened so that the laundry can be inputted, and has a diameter installed to be less than that of the tub 104 by approximately 15-20 mm in order to prevent interference with the tub 104 since the drum is rotated in the tub 104 .
[0010] A plurality of supporting springs 120 are installed between the upper portion of the tub 104 and the upper inner wall of the cabinet 102 , and a plurality of dampers 122 are installed between the lower portion of the tub 104 and the lower inner wall of the cabinet 102 , thereby supporting the tub 104 with buffering.
[0011] A gasket 124 is formed between the inlet 112 of the cabinet 102 and the opening 116 of the tub 104 so as to prevent washing water stored in the tub 104 from being leaked to a space between the tub 104 and the cabinet 102 . Also, a supporting plate 126 for mounting the driving motor 110 is installed at the rear side of the tub 104 . The driving motor 110 is fixed to a rear surface of the supporting plate 126 , and the driving shaft 108 of the driving motor 110 is fixed to a lower surface of the drum 106 , thereby generating a driving force by which the drum 106 is rotated.
[0012] In the conventional drum type washing machine, the diameter of the tub 104 is installed to be less than the width of the cabinet 102 with consideration of the maximum o vibration amount so as to prevent from being contacted to the cabinet 102 , and the diameter of drum 106 is also installed to be less than that of the tub 104 in order to prevent interference with the tub 104 since the drum is rotated in the tub 104 . According to this, so as to increase the diameter of the drum 106 which determines a washing capacity, a size of the cabinet 102 has to be increased.
[0013] Also, since the gasket 124 for preventing washing water from being leaked is installed between the inlet 112 of the cabinet 102 and the opening 116 of the tub 104 , a length of the drum 106 is decreased as the installed length of the gasket 124 . According to this, it was difficult to increase the capacity of the drum 106 .
SUMMARY OF THE INVENTION
[0014] Therefore, an object of the present invention is to provide a drum type washing machine which can increase a washing capacity without changing an entire size thereof, in which a cabinet and a tub is formed integrally and thus a diameter of a drum can be increased without increasing a size of the cabinet.
[0015] Another object of the present invention is to provide a drum type washing machine which can increase a washing capacity by increasing a length of a drum without increasing a length of a cabinet, in which the cabinet and a tub are formed integrally and thus a location of a gasket is changed.
[0016] To achieve these and other advantages and in accordance with the purpose of the present invention, as embodied and broadly described herein, there is provided a drum type washing machine comprising: a cabinet for forming an appearance; a tub fixed to an inner side of the cabinet and for storing washing water; a drum rotatably arranged in the tub for washing and dehydrating laundry; and a driving motor positioned at the rear side of the drum for generating a driving force by which the drum is rotated.
[0017] The tub is a cylindrical shape, and a front surface thereof is fixed to a front inner wall of the cabinet.
[0018] Both sides of the tub are fixed to both sides inner wall of the cabinet.
[0019] A supporting plate for mounting the driving motor is located at the rear side of the tub, and a gasket hermetically connects the supporting plate and the rear side of the tub, in which the gasket is formed as a bellows and has one side fixed to the rear side of the tub and another side fixed to an outer circumference surface of the supporting plate.
[0020] A supporting unit for supporting an assembly composed of the drum, the driving motor, and the supporting plate with buffering is installed between the supporting plate and the cabinet.
[0021] The supporting unit comprises: a plurality of upper supporting rods connected to an upper side of the supporting plate towards an orthogonal direction and having a predetermined length; buffering springs connected between the upper supporting rods and an upper inner wall of the cabinet for buffering; a plurality of lower supporting rods connected to a lower side of the supporting plate towards an orthogonal direction and having a predetermined length; and dampers connected between the lower supporting rods and a lower inner wall of the cabinet for absorbing vibration.
[0022] The drum is provided with a liquid balancer at a circumference of an inlet thereof for maintaining a balance when the drum is rotated.
[0023] The foregoing and other objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of the present invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention.
[0025] In the drawings:
[0026] FIG. 1 is a side sectional view showing a drum type washing machine in accordance with the conventional art;
[0027] FIG. 2 is a front sectional view showing the drum type washing machine in accordance with the conventional art;
[0028] FIG. 3 is a side sectional view showing a drum type washing machine according to one embodiment of the present invention;
[0029] FIG. 4 is a front sectional view showing the drum type washing machine according to one embodiment of the present invention;
[0030] FIG. 5 is a lateral view showing a state that a casing of the drum type washing machine according to one embodiment of the present invention is cut;
[0031] FIG. 6 is a front sectional view of a drum type washing machine according to a second embodiment of the present invention;
[0032] FIG. 7 is a front sectional view showing a drum type washing machine according to a third embodiment of the present invention;
[0033] FIG. 8 is a longitudinal sectional view of the drum type washing machine according to the third embodiment of the present invention; and
[0034] FIG. 9 is a rear sectional view showing the drum type washing machine according to the third embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0035] Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings.
[0036] FIG. 3 is a side sectional view showing a drum type washing machine according to one embodiment of the present invention, and FIG. 4 is a front sectional view showing the drum type washing machine according to one embodiment of the present invention.
[0037] The drum type washing machine according to one embodiment of the present invention comprises: a cabinet 2 for forming an appearance of a washing machine; a tub 4 formed integrally with the cabinet 2 and for storing washing water; a drum 6 rotatably arranged in the tub 4 for washing and dehydrating laundry; and a driving motor 8 positioned at the rear side of the drum 6 for generating a driving force by which the drum 6 is rotated.
[0038] The cabinet 2 is rectangular parallelepiped, and an inlet 20 for inputting and outputting laundry is formed at the front side of the cabinet 2 and a door 10 for opening and closing the inlet 20 is formed at the inlet 20 .
[0039] The tub 4 is formed as a cylinder shape having a predetermined diameter in the cabinet 2 , and the front side of the tub 4 is fixed to the front inner wall of the cabinet 2 or integrally formed at the front inner wall of the cabinet 2 . Both sides of the tub 4 are contacted to both sides inner wall of the cabinet 2 or integrally formed with both sides inner wall of the cabinet 2 thus to be prolonged.
[0040] Herein, since both sides of the tub 4 are contacted to both sides inner wall of the cabinet 2 , a diameter of the tub 4 can be increased.
[0041] Also, the supporting plate 12 is positioned at the rear side of the tub 4 and the gasket 14 is installed between the supporting plate 12 and the rear side of the tub 4 , thereby preventing washing water filled in the tub 4 from being leaked.
[0042] The gasket 14 is formed as a bellows of a cylinder shape and has one side fixed to the rear side of the tub 4 and another side fixed to an outer circumference surface of the supporting plate 12 .
[0043] The supporting plate 12 is formed as a disc shape, the driving motor 8 is fixed to the rear surface thereof, and a rotation shaft 16 for transmitting a rotation force of the driving motor 8 to the drum 6 is rotatably supported by the supporting plate 12 . Also, a supporting unit for supporting the drum 6 with buffering is installed between the supporting plate 12 and the inner wall of the cabinet 2 .
[0044] The supporting unit comprises: a plurality of upper supporting rods 22 connected to an upper side of the supporting plate 12 and having a predetermined length; buffering springs 24 connected between the upper supporting rods 22 and an upper inner wall of the cabinet 2 for buffering; a plurality of lower supporting rods 26 connected to a lower side of the supporting plate 12 and having a predetermined length; and dampers 28 connected between the lower supporting rods 26 and a lower inner wall of the cabinet 2 for absorbing vibration.
[0045] Herein, the buffering springs 24 and the dampers 28 are installed at a center of gravity of an assembly composed of the drum 6 , the supporting plate 12 , and the driving motor 8 . That is, the upper and lower supporting rods 22 and 26 are prolonged from the supporting plate 12 to the center of gravity of the assembly, the buffering springs 24 are connected between an end portion of the upper supporting rod 22 and the upper inner wall of the cabinet 2 , and the dampers 28 are connected between an end portion of the lower supporting rod 26 and the lower inner wall of the cabinet 2 , thereby supporting the drum 6 at the center of gravity.
[0046] A diameter of the drum 6 is installed in a range that the drum 6 is not contacted to the tub 4 even when the drum 6 generates maximum vibration in order to prevent interference with the tub 4 at the time of being rotated in the tub 4 .
[0047] Operations of the drum type washing machine according to the present invention are as follows.
[0048] If the laundry is inputted into the drum 6 and a power switch is turned on, washing water is introduced into the tub 6 . At this time, the front side of the tub 6 is fixed to the cabinet 2 and the gasket 14 is connected between the rear side of the tub 6 and the supporting plate 12 , thereby preventing the washing water introduced into the tub 6 from being leaked outwardly.
[0049] If the introduction of the washing water is completed, the driving motor 8 mounted at the rear side of the supporting plate 12 is driven, and the drum 6 connected with the driving motor 8 by the rotation shaft 16 is rotated, thereby performing washing and dehydration operations. At this time, the assembly composed of the drum 6 , the driving motor, and the supporting plate 12 is supported by the buffering springs 24 and the dampers 28 mounted between the supporting plate 12 and the inner wall of the cabinet 20 .
[0050] FIG. 6 is a front sectional view of a drum type washing machine according to a second embodiment of the present invention.
[0051] The drum type washing machine according to the second embodiment of the present invention has the same construction and operation as that of the first to embodiment except a shape of the tub.
[0052] That is, the tub 40 according to the second embodiment has a straight line portion 42 with a predetermined length at both sides thereof. The straight line portion 42 is fixed to the inner wall of both sides of the cabinet 2 , or integrally formed at the wall surface of both sides of the cabinet 2 . Like this, since the tub 40 according to the second embodiment has both sides fixed to the cabinet 2 as a straight line form, the diameter of the tub 40 can be increased. Accordingly, the diameter of the drum 6 arranged in the tub 40 can be more increased.
[0053] FIG. 7 is a front sectional view showing a drum type washing machine according to a third embodiment of the present invention, FIG. 8 is a longitudinal sectional view of the drum type washing machine according to the third embodiment of the present invention, and FIG. 9 is a rear sectional view showing the drum type washing machine according to the third embodiment of the present invention.
[0054] The drum type washing machine according to the third embodiment of the present invention comprises: a cabinet 2 for forming an appearance of a washing machine; a tub 50 formed integrally with the cabinet 2 and for storing washing water; a drum 6 rotatably arranged in the tub 50 for washing and dehydrating laundry; and a supporting unit positioned at the rear side of the tub 50 and arranged between the supporting plate 12 to which the driving motor 8 is fixed and the cabinet 2 for supporting the drum 6 with buffering.
[0055] The tub 50 is composed of a first partition wall 52 fixed to the upper front inner wall and both sides inner wall of the cabinet 2 ; and a second partition wall 54 integrally fixed to the lower front inner wall and both sides inner wall of the cabinet 2 .
[0056] The first partition wall 52 of a flat plate shape is formed at the upper side of the cabinet 2 in a state that the front side and both sides are integrally formed at the inner wall of the cabinet 2 or fixed thereto. Also, the second partition wall 54 of a semi-circle shape is formed at the lower side of the cabinet 2 in a state that the front side and both sides are integrally formed at the inner wall of the cabinet 2 or fixed thereto.
[0057] The supporting unit comprises: a plurality of upper supporting rods 56 connected to the upper side of the supporting plate 12 and having a predetermined length; buffering springs 58 connected between the upper supporting rods 56 and the upper inner wall of the cabinet 2 for buffering; a plurality of lower supporting rods 60 connected to the lower side of the supporting plate 12 and having a predetermined length; and dampers 62 connected between the lower supporting rods 60 and the lower inner wall of the cabinet 2 for absorbing vibration.
[0058] Herein, the upper supporting rods 56 are bent to be connected to the upper side of the supporting plate 12 and positioned at the upper side of the first partition wall 52 , and the buffering springs 58 are connected to the end portion of the upper supporting rods 56 . Also, the lower supporting rods 60 are bent to be connected to the lower side of the supporting plate 12 and positioned at the lower side of the second partition wall 54 , and the dampers 62 are connected to the end portion of the lower supporting rods 56 .
[0059] In the drum type washing machine according to the present invention, a size of the drum can be maximized by fixing the tub in the cabinet, thereby increasing washing capacity of the drum without increasing a size of the cabinet.
[0060] Also, since the front surface of the tub is integrally formed at the inner wall of the cabinet and the gasket is installed between the rear surface of the tub and the supporting plate, a length of the drum can be increased and thus the washing capacity of the drum can be increased.
[0061] As the present invention may be embodied in several forms without departing from the spirit or essential characteristics thereof, it should also be understood that the above-described embodiments are not limited by any of the details of the foregoing description, unless otherwise specified, but rather should be construed broadly within its spirit and scope as defined in the appended claims, and therefore all changes and modifications that fall within the metes and bounds of the claims, or equivalence of such metes and bounds are therefore intended to be embraced by the appended claims.
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A drum type washing machine is provided. The drum type washing machine may include a cabinet, a tub fixed to an inner side of the cabinet, a drum rotatably arranged in the tub, and a driving motor positioned at a rear side of the drum for generating a driving force that rotates the drum. The washing machine may also include a supporting plate to rotatably support a rotational shaft extending between the motor and the drum, and a plurality of supporters connected between the supporting plate and the cabinet. Such an arrangement may increase washing capacity by increasing a diameter of the drum without increasing an external size of the cabinet.
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RELATED APPLICATION
This application is a continuation application of U.S. application Ser. No. 12/283,481, entitled “Barbecue Cooking Apparatus With Folding Shelves” which was filed on Sep. 12, 2008, which is a continuation application of U.S. application Ser. No. 11/224,837, entitled “Barbecue Grill With Folding Shelf” which was filed on Sep. 14, 2005 and issued as U.S. Pat. No. 7,438,071; and which is a continuation application of U.S. application Ser. No. 11/098,721, entitled “Barbecue Grill and Support Frame Assembly” which was filed on Apr. 4, 2005 and issued as U.S. Pat. No. 6,976,485; which is a continuation application of U.S. application Ser. No. 10/319,421, entitled “Barbecue Grill and Support Frame Assembly” which was filed on Dec. 13, 2002 and issued as U.S. Pat. No. 6,910,476; and this application is also a continuation application of U.S. application Ser. No. 10/444,237, entitled “Portable Cooking Apparatus” which was filed on May 27, 2003 and issued as U.S. Pat. No. 6,981,497; which is a continuation-in-part of U.S. application Ser. No. 09/736,847, entitled “Cooking Apparatus” which was filed on Dec. 13, 2000 and issued as U.S. Pat. No. 6,606,987.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a barbecue cooking apparatus and more particularly, to a compact portable barbecue grill with foldable shelves for cooking food.
2. Description of the Related Art
Fixed outdoor fireplaces or barbecues have been known for many years. Typically, these fireplaces or barbecues are constructed of brick, masonry and/or metal. In recent years, portable outdoor fireplaces or barbecues have entered the marketplace. Such portable barbecues are compact and are readily movable from one location to another such as a beach or park, and readily transportable within a vehicle, such as an automobile.
Barbecue grills have grown in popularity in recent years. There are two primary types of barbecue grills commonly used: gas grills and solid fuel grills. Gas barbecue grills employ a gas burner or group of burners to cook food that is supported on a grate above the burner(s). The fuel source for gas barbecue grills is typically liquid propane or natural gas. Solid fuel barbecue grills use combustible solid fuel, typically charcoal, to cook the food. As a result, this type of grill is commonly referred to as a charcoal barbecue grill. Regardless of the type, the barbecue grill has a cooking chamber that includes a cover and a firebox. By movement of the cover, the cooking chamber is movable between an open position and a closed position. The cooking chamber may be in the closed position when the food is being cooked by the barbecue grill. Preferably, the cover is in the closed position when the grill is not in use, and instead is stored between uses.
During operation of the barbecue grill, food is placed on the grate for cooking, which results in grease and such byproducts from the food being released during cooking. The quantity of grease generated during the cooking process varies with a number of factors, including but not limited to the type of food cooked, the amount of food cooked, the amount of heat generated by the heat source such as a burner tube, and the ambient conditions. Over time and repeated use, grease and byproducts can accumulate within the cooking chamber. The accumulation of grease and byproducts can negatively affect the performance and operation of the barbecue grill assembly. For this reason, some barbecue grills incorporate an opening in the bottom of the lower portion of the cooking chamber for passage and collection of grease and/or debris.
Another aspect of conventional barbecue grills is to provide a frame or support structure to hold the cooking chamber in suitable location for use. Also, some commonly used grills include side work shelves, to provide area for resting food and utensils when using the grill. The support frame structures often serve as support for the side shelves, and sometimes provide collapsible shelves. In typical grill assemblies, the collapsible side shelves typically drop to a storage position toward the frame structure, usually into a generally vertical non-use position.
One example of such a common gas barbecue grill is shown in U.S. Pat. No. 4,677,964 to Lohmeyer et al. In FIG. 4, the cooking chamber 52 comprises the cover 58 and the firebox 56. A burner element 62 is positioned in a lower region of the firebox 56 and a grate 66 is positioned in an upper region of the firebox 56. A drip pan 98 collects grease and byproducts that pass through the drain opening in the lower portion of the firebox 56. The cover 58 is movably supported by a hinge 60 positioned at the rear of the cooking chamber 52. A rim defines a perimeter of the firebox 56. In the closed position of FIG. 4, the rim engages the angled front wall of the cover 58. The grill assembly also has a portable cart 22 that supports the lower housing 52 of the grill, as it is suspended on the side members 40 of the cart 22. The grill assembly further provides a working surface, such as a working board 170 supported on the side members of the cart 22, adjacent the cooking vessel 24. In a collapsible arrangement of the working board 172, the board is connected to the cart 22 by a hinge, and is supported by a rod 174.
Despite the popularity of grill and supporting cart or frame assemblies in use, there is a need for a barbecue grill and frame structure with compact arrangement and versatility of side shelves that pivot on the frame into the cooking chamber for storage of the grill. Further, there is a need for a grill and support frame structure that supports a heat shield and grease/debris collection chamber and serves to support a lower shield below the cooking chamber. The present invention is provided to resolve these and other needs.
Traditional barbecues included a fire bowl, a grill and a bag of charcoal, and most recently, gas tanks and separate utensils. The barbecues in the marketplace do not provide sufficient workspace during the cooking process. In addition, the barbecues are not specifically designed to be compact and to incorporate all the above components into the fire bowl during storage or transport of the barbecue and at the same time, being conveniently removable from the fire bowl prior to usage of the barbecue.
SUMMARY OF THE INVENTION
The present invention provides a cooking apparatus and system designed to be compact and functional during storage and transport and to provide convertible workspace during usage of the barbecue.
In one embodiment, the present invention relates to a portable barbecue grill assembly comprising: a base; a fire bowl having a topside opening, the fire bowl is mounted on the base, and the topside opening of the fire bowl is situated above the base; a grill situated within the fire bowl and is moveable within the fire bowl; and at least one shelf being pivotally attached to the base, and the shelf is foldable inwardly towards the topside opening of the fire bowl during a stowage position and extendable outwardly away from the topside opening of the fire bowl during a usage position.
In another embodiment, the shelf is directly attached to the base. In yet another embodiment, at least a portion of the shelf is situated above at least a portion of the topside opening of the fire bowl during the stowage position. In still another embodiment, the shelf is suspended over the topside opening of the fire bowl during the stowage position. In still yet another embodiment, the shelf is situated within the fire bowl during the stowage position.
In a further embodiment, the assembly further comprises a second shelf, and the shelf is pivotally attached to the base, and the shelf is foldable inwardly towards the topside opening of the fire bowl during a stowage position and extendable outwardly away from the topside opening of the fire bowl during a usage position.
In yet a further embodiment, the second shelf is directly and pivotally attached to the base. In still a further embodiment, the assembly further comprising at least one lid. In still yet a further embodiment, the lid is pivotally attached to the fire bowl. In another further embodiment, the lid is directly and pivotally attached to the fire bowl.
In another embodiment, the present invention provides for a portable barbecue assembly comprising: a base having opposing ends; a cooking chamber comprising a fire bowl and a topside opening, and the fire bowl is mounted on the base, and the topside opening of the fire bowl being situated above the base; a grill situated within the fire bowl and is moveable within the fire bowl; and at least two shelves, each shelf is pivotally attached to each of the opposing ends of the base, and the shelves are foldable inwardly towards the topside opening of the cooking chamber during a stowage position and extendable outwardly away from the topside opening of the cooking chamber during a usage position.
In yet another embodiment, each of the shelves is directly attached to each of the opposing ends of the base. In still another embodiment, at least a portion of each of the shelves is situated above at least a portion of the topside opening of the cooking chamber during the stowage position. In still yet another embodiment, the assembly further comprises at least one lid.
In a further embodiment, the fire bowl comprises a bottomside, and the base is attached to the bottomside of the fire bowl. In still a further embodiment, the fire bowl comprises external sidewalls, and the base is attached to the sidewalls of the fire bowl.
In yet a further embodiment, each of the shelves is suspended over the topside opening of the cooking chamber during the stowage position. In still yet a further embodiment, each of the shelves is situated within the fire bowl during the stowage position.
In another embodiment, the present invention relates to a cooking apparatus comprising: a base; a fire bowl comprising a topside opening and an internal cavity, and the fire bowl is mounted on the base; at least one grill is situated with the topside opening of the fire bowl, and the grill is moveable within the internal cavity of the fire bowl; and at least one shelf being pivotally attached to the base, and the shelf is foldable inwardly towards the topside opening of the fire bowl during a stowage position and extendable outwardly away from the topside opening of the fire bowl during a usage position, and the shelf is situated above the grill during the stowage position. In a further embodiment, the shelf is directly attached to the base.
In one embodiment, the present invention relates to a portable barbecue grill assembly comprising: a cooking chamber comprising a fire bowl mounted on a base; and at least one shelf being directly and pivotally attached to the base, the shelf being foldable inwardly towards the cooking chamber during a stowage position and extendable outwardly away from the cooking chamber during the usage position and having a distance between the shelf and the cooking chamber to avoid heat damage to the shelf when the cooking chamber is in use.
In another embodiment, at least a portion of the shelf is situated above and suspended over the cooking chamber during the stowage position. In still another embodiment, the base is a frame assembly. In yet another embodiment, the frame assembly comprises at least one main frame member, the main frame member has opposing ends, the shelf is directly and pivotally attached to at least one of the opposing ends of the main frame member.
In still yet another embodiment, the frame assembly comprises at least two main frame members, each of the main frame members comprising opposes ends, the shelf being directly and pivotally attached to at least one of each of the opposing ends of each of said main frame members. In a further embodiment, the assembly further comprises at least one handle connected to at least one of the opposing ends of the main frame member; and a lid mountable on the cooking chamber. In yet a further embodiment, the handle provides support for the shelf during the use position.
In still a further embodiment, the assembly further comprises a second shelf, the second shelf being directly and pivotally connected to the base, the shelf being foldable and situated above the fire bowl during a stowage position and extendable from the fire bowl during the usage position. In still yet a further embodiment, at least a portion of the second shelf is situated above and suspended over the cooking chamber during the stowage position. In another further embodiment, the assembly further comprises a second handle.
In another embodiment, the present invention provides for a portable barbecue grill assembly comprising: a cooking chamber comprising a fire bowl mounted on a base; and at least two shelves being directly and pivotally attached to the base, at least a portion of each of the shelves being foldable and situated above the cooking chamber during a stowage position and extendable from the cooking chamber during the usage position and having a distance between the shelf and the cooking chamber to avoid heat damage to the shelves when the cooking chamber is in use.
In a further embodiment, the present invention also provides for a portable barbecue grill assembly comprising: a cooking chamber comprising a fire bowl mounted on a base; and at least one shelf being directly and pivotally attached to the base, the shelf being foldable into the fire bowl during a stowage position and away from the fire bowl during the usage position and having a distance between the shelf and the fire bowl to avoid heat damage to the shelf when the fire bowl is in use.
In another embodiment, the present invention also relates to a portable barbecue grill assembly comprising: a cooking chamber comprising a fire bowl mounted on a supporting frame; and at least one shelf being directly and pivotally attached to the supporting frame, at least a portion of the shelf being foldable into the cooking chamber during a stowage position and extendable from the cooking chamber during the usage position and having a distance between the shelf and the cooking chamber to avoid heat damage to the shelf when the cooking chamber is in use.
In still another embodiment, the supporting frame comprises at least one main frame member, the main frame member has opposing ends, the shelf being directly and pivotally attached to at least one of the opposing ends of the main frame member. In yet another embodiment, the supporting frame comprises at least two main frame members, each of the main frame members comprising opposing ends, the shelf being directly and pivotally attached to at least one of each of the opposing ends of each of the main frame members.
In still yet another embodiment, the assembly further comprises at least one handle connected to at least one of the opposing ends of the main frame member; and a lid mountable on the cooking chamber. In a further embodiment, the handle provides support for the shelf during the use position. In another further embodiment, the assembly further comprises a second shelf and a second handle, the second shelf being directly and pivotally connected to the supporting frame, the shelf being foldable into the fire bowl during a stowage position and extendable from the fire bowl during the usage position. In yet a further embodiment, the second shelf is situated opposite of the first shelf, the second shelf is pivotally attached to each of the opposing ends of the main frame member and the second handle being situated opposite of the first handle, the second handle being connected to each of the opposing ends of each of the main frame members.
In one embodiment, the present invention relates to a cooking apparatus comprising a fire bowl and at least one shelf pivotally mounted to the fire bowl, wherein the shelf is movable between a stowage position within the fire bowl to a usage position located externally of the fire bowl. In another embodiment, the fire bowl has an internal chamber and the apparatus further comprises a grill located within the internal chamber. In another embodiment, the apparatus has a second shelf pivotally mounted to the fire bowl, wherein the second shelf is movable between a stowage position within the fire bowl to a usage position located exteriorly of the fire bowl. In still another embodiment, the first shelf is aligned with the second shelf in both the stowage position and the usage position. In yet another embodiment, fire bowl terminates into at least one end portion and the shelf is pivotally mounted to the end portion.
In still yet another embodiment, the fire bowl is mounted on a supporting frame and the apparatus further comprises at least one leg. In a further embodiment, the fire bowl is mounted on a supporting frame, and the supporting frame has at least one handle, and the shelf rests on the handle when the shelf is in the usage position. In still a further embodiment, the supporting frame includes a pair of leg members, each of the leg member are pivotally movable between a retracted position and an extended position, and the leg members are adapted to be in contact with the supporting surface in both the retracted position and the extended position, and the fire bowl is located further from the supporting surface when the leg members are in the extended position as opposed to the retracted position.
In yet a further embodiment, the shelf in the usage position has a working surface. In still yet a further embodiment, the shelf comprises at least one utensil retaining groove. In another embodiment, the shelf has a working surface in the usage position and a utensil is to be located within the utensil retaining groove so the utensil is located beneath the working surface when the shelf is in the usage position. For purposes of the invention, a utensil includes, but is not limited to, spatula, forks, and tongs. In still another embodiment, the first and second shelves have utensil storage grooves, which function to provide utensil storage locations when the first and second shelves are in the storage position.
In yet another embodiment, the apparatus comprises a lid mountable on the fire bowl. In still yet another embodiment, the lid is pivotally mounted to the fire bowl, and the lid being movable in a closed position wherein the lid covers the grill to an open position wherein the lid allows access to the grill. In a further embodiment, the supporting frame of the apparatus includes a pair of main frame members, each the main frame member are channel shaped defining an internal cavity, and the leg is mounted within the internal cavity.
In another embodiment, the first shelf is situated atop the second shelf in a staggered position during the stowage position. In still another embodiment, the shelf rests upon the grill during the stowage position.
In still a further embodiment, the barbecue cooking system comprises a fire bowl having an internal chamber, a grill located within the internal chamber; a lid mountable on the fire bowl; a stand for supporting the fire bowl; and at least one shelf pivotally mounted to the fire bowl, the shelf being foldable inwardly towards the fire bowl or cooking chamber during a storage position and extendable outwardly away from the fire bowl or cooking chamber during a usage position.
In one embodiment, the system is a stationary cooking system. In another embodiment, the system is a portable cooking system. The cooking apparatus and system of the present invention may be used for indoor and outdoor use.
In still another embodiment, the system further comprising a second shelf pivotally mounted to the fire bowl, the second shelf being foldable into the fire bowl during a stowage position and extendable from the fire bowl during a usage position. In yet another embodiment, the first shelf is aligned with the second shelf in both the storage position and the usage position.
In still yet another embodiment, the shelf comprises at least one working surface and at least one utensil retaining grooves. In a further embodiment, the stand comprises at least one movable leg. In still a further embodiment, the leg is retractable and extendable. In yet a further embodiment, the leg terminates into a wheel. In another embodiment, the fire bowl is situated upon the stand during a usage position and the stand being designed to fit onto the lid during a stowage position.
In still yet embodiment, the lid is pivotally mounted onto the fire bowl, the lid being movable from a closed position wherein the lid covers the grill to an open position wherein the lid allows access to the grill. In still yet another further embodiment, the internal chamber comprises a compartment for retaining burnable material such as coal.
In another embodiment, the system further comprising a propane tank, the tank is situated within the fire bowl during the stowage position and externally of the fire bowl during the usage position. In still another embodiment, the system further comprising at least one utensil, the utensil is positioned within the utensil-retaining groove of the shelf. In yet another embodiment, the fire bowl having a bottom which is connected to a pair of planar sidewalls with the bottom being located between the sidewalls, the bottom has an arcuate shape which extends from a fore end to an aft end, the sidewalls having a free upper edge which is substantially flush with the fore end and the aft end. In another embodiment, the shelf is foldable into the internal chamber of the fire bowl.
In a further embodiment, the present invention relates to a cooking apparatus comprising: a fire bowl having an internal chamber, a grill located within the internal chamber; a lid mountable on the fire bowl; and at least two shelves, each of the shelves are pivotally mounted to the fire bowl, each of the shelves being movable between a stowage position within the fire bowl to a usage position located exteriorly of the fire bowl. In another further embodiment, the first shelf is situated atop the second shelf in a staggered position during a stowage position. In still a further embodiment, the apparatus further comprising a stand, the fire bowl being situated upon the stand during a usage position, the stand being design to fit onto the lid during a stowage position. In yet a further embodiment, at least one of said shelves of the apparatus of present invention rests upon the grill during the stowage position.
In still another embodiment, the present invention relates to a cooking apparatus comprising: a fire bowl; and a supporting frame being mounted on the fire bowl, at least one pair of leg members being pivotally mounted on the supporting frame and movable between a retracted position and an extended position, the leg members adapted to be in contact with a supporting surface in both the retracted and extended positions, the fire bowl being located further from the supporting surface when the leg members are in the extended position as opposed to the retracted position. In yet another embodiment, the leg members are crossed when in the retracted position. In still yet another embodiment, the leg members are located parallel and spaced apart when in the extended position.
In another embodiment, the present invention relates to a method of manufacturing a cooking apparatus, the method comprising: providing a fire bowl having an internal chamber; positioning a grill within the internal reservoir; and pivotally mounting at least one shelf onto the fire bowl, the shelf being movable between a stowage position within the fire bowl to a usage position located exteriorly of the fire bowl.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings are included to provide a further understanding of the present invention. These drawings are incorporated in and constitute a part of this specification, illustrate one or more embodiments of the present invention, and together with the description, serve to explain the principles of the present invention.
FIG. 1 is a perspective view of a barbecue grill assembly according to the present invention, showing a frame structure and a cooking chamber in closed position;
FIG. 2 is a perspective view of the grill assembly of FIG. 1 showing the cooking chamber in an open position and collapsible shelves in non-use position;
FIG. 3 is a perspective view of the grill assembly of FIG. 1 showing the cooking chamber in a closed position and the collapsible shelves in an extended, or use, position;
FIG. 4 is a perspective view of the grill assembly of FIG. 3 showing the cooking chamber in an open position and the shelves in a use position, with a partial section view of the grate shown to provide a view of the inner portion of the bottom of the cooking chamber;
FIG. 5 is a front view of a portion of the grill shown in FIG. 3 , showing the left side of the grill and frame assembly, and a portion of the collapsible shelf in the use position;
FIG. 6 is an enlarged view of a portion of the grill assembly shown in FIG. 4 , showing the grill grate in partial section view to provide a view of a portion of the bottom area of the cooking chamber and the opening in the bottom of the cooking chamber;
FIG. 7 is a partial side perspective view of the grill assembly shown in FIG. 1 , showing detail of the mounting of a frame member to the cooking chamber, and showing detail of the grease collection tray in the frame assembly;
FIG. 8 is a partial view of the grill shown in FIG. 3 , taken along section lines 8 - 8 of FIG. 3 ;
FIG. 9 is an elevated perspective view of a side of the grill shown in FIG. 3 , showing the collapsible side shelf and frame assembly arrangement with the shelf in the use position and the cover in the closed position;
FIG. 10 is a cross sectional view of the grill along 10 - 10 of FIG. 3 ;
FIG. 11 is the grill assembly of FIG. 2 with the addition of showing cooking utensils secured to one of the shelves;
FIG. 12 is a cross sectional view of a portion of the grill assembly structure taken along 12 - 12 of FIG. 11 ;
FIG. 13 is an elevated perspective view of part of a side of the grill assembly of FIG. 1 , showing attachment of a gas tank as a fuel supply, with the gas tank being in the secured position with the grill assembly;
FIG. 14 is an isometric view of the cooking apparatus of the present invention showing an embodiment of the cooking apparatus in its most compact position with the lid being mounted on the fire bowl and the leg assembly of the supporting frame in a retracted position;
FIG. 15 is a cross-sectional view through the leg assembly of the supporting frame of the cooking apparatus taken along line 2 - 2 of FIG. 14 ;
FIG. 16 is an isometric view of the cooking apparatus showing the lid removed and also showing a propane tank and utensils being mounted in a stowed position in conjunction with a pair of shelves that are also located in a stowage position on the grill of the cooking apparatus and with the leg assembly of the supporting frame being located in the extended (usage) position;
FIG. 17 is a cross-sectional view through the leg assembly taken along line 4 - 4 of FIG. 16 ;
FIG. 18 is an isometric view of the cooking apparatus of this invention showing such in its typical usage position;
FIG. 19 is an isometric view of another embodiment of cooking apparatus of this invention showing the cooking apparatus in its most compact position with the lid being mounted on the fire bowl and the leg assembly of the supporting frame in the retracted position;
FIG. 20 is a cross-sectional view through the lid latching assembly of the cooking apparatus taken along line 7 - 7 of FIG. 19 with this latching assembly being also employed within all embodiments of this invention that utilize a propane tank;
FIG. 21 is an isometric view of the cooking apparatus showing the lid removed and also showing the propane tank and utensils being mounted in a stowed position in conjunction with a pair of shelves that are also located in a stowage position on the grill of the cooking apparatus and with the leg assembly of the supporting frame being located in the extended (usage) position;
FIG. 22 is an isometric view of the cooking apparatus of this invention with the pair of shelves being moved to an outwardly extended position and the cooking apparatus in position for usage;
FIG. 23 is an isometric view of still another embodiment of cooking apparatus of this invention showing the cooking apparatus in its most compact position with the lid being mounted on the fire bowl and the leg assembly of the supporting frame in a retracted position;
FIG. 24 is a cross-sectional view taken along line 11 - 11 of FIG. 23 showing the mounting arrangement;
FIG. 25 is a cross-sectional view similar to FIG. 24 showing the lid being disengaged from the fire bowl where in FIG. 24 the lid was engaged with the fire bowl;
FIG. 26 is a cross-sectional view through the latching mechanism for the leg assembly of the cooking apparatus of this invention taken along line 13 - 13 of FIG. 24 ;
FIG. 27 is an isometric view of the cooking apparatus showing the lid in an open position and the leg assembly in the extended position, which is the normal position for usage of the cooking apparatus; and
FIG. 28 is an isometric view of the fire bowl of the cooking apparatus showing the shelves being moved from the stowage position to an outwardly extended position.
Among those benefits and improvements that have been disclosed, other objects and advantages of this invention will become apparent from the following description taken in conjunction with the accompanying drawings. The drawings constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof.
DETAILED DESCRIPTION OF THE INVENTION
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 that may be embodied in various forms. The figures are not necessary to scale, some features may be exaggerated to show details of particular components. 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.
Referring now to FIGS. 1 to 13 , the present invention provides a barbecue grill assembly 10 , as is shown in the Figures of the invention. The barbecue grill assembly 10 generally includes a cooking chamber 12 and a support frame assembly 14 . The support frame assembly 14 is adapted to provide support to the cooking chamber 12 and has a front structure 14 a and a rear structure 14 b . The cooking chamber 12 includes a cover 16 that is preferably connected to a firebox 18 by a hinge mechanism 17 . The cover 16 has a lower edge 19 that is dimensioned to substantially mate with an upper edge 20 of the firebox. The mating of the cover lower edge 19 and the firebox upper edge 20 occurs when the cover 16 is placed over the firebox 18 such that the cooking chamber 12 is in a closed arrangement. In this manner, the upper edge 19 is in alignment with the lower edge 20 , even though there are preferably areas of the cooking chamber that provide an opening or a space 21 between the cover 16 edge 19 and the firebox 18 edge 20 (see FIGS. 8 , 9 , and 10 ). Such openings 21 between the cover 16 and the firebox 18 are provided for passage of side shelves 22 into the cooking chamber 12 for the shelf or shelves 22 to be placed into a non-use or storage configuration, such as is shown in FIGS. 1 , 2 and 11 through 13 .
A grate 24 is removably positioned generally within the firebox 18 . The grate 24 defines a cooking surface upon which food is placed during operation of the grill assembly 10 . In a preferred embodiment, at least one side shelf 22 resides above and adjacent the grate 24 when the shelf 22 is in the storage configuration. In the embodiment shown in the Figures, at least one shelf 22 is secured to a portion of the frame assembly 14 along a hinge line 26 . Rotation, or pivoting, of the shelf 22 along the hinge line 26 provides selected movement of the shelf 22 from a first position 22 a in which the shelf 22 resides adjacent the firebox 18 and in spaced relationship from the firebox 18 . When the shelf 22 is in the first position 22 a , at least a portion of the shelf 22 provides a work surface 28 of the shelf exposed for use during cooking. In the shelf arrangement of 22 a , the shelf 22 extends generally horizontally adjacent the cooking chamber 12 , thereby providing a generally horizontal platform of the work surface 28 .
When the shelf is moved to the storage arrangement 22 b , the shelf is pivoted about the hinge line 26 , such that the work surface 28 is positioned facing the grate 24 within the cooking chamber 12 . As shown in FIG. 2 , the shelf 22 in the second position 22 b thereby has at least a portion of the shelf 22 within the cooking chamber 12 , supported within the chamber 12 above the grate 24 . In this manner, the shelf 22 passes from the hinge line 26 adjacent and outside the firebox 18 , through the opening 21 between the cover 16 and the firebox 18 , to partially reside within the chamber 12 above the grate 24 . In a preferred embodiment, the shelf 22 is adapted to provide contact with the cooking chamber 12 such that the shelf 22 is supported by the cooking chamber at the contact. In the embodiment shown in the figures, the contact structure of the shelf 22 includes a projecting surface from the shelf 22 , such as at least one boss 30 of the shelf 22 . The boss 30 is adapted to provide supporting contact 32 ( FIG. 12 ) for the shelf 22 to be supported on a portion of the cooking chamber 12 , and preferably at the upper edge 20 of the firebox 18 . In the embodiment shown in the figures, the shelf 22 is formed of plastic or the like, and the boss 30 is a heat resistant material, such as a metal pin or grommet boss 30 . Also, in another embodiment, the boss 30 extends outward from the work surface 28 of the shelf 22 to provide the supporting contact 32 in spaced relationship from the firebox 18 , thereby assuring that the shelf 22 does not make contact directly with the cooking chamber 12 when in the second position 22 b.
The shelf 22 is supported primarily by the connection of the shelf 22 to the frame assembly 14 along hinge line 26 , wherein the support is provided as a cantilever support of the shelf 22 in the first position 22 a . In the embodiment shown in the figures, the shelf 22 is freely movable in rotation about the hinge line 26 from the first position 22 a to the second position 22 b , without being locked in either location. However, it is contemplated that the assembly 10 may also include a locking member (not shown) for the shelf 22 to be releasably secured in the first position 22 a and/or the second position 22 b.
In the embodiment shown in the figures, the shelf 22 is at least partially secured in the second position 22 b by being trapped between the firebox 18 and the cover 14 . In this embodiment, the shelf has a thickness 34 having an extent that substantially mates with the opening 21 for the shelf 22 to pass into the cooking chamber 18 . The thickness 34 of the shelf shown in the figures includes the combination of the work surface 28 , side edges 36 and at least one strengthening rib 38 or ridge positioned on the bottom surface 39 of the shelf 22 (see FIG. 11 ). In this arrangement of cooperative structure combining to form the thickness 34 to substantially cover the opening 21 , the ridge 38 is adapted to block water or the like from entering the cooking chamber along the surface 39 of the shelf 22 , even though adjacent areas of the surface 39 comprise a recess or compartment such as when the shelf is made with thinner material and the strengthening ridges 38 reside on the surface 39 to provide strength or beam-strength rigidity of the shelf 22 .
In still another embodiment, the assembly 12 includes two shelves 22 , a first shelf 40 and a second shelf 41 . The first shelf 40 is located on one side of the cooking chamber 12 and the second shelf 41 is located on a generally opposed side of the cooking chamber 12 . In this arrangement, the two shelves 40 , 41 each are rotatable about independent hinge lines 26 to move the shelves 40 , 41 into the cooking chamber area such that both shelves together fit in to shelf storage positions 22 b above the grate 24 . Further, at least one shelf 22 includes a utensil mounting assembly 42 , preferably located on the bottom surface 39 of the shelf 22 . The mounting assembly 42 is adapted to hold cooking utensils 43 on the shelf 22 for storage of the utensils 43 , by a locking component 44 adapted to provide frictional engagement of the utensil 43 to be removably secured, such as by the user pushing down on a portion of the utensil (see FIG. 12 ). Engagement of the utensil 43 to the locking component 44 preferably includes mating of a recess 46 and a projection 48 . In the embodiment shown, the recess 46 is positioned on the utensil 43 and the projection 48 is located on the locking component 44 . However, the location of the mating recess 46 and projection 48 may be in reversed arrangement on the structures. In the arrangement of the recess 46 and projection 48 , the user removes the utensil 43 by pushing at least a portion of the utensil 43 from a first position 49 a wherein the projection 48 is within the receiver 46 to a second position 49 b wherein the projection 48 is not within the receiver 46 and the utensil 43 may thereby be removed ( FIG. 12 ).
The frame assembly 14 is made up of a plurality of frame members. The frame members are preferably each of pre-formed construction having an upper portion 52 and a lower portion 54 . In yet another embodiment, the frame assembly 12 is comprised of at least two frame member assemblies, a first frame member 60 and a second frame member 62 . The first and second frame members 60 , 62 are secured in position for supporting the cooking chamber 12 by being mounted to the chamber 12 in spaced relationship, having an extent of space 64 between the frame members 60 , 62 ( FIGS. 7 and 10 ). The frame members 60 , 62 are secured at the spaced extent 64 by securement of the frame members 60 , 62 to the firebox by at least one mounting member 66 joining the frame members 60 , 62 to the firebox 18 of the cooking chamber 12 . In the embodiment shown in the Figures, the mounting member 66 includes a plurality of tabs ( FIG. 8 ) extending from the firebox 18 outer wall 68 , at the underside and bottom portion of the firebox 18 . The mounting members 66 thereby cooperatively mate with surfaces of the frame members 60 , 62 and a fastened to the frame to secure the frame assembly 14 adjacent, and in spaced relation to, the firebox 18 . In the grill shown, the mounting of the frame to the firebox 18 in this manner serves to secure the lower portion of the frame members 60 , 62 in position without the need for lateral cross members between the frame members 60 , 62 beneath the fastening at the mounting members 66 .
The frame assembly 14 also includes at least one cross member assembly 70 positioned at the upper portion of the frame members 60 , 62 . The cross member 70 is adapted to provide an upper frame connection perimeter for further fixing the frame members 60 , 62 in position and separated by an extent of space. The connection perimeter includes two cross members 70 , a first cross member 72 and a second cross member 74 . The cross members 70 preferably each have one end connected to the first frame member 60 , and an opposed end connected to the second frame member 62 . The mounting members 66 , as shown in the preferred form in the Figures, include elongated tabs of metal, the tabs are fastened to the firebox 18 and extend therefrom. The fastened tabs is especially useful to provide mounting for the frame 14 to the cooking chamber 12 , where the firebox is constructed of metal, such as sheet metal or cast metal (aluminum), and the frame 14 is at least partially constructed of other material such as plastic. Since the outer wall of the firebox inevitably will get hot when using the grill, securing a separate tab for mounting the firebox 18 to the plastic frame 14 will provide a mounting assembly that reduces heat transfer to the frame 14 .
In another embodiment of the invention, the shelf 22 has a void area 78 . The void area of the shelf 22 is located in the area between the hinge line 26 and the firebox 18 when the shelf 22 is in the first position 22 a , thereby providing a gap or space between the shelf and the side of the firebox 18 . This spacing of the shelf provides a distance for the shelf from the heat emitted at the side of the firebox, especially useful when the shelf is made of plastic. When the shelf 22 is placed in the second position 22 b , the void area 78 exposes a portion of the cross member that thereby provides a handle 80 for the user to move the grill.
In yet another aspect of the invention, the frame 14 is formed of generally X-shaped frame members 60 , 62 . The upper portion of the frame members 60 , 62 extend radially upward and outward from a central body region 76 , and the lower portion of the frame members 60 , 62 extend radially outward and downward from the central body region 76 . In this embodiment, mounting of the firebox 18 to the frame members 60 , 62 by the mounting members 66 is located at the central body region 76 of the frame members 60 , 62 . The lower extending portion of the frame members 60 , 62 thereby are adapted to serve as supporting legs of the grills assembly 10 . The legs are formed of a unified structure extending from the central body portion 76 , adapted to extend with sufficient rigidity to support the cooking chamber 12 with legs in spaced relationship 64 without the need for cross members securing the legs together. In this arrangement, the grill assembly frame 14 is formed solely from two frame assemblies joined by cross members at one portion of the frame 14 , in cooperation with being joined to the firebox at another portion of the frame 14 .
The upper cross member(s) 70 include a handle 80 with a gripping portion 80 a . Because the cross member is secured between the frame members 60 , 62 , the cross member 70 is securely fastened such that a portion of the cross member itself may be adapted to provide the handle 80 . This is shown in the Figures, as the cross member 70 includes a curved handle that is suitably dimensioned to provide a gripping portion 80 a for a user to grasp and transport or lift the grill assembly 10 . As is also shown, still yet another embodiment of this assembly 10 provides securement of the shelf 22 along the hinge line 26 immediately adjacent the cross member 70 . The shelf 22 is thereby supported in the first position 22 a by resting on at least a portion of the upper surface 82 of the cross member 70 . In a further embodiment, the shelf 22 is supported in the first position 22 a solely by the combination of the cantilever support at the hinge line 26 and contact of the shelf with the upper surface 82 of the cross member 70 .
The grill assembly 10 also includes a heat shield 90 mounted beneath the firebox 18 and attached to the frame 14 . The heat shield 90 is preferably formed of an elongated piece of metal sheet stock. The heat shield 90 also includes a collection chamber 92 , preferably in a central area of the heat shield 90 , for receiving drip of grease or debris from the firebox 18 . The firebox 18 has an opening 94 to allow grease or debris from cooking to fall from within the firebox 18 toward the bottom of the assembly 10 . The collection chamber preferably is adapted to receive a removable receptacle 96 that is positioned below he opening 94 .
The combination heat shield 90 and collection chamber 92 is preferably secured into position to substantially span the extent of the space 64 between the frame members 60 , 62 . The heat shield 90 thereby acts as a barrier between the bottom of the firebox 18 and the area beneath the heat shield 90 . This is especially useful for the grill configuration shown in the Figures, having a compact design with short leg portions of the frame 14 , as is desirable for a table-top grill design. Also, when the grill assembly is attached to a cart structure (not shown), removal of the grill assembly 10 from such a structure will not disrupt the mounting of the heat shield 90 and collection chamber 92 from position beneath the firebox 18 , as the heat shield 90 remains fixed in position by the frame 14 .
The heat shield 90 is secured in position on the frame by being supported on at least one lateral support surface 98 along an extent of the frame member ( FIG. 10 ). In the preferred form of the invention, the lateral support surface 98 is comprised of a groove 100 formed in the first and second frame assemblies 60 , 62 . The grooves 100 cooperatively form a lateral slot along a lateral sliding path residing along a plane 102 . The lateral slot is adapted to provide a path for the heat shield to pass into the space 64 between the frame assemblies 60 , 62 to be inserted in place, with the bottom surfaces of the grooves 100 providing a sliding surface of edge areas 104 of the heat shield 90 ( FIG. 9 ). At least one groove 100 further having a recess 106 with a lateral wall surface 107 adapted to prevent lateral movement of the shield 90 when the edge area 104 of the shield 90 is dropped from the lateral plane to a position on a lower plane 108 ( FIG. 10 ). In this arrangement of structure, the shield 90 is inserted by the user between the frame members 60 , 62 by insertion along the plane 102 , and then lowered into plane 108 for the shield to be supported in the groove and prevented from lateral sliding removal by the wall surface 107 .
The assembly 10 also includes an igniter 110 , used to ignite the burner element, which is preferably a gas burner such as is shown in the Figures, with a fuel source such as a fuel tank 112 . The igniter includes an igniter actuator control 114 as a button or switch, which is secured to the frame assembly 14 to be mounted securely to the grill 10 and yet be exposed for the user to activate the igniter distal end 116 which generates the spark or the like to ignite the gas from the burner for cooking. In the preferred form of the invention, the actuator 114 is located on one of the frame assemblies 60 and a portion of the actuator 114 passes through the frame assembly 60 to provide an exposed actuator button 118 on the frame 14 at a recess 120 in the frame 14 .
A support bracket 122 is provided on the frame at the side of the firebox 18 for supporting the fuel tank 112 . The support bracket 122 includes a loop having an inner perimeter that is cooperatively dimensioned to receive the outer perimeter of a standard and common size fuel tank 112 . The fuel tank is thereby held in place on the grill assembly by the combination of the support bracket 122 at one part of the tank 112 , and the tank being secured to the gas manifold 124 of the assembly 10 . In the embodiment shown in FIG. 13 , the support bracket 122 is mounted directly to the inside of a frame assembly 62 , preferably the rear frame structure 14 b . The mounting of the bracket 122 includes an attachment arm 126 that extends from the frame 14 to place the bracket perimeter in position for receiving the tank 112 .
Referring now particularly to FIGS. 14 to 28 , there is shown another embodiment of the cooking apparatus 10 of the present invention, which has a fire bowl 12 . The fire bowl 12 has a bottom 14 . Typically, the fire bowl 12 will be constructed of steel or iron. The bottom 14 assumes a smooth, arcuate shape so that the bottom 14 is basically concave relative to the internal chamber 16 of the fire bowl 12 . The fire bowl 12 also includes a front 18 and a back 20 . The sides of the front and back, 18 and 20 respectively, of the fire bowl 12 are slightly curved being convex from the exterior. The bottom 14 is also curved arcuately in the direction from front 18 to back 20 . This forming of the fire bowl 12 is to maximize the reflecting or application of heat from the heating unit 22 that is contained within the internal chamber 16 . Mounted at the upper end of the internal chamber 16 is a cooking grill 24 . It is to be noted that the upper edge of the front 18 and back 20 are substantially flush to the upper edge of the left side 26 and the right side 28 of the fire bowl 12 .
The bottom 14 of the fire bowl 12 is fixedly mounted onto a supporting frame 30 . The supporting frame 30 includes a pair of parallel, spaced apart arcuate main members 32 and 34 , which are in a bowl shape resembling a basic cradle configuration. Within that cradle is mounted the fire bowl 12 . Extending between the members 32 and 34 are cross braces 36 and 38 . The fire bowl 12 is fixedly mounted onto the cross braces 36 and 38 by mounts 40 .
One end of the supporting frame 30 terminates in a handle 42 with the opposite end of the supporting frame 30 terminating in a handle 44 . The handle 42 is located directly adjacent but slightly spaced from the left side 26 . The handle 44 is located directly adjacent but slightly spaced from the right side 28 .
The main member 32 , as well as main member 34 , is basically configured to be channeled shaped having an internal cavity 46 . This cavity 46 is open at the bottom. A leg assembly composed of leg members 48 and 50 is to be mounted between the main members 32 and 34 . The leg member 48 is pivotally mounted by pivot pins, 52 and 54 respectively, to the main members 32 and 34 . The leg member 48 includes legs 56 and 58 with leg 56 being pivotally mounted by the pivot pin 52 to the main member 32 and leg member 58 being pivotally mounted by the pivot pin 54 to the main member 34 . The outer end of the legs 56 and 58 has extending therebetween a cross member 60 .
The leg member 50 includes a similar pair of legs with only leg 62 being shown. The leg 62 is pivotally mounted by a pivot pin 64 to the main member 32 . Extending between the legs 62 and the not shown leg of the leg member 50 is a cross member 66 .
The leg members 48 and 50 can be located in a retracted position relative to the supporting frame 30 which will locate the cross member 60 in conjunction with a notch 68 formed within the main member 32 and the cross member 66 engaging with a notch 70 formed within the main member 32 . With the leg members 40 and 50 in this retracted position, the leg member 48 includes a pair of leg extensions 72 and 74 which are to be located on a supporting surface 76 . It is to be noted that in this position the main members 32 and 34 will be located also very near the supporting surface 76 , generally no more than a fraction of an inch therefrom. The leg member 50 also includes a similar pair of leg extensions with only leg extension 78 being shown.
When the leg member 48 is moved clockwise to an extended position, and the leg member 50 moved counterclockwise to an extended position, the leg member 78 moves within the internal cavity 46 of the main member number 32 . When the leg extension 78 contacts the upper end of the internal cavity 46 , this will define the limit of movement of the leg member 50 to the extended position. Such also is to occur for the leg member 48 with the leg extensions 72 and 74 as well as the not shown leg extension for leg member 50 . It is to be noted when the leg members 48 and 50 are in the retracted position, the shape of the legs 56 , 58 , 62 and the not shown leg of leg member 50 will nest within the internal cavity 46 in a close conforming manner of the main members 32 and 34 respectively. It is to be noted that the leg members 40 and 50 will automatically remain in their retracted position until such is moved from the retracted position to the extended position. The extended position of the leg members 48 and 50 locates the outer end of the leg members 48 and 50 against the supporting surface 76 .
Fixedly mounted to the fire bowl 12 at the fore end 26 is a mounting bar 80 . A similar mounting bar 82 is fixedly mounted to the fire bowl 12 at the aft end 28 . Mounted on the mounting bar 80 is a pivot rod 84 . A similar pivot rod 86 is pivotally mounted on the mounting bar 82 . Connected to the pivot rod 84 is the inner end of a first shelf 88 . The inner end of a second shelf 90 is connected to the pivot rod 86 . The first shelf 88 is capable of being pivoted from a stowage position located within the confines of the internal chamber 16 shown in FIG. 17 of the drawings to an extended position, which is shown in FIG. 18 of the drawings. Similarly, the second shelf 90 is capable of being pivoted one hundred eighty degrees from the stowage position shown in FIG. 16 to an extended position shown in FIG. 18 . In the stowage position shown in FIG. 16 , the shelves 88 and 90 are located in juxtaposition and in alignment. In FIG. 18 , the shelves 88 and 90 are no longer in juxtaposition but still in alignment. The shelf 88 has a planar working surface 92 , and shelf 90 has a planar working surface 94 . When shelf 88 is in the extended position as shown in FIG. 18 , the underside of the shelf 88 rests on the handle 42 . Similarly, when the shelf 90 is in the extended position as shown in FIG. 18 , the underside of the shelf 90 rests on the handle 44 .
The bottom side of the shelves 88 and 90 is what are located in an upward facing direction when the shelves 88 and 90 are in the stowage position shown in FIG. 16 . The undersurface of the shelves 88 and 90 includes a plurality of spaced-apart brace members 96 each of which includes notches 98 . These notches 98 are to facilitate stowage of utensils, such as a spatula 100 , tongs 102 and a fork 104 . Also, there is provided sufficient space on the underside of the shelves 88 and 90 to accommodate a propane gas tank 106 . The gas tank 106 can be removed and mounted on the supporting surface 76 in close proximity to the fire bowl 12 . The forward end of the gas tank 106 is to be mounted in conjunction with a support 108 , which is to rest on the supporting surface 76 . It is necessary that the forward end of the gas tank 106 be at an elevated position to the rear end of the gas tank 106 in order for the gas tank 106 to supply gas properly through the conduit 110 to the heating unit 22 . Control of the gas from the tank 106 to the heating unit 22 is by a regulator 184 . Igniting of the gas within the heating unit 22 would normally be accomplished by use of an ignition device such as a conventional match, which is not shown.
The lid 114 is to be removed by unlatching of a latch mechanism (not shown) in FIGS. 14 to 18 by turning of knob 112 and grasping of handle 116 from its position totally enclosing of the internal chamber 16 and separating of the lid 114 completely from the fire bowl 12 , as is shown in FIG. 16 . Propane tank 106 is then to be removed and placed as shown in FIG. 18 , and the conduit 110 is connected to an appropriate connection, which is not shown, mounted on the bottom 14 of the fire bowl 12 . The spatula 100 , tongs 102 and fork 104 are then removed and shelf 88 pivoted one hundred eighty degrees to rest on the handle 42 , and shelf 90 then being pivoted one hundred eighty degrees to rest on the handle 44 . The handle of the spatula 100 is to be located within the longitudinal groove 118 formed within the working surface 92 of the shelf 88 . Similarly, the tongs 102 is to be mountable in conjunction with a pair of elongated grooves 120 formed within the working surface 92 . Similarly, the handle of the fork 104 is to be locatable in longitudinal groove 122 formed within the working surface 92 . The depths of the grooves 118 , 120 and 122 are such that the spatula 100 , tongs 102 and fork 104 are located below the working surface 92 so that the working surface 92 is capable of being used by locating of a plate or other object thereon during performing of cooking on grill 24 even when the utensils are still mounted with the shelf 88 . However, by using the longitudinal grooves 118 , 120 and 122 , the spatula 100 , the tongs 102 and the fork 104 are ready at hand available for usage.
The lid 114 is connectable to the fire bowl 12 which is discussed in relation to the third embodiment of this invention which follows in the specification that permits the lid 114 to move to a tilted position, shown in FIG. 18 , which provides access into the grill 24 without having the lid 114 separated completely from fire bowl 12 . This position of the lid 114 , which is shown in FIG. 18 , would be common during cooking of food on the grill 24 . The lid 114 includes a latching pawl 128 , which is to engage with the side 18 in order to lock in position the lid 114 when it is in the completely closed position, which is shown in FIG. 14 .
It is to be understood that the initial position of the grill will normally be that of FIG. 14 . The operator will first put the leg members 48 and 50 to the extended position and then remove the lid 114 from the fire bowl 12 . The propane tank 106 and the utensils 100 , 102 and 104 are removed from the back side of the shelves 88 and 90 . The shelves 88 and 90 are then moved to the extended position, which is shown in FIG. 18 . The spatula 100 is located in conjunction with the longitudinal groove 118 , the tongs 102 is located in conjunction with the longitudinal groove 120 and the fork 104 is located in conjunction with the longitudinal groove 122 . The lid 114 can then be located in the tilted position in conjunction with side extensions 124 and 126 . Turning of the knob 112 will initiate the supplying of the gas through conduit 110 to the heating unit 22 and upon ignition of the gas of the heating unit 22 , the cooking apparatus 10 of this invention is now ready for usage. After usage, the procedure is reversed to place the cooking apparatus 10 back in the position shown in FIG. 14 , which would mean that the cooking apparatus 10 is in a position for transportation and storage.
Referring particularly to FIGS. 19 to 22 , there is shown another further embodiment 130 of cooking apparatus of this invention. The embodiment 130 includes a fire bowl 12 , which has a bottom 14 , an internal chamber 16 and sides 18 and 20 . Mounted within the internal chamber 16 is the heating unit 22 and grill 25 . The fire bowl 26 also has a fore end 26 and an aft end 28 . Turning of knob 112 causes knob 112 to pivot relative to block 132 mounted on the exterior surface of the side 18 . The knob 112 has fixedly connected thereto a rod 134 . Rod 134 extends through a hole formed in the side 18 and is fixed to hook 136 . Hook 136 can be pivoted into engagement with retainer 138 . Retainer 138 is fixedly mounted on the inside surface of the lid 114 . When the control knob 112 is turned counterclockwise to the maximum, the hook 136 will engage with the retainer 138 , as is shown in FIG. 20 of the drawings. Movement of the control knob 112 ninety degrees in a counterclockwise direction will cause the hook 136 to become disengaged from the retainer 138 which will permit the lid 114 to be pivoted to an almost ninety degree tilted position, which is clearly shown in FIG. 22 of the drawings. The lid 114 has a peripheral depending lip 140 , which is to overhangingly connect with in a close conforming manner an upstanding free edge 142 of the fire bowl 12 . Mounted on the exterior surface of the lid 114 there may be included a manufacturing identifying emblem 144 .
Fixedly mounted to the exterior surface of the bottom 14 is a pair of parallel spaced apart cross braces 146 and 148 . The cross braces 146 and 148 are fixedly mounted to the bottom 14 by means of short rods 150 . The outer end of each cross brace 146 and 148 has an enlarged head 152 . The cross braces 146 and 148 are located transverse to the sides 18 and 20 .
An arcuately shaped supporting stand 154 has a pair of parallel oriented spaced apart curved main members 156 and 157 . Connecting between the main members 156 and 157 adjacent their ends thereof are connecting braces 158 and 160 . Within the convex edge 162 of the main member 156 are mounted a pair of spaced apart protruding feet 164 . Also formed within the convex edge 162 is a pair of slots 166 . Cross brace 146 is to connect with a pair of the slots 166 with one slot 166 being in main member 156 and the other slot 166 being in the main member 157 that is parallel to and spaced from main member 156 . Similarly, cross brace 148 is to be connectable with a similar pair of aligned slots 166 . The connection of the cross braces 146 and 148 within the respective slots 166 is in a snug manner so that the support stand 154 will be held in position in conjunction with the cross braces 146 and 148 . When the cross braces 146 and 148 are located within the slots 166 , the support stand 154 is mounted so as to space the fire bowl 12 some distance away from the supporting surface with it being understood that the outer ends of the main members, such as main member 156 , are resting on the supporting surface 168 .
Each of the main members 156 and 157 have formed on their inside surface a pair of slots 170 which are similar to slots 166 . Each cross brace 146 and 148 can snugly connect with an aligned set of slots 170 which will locate the support stand 154 in the position shown within FIG. 19 of the drawings. This is the stowage position of the support stand 154 , which is to be utilized when the second embodiment 130 is not being operated.
Pivotally mounted to the fore end 26 is a first shelf 88 with a second shelf 90 being pivotally mounted to the aft end 28 . This pivot mounting is obtained by using pivot rods 84 and 86 respectively. The shelves 88 and 90 can be pivoted to an outward extending position with first shelf 88 resting on handle 161 and shelf 90 resting on handle 163 . The handles 161 and 163 are also to function to physically pick up and transport the second embodiment 186 of cooking apparatus. The inside surface of the first shelf 88 includes a series of recesses which facilitate stowage of utensils, such as the spatula 172 and the fork 174 . Mounted on the undersurface of the shelf 90 is a wire holder in the form of a pair of wire hangers 176 and 178 . The wire hangers 176 and 178 connect with the propane tank 180 . When the shelf 90 is pivoted one hundred eighty degrees from the position shown in FIG. 21 to the position shown in FIG. 22 , which is the extended position of the shelf 90 , propane tank 180 will be held in position against the under surface of the shelf 90 but permitted to be located at approximately a thirty degree inclined angle. This inclination is necessary in order for the propane to move the flow in a desirable manner through the connecting hose 182 to the burner unit, which is not shown. It is to be noted that the second embodiment 130 is of a smaller configuration than the first embodiment 10 . Because of this, it was necessary to fold in half the utensils composing of the spatulas 172 and 174 so as to cut down the length of such in order to achieve stowage against the under surface of the shelf 88 . The shelf 88 in FIG. 22 has within its working surface 188 , which is the upper surface, a pair of elongated grooves 190 and 192 . When the fork 174 is pivoted about its pivot joint 194 from the collapsed position to the expanded position, it then can be mounted within the groove 190 so that the fork 174 is located totally beneath the working surface and does not interfere with the utilization of the working surface 188 . The same is true for the spatula 172 if it is pivoted from its collapsed position about pivot joint 196 to the expanded position and inserted within the groove 192 .
Referring particularly to FIGS. 23 to 28 of the drawings, there is shown another further embodiment 186 of cooking apparatus of this invention. This embodiment 186 is to be the largest of the embodiments, and because of its size, it is not easily as portable as embodiment 10 and embodiment 130 . The fire bowl 12 of the third embodiment 186 is substantially larger in size. The backside of the lid 114 includes a pair of spaced apart protuberances 198 and 200 . Each protuberance 198 and 200 is to connect with a hole formed within the fire bowl 12 with only hole 202 being shown. The holes, such as hole 202 , are formed within the free edge 142 of the fire bowl 12 . The connection arrangement between the protuberances 98 and the holes 202 is such that it will permit the lid 114 to pivot to an upward position and be supported in that position with the lid 114 assuming a tilted position.
Fixedly mounted to the bottom 14 of the fire bowl 12 are four in number of short rods 204 . Two of the short rods 204 are fixed to cross brace 206 with the remaining two in number of short rods 204 being fixed to the cross brace 208 . The cross braces 206 and 208 are fixed between a pair of main members 210 and 212 of the supporting frame 214 . The left end of the supporting frame 214 terminates in a handle 216 with the right end of the supporting frame 214 terminating in a handle 218 . Mounted underneath each handle 216 and 218 is a latch plate with only latch plate 220 being shown for handle 216 . The latch plate 220 is forced by a coil spring 222 to an at-rest position. This at-rest position will lock the leg assembly 224 in its upper position, which is shown in FIG. 23 of the drawings. Connected between the leg members 226 and 228 of the leg assembly 224 is a rod 230 . The latch plate 220 has a pair of pawls 232 and 234 located at opposite ends of the plate 220 . The pawls 232 and 234 are to engage respectively with recesses 236 and 238 , which are formed respectively within spools 240 and 242 , which are fixedly mounted onto the rod 230 . When the latch plate 220 is lifted in the direction of arrow 244 , the pawls 232 and 234 are removed from their respective recesses 236 and 238 , which will permit the leg assembly 224 to be pivoted to the outwardly extending position shown in FIG. 27 . In this outwardly extending position, knob 236 can be manually tightened so as to fix in position the leg assembly 224 in this outwardly extended position. In a similar manner, knob 238 can be tightened which will further fix in position the leg assembly 224 in this outwardly extended position.
In a similar manner, a latch plate, which is mounted under the handle 218 is to be moved in the same way in order to permit the leg assembly 250 to be pivoted to an outwardly extended position. Again, knobs 252 are to be tightened which will secure in position the leg assembly 250 in this outward extended position. The leg assembly 250 is to include wheels 254 and 256 . The wheels 254 and 256 facilitate low frictional rolling movement of the third embodiment 186 of this invention by lifting on handle 216 and then rolling of the third embodiment 186 on the wheels 254 and 256 . It is to be noted that the leg assembly 250 assumes a crossed position relative to the leg assembly 224 when in the upper or retracted position shown in FIG. 23 . The leg assembly 250 is essentially parallel to the leg assembly 224 when in the outwardly extended or usage position shown in FIG. 27 .
Mounted on the grill 24 is a pair of shelves 88 and 90 . The only difference is that because of the size of the fire bowl 12 , there will be normally included two separate burners within the internal chamber of the fire bowl 12 . Therefore, each burner has to have its own separate butane tank with their being two butane tanks 180 hung by wire hangers 176 and 178 with there being a separate butane tank 258 located under each shelf 88 and 90 .
Along with the utensils 260 and 262 , which can be mounted in a stowage position between the shelves 88 and 90 when such are mounted on the grill 24 , there also may be included a basting container 262 . This basting container 262 can be disengaged from the backside of shelf 88 and mounted on the shelf 90 , as is shown in FIG. 28 . The utensils 260 and 262 , which comprise a spatula and fork respectively, can also include tongs 264 . When the shelves 88 and 90 are in an outwardly extended position with shelf 88 being supported on the handle 216 and shelf 90 being supported on the handle 218 , the spatula 260 , the fork 262 and the tongs 264 can be mounted within grooves 266 formed in the upper surface of shelf 88 . Again, the mounting of the spatula 260 , fork 262 and tongs 264 are such that it is located beneath the working surface of the shelf 88 .
While the specific embodiments have been illustrated and described, numerous modifications come to mind without significantly departing from the spirit of the invention and the scope of protection is only limited by the scope of the accompanying Claims.
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A portable barbecue cooking apparatus is provided, the apparatus comprising a base; a fire bowl having a topside opening, and the fire bowl is mounted on the base, and the topside opening of the fire bowl is situated above the base; a grill situated within the fire bowl and is moveable within the fire bowl; and at least one shelf is pivotally attached to the base, and the shelf is foldable inwardly towards the topside opening of the fire bowl during a stowage position and extendable outwardly away from the topside opening of the fire bowl during a usage position.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of provisional application Serial No. 60/360,471 filed Feb. 27, 2002.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] N/A
COPYRIGHT NOTICE
[0003] A portion of the disclosure of this patent document contains material that is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or patent disclosure as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyrights rights whatsoever.
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] This invention relates generally to a washing device and system, and more particularly, to a personal body and clothing washing system that selectively mixes and dispenses water, soap, detergent, fragrance and, or disinfectants.
[0006] 2. Description of the Background Art
[0007] Washing systems, such as bidets, are well known in the art, and common in Europe and expensive homes. Public restrooms and average homes, however, do not have bidets. In many instances, this is because of size and, or budget constraints. Because of the cleaning advantages afforded by bidet systems and the practical limitations preventing wide spread use of bidets, there exist a need for a personal washing device that is more widely available, easily adaptable for use in existing bathrooms and with existing toilets and faucets, transportable and affordable. The instant invention addresses this need.
BRIEF SUMMARY OF THE INVENTION
[0008] Based on the foregoing, it is a primary object of the present invention to provide a personal washing device that is adaptable for use in existing bathrooms for personal hygiene.
[0009] It is an object of the instant invention to provide a personal washing device that may be used for washing clothes.
[0010] It is another object of the instant invention to provide a personal washing device that is removably installable and, or portable and readily attachable to existing sources of water.
[0011] It is also an object of the present invention to provide a personal washing device that is readily available and ergonomically adapted for washing personal body areas.
[0012] It is another object of the present invention to provide a personal washing device that is relatively less expensive to manufacture and install compared to conventional washing systems, such as bidets.
[0013] It is a further object of the present invention to provide a personal washing device that provides proper and hygienic cleansing whenever and wherever needed.
[0014] It is yet another object of the present invention to provide a personal washing device that offers a convenient and easy system for the physically challenged.
[0015] It is yet an additional object of the present invention to provide a personal washing device that provides proper and hygienic cleansing whenever and wherever needed.
[0016] It is yet a further object of the present invention to provide a personal washing device that is easily installed and removed.
[0017] It is still another object of the present invention to provide a personal washing device that can be used for storing and replacing various washing agents.
[0018] It is still an additional object of the present invention to provide a personal washing device that can be used for storing and applying cleaning agents for washing and, or removing stains from fabrics.
[0019] In light of these and other objects, the instant invention provides a personal washing device that is primarily for cleaning personal body areas, self-contained in protective enclosure and adapted for use with existing commodes and, or faucets as an installed or portable unit. The personal washing device comprises a purifying chamber, mixing chamber, structure for receiving water and washing additives, such as soap, detergent or other conventional cleaning agents, injection system, applicator and enclosure for securing, holding and protecting the system components. The noted components of the instant invention mechanically cooperate and fluidly communicate to dispense a washing solution made by the instant invention.
[0020] The personal washing device has an inlet and at least one hose or other type of conduit having a connector, for tapping into and receiving a source of water. Water is received through the inlet and passes through the purifying chamber, injection system, mixing chamber, application hose and intervening conduit, tubing or hoses. The injection system may comprise an air pump or charged gas system, which provides the force for forcing the water and cleaning solution through the system. The purifying chamber has a filter and removes impurities and targeted minerals from the water. The water then passes into the mixing chamber, which is fluidly connected to a cleaning agent source. The water and cleaning agent are mixed together in the mixing chamber to make a cleaning solution. The cleaning agents are preferably fluidly connection to the injection system, but may be connected directly to the mixing chamber. The cleaning solution is dispensed, such as by spraying, through the application hose and nozzle. The nozzle has an ergonomically designed, replaceable head for directing the mixing solution as it exits the system. The nozzle preferably has a control valve connected between the head and nozzle for closing and, or adjusting pressure. The personal washing system may include spare heads and various head styles for varying the spray configurations. The instant invention may also include spare gas cartridges and cleaning agent refills and accessories such as pre-moistened disinfectant towels, pre-moistened detergent towels and packaged single-use concentrate.
[0021] The personal hygiene device is conveniently stored and secured in a protective enclosure. The enclosure preferably defines two compartments that are attached together along a common edge by hinges and locked together by a latch. One compartment contains the purifying chamber, mixing chamber and injection system fluidly connected together, application hose with the nozzle and any accessories, hoses or tubing that might be needed, such as tubing for connecting to a water source. The system preferably employs quick connecting valves, adapters and tubing for convenient set-up. The other compartment preferably stores other accessories, such as the disinfectant towels, detergent towels, spare gas cartridges and spare nozzle heads. The inside of the enclosure may be lined with foam and, or insulation for protecting the contents from impact. The enclosure may be adapted for temporary or semi-permanent installation in a bathroom or washroom. The enclosure may also be designed as a portable unit for use at work or while traveling.
[0022] In accordance with the summary of the invention, listed objects and other objects, which will become apparent hereinafter, the instant invention will now be described with particular reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0023] [0023]FIG. 1 is an elevational view of the personal hygiene device in accordance with the preferred embodiment of the instant invention showing the mixing and pumping system.
[0024] [0024]FIG. 2 is an elevational view of the personal hygiene device in accordance with another preferred embodiment of the instant invention showing the mixing and pumping system.
[0025] [0025]FIG. 3 is an elevational view of the personal hygiene device in accordance with the preferred embodiment of the instant invention illustrating a complete system.
[0026] [0026]FIG. 4 is an elevational view of the personal hygiene device' accessory compartment in accordance with the preferred embodiment of the instant invention
DETAILED DESCRIPTION OF THE INVENTION
[0027] With reference to the drawings, FIGS. 1 - 4 depict the preferred and alternative embodiments of the instant invention which is generally referenced as a personal hygiene device and, or by numeric character 10 . The personal hygiene device 10 comprises a self contained, personal transportable washing bidet system for attachment to and use with standard toilets and, or faucets. The device 10 allows the user to perform personal cleansing wherever and whenever they desire. The device 10 can also be used to wash stains from clothing. The invention 10 allows the user to “freshen up” whenever they desire as well as have washing solution available for personal uses.
[0028] Referring to the drawings, the personal hygiene device 10 comprises an enclosure 12 , mixing chamber 18 , purifying chamber 20 , injection system 22 , application hose 28 with a replaceable nozzle 29 . The system 10 may also include additional tubing, such as a water source tapping hose 32 and quick-connect adapters and valves, such as 26 , 27 and 35 , water source hose with adapter 32 and, or gas cartridges 38 for a gas charged injection system. The system 10 may also comprise cleaning agents and spare parts, and preferably pre-moistened disinfectant towels 42 , pre-moistened detergent towels 44 , packaged single-use cleaning agent concentrate cartridges 46 , spare gas cartridges 38 and spare nozzle heads 30 .
[0029] With reference to FIG. 3, the enclosure 12 comprises a first compartment 14 and second compartment 13 , which are connected along a common edge by at least one hinge 13 and can be securely closed by a latch or lock 21 . The first compartment 14 preferably contains the purifying chamber 20 , mixing chamber 18 and injection system 22 , which are fluidly connected together in the compartment 14 , application hose 28 with the nozzle 30 and any accessories, hoses or tubing that might be needed, such as tubing 32 for connecting to an adapter 39 to a water source 1 . The second compartment 13 preferably stores other accessories, such as the pre-moistened disinfectant towels 42 , detergent towels 44 , packaged cleaning agents 46 , spare gas cartridges 38 and, or spare nozzle heads 30 . The enclosure 12 is preferably made from a hardened, durable plastic or plastic-based material. The inside of the enclosure 12 may be lined with foam and, or insulation for protecting the contents from impact. The enclosure may be adapted for temporary or semi-permanent installation in a bathroom or washroom. The enclosure may also be designed as a portable unit for use at work or while traveling.
[0030] With reference to FIGS. 1 and 2, the purifying chamber 20 is fluidly connected at one end to a water source 1 , such as with a water source tube 32 having quick connects 36 , and to the injector system 22 at the other end by a tube or conduit 25 . The injection system 22 may comprise an air pump or gas charged pump. The cleaning agent packages 46 may be connected directly to the injection system for drawing cleaning agents and controlling the amount of cleaning agent be mixed in the mixing chamber 18 . The mixing chamber 18 is fluidly connected to the injection system's 22 outlet at one end and a cleaning solution dispensing tube 24 at the other end. The nozzle 29 is connected to the exit end of the application hose 28 and includes a control valve 31 for controlling the pressure of the spray and a nozzle head 30 for directing flow. The application hose 28 releasably connects to the tube 24 with quick-connect 36 .
[0031] Still referring to FIGS. 1 and 2, the purifying chamber 20 fluidly communicates with the mixing chamber 18 and comprises a filter for cleaning the water. The mixing chamber 18 combines the purified water and cleaning agent in proper concentration for delivery through the tubing 24 and the application hose 28 and nozzle 29 assembly. The mixed solution is dispensed from and directed by the nozzle head 30 . The injection system 22 and air pump connection tubing 23 facilitate the mixing and dispensing of the water and solution. The injection system 22 is activated and deactivated by engaging an activation button. The control valve 31 comprises a push button valve and resides in the nozzle 29 and controls the flow of solution out the nozzle head 30 . The gas cylinder 38 charges the mixing chamber 18 and is connected to a shut off valve for controlling the charging process, as shown in FIG. 2.
[0032] The convenience of the instant invention is enhanced by the use of quick-connect adapters, such as saddle valves. The water source hose 32 preferably includes saddle valve adapters 34 and 35 at its ends for providing a quick-connection to a water source. The personal hygiene device 10 preferably uses saddle valves or quick-connect adapters for all tubing connections including connectors 27 , 26 , 39 , 34 , 35 , and 36 . The personal hygiene device 10 may be fitted with other quick connect and disconnect couplings to allow the device to be used with pre-existing water valves instead of having to use and abandon a saddle valve.
[0033] Input water is initially forced through the purifying chamber 20 and into the mixing chamber 18 where soap, detergent, fragrance or disinfectant are added as needed. The mixed solution is transferred via the length of tubing 24 and hose 28 to a hand held nozzle 29 for application of the cleansing solution to the desired area. The mixing chamber 18 may be bypassed for using purified water from the purifying chamber 20 to rinse the desired area.
[0034] The mixing chamber 18 is connected in line with the purifying chamber 20 . The invention 10 has provisions for the connection of one or more replaceable canisters of concentrated soap, detergent, fragrance or disinfectant to an injection manifold, as shown in FIGS. 2 and 4. An injection manifold is connected to the mixing chamber 18 to allow the introduction of concentrated additives. The coiled length of tubing 28 connects the mixing chamber 18 to the hand held nozzle 29 . The hand held nozzle 29 has a push button regulating or control valve 31 to monitor the amount of cleansing solution to be applied. The hand held nozzle 29 has detachable, replaceable heads 30 for producing various spray patterns. The invention 10 has a provision to direct the purified water from the purifying chamber 20 directly into the dispensing nozzle 29 bypassing the mixing chamber 18 . The purifying chamber 20 is connected with quick disconnect fittings that do not require tools for disassembly. The concentrated additive canisters 46 are connected with quick disconnect fittings that do not require tools for disassembly. The invention is contained in a small plastic case 12 fitted with a hinged door for easy access to the internal components.
[0035] The entire invention is contained in a small case 12 . The first compartment 13 and second compartment 14 are connected by hinges 19 for opening and closing the case. The case 12 also includes a handle 15 for transporting the personal hygiene device 10 . The case 12 comprises a molded acrylonitrile-butadiene-styrene (ABS) co-polymer or polyvinyl chloride (PVC) plastic cabinet with a hinged door. The replaceable gas cartridges 38 are made from PVC plastic and are equipped with easily connected and disconnected fittings. The disposable purifying chamber 20 contains a particulate filter and an activated charcoal filter to remove odors and microorganisms from the input water. The mixing chamber 18 is made from PVC plastic for long life and resistance to chemical action from concentrated materials used with the system.
[0036] Soap, detergent, fragrance or disinfectant is stored in small stainless steel or PVC plastic canisters and a measured amount is introduced into the mixing chamber via small push button stainless steel or PVC plastic injection valves. The mixed solution is transferred from the mixing chamber via a length of flexible PVC tubing to a hand held PVC plastic nozzle fitted with a metering valve.
[0037] The instant invention is used as follows. The personal hygiene device 10 is connected to a source of pressurized water using the saddle valve or quick connect fittings 36 and 34 or 35 . The input water is turned on to provide flow. The desired amount of concentrated additive is injected into the mixing chamber 18 using the push button valves. The push button valve 31 on the dispensing nozzle 29 is temporarily opened to allow flow of input water into the mixing chamber 18 . The mixed solution is dispensed in the quantity needed using the desired nozzle head 30 . The by-pass valve is actuated when purified water only is desired. After use the input valve is turned off, the dispensing control valve 31 actuated to remove excess pressure and the dispensing assembly stored in the cabinet for future use. Replacement canisters 46 of concentrated additive are exchanged as necessary.
[0038] The instant invention has been shown and described herein in what is considered to be the most practical and preferred embodiment. It is recognized, however, that departures may be made therefrom within the scope of the invention and that obvious structural and/or functional modifications will occur to a person skilled in the art.
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A personal washing system having a water purification chamber, cleaning agent injection system, mixing chamber for mixing a cleaning agent with water to produce a cleaning solution, and application hose and nozzle for applying the cleaning solution to an area being cleaned.
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FIELD OF INVENTION
[0001] This present invention relates to a method for the disposal of greases and manufacture of industrial fuels therefrom and it is a new chemical approach particularly to dispose greases. In this method, during the separation of base oil from soap, a degrading agent is added which results into the rupture of soap matrices, thereby facilitates the separation of base oil from soap. The primary role of degrading agent in this invention is to speed up the separation process by weakening molecular forces within soap matrices resulting easy removal of base oil from thickener. The uniqueness of the present invention is to convert waste grease into a useful industrial fuel thru more environment friendly and economically viable ways & means.
BACKGROUND OF INVENTION
[0002] Lubricating greases are being used in various industries namely, Automotive, Steel, Power, Mining, cement, Agro machineries, Chemical etc. Total worldwide volume of lubricating grease is over 7, 63,000 MTPA, where India & Indian sub continents constitute around 10-12% of total volume. (The grease composition employs an oil of lubricating viscosity, particularly including natural oils. Natural oils include animal oils, vegetable oils, mineral oils, solvent or acid treated mineral oils, and oils derived from coal or shale.
[0003] As more than 90% lubricating oils & greases are mineral oil based, which are non-biodegradable and therefore these are not environment friendly. Hence, it is becoming growing concern to dispose oils & greases more efficiently as well as safely. Although quite few methods and practices are adapted to dispose only used lubricating oils, however there is no viable method, which disposes lubricants both economically and environmentally. Currently, there are two major approaches are being followed worldwide to dispose used oil, namely
Reclamation Recycling
[0006] Reclamation in general involves cleaning, drying and perhaps adsorption to remove color, acids & sludge. The reclaiming of lube oil is essentially a non-chemical process that restores in service lubricating oil for reuse in a system. Recycling: Reuse of waste oil can include burning with out treatment (not advised), reprocessing to industrial fuel, re-refining to new lube oil and disposal to landfill (to be avoided). In some countries used oil collection schemes are in place and used oil is recycled, however it is still the case that most used oil is burned as industrial fuel like in cement mills, lime kilns, coke ovens, and blast furnaces. Re-refining is another disposal route, which requires capital investment, but only small fraction of used oil is currently recycled mainly because quality of refined oil is inconsistent and often leads to poor performance characteristics for finished lubricants blended from them.
[0007] One of the alternate approaches in the industry is going for long drain interval oils and using greases having longer life and even fill-for-life concept is emerging in the market. This approach definitely reduces the amount of pressure to dispose lubricant however the issue of disposal of lubricant via most acceptable method remains unresolved. When the scrap greases are either incinerated or buried in the pit one should not ignore the likely damages it may have to the environment. Though in India, environment laws are not strict as in United States and European countries, however in view of user industries are forced to follow only eco-friendly disposal method but the fact is that as on date there is no foolproof method available for the disposal of greases. In comparison to lubricating oil, in the past, worldwide not much importance was given to grease; however there is a growing environmental consciousness nowadays and there is need & some time enforcement by various agencies to adopt suitable disposal methods for greases as the various current practices adopted by industry like burning of greases, disposal to landfill etc are not acceptable by the environmentalists.
[0008] Currently, the market for used grease has stymied many recycling and reclamation efforts. Only a limited amount of used grease is reclaimed and converted into a recycled oil product. Used grease retains a high energy potential however, hazards and cost associated with collecting, storing, transporting, and general handling of used grease has limited the efforts to collect used grease for disposal or recycling. There is a need for improvement within the art of converting used grease to a high quality energy source. Therefore, used greases as well as off specification greases have now become a grave concern for disposal.
OBJECT OF THE INVENTION
[0009] The primary object of this invention is to propose a novel method for the disposal of lubricating greases and manufacture of industrial fuels therefrom.
[0010] Another object of this invention is to propose a more viable chemical method to dispose bio and non-biodegradable greases.
[0011] Further object of this invention is to use commercially viable diluents/gas oil to facilitate the separation of mineral oil & soap.
[0012] Yet another object of this invention is to propose a novel method to dispose the waste greases and off specification greases at commercial level by way of using cost effective diluents/gas oil in an equipment having relatively simple design.
[0013] Yet another object of this invention is directed towards the art of converting grease to a useable fuel source.
[0014] Yet another object of this invention is to propose chemical process to ease efficiently extract mineral oil from grease and convert them into a useful energy.
[0015] Further objects and advantages of the invention become more apparent in light of the following detailed description of the preferred embodiments of the invention.
SUMMARY OF THE INVENTION
[0016] The present invention provides a convenient chemical method for disposing of greases by using suitable degrading agent at an optimized process conditions followed by effective separation of soap & mineral oil from used grease. In other words, by this novel method a thick solution of grease in diluents is treated with strong alkali at moderate temperature (60-80° C.). The soap separated from mineral oil in grease is allowed to sediment at the bottom. The soap considered as biodegradable, is disposed as such where as mineral oil containing sizeable amount of diluents could be used as an industrial fuel similar to the existing practices as burning waste oil to produce energy is an inexpensive solution and it does not damage the environment.
DETAILED DESCRIPTION OF THE INVENTION
[0017] Greases are typically prepared by thickening an oil base stock. The greases taken for this invention are oil-based, that is, they comprise oil, which has been thickened with a thickener, also referred to as a thickening agent. Greases are generally distinguished from oils in that they exhibit a yield point (at room temperature or at the temperature of use) while oils do not. That is, below a certain level of applied stress, greases will generally not flow; whereas oils will flow under an arbitrarily small stress, if very slowly. In practice this often means that greases cannot be poured and appear to be a solid or semisolid, while oils can be poured and have the characteristics of a fluid, even if a very viscous fluid. Compositionally, greases are often heterogeneous compositions, comprising a suspension of one material, often a fibrous crystalline material in another. On the other hand, oils are normally more uniform, at least on a macroscopic scale, often comprising an apparently homogeneous solution of materials. Oils often exhibit Newtonian flow behavior; greases do not. In greases, oil is held in grease structure (fibrous material) by molecular and capillary forces. These simple physical phenomenons emphasize the fact that unlike oil, grease is more complex in nature and therefore difficult to separate by conventional methods.
[0018] In traditional grease formulation, thickeners are incorporated into a base oil, typically, an oil of lubricating viscosity in amounts typically from 1 to 30% by weight, more often from 1 to 15% by weight, of the base grease composition. The specific amount of thickener required often depends on the thickener employed. The type and amount of thickener employed is frequently dictated by the desired nature of the grease. The type and amount are also dictated by the desired consistency, which is a measure of the degree to which the grease resists deformation under application of force. Consistency is usually indicated by the ASTM Cone penetration test, ASTM D-217 or ASTM D-1403. Types and amounts of thickeners to employ are well known to those skilled in the grease art and are further described in the NLGI Lubricating Grease Guide.
[0019] To achieve the said objects, the present invention provides a viable chemical process for disposing lubricating grease. The scale of experiment varies from 0.5 Kg to 6.0 Kg. In the first phase, the experiments were done in laboratory scale, say 0.5 to 2 Kg and later in the second phase, experiments on selected compositions were done in the pilot scale, say 4 to 6 Kg. The chemical process comprises of the following steps.
i. Taking known quantity of grease & diluents in a appropriate container equipped with heating and strong agitating device ii. Heating the diluted grease to about 40-90° C. iii. Adding slowly required quantity of degrading agent with mixing iv. Holding the temperature of the mixture at 60-80° C. for about 2-3 hrs with continuous agitation v. Cool the mixture to ambient temperature and leave it undisturbed for about 5-8 hrs.
[0025] The mixture is heated in step (i) up to 70-80° C. The amount of diluents used in this process is 3 times more than the total quantity of used grease taken for disposal. The amount of degrading agent (10-20% aqueous alkali solution) used in this process is equal to the quantity of used grease. The process temperature and concentration of degrading agent may vary slightly with the respect to the amount of thickener present in the grease. It can be observed that proper agitation facilitates the mixing of diluents in grease and helps in reducing process temperature. It is found that the presence of bituminous material/fillers in the grease hinders the separation of soap from base oil. The diluents are mineral spirit, ethyl acetate, acetonitrile, toluene, kerosene, diesel or light diesel oil or combinations thereof. The degrading agent is either aqueous solution of alkali carbonates, bicarbonates & hydroxides or glacial acetic acid or perchloric acid. The soap deposited at the bottom is separated from diluents can be disposed as such after diluting with water where as the diluents, containing the mineral oil. The mineral oil so obtained can be used as an industrial fuel as all the greases generally contains mineral oils/synthetic oils as base oil in the consideration of 70-90%.
[0026] The following examples are given as non-limitative illustrations of aspects of the present invention.
EXAMPLE 1
[0027] To a 5 L steel container equipped with agitating (high torque stirrer) and heating devices, is charged with 0.5 Kg of Li soap based grease. To the container is added 2.5 L of hexane or petroleum ether (40-60° C. fraction). The mixture is added 0.5 L of 10% aqueous NaOH solution. The mixture is heated slowly to 50-60° C. for 2-3 hrs with continuous agitation. Thereafter the mixture is allowed to cool and left undisturbed for at least 3 hrs. A clear separation of oil layer (top) and aqueous alkali layer (bottom) is obtained. Analysis of top portion reveals that base oil & soluble additives are present in major amount and it has the characteristics of furnace oil/Light Diesel oil (Table-1). Bottom layer contains soap, water & alkali, which may be washed once with aliquot amount of hexane to remove residual oil, dried and diluted further with water to make it readily disposable.
[0000]
TABLE 1
Comparative test data of organic layer (top portion)
S.
Test
Furnace
Light
Organic
No
Property
Method
oil
diesel oil
layer
1
Acidity, inorganic
P:2
NIL
NIL
NIL
mg, KOH/gm
2
Ash, % wt
P:4
0.1
0.02
0.02
3
Flash Point, C.
P:21
66
66
63
(PMCC)
4
KV at 50 deg C.,
P:25
80/125/180/
2.5–15.7
30–40
cSt
370
5
Sediments, % wt
P:30
0.25
0.10
NIL
6
Sulphur, total % wt
XRF
8.5–14.5
1.8
—
7
Water, % vol, max
P:40
1.0
0.25
0.20
EXAMPLE 2
[0028] Example 1 is substantially repeated except that Li complex soap based grease is used in place of Li soap grease and aqueous KOH solution in place of NaOH solution. Up on cooling the final mixture, a distinct oil layer (top) and aqueous alkali layer (bottom) is obtained. Analysis of organic layer (top portion) is found to have physico-chemical characteristics similar to that of furnace oil/light diesel oil as given in Table-2.
[0000]
TABLE 2
Comparative test data of organic layer (top portion)
S.
Test
Furnace
Light
Organic
No
Property
Method
oil
diesel oil
layer
1
Acidity, inorganic
P:2
NIL
NIL
NIL
mg, KOH/gm
2
Ash, % wt
P:4
0.1
0.02
0.05
3
Flash Point, C.
P:21
66
66
65
(PMCC)
4
KV at 50 deg C.,
P:25
80/125/180/
2.5–15.7
30–40
cSt
370
5
Sediments, % wt
P:30
0.25
0.10
NIL
6
Sulphur, total % wt
XRF
8.5–14.5
1.8
—
7
Water, % vol, max
P:40
1.0
0.25
0.30
EXAMPLE 3
[0029] To a 5 L steel container equipped with agitating and heating devices, is charged with 0.5 Kg of Li soap based grease. To the container is added 2.5 L of hexane or petroleum ether (40-60° C. fraction). The mixture is added 100 g of glacial acetic acid. The mixture is heated slowly to 60-70° C. for 3-5 hrs with continuous agitation. Thereafter the mixture is allowed to cool and left undisturbed for at least 5 hrs. The mixture separated to give oil layer at the top and slurry at the bottom. There is no complete separation as significant amount of oil & diluent found to present in the slurry.
EXAMPLE 4
[0030] To a 5 L steel container equipped with agitating and heating devices, is charged with 0.5 Kg of Li soap based grease. To the container is added 2.5 L of mixture of hexane & kerosene (1:4 ratio). The mixture is added 0.5 L of 10% aqueous NaOH solution. The mixture is heated slowly to 60-70° C. for 3-5 hrs with continuous agitation. Thereafter the mixture is allowed to cool and left undisturbed for at least 8 hrs. A clear separation of oil layer (top) and aqueous alkali layer (bottom) is obtained, which then processed as described in Example 1.
EXAMPLE 5
[0031] To a 15 Kg grease kettle equipped with strong agitating & heating devices is charged with 2 Kg of grease (either Li or Li complex soap based). To the kettle is added 6 Kg of Diesel. The mixture is agitated vigorously for an hour. To the mixture is added 2 Kg of 20% aqueous NaOH solution and thereafter the mixture is heated slowly to 60-70° C. for 3-5 hrs with continuous agitation. After cooling down the mixture to ambient temperature, it is kept undisturbed for at least 5 hrs. A clear separation of oil layer (top) and aqueous alkali layer (bottom) is obtained. Analysis of top portion reveals that base oil & soluble additives are present in major amount and it has the characteristics of furnace oil/Light Diesel oil (Table-3). Bottom layer contains soap, water & alkali, which may be washed once with aliquot amount of mineral spirit to remove residual oil, dried and diluted further with water to make it readily disposable.
[0000]
TABLE 3
Comparative test data of organic layer (top portion)
S.
Test
Furnace
Light
Organic
No
Property
Method
oil
diesel oil
layer
1
Acidity, inorganic
P:2
NIL
NIL
NIL
mg, KOH/gm
2
Ash, % wt
P:4
0.1
0.02
0.06
3
Flash Point, C.
P:21
66
66
70
(PMCC)
4
KV at 50 deg C.,
P:25
80/125/180/
2.5–15.7
30–40
cSt
370
5
Sediments, % wt
P:30
0.25
0.10
0.07
6
Sulphur, total % wt
XRF
8.5–14.5
1.8
—
7
Water, % vol, max
P:40
1.0
0.25
0.30
EXAMPLE 6
[0032] To a 15 Kg kettle is charged with 2 Kg of grease (Li or Li complex soap). To the kettle is added 6 Kg of Light Diesel Oil and the mixture is agitated vigorously for an hour. To the mixture is added 2 Kg of 20% aqueous NaOH solution and thereafter the mixture is heated slowly to 50-60° C. for 3 hrs with continuous agitation. After cooling the mixture to ambient temperature, it is left undisturbed for about 8 hrs. A clear separation of oil layer (top) and aqueous alkali layer (bottom) is obtained. As described in Example 5 both top and bottom portions are collected separately and analyzed. Top portion may be washed once with water to remove residual alkali/alkali salt and then the mixture may be treated as a source for energy. The bottom portion which is biodegradable may be disposed as such after diluting with copious amount of water.
EXAMPLE 7
[0033] To a 15 Kg kettle is charged with 2 Kg of Li—Ca mixed soap based grease. To the kettle is added 6 Kg of Diesel and the mixture is agitated vigorously for 1-2 hrs. To the mixture is added 2 Kg of 20% aqueous NaOH solution and thereafter the mixture is heated slowly to 70-80° C. for 5 hrs with continuous agitation. After cooling the mixture to ambient temperature, it is left undisturbed for about 8 hrs. A clear separation of oil layer (top) and aqueous alkali layer (bottom) is obtained. Analysis of top portion reveals that base oil & soluble additives are present in major amount and it has the characteristics of furnace oil/Light Diesel oil (Table-4). Bottom layer contains soap, water & alkali, which may be washed once with aliquot amount of mineral spirit to remove residual oil, dried and diluted further with water to make it readily disposable.
[0000]
TABLE 4
Comparative test data of organic layer (top portion)
S.
Test
Furnace
Light
Organic
No
Property
Method
oil
diesel oil
layer
1
Acidity, inorganic
P:2
NIL
NIL
NIL
mg, KOH/gm
2
Ash, % wt
P:4
0.1
0.02
0.05
3
Flash Point, C.
P:21
66
66
66
(PMCC)
4
KV at 50 deg C.,
P:25
80/125/180/
2.5–15.7
40
cSt
370
5
Sediments, % wt
P:30
0.25
0.10
0.10
6
Sulphur, total % wt
XRF
8.5–14.5
1.8
—
7
Water, % vol, max
P:40
1.0
0.25
0.35
EXAMPLE 8
[0034] In the examples 1-7 mentioned above, the distinct oil layer (top portion) obtained upon cooling the final mixture can be distilled to get the respective diluent, which can be used further and the distillate (used oil) thus collected may possibly either dispose by following the existing practices for the disposal of used lubricating oils or by reclamation/recycling technique. The bottom portion that contains soap, water & alkali, may be washed once with aliquot amount of mineral spirit to remove any residual oil, dried and since it is in strong alkaline medium, it may be diluted further with profuse amount of water to make it readily disposable.
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A novel chemical process has been developed for the first time for the disposal of greases and manufacture of industrial fuels therefrom. Details of the method for disposing by the new chemical approach have been described. The “degrading agent” used in this method ruptures soap matrices and helps the separation of soap and base oil. The solution derived from the research work is waste-to-energy process and can be used as cost effective fuel for industrial purpose.
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BACKGROUND OF THE INVENTION
(1) Field of the Invention
The present invention relates to hinges for furniture or the like which including a damping mechanism for damping a movement of a movable furniture part on a piece of furniture.
(2) Description of Related Art
A damping device of the general kind set forth is known for example from WO 2009/140706 A1 to the present applicant, wherein the damping function of the damping device can be deactivated when not in use by way of a switch member to be displaced manually. In that document in the state of the art, in accordance with a variant, the cylinder of the linear damper is arrested by way of the switch member so that the piston can perform a relative movement with respect to the stationary cylinder in the damping stroke, whereby a damping action is also generated. To deactivate the damping function, the switch member is displaced, whereby the cylinder is unlocked. If now the damper is acted upon by force the cylinder will move within the damper housing, but in that case also no damping action is generated in the absence of the relative movement between cylinder and piston. A disadvantage in that case is that the structural space occupied by the damper has to be of relatively large size because of the displaceable cylinder.
BRIEF SUMMARY OF THE INVENTION
Therefore the object of the present invention is to provide a damping device of the general kind set forth in the opening part of this specification, avoiding the above-mentioned disadvantage.
The present invention concerns a damping device for damping a movement of a movably mounted furniture part or a movably mounted furniture fitment component of a furniture fitment, comprising a piston arranged in a fluid chamber, wherein a damping action is produced by a relative movement between the fluid chamber and the piston and wherein the piston assumes a pressed-in end position at the end of the damping stroke relative to the fluid chamber and wherein the damping device for deactivation of the damping action has a locking device having an arresting element which is to be actuated manually or with the aid of a tool.
In addition the invention relates to a furniture hinge comprising a damping device for damping a closing movement and/or an opening movement of the furniture hinge.
According to the invention therefore it is provided that the relative position between the fluid chamber and the piston can be releasably arrested in the pressed-in end position by the arresting element of the locking device—that is to be actuated manually and/or with a tool.
In that way it is therefore possible for the damping device to be releasably arrested in the condition of being completely moved in (that is to say when the piston is in or close to the end region of the fluid chamber), in which case the deactivated or compressed damping device can assume a very compact and space-saving position. An advantage here is that the deactivated damping device can remain in its mounting position, wherein a movable furniture part or a movably mounted furniture fitment component cannot act on the retracted damper.
The proposed damping device can be used in particular in connection with furniture hinges which have a hinge cup. The hinge cup can be sunk in known manner in a—preferably circular—standard bore in an article of furniture. In that case the damping device can be arranged in the mounting position within the cavity in the hinge cup, wherein the damping device can be acted upon from a predetermined relative position of the furniture hinge, by a hinge lever, which can move into the hinge cup, of the furniture hinge. By virtue of its compact deactivation position the damping device can remain in the hinge cup and can also not be acted upon by the hinge lever in that deactivated operative position. The closing movement and/or the opening movement of the furniture hinge therefore take place in undamped fashion. The damping function can be activated again by displacement of the arresting element, by the arresting action on the piston which is moved completely into the fluid chamber being released again. The damping device can then be moved again back into a readiness position provided for the next damping stroke, for example by means of a return spring.
In an embodiment of the invention it can be provided that the piston is arranged stationarily in the mounting position and the fluid chamber is mounted displaceably in the damping stroke relative to the stationary piston. That structure has the advantage that a housing accommodating the fluid chamber can also be used as a slider for applying force. It will be appreciated that, as a mechanical reversal, it is also possible for the fluid chamber to be arranged stationarily in the mounting position and for the piston to be mounted displaceably in the damping stroke relative to the stationary fluid chamber.
In a preferred embodiment of the invention it can be provided that the arresting element is in the form of a linearly displaceable switch having at least two switch positions, wherein the damping action of the damping device is activated in a first switch position and the damping action of the damping device is deactivated in a second switch position. In this connection it may be advantageous if the direction of the movement between the first switch position and the second switch position of the switch extends transversely relative to the direction of the damping stroke, preferably substantially at a right angle. In that way the switch can be displaced transversely relative to the longitudinal direction of the piston rod without the movement of the switch leading to a relative movement between cylinder and piston. If the damping device is fitted in a hinge cup of a furniture hinge the switch can then be displaced without the damping device being able to move out of the mounting position by virtue of the displacement of the switch. A further advantage is the short switching movement of the switch, that is required for activation and deactivation of the damping function.
The fluid chamber can be formed by an internal cavity in a damper housing or the internal cavity in a cylinder. Air, gas or a liquid can be used as the damping fluid. It is also possible to generate a damping action by solid-state friction.
For resetting the damping device to a readiness position for the next damping stroke it may be advantageous if there is provided a return mechanism—preferably having at least one return spring—, by which the piston—also after the arresting action is released—is movable again into an extended end position relative to the fluid chamber.
The furniture hinge according to the invention is characterized by a damping device of the kind described.
In a possible development it can be provided that the furniture hinge has a carcass-side fitting member and a hinge cup hingedly connected thereto for fixing to furniture parts, wherein the damping device in the mounting position is arranged substantially completely within the hinge cup, or wherein the damping device—with the fitting member and the hinge cup already hingedly connected together—can be fitted from above into the hinge cup and can be arranged within the hinge cup, wherein the damping device can be connected to the hinge cup by way of cooperating securing means in said mounting position.
BRIEF DESCRIPTION OF THE DRAWINGS
Further details and advantages of the present invention will be described below with reference to the drawings in which:
FIG. 1 shows a perspective view of an article of furniture having a door mounted pivotably by way of furniture hinges relative to a furniture carcass,
FIGS. 2 a and 2 b show perspective views of a furniture hinge with a damping device which is to be arranged in the hinge cup and a damping device which is arranged in the hinge cup,
FIGS. 3 a - 3 c show the damping device in a perspective view and enlarged views of the arresting element in two different switch positions,
FIGS. 4 a - 4 c show the damping device in an exploded view, an enlarged detail view of the slider and the arresting element in a perspective view from below,
FIGS. 5 a - 5 c show various longitudinal sections of the damping device, showing time successions of the arresting process for deactivation of the damping function,
FIGS. 6 a and 6 b show a furniture hinge with a damping device integrated in the hinge cup and an enlarged detail view thereof, and
FIG. 7 shows a perspective sectional view of the damping device with a return mechanism.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a perspective view of an article of furniture 1 , wherein a movable furniture part 3 in the form of a door 3 a is mounted pivotably relative to a furniture carcass 2 by way of two or more furniture hinges 4 . In known manner the furniture hinges 4 have a fitting member 5 to be fixed to a frame 2 a and a hinge cup 6 connected pivotably to the fitting member 5 . Mounted in the internal cavity in the hinge cup 6 is a respective damping device (not visible here), by which a closing movement of the furniture hinge 4 towards the fully closed end position can be damped. Depending on the respective size and weight of the movable furniture part 3 , the damping capacity of the damping devices may not be suitably adapted, that is to say if the damping capacity is excessively strong the movable furniture part 3 can either move into the completely closed position too slowly, or not at all. For that reason the damping action of the damping devices can be completely deactivated by way of a locking device. In that case it may be for example desirable for the damping action of a first furniture hinge 4 to be completely deactivated while a second furniture hinge 4 provides an active damping action which permits a desired damped closing movement of the movable furniture part 3 to the completely closed position.
FIG. 2 a shows a perspective view of a furniture hinge 4 , wherein the hinge cup 6 is connected by way of at least one hinge lever 7 pivotably to the fitting member 5 which is in the form of a hinge arm 5 a . The furniture hinge 4 can be moved into the completely closed position and/or the completely open position by way of a spring device 8 . To damp that spring-assisted movement into the end position or positions, there is provided a damping device 9 having a housing 12 and a slider 13 movable relative thereto. The damping device 9 is either already pre-fitted into the internal cavity 10 in the hinge cup 6 , as from the factory, or alternatively—with the fitting member 5 and the hinge cup 6 fitted in place—it can be inserted from above into the hinge cup 6 in a retrofitting procedure and can be arranged within the hinge cup 6 , in which case the damping device 9 can be releasably connected together in the mounting position by way of cooperating securing means 11 a , 11 b . In the illustrated embodiment the damping device 9 has first securing means 11 a in the form of a guide groove which can be releasably connected to securing means 11 b arranged on the hinge cup 6 , in the form of a securing projection. The damping device 9 has an introduction opening 14 , through which the securing projection 11 b can be arranged in the guide groove 11 a . For deactivation of the damping function the damping device 9 has a locking device 15 with a displaceable arresting element 15 a in the form of a switch, by which the slider 13 can be releasably arrested in the completely pressed-in position.
FIG. 2 b shows a perspective view of the furniture hinge 4 with the damping device 9 in the mounting position. The damping device 9 is arranged completely in the internal cavity 10 in the hinge cup 6 . In the closing movement of the furniture hinge 4 the hinge lever 7 abuts the slider 13 , whereby the damping operation is initiated. In the course of the further closing movement the slider 13 can be pressed relative to the housing 12 into a complete end position, wherein that end position can be releasably arrested by the locking device 15 . The slider 13 can no longer be returned in the arresting position, in which case therefore the damping action is deactivated.
FIG. 3 a shows a perspective view of the damping device 9 . It has a housing 12 and a slider 13 displaceable relative thereto. The damping device 9 is in the form of a linear damper and includes a piston rod 17 connected to the housing 12 . In this embodiment therefore it is provided that the piston rod 17 (and therewith a piston connected to the piston rod 17 ) is arranged stationarily in the mounting position while a fluid chamber provided in the slider 13 moves relative to that stationary piston rod 17 . The slider 13 is in the form of a sliding wedge and has an inclined abutment surface 16 which can be acted upon by the hinge lever 7 ( FIG. 2 b ) as from a predetermined relative position of the furniture hinge 4 . FIG. 3 b shows an enlarged detail view of the arresting element 15 a which in the illustrated embodiment is in the form of a switch with at least two switch positions. In a first switch position ( FIG. 3 b ) the damping action of the damping device 9 is activated while in a second switch position ( FIG. 3 c ) the damping action of the damping device 9 is deactivated.
FIG. 4 a shows an exploded view of the damping device 9 . Provided in the interior of the slider 13 is at least one fluid chamber in which at least one piston (not visible here) with a piston rod 17 is mounted displaceably. It is possible clearly to see the securing means 11 a in the form of guide grooves at both sides, by which the slider 13 is displaceable in the damping stroke relative to the securing projections 11 b of the hinge cup 6 . The securing projection 11 b can be arranged in the guide groove 11 a through the introduction opening 14 . The housing 12 has a mounting 18 , to which the piston rod 17 is to be secured. Arranged on the slider 13 is a first fixing element 19 which can be fixed in the pressed-in end position of the slider 13 relative to a second fixing element 20 arranged on the switch 15 a.
FIG. 4 b shows an enlarged detail view of the slider 13 , on which there is provided a first fixing element 19 in the form of a resilient tongue. FIG. 4 c shows a perspective view from below of the arresting element 15 a in the form of a switch. Arranged at the underside of the arresting element 15 a is a second substantially rigid fixing element 20 , by which the first fixing element 19 of the slider 13 can be fixed in the completely pressed-in end position of the slider 13 .
FIGS. 5 a - 5 c show time successions of the arresting effect for deactivation of the damping action in various cross-sections. It is possible to see in FIG. 5 a the slider 13 in which there is provided a fluid chamber 21 in which there is mounted a piston 22 having a piston rod 17 , which in the illustrated embodiment is arranged stationarily. In the closing movement of the furniture hinge 4 the hinge lever 7 ( FIG. 2 b ) impinges on the inclined abutment surface 16 of the slider 13 , whereupon the slider 13 is displaceable relative to the stationary piston 22 . The damping device 9 can also be deactivated with the slider 13 extended, by firstly the arresting element 15 a which is in the form of the switch being moved into the corresponding deactivation position ( FIG. 5 a ). It is possible to see the fixing element 19 arranged on the slider 13 and the fixing element 20 on the switch 15 a . In the damping stroke firstly the fixing element 19 on the slider 13 abuts the rigid fixing element 20 of the switch 15 a ( FIG. 5 a ), wherein in the deactivation position of the switch 15 a the resilient fixing element 19 is movable beyond the rigid fixing element 20 , in which case the resilient fixing element 19 is bendable against the force of its resilient action and the resilient fixing element 19 can be fixed relative to the rigid fixing element 20 due to a snapping back action ( FIG. 5 c ). In FIG. 5 c therefore the fixing element 19 arranged on the slider 13 is arrested so that the slider 13 cannot be extended again, for example by a return mechanism. The damping action of the damping device 9 is thus deactivated. By moving the switch 15 a into an activation position the fixing element 19 is released again so that the slider 13 can be returned again.
FIG. 6 a shows a cross-section through a furniture hinge 4 with the damping device 9 in the mounting position. The furniture hinge 4 has a fitting member 5 which is in the form of a hinge arm 5 a —and which is preferably L-shaped—and which is connected pivotably by way of a hinge lever 7 to a hinge cup 6 . The hinge lever 7 is mounted pivotably about an axis of rotation 23 at the hinge cup side. FIG. 6 b shows an enlarged detail view of the region circled in FIG. 6 a . Towards the end of the closing movement the hinge lever 7 meets the inclined abutment surface 16 of the slider 13 and displaces it relative to the stationary piston 22 . The damping stroke of the damping device 9 runs substantially at a right angle relative to the axis of rotation 23 . The slider 13 can be arrested by the switch 15 a in the pressed-in end position relative to the housing 12 of the damping device 9 whereby the damping action can be deactivated.
FIG. 7 shows a longitudinal section of the damping device 9 . The piston 22 with the piston rod 17 is mounted within the fluid chamber 21 . It is possible to see a return mechanism 26 which is arranged outside the fluid chamber 21 , in the form of two return springs which are supported on the one hand against abutments 24 of the housing 12 and on the other hand against counterpart abutments 25 of the slider 13 . After the damping stroke has been performed the slider 13 can be returned again by the return mechanism 26 into a readiness position intended for the next damping stroke. It will be appreciated that it is also possible to arrange a return spring in the interior of the fluid chamber 21 , which spring can be supported on the one hand against the end 30 of the fluid chamber 21 and on the other hand against the piston 22 thereby to push the piston 22 into the readiness position again.
The present invention is not limited to the illustrated embodiment but extends to all variants and technical equivalents which can fall within the scope of the accompanying claims. The positional references adopted in the description such as for example up, lateral and so forth are also related to the directly illustrated Figure and are to be appropriately transferred to the new position upon a change in position.
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A damping device for damping a motion of a movably mounted furniture part or of a movably mounted furniture fitting component of a furniture fitting includes a piston arranged in a fluid chamber. A damping effect is caused by a relative motion between the fluid chamber and the piston and the piston assumes a pressed-in end position relative to the fluid chamber at the end of the damping stroke. The damping device has a locking device which has a locking element that can be operated manually or by means of a tool in order to deactivate the damping effect. The relative position between the fluid chamber and the piston can be releasably locked in the pressed-in end position by the locking element of the locking device.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a national phase application of PCT Application No. PCT/EP2009/006252 filed pursuant to 35 U.S.C. §371, which claims priority to DE 10 2008 044 947.4 filed Aug. 29, 2008. Both applications are incorporated by reference herein in their entirety.
TECHNICAL FIELD
[0002] The present invention relates to three variants for producing a mixture of cyclic diesters derived from lactic acid and in particular of a racemate of dilactide. In some embodiments, the process can start from the corresponding α-hydroxycarboxylic acids, the corresponding cyclic diesters or oligomers of the corresponding α-hydroxycarboxylic acids. All 3 variants of the method have in common a racemisation of the chiral carbon atom of the educts.
BACKGROUND
[0003] Polylactic acid is a promising biopolymer having a low thermostability. Were it possible to achieve better thermal properties, the possible applications would increase greatly.
[0004] In order to be able to produce PLLA with optimal thermal properties, (optically) very pure L-lactide (L-LA) is required. Currently, the most used method for producing L-lactide includes a two-stage polycondensation of lactic acid to form an oligomer followed by a depolymerization. Because of the prevailing high temperatures, which are required for a rapid reaction course, and also because of cationic impurities of the lactic acid or of the reaction vessels (e.g. by corrosion), racemisation can occur, as a result of which meso-lactide is produced as by-product. This product must be separated from the main product since meso-lactide (M-LA) has a negative effect on the properties of the polymer produced during the polymerization of L-lactide. The result thereby is a notable reduction in the melting temperature and also in the glass transition temperature as shown in Table 1 below, while the mechanical properties likewise change.
[0000]
TABLE 1
PLLA
PRLA
PMLA (a/s)
sc-PLA
sbc-PLA
Tg ° C.
55-60
50-55
40-45/34
80-90
50-55
Tm ° C.
140-170
—
—/153
210-230
185-195
Tg: glass transition temperature
Tm: melting point
PLLA: L-polylactic acid
PRLA: racemic polylactic acid
PMLA: meso-polylactic acid
a: amorphous
s: syndiotactic
sc: stereocomplex
sbc: stereoblock copolymer
[0005] Meso-lactide, like L-lactide, is a cyclic diester with two optically active carbon atoms in the ring. It has an optical R- and an S-center and is therefore optically inactive. The polymerization of meso-lactide leads to an amorphous polymer. A syndiotactic polymer can be produced using a stereoselective catalyst (Tina M. Quitt and Geoffrey W. Coates, J. Am. Chem. Soc. 1999, 121, 4072-4073), the thermal properties of which are however poorer than those of PLLA.
[0006] Stereocomplexes of polylactic acid (PLA) can resolve the problem of low thermal stability but the optical counterpart of L-polylactic acid (PLLA) is required for the production of stereocomplexes. D-polylactic acid (PDLA) is available only in small quantities and is very expensive.
[0007] Rac-lactide has been obtained to date from equal quantities of D,D- and L,L-lactide by melting. Since D,D-lactide is relatively expensive because of the great complexity for producing D-lactic acid, reuse as a monomer for the polylactic acid production has to date been more of theoretical interest. The properties of D,D-L, L-stereopolymers are thereby of great interest since they have significantly better thermostabilities and hence could eliminate one of the disadvantages of polylactic acid.
[0008] Dilactides that are composed of the enantiomers of lactic acid are already known. WO 1984/04311 A1 describes a method for the production of a polymer from caprolactone and lactide that is used for the production of everyday objects in medicine and care technology. The dilactide is commercially available and is predominantly composed of the two enantiomers of lactic acid, L-(−)- and D-(+)-lactic acid. This mixture is frequently associated with dilactide and includes the same enantiomers of lactic acid, namely D-lactic acid or L-lactic acid. No allusion to the production of these dilactides composed of the same enantiomers is given.
[0009] The polymerization of a mixture of meso-lactide and L-lactide leads to a copolymer, the thermal properties of which are inferior to those of PLLA. Meso-lactide can also be used in the production of racemic lactic acid (D/L-LA) by hydrolysis with water. However, these applications are only of subordinate interest from a commercial point of view so that an increase in the economic value is sought.
SUMMARY
[0010] In some embodiments, the present invention is directed to a method that enables the production of a mixture of the cyclic diesters of the general Formulae Ia, Ib and/or Ic
[0000]
[0011] In some embodiments, a mixture of the cyclic diesters of the general Formula Ia, Ib and Ic can be produced from one of:
a) an α-hydroxycarboxylic acid of Formula IIa and/or IIb
[0000]
b) a substantially or completely stereoisomer-pure compound of Formula Ia, Ib or Ic or a mixture of two or three of the compounds, or
c) an oligomeric or polymeric hydroxycarboxylic acid of the general Formula III
[0000]
[0000] wherein respectively in the compounds of Formulae I, II and III, R stands for a linear or branched aliphatic alkyl radical with 1 to 6 C-atoms and n=1 to 50 is meant in Formula III. The starting material is converted with a catalyst or a mixture of at least two catalysts.
[0015] In some embodiments, an equimolar mixture of the two enantiomers of the dilactide of lactic acid, D,D-dilactide and L,L-dilactide can be produced via the following steps:
a) (−)-form L-(−)-lactic acid is converted with trioctylamine into trioctyl ammonium lactate, b) the trioctyl ammonium lactate is distilled in the presence of a catalyst, a fraction being obtained which is composed essentially of the two enantiomers of the dilactide of lactic acid, D,D-dilactide and L,L-dilactide and can still contain D,L-lactide, and c) the above-mentioned fraction is mixed with acetone and hence recrystallized to obtain colorless crystals having a melting point of 112 to 119° C. The colorless crystals are composed substantially equimolarly or equimolarly of D,D-dilactide and L,L-dilactide.
[0019] In some embodiments, a mixture of the cyclic diesters can be used to produce amorphous polylactides. In some embodiments, the mixture can be used to produce stereocomplex polylactice acid and/or stereoblock copolymers of lactic acid.
BRIEF DESCRIPTION OF THE FIGURES
[0020] FIG. 1 illustrates a method in accordance with an embodiment of the invention.
[0021] FIG. 2 illustrates a method in accordance with an embodiment of the invention.
[0022] FIG. 3 illustrates a method in accordance with an embodiment of the invention.
[0023] FIG. 4 illustrates a method in accordance with an embodiment of the invention.
DETAILED DESCRIPTION
[0024] In some embodiments, a mixture of the compounds of Formulae Ia, Ib and/or Ic (below) can be produced:
[0000]
[0025] In some embodiments, an α-hydroxycarboxylic acid of Formula IIa and/or IIb
[0000]
[0000] (respectively in the compounds of Formulae I and II, R standing for a linear or branched aliphatic alkyl radical with 1 to 6 C-atoms) is converted with a catalyst or a mixture of at least two catalysts.
[0026] In some embodiments, the production of the mixture of compounds Ia, Ib and/or Ic, starts from an α-hydroxycarboxylic acid of Formulae IIa and/or IIb that is converted in the presence of a plurality of catalysts. Both respectively the compounds IIa and IIb can thereby be used as substantially or completely enantiomer-pure compounds, the process can also start however from a mixture of the two enantiomer-pure compounds in any stoichiometric ratio. There is understood by “substantially enantiomer-pure” a mixture of compounds IIa and IIb with an enantiomer excess (ee) of more than 99%. ee.
[0027] In some embodiments, production of the above-mentioned mixture of compounds Ia, Ib and/or Ic, a substantially or completely stereoisomer-pure compound of Formulae Ia, Ib or Ic or also mixtures of Ia, Ib and Ic is converted with a catalyst or a mixture of at least two catalysts. There is thereby understood by “substantially stereoisomer-pure” the mixture of compounds Ia, Ib and/or Ic, in which one of the mentioned compounds is present in an excess with respect to the sum of the two other compounds of at least 99%. In this embodiment, the process starts with a single compound of Formulae Ia, Ib or Ic, a conversion of the stereocenters of the cyclic diesters that are used taking place in the course of the process. If the process starts with a mixture of compounds Ia, Ib and/or Ic, a mixture of these compounds is obtained again but with a changed composition.
[0028] In some embodiments, the mixture of compounds Ia, Ib and/or Ic, can be produced by converting with a catalyst or a mixture of at least two catalysts an oligomeric or polymeric hydroxycarboxylic acid of the general Formula III
[0000]
[0000] (n=1 to 50 being meant in Formula III).
[0029] In some embodiments, an oligomeric or polymeric hydroxycarboxylic acid of Formula III is depolymerized. In some embodiments, all possible stereoisomers can be used for the hydroxycarboxylic acid of Formula III. This is indicated in Formula III by the tortuous bond of the radical R. The absolute configuration of the respective stereocenter (R or S) is thereby irrelevant.
[0030] In some embodiments, the catalyst can be chosen for all of the three above-mentioned variants of the method according to the invention from the group consisting of metal compounds of groups 1 to 14 of the periodic table. In some embodiments, the catalyst may be a metallic salt, an organometallic compound, an alkoxide, an oxide or a salt of an organic acid. In some embodiments, the catalyst may be metallic salts and/or organometallic compounds of Na, K, Mg, Ca, Fe, Ti, Zn, Sn or Sb. In some embodiments, the catalyst may be oxides, hydroxides, carbonates, benzoates, lactates or octoates of Na, K, Mg, Ca, Fe, Ti, Zn, Sn or Sb. In some embodiments, the catalyst may be MgO, CaO, K 2 CO 3 , sodium lactate, potassium benzoate, tin octoate SnOc 2 , dibutyltin oxide Bu 2 SnO, BuSnOc 3 or SnO.
[0031] In some embodiments, the catalyst may be nitrogen-containing or phosphorus-containing organic compounds. In some embodiments, the catalyst is a primary, secondary and/or tertiary amine and/or an aliphatic, aromatic N-heterocyclic compound with 5-7 ring atoms or a phosphines. In some embodiments, the catalyst may be a primary, secondary and/or tertiary amine with 1 to 20 C-atoms. In some embodiments, the catalyst may be triethylamine, ethyldiisopropylamine, dibutylamine, tributylamine, trioctylamine, dicyclohexylamine, 4-(N,N-dimethyl)-aminopyridine, 2,2,6,6-tetramethylpiperidine, 1,2,2,6,6-pentamethylpiperidine and/or tributylphosphine.
[0032] In some embodiments, the catalysts may be considered as being polymerization catalysts, racemization catalysts or steroselective catalysts.
Polymerization Catalysts
[0033] A large number of compounds are known as polymerization catalysts for PLA. They are frequently metallic- or organometallic salts, such as alkoxides, oxides, salts of organic acids etc. Tin octoate is most often used. Furthermore, also other tin compounds, such as e.g. butyl tin octoate, dibutyl tin oxide, SnO or also tin are used. Also the use of compounds of Ti, Fe, Zn, Sb etc. is possible.
Racemization Catalysts
[0034] Racemization catalysts that are used for the racemization of lactides should be weakly alkaline compounds and effect no ring-opening polymerisation (ROP). There are three compound classes of racemization catalysts:
a) Group 1a and 2a metal oxides, carbonates, hydroxides or salts of organic acids, such as e.g. sodium lactate, potassium benzoate, K 2 CO 3 , MgO, CaO etc. b) Amines, primary, secondary or tertiary amines with a boiling or melting point which is high enough that the compound remains in the reaction. Examples include secondary or tertiary amines, such as e.g. triethylamine (TEA), tributylamine (TBA), trioctylamine (TOA), dibutylamine (DBA), di-cyclohexylamine (DCHA), dimethylaminopyridine (DMAP) etc. c) Primary, secondary or tertiary phosphines.
[0038] For all the volatile catalysts mentioned here, it applies that the boiling point must be high enough that the compound remains in the reaction.
[0039] In some embodiments, in selecting a racemization catalyst, care must be taken that the catalyst catalyzes only a racemization and no ring-opening of the lactide. These two conflicting reactions depend upon the chemical and steric structure of the catalyst. A ring-opening makes the separation of a lactide mixture after the racemization more difficult and lowers the yield. The purity of the racemic lactide mixture after the separation is important for a stereoselective catalysis for producing sc-PLA and sbc-PLA.
[0040] In some embodiments, secondary and tertiary amines and phosphines are selected as catalysts because of steric hindrance of the active center. In some embodiments, the catalysts are voluminous organic radicals, such as e.g. the cyclohexyl group in DCHA.
[0041] The ring-opening is hindered by them and their weak alkaline activity is sufficient for the racemization. However, it applies for all the mentioned catalysts that they lose their selectivity with high temperatures or long reaction times.
Stereoselective Catalysts
[0042] Stereoselective catalysts (Spassky et al., Macromol. Chem. Phys. (1996), 197, 2672; Ovitt and Coates, J. Am. Chem. Soc., (2002), 124, 1316; Radano and Baker, J. Am. Chem. Soc., (2000), 122, 1552) are very specific polymerization catalysts that have a chiral center. They catalyze exclusively the polymerization reaction of specific isomers. Different types are differentiated here. One class of these catalysts can catalyze only the reaction of the isomer (L,L/D,D-lactide+ssc→PLLA+D,D-lactide), whereas another type with two active centers can polymerize two isomers at the same time (L,L/D,D-lactide+ssc→PLLA+PDLA=sc-PLA). Catalysts are also known which can polymerize L- or D-lactide alternately (L,L/D,D-lactide+ssc→(PLLA-co-PDLA) n =sbc-PLA).
[0043] Furthermore, in some embodiments, it is advantageous respectively with the above-mentioned variants of the method according to the invention if the catalyst, with respect to the respective educts of the different variants, i.e. the α-hydroxycarboxylic acid of Formula IIa and/or IIb, of substantially stereoisomer-pure or stereoisomer-pure compound of Formula Ia, Ib or Ic or a mixture of two or three of the compounds, or of the oligomeric or polymeric hydroxycarboxylic acid of the general Formula III, is used in a weight ratio between 1:1 and 1:10,000. In some embodiments, the weight ratio is between 1:10 and 1:5,000. In some embodiments, the weight ratio is between 1:100 and 1:1,000.
[0044] Surprisingly, it was able to be established that in some embodiments, the molar ratio of the compounds of Formula Ia and Ib, obtained in the method, is between 1:2 and 2:1. In some embodiments, the molar ratio is between 1:1.2 and 1.2:1. In some embodiments, the molar ratio is about 1:1.
[0045] Furthermore, it was found surprisingly that in some embodiments, the molar ratio of the sum of the compounds of Formula Ia and Ib, obtained in the method, to the compound of Formula Ic
[0000] (Ia+Ib)/Ic
[0000] is between 10:1 and 1:1. In some embodiments, the molar ratio of the sum is between 10:1 and 2:1.
[0046] In some embodiments, the conversion is implemented at temperatures between 80 and 300° C. In some embodiments, the conversion takes place between 100 and 200° C. In some embodiments, the conversion takes place between 120 and 160° C.
[0047] In some embodiments, the conversion is implemented over a time period between 1 min and 48 hours. In some embodiments, the conversion is implemented over a time period between 0.5 and 4 hours.
[0048] In some embodiments, subsequent to or at the same time during the conversion, at least one purification step of the mixture of compounds of Formulae Ia, Ib and/or Ic, obtained by the conversion, follows or is implemented, the ratio of the sum of the compounds of Formula Ia and Ib to the compound of Formula Ic
[0000] (Ia+Ib)/Ic
[0000] being increased to at least 10:1. In some embodiments, the ratio is increased to at least 100:1. In some embodiments, the ratio is increased to at least 1,000:1. In some embodiments, the compound of Formula Ic is substantially completely or completely removed. There is thereby understood by “substantially complete removal” a reduction in the content of compound Ic to concentrations in the 0/00 range.
[0049] In some embodiments, production of a mixture that only includes the compounds of Formulae Ia and Ib is hence made possible. In some embodiments, this mixture is a racemate, i.e. an equimolar mixture of compounds Ia and Ib which is termed racemic lactide.
[0050] In some embodiments, the previously mentioned purification step is thereby selected from the group consisting of filtration, washing, distillation, crystallization and/or recrystallization of the mixture of the compounds of Formula Ia, Ib and/or Ic, and also combinations of the mentioned purification steps. Combinations can thereby be implementation of the previously mentioned purification methods, following each other in succession or at the same time. For example, filtration or washing of the mixture obtained during the conversion are possible for this purpose, followed by a distillation or a crystallization; however, for example a distillation followed by a crystallization is likewise possible.
[0051] The crystallization and/or recrystallization can be implemented from the melt or from solvents. In some embodiments, the solvent may be selected from the group of alcohols, esters, ketones, hydrocarbons etc., e.g. acetone, iso-propanol, ethylacetate, toluene and/or combinations hereof. In some embodiments, the crude obtained product from Ia, Ib and Ic is purified by recrystallization from the melt, Ia and Ib being crystallized out as pure product.
[0000]
TABLE 2
Melting temperatures of the lactides
L,L-lact.
D,D-lact.
M-lact.
L,L/D,D-lact.
Tm ° C.
97
97
54
129
[0052] After separating the melt that remains during the crystallization and contains compound Ic possibly in the mixture with Ia and/or Ib, the latter can be returned to the reaction stage. In this way, e.g. complete conversion of Ic can be transformed into an equimolar mixture of Ia and Ib.
[0053] In some embodiments, a substantially enantiomer-pure or enantiomer-pure compound of Formula IIa or IIb can be used according to variant 1).
[0054] In some embodiments, the method according to the invention relates to the production of an equimolar mixture of the two enantiomers of the dilactide of lactic acid, D,D-dilactide and L,L-dilactide, in which
a) (−)-form L-(−)-lactic acid is converted with trioctylamine into trioctyl ammonium lactate, b) the trioctyl ammonium lactate is distilled in the presence of a catalyst, a fraction being obtained which is composed essentially of the two enantiomers of the dilactide of lactic acid, D,D-dilactide and L,L-dilactide and can still contain D,L-lactide, c) the above-mentioned fraction being mixed with acetone and hence recrystallized, and colorless crystals being obtained with a melting point of 112 to 119° C. which are composed substantially equimolarly or equimolarly of D,D-dilactide and L,L-dilactide.
[0058] According to some embodiments of the invention, the production of a racemate of L,L-dilactide and D,D-dilactide is hence made possible. The conversion (reaction with the catalyst) and the first purification step (distillation) thereby take place simultaneously.
[0059] Possibilities for use according to the invention of the mixture produced according to the method according to the invention are for example the subsequent (e.g. directly after the method according to the invention) production of amorphous polylactides and in particular the production of stereocomplex polylactic acid and/or stereoblock copolymers of lactic acid with stereoselective catalysts.
[0060] In some embodiments, the invention relates to a method for producing an equimolar mixture of D,D-dilactide and L,L-dilactide, the process for the production of these substances starting with L-(−)-lactic acid which is converted with trioctylamine into trioctyl ammonium lactate which is subjected to distillative resolution (in the sense of a condensation of two lactic acid units with racemization), a distillate being obtained which is recrystallized from acetone and thus the dilactide according to the invention is obtained.
[0061] It was now found that the dilactide mixture that includes in equal parts D,D-dilactide and L,L-dilactide can be produced simply if the distillate which is obtained from the thermolysis of the ammonium lactate is subjected to recrystallization. The thus obtained dilactide mixture has substantial advantages in the production of polymers from lactic acid which have improved physical properties.
[0062] In order to produce this dilactide, the process starts with L-lactic acid which is converted with trioctylamine into trioctyl ammonium lactate. In some embodiments, tri-n-octylamine is used as trioctylamine. Trioctyl ammonium lactate is thereby formed, which is subjected to distillative resolution (in the sense of a condensation of two lactic acid units with racemization). During the distillative resolution, a mixture that includes lactic acid and trioctylamine is obtained. A further fraction includes dilactide that is distilled over firstly to be water-white and then increasingly yellow. The distillative resolution (in the sense of a condensation of two lactic acid units with racemization) takes place in the presence of a catalyst. The fraction from the distillative resolution, which predominantly includes dilactide, is recrystallized after chilling. In some embodiments, acetone is used as solvent. Colorless crystals which have a melting point of 112° C. to 119° C. are thereby obtained.
[0063] The obtained crystals were subjected to analysis by gas chromatography using a chiral separation column. During the analysis, two equal area signal peaks were observed that could be assigned to D,D-dilactide and L,L-dilactide. The stereochemical configuration of the dilactides was confirmed by an enzymatic hydrolysis of the dilactides, in which a mixture composed with the same mass of lactic acid of respectively one stereochemical configuration was obtained. In the unpurified distillate, a further, significantly weaker signal which was assigned to the meso-lactide (dimer of D- and L-lactic acid) is observed during the hydrolysis in the process of the gas-chromatographic analysis.
[0064] In some embodiment, a method is described for producing an equimolar mixture of the two enantiomers of the dilactide of lactic acid, the one enantiomeric dilactide termed D,D-dilactide being formed from two (+)-form enantiomers of lactic acid and the other enantiomeric dilactide termed L,L-dilactide being formed from two (−)-form enantiomers of lactic acid, wherein
trioctyl ammonium lactate is produced firstly from (−)-form L-(−)-lactic acid and trioctylamine, the thus obtained trioctyl ammonium lactate is subjected to distillative resolution (a mixture of trioctylamine and lactic acid being distilled over) and the distillative resolution of the trioctyl ammonium lactate is implemented in the presence of a catalyst, and a further fraction which is composed to a predominant proportion of the dilactide of lactic acid and which can still contain D,L-dilactide is obtained, and this fraction is mixed with acetone and hence recrystallized so that colorless crystals with a melting point of 112 to 119° C. which are composed equimolarly of D,D-dilactide and L,L-dilactide are obtained.
[0070] The formation of the enantiomer-similar dilactides from enantiomer-pure lactic acid as starting material can be explained in that the content of trioctylamine during the distillation effects a racemization of the lactic acid which then forms a racemic trioctyl ammonium lactate which after the distillative resolution, in some embodiments crystallizes to form enantiomer-like dilactide. The starting material had an enantiomer purity of approx. 1 percent by mass of D-lactic acid.
[0071] In some embodiments, a method is described in which a mixture is formed, which mixture is composed, in respectively equal parts, of 40 to 50 percent by mass of D,D-dilactide and L,L-dilactide and which contains as remaining component for example meso-lactide (D,L-dilactide). According to the production, the remaining constituent amount can also include oligolactides or further products of the distillative resolution.
[0072] In some embodiments, the distillative resolution of the trioctylammonium lactate is implemented in the presence of a catalyst. Organotin compounds are particularly suitable for this purpose. By way of example, dibutyltin oxide is used as catalyst in a quantity of 0.1 to 1 percent by mass, relative to the mixture in the distillation sump during the distillative resolution. According to the desired purity and yield of the dilactide, the distillatve resolution is implemented in the presence of a distillation column. When using a distillation column, it is advantageous to implement the distillation in a vacuum (e.g. 20 mbar).
[0073] During the distillative resolution, a precursor that includes lactic acid and trioctylamine of an unknown composition is obtained. This corresponds to a constituent amount of 30 to 35 percent by mass of the starting quantity of trioctyl ammonium lactate. This proportion is dependent upon the evaporator temperature. Amine contents of 15 percent by mass (140° C.) to 25 percent by mass (165° C.) were measured in the distillate. Obviously, in addition to the lactic acid and amine, also certain constituent amounts of oligolactides are still contained in the distillate. The remaining constituent amount is distilled over as dilactide. In the distillation sump, approx. 2 to 3 percent by mass of a dark brown liquid remain.
[0074] In some embodiments, a dilactide of lactic acid is characterized in that it concerns a mixture which is composed respectively in equal parts of 50 percent by mass of D,D-dilactide and L,L-dilactide and which is produced with the method according to the invention. According to the production process, the mixture can also contain impurities. Therefore, a dilactide of lactic acid may include a mixture of D,D-dilactide and L,L-dilactide and further components, said mixture being produced with the method according to the invention.
[0075] The embodiment of the method according to the invention is explained by a general production diagram and experimental examples, these examples representing only typical embodiments.
General Production Diagram
[0076] In some embodiments, during the production of lactide, a racemization is effected and, in addition to the desired R-LA, M-LA is formed. The racemization takes place on the lactide molecule. The proton on the asymmetrical carbon atom is sensitive to weakly alkaline compounds and is removed in an equilibrium reaction. By replacing the proton, the stereogenic centre can be changed and a different steric configuration can be formed. This is shown below:
[0000]
[0077] For direct production of rac-lactide, the process starts with L-, D- or D,L-lactic acid. After dewatering of the lactic acid, a tin compound is added as catalyst, as was already described, and also a weakly alkaline compound and then the distillation is started. Both an rac-lactide and a further compound which was identified as meso-lactide were found.
[0078] In some embodiments, the process may be represented by:
[0000] Diagram A: LAC→PLA→LA
LAC=lactic acid PLA=polylactic acid LA=lactide
[0082] In some embodiments, the process may be represented by:
[0000]
[0083] As next step, a reaction with a PLA with a low molecular weight and the above-mentioned catalysts was implemented. Here also, an identical reaction product was obtained, i.e. a mixture of rac-lactide and meso-lactide, as shown below:
[0000]
[0084] Furthermore, a reaction analogous to L-, D- and meso-lactide was implemented. In each of these reactions, a lactide mixture was obtained as shown below:
[0000]
[0085] This method for the production of rac-lactide in which all possible types of lactic acid or the derivatives thereof are used makes it possible to produce a monomer for the polymerisation of PLA without material loss since the meso-lactide can be used again after separation of rac-lactide during the racemization.
[0086] FIGS. 1 through 3 illustrate methods in accordance with embodiments of the invention. In FIG. 1 , PB represents by-products while Pol represents the polymer. In FIG. 2 , PC represents PLA with a low molecular weight, Dep represents depolymerization and DIST represents distillation. In FIG. 3 , CRYST represents crystallization.
[0087] As shown in FIGS. 1-3 , it is possible to produce sc-PLA or sbc-PLA via stereoselective catalysts, which have a higher thermostability without separate production possibilities being provided for optically pure L-lactide and D-lactide and the polymers PLLA and PDLA thereof which have been required to date to produce stereocomplexes.
Polymer-Production Chain:
[0000]
Previously:
[0000]
New:
[0000]
[0090] FIG. 4 illustrates a polymer chain method in which CON represents the LAC concentrator, RDR2 represents a reactive distillation and racemization reactor, MC represents a melt crystallizer, and POL represents a polymerization reactor.
EXPERIMENTAL
Analysis Methods:
[0091] 1 H-NMR NMR-spectra were recorded with a 500 MHz Varian-Inova spectrometer at a frequency of 499.85 MHz. The samples were measured in an approx. 5% CDCl 3 solution with tetramethylsilane as internal standard
[0092] HPLC Knauer system with a Smartline 1000 pump and a Smartline 2500 UV-Detector. A Eurocel 03 column 5 μm 250×4.6 mm. Solvent hexane:ethanol=90:10 (v:v) 1 ml/min. Sample concentration 1-10 mg/ml.
[0093] GC Perkin-Elmer Clarus 500 with an FID; an FS-CW20M-CB-0.25 column (length=25 m, diameter=0.25 mm, film thickness=0.22 μm) inj. 200° C. temp. prog. 50-200° C., inj. vol.=1.0 μl, gas=nitrogen.
EXAMPLE 1
[0094] In a mixing vessel, trioctylamine and L-lactic acid with an optical purity of 99% L-lactic acid was converted by heating to form trioctyl ammonium lactate. This was placed in a distillation vessel that was equipped with a reducing Liebig cooler and an Anschütz-Thiele distillation adaptor. Furthermore, 1 percent by mass (relative to lactic acid) dibutyltin oxide was placed as catalyst in the recipient vessel.
[0095] Heating to 250° C. then takes place. Firstly, two fractions at 140° C. and 165° C. distillation temperature were obtained, which, according to a gas chromatographical analysis, include 15 percent by mass (140° C.) and 25 percent by mass (165° C.) of amine. Thereafter, a water-white liquid was distilled over and became yellow-colored in the course of the distillation. The liquid was cooled and placed in acetone, out of which colorless crystals of melting point 112° C. to 119° C. were crystallized. The composition thereof was determined by GC analysis and hydrolytic resolution by enzymes as up to respectively 50 percent by mass of D,D-dilactide and L,L-dilactide of lactic acid.
EXAMPLE 2
[0096] A further variant of the above-mentioned method according to the invention provides in particular to racemize substantially enantiomer-pure dilactide or meso-dilactide and also to convert mixtures of L-lactide and/or D-lactide and/or meso-lactide by racemization (variant 2).
[0097] It was found surprisingly that the above-indicated catalysts change pure meso-lactide or mixtures of meso-lactide and L,L-lactide in their composition. After purification and analysis, it was established that racemic lactide was obtained, consequently the catalyst had converted meso-lactide into racemic lactide.
[0098] Racemic lactide can be produced from racemic lactic acid by polycondensation and subsequent depolymerization. On the one hand, the large quantity of meso-lactide which is produced as by-product (40-60%) and the availability and the price of lactic acid racemate is thereby problematic.
[0099] The racemization of meso-lactide into racemic lactide offers a great chance of increasing the value of the meso-lactide since, with available stereoselective catalysts, the production of sc-PLA and/or sbc-PLA is possible. From an economic point of view, these products are very interesting materials since they have good thermal properties compared with PLLA.
[0100] Inspired by this knowledge, the inventors tested a large number of compounds for their catalytic activity in this reaction and surprisingly found that several classes of compounds showed an effect. The compounds were also tested for their activity for the reaction of L-lactide and D-lactide: racemization was also able to be established here.
EXAMPLE 3
[0101] In a round flask with a distillation attachment, Liebig cooler and Anschütz-Thiele distillation adaptor, pure L-lactic acid 99% and trioctylamine were mixed. After the addition of 1% by weight of dibutyltin oxide (relative to the lactic acid), the mixture was heated to 250° C. and two fractions were collected, one at T<140° C. and one at T=140-165° C. By means of GC analysis, an amine content of 15 and 25% by weight was determined. The third fraction was a clear liquid from which colorless crystals were obtained. The melting point of the crystals was 112-119° C. and, by means of GC analysis and a hydrolysis with enzymes, a 50:50 mixture of D,D-lactide and L,L-lactide was established.
EXAMPLE 4
[0102] A distillation structure was filled with 396.8 g L-LAC and 2.93 g KOH. After removing water by means of a vacuum, 0.506 g SnOc 2 was added; the temperature was increased from 150° C. to 240° C. and the pressure was lowered to 10 mbar. Three fractions which were collected in a temperature range of 100° C. to 150° C. contain the compounds. The total yield was 46% (L-LA:D-LA:M-LA=54:18:28).
EXAMPLE 5
[0103] A distillation structure was filled with 253 g PLLA (Mn=750), 0.97 g Acima TW-30 (SnOc 2 ) and 2.53 g K 2 CO 3 . The temperature was increased to 210° C. and the pressure was lowered to 10 mbar. A fraction was collected in a temperature range of 140° C. to 148° C., an analysis producing a composition of 33% L-lactide, 30% D-lactide and 37% meso-lactide at a yield of 75% (variant 3).
EXAMPLE 6
[0104] In a headspace jar, the lactide and the racemization catalyst were mixed and heated to 105° C. to 155° C. After 1 to 6 hours, the reaction was stopped by cooling the flask. The reaction product was analysed by 1 H-NMR.
[0105] The precise reaction conditions and also educts and catalysts which are used are indicated in Tables 3 to 7.
[0000]
TABLE 3
Racemization of meso-lactide
Mol.
% L,L/
Exp.
Temp
Time
Lac./
Mono-
% m-
D,D-
No.
° C.
H
Cat.
Cat.
mer
LACT*
LACT*
1
140
4
K 2 CO 3
824
82
37
63
2
140
6
K 2 CO 3
825
77
27
73
3
140
6
TBA
679
94
30
70
4
140
6
DCHA
693
95
34
66
5
140
24
DCHA
690
87
24
76
6
140
6
DMAP
709
84
27
73
7
140
24
DMAP
708
20
20
80
8
140
6
TBP
718
94
47
53
9
140
24
TBP
690
89
31
69
TBA = tributylamine
DCHA = dicyclohexylamine
DMAP = dimethylaminopyridine
TBP = tributylphosphine
*NMR-data; meso-lactide: 97% meso, 3% L
[0000]
TABLE 4
Racemization of meso-lactide
Mol.
% L,L/
Exp.
Temp
Time
Lac./
Mono-
% m-
D,D-
No.
° C.
H
Cat.
Cat.
mer
LACT*
LACT*
1
125
1
DCHA
124
§
22
78
2
125
2
DCHA
124
§
19
81
3
125
3
DCHA
124
§
18
82
4
125
1
TMPIP
98
§
26
74
5
125
1
PMPIP
108
§
37
63
6
125
1
EDiPA
90
§
37
63
7
125
1
TBA
129
§
42
58
8
125
1
TOA
245
§
37
63
9
125
1
K 2 CO 3
96
&
17
83
§ = no by-products
& = by-products
TMPIP = 2,2,6,6-tetramethylpiperidine
PMPIP = 1,2,2,6,6-pentamethylpiperidine
EDiPA = ethyldiisopropylamine
TBA = tributylamine
TOA = trioctylamine
*NMR-data; meso-lactide: 90% meso, 10% L
[0000]
TABLE 5
Racemization of meso-lactide
Mol.
% L,L/
Exp.
Temp
Time
Lac./
Mono-
% m-
D,D-
No.
° C.
H
Cat.
Cat.
mer
LACT*
LACT*
1
155
0.5
DCHA
124
&
25
75
2
155
1
DCHA
124
§
20
80
3
155
1
TMPIP
98
§
20
80
4
155
1
PMPIP
108
§
19
81
5
155
1
EDiPA
90
§
20
80
6
155
1
TBA
129
§
24
76
7
155
1
KBenz
111
§
16
84
8
155
1
MgO
28
§
43
57
9
155
1
CaO
39
§
36
64
§ = no by-products
& = by-products
KBenz = potassium benzoate
*NMR-data; meso-lactide: 90% meso, 10% L
[0000]
TABLE 6
Racemization of L-lactide
Mol.
% L,L/
Exp.
Temp
Time
Lac./
Mono-
% m-
D,D-
No.
° C.
H
Cat.
Cat.
mer
LACT*
LACT*
1
100
12
DCHA
20
—
18
82
2
130
20
TOA
245
—
24
76
3
130
1
TOA
10
—
18
82
4
130
1
TEA
5
30
0#)
100#)
5
130
1
TOA
15
89
0#)
100#)
#)after with washing with H 2 O
TEA = triethylamine
*NMR-data
[0000]
TABLE 7
Racemization of meso-lactide
Mol.
%
%
Exp.
Temp
Time
Lac./
Mono-
% m-
L,L-
D,D-
No.
° C.
H
Cat.
Cat.
mer
LACT*
LACT@
LACT@
1
140
2
TBP
694
98
79
13
8
2
140
6
TBP
718
94
42
30
28
3
140
24
TBP
690
89
31
35
34
TBP = tributylphosphine
*NMR-data; @ HPLC data; meso-lactide: 96% meso, 4% L
EXAMPLE 7
Purification
[0106] Purification of the reaction products can be effected by means of fractionated distillation and/or crystallization. In some embodiments, crystallization can be implemented as liquid crystallization or as melt crystallization. In this way, only one separation of the meso-lactide is possible, L- and D-lactide (stereoisomers) cannot be separated by these physical methods. The experienced chemist will use ethyl acetate or toluene for the crystallization of lactide mixtures. Also alcohols, ketones etc. or mixtures hereof can serve for separation. In some embodiments, melt crystallization is used for the separation of lactides.
[0107] In a crystallization device, the melt of the lactide which has a temperature of 135° C. was slowly cooled and the solidified material (temperature 125° C.) was collected from the walls after the melt was removed. This process was repeated with the collected material until the desired purity was achieved. The melting temperature of the racemic lactide was 129° C. The remaining melt can be used again in the racemization reaction and the purification process can be repeated.
|
A mixture of cyclic diesters derived from lactic acid and in cases a mixture of a racemate of dilactide may be produced in several different processes. In some instances, the process can thereby start from the corresponding alpha-hydroxycarboxylic acids, the corresponding cyclic diesters or oligomers of the corresponding alpha-hydroxycarboxylic acids.
| 2
|
[0001] The present application is based on Japanese Patent Application No. 2002-140629, the entire contents of which are incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a ventilation member fixed to a housing for automobile electrical components or the like, and the housing to which the ventilation member is fixed.
[0004] 2. Related Art
[0005] Ventilation members are attached to various housings of automobile electrical components such as ECUs (Electronic Control Units), lamps, motors, various sensors, pressure switches and actuators; cellular phones; cameras; electric shavers; electric toothbrushes; and lamps for outdoor use.
[0006] Each of the ventilation members prevents water or dust from invading the inside of a housing while playing various roles in accordance with the kind of housing to which the ventilation member is attached. The roles include propagation of voice, discharge of gas generated inside the housing, and relaxation of a change of pressure inside the housing caused by a change of temperature.
[0007] [0007]FIGS. 13A and 13B show an example of a related-art ventilation member. A ventilation member 51 shown in each of FIGS. 13A and 13B is used for an equipment housing to be exposed to contaminants such as rain, muddy water or oils, for example, for automobile electric components. The ventilation member 51 has an L-shaped or U-shaped (not shown) tubular body. The ventilation member 51 may have a structure having a maze 52 internally. One end of the ventilation member 51 is outer-fitted to a neck portion 50 a provided in a housing 50 so that the ventilation member 51 is fixed to the housing.
[0008] [0008]FIGS. 14A and 14B show another example of a related-art ventilation member. In a ventilation member 60 shown in FIGS. 14A and 14B, a substantially cylindrical body 62 is fitted to the inside of a cover part 61 so as to form a ventilation path between the inner circumference of the cover part 61 and the outer circumference of the substantially cylindrical body 62 and between the bottom surface of the cover part 61 and the bottom portion of the substantially cylindrical body 62 . When an opening in the bottom portion of the substantially cylindrical body 62 is covered with a filter 63 , the ventilation member 60 can also exert a higher water-proofing property and a higher dust-proofing property (disclosed in Japanese Patent Laid-Open No. 2001-143524). An opening 62 a in the top portion of the substantially cylindrical body 62 is outer-fitted to the neck portion 50 a of the housing 50 so that the ventilation member 60 is fixed to the housing.
[0009] [0009]FIG. 15 shows another example of a related-art ventilation member. In a ventilation member 70 shown in FIG. 15, a tapered insertion portion 71 a is formed in one end portion of a disc-like elastomer member 71 , while a splash guard cover 71 b is formed on the other end portion of the disc-like elastomer member 71 , and a breathable film 72 is fixedly deposited on the way of a ventilation flow path penetrating between the one end portion and the outer circumference of the other end portion. A sealing/fixing portion 71 c for fixedly retaining a housing 7 in cooperation with the insertion portion 71 a is formed in the outer circumference of the elastomer member 71 (disclosed in Japanese Patent Laid-Open No. 85536/1998). The insertion portion 71 a is pressed into the opening portion of the housing so that the ventilation member 70 is fixed to the housing.
[0010] However, the ventilation members have the following problems.
[0011] Each of the ventilation members 51 and 60 shown in FIGS. 13A and 13B and FIGS. 14A and 14B is fixed to the housing 50 only by outer fitting to the neck portion 50 a of the housing 50 . Therefore, there is a possibility that the ventilation member may be pulled out of the housing.
[0012] On the other hand, in the ventilation member 70 shown in FIG. 15, the surface abutting against the housing 7 is made of elastomer. Therefore, when oil invades a part of the surface of the ventilation member 70 abutting against the housing 7 , it becomes easy to detach the ventilation member 70 from the housing. It cannot be therefore said that the ventilation member 70 is suitable as a ventilation member for a housing used in an environment easy for oil to adhere to the ventilation member.
SUMMARY OF THE INVENTION
[0013] According to the invention, there is provided a ventilation member having: a breathable film transmitting gas passing through an opening portion of a housing in a state in which the breathable film is fixed to the opening portion; and a support including a supporting portion for supporting the breathable film and an insertion portion to be inserted into the opening portion of the housing; wherein a lock structure for locking the support in the housing by rotating the support around a central axis of the support is formed in the insertion portion.
[0014] According to the ventilation member of the invention, the possibility that the ventilation member is pulled out of the housing can be reduced.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] [0015]FIG. 1 is an exploded view showing an example of a ventilation member according to the invention;
[0016] [0016]FIG. 2A is a view for explaining the state where the ventilation member shown in FIG. 1 has been fixed to a housing, and FIG. 2B is a sectional view taken on line A-A′ in FIG. 2A;
[0017] [0017]FIG. 3 is a sectional view showing another example of the ventilation member according to the invention;
[0018] [0018]FIG. 4A is an exploded view showing another example of the ventilation member according to the invention, and FIG. 4B is a sectional view of the ventilation member shown in FIG. 4A;
[0019] [0019]FIGS. 5A to 5 G are views of supports of ventilation members according to the invention when observed in the gas permeable direction;
[0020] [0020]FIGS. 6A to 6 F are views of supports of ventilation members according to the invention when observed in the gas permeable direction;
[0021] [0021]FIG. 7A is an exploded view showing an example of a ventilation member according to the invention, and FIG. 7B is a sectional view of the ventilation member shown in FIG. 7A; and
[0022] [0022]FIGS. 8A to 8 C are views for explaining the operation of fixing the ventilation member shown in FIGS. 7A and 7B to a housing;
[0023] [0023]FIG. 9A is a perspective view of a connector to which a ventilation member according to the invention has been fixed, and FIG. 9B is a sectional view taken on line B-B′ in FIG. 9A;
[0024] [0024]FIG. 10A is a perspective view of an automobile lamp to which a ventilation member according to the invention has been fixed, and FIG. 10B is a sectional view taken on line C-C′ in FIG. 10A;
[0025] [0025]FIG. 11 is a partially sectional view of an electric toothbrush to which a ventilation member according to the invention has been fixed;
[0026] [0026]FIG. 12A is a perspective view of an ECU to which a ventilation member according to the invention has been fixed, and FIG. 12B is a back view of a top cover of an ECU cover;
[0027] [0027]FIGS. 13A and 13B are sectional views for explaining an example of a related-art ventilation member;
[0028] [0028]FIG. 14A is an exploded view for explaining another example of a related-art ventilation member, and FIG. 14B is a sectional view of the ventilation member shown in FIG. 14A; and
[0029] [0029]FIG. 15 is a sectional view for explaining another example of a related-art ventilation member.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] Preferred embodiments of the invention will be described with reference to the drawings.
[0031] (Embodiment 1)
[0032] Description will be made about an embodiment of a ventilation member according to the invention with reference to FIGS. 1, 2A, 2 B, 3 , 4 A, 4 B, 5 A to 5 G, 6 A to 6 F, 7 A, and 7 B.
[0033] A ventilation member 1 shown in FIGS. 1, 2A and 2 B is a ventilation member including a breathable film 4 . The breathable film 4 transmits gas passing through an opening portion 8 of a housing 7 when the breathable film 4 is fixed to the opening portion 8 . The ventilation member 1 further includes a support 2 . The support 2 includes a supporting portion 2 a for supporting the breathable film 4 , and an insertion portion 2 b to be inserted into the opening portion 8 of the housing 7 . A spiral groove 2 c is formed in the outer circumference of the insertion portion 2 b . By screwing the insertion portion 2 b down to a female screw 8 a formed in the opening portion 8 of the housing 7 , the ventilation member 1 can be fixed to the opening portion 8 of the housing 7 . Thus, the possibility that the ventilation member 1 is pulled out of the housing 7 can be reduced. In addition, the ventilation member 1 can be removed from the housing 7 in accordance with necessity.
[0034] Through holes 3 penetrating the supporting portion 2 a and the insertion portion 2 b are formed in a central portion of the support 2 . The breathable film 4 is fixedly attached to the supporting portion 2 a so as to cover the through holes 3 . The size of the through holes 3 may be determined appropriately in consideration of the kind of housing to which the ventilation member 1 is fixed and the permeability of the breathable film 4 . The area of the through holes 3 (area on a plane perpendicular to the gas permeable direction) may be set to be 0.001-100 cm 2 .
[0035] In addition, a plurality of through holes 3 are provided in the surface abutting against the breathable film 4 as shown in FIG. 2B. When a plurality of through holes 3 are formed in the surface covered with the breathable film 4 in such a manner, the center of the breathable film 4 is also supported by the supporting portion 2 a . It is therefore possible to suppress the damage of the breathable film 4 from external force.
[0036] The shape of the supporting portion 2 a is not limited particularly, but may be like a disc having a larger diameter than that of the insertion portion 2 b , as shown in FIGS. 1, 2A and 2 B. The supporting portion 2 a may have a larger diameter than that of the opening portion 8 formed in the housing 7 so as to be disposed to cover the opening portion 8 .
[0037] In addition, the surface of the supporting portion 2 a abutting against the breathable film 4 is formed into a curved surface as shown in FIG. 2B. In such a manner, when the curved surface having a circumferential edge portion lower in height than a central portion is used as the supporting surface, the property of water drainage is improved suitably as a property of a ventilation member for a housing for use in an environment easy to be affected by water. Incidentally, in place of the curved surface of the supporting portion 2 a abutting against the breathable film 4 as described above, for example, the shape of the supporting portion 2 a may be formed into a conical shape. In this case, the breathable film 4 is fixedly attached to the slope of the conical shape so that the property of water drainage can be improved.
[0038] Thermoplastic resin easy to mold is preferably used as the material of the support 2 without any particular limitation. Examples of such thermoplastic resin to be used include polybutyleneterephthalate (PBT), polyphenylene sulfide (PPS), polysulfone (PS), polypropylene (PP), polyethylene (PE), ABS resin, thermoplastic elastomer, or composite materials of these thermoplastic resins. Other than the thermoplastic resins, composite materials in which reinforcement materials such as glass fibers or carbon fibers, or metal is compounded with thermoplastic resin so as to improve the heat resistance, the dimensional stability and the rigidity may be used.
[0039] When the housing to which the ventilation member is fixed is used in an environment having a large change in temperature, it is preferable that materials low in deterioration caused by heat, for example, the thermoplastic resins other than thermoplastic elastomer are used as the material of the support. Particularly, PBT, PPS or PS is preferred.
[0040] The method for forming the support 2 is not limited particularly. For example, the support 2 may be formed by injection molding or cutting.
[0041] The material, structure and form of the breathable film 4 are not limited particularly if sufficient permeability can be secured. It is, however, preferable to select at least one kind from fluororesin porous materials and polyolefin porous materials. Examples of fluororesins include polytetrafluoroethylene (PTFE), polychlorotrifluoroethylene, tetrafluoroethylene-hexafluoropropylene copolymer, tetrafluoroethylene-perfluoro alkyl vinyl ether copolymer, and tetrafluoroethylene-ethylene copolymer. Examples of polyolefin monomers include ethylene, propylene, 4-methylpentene-1, and 1-butene. Polyolefins obtained by simply polymerizing or copolymerizing these monomers may be used. In addition, two or more kinds of such polyolefins may be blended, or laminated in layers. Of these, PTFE porous material is particularly preferred because it can keep permeability even in a small area and has a high function of preventing water or dust from invading the inside of the housing.
[0042] As shown in FIG. 1 and FIG. 2B, a reinforcement material 5 may be laminated to the breathable film 4 . When the reinforcement material 5 is laminated to one side of the breathable film 4 in such a manner, the reinforcement material 5 may be laminated to a surface opposite to the surface shown in FIGS. 1 and 2B. The material, structure and form of the reinforcement material 5 are not limited particularly. It is, however, preferable to use a material having a pore size larger than that of the breathable film 4 and superior in gas permeability, such as woven fabric, nonwoven fabric, mesh, net, sponge, foam, metal porous material, or metal mesh. When heat resistance is required, it is preferable to use a reinforcement material made of polyester, polyamide, aramid resin, polyimide, fluororesin, ultra high molecular weight polyethylene, or metal. Incidentally, although the reinforcement material 5 is laminated to one side of the breathable film 4 in the embodiment shown in FIGS. 1 and 2B, the reinforcement material 5 may be laminated to the both sides of the breathable film 4 .
[0043] As for the method for laminating the reinforcement material 5 to the breathable film 4 , they may be put on top of each other simply, or joined to each other. For example, the joining may be performed in a method of adhesive lamination, thermal lamination, heating deposition, ultrasonic deposition, or adhesion with an adhesive agent. For example, when the breathable film 4 and the reinforcement material 5 are laminated by thermal lamination, a part of the reinforcement material 5 may be heated and melted to be bonded to the breathable film 4 . Alternatively, the breathable film 4 and the reinforcement material 5 may be bonded through a fusion bonding agent such as hot melt powder.
[0044] Liquid-repellent treatment such as water-repellent treatment or oil-repellent treatment may be given to the breathable film 4 in accordance with the application of the housing. The liquid-repellent treatment can be carried out by applying the breathable film 4 with a substance having a small surface tension, drying the substance and then curing the substance. The liquid-repellent agent is not limited particularly so long as a coat lower in surface tension than the breathable film can be formed as the liquid-repellent agent. It is, however, preferable to use polymer having a perfluoro alkyl group. Examples of such polymers for use include Fluorad (made by Sumitomo 3M Ltd.), Scotchguard (made by Sumitomo 3M Ltd.), Texguard (made by Daikin Industries, Ltd.), Unidyne (made by Daikin Industries, Ltd.), and Asahi Guard (made by Asahi Glass Co., Ltd.) (all under trade names). The liquid-repellent agent may be applied by impregnation or spraying.
[0045] As for the method for supporting the breathable film 4 on the supporting portion 2 a , a method of heating deposition, ultrasonic deposition or adhesion using an adhesive agent is suitable because peeling or floating hardly occurs. From the point of view of handiness, heating deposition or ultrasonic deposition is preferred. When the reinforcement material 5 is laminated to the breathable film 4 , any supporting method may be employed without particular limitation as long as the reinforcement material 5 can be fixedly attached to the support 2 . Incidentally, when a high liquid-repellent property is required, preferably, the reinforcement material 5 is fixedly attached to the support 2 while the surface higher in liquid-repellent property faces the outside of the housing.
[0046] As another method for supporting the breathable film 4 on the supporting portion 2 a , the breathable film 4 may be disposed in a mold for forming the support 2 when the support 2 is injection-molded. In this case, the breathable film 4 is integrated with the support 2 .
[0047] In addition, when a seal portion 2 d is provided on the surface of the supporting portion 2 a facing the housing as shown in FIG. 3, the adhesion or air tightness between the housing 7 and the ventilation member 1 can be enhanced. Particularly, when thermoplastic resin other than elastomer is used for the supporting portion 2 a , it is preferable to form the seal portion 2 d so as to enhance the sealing performance.
[0048] Examples of preferred materials for the sealing portion 2 d include elastomers or foams such as nitrile-butadiene rubber (NBR), ethylene-propylene rubber (EPM or EPDM) and silicone rubber.
[0049] For example, the seal portion 2 d may be provided by outer fitting an O-ring of the above-mentioned material to the insertion portion 2 b , or may be formed on one side of the supporting portion 2 a by two-color molding.
[0050] In addition, when the support 2 has a protective portion 2 e covering at least a part of the breathable film 4 from above of the breathable film 4 as shown in FIGS. 4A and 4B, it is possible to reduce the possibility that the breathable film 4 is damaged by external force or the ventilation is blocked by sand or mud accumulated on the surface of the breathable film.
[0051] The shape of the protective portion 2 e is not limited particularly as long as it is a shape not spoiling the permeability of the ventilation member 1 . It is, however, preferable that a plurality of opening portions 2 f are formed in positions where they cannot be viewed when observed in the gas permeable direction, for example, in the side surface of the protective portion 2 e as in the embodiment shown in FIGS. 4A and 4B. Incidentally, opening portions 2 f maybe also formed in an upper surface 2 g of the protective portion 2 e as long as the opening portions 2 f do not spoil the effect of protecting the breathable film 4 . In addition, it is preferable that the opening portions 2 f are formed as divided small holes from the point of view of keeping the strength of the support 2 and effectively preventing invasion of matters.
[0052] As the material of the protective portion 2 e , a material similar to that of the other portion of the support 2 may be used. The method for integrating the protective portion 2 e with the other portion of the support 2 is not limited particularly. The integration may be attained in a method of heating deposition, ultrasonic deposition, vibration deposition, adhesion using an adhesive agent, fitting, or screwing. Particularly, heating deposition or ultrasonic deposition is preferred because of its low cost and easiness.
[0053] In addition, in order to make the ventilation member 1 easy to screw down with a tool or fingers, it is preferable that the outer shape of the support 2 is a shape selected from a circle and polygons when the support 2 is observed in the gas permeable direction. Examples of such a shape include a perfect circle, an ellipse, a hexagon, a pentagon, a quadrangle, and a triangle as shown in FIGS. 5A to 5 F. In addition to the shapes described above, for example, as shown in FIG. 5G, the outer shape of the support 2 observed in the gas permeable direction may be a shape having a straight line portion in its outline, preferably a shape having a pair of straight line portions parallel with each other.
[0054] In addition, when an engagement structure with which a tool can be engaged is provided in the support 2 , the ventilation member 1 can be fixed to the housing 7 efficiently. It is preferable that the engagement structure includes at least one kind selected from a convex portion and a concave portion. In addition, it is preferable that the engagement structure is formed in at least one surface selected from the surface of the support which can be viewed when the support is observed in the gas permeable direction from the outside of the housing, and the outer circumferential surface of the support.
[0055] The engagement structure is, for example, of convex or concave portions 2 h formed in the surface of the support which can be viewed when the support 2 is observed in the gas permeable direction from the outside of the housing, as shown in FIG. 6A. The convex or concave portions 2 h are formed symmetrically with respect to the center of this surface. The outer shape of each of the convex or concave portions 2 h is circular. Alternatively, as shown in FIGS. 6B to 6 D, the engagement structure may be formed into a convex or concave portion 2 i having a− (minus) shape as its outer shape formed in the surface of the support 2 which can be viewed when the support 2 is observed in the gas permeable direction from the outside of the housing, a convex or concave portion 2 j having a+ (plus) shape as its outer shape likewise, or a convex or concave portion 2 k having a polygonal shape as its outer shape likewise. Alternatively, as shown in FIG. 6E or 6 F, the engagement structure may be formed into concave portions 2 m or convex portions 2 n , which are formed in the outer circumferential surface of the support 2 and symmetrically with respect to the central axis of the support 2 and whose outer shape is semicircular when the support 2 is observed in the gas permeable direction.
[0056] In addition, if the convex portions 2 h , 2 i , 2 j , 2 k and 2 n are designed to be broken when force not smaller than predetermined one is applied thereto, it becomes difficult to detach the ventilation member 1 from the housing 7 after the ventilation member 1 is fixed to the housing 7 . Thus, it is possible to prevent the ventilation member 1 from being detached from the housing 7 .
[0057] (Embodiment 2)
[0058] Another embodiment of a ventilation member according to the invention will be described with reference to FIGS. 7A and 7B and FIGS. 8A to 8 C.
[0059] A ventilation member 21 shown in FIGS. 7A and 7B is a ventilation member including a breathable film 4 . The breathable film 4 transmits gas passing through an opening portion 8 of a housing 7 when the breathable film 4 is fixed to the opening portion 8 . The ventilation member 21 further includes a support 2 . The support 2 includes a supporting portion 2 a for supporting the breathable film 4 , and an insertion portion 2 b to be inserted into the opening portion 8 of the housing 7 . At least one protrusion portion 2 p is formed in the outer circumference of the insertion-start-side end portion of the insertion portion 2 b.
[0060] The insertion portion 2 b has a columnar shape whose diameter is substantially the same as that of the opening portion 8 of the housing 7 in the embodiment shown in FIGS. 7A and 7B. Four protrusion portions 2 p are formed in the outer circumference of the insertion-start-side end portion of the insertion portion 2 b . When the ventilation member 21 is fixed to the housing 7 , first, the insertion portion 2 b is inserted into the opening portion 8 of the housing 7 while fitting the protrusion portions. 2 p into guide grooves 8 b formed in the inner surface of the opening portion 8 . Successively, when the support 2 is rotated in one direction around the central axis of the support 2 , the protrusion portions 2 p are fitted to fitting grooves 7 b formed in the inner surface of the housing 7 so that the ventilation member 21 can be fixed to the opening portion 8 of the housing 7 .
[0061] Description will be made further in detail. As shown in FIGS. 8A to 8 C, a tapered surface 7 a getting higher in height in the direction of rotating the support 2 is formed in the inner surface of the housing 7 , and the fitting grooves 7 b for fitting the protrusion portions 2 p thereto are formed ahead of the tapered surface 7 a . After the protrusion portions 2 p have climbed over the tapered surface 7 a and fitted into the fitting grooves 7 b , the support 2 cannot be detached from the housing 7 easily. Thus, the possibility that the ventilation member 21 is pulled out of the housing 7 is reduced.
[0062] Incidentally, although four protrusion portions 2 p are formed in the embodiment shown in FIGS. 7A and 7B and FIGS. 8A to 8 C, the invention is not limited thereto. It will go well if at least one protrusion portion 2 p is formed. When a plurality of protrusion portions are formed circumferentially at an equal interval, the ventilation member 21 can be firmly fixed to the housing 7 .
[0063] Next, FIGS. 9A, 9B, 10 A, 10 B, 11 , 12 A and 12 B show examples of vented housings to which ventilation members according to the invention have been fixed respectively. The ventilation member 1 shown in FIG. 1 has been fixed to a connector shown in FIGS. 9A and 9B. The ventilation member 21 shown in FIGS. 7A and 7B has been fixed to an automobile lamp shown in FIGS. 10A and 10B. The ventilation member 21 shown in FIGS. 7A and 7B has been fixed to an electric toothbrush shown in FIG. 11. The ventilation member 1 shown in FIG. 1 has been fixed to an ECU shown in FIGS. 12A and 12B. However, housings to which ventilation members according to the invention are fixed are not limited to these housings. In addition, the number of ventilation members according to the invention to be fixed to a housing is not limited particularly. A plurality of ventilation members may be attached to different sides of a housing or one and the same side of a housing.
EXAMPLES
[0064] Although the invention will be described below in further detail by use of its examples, the invention is not limited to the following examples.
Example 1
[0065] As Example 1, the ventilation member 1 shown in FIGS. 4A and 4B was produced as follows.
[0066] First, the support 2 having a structure shown in FIGS. 4A and 4B was obtained by injection molding out of PBT (CG7640 made by Teijin Ltd., melting point 225° C.). The supporting portion 2 a of the obtained support was 2.5 mm in thickness and 16 mm in outer diameter, the insertion portion 2 b of the obtained support was 12 mm in outer diameter, and the through holes 3 provided in the insertion portion 2 b were 8 mm in inner diameter.
[0067] Next, a PTFE porous material (Microtex NTF1131 made by Nitto Denko Corp., melting point 327° C.) 0.085 mm in thickness and 20 mm in outer diameter was prepared as the breathable film 4 , and polyester-based nonwoven fabric (Axtar made by Toray Industries, Inc., melting point 230° C.) 0.2 mm in thickness was prepared as the reinforcement material 5 . The breathable film 4 and the reinforcement material 5 were contact-bonded by heating deposition at a temperature of 260° C. and at a pressure of 5.0×10 5 Pa for 10 seconds. Thus, a laminate 6 was obtained.
[0068] Successively, the laminate 6 was punched out with an outer diameter of 10 mm. The reinforcement material 5 of the laminate 6 was brought into contact with the supporting portion 2 a so as to cover the through holes 3 provided in the supporting portion 2 a , and contact-bonded to the supporting portion 2 a by heating deposition at a temperature of 260° C. and at a pressure of 5.0×10 5 Pa for 30 seconds. Next, the protective portion 2 e was produced by injection molding out of PBT (CG7640 made by Teijin Ltd., melting point 225° C.). The protective portion 2 e was 3.5 mm in thickness and 16 mm in outer diameter. Next, the protective portion 2 e and the supporting portion 2 a were fixedly attached to each other by heating deposition. Finally, an O-ring made of EPDM as the seal portion 2 d was fitted onto the insertion portion 2 b . Thus, the ventilation member 1 was obtained.
[0069] On the other hand, a housing 7 to which the ventilation member 1 was to be fixed was produced by injection molding out of PBT (CG7640 made by Teijin Ltd., melting point 225° C.). The outer wall of the obtained housing 7 was 2 mm in thickness, and the opening portion 8 was 12 mm in inner diameter. The ventilation member 1 was screwed to the housing 7 by hand. Thus, a vented housing was obtained.
Example 2
[0070] As Example 2, the ventilation member 1 shown in FIGS. 4A and 4B was produced as follows.
[0071] First, the support 2 having a structure shown in FIGS. 4A and 4B was obtained by injection molding out of PP (AW564 made by Sumitomo Chemical Co., Ltd., melting point 165° C.). The supporting portion 2 a of the obtained support was 2.5 mm in thickness and 16 mm in outer diameter, the insertion portion 2 b of the obtained support was 12 mm in outer diameter, and the through holes 3 provided in the insertion portion 2 b were 8 mm in inner diameter.
[0072] Next, a PTFE porous material (Microtex NTF1026 made by Nitto Denko Corp., melting point 327° C.) 0.02 mm in thickness and 20 mm in outer diameter was prepared as the breathable film 4 , and polyester-based nonwoven fabric (Axtar made by Toray Industries, Inc., melting point 230° C.) 0.2 mm in thickness was prepared as the reinforcement material 5 . The breathable film 4 and the reinforcement material 5 were contact-bonded by heating deposition at a temperature of 260° C. and at a pressure of 5.0×10 5 Pa for 10 seconds. Thus, a laminate 6 was obtained.
[0073] Successively, the laminate 6 was punched out with an outer diameter of 10 mm. The reinforcement material 5 of the laminate 6 was brought into contact with the supporting portion 2 a so as to cover the through holes 3 provided in the supporting portion 2 a , and contact-bonded to the supporting portion 2 a by heating deposition at a temperature of 260° C. and at a pressure of 5.0×10 5 Pa for 30 seconds. Next, the protective portion 2 e was produced by injection molding out of PP (AW564 made by Sumitomo Chemical Co., Ltd., melting point 165° C.). The protective portion 2 e was 3.5 mm in thickness and 16 mm in outer diameter. Next, the protective portion 2 e and the supporting portion 2 a were fixedly attached to each other by heating deposition. Finally, an O-ring made of NBR as the seal portion 2 d was outer-fitted to the insertion portion 2 b . Thus, the ventilation member 1 was obtained. The ventilation member 1 was screwed to the opening portion 8 of a housing 7 similar to that in Example 1 by hand. Thus, a vented housing was obtained.
Example 3
[0074] As Example 3, the ventilation member 21 shown in FIGS. 7A and 7B was produced as follows.
[0075] First, the support 2 having a structure shown in FIGS. 7A and 7B was obtained by injection molding out of PBT (CG7640 made by Teijin Ltd., melting point 225° C.). The supporting portion 2 a of the obtained support was 2.5 mm in thickness, the insertion portion 2 b of the obtained support was 9.8 mm in outer diameter, the portion where the protrusion portions 2 p were formed was 11.4 mm in outer diameter, and the through holes 3 provided in the insertion portion 2 b were 7 mm in inner diameter. The outer shape of the supporting portion 2 a observed in the gas permeable direction was an orthohexagon, 8 mm each side.
[0076] Next, a PTFE porous material (Microtex NTF1131 made by Nitto Denko Corp., melting point 327° C.) 0.085 mm in thickness and 20 mm in outer diameter was prepared as the breathable film 4 , and polyester-based nonwoven fabric (Axtar made by Toray Industries, Inc., melting point 230° C.) 0.2 mm in thickness was prepared as the reinforcement material 5 . The breathable film 4 and the reinforcement material 5 were contact-bonded by heating deposition at a temperature of 260° C. and at a pressure of 5.0×10 5 Pa for 10 seconds. Thus, a laminate 6 was obtained.
[0077] Successively, the laminate 6 was punched out with an outer diameter of 8 mm. The reinforcement material 5 of the laminate 6 was brought into contact with the supporting portion 2 a so as to cover the through holes 3 provided in the supporting portion 2 a , and contact-bonded to the supporting portion 2 a by heating deposition at a temperature of 260° C. and at a pressure of 5.0×10 5 Pa for 30 seconds. Next, the protective portion 2 e was produced by injection molding out of PBT (CG7640 made by Teijin Ltd., melting point 225° C.). The protective portion 2 e was 3.5 mm in thickness. In addition, the outer shape of the protective portion 2 e observed in the gas permeable direction was an orthohexagon, 8 mm each side.
[0078] Next, the protective portion 2 e and the supporting portion 2 a were fixedly attached to each other by heating deposition. Finally, an O-ring made of EPDM as the seal portion 2 d was inserted into the insertion portion 2 b . Thus, the ventilation member 21 was obtained.
[0079] On the other hand, a housing to which the ventilation member 21 was to be fixed was produced by injection molding out of PBT (CG7640 made by Teijin Ltd., melting point 225° C.). The outer wall of the obtained housing was 2 mm in thickness, and the opening portion 8 was 12 mm in inner diameter in the portion where the guide grooves 8 b were formed and 10 mm in inner diameter in the other portion. The ventilation member 21 was rotated to be inserted into the opening portion 8 of the housing 7 . Thus, a vented housing was obtained.
Example 4
[0080] As Example 4, the ventilation member 21 shown in FIGS. 7A and 7B was produced as follows.
[0081] First, the support 2 having a structure shown in FIGS. 7A and 7B was obtained by injection molding out of PP (AW564 made by Sumitomo Chemical Co., Ltd., melting point 165° C.). The supporting portion 2 a of the obtained support was 2.5 mm in thickness, the insertion portion 2 b of the obtained support was 9.8 mm in outer diameter, the portion where the protrusion portions 2 p were formed was 11.4 mm in outer diameter, and the through holes 3 provided in the insertion portion 2 b were 7 mm in inner diameter. The outer shape of the supporting portion 2 a observed in the gas permeable direction was an orthoquadrangle, 16 mm each side.
[0082] Next, a PTFE porous material (Microtex NTF1026 made by Nitto Denko Corp., melting point 327° C.) 0.02 mm in thickness and 20 mm in outer diameter was prepared as the breathable film 4 , and polyester-based nonwoven fabric (Axtar made by Toray Industries, Inc., melting point 230° C.) 0.2 mm in thickness was prepared as the reinforcement material 5 . The breathable film 4 and the reinforcement material 5 were contact-bonded by heating deposition at a temperature of 260° C. and at a pressure of 5.0×10 5 Pa for 10 seconds. Thus, a laminate 6 was obtained.
[0083] Successively, the laminate 6 was punched out with an outer diameter of 8 mm. The reinforcement material 5 of the laminate 6 was brought into contact with the supporting portion 2 a so as to cover the through holes 3 provided in the supporting portion 2 a , and contact-bonded to the supporting portion 2 a by heating deposition at a temperature of 260° C. and at a pressure of 5.0×10 5 Pa for 30 seconds. Next, the protective portion 2 e was produced by injection molding out of PP (AW564 made by Sumitomo Chemical Co., Ltd., melting point 165° C.). The protective portion 2 e was 3.5 mm in thickness. In addition, the outer shape of the protective portion 2 e observed in the gas permeable direction was an orthoquadrangle, 16 mm each side. Next, the protective portion 2 e and the supporting portion 2 a were fixedly attached to each other by heating deposition. Finally, an O-ring made of NBR as the seal portion 2 d was outer-fitted to the insertion portion 2 b . Thus, the ventilation member 21 was obtained. The ventilation member 21 was rotated to be inserted into the opening portion 8 of the housing 7 similar to that in Example 3. Thus, a vented housing was obtained.
Comparative Example 1
[0084] The ventilation member 51 shown in FIG. 13A was produced by molding and hot curing out of a material having styrene-butadiene rubber (Tufdene 1000 made by Asahi-Kasei Corp., bending modulus 4.0×10 8 N/m 2 ) as its chief component. The obtained ventilation member 51 was 7.5 mm in inner diameter, 11.5 mm in outer diameter, 2 mm in thickness, and 40 mm in height H.
[0085] On the other hand, the housing 50 shown in FIG. 13A was produced by injection molding as a housing to which the ventilation member 51 was to be fixed. The neck portion 50 a was formed into a hollow columnar shape, whose outer diameter was larger by 20% than the inner diameter of the ventilation member 51 . The ventilation member 51 was outer-fitted to the neck portion 50 a for 8 mm. Thus, a vented housing was obtained.
Comparative Example 2
[0086] The cover part 61 and the substantially cylindrical body 62 shown in FIGS. 14A and 14B were produced by injection molding out of PP (UBE Polypro J815HK made by Ube Industries, Ltd., bending modulus 1.47×10 9 N/m 2 ) and out of thermoplastic elastomer (Milastomer 6030 made by Mitsui Chemicals Inc., bending modulus 4.41×10 8 N/m 2 ), respectively. The obtained cover part 61 was 17.5 mm in outer diameter and 15.5 mm in inner diameter, and the obtained substantially cylindrical body 62 was 15.5 mm in maximum outer diameter and 7.5 mm in inner diameter in the top portion opening portion 62 a.
[0087] In addition, a PTFE porous material (Microtex NTF1026 made by Nitto Denko Corp., 0.02 mm in thickness, 0.6 μmin average pore size, and 80% in porosity) was prepared as the ventilation filter 63 . Next, the ventilation filter 63 was brought into contact with the bottom portion of the obtained substantially cylindrical body 62 , and then pressed against the bottom portion of the obtained substantially cylindrical body 62 by heating deposition at a temperature of 150° C. and at a pressure of 10×10 4 Pa for 10 seconds. Then, the substantially cylindrical body 62 was fitted to the upper cover part 61 . Thus, the ventilation member 60 was obtained.
[0088] On the other hand, the housing 50 shown in FIG. 14B was produced by injection molding as a housing to which the ventilation member 60 was to be fixed. The neck portion 50 a was formed into a hollow columnar shape, whose outer diameter was larger by 20% than the inner diameter of the top portion opening portion 62 a . The ventilation member 60 was outer-fitted to the neck portion 50 a for 8 mm. Thus, a vented housing was obtained.
[0089] Pull-out force was measured in the following method upon the vented housings obtained thus. Table 1 shows the measurement results.
[0090] In the “pull-outtest”, each ventilation member was pulled under the condition of a rate of pulling of 8.33×10 −4 m/s in the direction to pull the ventilation member out of the housing. Then, the maximum value at that time was regarded as pull-out force. Incidentally, when the pull-out force was not smaller than 30 N, it was judged to be impossible to pull out.
TABLE 1 Pull-Out Force (N) Example 1 impossible to pull out Example 2 impossible to pull out Example 3 impossible to pull out Example 4 impossible to pull out Comparative Example 1 7.5 Comparative Example 2 19.0
[0091] As described above, according to the invention, a ventilation member in which the possibility that the ventilation member is pulled out of a housing has been reduced, and a vented housing using the ventilation member can be provided.
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A ventilation member having: a breathable film transmitting gas passing through an opening portion of a housing in a state in which the breathable film is fixed to the opening portion; and a support including a supporting portion for supporting the breathable film and an insertion portion to be inserted into the opening portion of the housing; wherein a lock structure for locking the support in the housing by rotating the support around a central axis of the support is formed in the insertion portion.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The field of invention relates to vehicular ramp structure, and more particularly pertains to a new and improved vehicular ramp apparatus wherein the same is arranged to latch a vehicular wheel on the ramp structure.
2. Description of the Prior Art
Vehicular ramps of various types are utilized in the prior art and exemplified by U.S. Pat. Nos. 4,050,403; 3,917,227; 5,033,146; and 5,001,798.
The instant invention attempts to overcome deficiencies of the prior art by providing for a compact operative organization arranged to latch a vehicular wheel on the ramp structure 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 vehicular ramp apparatus now present in the prior art, the present invention provides a vehicular ramp apparatus utilizing forward and rear abutment plates arranged for engaging and abutting opposed sides of a vehicular wheel upon the support ramp structure. As such, the general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new and improved vehicular ramp apparatus which has all the advantages of the prior art vehicular ramp apparatus and none of the disadvantages.
To attain this, the present invention provides a vehicular ramp including a support plate having forward and rear abutment plates for positioning and arranged for latching on opposed sides of a vehicular wheel positioned upon the ramp structure.
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 vehicular ramp apparatus which has all the advantages of the prior art vehicular ramp apparatus and none of the disadvantages.
It is another object of the present invention to provide a new and improved vehicular ramp 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 vehicular ramp apparatus which is of a durable and reliable construction.
An even further object of the present invention is to provide a new and improved vehicular ramp 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 vehicular ramp apparatus economically available to the buying public.
Still yet another object of the present invention is to provide a new and improved vehicular ramp 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 top view of the invention.
FIG. 2 is an orthographic side view of the invention.
FIG. 3 is an isometric illustration of the actuator rod structure in an exploded view.
FIG. 4 is an orthographic view, taken along the lines 4--4 of FIG. 1 in the direction indicated by the arrows.
FIG. 5 is an orthographic top view of the forward abutment plate.
FIG. 6 is an orthographic view, taken along the lines 6--6 of FIG. 5 in the direction indicated by the arrows.
FIG. 7 is an orthographic bottom view of the forward abutment plate.
FIG. 8 is an orthographic cross-sectional illustration of the apparatus.
FIG. 9 is an orthographic side view of a rear wheel chock for use by the invention.
FIG. 10 is an orthographic view, taken along the lines 10--10 of FIG. 9 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 10 thereof, a new and improved vehicular ramp apparatus embodying the principles and concepts of the present invention and generally designated by the reference numeral 10 will be described.
More specifically, the vehicular ramp apparatus 10 of the instant invention essentially comprises a base plate 11 having a first end wall 12 spaced from a second end wall 13, with a vehicular support plate 14 positioned above the base plate, with the vehicular support plate 14 having a ramp plate 15 mounted to the vehicular support plate at an intersection and canted from the vehicular support plate 14 downwardly to a horizontal alignment with the base plate 11 and the ramp plate mounted at a first end to the intersection at a ramp plate second end to the horizontal alignment, with the base plate 11 spaced from the base plate and the second end wall 13. The ramp plate 15, as indicated in FIG. 1, includes a ramp plate top surface 16 having spaced side rails 19 in a parallel relationship along the ramp plate and extending along the support plate 14. A plurality of parallel friction strips 17 are mounted along the ramp plate top surface 16, as well as drain apertures 18 directed through the ramp plate 15. A support brace 20 extends from a further intersection of the first end wall 12 and the base plate to the ramp plate 15 for affording structural integrity to the organization.
An actuator rod 21 is slidably directed through the first end wall 12 and includes an actuator rod abutment 22 projecting from the actuator rod 21 towards the support plate 14. An actuator rod first end portion 23 is arranged for slidable reception through a first end wall opening 12, in a manner as indicated in FIG. 1, with the actuator rod first end portion having first and second guide slots 24 and 25 that are arranged in coextensive alignment relative to one another of a split housing portion of the first end portion, wherein the split housing portion captures a plurality of lock plates 27 spring-biased for projection exteriorly of the first end portion in a biased orientation to project beyond the first end portion, with a lock rod 26 slidably received through the first and second guide slots 24 and 25, having a lock rod spring 26a in cooperative association between the lock rod and the lock plates 27, whereupon sliding of the lock rod 26 in a spaced relationship relative to and away from a lock plate pivotal axle 28 pivotally mounting the lock plates 27 effects biasing of the lock plates 27 towards the lock rod and within the actuator rod first end portion 23. Release of the lock rod 26 biased the lock rod 26 towards the lock plate pivotal axle 28 permitting projection of the lock plates, in a manner as indicated in FIG. 3. The actuator rod having an actuator rod second end includes an actuator rod second end pivot axle 29 directed therethrough and through an associated actuator rod slot 30. A guide link 31 is included (see FIG. 8 for example), with the guide link including a first end having a first end axle 32 slidably mounted within a guide link slot 34 through the second end wall 13, with the guide link second end pivotally mounted to the actuator rod second end pivot axle 29 within the actuator rod slot 30. An arcuate actuator link 35 is provided, having an actuator link first end 36 pivotally mounted to the actuator rod pivot axle 29 within the slot 30, and an actuator rod link second end 37 terminating in a tube to receive an actuator link axle 38 therethrough that in turn is pivotally mounted to a forward abutment plate 39, and more specifically, to the forward abutment plate first end. The forward abutment plate second end 40 includes a forward abutment plate axle 41 that in turn is mounted at the intersection of the support plate and the ramp plate 14 and 15 respectively, as indicated in FIG. 8.
A rear abutment plate 42 is arranged for upward projection and latching upon projection of the actuator rod 21 towards the second end wall 13, whereupon the rear abutment plate 42 includes a rear abutment plate axle 43 medially of the rear abutment plate mounted rotatably to the support plate 14 parallel to the forward abutment plate axle 41 and the actuator link axle 38. A rear abutment plate first end lug 44 is arranged for engagement with the actuator rod abutment 22 to prevent the rear abutment plate 42 from pivoting relative to the actuator rod abutment 22.
Further, optionally employed are at least one of a plurality of wheel chocks 46 of cross-sectional configuration, having friction strips thereon and the friction strips 47, as indicated, are arranged for enhanced frictional engagement with a rear wheel structure of an associated vehicle.
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 vehicular ramp includes a support plate having forward and rear abutment plates for positioning and arranged for latching on opposed sides of a vehicular wheel positioned upon the ramp structure.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to Provisional Application No. 61/215,999, filed May 12, 2009, the entirety of which is incorporated herein by reference and is to be considered part of this specification.
BACKGROUND OF THE INVENTION
Field of the Invention
[0002] Programmable thermostats have been available for more than 20 years. Programmable thermostats offer two types of advantages as compared to non-programmable devices. On the one hand, programmable thermostats can save energy in large part because they automate the process of reducing conditioning during times when the space is unoccupied, or while occupants are sleeping, and thus reduce energy consumption.
[0003] On the other hand, programmable thermostats can also enhance comfort as compared to manually changing setpoints using a non-programmable thermostat. For example, during the winter, a homeowner might manually turn down the thermostat from 70 degrees F. to 64 degrees when going to sleep and back to 70 degrees in the morning. The drawback to this approach is that there can be considerable delay between the adjustment of the thermostat and the achieving of the desired change in ambient temperature, and many people find getting out of bed, showering, etc. in a cold house unpleasant. A programmable thermostat allows homeowners to anticipate the desired result by programming a pre-conditioning of the home. So, for example, if the homeowner gets out of bed at 7 AM, setting the thermostat to change from the overnight setpoint of 64 degrees to 70 at 6 AM can make the house comfortable when the consumer gets up. The drawback to this approach is that the higher temperature will cost more to maintain, so the increase in comfort is purchased at the cost of higher energy usage.
[0004] But all of the advantages of a programmable thermostat depend on the match between the preferences of the occupants and the actual settings employed. If, for example, the thermostat is set to warm up the house on winter mornings at 7 AM, but the homeowner gets up at 5:30, the homeowner is likely to be dissatisfied. If a homeowner has programmed her thermostat to cool down the house at 5 PM each afternoon based on the assumption that she will come home at 6 PM, but her schedule changes and she begins to arrive home at 4:30 each day, she is likely to be uncomfortable and either make frequent manual changes or go through the generally non-intuitive process of reprogramming the thermostat to match her new schedule. Because the limited interface on most thermostats, that process may take considerable effort, which leads many users to avoid reprogramming their thermostats for long periods or even to skip doing so entirely.
[0005] But even if a homeowner is able to align her schedule with the programming of her thermostat, there are additional difficulties associated with choosing proper temperatures at those times. If the temperatures programmed into a thermostat do not accurately reflect the preferences of the occupants, those occupants are likely to resort to manual overrides of the programmed settings. The need to correct the “mistakes” of the thermostat is likely to annoy many users. And because people tend to overshoot the desired temperature when they make such manual changes, these overrides are likely to result in excessive heating and cooling, and thus unnecessary energy use. That is, if a person feels uncomfortable on a summer afternoon when the setting is 73 degrees, they are likely to change it to 68 or 69 rather than 71 or 72 degrees, even if 72 degrees might have made enough of a difference.
[0006] It would therefore be advantageous to have a means for adapting to signaling from occupants in the form of manual temperature changes and incorporating the information contained in such gestures into long-term programming. It would also be desirable to take into account both outside weather conditions and the thermal characteristics of individual homes in order to improve the ability to dynamically achieve the best possible balance between comfort and energy savings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 shows an example of an overall environment in which an embodiment of the invention may be used.
[0008] FIG. 2 shows a high-level illustration of the architecture of a network showing the relationship between the major elements of one embodiment of the subject invention.
[0009] FIG. 3 shows an embodiment of the website to be used as part of the subject invention.
[0010] FIG. 4 shows a high-level schematic of the thermostat used as part of the subject invention.
[0011] FIG. 5 shows one embodiment of the database structure used as part of the subject invention.
[0012] FIG. 6 shows how comparing inside temperature against outside temperature and other variables permits calculation of dynamic signatures.
[0013] FIG. 7 shows how manual inputs can be recognized and recorded by the subject invention.
[0014] FIG. 8 shows how the subject invention uses manual inputs to interpret manual overrides and make short-term changes in response thereto.
[0015] FIG. 9 shows how the subject invention uses manual inputs to alter long-term changes to interpretive rules and to setpoint scheduling.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0016] FIG. 1 shows an example of an overall environment 100 in which an embodiment of the invention may be used. The environment 100 includes an interactive communication network 102 with computers 104 connected thereto. Also connected to network 102 are one or more server computers 106 , which store information and make the information available to computers 104 . The network 102 allows communication between and among the computers 104 and 106 .
[0017] Presently preferred network 102 comprises a collection of interconnected public and/or private networks that are linked to together by a set of standard protocols to form a distributed network. While network 102 is intended to refer to what is now commonly referred to as the Internet, it is also intended to encompass variations which may be made in the future, including changes additions to existing standard protocols.
[0018] One popular part of the Internet is the World Wide Web. The World Wide Web contains a large number of computers 104 and servers 106 , which store HyperText Markup Language (HTML) and other documents capable of displaying graphical and textual information. HTML is a standard coding convention and set of codes for attaching presentation and linking attributes to informational content within documents.
[0019] The servers 106 that provide offerings on the World Wide Web are typically called websites. A website is often defined by an Internet address that has an associated electronic page. Generally, an electronic page is a document that organizes the presentation of text graphical images, audio and video.
[0020] In addition to the Internet, the network 102 can comprise a wide variety of interactive communication media. For example, network 102 can include local area networks, interactive television networks, telephone networks, wireless data systems, two-way cable systems, and the like.
[0021] Network 102 can also comprise servers 106 that provide services other than HTML documents. Such services may include the exchange of data with a wide variety of “edge” devices, some of which may not be capable of displaying web pages, but that can record, transmit and receive information.
[0022] In one embodiment, computers 104 and servers 106 are conventional computers that are equipped with communications hardware such as modem or a network interface card. The computers include processors such as those sold by Intel and AMD. Other processors may also be used, including general-purpose processors, multi-chip processors, embedded processors and the like.
[0023] Computers 104 can also be handheld and wireless devices such as personal digital assistants (PDAs), cellular telephones and other devices capable of accessing the network.
[0024] Computers 104 may utilize a browser configured to interact with the World Wide Web. Such browsers may include Microsoft Explorer, Mozilla, Firefox, Opera or Safari. They may also include browsers used on handheld and wireless devices.
[0025] The storage medium may comprise any method of storing information. It may comprise random access memory (RAM), electronically erasable programmable read only memory (EEPROM), read only memory (ROM), hard disk, floppy disk, CD-ROM, optical memory, or other method of storing data.
[0026] Computers 104 and 106 may use an operating system such as Microsoft Windows, Apple Mac OS, Linux, Unix or the like.
[0027] Computers 106 may include a range of devices that provide information, sound, graphics and text, and may use a variety of operating systems and software optimized for distribution of content via networks.
[0028] FIG. 2 illustrates in further detail the architecture of the specific components connected to network 102 showing the relationship between the major elements of one embodiment of the subject invention. Attached to the network are thermostats 108 and computers 104 of various users. Connected to thermostats 108 are HVAC units 110 . The HVAC units may be conventional air conditioners, heat pumps, or other devices for transferring heat into or out of a building. Each user may be connected to server 106 via wired or wireless connection such as Ethernet or a wireless protocol such as IEEE 802.11, and router and/or gateway or wireless access point 112 that connects the computer and thermostat to the Internet via a broadband connection such as a digital subscriber line (DSL) or other form of broadband connection to the World Wide Web. In one embodiment, thermostat management server 106 is in communication with the network 102 . Server 106 contains the content to be served as web pages and viewed by computers 104 , as well as databases containing information used by the servers, and applications used to remotely manage thermostats 108 .
[0029] In the currently preferred embodiment, the website 200 includes a number of components accessible to the user, as shown in FIG. 3 . Those components may include a means to store temperature settings 202 , a means to enter information about the user's home 204 , a means to enter the user's electricity bills 206 , and means to elect to enable the subject invention 208 .
[0030] FIG. 4 shows a high-level block diagram of thermostat 108 used as part of the subject invention. Thermostat 108 includes temperature sensing means 252 , which may be a thermistor, thermal diode or other means commonly used in the design of electronic thermostats. It includes a microprocessor 254 , memory 256 , a display 258 , a power source 260 , and at least one relay 262 , which turns the HVAC system on and off in response to a signal from the microprocessor, and contacts by which the relay is connected to the wires that lead to the HVAC system. To allow the thermostat to communicate bi-directionally with the computer network, the thermostat also includes means 264 to connect the thermostat to a local computer or to a wired or wireless network. Such means could be in the form of Ethernet, wireless protocols such as IEEE 802.11, IEEE 802.15.4, Bluetooth, or other wireless protocols. The thermostat may be connected to the computer network directly via wired or wireless Internet Protocol connection. Alternatively, the thermostat may connect wirelessly to a gateway such as an IP-to-Zigbee gateway, an IP-to-Z-wave gateway, or the like. Where the communications means enabled include wireless communication, antenna 266 will also be included. The thermostat 250 may also include controls 268 allowing users to change settings directly at the thermostat, but such controls are not necessary to allow the thermostat to function.
[0031] The data used to generate the content delivered in the form of the website and to automate control of thermostat 108 is stored on one or more servers 106 within one or more databases. As shown in FIG. 5 , the overall database structure 300 may include temperature database 400 , thermostat settings database 500 , energy bill database 600 , HVAC hardware database 700 , weather database 800 , user database 900 , transaction database 1000 , product and service database 1100 and such other databases as may be needed to support these and additional features.
[0032] The website will allow users of connected thermostats 108 to create personal accounts. Each user's account will store information in database 900 , which tracks various attributes relative to users. Such attributes may include the make and model of the specific HVAC equipment in the user's home; the age and square footage of the home, the solar orientation of the home, the location of the thermostat in the home, the user's preferred temperature settings, etc.
[0033] As shown in FIG. 3 , the website 200 will permit thermostat users to perform through the web browser substantially all of the programming functions traditionally performed directly at the physical thermostat, such as temperature set points, the time at which the thermostat should be at each set point, etc. Preferably the website will also allow users to accomplish more advanced tasks such as allow users to program in vacation settings for times when the HVAC system may be turned off or run at more economical settings, and set macros that will allow changing the settings of the temperature for all periods with a single gesture such as a mouse click.
[0034] In addition to using the system to allow better signaling and control of the HVAC system, which relies primarily on communication running from the server to the thermostat, the bi-directional communication will also allow the thermostat 108 to regularly measure and send to the server information about the temperature in the building. By comparing outside temperature, inside temperature, thermostat settings, cycling behavior of the HVAC system, and other variables, the system will be capable of numerous diagnostic and controlling functions beyond those of a standard thermostat.
[0035] For example, FIG. 6 a shows a graph of inside temperature, outside temperature and HVAC activity for a 24-hour period. When outside temperature 302 increases, inside temperature 304 follows, but with some delay because of the thermal mass of the building, unless the air conditioning 306 operates to counteract this effect. When the air conditioning turns on, the inside temperature stays constant (or rises at a much lower rate or even falls) despite the rising outside temperature. In this example, frequent and heavy use of the air conditioning results in only a very slight temperature increase inside the house of 4 degrees, from 72 to 76 degrees, despite the increase in outside temperature from 80 to 100 degrees.
[0036] FIG. 6 b shows a graph of the same house on the same day, but assumes that the air conditioning is turned off from noon to 7 PM. As expected, the inside temperature 304 a rises with increasing outside temperatures 302 for most of that period, reaching 88 degrees at 7 PM. Because server 106 logs the temperature readings from inside each house (whether once per minute or over some other interval), as well as the timing and duration of air conditioning cycles, database 300 will contain a history of the thermal performance of each house. That performance data will allow server 106 to calculate an effective thermal mass for each such structure—that is, the speed with the temperature inside a given building will change in response to changes in outside temperature. Because the server will also log these inputs against other inputs including time of day, humidity, etc. the server will be able to predict, at any given time on any given day, the rate at which inside temperature should change for given inside and outside temperatures.
[0037] The ability to predict the rate of change in inside temperature in a given house under varying conditions may be applied by in effect holding the desired future inside temperature as a constraint and using the ability to predict the rate of change to determine when the HVAC system must be turned on in order to reach the desired temperature at the desired time.
[0038] In order to adapt programming to take into account the manual overrides entered into the thermostat, it is first necessary to determine when a manual override has in fact occurred. Most thermostats, including two-way communicating devices discussed herein, do not record such inputs locally, and neither recognize nor transmit the fact that a manual override has occurred. Furthermore, in a system as described herein, frequent changes in setpoints may be initiated by algorithms running on the server, thereby making it impossible to infer a manual override from the mere fact that the setpoint has changed. It is therefore necessary to deduce the occurrence of such events from the data that the subject invention does have access to.
[0039] FIG. 7 illustrates the currently preferred method for detecting the occurrence of a manual override event. In step 1002 , the server retrieves the primary data points used to infer the occurrence of a manual override from one or more databases in overall database structure 300 . The data should include each of the following: for the most recent point for which it can obtain such data (time 0 ) the actual setpoint as recorded at the thermostat (A 0 ); for the point immediately prior to time 0 , (time−1), the actual setpoint recorded for the thermostat (A−1); for time 0 the setpoint as scheduled by server 106 according to the standard setpoint programming (S 0 ), and for time 0 the setpoint as scheduled by server 106 according to the standard setpoint programming (S−1). In step 1004 , the server retrieves any additional automated setpoint changes C that have been scheduled for the thermostat by server 106 at time 0 . Such changes may include algorithmic changes intended to reduce energy consumption, etc. In step 1006 the server calculates the difference (dA) between A 0 and A−1; for example, if the setpoint at T 0 is 67 degrees at T−1 and 69 at T 0 , dA is +2; if the setpoint at T−1 is 70 and the setpoint at T 0 is 66, dA is −4. In step 1008 , the server performs similar steps in order to calculate dS, the difference between S 0 and S−1. This is necessary because, for example, the setpoint may have been changed because the server itself had just executed a change, such as a scheduled change from “away” to “home” mode. In step 1010 the server evaluates and sums all active algorithms and other server-initiated strategies to determine their net effect on setpoint at time 0 . For example, if one algorithm has increased setpoint at time 0 by 2 degrees as a short-term energy savings measure, but another algorithm has decreased the setpoint by one degree to compensate for expected subjective reactions to weather conditions, the net algorithmic effect sC is +1 degree.
[0040] In step 1012 , the server calculates the value for M, where M is equal to the difference between actual setpoints dA, less the difference between scheduled setpoints dS, less the aggregate of algorithmic change sC. In step 1014 the server evaluates this difference. If the difference equals zero, the server concludes that no manual override has occurred, and the routine terminates. But if the difference is any value other than zero, then the server concludes that a manual override has occurred. Thus in step 1016 the server logs the occurrence of an override to one or more databases in overall database structure 300 .
[0041] The process of interpreting a manual override is shown in FIG. 8. 1102 is the detection of an override, as described in detail in FIG. 7 In step 1104 the server retrieves contextual data required to interpret the manual override. Such data may include current and recent weather conditions, current and recent inside temperatures, etc. This data is helpful because it is likely that manual overrides are at least in part deterministic: that is, that they may often be explained by such contextual data, and that such understanding can permit anticipation of the desire on the part of the occupants to override and to adjust programming accordingly, so as to anticipate and obviate the need for such changes. In step 1106 the server retrieves any override data from the period preceding the specific override being evaluated that has not yet been evaluated by and incorporated into the long-term programming and rules engines as described below in FIG. 9 . The amount of data may be for a period of a few hours to as long as several days or more. Recent data will be more heavily weighted than older data in order to assure rapid adaptation to situations in which manual overrides represent stable changes such as changes in work schedules, etc. In step 1108 the server retrieves the stored rules for the subject thermostat 108 . Such rules may include weather and time-related inferences such as “if outside temperature is greater than 85 degrees and inside temperature is more than 2 degrees above setpoint and manual override lowers setpoint by 3 or more degrees, then revert to original setpoint in 2 hours,” or “if heating setpoint change is scheduled from “away” to “home” within following 2 hours after detected override, and override increases setpoint by at least 2 degrees, then change to “home” setting,” or the like. In step 1110 the server applies the rules to the override and determines which rule, if any, should be applied as a result of the override. In step 1112 the server determines whether to alter the current setpoint as a result of applying the rules in step 1110 . If no setpoint change is indicated, then the server proceeds to step 1118 . If a setpoint change is indicated, then in step 1114 the server transmits the setpoint change to the thermostat, and in step 1116 it records that change to one or more databases in overall database structure 300 .
[0042] In order to ensure that both the stored rules for interpreting manual overrides and the programming itself continue to most accurately reflect the intentions of the occupants, the server will periodically review both the rules used to interpret overrides and the setpoint scheduling employed. FIG. 9 shows the steps used to incorporate manual overrides into the long-term rules and setpoint schedule. In step 1202 the server retrieves the stored programming for a given thermostat as well as the rules for interpreting overrides for that thermostat. In step 1204 the server retrieves the recent override data as recorded in FIGS. 7 and 8 to be evaluated for possible revisions to the rules and the programming. In step 1206 the server retrieves the contextual data regarding overrides retrieved in step 1204 (Because the process illustrated in FIG. 9 is not presently expected to be executed as a real-time process, and to be run anywhere from once per day to once per month, the range and volume of contextual data to be evaluated is likely to be greater than in the process illustrated in FIG. 8 ). In step 1208 the server interprets the overrides in light of the existing programming schedule, rules for overrides, contextual data, etc. In step 1210 the server determines whether, as a result of those overrides as interpreted, the rules for interpreting manual overrides should be revised. If the rules are not to be revised, the server moves to step 1214 . If the rules are to be revised, then in step 1212 the server revises the rules and the new rules are stored in one or more databases in overall database structure 300 . In step 1214 the server determines whether any changes to the baseline programming for the thermostat should be revised. If not the routine terminates. If revisions are warranted, then in step 1216 the server retrieves from database 900 the permissions the server has to make autonomous changes to settings. If the server has been given permission to make the proposed changes, then in step 1218 the server revises the thermostat's programming and writes the changes to one or more databases in overall database structure 300 . If the server has not been authorized to make such changes autonomously, then in step 1220 the server transmits the recommendation to change settings to the customer in the manner previously specified by the customer, such as email, changes to the customer's home page as displayed on website 200 , etc.
[0043] FIG. 10 shows an example of some of the contextual data that may be used by the server in order to interpret manual overrides. Such data may include inside temperature 1302 , outside temperature 1304 , cloud cover 1306 , humidity 1308 , barometric pressure 1310 , wind speed 1312 , and wind direction 1314 .
[0044] Each of these data points should be captured at frequent intervals. In the preferred embodiment, as shown in FIG. 10 , the interval is once every 60 seconds.
[0045] Additional means of implementing the instant invention may be achieved using variations in system architecture. For example, much or even all of the work being accomplished by remote server 106 may also be done by thermostat 108 if that device has sufficient processing capabilities, memory, etc. Alternatively, some or all of these steps may be undertaken by a local processor such as a local personal computer, gateway 112 , or by a dedicated appliance having the requisite capabilities.
[0046] While certain embodiments of the inventions have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Indeed, the novel methods and systems described herein may be embodied in a variety of other forms; furthermore, various omissions, substitutions and changes in the form of the methods and systems described herein may be made without departing from the spirit of the inventions. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the inventions.
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Systems and methods are disclosed for incorporating manual changes to the setpoint for a thermostatic controller into long-term programming of the thermostatic controller. For example, one or more of the exemplary systems compares the actual setpoint at a given time for the thermostatic controller to an expected setpoint for the thermostatic controller in light of the scheduled programming. A determination is then made as to whether the actual setpoint and the expected setpoint are the same or different. Furthermore, a manual change to the actual setpoint for the thermostatic controller is compared to previously recorded setpoint data for the thermostatic controller. At least one rule is then applied for the interpretation of the manual change in light of the previously recorded setpoint data.
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FIELD OF THE INVENTION
The present invention relates to an anti-frost concrete mould.
BACKGROUND OF THE INVENTION
The use of forms, casings, moulds and shells is well known in the construction of cast-in-place concrete footings, piers and piles. These footings, piers and piles are used to transfer the loads of buildings, bridges, decks, porches, raised walkways, ramps, mini-home supports, highway sign posts and add-ons of existing structures to the underlying supporting soil. The concrete of a cast-in-place pile or footing is cast inside a mould that usually consists of a tin metal, plastic or paper shell left in the ground. The mould is usually so thin that its strength is disregarded in evaluating the structural capacity of the pile or footing. However, the mould must have adequate strength to resist collapse under the pressure from the surrounding backfill before it is filled with concrete. Similarly, if the mould is filled with concrete without the support of backfill, the mould must have sufficient strength to resist bursting pressures.
In northern latitudes, such as those which encompass Canada, northern Europe and the northern portions of the United States, soils, and particularly fine grained water saturated soils, are susceptible to the formation of ice lenses and frost heave. These phenomena can greatly diminish the stability and integrity of structures embedded in such soils. Therefore, footings are placed at a depth of not less than the depth of normal frost penetration. This prevents damage to the footing from the swelling and shrinkage of the surrounding soil caused by freeze-thaw cycles or displacement from frost heaving. However, while placing the footing below the depth of frost penetration will protect the footing from the effects of frost action, the pier that transfers the loads from the supported structure to the footing remains above the frost line and therefore remains vulnerable to frost and ice action.
The mechanisms of frost heave and frost action are well known to persons skilled in the art. The main phenomenon of concern to the construction industry is the displacement, laterally and vertically, of foundation members due to loads placed upon them from frost action. Where surrounding soil is frozen to a pier connecting a supported structure to a supporting footing, movement of the soil frozen to the pier will displace the pier. This will diminish the stability of the footing and structure to which it is attached no matter the depth of the footing below the frost line. In northern climates, a pier must be of a significant length to connect a footing placed below the frost line to the structure on the surface. Most of the entire length of the pier embedded in frost susceptible soil will be vulnerable to frost action.
Many examples of concrete moulds are known. However, none of these addresses the problem of being able to resist upward displacement due to frost heave in the surrounding soil. The problem is particularly acute in climates where the footing must be placed at a significant depth below the surface to remain unaffected by frost. One example of the known art is described in U.S. Pat. No. 5,271,203 issued to Nagle on Dec. 21, 1993 and entitled “Support Form For A Setable Material”. Nagle recognizes the problems associated with frost heave and compares the advantages of his invention over conventional thin-walled constant diameter moulds, such as the SONATUBE™, which he states are vulnerable to tipping and leaning due to lateral forces caused by frost heave in surrounding soil. While the Nagle invention relies upon its conical shape to resist frost heave, it possesses longitudinal ribs that could permit water to collect and freeze therein thus allowing localized frost action to act detrimentally upon the mould.
Furthermore, the dimensions of the Nagle invention, specifically its height to width ratio, approaches unity. Therefore, for deep frost line applications, where the mould would have to be embedded deeply into the soil and remain connected to the above surface supported structure, the resulting mould of the Nagle design would have to be very large. This would result in greater expense and the mould would require a significant volume of setable material to fill it.
An additional disadvantage of the Nagle invention is that it is of a fixed height and cannot be adjusted at the work site to adapt to the variable depth of excavations. Furthermore, the Nagle invention does not possess anchoring means to prevent the mould from shifting as the concrete is poured. Furthermore, if the Nagle invention is left exposed to the elements for several days before the setable material is poured, there are no means to anchor the Nagle invention to the ground to prevent wind and rain forces from displacing the Nagle invention.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an improved concrete mould that resists the detrimental action of frost heave.
In accordance with an aspect of the present invention there is provided an anti-frost concrete mould that resists the adhesion of frost, ice and frozen soils. The mould generally resembles a cone and comprises an upper frustoconical portion coaxially aligned with a lower drum portion whose outer surface extends outwardly and downwardly from a transitional shoulder. The shoulder connects the upper portion of the mould with the lower portion of the mould. The mould has opposed top and bottom ends and a continuous and smooth exterior surface. The mould is manufactured from recycled material bound with a binding agent. The bottom end of the mould has an integral anchor flange extending horizontally from it. The anchor flange is apertured at regular intervals for holding anchoring means in the form of pins, nails, dowels and other hold-down devices. The mould is sufficiently resilient and rigid to withstand the pressure from surrounding soil attempting to collapse the mould inwardly. The mould is further able to withstand fluid pressures from the fluid setable material contained therein attempting to burst the mould outwardly. The mould has a smooth outer and inner surface.
In a further aspect of the present invention there is provided an inexpensive and simple method of manufacturing the mould comprising the steps of: determining the appropriate dimensions of the mould to suit the intended purpose; producing a die in obedience to the desired dimensions of the mould; covering said die with a non-stick fabric; applying a plurality of layers of a mixture of binding agent and recycled material to the fabric covering the die until a mould of the desired thickness is formed; finishing the mould with a smooth surface of binding agent.
In a further embodiment of the invention, the mould may be manufactured using injection moulding techniques.
In yet another aspect of the present invention it is contemplated that the mould be manufactured from resilient, rigid and light weight recycled materials, such as, wood, plastic, cloths, fabrics or other synthetic or natural materials bound together using a binding agent. The outer surface of the mould will have a smooth surface with frost and ice adhesion resistant properties.
Yet another aspect of the present invention contemplates a method of using the mould comprising the steps of: excavating a cavity in the earth; placing a mould of desired dimensions into the cavity; anchoring the mould through the anchoring flange using anchoring means; adjusting the height of the mould as necessary by cutting away excess mould along the grooves at the top end of the mould; backfilling the excavation around the mould; if necessary, capping the open top end of the mould with capping means to prevent water from collecting within the mould; when convenient, filling the mould with a setable material, generally concrete; insert the desired structure to be supported by the concrete before setting or alternatively allow the concrete to set and then affix the concrete mould to the structure to be supported; and, leaving the mould in place.
Advantages of the present invention are that the mould can be used in locations where there is a deep penetration of frost and a frequent cycle of soil freezing and thawing without being displaced. The mould is also easy and inexpensive to manufacture being made from recycled materials.
BRIEF DESCRIPTION OF DRAWINGS
The present invention will be further understood from the following description with references to the drawings in which:
FIG. 1 illustrates an example of the known art.
FIG. 2 illustrates in perspective view one embodiment of the present invention.
FIG. 3 illustrates in sectional side view another embodiment of the present invention.
FIG. 4 illustrates a side-view of one embodiment of the present invention.
FIG. 5 illustrates a top view of one embodiment of the present invention.
FIG. 6 illustrates a bottom view of one embodiment of the present invention.
FIG. 7 illustrates a sectional side view of one embodiment of the present invention showing possible dimensions to suit one application of the present invention.
FIG. 8 illustrates a top view of one embodiment of the present invention showing possible dimensions to suit one application of the present invention.
FIG. 9 illustrates a bottom view of one embodiment of the present invention showing possible dimensions to suit one application of the present invention.
DETAILED DESCRIPTION
An example of a known concrete mould is shown in FIG. 1 and has been previously discussed.
FIG. 2 shows one embodiment of the present invention ( 10 ) comprising a hollow rigid elongated mould ( 12 ) generally resembling a cone. The mould has opposed top ( 14 ) and bottom ( 16 ) ends. In a preferred embodiment of the present invention the diameter of the top end is approximately 33% the diameter of the bottom end. The mould ( 12 ) has a continuous and smooth exterior surface ( 18 ). The mould is manufactured from material which resists the adhesion of frost, ice and frozen soils.
The bottom end of the mould has an integral anchor flange ( 20 ) perforated at regular intervals ( 22 ) to hold anchoring means.
FIG. 3 shows another embodiment of the present invention in sectional side view in which the mould ( 12 ) comprises an upper frustoconical portion ( 30 ) coaxially aligned with a lower drum portion ( 34 ) whose outer surface extends outwardly and downwardly from a transitional shoulder ( 32 ) connecting the upper portion with the lower portion of the mould. In a preferred embodiment of the present invention, the diameter of the top opening ( 14 ) of the conical upper portion ( 30 ) is approximately 50% of the diameter of the bottom opening ( 15 ) of the upper conical portion ( 30 ). In a preferred embodiment of the present invention, the height of the upper conical portion ( 30 ) represents approximately 85% of the total height of the mould. Therefore, the upper conical portion ( 30 ) of the mould ( 12 ) acts as a pier connecting the supported structure to the supporting soil. In a preferred embodiment of the present invention, the interior angle ( 17 ) of the wall of the upper conical portion ( 30 ) of the mould ( 12 ) is approximately 85 degrees from a horizontal plane bisecting the bottom end ( 15 ) of conical portion ( 30 ). In a preferred embodiment of the present invention, the thickness of the mould ( 12 ) at the top end ( 14 ) of the upper conical portion ( 30 ) is approximately ⅜ inches and the thickness at the bottom end ( 15 ) of the upper conical portion ( 30 ) is approximately ½ inches.
Attached and integral to the bottom ( 15 ) of the upper conical portion ( 30 ) is transitional shoulder ( 32 ). Transitional shoulder ( 32 ) is also attached and integral to the upper end of the drum portion ( 34 ) of the mould ( 12 ). As seen from inside the mould, and from the top to the bottom of the transitional shoulder, transitional shoulder ( 32 ) comprises a first convex ( 32 a ) surface and a second concave surface ( 32 b ) joined together. In a preferred embodiment of the present invention, each surface ( 32 a & 32 b ) has a radius of approximately 1 inch. The resulting effect of the transitional shoulder ( 32 ) is to expand the diameter of the mould ( 12 ) by approximately 50% from the lower end of the conical portion ( 30 ) to the lower end of the drum portion ( 34 ). In a preferred embodiment of the present invention, the height of the transitional shoulder ( 32 ) is approximately 4% of the total height of the mould ( 12 ).
Stacking supports ( 36 ) are attached to the mould ( 12 ) at the shoulder ( 32 ) and are spaced equidistantly about the circumference of the mould. In a preferred embodiment of the present invention, there are four stacking supports equidistantly spaced about the circumference of the mould, approximately ½ inches wide by 1 ¼ inches long by approximately 3½ inches in height.
The lower drum portion ( 34 ) of the mould ( 12 ) extends downwardly and outwardly from the transitional shoulder ( 32 ). In a preferred embodiment of the present invention, the interior angle formed by the wall of the drum portion to a horizontal plane bisecting the lower drum portion at ( 16 ) is approximately 85 degrees so that the walls of the upper conical portion ( 30 ) and the walls of the lower drum portion ( 34 ) are substantially parallel. In a preferred embodiment of the present invention, the height of the drum portion ( 34 ) is approximately 10% of the total height of the mould ( 12 ). The diameter of the mould at the bottom end ( 16 ) of the drum portion is approximately 300% of the diameter of the top portion ( 14 ).
The anchor flange ( 38 ) is attached and integral to the bottom of the drum portion ( 34 ) of mould ( 12 ). The anchor flange ( 38 ) is sufficiently dimensioned to withstand potential shearing forces which may be developed between the anchor flange and the anchor means ( 40 ) fixing the mould to the soil. The anchor means may comprise nails, hold-downs, pins, bolts, dowels and similar devices inserted through the apertures in the anchor flange which anchor means are of sufficient length to fix the mould in the desired location. In a preferred embodiment of the present invention, the outer diameter of the anchor flange is approximately 125% the inner diameter of the lower end of the drum portion ( 34 ) and the thickness of the mould from the transitional shoulder to the tip of the anchor flange is approximately ½ inches.
While FIG. 3 shows an embodiment of the present invention with the bottom end ( 16 ) of mould ( 12 ) open so that the setable material is in direct contact with the supporting soil, it may also be closed. Whether open or closed, the diameter of the lower end ( 16 ) of the drum portion ( 34 ) is adequately large enough to transfer the loads from the supported structure to the underlying soil.
As shown in FIG. 3, the present invention must be sufficiently rigid and resilient to resist crushing pressure from surrounding soil and bursting pressure from the setable material contained therein before setting.
Referring to FIG. 4, one embodiment of the present invention shows the plurality of spaced concentric rings ( 41 ) located at the top of the frustoconical portion ( 30 ) of mould ( 12 ) which circumscribe the outer surface of the cone. In the preferred embodiment of the present invention, these rings are spaced at two inch intervals from the top of the cone down to approximately 18 inches from the top of the cone. A worker uses these rings as a guide to remove excess material from the top of the cone. In a preferred embodiment of the invention these rings comprise a series of raised dots approximately ⅛ inches in height.
FIG. 5 shows a top view of one embodiment of the present invention illustrating the spacial relationship between the top of the cone ( 14 ); the concentric rings ( 41 ); the stacking shoulders ( 36 ); and the anchor flange ( 38 ). Also shown is a plurality of holes ( 22 ) through which anchoring means are placed.
FIG. 6 shows a bottom view of one embodiment of the present invention illustrating the spacial relationship between the anchor flange ( 38 ); the holes through which the anchor means are placed ( 22 ); the drum portion of the mould ( 34 ); the transitional shoulder ( 32 ); between the drum portion ( 34 ); and, the frustoconical cone portion ( 30 ) of the mould ( 12 ). While FIG. 6 shows an embodiment of the present invention with an open bottom, it is contemplated that the bottom may be sealed.
Although it is understood by a person skilled in the art that the size and dimensions of the mould can be varied to suit the intended purpose, FIGS. 7, 8 and 9 show examples of the dimensions of embodiments of the present invention to suit a specific application.
The present invention contemplates that the mould is to be manufactured from resilient, rigid and light weight recycled materials, such as, wood, plastic, cloths, fabrics or other synthetic or natural materials bound together using a binding agent. The outer surface of the mould will have a smooth surface with frost and ice adhesion resistant properties.
Numerous modifications, variations, and adaptations may be made to the particular embodiments of the invention described above without departing from the scope of the invention, which is defined in the claims.
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An anti-frost concrete mold having an upper frustoconical portion, a transitional shoulder portion and a lower drum portion. The top portion of the mold is adjustable in height. The mold is fabricated simply by molding it over a die. The mold is fabricated from various suitable recycled materials bound with a binding agent.
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BACKGROUND OF THE INVENTION
Modern looms place increasing demands on the precision of components. This applies especially to the heddle shafts. They are operating at very high speeds during the weaving operation. It is absolutely necessary that heddle shafts are guided in a sufficiently precise manner to avoid added stress. However, it is an essential prerequisite that the heddle shafts themselves are manufactured in a sufficiently precise manner. Additionally, they must be constructed in such a way that the side struts may be simply disassembled for the insertion of heddles and re-assembled thereafter by having the original precision. Multiple changing of components in weaving mills has the consequence that shaft rods and side struts will be mixed up. Components being manufactured with higher precision solve this problem only to a small degree since larger differences from one production lot to the other is unavoidable. A novel constructional solution is thereby necessary. Corner edge connections from prior art do not, however, fulfill the requirements.
Various attempts are known from the prior art. Since it may be assumed that precise alignment of side struts was not the object of the proposed solution at the time of their creation, one must not be surprised that the precision reached up to now is not sufficient for current demands. According to that disclosed in Swiss patent 427 688 there cannot be achieved sufficient precision merely because of the tolerance or play which the bolt requires within the threads. As disclosed in U.S. Pat. No. 3,180,367 the bolts 22 shown therein would need to be dowel bolts fitted into correspondingly precise borings. However, such a solution is not achievable because of the stress that is currently placed on heddle shafts. The marginal portions 13 according to this prior art patent are either no longer in existence or they must not be weakened anymore by longitudinal borings. The invention disclosed in Japanese patent 56-39 478 has no elements that would make sufficiently precise alignment possible. The same applies for Japanese patent 56-14 3286 and Russian patent 105 143.
A solution for this problem is proposed in Japanese patent 37-31581. However, this is inapplicable for modern heddle shafts based on a completely different shaft profile in its design.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to propose a corner connection for a heddle shaft that assures simple and precise alignment of side struts and shaft rods in one place at all times, and which additionally fulfills present demands in total to which the heddle shafts are exposed. The invention allows the exchange of side struts and shaft rods with one another while nevertheless maintaining the necessary precision during assembly without extraordinary measures. The main objective is to achieve an alignment of the side struts and the shaft rods in one plane in a simple and repeatable manner.
A corner connection of a heddle shaft is provided according to the invention whereby on or in the shaft rod there is at least a first guide surface provided, which extends nearly parallel to the longitudinal axis of the shaft rod and which engages with a positive fit a second guide surface extending along a projection of the side strut at least nearly parallel to the shaft rod or perpendicular to the side strut.
The solution according to the invention has also the object to provide a corner connection which allows simple detachment of side struts and which always assures the same positioning precision of components during assembly. The positioning precision relates thereby to the twisting of components against one another and their alignment in one plane. Positioning is achieved according to the invention whereby guide surfaces are placed on the ends of the shaft rods and on each projection of the side strut, respectively, which ensures precise positioning as soon as said guide surfaces engage one another. The same precision in positioning is also achieved after detachment of the connection and reassembly of the components.
In a preferred embodiment, guide surfaces required for the side struts are placed directly on the projection of the side strut, which engages the shaft; whereby the guide elements, having the cooperating guide surface (s), are mounted or attached in or on the shaft rod by means of rivets, for example. The guide surfaces of the elements on the shaft rod are designed in the shape of ridges, whereas the ones on the counter-support are designed as grooves, for example. An exactly converse configuration is possible, of course, and it would not change the inventive effect. This effect is achieved in that the guide surfaces interlock with positive fit.
The projection of the side strut is inserted into the shaft rod to couple the shaft rod to the side strut. The guide surfaces of all components come thereby into contact with one another. The guide elements attached to the shaft rod may be drawn together by means of a tensioning bolt to secure the coupling whereby the side struts are held by clamping of their projections. A slot may be placed parallel to the longitudinal axis of the shaft rod and between the two guide elements to achieve the necessary flexibility on the shaft rod. In addition, one of the guide elements may be provided with threads for a tensioning bolt. The projection of the side strut may be provided with a cavity on the inside, extending parallel to the plane of the assembled shaft whereby the space of the cavity extending cross-wise to the plane is slightly larger than the diameter of the bolt. The depth of the cavity is sized in such a manner that the tensioning bolt may be rotated freely in the assembled condition of the side strut and shaft rod. This cavity, which is open toward the shaft rod, makes it possible to separate the side strut from the shaft rod while the tensioning bolt is slightly loosened so that the tensioning bolt does not have to be completely unscrewed from the threads and removed from the shaft rod. Loosening of the tensioning bolt is thereby prevented. Assembly of the side strut and shaft rod is possible in the same fashion. The bolt has to be rotated only slightly thereby.
Additional preferred embodiments of the corner connection defined in the invention are characterized in the dependent claims.
The invention is now explained in more detail by examples in reference to accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevational view an embodiment of the corner connection according to the invention;
FIG. 2 is a view similar to FIG. 1 of another embodiment of the corner connection of the invention;
FIG. 3 and FIG. 4 are perspective views of the so-called stop element of FIG. 1 and FIG. 2, respectively;
FIG. 5 is a sectional view taken substantially along the line A—A of FIG. 1, rotated 180°, showing the guide surfaces provided for interlocking with positive fit;
FIG. 6 is an expanded view, in perspective, of the elements of FIG. 3 and FIG. 4 together with a side strut; and
FIG. 7 is a view similar to FIG. 6 of an alternatively structured side strut.
DETAILED DESCRIPTION OF THE INVENTION
Shown in FIG. 1 is a hollow heddle shaft 1 , partly broken away, onto which the heddle shaft support bar 9 is attached. A side strut 2 , partly broken away, has a projection 11 extending into an end of hollow shaft 1 for engagement between two guide elements, which are firmly arranged in or on the shaft 1 , having a stop element 3 and a threaded plate 4 . The projection 11 of the side strut is arrested between stop element 3 and threaded plate 4 , which are attached in or on the shaft rod 1 , whereby the stop element 3 is urged toward the threaded plate 4 . This is made possible because the shaft rod has a specific flexibility by the provision of a slot 6 at the end section of the shaft rod. The stop element 3 is provided additionally with a machined surface 10 (see also FIG. 3 ), which serves to position the side strut 2 in longitudinal direction of the profile of shaft 1 . According to the embodiment in FIG. 1, there is also a drive element 7 attached to the side strut 2 by means of riveting 8 .
FIG. 2 shows a corner connection configured essentially the same as in FIG. 1, whereby the stop element 3 ′ is designed considerably larger so that a drive element 7 ′ for the heddle shaft may be fastened directly to stop element 3 ′ instead of being fastened to side strut 2 as in FIG. 1, for example. Also, the tensioning bolt 5 may be arranged at an angle to the longitudinal axis of the shaft profile 1 instead of vertically as shown in FIG. 1 .
FIG. 3 is a perspective view of a typical embodiment of a guide element or stop element 3 according to FIG. 1 shown rotated 180°. The positioning elements or surfaces 10 and 14 are clearly visible. The surface 10 is essentially a stop surface for the side strut. The function of guide element 14 is explained in more detail in FIG. 5, stop element 3 being identified therein by reference numeral 20 for clarification.
Holes 13 may extend through stop element 3 for use as rivet holes for attachment of stop element 3 in the cavity of shaft rod 1 . Other fastening means such as welding or gluing may be used, depending on the type of material used. Hole 12 serves as a passage for a tensioning bolt 5 according to FIG. 1 .
FIG. 4 is a perspective view of a typical embodiment of a guide element or stop element 3 ′ shown in FIG. 2 . The positioning elements 10 ′ and 14 ′ are better visible therein. The surface 10 ′ is essentially a stop surface for the side strut. The function of element 14 ′ is explained in more detail in FIG. 5 and it is identified therein by reference numeral 22 for clarification.
Holes 13 ′ may extend through element 3 ′ for use as rivet holes for attachment of stop element 3 ′ in the cavity of the shaft rod 1 . Other fastening means such as welding or gluing may be used, depending on the type of material used. The through hole 12 ′ serves as a passage for tensioning bolt 5 according to FIG. 2 .
FIG. 5 shows a schematic cross-sectional view taken through the positioning element of the corner connection of the invention along the line A—A in FIG. 1 . The sectioned stop 14 of the stop element 3 from FIG. 3 is identified by reference numeral 20 for clarification. It is provided with the surfaces 23 and 23 ′ for positioning in a Y-direction and with the surfaces 24 and 24 ′ for positioning in an X-direction of the guide or stop element 3 of FIG. 3 .
The surfaces 25 and 25 ′ of section 21 serve as counterparts that respectively come into contact with the surfaces 23 and 23 ′, and surfaces 26 and 26 ′ of section 21 respectively come into contact with surfaces 24 and 24 ′. The surfaces 28 and 28 ′ as well as 27 and 27 ′ are also located on section number 21 , which is a section through the projection 11 of the side strut 2 according to FIG. 1 . And, surfaces 28 and 28 ′ as well as 27 and 27 ′ make contact with the cooperating surfaces 30 and 30 ′ or 29 and 29 ′, respectively, which extend in a longitudinal direction on threaded plate 4 according to FIG. 1, which is identified here in the section by reference numeral 22 .
The surfaces 30 and 30 ′ on the sectioned threaded plate serve for positioning in a Y-direction the projection 11 of the side strut 2 according to FIG. 1 and the surfaces 29 and 29 ′ for positioning in an X-direction, the projection being identified by reference numeral 21 in the cross-section.
The aforedescribed positioning surfaces acting between projection 11 and threaded plate 4 and stop element 3 of FIG. 1 are the same in shape and function as the positioning surfaces acting between projection 11 and threaded plate 4 and stop element 3 ′ of FIG. 2 .
With sufficiently large contact areas of the surfaces 23 , 23 ′; 24 , 24 ′, 25 , 25 ′ and 26 , 26 ′, the symmetrically arranged surfaces 27 , 27 ′; 28 , 28 ′; 29 , 29 ′ and 30 , 30 ′ may be eliminated. Since precise machining of the surfaces becomes, nevertheless, more difficult and costly with its increasing size, the configuration shown in cross-sectional view in FIG. 5 is preferred.
The cooperating surfaces 23 , 23 ′ or 30 , 30 ′ as well as 24 , 24 ′ or 29 , 29 ′ reliably prevent twisting of the side strut relative to the shaft rod—even when these surfaces are small in size. This is an important function since an even surface of the entire shaft layout can be assured only through this function. All embodiments known from prior art, having projections on the side strut engaging the cavity of the shaft rod, do not fulfill this requirement since sufficiently precise machining inside the cavity of the shaft rod would have been very difficult and very costly. The guide elements may, according to the invention, be manufactured in a precise manner with simple means and may, above all, be reproduced in large numbers at low manufacturing cost.
An additional un-illustrated embodiment of the surfaces 24 , 24 ′; 26 , 26 ′; 29 , 29 ′and 27 , 27 ′ is possible whereby these surfaces are angled to facilitate dovetail engagement between sections 21 , 20 and 21 , 22 .
The embodiment shown in FIG. 2 is preferably used when drive elements 7 ′ are to be fastened to the outer end of the shaft rod 1 . In that case, the shape of the stop element 3 ′ assures that the drive forces, which act upon element 7 ′, are directly transferred to the side strut 2 or its projection 11 so that the shaft profile 1 does not have to transfer such force and be additionally stressed thereby. The same application can also be used with a bolt 5 , which is arranged perpendicular to the longitudinal axis of the shaft rod 1 as shown in FIG. 1, as long as this is allowed by the position of the drive element. This will always be the case whenever the distance to the side strut 2 is sufficiently large.
FIG. 6 is a perspective illustration of the elements 3 and 4 from FIG. 2 —together with a perspective and somewhat simplified illustration of the side strut 2 with a projection 11 thereof to clarify interlocking of the three elements. The cavity 18 for the bolt 5 is also visible therein. The depth of the cavity is at the most about three-fourths the length of projection 11 .
Shaft rod 1 may be of shaped aluminum or steel. And, side strut 2 may be of shaped aluminum or steel pipe. Further, the side strut may be of unitary construction as shown in FIGS. 1 and 2, or may be constructed of parts welded together as at 31 shown in FIG. 7 . Otherwise, the shaft rod and/or the side strut may be of a fiber-reinforced synthetic material or a combination of various metals and fiber-reinforced synthetic material, without departing from the invention.
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In a connection of a shaft rod to a side strut of a heddle shaft there is at least one guide surface provided in or on the shaft rod. The guide surface extends substantially parallel to the longitudinal axis of the shaft rod. The guide surface engages with a positive fit to a second guide surface extending along a projection of the side strut substantially parallel to the shaft rod or perpendicular to the side strut.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This Application is a Continuation-in-Part of application Ser. No. 12/940,229, filed Nov. 5, 2010, now pending, and entitled Charging Device and Associated Electrical Appliances.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The instant disclosure relates to a charging device and associated electrical appliances; in particular, a charging device and associated composite power strip, composite wall outlet assembly, and composite lighting structure.
[0004] 2. Description of the Related Art
[0005] Utility power is often accessed through wall sockets. When portable electronics such as mobile phones, digital cameras, and PDAs (Personal Digital Assistant) need to be recharged, a charger is plugged into an electrical outlet to charge the mobile devices.
[0006] However, the use of cables can cause inconvenience to the users. Wireless charging would eliminate the need for cable connections.
[0007] In the Taiwan Publication No. 592378, titled “Universal Serial Bus Transformer”, the inventor previously disclosed a transformer that supplies standard power source. The user would not require to purchase device-specific transformers. However, the transformer can not perform wireless charging.
[0008] To resolve the above shortcoming, the inventor proposes the following solution.
SUMMARY OF THE INVENTION
[0009] The object of the instant disclosure is to provide a charging device and associated electrical appliances, where charging can be performed using cable connection and wireless method.
[0010] To achieve the above object, the instant disclosure provides a composite power strip, which includes a housing having a body, which has at least one electrical outlet, where the electrical outlet is wired to a power source, and a receiving compartment is formed upon the body, with the receiving compartment having at least one first terminal; and a charging device having at least one electrical interface, a wireless charging transmitter, and at least one second terminal, where the charging device is removably attached to the receiving compartment, with the second terminal connecting electrically to the first terminal.
[0011] The instant disclosure also provides a composite wall outlet assembly, which includes a housing having a body, with at least one electrical outlet positioned thereupon, where a receiving compartment is defined by the body, and the receiving compartment has at least one first terminal; and a charging device having at least one electrical interface, a wireless charging transmitter, and at least one second terminal, where the charging device is removably attached to the receiving compartment, with the second terminal connecting electrically to the first terminal.
[0012] The instant disclosure further provides a composite lighting structure. The composite lighting structure has a base, which defines a receiving compartment having at least one first terminal; a light source attached to the base; and a charging device having at least one electrical interface, a wireless charging transmitter, and at least one second terminal, where the charging device is removably attached to the receiving compartment, with the second terminal connecting electrically to the first terminal.
[0013] The instant disclosure still further provides a charging device having at least one electrical interface, a wireless charging transmitter, and at least one first terminal.
[0014] The instant disclosure presents the following advantages. First, the charging device can charge one or more electronic device via the electrical interface, and also provides wireless charging to an electronic device having a wireless charging receiver. Second, a bad charging device can be discarded from the electrical appliance body for replacement purpose. Similarly, the wireless charging transmitter can be replaced separately from the charging device also. For cost-effectiveness, the electrical appliance itself can be saved by only replacing the bad charging device or transmitter.
[0015] In order to further appreciate the characteristics and technical contents of the instant disclosure, references are hereunder made to the detailed descriptions and appended drawings in connection with the instant disclosure. However, the appended drawings are merely shown for exemplary purposes, rather than being used to restrict the scope of the instant disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 shows an exploded view of a composite power strip of the first embodiment.
[0017] FIG. 2 shows an isometric view of a composite power strip of the first embodiment.
[0018] FIG. 3 shows a schematic view of a composite power strip in use of the first embodiment.
[0019] FIG. 4 shows an exploded view of a composite power strip of the second embodiment.
[0020] FIG. 5 shows an exploded view of a composite power strip of the third embodiment.
[0021] FIG. 6 shows an isometric view of a composite power strip of the third embodiment.
[0022] FIG. 7 shows a schematic view of a composite power strip in use of the third embodiment.
[0023] FIG. 8 shows an isometric view of a composite power strip of the fourth embodiment.
[0024] FIG. 9 shows an isometric view of a composite wall outlet assembly of the fifth embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] For the first embodiment shown in FIGS. 1 and 2 , a composite power strip has a housing 1 , which includes a body 11 having at least one electrical outlet 12 and an on/off switch 13 . The electrical outlet 12 has slots 121 and a conductive strip therein (not shown). The electrical outlet 12 is not restricted in type and can be any electrical connector. A power cord 14 is electrically connected to the electrical outlet 12 for propagating electrical current from the power source to the electrical outlet 12 . A charging device 2 is removably attached to a receiving compartment 15 formed upon the body 11 . The receiving compartment 15 is sized according to the dimensional aspect of the charging device 2 . The receiving compartment 15 has at least one first terminal 16 for mating electrically to an at least one second terminal 23 on the charging device 2 . The first terminal 16 can be located on the side or bottom surface of the receiving compartment 15 and is connected electrically to the power cord 14 . Thereby, the charging device 2 can connect electrically to the interior electrical circuitry of the housing 1 and receive the power accordingly.
[0026] As depicted in FIG. 1 , the charging device 2 of the instant disclosure has at least one electrical interface 21 for charging using cable connection and a transmitter 22 for charging wirelessly. Among others the electrical interface 21 can be a USB connector, IEEE 1394 connector, HDMI connector, A/V connector, or DC connector. Meanwhile, the charging device 2 has a square-shaped body, but can alternatively be formed in many shapes and sizes according to the operation requirement. As shown in FIGS. 1 to 3 , the charging device 2 has a recess 25 for receiving the removable transmitter 22 . The transmitter 22 and the recess 25 have a first and second electrical contact 221 and 251 respectively. The first electrical contact 221 can connect electrically to the second electrical contact 251 , thus allowing the transmitter 22 to be electrically connected to the internal electrical circuitry of the charging device 2 . The charging device 2 can further includes a retrievable cord 26 having a power connector 27 on the free end. A built-in transformer, signal light, sensor, timer, or GCFI (ground fault circuit interrupter) may also be included in the charging device 2 .
[0027] Notably, the transmitter 22 can also be integrally fixed to the charging device 2 as depicted in FIGS. 5 , 6 , 8 , and 9 .
[0028] In use, a battery 3 ′ having a charging receiver can be placed on the charging device 2 as depicted in FIG. 3 . Then, the battery 3 ′ is charged via electromagnetic induction, cord-and wire-free. FIG. 7 shows another example, where an electronic device 3 , such as a mobile phone, can be recharged by connecting electrically to the electrical interface 21 via a connection cable. On the other hand, if the mobile phone includes a charging receiver 31 , the mobile phone can be placed on the charging device 2 for charging wirelessly.
[0029] According to another embodiment, the composite power strip can further include a cable 5 to provide more secured connection as shown in FIG. 4 . The cable 5 is connected to a first connector 51 on one end and a second connector 52 on the other end. Moreover, a receiving space 18 is formed near an edge of the body 11 and corresponded to the position of the electrical interface 21 of the charging device 2 , so that the first connector 51 can be inserted into the receiving space 18 and electrically connected to the electrical interface 21 of the charging device 2 . To charge an electronic device, the first connector 51 of the cable 5 is inserted into the receiving space 18 and electrically connected to the electrical interface 21 of the charging device 2 . Meanwhile, the second connector 52 of the cable 5 is electrically connected to the electronic device, such as a mobile phone, for charging operation. Functionally, the receiving space 18 shelters the first connector 51 to protect the cable connection. Furthermore, a first slot 19 and a second slot 20 can further be formed on the body 11 for receiving the cable 5 and the second connector 52 while not in use. Thus, when the cable 5 and second connector 52 are not in use, the user needs not to remove the cable 5 and the second connector 52 from the body 11 because the cable 5 and the second connector 52 can be stored in the first slot 19 and the second slot 20 of the body 11 without occupying a large space. Moreover, when the user needs to use the cable 5 , the user does not need to find the cable 5 somewhere. That is very convenient for the user. Preferably, the receiving space 18 and the second slot 20 are in communication with the first slot 19 , and a shape of the second slot 20 is corresponded to a shape of the second connector 52 .
[0030] To secure the electronic device on the charging device 2 while charging, the charging device 2 can further include at least one magnetic member 24 as shown in FIGS. 5 and 6 for a third embodiment. While the electronic device is placed on the charging device 2 , the magnetized charging device 2 will attract the electronic device having an outer casing made of magnetic material to better secure the electronic device while charging.
[0031] In a fourth embodiment as shown in FIG. 8 , the power strip can further include a support plate 17 . Namely, the body 11 of the housing 1 comprises the hinged support plate 17 that radially releases for resting the electronic device 3 .
[0032] In a fifth embodiment, as shown in FIG. 9 , the instant disclosure provides a composite wall outlet assembly having a charging device 2 . For the composite wall outlet assembly, the body 11 of the housing 1 is rectangular-shaped, but can alternatively be formed in any shape. The body 11 is made of one or more plate and secured to the wall. The body 11 can also include a hinged support plate 17 that radially releases for resting the electronic device 3 .
[0033] In summary, the charging device 2 and associated electrical appliances of the instant disclosure provide charging using cable connection and wireless option. The option of using USB type connector for the electrical interface 21 offers a standard charging mode of using cable connection. Furthermore, more than one electronic device can be charged simultaneously for flexibility and convenience.
[0034] The descriptions illustrated supra set forth simply the preferred embodiments of the instant disclosure; however, the characteristics of the instant disclosure are by no means restricted thereto. All changes, alternations, or modifications conveniently considered by those skilled in the art are deemed to be encompassed within the scope of the instant disclosure delineated by the following claims.
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A charging device and associated electrical appliances are provided. More than one electronic device can be charged simultaneously, with a wireless charging option available. Thus, the user has greater flexibility in selecting the desired charging option. Each associated appliance has a receiving compartment to hold the charging device, and the receiving compartment is configured with at least one first terminal. The charging device has at least one electrical interface for cable connection, a wireless charging transmitter, and at least one second terminal for mating electrically to the first terminal.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates generally to a mechanism that will dispense a single unit of paper literature when manually actuated. The mechanism is attached to a coin slide to enable collection of coinage for each unit of literature dispensed. The mechanism is mounted in a container in a manner which allows it to remove the lower unit from a stack of literature. This container also facilitates secure holding of coinage used in the coin slide.
2. Description of the Prior Art
The current literature distribution systems in common usage are simple box containers that allow removal of one or more pieces of literature at no charge. The current systems are generally unprofessional in appearance and present several problems. The current systems do not prevent the public from taking multiple copies of the literature. They do not allow the owner to collect a fee for each piece of literature that is distributed. Current systems are not weather resistant and often allow damage to the contents from the elements such as moisture and sunlight. This invention provides a solution to all of these problems.
SUMMARY OF THE INVENTION
This invention relates to a literature dispensing mechanism that is housed in a weather resistant box and is activated by a vending coin slide.
The mechanism consists of a connecting bar which is attached to the coin slide. A U-bolt attaches to the connecting bar by means of a bearing attachment that allows the u-bolt to rotate. Pieces of square metal bar, ejector bars, have holes drilled through them and are bolted to each end of the u-bolt, perpendicular to the bolt and point upward. A small flat plate, ejector plate, is welded to the upper end of the square bars. A friction material, ejector friction pad, is attached to the upper side of this ejector plate. Just below this ejector plate a guide shaft is installed through holes in the upper ends of both ejector bars. A roller bearing is press fitted on each end of this shaft. These roller bearings are guided in a track cut in a plastic material, plastic guide track plates, which is attached to the side walls of the vending box. This track is cut in a somewhat elliptical pattern to route the guide shaft roller bearings through a somewhat elliptical route as the coin slide is pushed in and then pulled out.
When the coin slide is pushed in, the mechanism forces the roller bearings on the guide shaft to travel inward and upward along the elliptical path cut in the plastic guide track plates. As the coin slide reaches its inward most position, torsion springs cause each end of the guide shaft to stay on the upper plan of the elliptical path. The torsion springs prevent the shaft from falling backwards and reversing direction of travel in the track. At this point, the guide shaft has been raised to its upper level position and the ejector friction pad makes contact with the literature through an opening in the floor plate of the literature holding area. As the coin slide is pulled back to its starting position, the guide shaft and roller bearing follow the upper level track towards the front of the box. The ejector friction material on the ejector plate pulls the lowermost piece of literature from the holding rack and slides it partially out through an opening in the face of the literature dispensing box. Just before the coin slide reaches the original starting position the guide shaft roller bearings are allowed to travel downward in the elliptical track in the guide track plates and releases the ejector friction material on the slide plate from the literature unit. The guide shaft roller bearings then follow in the track back to the starting position in the lower plane of the elliptical track. An adjustable gate tab extends down into most of the literature dispensing opening and prevents more than one unit of literature from exiting the container at a time and allows only one unit of literature to be dispensed each time the ejector friction pad pulls it out of the box.
The lid is removable from the box to allow easy loading and includes a lid lock to secure contents. The box has a front literature display holder of clear material to display one cover sheet of the literature being dispensed. It also displays operating instructions. Coinage falls out of the coin slide when it is actuated and falls down into a coin collection area. Access to this coin collection area is through a coin access panel secured with a coin access panel lock. It is the object of the invention to provide a mechanism that will dispense a single unit of paper literature when manually actuated and to enable collection of coinage for each unit of literature dispensed.
BRIEF DESCRIPTION OF THE DRAWINGS
For illustration of the invention, reference is made to the accompanying drawings in which;
FIG. 1 is a pictorial view of this invention.
FIG. 2 is a front cross-sectional view of this invention taken along line 2--2 of FIG. 1 with the upper half of the lower front panel not shown and the lid removed for clarity.
FIG. 3 is a top cross-sectional view of this invention taken along line 3--3 of FIG. 1. This view is shown with the literature holding rack empty, the lid removed and the literature removal mechanism in the starting position.
FIG. 4 is a side cross-sectional view of the literature removing mechanism of this invention taken along line 4--4 of FIG. 1. This cross-sectional shows the mechanism in the starting position.
FIG. 5 is the same view as FIG. 4, but the mechanism is in the literature contact position.
FIG. 6 is the same view as FIG. 4, but with the literature removal mechanism in the literature dispensing position.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates a literature dispensing box which dispenses a single unit of literature through a slot opening each time the coin slide 49 is actuated. The literature dispensing box comprises a housing defined by a lower front panel 50 which attaches to side panels 51, 52 and a bottom panel 53, a back panel 54 attached to the side panels 51, 52 and a bottom panel 53 and a removable lid 7 that attaches to the back panel 54, sides 51, 52 and lower front panel 50 by means of pins and a front lid lock 8 as shown in FIG. 4. The pins are attached to the back panel 54 and extend to the rear. The pins fit through two corresponding holes in the back lip of the lid 7.
Referring to FIG. 4 a lid locking bar 9 is attached to side panels 51 and 52. A lid lock 8 is attached to the lid 7. A seal strip 10 is attached to a seal mounting bar 11 that is attached to the side panels 51 and 52 along the top edges and the front exposed edges. A seal strip 10 and seal mounting bar 11 also are attached near the top edge of the back panel 54. An advertising panel is attached to the front panel of the lid 7 by means of screws. A weather cap 12 is attached to the bottom edge of the lid 7. Mounting brackets 13 can be added to the back panel 54.
A coin access opening is cut into the lower front panel 50 A long top security bar 16 is attached to the inside top edge of the coin access opening in the lower front panel 50. A short top security bar 17 is attached to the long top security bar 16. A bottom security bar 18 is attached to the inside bottom of the coin access opening in the lower front panel 50. Side security bars 19 are attached to the inside of the coin access opening in the lower front panel 50. A coin access panel lock 15 is mounted in the coin access panel 14. A security lip 20 is attached to the inside bottom edge of the coin access panel 14. The coin access panel 14 attaches to the lower front panel 50 by means of a coin access panel lock 15 and the security lip 20.
Referring to FIG. 1, a literature holding rack is located in the upper portion of the literature dispensing box. It is comprised of a front literature holding rack panel 21 that slides in guide channels 22 that are attached to the side panels 51 & 52. Side spacer bars 23 are attached to the side panels 51 & 52. Side literature holding rack panels 24 are attached to the side spacer bars 23 by means of flathead machine screws. Vertical slots are cut into the side literature holding rack panels 24. Theses slots are used to hold a rear literature holding rack panel 25. This rear literature holding rack panel 25 can be adjusted for various lengths of literature by placing it in various slots. A literature holding rack floor plate 26 with a rectangular opening is located at the bottom of the literature holding area. Adjustable gate tabs 27 are attached to a gate tab mounting bar 28 by means of bolts 29 and a gate tab retaining bar 30. The gate mounting bar 28 is drilled and tapped to accept the bolts 29.
Referring to FIG. 2, the plastic guide track plates 31 & 32 are attached to the side panels 51 & 52 by means of screws 33. The floor plate 26 is placed on top of the plastic guide track plates 31 & 32 and is held in place by the side literature holding rack panels 24 as shown in FIG. 1. Referring again to FIG. 2, a guide shaft 34 extends through two holes in the ejector bars 35. The guide shaft 34 is held in place by 2 "E" retainer rings 36. Roller bearings 37 are attached to each end of the guide shaft 34 by press fit. The bearings 37 travel in a groove that is out in an elliptical path into the guide track plates 31 & 32. A torsion spring 38 is attached to the plastic guide track plate 31 by means of a screw 39. The torsion spring has a short tension tab that is inserted into a hole in the guide track plate 31.
Referring to FIG. 4. a coin slide 49 is attached to the lower front panel 50 by means of vandal resistant machine screws 40. The coin slide 49 is attached to a connecting bar 41 by means of machine screws & nuts 42. A bearing surface has been grooved in each of two plastic blocks 43. The two plastic blocks 43 are placed together around a u-bolt 45 and then bolted to connecting bar 41 by means of machine screws and nuts 44. The u-bolt 45 is threaded on both ends and connects to the two ends of ejector bars 35 by means of lock nuts 46. The ejector bars 35 are attached to an ejector plate 47. An ejector friction pad 48 is attached to the ejector plate 47.
Referring to FIG. 5 which depicts the literature removal mechanism in the literature contact position, the coin slide 49 is pushed all the way inward and has forced the roller bearings 37 to follow the grooved track in the guide track plates 31 and 32 and depress the torsion spring 38. The ejector plate 47 and ejector friction pad 48 have raised up just barely through the opening in the literature holding rack floor plate 26 and makes contact with a piece of literature. Directional arrows 100 show the direction of movement of the coin slide 49 and the roller bearings 37, guide shaft 34 and literature ejection assembly.
Referring to FIG. 6 which depicts the literature removal mechanism in the ejection position, the coin slide 49 is pulled to near its starting position and has forced the roller bearings to follow the grooved track in the guide track plates 31 and 32. The torsion spring forces the mechanism to stay on the upper track. As the friction pad is pulled along, a piece of literature A. is also pulled along. Directional arrows 101 show the direction of movement of the coin slide 49 and the roller bearings 37, guide shaft 34 and literature ejection assembly. The gate tabs 27 prevent more than one unit of literature from the stack of literature A from going past. The single piece of literature A1 is ejected from the machine.
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A literature dispensing mechanism which will dispense a single unit of literature from an orderly stack of literature when manually actuated by a coin slide.
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BACKGROUND OF THE INVENTION
Modern farming methods employ such devices as bale rollers which roll a swath or windrow of hay or other long fiber forage crops into hugh rolls which are left in the field, or straw bunchers which take the straw from a combine and drop it in large bunches about a field. The prior art contains a number of specialized transport devices which have a normally horizontal bed that may be tilted rearwardly in order that a tractor may back the transport device under a large bale or under a bunch of straw, after which the bed is returned to its horizontal transport position so the hay or straw may be moved to a place of storage. Commonly, such transport devices are provided with conveyor chains that extend the whole length of the bed and that may be driven to push the load off the rear of the bed. In some cases, the chains carry a movable upright wall which bears against the front of the bale or bunch. In other cases they have upstanding hay engaging fingers at intervals along the chains so that by using a reversible drive the conveyors may assist in loading the transport device as well as in unloading it.
Typical of such prior art devices are those disclosed in U.S. Pat. Nos. 2,761,577; 3,366,257; 3,415,400; 3,209,932; and 3,624,786.
A difficulty with all such devices is that they may be loaded only by backing the tractor which requires considerable skill to drive the transport device directly beneath the load in a straight line and which also requires that the tractor operator guess when the entire load is on the transport device or else dismount from the tractor to go to the rear of the transport device.
SUMMARY OF THE INVENTION
The present invention provides a carrier for hay or the like which may be tilted either rearwardly for rear loading or forwardly for front loading, and which has its draft tongue secured adjacent a front corner of the carrier bed so that it may be swung laterally between a transport position in which the carrier is directly behind the tractor and a front loading position in which the carrier is completely offset to one side of the tractor. This permits the operator to swing the carrier to a position to one side of the line of travel of the tractor, tilt the carrier for forward loading, and drive the tractor forward alongside the bale or bunch where he can see exactly what is happening and can tell when the entire load is on the carrier.
In addition, the carrier of the invention has a unique bed structure that consists of forward and rearward sets of longitudinal rails which have their inner ends overlapping so that a single drive shaft may extend through the overlapping ends of both sets and carry the drive sprockets for chain conveyors which are mounted one on each rail of each set with only idler sprockets and no shafts at the ends of the rails. Eliminating the cross shafts at the ends of the rails makes it easier to push the rails beneath a bale or bunch of material during loading.
The principal object of the invention, therefore, is to provide an improved apparatus for picking up and transporting a mass of material such as hay or straw.
Another object of the invention is to provide such an apparatus which may be loaded and discharged either from the front or from the rear.
Still another object of the invention is to provide such an apparatus in which a chain conveyor system which is used to unload the apparatus and which may be used to assist in loading it has no shafts at the ends of the carrier bed.
THE DRAWINGS
FIG. 1 is a side elevational view of a first embodiment of the apparatus of the invention illustrated in a transport position in full lines and in a forwardly tilted loading position in broken lines, with a tractor also illustrated in broken lines;
FIG. 2 is a plan view of the apparatus of the invention in transport position with a tractor illustrated in broken lines;
FIG. 3 is a side elevational view of the apparatus in rearwardly tilted, rear loading position;
FIG. 4 is a plan view of the apparatus in its forwardly tilted, laterally displaced forward loading position and with the hitch tongue illustrated in broken lines in transport position;
FIG. 5 is a fragmentary plan view on an enlarged scale to illustrate details of the actuating pistons and the drive for the conveyors and with the front and rear skids omitted for clarity; FIG. 6 is a sectional view taken substantially as indicated along the line 6--6 of FIG. 5; and
FIG. 7 is a fragmentary plan view of a second embodiment of the apparatus which differs from the first in the structure of its draft tongue.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawings, the apparatus of the invention consists of a mobile frame, indicated generally at 10, which is surmounted by a bed, indicated generally at 11. At a front corner of the apparatus is a draft tongue, indicated generally at 12; and associated with the draft tongue is a hydraulic bed tilting means, indicated generally at 13. Conveyor means associated with the bed 11 is indicated generally at 14.
The mobile frame consists of a pair of deep, transverse channel members 15 along the lower ends of which are transverse box beams 16, longitudinal webs 17 connect the channels 15, and fore-and-aft extending webs 18 project from the channels 15. Mounted in the webs 17 are axles 19 for dual wheels 20. A rear cross beam 21 and a front cross beam 22 are connected by longitudinal side bars 23.
As seen in FIG. 2, the bed 11 consists of a set of parallel longitudinal rear rail 24 which are supported upon the cross webs 15 and the rear and front cross beams 21 and 22 and which have their forward ends supported upon a front cross member 25; and a set of parallel longitudinal front rails 26 which alternate with the rear rails 24 and are supported upon the cross members 22 and 25 between which the rear rails and the front rails have an overlapping area 27.
As best seen in FIG. 5, a shaft 25a extends laterally from the front cross member 25 and has its outboard end supported in a frame plate 28. The draft tongue assembly 12 includes a sleeve 29 which is rotatably mounted upon the shaft 25a and carries a yoke 30 which is thus rotatable about a transverse axis provided by the shaft 25a. As seen in FIG. 1, the underside of the yoke 30 is provided with a skid 31 which rests upon the ground when the apparatus is in its forwardly tilted front loading position. At the front of the yoke 30 is an upright pivot 32 which receives the rear end of a draft tongue 33 which is laterally swingable about the pivot 32 between a transport position which is illustrated in FIG. 2 and a laterally offset front loading position which is illustrated in FIG. 4. The draft tongue 33 has a rearward portion 34 which is parallel to the longitudinal rails 24 and 26 in transport position, and a forward portion 35 which extends diagonally inwardly so that a yoke 36 at its forward end is substantially on the longitudinal median line of the apparatus when the tongue is in transport position. The draft tongue yoke 36 is mounted at the forward extremity of the draft tongue 33 upon a transverse pivot 36a and may be connected to a hitch H of a tractor T by means of a pintle P in the conventional way.
Also secured to the sleeve 29 is a bracket 37, and on the rearward portion 34 of the hitch tongue is a laterally extending bracket 38; and mounted between the brackets 37 and 38 on upright pivots 37a and 38a is a hydraulic cylinder and piston unit 39 which is seen to have its piston rod 39a extended when the draft tongue 33 is in transport position. Retraction of the piston rod 39a swings the draft tongue 33 laterally to its front loading position as seen in FIG. 4.
The means for tilting the apparatus between its horizontal transport position and its front and rear loading positions constitutes a cylinder and piston unit 40 which has one end connected to a transverse pivot on a bracket 41 which is on the forward cross beam 22, and which has its other end connected to a transverse pivot on a rib 42 that is seen in FIG. 1 to extend upwardly and rearwardly from the yoke 30 so that the transverse pivot for the forward end of the cylinder and piston unit 40 is above the transverse pivot axis of the yoke.
In the transport position illustrated in solid lines in FIG. 1 the piston rod 40a of the cylinder and piston unit 40 is in a partially extended position, and the apparatus is swung to the front loading, broken line position of FIG. 1 by retracting the piston rod. Extension of the piston rod 40a moves the apparatus to the rear loading position of FIG. 3.
It is obvious that the draft tongue 33 may be swung to its laterally displaced position for front loading only while the tractor and the apparatus are in motion. The cylinder and piston units 39 and 40 are connected to the tractor hydraulic system by a conventional set of pressure hoses (not shown), and the system includes valve means mounted on the tractor in a position to be conveniently manipulated by an operator sitting on the tractor seat. The valve means controls the retraction and extension of both cylinder and piston units.
Either front loading or rear loading of the apparatus requires that an end of the bed 11 be moved into contact with the ground as illustrated in FIGS. 1 and 3, and to prevent the ends of the rails from digging into the ground during loading, the underside of each of the rails 24 is provided with a skid 24a, and the underside of each of the rails 26 is provided with a skid 26a.
As best seen in FIG. 5, the conveyor system 14 includes a cross shaft 43 which is journalled in the overlapping portions 27 of the rails 24 and 26, and in the top of each rail above the shaft 43 is an opening 44 through which a sprocket 45 on the shaft projects. At the rear end of each of the rear rails 24 is an idler sprocket 46, and trained around each idler sprocket 46 and the aligned sprocket 45 is a conveyor chain 47. Similarly, at the front of each of the front rails 26 is a sprocket 48, and a chain 49 is trained around each of the sprockets 48 and the aligned sprockets 45.
Power for driving the conveyor means 14 is provided by a hydraulic motor 50 which is supported beneath one of the forward rails 26 and has an output sprocket 51. An intermediate shaft 52 has an input sprocket 53 which is driven from the motor sprocket 51 by a chain 54; and an output sprocket 55 on the shaft 52 is connected by a chain 56 with an input sprocket 57 on the conveyor shaft 43. The hydraulic motor 50 is reversible so that the conveyor chains 47 and 49 may be driven in either direction; and the motor is connected with the tractor hydraulic system through pressure conduit (not shown) and a three position control valve on the tractor which has an open center and a control handle which is moved one way or the other to put hydraulic pressure on one side or the other of the motor 50.
The second embodiment of FIG. 7 is the same as the first embodiment, except that it has a draft tongue means 112 which is different from the draft tongue means 12. Accordingly, only that portion of the apparatus of FIG. 7 is described in detail, and other components are given the same numbers that they bear in FIGS. 1 to 6.
The alternative draft tongue means of FIG. 7 includes a small sleeve 129 which is journalled upon a rod 25a; and a draft tongue 133 includes a rearward portion 134 which is integral with the sleeve 129 and extends forwardly parallel to the forward rails 26, and it also includes a forward portion 135 which is mounted on an upright pivot 135a at the front end of the fixed draft tongue portion 134. Projecting laterally from the fixed draft tongue portion 134 is a bracket 137, while projecting laterally from the swingable forward draft portion 135 is a bracket 138; and a cylinder and piston unit is mounted between upright pivots 137a and 138a on the respective brackets 137 and 138. As in the first embodiment of the apparatus, the cylinder and piston unit 139 is connected to the tractor hydraulic system and is controlled by means of a valve which is manipulated by an operator on the tractor seat.
The reversible conveyor system 14 of the apparatus is significant to the operation of the unit for two reasons. First, placing the conveyor drive shaft 43 at the overlapping inner end portions 27 of the rails 24 and 26 permits the idler sprockets 46 and 48 at the extremities of the rails to be journalled without the need for a continuous cross shaft as has previously been used in apparatus of the present general type. A cross shaft at the end of the rails interferes with loading, and the prior art devices have used various expedients in an effort to minimize the interference with loading which is caused by the cross shaft at the end of the rails.
In addition, the conveyor means 14 may be used to assist in loading either from the front or from the rear, and may also be used in unloading either to the rear or to the front. However, in most instances the apparatus is unloaded to the rear.
Furthermore, the present structure, and in particular the conveyor system without cross shafts at their ends, permits a bale or other mass of hay to be loaded without rotation of the mass, so that cylindrical bale may be loaded with the bale moved onto the apparatus either endwise or sidewise.
The foregoing detailed description is given for clearness of understanding only and no unnecessary limitations should be understood therefrom as modifications will be obvious to those skilled in the art.
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A wheeled carrier for hay or the like has a low bed that may be tilted from a horizontal transport position rearwardly for rear loading or forwardly for front loading, and has a draft tongue secured by a transverse pivot adjacent a front corner of the bed and swingable laterally about an upright pivot so that the carrier may be towed directly behind a tractor for transporting a load or offset from the tractor for front loading. The bed consists of a set of short front parallel rails and a set of long rear parallel rails; and longitudinal chain conveyor means for both sets of rails has a single drive shaft that extends through overlapping inner end portions of both sets and may be driven in either direction. The extremities of the conveyor means are on idler sprockets with no continuous cross shafts.
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