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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a method of enhancing the extraction of a proteinase inhibitor, and more specifically, to a method of improving the yield and purity of Proteinase Inhibitor-II (PI2) extracted from whole potatoes.
[0003] 2. Background of the Prior Art
[0004] The extraction, isolation and purification of plant-derived proteins is well known in the field of biochemistry. In 1972, Melville and Ryan reported a large-scale preparation for isolating Chymotrypsin Inhibitor I from potato tubers (Melville, J. C. and Ryan, C. A. Chymotrypsin inhibitor I from potatoes. J. Biological Chem., 247: 3445-3453, 1972). According to the method of Melville and Ryan, potatoes were sliced with peels intact and soaked in a sodium dithionite solution, homogenized, and expressed through nylon cloth. The resulting juice was adjusted to pH 3, centrifuged at 1000× g for 15 minutes at 5° F., and the supernatant collected and fractionated with ammonium sulfate.
[0005] Purification was achieved through water washing and heat treatment whereby clear filtrates of heated fractions were pooled and lyophilized. Suspending the lyophilized powder in water, dialyzing it against water for 48 hours, and lyophilizing the resulting clear filtrate obtained a crude extract. Resuspended extract was then centrifuged and applied to a column of Sephadex G-75. Collected fractions containing the Inhibitor I were pooled, evaporated, and desalted on a column of Sephadex G-25. The resulting gel-filtered inhibitor product was determined to be approximately 90% Inhibitor I protein purified by dissociation on a Sephadex G-75 column and desalted on a column of Sephadex G-25.
[0006] The Ryan lab followed-up by reporting the isolation and characterization of Proteinase Inhibitor II in much the same manner as described for Inhibitor I (Bryant, J., Green, T. R., Gurusaddaiah, T., Ryan, C. L. Proteinase inhibitor II from potatoes: Isolation and characterization of its protomer components. Biochemistry 15: 3418-3424, 1976). Bryant et al. differentiated potato-derived proteinase inhibitors into two groups based on their respective stabilities to a temperature of 80° C. for 10 minutes. Proteinase Inhibitor I (PI 1 ) is characterized as a tetrameric protein composed of four hybridized isoinhibitor protomer species having a molecular weight of 39,000, whereas PI 2 is characterized as a dimeric inhibitor comprising four isoinhibitor promoter species having a molecular weight of 21,000.
[0007] The extraction and isolation of proteinase inhibitor proteins from potatoes is described in WO 99/01474. Proteins from potato tubers are extracted in soluble form in an aqueous/alcohol extraction medium, such as dilute formic acid and 20% ethanol. The alcohol extract is heated to a first temperature to denature most of the unwanted proteins and cooled to a second temperature to form a precipitate phase constituting the debris and a soluble phase that contains the heat stable proteinase inhibitor proteins. The heat stable proteinase inhibitor proteins are precipitated from the soluble phase by dialysis against a suitable dialysis medium, such as dilute formic acid.
[0008] Recently, PI 2 has been implicated in playing a role in extending satiety in subjects fed a nutritional drink composition containing PI 2 . U.S. patent application Ser. No. 09/624,922 describes that subjects reported a significant reduction in hunger for up to 3½ hours post meal when fed a meal comprising a nutritional drink composition containing PI 2 . Likewise, fullness ratings were enhanced, and each study subject lost an average of 2 kg over a 30-day period without experiencing the adverse side effects typically associated with appetite suppressing compounds. Mechanistically, it is thought that as a trypsin and chymotrypsin inhibitor, when consumed by a subject, PI 2 stimulates the release of endogenous cholecystokinin, a known putative feedback agent effective in reducing the desire to intake food.
[0009] Existing methods for the extraction of proteinase inhibitors involve several laborious and time consuming steps and result in losses of yield and reduced purity of the recovered proteinase inhibitor. In addition, the most promising prior art methods rely on the use of ethanol in the extractant solution which, at the concentrations used, makes the solution flammable. None of the prior art processes have been demonstrated on a commercial scale. Accordingly, a need exists for a large-scale extraction process to extract PI 2 in a cost-effective and efficient manner meeting industrial qualitative and quantitative standards.
SUMMARY OF THE INVENTION
[0010] Plant material containing a desired proteinase inhibitor is combined with a solution of an organic acid and a salt. The plant material is comminuted, forming a slurry in the acid and salt solution, to reduce the particle size and increase the surface area of the particles to improve the efficiency of the extraction. The process of comminution is selected to reduce the particle size without denaturing the desired proteinase inhibitor through local heating effects. The acid and salt solution enhances the extraction of the proteinase inhibitor from the comminuted plant material and protects it against degradation by other compounds that may be released from the ruptured plant cells. Once extracted into solution, the proteinase inhibitor is isolated and purified by centrifugation, clarification, filtration and drying of the extract solution. The acid and salt are removed during the filtration stage so as not to adulterate the purified proteinase inhibitor product.
[0011] In a preferred embodiment, proteinase inhibitor II (PI2) is extracted from whole potato tubers. Organic acids known to be effective in the process include acetic, ascorbic, citric and formic acid. Formic acid was found to result in the highest purity and highest yield of the final PI2 product. The formic acid content of the solution is adjusted in the range of 0.5% to 2.5% w/w, with a preferred content of approximately 1.5%. Sodium chloride is added to the extractant solution to increase the solubility of the potato proteins. Sodium chloride concentrations of between 1 N and 3 N are used. with a preferred concentration of approximately 1.5 N. The solution is added to the potatoes in a weight ratio of between 1:1 and 1:10, with a preferred ratio of 1:2.5 extraction solution:potato, w/w, respectively.
[0012] Comminution is accomplished by grinding. A target particle size is in the range of 100 to 1500 m. In this range, product yields were increased and flow characteristics of the slurry were acceptable. Decreasing the particle size below m resulted in a lower recovery of PI2 and did not improve the flow characteristics. Grinding for an extended period of time also resulted in a reduced PI2 yield, most likely due to an increase in temperature and the release of undesired proteases that reduce the PI2 yield. The formic acid and sodium chloride are efficiently removed during the filtration stage.
[0013] An object of the present invention is to provide an improved method for the extraction of proteinase inhibitors from plant materials.
[0014] Another object of the invention is to provide an improved method for the extraction of proteinase inhibitor II from potato tubers which does not rely on the use of ethanol in the extraction solution.
[0015] A further object of the invention is to provide a method of extracting proteinase inhibitor II from potato tubers that is efficient and cost-effective on a commercial scale.
DETAILED DESCRIPTION OF THE INVENTION
[0016] The extraction and isolation of PI2 from potatoes begins with the addition of an organic acid, preferably formic acid, and a salt, preferably sodium chloride, to raw potatoes. The mixture is subjected to comminution to reduce the particle size of the potato particles and extract soluble proteins. Centrifugation is used to remove solids and the liquid fraction is heated at a temperature sufficient to denature many undesired proteins but not PI2. The solution is again centrifuged to remove the insoluble denatured proteins and the liquid fraction is microfiltered to remove relatively large particles. Ultrafiltration is used to remove the organic acid and salt and further purify the PI2 in the retentate.
[0017] A process for the extraction of PI2 from whole potatoes was developed in an attempt to maximize yield, minimize impurities, minimize cost, and achieve commercial feasibility. The extraction solution was evaluated based on the ability of the process to solubilize the PI 2, protect the PI2 from degradation, and maximize total PI2 removed from the insoluble potato components, while minimizing the amount of co-solubilized proteins. The extraction solution incorporated the solubility and functional stability of PI2 in acidic media and at elevated temperatures. An extraction solution containing sodium chloride and formic acid has been found effective for this purpose. The ratio of extraction solution utilized to raw material extracted was minimized for cost purposes, while producing the maximum yield of PI2 per kilogram of raw potato tubers.
[0018] Reverse Phase HPLC Method
[0019] The amount of PI2, Kunitz and carboxypeptidase inhibitors was measured using reverse phase HPLC. A Microsorb C-18 column (4.6 mm×250 mm, 5 μm particles with 300 Angstrom pore size; Varian Analytical Instruments) was used. Two mobile phase solvents were prepared, solvent A was 800 g deionized H 2 O, 150 g acetonitrile, and 0.95 trifluoroacetic acid, and solvent B was 850 g acetonitrile and 0.85 g trifluoroacetic acid. Approximately 50 mg of the sample was added to 100 ml of solvent A. The sample was vortexed for 30 seconds, and then centrifuged at 10,000 rpm for 10 minutes. The supernatant was collected for RP-HPLC analysis. One hundred μl of the sample was injected into the column, with the pump set at 800-2500 psig, and a temperature of 30.0° C. The other flow rate, time, and solvent compositions are as set out in Table 1. The diode array of the detector was set at 220 nm.
TABLE 1 HPLC Conditions Solvent Composition Time (min) Flow rate (ml/min) (volume %) 0 1 100% A 5 1 100% A 34 1 38% A 38 1 100% B 40 2 100% B 45 2 100% B 50 1 100% A 55 1 100% A
[0020] An external standard was prepared to construct a standard curve for calibration of the column. Five mg of BSA were dissolved in 10 ml of solvent A. Four volumes, i.e., 25, 50, 75, and 100 μl, were injected into the column. A calibration curve was generated from the results.
EXAMPLE 1
[0021] Five hundred grams of potato tubers were extracted with 213 ml of 1% formic acid solution in a Waring blender for 2.5 minutes. The slurry was centrifuged at 110,000 rpm for 40 minutes. The liquid was decanted and filtered through #4 Whatman filter paper, yielding 486 g of clarified extract. Fifty grams of this clarified extract was poured into each of six 125 ml Erlenmeyer flasks equipped with magnetic stir bars. The amount of NaCl corresponding to Table 2 was added to each flack and stirred until the salt was dissolved. The flasks were then heated on high with stirring on a hot plate until the temperature of the extract reached 70° C. After ambient cooling to room temperature, the solutions were centrifuged at 12,000 rpm for 5 minutes and then analyzed using the above-described reverse phase HPLC method. The reported level of PI2 was calculated by integrating the area of the PI2 peak. The injection volume was 100 l and the following equation was used to equate peak areas to protein levels:
Protein ( mg / ml ) = [ ( peak area 4 ) × 8.17 × 10 - 5 ] + 0.0338
[0022] To clarified potato extract was added varying amounts of sodium chloride, followed by heating to 70° C. for 10 minutes. After cooling to room temperature, the solutions were analyzed for the protein eluting after PI2 in the HPLC method for PI2 quantification. The results are shown in Table 2.
TABLE 2 Protein Removal with Varying Sodium Chloride Levels Protein Eluting at 16-30 Protein Eluting at PI2 Level [NaCl] N minutes mg/ml ˜23-30 minutes mg/ml mg/ml 0.0 0.504 0.378 0.167 0.1 0.298 0.184 0.160 0.2 0.245 0.141 0.172 0.3 0.178 0.076 0.149 0.4 0.150 0.071 0.169 0.5 0.119 0.076 0.189
[0023] To establish the removal of Kunitz impurities from the potato extract, which have been shown to diminish the effectiveness of PI2 to increase satiety, the reverse phase HPLC method was used on a commercially available Kunitz standard purchased from SIGMA. A chromatograph of the Kunitz standard revealed that the major peak of the Kunitz impurities appears at approximately 25 minutes. Another inhibitor known to be present in potatoes is the carboxypeptidase inhibitor. The reverse phase HPLC method was used on a commercially available carboxypeptidase standard purchased from SIGMA. A chromatograph of the carboxypeptidase standard revealed that the major peaks of the carboxypeptidase impurities is a doublet that appears at approximately 17 minutes. At a level of 0.3 N sodium chloride and above, the post heat-treatment protein level remains relatively constant. The amount of PI2 remained relatively constant for all trials, indicating that at 70° C. no PI2 is precipitated at the salt levels up to 0.5 N. In order to reach the level of NaCl required in the heat-treatment phase, it is necessary to use an extractant with approximately 2 times the desired final salt concentration. Accordingly, a salt level of at least 0.3 N is desirable in the extraction solution during heat treatment at 70° C. to ensure efficient removal of Kunitz type proteins. Purity of the final PI2 product can be improved with greater amounts of sodium chloride.
EXAMPLE 2
[0024] An optimization study was performed to determine both the proper NaCl content and formic acid content of the extraction solution. The ideal extraction solution formulation would maximize the amount of PI2 liberated from the potato matrix, while minimizing the amount of protein contaminants solubilized. The liberation of PI2 was measured as yield, normalized to an extraction solution composition of 1.0 N NaCl. This was chosen as the normalization basis due to the previously stated prediction necessitating a two-fold increase of NaCl beyond the 0.5 N system shown effective for impurity removal in the heat-treatment stage. For optimization purposes, PI2 protein purity was measured and compared empirically to the normalized extraction yields. Extraction solutions containing NaCl concentrations from 0.0 N to 2.0 N were examined. In a similar manner, the formic acid content of the extraction solution was optimized. Formic acid contents ranging from 0.0 percent to 2.5 percent were studied.
TABLE 3 Sodium Chloride Optimization Data Doublet Time “Kunitz” [NaCl] N PI2 Area Area (min) Area Time (min) 0.0 4283.0 6402.2 17.28 83436.8 ˜23.5-29.0 1.0 6627.8 6294.6 17.28 131502.6 ˜23.5-29.0 1.0 4771.1 5571.2 16.97 113666.7 ˜23.5-29.0 2.0 5146.2 5306.3 16.95 120910.1 ˜23.5-29.0 0.0 4712.8 6231.8 17.48 83908.4 ˜23.5-29.0 0.5 6592.7 6932.0 17.48 125256.4 ˜23.5-29.0 1.0 7578.4 7425.0 17.47 128660.5 ˜23.5-29.0 2.0 6822.6 6890.4 17.46 130632.2 ˜23.5-29.0 0.0 4235.2 6130.1 17.74 90357.4 ˜24.0-29.5 0.7 5964.6 6606.2 17.72 135932.2 ˜24.0-29.5 1.0 6746.7 6531.5 17.50 126617.3 ˜23.5-29.0 1.3 6062.5 6163.9 17.69 142488.8 ˜24.0-29.5 0.0 4699.6 6065.3 17.54 89125.2 ˜23.75-29.25 1.0 7768.5 6008.5 17.54 138907.2 ˜23.75-29.25 1.3 8095.2 6513.1 17.54 151858.8 ˜23.75-29.25 0.0 4743.7 5563.6 17.70 80937.5 ˜24.0-29.5 0.5 5825.3 5577.7 17.69 120352.4 ˜24.0-29.5 1.0 6848.1 5260.6 17.75 129407.5 ˜24.0-29.5 1.3 7173.2 5365.8 17.53 142758.6 ˜24.0-29.5
[0025] [0025] TABLE 4 Sodium Chloride Optimization Data Continued PI2 PI2 Doublet Protein “Kunitz” Protein [NaCl] N Area (mg/ml) Area (mg/ml) Area (mg/ml) 0.0 4283.0 0.16 6402.2 0.20 83436.8 1.73 1.0 6627.8 0.21 6294.6 0.20 131502.6 2.68 1.0 4771.1 0.17 5571.2 0.19 113666.7 2.32 2.0 5146.2 0.18 5306.3 0.18 120910.1 2.47 0.0 4712.8 0.17 6231.8 0.20 83908.4 1.73 0.5 6592.7 0.21 6932.0 0.21 125256.4 2.55 1.0 7578.4 0.23 7425.0 0.22 128660.5 2.62 2.0 6822.6 0.21 6890.4 0.21 130632.2 2.66 0.0 4235.2 0.16 6130.1 0.20 90357.4 1.86 0.7 5964.6 0.19 6606.2 0.21 135932.2 2.76 1.0 6746.7 0.21 6531.5 0.20 126617.3 2.58 1.3 6062.5 0.20 6163.9 0.20 142488.8 2.89 0.0 4699.6 0.17 6065.3 0.20 89125.2 1.84 1.0 7768.5 0.23 6008.5 0.19 138907.2 2.82 1.3 8095.2 0.24 6513.1 0.20 151858.8 3.08 0.0 4743.7 0.17 5563.6 0.19 80937.5 1.68 0.5 5825.3 0.19 5577.7 0.19 120352.4 2.46 1.0 6848.1 0.21 5260.6 0.18 129407.5 2.63 1.3 7173.2 0.22 5365.8 0.18 142758.6 2.90
[0026] [0026] TABLE 5 Sodium Chloride Optimization Data Continued PI2 PI2 Normalized Doublet Doublet Kunitz Total Kunitz [NaCl] N (mg/ml) mg yield (mg/ml) (mg) (mg/ml) (mg) Purity 0.0 0.16 78.25 77.51% 0.20 98.76 1.73 844.50 7.66% 1.0 0.21 100.75 100.00% 0.20 97.53 2.68 1307.21 6.69% 1.0 0.17 79.59 100.00% 0.19 87.02 2.32 1090.74 6.33% 2.0 0.18 82.23 104.38% 0.18 83.70 2.47 1146.21 6.27% 0.0 0.17 81.88 74.82% 0.20 96.49 1.73 843.57 8.01% 0.5 0.21 100.78 91.34% 0.21 104.07 2.55 1251.43 6.92% 1.0 0.23 104.63 100.00% 0.22 103.22 2.62 1218.05 7.34% 2.0 0.21 97.11 93.36% 0.21 97.73 2.66 1228.97 6.82% 0.0 0.16 72.99 82.29% 0.20 90.21 1.86 855.33 7.17% 0.7 0.19 88.27 92.58% 0.21 94.07 2.76 1263.08 6.11% 1.0 0.21 100.78 100.00% 0.20 98.72 2.58 1246.21 6.97% 1.3 0.20 93.49 93.51% 0.20 94.45 2.89 1386.67 5.94% 0.0 0.17 80.77 73.47% 0.20 93.75 1.84 883.03 7.64% 1.0 0.23 111.08 100.00% 0.19 94.18 2.82 1370.31 7.05% 1.3 0.24 113.59 102.82% 0.20 98.48 3.08 1486.42 6.69% 0.0 0.17 80.41 80.24% 0.19 88.13 1.68 797.53 8.32% 0.5 0.19 92.04 90.39% 0.19 89.68 2.46 1187.23 6.72% 1.0 0.21 100.96 100.00% 0.18 85.91 2.63 1263.04 6.96% 1.3 0.22 99.55 103.05% 0.18 83.15 2.90 1329.54 6.58%
[0027] [0027] TABLE 6 Average Normalized Yields and Purities With Varying NaCl NaCl Normality Average Yield Average Purity 0.0 77.67% 7.76% 0.5 90.87% 6.82% 0.7 92.58% 6.11% 1.0 100.00% 6.89% 1.3 99.80% 6.40% 2.0 98.87% 6.54%
[0028] While NaCl normalities of 0.5 N and above were seen to give high yields, a normality of 1.0 N was selected as maximizing both yield and purity.
TABLE 7 Formic Acid Optimization Data For- Im- mic purity acid PI2 Peak Time Doublet Time “Kunitz” Time conc. Area Area (min) Area (min) Area (min) 0.0% 7483.6 2453.50 15.63 6848.6 17.56 225054.1 ˜23.75- 31.0 1.5% 7768.5 797.67 15.73 6008.5 17.54 138907.2 ˜23.75- 29.25 0.1% 8252.0 2867.90 15.59 7071.5 17.54 226680.4 ˜23.75- 30.5 0.5% 7165.9 2071.70 15.65 6198.6 17.53 203839.7 ˜23.75- 30.5 1.0% 8353.7 813.80 15.61 5873.0 17.50 161433.2 ˜23.75- 29.25 1.5% 7939.3 893.50 15.64 5979.0 17.54 135420.3 ˜23.75- 29.25 0.1% 7005.0 1805.90 14.85 7788.5 17.00 233105.7 ˜23.25- 30.0 1.5% 7407.2 962.20 15.10 6109.7 16.98 144764.2 ˜23.5- 29.0 2.0% 7116.2 1117.55 15.11 6441.2 16.97 187670.8 ˜23.25- 30.0 2.5% 7318.8 1176.40 15.07 6649.6 16.97 180476.2 ˜23.25- 30.0
[0029] [0029] TABLE 8 Formic Acid Optimization Data Formic acid PI2 PI2 Impurity Protein Doublet Protein “Kunitz” Protein conc. Area (mg/ml) Peak Area (mg/ml) Area (mg/ml) Area (mg/ml) 0.0% 7483.6 0.19 2453.50 0.09 6848.6 0.17 225054.1 4.37 1.5% 7768.5 0.23 797.67 0.09 6008.5 0.19 138907.2 2.82 0.1% 8252.0 0.20 2867.90 0.10 7071.5 0.18 226680.4 4.40 0.5% 7165.9 0.18 2071.70 0.08 6198.6 0.16 203839.7 3.96 1.0% 8353.7 0.20 813.80 0.06 5873.0 0.16 161433.2 3.15 1.5% 7939.3 0.19 893.50 0.06 5979.0 0.16 135420.3 2.65 0.1% 7005.0 0.18 1805.90 0.08 7788.5 0.19 233105.7 4.53 1.5% 7407.2 0.18 962.20 0.06 6109.7 0.16 144764.2 2.83 2.0% 7116.2 0.18 1117.55 0.06 6441.2 0.17 187670.8 3.65 2.5% 7318.8 0.18 1176.40 0.06 6649.6 0.17 180476.2 3.52
[0030] [0030] TABLE 9 Formic Acid Optimization Data Formic acid PI2 PI2 Imp. Impurity Doublet Doublet “Kunitz” “Kunitz” conc. (mg/ml) mg (mg/ml) mg (mg/ml) mg (mg/ml) mg Yield Purity 0.0% 0.19 88.80 0.09 42.64 0.17 82.97 4.37 2085.22 79.93% 3.86% 1.5% 0.23 111.08 0.09 44.15 0.19 94.18 2.82 1370.31 100.00% 6.86% 0.1% 0.20 98.57 0.10 47.76 0.18 87.43 4.40 2159.78 104.57% 4.12% 0.5% 0.18 85.43 0.08 38.93 0.16 76.60 3.96 1880.60 90.63% 4.10% 1.0% 0.20 94.56 0.06 28.10 0.16 75.38 3.15 1529.05 100.56% 5.69% 1.5% 0.19 94.26 0.06 28.71 0.16 76.02 2.65 1280.14 100.00% 6.37% 0.1% 0.18 88.79 0.08 38.60 0.19 96.35 4.53 2271.21 96.55% 3.56% 1.5% 0.18 91.96 0.06 30.23 0.16 79.53 2.83 1407.70 100.00% 5.71% 2.0% 0.18 88.75 0.06 31.56 0.17 82.31 3.65 1809.93 96.50% 4.41% 2.5% 0.18 88.56 0.06 31.37 0.17 82.33 3.52 1700.64 96.30% 4.65%
[0031] [0031] TABLE 10 Average Normalized Yields and Purities With Varying Formic Acid % Formic acid Average yield Average purity 0.0 79.93% 3.86% 0.1 100.56% 3.84% 0.5 90.63% 4.10% 1.0 100.56% 5.69% 1.5 100.00% 6.31% 2.0 96.50% 4.41% 2.5 96.30% 4.65%
[0032] The data indicate the use of 1.5% formic acid content for the extraction solution. While other formic acid concentrations offer similar yield, 1.5% formic acid content clearly maximizes purity.
EXAMPLE 3
[0033] An experiment was conducted to determine the effect on yield by using varying amounts of the extraction solution comprised of 1.5% formic acid and 1.0 N NaCl in water. The weight ratio of potatoes to extraction solution was varied from 1:1 to 1:10. The ratios used and the observed yields are reported in Table 11.
TABLE 11 Average Normalized PI2 Yield and Liquid Yield With Varying Extraction Ratio Extraction Normalized, Average Average Yield in ratio Yield mg/kg 0.1 22.38% 24.07 0.2 60.47% 64.94 0.3 85.56% 91.98 0.4 100.00% 107.32 0.5 100.42% 107.76 0.6 101.03% 108.49 0.7 100.42% 107.74 0.8 100.74% 108.09 0.9 101.21% 108.57 1.0 101.38% 108.81
[0034] While the highest yield is achieved with the highest ratio of extraction solution, the gain in total yield is minimal above the 0.4 to one ratio (1:2.5 w/w extraction solution to potatoes, respectively). This ratio has been selected, in order to minimize extraction solution cost and material handling concerns, such as heating, cooling and evaporation.
[0035] The data dictate the choice of approximately 1.0 N sodium chloride as the preferred concentration in the extraction solution for the isolation of PI2. Using 1.0 N sodium chloride results in maximized yield of PI2 under the tested conditions, and although other concentrations are capable of producing similar yields, the PI2 protein purity that is represented by the use of 1.0 N NaCl is maximized at 1.0 N. Higher PI2 protein purity could be achieved by using less sodium chloride, however this would result in a reduced PI2 yield. This level of sodium chloride is also appropriate for the removal of the Kunitz type impurities. Similarly, the data dictate the selection of 1.5% formic acid as the preferred concentration for the extraction of PI2. An extraction solution that contains 1.5% formic acid exhibits beneficial antimicrobial and anti-proteolytic behavior. The yield of PI2 is maximized under the tested conditions at 1.5% formic acid content in the extraction solution, and this concentration also provides the highest PI2/Kunitz purity of the formulations that attain comparable yields. There is no significant increase in total yield when creating a slurry that is composed of greater than thirty percent extraction solution by weight. A slurry of thirty percent extraction solution composition is roughly equivalent to a one-part extraction solution to two and one-half parts raw material (1:2.5 solvent:solid ratio).
EXAMPLE 4
[0036] A liquid extraction solution containing approximately 1.0 N sodium chloride and 1.5% formic acid was found to be solubilizing PI2 while retaining its functional stability. The extraction system was examined to optimize the release of the target protein from the potato cellular matrix. physical grinding is necessary to rupture the potato tuber cells and thereby release the protein into the liquid phase. The final grind profile of the potato slurry was examined for complete release of soluble proteins into liquid phase, minimal PI2 degradation, and ease of liquid/solid separation. Grind profile and extraction efficiency correlations were examined, followed by separation ease of the optimized grind profile.
[0037] A set of stackable sieves conforming to ASTM specification 11 is assembled with the largest sieve size on top and the rest placed in descending sieve size. The sieve size range should be chosen so as to capture at least 95% of the solids in the suspension to be sized. Approximately 250 grams of the suspension to be sized is poured onto the top of the sieve stack. The top sieve is washed repeatedly with water until no more solids appear to be passing through the sieve. This sieve is then removed and this washing repeated for each sieve. The contents of each sieve are placed in pre-weighed weigh boats and placed in a vacuum oven at less than 100° C., but more than 50° C., to dry for at least 12 hours. After the solids are dry their weights are measured on an analytical balance and recorded. The particle size distribution is reported as the dry weight of the solids retained on each sieve expressed as a percentage of total dry solids retained. Results are reported in Table 12 using micrometers as the size unit.
TABLE 12 Sample Size Distribution Report Particle Size μ (micrometers) % Solids Retained 1170 11 1080 32 625 38 400 19
[0038] For these trails whole, raw potatoes were extracted using an aqueous solution of 1.5% formic acid and 1.0 N NaCl in a weight ratio 1:2.5 extraction solution to potatoes. PI2 concentration was derived sing reverse phase HPLC method described previously.
[0039] The degree of disintegration of the potato in the presence of the extraction solution has been studied. To test this aspect of the extraction, samples of the optimized extraction solution and whole, raw potatoes were ground using commercially available Commitrol grinders. The test protocol was designed to determine the grinding device's ability to generate to a number of consistent target profiles, and examine the particle size distribution within these grinds. The experimentally ground slurries were analyzed for PI2 content. A trend was discovered in which a finer grind profile exhibited increased yield of PI2 on a mg/kg basis. Extractions with an average particle size of greater than 1000 μm showed a marked diminution of PI2 extraction efficacy.
[0040] When ground on a Urschel grinder to a nominal particle size of less than 100 μm, the samples yielded 85 mg PI2 per kg of potato. A similar test done using the same lot of potatoes and extractive solution using a Hobart grinder giving a grind size of approximately 1500 μm afforded 70 mg PI2 per kg of potato.
TABLE 13 Comparison of Coarse and Fine Grind Processes Average particle Potatoes Extraction size-μm Total PI2 mg/kg Grinder (kg) solution (micrometers) slurry (kg) potato Hobart 5.59 2.24 ˜1500 7.83 70 Coarse Urschel 5.72 2.29 <90 11.03 85 Fine
[0041] There was not an appreciable difference of ease of filtration under the conditions adopted for this experiment. The final pulp recovered from the Urschel grind was 17.3% by weight of the slurry and contained a moisture level of 49.8%. The pulp recovered from the Hobart grind was 31.9% by weight of the slurry and contained a moisture level of 60.5%. This represents a potential loss in yield of approximately 10 percent in the more coarse grind profile, using a liquid yield weight percentage (7.1% residual liquid in the finely ground waste solids as opposed to 17.2% residual liquid in the coarsely ground waste solids).
[0042] In addition to PI2 and mass balance losses, the finer grind does exhibit a greater amount of total protein extracted using the finer grind protocol. The resulting liquid extracts were assayed using the reverse phase HPLC method. The fine grind extract does contain a greater concentration of undesirable proteins. In particular, the PI2/Kunitz purity (taken as the concentration of PI2 divided by the total concentration of the Kunitz impurities and the PI2) decreases from 7.41 percent purity for the coarse grind and 5.99 percent purity in the extract resulting from the fine grind.
[0043] A further study examined the yield of PI2 using a variety of grind profiles. The grind profiles examined varied from 300 μm average particle size to 1200 μm average particle size.
TABLE 14 Optimization of Grinding Profile and PI2 Yield PI2/ Average grind PI2 Kunitz ‘Kunitz’ Temperature profile Gap yield content purity increase Approx. 300 214 μ 98.55% 105.77% 48.23% 13.1° C. micron Approx. 500 388 μ 100.00% 100.00% 50.00% 10.4° C. micron Approx. 700 633 μ 93.68% 97.94% 48.89% 8.8° C. micron Approx. 900 968 μ 91.32% 94.88% 49.05% 6.7° C. micron Approx. 1200 1519 μ 86.57% 84.97% 50.47% 5.2° C. micron
[0044] Table 14 presents the optimization study for final grind profile with respect to PI2 yield. The yields and purities are normalized to the highest PI2 yield in the sample set. The highest yield was observed at approximately 500 μm average particle size. The PI2/Kunitz purity is also acceptable, only one other grind profile exhibited a higher purity, however with an unacceptable sacrifice in PI2 yield. In order to produce the desired grind profile at the pilot scale, a “Microcut Head Assembly” was used. The final grind profile is determined by several mechanical characteristics of the grinding head, such as the number, spacing and angle of blades in the head as well as the speed and type of impeller. The Microcut head features 190 tungsten carbide blades, each 0.084 inches thick. This thickness allows for a spacing of 0.0153 inches (388.62 μ) between each blade. The product is pushed through the spaces between the blades by the impeller. The impeller being used is a “veri-cut” due to its durability and the uniform particle size it produces. This impeller, in conjunction with this head assembly, produces a depth of cut of 0.0016 inches (40.64 μ). The interaction of the impeller, grinding blades and raw materials generates the friction responsible for the observed temperature rise. A rise of ten degrees was not considered harmful, due to the heat stability of PI2 (70° C. for ore than 3 hours). The depth of cut may vary slightly with the speed of the impeller, which is determined by the motor. For these studies, a consistent grind profile was used to provide an average particle size of approximately 500 μ.
[0045] Trials were then conducted, using the optimized grind profile, to determine the proper separation conditions of the liquid/solid slurry. There are many techniques available to separate solids from liquids. A basket type centrifuge was identified as appropriate for the separation of potato solids from the extraction solution mixture. The target goals for the separation process were to maximize the liquid extracted from the slurry, while generating a cake with a minimized moisture content. As the PI2 is expected to disperse within the liquid fraction, maximizing liquid recovery is of primary importance to maximizing the yield of PI2. Pilot trials were performed, using a pilot model that would be directly scaleable to a full production model. The characteristic of the centrifuge that was optimized by these trials was the filter-mesh screen size.
TABLE 15 Screen Mesh Trial for Optimization Solid moisture Suspended Time per L Mesh size Liquid recovery content solid collected 100 μ 100.00% 5.35% 5.35% 0.972 L/min 75 μ 99.87% 5.78% 4.55% 0.968 L/min 50 μ 99.54% 5.94% 1.05% 0.967 L/min 35 μ 99.13% 6.05% 0.25% 0.960 L/min 15 μ 98.65% 6.74% 0.15% 0.933 L/min
[0046] The liquid recovery data was normalized to the highest yield examined over the data set, the moisture content if the solid cake was measured via vacuum oven digestion, and the suspended solids were determined via gyro-testing. Based on the data from Table 15, a 35μ filter bag mesh was chosen for continued pilot study, and for full production. The liquid yield is maximized (over the sample set tested) utilizing the largest screen mesh. Unfortunately, this screen mesh also generates the highest amount of suspended solid in the filtered extract. It can be observed that a dramatic reduction in the amount of suspended solid is observed using filter bags below 75μ. The reduction of suspended solids achieved using a 35μ filter, combined with the acceptable yield and collection rate, made the 35μ bag the preferred choice.
[0047] The foregoing description comprise illustrative embodiments of the present inventions. The foregoing embodiments and the methods described herein may vary based on the ability, experience, and preference of those skilled in the art. Merely listing the steps of the method in a certain order does not necessarily constitute any limitation on the order of the steps of the method. The foregoing description and drawings merely explain and illustrate the invention, and the invention is not limited thereto, except insofar as the claims are so limited. Those skilled in the art who have the disclosure before them will be able to make modifications and variations therein without departing from the scope of the invention.
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The present invention provides a method for the extraction of a proteinase inhibitor from plant tissue. The extraction of the proteinase inhibitor begins with the addition of an alcohol-free, aqueous solution of an organic acid and a salt to plant tissue. The extraction solution and plant tissue are comminuted to reduce the average particle size of the plant tissue to improve extraction efficiencies. A weight ratio of between about 1:1 and about 1:10 extraction solution to plant tissue is used. In extracting proteinase inhibitor II from potato tubers, the extraction solution utilizes formic acid and sodium chloride, and the average particle size is reduced to between about 100 and 1500 microns. The process has been demonstrated to be cost-effective and provide high yields of the target proteinase inhibitor on commercial scales.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 11/319,251, filed Dec. 27, 2005, now U.S. Pat. No. 7,573,806, issued Aug. 11, 2009, which pursuant to 35U.S.C. §119(a) claims the benefit of earlier filing date and right of priority to Korean Application No. 10-2004-0112990, filed on Dec. 27, 2004, Korean Application No. 10-2005-0002266, filed on Jan. 10, 2005, and Korean Application No. 10-2005-0035405, filed on Apr. 28, 2005, the contents of which are hereby incorporated by reference herein in their entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to a broadband wireless access system, and more particularly, to communicating a non-coherent detectable signal for use in an orthogonal frequency division multiplexing (OFDM) access system.
BACKGROUND OF THE INVENTION
[0003] In order to enable a plurality of users to simultaneously use limited radio resources, a multiplexing scheme is required. The multiplexing scheme divides a single line or transmission path into a plurality of channels capable of simultaneously transmitting/receiving individual independent signals. There are a variety of multiplexing schemes, for example, a Frequency Division Multiplexing (FDM) scheme for dividing a single line into a plurality of frequency bands and performing signal multiplexing, and a Time Division Multiplexing (TDM) scheme for dividing a single line into a plurality of very short time intervals and performing signal multiplexing.
[0004] Currently, due to the increasing demands of multimedia data in mobile communication, a multiplexing method for effectively transmitting a large amount of data is required. A representative multiplexing method is an orthogonal frequency division multiplexing (OFDM) scheme.
[0005] The OFDM scheme is indicative of a digital modulation scheme capable of improving a transfer rate per bandwidth and preventing multi-path interference from being generated. The OFDM scheme is characterized in that it acts as a multi-sub-carrier modulation scheme using a plurality of sub-carriers, wherein individual sub-carriers are orthogonal to each other. Therefore, although frequency components of individual sub-carriers overlap with each other, the OFDM scheme is problem free. The OFDM scheme can perform multiplexing of many more sub-carriers than those of a general frequency division multiplexing (FDM) scheme. Thus, high frequency use efficiency is implemented.
[0006] A mobile communication system based on the above-mentioned OFDM scheme currently uses a variety of multiple access schemes capable of allocating radio resources to a plurality of users, for example, an OFDM-FDMA (OFDMA) scheme, an OFDM-TDMA scheme, and an OFDM-CDMA scheme, etc. Specifically, the OFDMA (Orthogonal Frequency Division Multiple Access) scheme allocates some parts of all sub-carriers to individual users, such that it can accommodate a plurality of users.
[0007] FIG. 1 illustrates a method for allocating radio resources in accordance with the related art. Referring to FIG. 1 , a broadband wireless access system comprises a specific configuration of FIG. 1 as a basic unit for allocating OFDMA uplink radio resources. This specific configuration shown in FIG. 1 is referred to as a tile structure. In the case of the above-mentioned tile structure, data of a Channel Quality Indication Channel (CQICH) or data of an Acknowledge Channel (ACKCH) is transmitted via a plurality of data sub-carriers 102 , 103 , 105 , 106 , 107 , 108 , 110 , and 111 . A pilot channel is transmitted via pilot sub-carriers 101 , 104 , 109 , and 112 . Each sub-carrier transmitted via the tile structure is referred to as a constituent unit of the tile structure.
SUMMARY OF THE INVENTION
[0008] The present invention is directed to communicating a non-coherent detectable signal for use in an orthogonal frequency division multiplexing (OFDM) access system.
[0009] Additional features and advantages of the invention will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
[0010] To achieve these and other advantages and in accordance with the purpose of the present invention, as embodied and broadly described, the present invention is embodied in a method of allocating a radio resource in a wireless communication system utilizing orthogonal frequency division multiplexing (OFDM), the method comprising receiving in a mobile station data associated with a radio resource allocation map from a base station, wherein the radio allocation map comprises control parameters for transmitting an uplink channel, wherein the uplink channel comprises at least one OFDM tile comprising a first set of subcarriers associated with representing at least part of an n-bit data payload, and a second set of subcarriers associated with representing at least part of a non-pilot m-bit data payload wherein each subcarrier carries a modulated data, and the first and the second set of subcarriers are exclusive to each other, and transmitting the uplink channel from the mobile station to the base station.
[0011] Preferably, the uplink channel comprises a primary tile comprising the following Table 1A.
[0000]
TABLE 1A
Subcarrier 0
Subcarrier 1
Subcarrier 2
Subcarrier 3
Symbol 0
NULL
Mn, 8m
Mn, 8m + 1
NULL
Symbol 1
Mn, 8m + 2
Mn, 8m + 3
Mn, 8m + 4
Mn, 8m + 5
Symbol 2
NULL
Mn, 8m + 6
Mn, 8m + 7
NULL
[0012] Table 1A can be depicted in a drawing format like FIG. 10A , wherein an x-axis represents a time domain and a y-axis represents a frequency domain.
[0013] Preferably, the uplink channel further comprises a secondary tile comprising the following Table 1B.
[0000]
TABLE 1B
Subcarrier 0
Subcarrier 1
Subcarrier 2
Subcarrier 3
Symbol 0
Mn, 4m
NULL
NULL
Mn, 4m + 1
Symbol 1
NULL
NULL
NULL
NULL
Symbol 2
Mn, 4m + 2
NULL
NULL
Mn, 4m + 3
[0014] Table 1B can be depicted in a drawing format like FIG. 10B , wherein an x-axis represents a time domain and a y-axis represents a frequency domain.
[0015] In one aspect of the invention, information associated with the use of one of the first and the second sets of subcarriers is received in the mobile station using a normal map information element.
[0016] In another aspect of the invention, information associated with the use of one of the first and the second sets of subcarriers is received in the mobile station using a HARQ map information element.
[0017] Preferably, the first set of subcarriers is associated with representing at least part of a 6-bit data payload. Preferably, the second set of subcarriers is associated with representing at least part of a 4-bit data payload.
[0018] In a further aspect of the invention, the uplink channel is associated with transmitting one of channel quality information, antenna selection option and precoding matrix code book.
[0019] Preferably, the uplink channel is associated with transmitting one of fast down link measurement, MIMO mode, antenna grouping, antenna selection, reduced codebook, quantized precoding weight feedback, index to precoding matrix in codebook, channel matrix information and per stream power control.
[0020] Preferably, the use of the second set of subcarriers for transmitting at least part of the m-bit data payload is requested by one of the base station or the mobile station.
[0021] Preferably, six OFDM tiles comprise one OFDM slot for representing a 4-bit data payload, wherein the 4-bit data payload is represented as follows:
[0000]
Vector indices per tile
Tile(0), Tile(1),
4 bit
Tile(2), Tile(3),
payload
Tile(4), Tile(5)
0b0000
a, a, a, b, b, b
0b0001
b, b, b, a, a, a
0b0010
c, c, c, d, d, d
0b0011
d, d, d, c, c, c
0b0100
a, b, c, d, a, b
0b0101
b, c, d, a, b, d
0b0110
c, d, a, b, c, d
0b0111
d, a, b, c, d, a
0b1000
a, a, b, d, c, c
0b1001
b, d, c, c, d, b
0b1010
c, c, d, b, a, a
0b1011
d, d, b, a, b, b
0b1100
a, a, d, c, a, d
0b1101
b, c, a, c, c, a
0b1110
c, b, d, d, b, c
0b1111
d, c, c, b, b, c
[0022] wherein
[0000]
Vector Index
M n,4m , M n,4m+1 , M n,4m+2 , M n,4m+3
A
P0, P0, P0, P0
B
P0, P2, P0, P2
C
P0, P1, P2, P3
D
P1, P0, P3, P2
[0023] In accordance with another embodiment of the present invention, a method of allocating a radio resource in a wireless communication system utilizing orthogonal frequency division multiplexing (OFDM) comprises transmitting data associated with a radio resource allocation map to a mobile station, wherein the radio allocation map comprises control parameters for receiving an uplink channel, wherein the uplink channel comprises at least one OFDM tile comprising a first set of subcarriers associated with representing at least part of an n-bit data payload, and a second set of subcarriers associated with representing at least part of a non-pilot m-bit data payload wherein each subcarrier carries a modulated data, and the first and the second set of subcarriers are exclusive to each other, and receiving the uplink channel from the mobile station.
[0024] In accordance with another embodiment of the present invention, a mobile communication device for allocating a radio resource in a wireless communication system utilizing orthogonal frequency division multiplexing (OFDM) comprises a receiver for receiving data associated with a radio resource allocation map from a base station, wherein the radio allocation map comprises control parameters for transmitting an uplink channel, wherein the uplink channel comprises at least one OFDM tile comprising a first set of subcarriers associated with representing at least part of an n-bit data payload, and a second set of subcarriers associated with representing at least part of a non-pilot m-bit data payload wherein each subcarrier carries a modulated data, and the first and the second set of subcarriers are exclusive to each other, and a transmitter for transmitting the uplink channel from the mobile communication device to the base station.
[0025] It is to be understood that both the foregoing general description and the following detailed description of the present invention are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] 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. Features, elements, and aspects of the invention that are referenced by the same numerals in different figures represent the same, equivalent, or similar features, elements, or aspects in accordance with one or more embodiments.
[0027] FIG. 1 illustrates a method for allocating radio resources in accordance with the related art.
[0028] FIG. 2 illustrates a method for allocating a CQICH (Channel Quality Indication Channel) area and an ACKCH (Acknowledge Channel) area in an OFDM uplink in accordance with one embodiment of the present invention.
[0029] FIG. 3 illustrates a tile structure for when a new signal is transmitted using a sub-carrier having transmitted a pilot signal in accordance with one embodiment of the present invention.
[0030] FIG. 4 illustrates a method for acquiring a secondary ACKCH from a CQICH tile structure in accordance with one embodiment of the present invention.
[0031] FIG. 5 illustrates a method for acquiring a secondary ACKCH from two ACKCH tile structures in accordance with one embodiment of the present invention.
[0032] FIG. 6 illustrates a method for acquiring a secondary CQICH from two CQICH tile structures in accordance with one embodiment of the present invention.
[0033] FIG. 7 illustrates a method for acquiring a secondary CQICH from four ACKCH tile structures in accordance with one embodiment of the present invention.
[0034] FIG. 8 illustrates a tile structure for use in a method for allocating a codeword using an additional sub-carrier in accordance with one embodiment of the present invention.
[0035] FIGS. 9A and 9B illustrate a structure of a transmitter unit and receiver unit of a mobile communication device in accordance with one embodiment of the present invention.
[0036] FIGS. 10A and 10B respectively illustrate an uplink channel primary tile and an uplink channel secondary tile, where the x-axis represents a time domain and a y-axis represents a frequency domain.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0037] The present invention relates to allocating a radio resource in a wireless communication system utilizing orthogonal frequency division multiplexing (OFDM).
[0038] Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
[0039] Preferably, the present invention is applied to a broadband wireless access system, such as the system disclosed in IEEE 802.16e. However, it is contemplated that the present invention may be utilized in other types of wireless access systems.
[0040] Typically, channel estimation is performed on a data sub-carrier on the basis of the pilot sub-carrier, such that a coherent detection scheme is used for the data sub-carrier. However, an ACKCH or CQICH may use a non-coherent detection scheme without performing the channel estimation. In the meantime, the ACKCH or CQICH uses orthogonal codewords to implement a non-coherent detection scheme.
[0041] The following Table 1 exemplarily shows codewords for modulating ACKCH sub-carriers when ACK information of 1 bit is provided.
[0000]
TABLE 1
Vector indices per tile
ACK 1-bit symbol
Tile(0), Tile(1), Tile(2)
0
0, 0, 0
1
4, 7, 2
[0042] The following Table 2 exemplarily shows codewords for modulating CQICH sub-carriers when CQI information of 6 bits is provided.
[0000]
TABLE 2
Fast Feedback vector indices per
6-bit payload
tile Tile(0), Tile(1), . . . , Tile(5)
0b000000
0, 0, 0, 0, 0, 0
0b000001
1, 1, 1, 1, 1, 1
0b000010
2, 2, 2, 2, 2, 2
0b000011
3, 3, 3, 3, 3, 3
.
.
.
.
.
.
[0043] The following Table 3 exemplarily shows codewords for modulating CQICH sub-carriers when CQI information of 5 bits is provided.
[0000]
TABLE 3
Fast Feedback vector indices per tile
5-bit payload
Tile(0), Tile(1), . . . , Tile(5)
0b00000
0, 0, 0, 0, 0
0b00001
1, 1, 1, 1, 1
0b00010
2, 2, 2, 2, 2
0b00011
3, 3, 3, 3, 3
.
.
.
.
.
.
[0044] The following Table 4 exemplarily shows codewords for modulating CQICH sub-carriers when CQI information of 4 bits is provided.
[0000]
TABLE 4
Fast feedback vector indices per tile
4-bit payload
Tile(0), Tile(1), . . . , Tile(5)
0b0000
0, 0, 0, 0, 0, 0
0b0001
1, 1, 1, 1, 1, 1
0b0010
2, 2, 2, 2, 2, 2
0b0011
3, 3, 3, 3, 3, 3
.
.
.
.
.
.
[0045] With reference to Table 4, a vector for each tile includes 8 Quadrature Phase Shift Keying (QPSK) symbols, such that a signal can be transmitted via 8 data sub-carriers.
[0000]
TABLE 5
Vector Index
M n,m8 , M n,8m+1 , . . . M n,8m+7
0
P0, P1, P2, P3, P0, P1, P2, P3
1
P0, P3, P2, P1, P0, P3, P2, P1
2
P0, P0, P1, P1, P2, P2, P3, P3
3
P0, P0, P3, P3, P2, P2, P1, P1
4
P0, P0, P0, P0, P0, P0, P0, P0
5
P0, P2, P0, P2, P0, P2, P0, P2
6
P0, P2, P0, P2, P2, P0, P2, P0
7
P0, P2, P2, P0, P2, P0, P0, P2
[0046] With reference to Table 5, P0, P1, P2, and P3 are denoted by the following Equation 1:
[0000]
P
0
=
exp
(
j
π
4
)
,
P
1
=
exp
(
j
3
π
4
)
,
P
2
=
exp
(
-
j
3
π
4
)
,
P
3
=
exp
(
-
j
π
4
)
[
Equation
1
]
[0047] A single sub-channel includes 6 tiles. The CQICH can use a single sub-channel, and the ACKCH can use half of the sub-channel. In other words, the CQICH can use 6 tiles, and the ACKCH can use 3 tiles.
[0048] FIG. 2 illustrates a method for allocating a CQICH (Channel Quality Indication Channel) area and an ACKCH (Acknowledge Channel) area in an OFDM uplink in accordance with one embodiment of the present invention. Referring to FIG. 2 , some areas of a two-dimensional map of an uplink are pre-assigned to the ACKCH dedicated area 201 , and the remaining areas other than the above-mentioned areas are pre-assigned to the CQICH dedicated area 202 .
[0049] Individual sub-channels are assigned to an ACKCH dedicated area 201 and a CQICH dedicated area 202 , such that a specific Mobile Subscriber Station (MSS) can use the ACKCH dedicated area 201 and the CQICH dedicated area 202 . Referring to FIG. 2 , an MSS# 1 may be assigned to an ACK# 1 , an MSS# 2 may be assigned to an ACK# 2 , . . . , an MSS# 8 may be assigned to an ACK# 8 , an MSS# 9 may be assigned to a CQICH# 1 , an MSS# 10 may be assigned to a CQICH# 2 and a CQICH# 3 , and an MSS# 11 may be assigned to a CQICH# 4 .
[0050] If a base station uses a non-coherent detection scheme, there is no need to use pilot sub-carriers. In this case, it is not necessary to use 4 pilot sub-carriers assigned to each tile, and the uplink's radio resources and terminal's transmission power are unnecessarily consumed.
[0051] Therefore, new information is loaded on a sub-carrier assigned to a pilot channel, and is then transmitted to the CQICH and ACKCH tile structures, such that specific information based on the non-coherent detection scheme in the same manner as in the CQICH or ACKCH can be transmitted using a conventional sub-carrier equipped with a pilot signal.
[0052] FIG. 3 illustrates a tile structure for when a new signal is transmitted using a sub-carrier having transmitted a pilot signal in accordance with one embodiment of the present invention. Referring to FIG. 3 , a new signal can be transmitted using sub-carriers 301 , 304 , 309 , and 312 . These sub-carriers used to transmit a pilot signal.
[0053] As stated above, if the new signal is loaded on the sub-carrier having transmitted the pilot signal in the tile structure for the CQICH and the ACKCH, the sub-carrier having transmitted each pilot signal is referred to as an additional sub-carrier. If the additional sub-carrier formed by the grouping of unit tile structures is used, a secondary CQICH and a secondary ACKCH other than a primary ACKCH and a primary CQICH can be acquired.
[0054] FIG. 4 illustrates a method for acquiring a secondary CQICH from a CQICH tile structure in accordance with one embodiment of the present invention. Referring to FIG. 4 , a single CQICH includes 6 tile units (1 subchannel), wherein 4 additional sub-carriers may be acquired from each tile unit, such that a total of 24 additional sub-carriers may be acquired from each CQICH. Meanwhile, an ACKCH or a secondary CQICH may include 3 tile units (1/2 subchannel), wherein each tile unit includes 8 sub-carriers, such that a single ACKCH or a secondary CQICH may be constructed using 24 sub-carriers. Therefore, a single ACKCH (i.e., the secondary ACKCH) or a secondary CQICH may be constructed using 24 additional sub-carriers capable of being acquired from a single CQICH.
[0055] FIG. 5 illustrates a method for acquiring a secondary ACKCH from two ACKCH tile structures in accordance with one embodiment of the present invention. Referring to FIG. 5 , a single ACKCH may include 3 tile units, wherein 4 additional sub-carriers may be acquired from each tile unit, such that a total of 24 additional sub-carriers can be acquired from two ACKCHs. Meanwhile, a single ACKCH may be constructed using 24 sub-carriers, such that a single ACKCH (i.e., the secondary ACKCH) can be constructed when additional sub-carriers are acquired from a group comprising 2 ACKCHs, as shown in FIG. 5 .
[0056] FIG. 6 illustrates a method for acquiring a secondary CQICH from two CQICH tile structures in accordance with one embodiment of the present invention. Referring to FIG. 6 , each CQICH may include 6 tile units, wherein 4 additional sub-carriers are acquired from each tile unit, such that a total of 48 additional sub-carriers may be acquired from two CQICHs. Meanwhile, a CQICH may also include 6 tile units, wherein each tile unit includes 8 sub-carriers, such that a single CQICH may be constructed using 48 sub-carriers. Therefore, a single CQICH (i.e., the secondary CQICH) may be constructed using 48 additional sub-carriers capable of being acquired from two CQICHs.
[0057] FIG. 7 illustrates a method for acquiring a secondary CQICH from four ACKCH tile structures in accordance with one embodiment of the present invention. Referring to FIG. 7 , a single ACKCH may include 3 tile units, wherein 4 additional sub-carriers may be acquired from each tile unit, such that a total of 48 additional sub-carriers may be acquired from 4 ACKCHs. Meanwhile, a CQICH may include 6 tile units, wherein each tile unit includes 8 sub-carriers, such that a single CQICH may be constructed using 48 sub-carriers. Therefore, a single CQICH (i.e., the secondary CQICH) may be constructed using 48 additional sub-carriers capable of being acquired from 4 ACKCHs.
[0058] Preferably, the following methods can be adapted to assign a codeword to a sub-carrier. According to a first preferred embodiment of the present invention, 12 tiles contained in either a single CQICH or two ACKCHs are grouped into 6 sets, each of which comprises 2 tiles, and the codeword can be assigned, as shown in the following Tables 6-9.
[0059] The following Table 6 exemplarily shows a method for assigning a codeword to modulate a secondary ACKCH sub-carrier when ACK information of 1 bit is provided.
[0000]
TABLE 6
Vector indices per tile
Additional ACKCH 1-
(Tile(0), Tile(1)), (Tile(2),
bit symbol
Tile(3)), (Tile(4), Tile(5))
0
0, 0, 0
1
4, 7, 2
[0060] The following Table 7 exemplarily shows a method for assigning a codeword to modulate a CQICH sub-carrier when CQI information of 6 bits is provided.
[0000]
TABLE 7
Fast Feedback vector indices per tile
6-bits
(Tile(0), Tile(1)), (Tile(2), Tile(3)),
payload
(Tile(4), Tile(5)), . . . (Tile(10), Tile(11))
0b000000
0, 0, 0, 0, 0, 0
0b000001
1, 1, 1, 1, 1, 1
0b000010
2, 2, 2, 2, 2, 2
0b000011
3, 3, 3, 3, 3, 3
.
.
.
.
.
.
[0061] The following Table 8 exemplarily shows a codeword for modulating a CQICH sub-carrier when CQI information of 5 bits is provided.
[0000]
TABLE 8
Fast Feedback vector indices per tile
(Tile(0), Tile(1)), (Tile(2), Tile(3)), (Tile(4),
5-bits payload
Tile(5)), . . . (Tile(10), Tile(11))
0b00000
0, 0, 0, 0, 0
0b00001
1, 1, 1, 1, 1
0b00010
2, 2, 2, 2, 2
0b00011
3, 3, 3, 3, 3
.
.
.
.
.
.
[0062] The following Table 9 exemplarily shows a codeword for modulating a CQICH sub-carrier when CQI information of 4 bits is provided.
[0000]
TABLE 9
Fast Feedback vector indices per tile
(Tile(0), Tile(1)), (Tile(2), Tile(3)),
4-bits payload
(Tile(4), Tile(5)), . . . (Tile(10), Tile(11))
0b00000
0, 0, 0, 0, 0, 0
0b00001
1, 1, 1, 1, 1, 1
0b00010
2, 2, 2, 2, 2, 2
0b00011
3, 3, 3, 3, 3, 3
.
.
.
.
.
.
[0063] Meanwhile, according to a second preferred embodiment of the present invention, a codeword can be assigned to each of 12 tiles contained in either a single CQICH or two ACKCHs, as shown in the following Tables 10-11.
[0064] The following Table 10 exemplarily shows a method for assigning a codeword to modulate a secondary ACKCH sub-carrier when ACK information of 1 bit is provided.
[0000]
TABLE 10
additional ACK
Vector indices per tile
1-bit symbol
Tile(0), Tile(1), Tile(2), Tile(3), Tile(4), Tile(5)
0
a, a, a, a, a, a
1
b, b, b, b, b, b
[0000]
TABLE 11
additional
Fast Feedback vector indices per tile
CQICH 6-bits, 5-bits and
Tile(0), Tile(1), Tile(2), Tile(3), Tile(4),
4-bits payload
Tile(5), . . . Tile(10), Tile(11)
0b000000, 0b00000, 0b0000
a, a, a, a, a, a, a, a, a, a, a, a
0b000001, 0b00001, 0b0001
b, b, b, b, b, b, b, b, b, b, b, b
0b000010, 0b00001, 0b0001
c, c, c, c, c, c, c, c, c, c, c, c
0b000011, 0b00011, 0b0011
d, d, d, d, d, d, d, d, d, d, d, d
[0065] Additional sub-carriers of the tile applied to the codeword allocation shown in Table 11 are depicted in FIG. 8 .
[0066] FIG. 8 illustrates a tile structure for use in a method for allocating a codeword using an additional sub-carrier in accordance with one embodiment of the present invention.
[0067] Referring to FIG. 8 and the following Table 12, a vector assigned to each tile includes 4 modulation symbols in order to perform signal transmission via 4 additional sub-carriers.
[0000]
TABLE 12
Vector Index
M n,4m , M n,4m+1 , M n,4m+2 , M n,4m+3
a
P0, P0, P0, P0
b
P0, P2, P0, P2
c
P0, P1, P2, P3
d
P1, P0, P3, P2
[0068] The secondary ACKCH can be constructed using 24 sub-carriers assigned to a pilot channel. A method for constructing the ACKCH using the 24 pilot sub-carriers can be implemented with additional sub-carriers in various ways other than exemplary methods shown in FIGS. 9-10 .
[0069] The secondary ACKCH can be configured using 3 tiles. The following Table 13 exemplarily shows a codeword available for the above-mentioned case in which the secondary ACKCH includes 3 tiles.
[0000]
TABLE 13
Secondary ACK
1-bit symbol
Vector indices per tile Tile(0), Tile(1), Tile(2)
0
a, a, a
1
b, b, b
[0070] The secondary CQICH can be constructed using 48 pilot sub-carriers. A method for constructing the ACKCH using the 48 pilot sub-carriers can be implemented with additional sub-carriers in various ways other than the exemplary methods shown in FIGS. 6-7 .
[0071] The secondary CQICH can be configured using 6 tiles. The following Table 14 exemplarily shows a codeword available for the above-mentioned case in which the secondary CQICH includes 6 tiles.
[0000]
TABLE 14
Vector indices per tile
Secondary CQICH
Tile(0), Tile(1),
4 bit
Tile(2), Tile(3),
payload
Tile(4), Tile(5)
0b0000
a, a, a, b, b, b
0b0001
b, b, b, a, a, a
0b0010
c, c, c, d, d, d
0b0011
d, d, d, c, c, c
0b0100
a, b, c, d, a, b
0b0101
b, c, d, a, b, d
0b0110
c, d, a, b, c, d
0b0111
d, a, b, c, d, a
0b1000
a, a, b, d, c, c
0b1001
b, d, c, c, d, b
0b1010
c, c, d, b, a, a
0b1011
d, d, b, a, b, b
0b1100
a, a, d, c, a, d
0b1101
b, c, a, c, c, a
0b1110
c, b, d, d, b, c
0b1111
d, c, c, b, b, c
[0072] Meanwhile, a new codeword can be constructed using binary phase-shift keying (BPSK), as shown in the following Table 15.
[0000]
TABLE 15
Vector Index
M n,4m , M n,4m+1 , M n,4m+2 , M n,4m+3
a
1, 1, 1, 1
b
1, −1, 1, −1
c
1, 1, −1, −1
d
1, −1, −1, 1
[0073] A base station can use messages shown in the following Table 16 to inform a mobile subscriber station (MSS) of information associated with the secondary ACKCH.
[0000]
TABLE 16
Syntax
Size(bits)
Notes
Compact_UL_MAP_IE( ){
UL-MAP Type
3
Type = 7
UL-MAP Sub-type
5
Sub-type = 3
Length
4
Length of the IE
bytes
Primary/Secondary H-ARQ Region
1
0 = no region
Change Indication
change
1 = region change
If(Primary/Secondary H-ARQ Region
Change indication==1){
OFDMA Symbol Offset
8
Subchannel Offset
8
No. OFDMA Symbols
8
No. Subchannels
8
}
Reserved
3
}
[0074] With reference to Table 16, the “UL-MAP TYPE” field and the “Sub-Type” field are adapted to inform an MSS of message type information. In other words, the MSS can recognize content information of a corresponding message by referring to the above-mentioned “UL-MAP TYPE” and “Sub-Type” fields. Meanwhile, the “Length” field informs the MSS of size information of overall messages including the “Length” field in byte units.
[0075] The “Primary/Secondary H-ARQ Region Indication” field has a value of 1 either when a current frame has an H-ARQ region different from that of a previous frame or when another H-ARQ region is present in the same frame. The “OFDMA Symbol Offset” field informs the MSS of coordinates at which the “H-ARQ” region begins at an uplink in symbol units. The “Subchannel Offset” field informs the MSS of coordinates at which the “H-ARQ” region begins at an uplink in sub-channel units. The “No. OFDMA symbols” field informs the MSS of size information occupied by the “H-ARQ” region at an uplink in symbol units. The “No. Sub-channels” field informs the MSS of size information occupied by the “H-ARQ” region at an uplink in subchannel units.
[0076] Meanwhile, a base station may use messages shown in the following Table 17 to inform the MSS of information associated with the secondary CQICH.
[0000]
TABLE 17
Syntax
Size(bits)
Notes
Compact_UL_MAP_IE( ){
UL-MAP Type
3
Type = 7
UL-MAP Sub-type
5
Sub-type = 3
Length
4
Length of the IE bytes
Primary/Secondary H-ARQ Region
1
0 = no region change
Change Indication
If(Primary/Secondary H-ARQ Region
1 = region change
Change indication==1){
OFDMA Symbol Offset
8
Subchannel Offset
8
No. OFDMA Symbols
8
No. Subchannels
8
}
Reserved
3
}
[0077] With reference to Table 17, the “UL-MAP TYPE” field and the “Sub-Type” field are adapted to inform the MSS of message type information. In other words, the MSS can recognize message content information by referring to the above-mentioned “UL-MAP TYPE” and “Sub-Type” fields. Meanwhile, the “Length” field informs the MSS of size information of overall messages including the “Length” field in byte units.
[0078] The “Primary/Secondary CQICH Region Indication” field has a value of 1 either when a current frame has a CQICH region different from that of a previous frame or when another CQICH region is present in the same frame. The “OFDMA Symbol Offset” field informs the MSS of coordinates at which the “CQICH” region begins at an uplink in symbol units. The “Subchannel Offset” field informs the MSS of coordinates at which the “CQICH” region begins at an uplink in subchannel units. The “No. OFDMA symbols” field informs the MSS of size information occupied by the “CQICH” region at an uplink in symbol units. The “No. Sub-channels” field informs the MSS of size information occupied by the “CQICH” region at an uplink in subchannel units.
[0079] Information transmitted via the secondary CQICH according to the present invention can be used in various ways according to feedback types. For example, if information associated with a Signal-to-Noise Ratio (SNR) is transmitted to the base station, a payload of the above-mentioned information may occur as depicted in the following Equation 2:
[0000]
4
bit
payload
bit
nibble
=
{
0
,
S
/
N
<
-
2
dB
n
,
2
n
-
4
<
S
/
N
<
2
n
-
2
,
0
<
n
<
15
15
,
S
/
N
>
26
dB
[
Equation
2
]
[0080] Meanwhile, in the case of a Multi-Input Multi-Output (MIMO) mode, a payload depicted in the following Table 18 may occur.
[0000]
TABLE 18
Value
Description
0b0000
STTD and PUSC/FUSC permutation
0b0001
STTD and adjacent-subcarrier permutation
0b0010
SM and PUSC/FUSC permutation
0b0011
SM and adjacent-subcarrier permutation
0b0100
Closed-loop SM and PUSC/FUSC permutation
0b0101
Closed-loop SM and adjacent-subcarrier permutation
0b0110
Closed-loop SM + Beamforming and adjacent-subcarrier
permutation
0b0111-0b1111
Interpretation according to table 296e, 296f or 296g,
depending on if antenna grouping, antenna selection or
a reduced precoding matrix code book is used.
[0081] The following Table 19 exemplarily shows antenna grouping methods corresponding to individual values shown in Table 18.
[0000]
TABLE 19
Value
Description
0b0111
Antenna Group A1 for rate 1
For 3-antenna BS, See 8.4.8.3.4
For 4-antenna BS, See 8.4.8.3.5
0b1000
Antenna Group A2 for rate 1
0b1001
Antenna Group A3 for rate 1
0b1010
Antenna Group B1 for rate 2
For 3-antenna BS, See 8.4.8.3.4
For 4-antenna BS, See 8.4.8.3.5
0b1011
Antenna Group B2 for rate 2
0b1100
Antenna Group B3 for rate 2
0b1101
Antenna Group B4 for rate 2 (only for 4-antenna BS)
0b1110
Antenna Group B5 for rate 2 (only for 4-antenna BS)
0b1111
Antenna Group B6 for rate 2 (only for 4-antenna BS)
[0082] The following Table 20 exemplarily shows antenna selection methods corresponding to individual values shown in Table 18.
[0000]
TABLE 20
Value
Description
0b0111
Antenna selection option 0
0b1000
Antenna selection option 1
0b1001
Antenna selection option 2
0b1010
Antenna selection option 3
0b1011
Antenna selection option 4
0b1100
Antenna selection option 5
0b1101
Antenna selection option 6
0b1110
Antenna selection option 7
0b1111
Reserved
[0083] The following Table 21 exemplarily shows a method for employing reduced precoding matrix code books corresponding to individual values shown in Table 18.
[0000]
TABLE 21
Value
Description
0b0111
Reduced Precoding matrix code book entry 0
0b1000
Reduced Precoding matrix code book entry 1
0b1001
Reduced Precoding matrix code book entry 2
0b1010
Reduced Precoding matrix code book entry 3
0b1011
Reduced Precoding matrix code book entry 4
0b1100
Reduced Precoding matrix code book entry 5
0b1101
Reduced Precoding matrix code book entry 6
0b1110
Reduced Precoding matrix code book entry 7
0b1111
Reserved
[0084] The base station transmits information associated with the above-mentioned feedback type information to an MSS via a “CQICH_Enhanced_Alloc_IE” field.
[0085] The following Tables 22 and 23 exemplarily show some parts of the “CQICH_Enhanced_Alloc_IE” field including the above-mentioned feedback type information.
[0000]
TABLE 22
CQICH_Enhanced_Alloc_IE( ){
. . .
. . .
. . .
Feedback type
3 bits
0b000 = Fast DL Measurement
0b001 = MIMO Mode selection/Antenna Grouping
0b010 = MIMO Mode selection/Antenna Selection
0b011 = MIMO Mode Selection/Reduced Codebook
0b100 = Quantized Precoding Weight Feedback
0b101 = Index to Precoding Matrix in Codebook
0b110 = Channel Matrix Information
0b111 = Per Stream Power Control
. . .
. . .
. . .
[0000]
TABLE 23
CQICH_Enhanced_Alloc_IE( ){
...
...
...
Feedback type
3 bits
0b000 = Fast DL measurement/Antenna grouping
for 6bit payload
= Fast DL measurement for 4bit payload
0b001 = Fast DL measurement/Antenna selection
for 6bit payload
= MIMO mode/Antenna grouping for 4bit
payload
0b010 = Fast DL measurement/Reduced codebook
for 6bit payload
= Antenna selection/Reduced Codebook for
4bit payload
0b011 = Quantized precoding weight feedback
0b100 = Index to precoding matrix in codebook
0b101 = Channel Matrix Information
0b110 = Per stream power control
0b111 = reserved
[0086] Meanwhile, if only information associated with the SNR is transmitted to the base station, a payload of information transmitted via the secondary CQICH according to the present invention may occur as depicted in the following Equation 3:
[0000]
4
bit
payload
bit
nibble
=
{
0
,
S
/
N
<
-
2
dB
n
,
2
n
-
4
<
S
/
N
<
2
n
-
2
,
0
<
n
<
15
15
,
S
/
N
>
26
dB
[
Equation
3
]
[0087] Information associated with feedback types capable of transmitting only SNR-associated information to the base station is transmitted to the MSS via the “CQICH_Enhanced_Alloc_IE” field.
[0088] The following Table 24 exemplarily shows some parts of the “CQICH_Enhanced_Alloc_IE” field including the above-mentioned feedback type information.
[0000]
TABLE 24
CQICH_Enhanced_Alloc_IE( ){
...
...
...
Feedback type
3 bits
0b000 = Fast DL measurement/Antenna
grouping for 6bit payload
= Fast DL measurement for 4bit
payload
0b001 = Fast DL measurement/Antenna
selection for 6bit payload
= Fast DL measurement for 4bit payload
0b010 = Fast DL measurement/Reduced
codebook for
6bit payload
= Fast DL measurement for 4bit payload
0b011 = Quantized precoding weight
feedback
0b100 = Index to precoding matrix in codebook
0b101 = Channel Matrix Information
0b110 = Per stream power control
0b111 = reserved
...
...
...
[0089] Meanwhile, information transmitted via the secondary CQICH can be used in various ways according to feedback types. In other words, the above-mentioned secondary CQICH can be used only for MIMO mode selection. If the secondary CQICH is used only for the MIMO mode selection, a payload may occur as shown in the following Table 25.
[0000]
TABLE 25
Value
Description
0b0000
STTD and PUSC/FUSC permutation
0b0001
STTD and adjacent-subcarrier permutation
0b0010
SM and PUSC/FUSC permutation
0b0011
SM and adjacent-subcarrier permutation
0b0100
Closed-loop SM and PUSC/FUSC permutation
0b0101
Closed-loop SM and adjacent-subcarrier permutation
0b0110
Closed-loop SM + Beamforming and adjacent-subcarrier
permutation
0b0111-0b1111
Interpretation according to table 296e, 296f or 296g,
depending on if antenna grouping, antenna selection or a
reduced precoding matrix code book is used.
[0090] The following Table 26 exemplarily shows antenna grouping methods corresponding to individual values shown in Table 25.
[0000]
TABLE 26
Value
Description
0b0111
Antenna Group A1 for rate 1
For 3-antenna BS, See 8.4.8.3.4
For 4-antenna BS, See 8.4.8.3.5
0b1000
Antenna Group A2 for rate 1
0b1001
Antenna Group A3 for rate 1
0b1010
Antenna Group B1 for rate 2
For 3-antenna BS, See 8.4.8.3.4
For 4-antenna BS, See 8.4.8.3.5
0b1011
Antenna Group B2 for rate 2
0b1100
Antenna Group B3 for rate 2
0b1101
Antenna Group B4 for rate 2 (only for 4-antenna BS)
0b1110
Antenna Group B5 for rate 2 (only for 4-antenna BS)
0b1111
Antenna Group B6 for rate 2 (only for 4-antenna BS)
[0091] The following Table 27 exemplarily shows antenna grouping methods corresponding to individual values shown in Table 25.
[0000]
TABLE 27
Value
Description
0b0111
Antenna selection option 0
0b1000
Antenna selection option 1
0b1001
Antenna selection option 2
0b1010
Antenna selection option 3
0b1011
Antenna selection option 4
0b1100
Antenna selection option 5
0b1101
Antenna selection option 6
0b1110
Antenna selection option 7
0b1111
Reserved
[0092] The following Table 28 exemplarily shows a method for employing reduced precoding matrix code books corresponding to individual values shown in Table 25.
[0000]
TABLE 28
Value
Description
0b0111
Reduced Precoding matrix code book entry 0
0b1000
Reduced Precoding matrix code book entry 1
0b1001
Reduced Precoding matrix code book entry 2
0b1010
Reduced Precoding matrix code book entry 3
0b1011
Reduced Precoding matrix code book entry 4
0b1100
Reduced Precoding matrix code book entry 5
0b1101
Reduced Precoding matrix code book entry 6
0b1110
Reduced Precoding matrix code book entry 7
0b1111
Reserved
[0093] The base station transmits information associated with the above-mentioned feedback type information to an MSS via the “CQICH_Enhanced_Alloc_IE” field.
[0094] The following Table 29 exemplarily shows some parts of the “CQICH_Enhanced_Alloc_IE” field including the above-mentioned feedback type information.
[0000]
TABLE 29
CQICH_Enhanced_Alloc_IE( ){
...
...
...
Feedback type
3 bits
0b000 = Fast DL measurement/Antenna grouping
for 6bit payload
= MIMO mode/Antenna grouping for 4bit
payload
0b001 = Fast DL measurement/Antenna selection
for 6bit payload
= MIMO mode/Antenna selection for 4bit payload
0b010 = Fast DL measurement/Reduced
codebook for 6bit payload
= MIMO mode/Reduced codebook for 4bit
payload
0b011 = Quantized precoding weight feedback
0b100 = Index to precoding matrix in codebook
0b101 = Channel Matrix Information
0b110 = Per stream power control
0b111 = reserved
...
...
...
[0095] Although the use of the secondary fast feedback channel is requested by the BS to the MSS, the MSS has an option to request the usage by sending a request message to the BS. As apparent from the above description, a method for receiving a non-coherent detectable signal in a broadband wireless access system according to the present invention can transmit other signal(s) instead of a pilot signal when signal detection can be performed according to the non-coherent detection scheme, resulting in the implementation of increased transmission efficiency.
[0096] Although the present invention is described in the context of mobile communication, the present invention may also be used in any wireless communication systems using mobile devices, such as PDAs and laptop computers equipped with wireless communication capabilities.
[0097] The preferred embodiments may be implemented as a method, apparatus or article of manufacture using standard programming and/or engineering techniques to produce software, firmware, hardware, or any combination thereof. The term “article of manufacture” as used herein refers to code or logic implemented in hardware logic (e.g., an integrated circuit chip, Field Programmable Gate Array (FPGA), Application Specific Integrated Circuit (ASIC), etc.) or a computer readable medium (e.g., magnetic storage medium (e.g., hard disk drives, floppy disks, tape, etc.), optical storage (CD-ROMs, optical disks, etc.), volatile and non-volatile memory devices (e.g., EEPROMs, ROMs, PROMs, RAMs, DRAMs, SRAMs, firmware, programmable logic, etc.).
[0098] Code in the computer readable medium is accessed and executed by a processor. The code in which preferred embodiments are implemented may further be accessible through a transmission media or from a file server over a network. In such cases, the article of manufacture in which the code is implemented may comprise a transmission media, such as a network transmission line, wireless transmission media, signals propagating through space, radio waves, infrared signals, etc. Of course, those skilled in the art will recognize that many modifications may be made to this configuration without departing from the scope of the present invention, and that the article of manufacture may comprise any information bearing medium known in the art.
[0099] FIGS. 9A and 9B illustrate a structure of a transmitter unit and receiver unit of a mobile communication device in accordance with one embodiment of the present invention. Referring to FIG. 9A , a transmitter unit 500 preferably comprises a processor 510 for processing a signal to be transmitted. Before transmission, data bits are channel coded in a channel coder 520 , wherein redundancy bits are added to data bits. The data bits are then mapped to a signal such as QPSK or 16QAM in a symbol mapper 530 . Subsequently, the signal goes through subchannel modulation in a subchannel modulator 540 wherein the signal is mapped to the OFDMA subcarriers. Afterward, an OFDM waveformed-signal is constructed by combining several subcarriers through an Inverse Fast Fourier Transform (IFFT) 550 . Finally, the signal is filtered through filter 560 , converted to an analog signal by a digital-to-analog converter (DAC) 570 and transmitted to a receiver by an RF module 580 .
[0100] Referring to FIG. 9B , a structure of a receiver 600 of the present invention is similar to that of the transmitter 500 ; however, the signal goes through a reverse process. Preferably, a signal is received by an RF module 680 and subsequently converted to a digital signal by an analog-to-digital converter 670 and filtered through filter 660 . Upon filtering, the signal goes through a Fast Fourier Transform (FFT) 650 for deconstructing the waveformed-signal. The signal is then subchannel demodulated in subchannel demodulator 640 , symbol demapped by symbol demapper 630 and channel decoded by channel decoder 620 prior to being forwarded to a processor 610 for processing.
[0101] Preferably, when a user enters instructional information, such as a phone number, for example, into the mobile communication device by pushing buttons of a keypad or by voice activation using a microphone, the processor 510 or 610 receives and processes the instructional information to perform the appropriate function, such as to dial the telephone number. Operational data may be retrieved from a storage unit to perform the function. Furthermore, the processor 510 or 610 may display the instructional and operational information on a display for the user's reference and convenience.
[0102] The processor issues instructional information to the RF module 580 or 680 , to initiate communication, for example, transmit radio signals comprising voice communication data. The RF module comprises a receiver and a transmitter to receive and transmit radio signals. An antenna facilitates the transmission and reception of radio signals. Upon receiving radio signals, the RF module may forward and convert the signals to baseband frequency for processing by the processor. The processed signals would be transformed into audible or readable information outputted via a speaker, for example.
[0103] The processor is adapted to store message history data of messages received from and messages transmitted to other users in the storage unit, receive a conditional request for message history data input by the user, process the conditional request to read message history data corresponding to the conditional request from the storage unit, and output the message history data to the display unit. The storage unit is adapted to store message history data of the received messages and the transmitted messages.
[0104] FIGS. 10A and 10B respectively illustrate an uplink channel primary tile and an uplink channel secondary tile, where the x-axis represents a time domain and a y-axis represents a frequency domain.
[0105] It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the spirit or scope of the inventions. Thus, it is intended that the present invention covers the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.
|
The present invention relates to allocating a radio resource in a wireless communication system utilizing orthogonal frequency division multiplexing (OFDM). Preferably, the present invention comprises receiving in a mobile station data associated with a radio resource allocation map from a base station, wherein the radio allocation map comprises control parameters for transmitting an uplink channel, wherein the uplink channel comprises at least one OFDM tile comprising a first set of subcarriers associated with representing at least part of an n-bit data payload, and a second set of subcarriers associated with representing at least part of a non-pilot m-bit data payload wherein each subcarrier carries a modulated data, and the first and the second set of subcarriers are exclusive to each other, and transmitting the uplink channel from the mobile station to the base station.
| 7
|
This application is a divisional of application Ser. No. 10,969,758 filed Oct. 20, 2004, which in turn claims the benefit of prior filed U.S. divisional application Ser. No. 10/251,633 filed Sep. 20, 2002, which is in turn claims the benefit of prior filed U.S. divisional application Ser. No. 09/393,438, filed Sep. 9, 1999 (now U.S. Pat. No. 6,472,122 issued Oct. 29, 2002), continuation application Ser. No. 08/994,515 filed Dec. 19, 1997 (now U.S. Pat. No. 6,043,437 issued Mar. 28, 2000) and U.S. provisional Application Ser. No. 60/033,637 filed Dec. 20, 1996, the contents of each are incorporated by reference herein.
BACKGROUND OF THE INVENTION
The present invention relates to very thin layers of electrical insulation that may be used to coat and protect microminiature components and devices that are intended to be implanted in living tissue and/or to maintain electrical leakage of such components/devices within acceptable limits, e.g., less than 1 μA/cm 2 when the components and/or devices are submerged in water or salt water. More particularly, the invention relates to the use of alumina or aluminum oxide as a safe, biocompatible, coating material that provides a reliable, protective and insulative layer or coating for components, or devices comprised of components, wherein the insulating layers can be made extremely thin, on the order of microns, yet wherein the electrical leakage through the thin insulative layer (when the coated component or device is implanted or otherwise immersed in a saline solution or in distilled water) is less than about 1 μA/cm 2 (or less than about 12.1 nA for an area of 0.075 inches×0.025 inches, corresponding to an area of 0.1905 cm by 0.0635 cm).
The use of alumina as a thick insulator for use with implantable devices has previously been disclosed, for example, in U.S. Pat. Nos. 4,940,858 and 4,678,868 assigned to Medtronic, Inc. In these applications, however, the alumina insulator is very thick and is used only as part of the feedthrough for the implantable device and is often carried by a metal ferrule. Such use of alumina (or other ceramic) as an insulator requires a relatively thick layer. Many materials work well as an insulator when put down in a thick layer, e.g., in a layer thicker than 25 microns (where 1 micron=1×10 −6 meter). But all such materials, except as discussed herein, typically leak at a rate greater than about 1 μA/cm 2 . Applicants invention, as set forth below, uses a nonconductive ceramic, such as alumina, in very thin layers, e.g., less than about 25 microns.
It is also known to use the ceramic alumina as a case material for an implanted device as disclosed in U.S. Pat. No. 4,991,582, incorporated herein by reference. Again, however, the alumina, while comprising a material that is biocompatible (and is thus not harmful to, and is not harmed by, living tissue and fluids wherein it is implanted), is relatively thick, e.g., greater than 25 microns.
A problem with the related art is that the thickness of the insulation needed for implantable devices is typically on the order of about several millimeters thick. None of the related art, to applicant's knowledge, has heretofore achieved an insulating layer with very small dimensions and free of micro-holes. The presence of a micro-hole, or “pin-hole”, destroys the insulating properties which may lead to eventual failure of the implantable device.
Further, some components or devices which need to be implanted in living tissue, such as magnets, are susceptible to extremely high temperatures, i.e., extremely high temperatures may damage or destroy such components. When such components or devices must be implanted, it is important therefore that whatever coating or encapsulating material is used to coat them be one that can be applied without subjecting the component or device to extremely high temperatures. That is, the coating or application process must not subject such components to extremely high temperatures.
It is seen, therefore, that what is needed is a way to utilize a very thin layer of a suitable insulating material, such as alumina (aluminum oxide), zirconia (zirconium oxide), or alloys of alumina and/or zirconia, at relatively low temperatures, as a coating to cover, insulate and/or encapsulate any type of component or device that must be implanted, thereby effectively rendering such coated component or device biocompatible and safe for implantation. In particular, it is seen that what is needed is a very thin insulative coating that can be applied at relatively low temperatures for the purpose of insulating electrical connections on implantable devices and other microminiature devices, or for coating non-biocompatible components (thereby making the coated component biocompatible) wherein the coating can be as thin as about 1/1000 of an inch or less yet still maintain the electrical leakage through the insulator at or below acceptable levels.
The present invention addresses the above and other needs.
SUMMARY OF THE INVENTION
The present invention provides a protective, biocompatible coating or encapsulation material that may be applied to a component or device intended to be implanted in living tissue. The coating or encapsulation material comprises a thin layer or layers of alumina, zirconia, and/or alloys of alumina and/or zirconia. Advantageously, a thin alumina or zirconia layer applied in accordance with the present invention may be applied at relatively low temperature. Once applied, the coating provides excellent hermeticity, and prevents electrical leakage, while retaining a microminiature size. The layer of alumina or zirconia insulation can be made as thin as about 1/1000 of an inch (Note: 1/1000 inch=0.001 inch=1 mil=25.4 microns) or less while still retaining excellent insulating characteristics. For example, in accordance with one aspect of the present invention, an alumina coating having a thickness that is less than about 5–10 microns provides an insulative coating that exhibits less than about 12 nA of leakage current over an area 75 mils by 25 mils while soaking in a saline solution at temperatures up to 80° C. over a three month period.
Advantageously, the invention may be used to encapsulate or coat (and thereby insulate) passive electrical and/or magnetic components, such as resistors, capacitors, inductors, wire, conductive strips, magnets, diodes, etc., and/or active electrical components, such as transistors, integrated circuits, etc., and/or assemblies or combinations of such passive and/or active components. Because the coating layer can be made extremely thin, yet still provide the needed insulative properties required for an implanted component or device, the overall size of such components or devices does not increase significantly from the normal size (non-implanted size) of such components or devices. For many applications, e.g., as taught in U.S. Pat. No. 5,193,539, incorporated herein by reference, a complete implanted device, comprised of many different components, may be coated and maintained at a microminiature size. For other applications, e.g., the implantation of one or more permanent magnets, such magnets may be coated with the alumina or zirconia coating, thereby effectively hermetically sealing the magnets in an alumina or zirconium encapsulation that renders the magnets suitable for direct implantation in living body tissue at a desired location.
It is an object of the invention to provide a biocompatible, thin, insulative coating that is easy to apply to a wide variety of different shapes and sizes of components and devices, and that once applied provides excellent insulative properties for the covered component or device over a long period of time, thereby allowing the covered component or device to be safely implanted in living tissue for long periods of time.
It is a further object of the invention, in accordance with one aspect thereof, to provide a biocompatible, insulative coating that may be applied to implantable components or devices of various shapes and sizes, and wherein the coating is: (1) less than about 10 microns thick; (2) submersible for long periods of time in water or saline solution or any other conductive fluids; (3) made from alumina, zirconia or alloys of alumina and/or zirconia, or other substances having properties the same as or similar to alumina, zirconia and/or alloys of alumina and/or zirconia; (4) amenable to being applied using a batch process, e.g., a process wherein 1000 or more devices or components may be coated at the same time using the same process, such as an evaporative coating, vapor deposition, or ion-beam deposition (IBD) process; and/or (5) extremely strong in the lateral direction.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other aspects, features and advantages of the present invention will be more apparent from the following more particular description thereof, presented in conjunction with the following drawings, wherein:
FIG. 1A illustrates an electronic device that has been coated with a thin insulative layer in accordance with the present invention;
FIG. 1B shows an enlarged side view of a portion of the substrate of FIG. 1A so as to depict the alumina layer thereon;
FIG. 2 shows a component coated with a thin insulative layer in accordance with the invention, thereby rendering such component (which without the coating may be non-bio-compatible and non-implantable) both biocompatible and implantable; and
FIG. 3 is a flow chart that depicts, in general steps, the method of applying a coating in accordance with the invention.
FIG. 4 schematically depicts one method that may be used to coat five of six sides of an object with an insulative coating in accordance with the present invention;
FIG. 5 is a more detailed flow chart of a preferred method of applying a coating to an object in accordance with the invention; and
FIG. 6 is a flow chart that illustrates a preferred test used to determine how many layers of a coating need to be applied, i.e., how thick of a coating is needed, in order to provide a coating free of micro-holes (also called “pinholes”).
DETAILED DESCRIPTION OF THE INVENTION
The following description is of the best mode presently contemplated for carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of describing the general principles of the invention.
In the description of the invention herein, reference is frequently made to a “layer of alumina” or to an “alumina insulation layer” as the preferred material for the coating or layer that comprises the invention. Alumina, as is known in the art, comprises a shorthand notation for aluminum oxide, Al 2 O 3 . It is to be understood that all such references to an insulating layer or coating made from “alumina” also apply to an insulating layer made from other suitable substances, such as magnesium oxide, zirconium oxide (zirconia), alloys of alumina and/or zirconia, and the like. In general, such oxides may be referred to as ceramics.
An alumina insulation layer or coating for microminiature or other devices is applied by depositing one or successive layers of alumina to electrical connections and/or other electronic circuitry or components. In some cases, the component or object to be coated may comprise an IC chip by itself.
Each insulating layer applied is preferably made by depositing aluminum oxide (“alumina”), or other suitable insulating material, so as to coat the desired surface of the component or device.
A common application for the alumina insulating coating of the present invention is to insulate or encapsulate the entire surface of a hybrid integrated circuit 12 formed on a ceramic substrate 14 , once the hybrid integrated circuit 12 has been formed, with an insulative layer 16 , as illustrated in FIG. 1A . In FIG. 1A , by way of example, the substrate 14 may have a capacitor 18 and an integrated circuit chip 20 mounted thereon, both of which are also coated with the insulative layer 16 . Depending upon the function of the hybrid circuit 12 , an electrode 22 may also be connected thereto via a coated wire 24 . Also, to provide a return path from the electrode 22 , a portion of the layer 16 that covers on end of the substrate 14 may be removed, thereby exposing a return electrode 26 .
For other applications, the alumina insulating coating is applied to insulate or encapsulate just the integrated circuit (IC) chip 20 by itself. Any electrical connections that may need to be made to the IC chip, e.g., via an insulated wire, may be made prior to application of the insulating coating. In such instance, the IC 20 once coated could then be implanted directly into living tissue yet still perform its intended function.
The insulative layer 16 is very thin, having a thickness “t” on the order of 5–25 microns. Thus, the layer 16 is not readily visible in FIG. 1A , but is represented in the enlarged and magnified side-view of FIG. 1B .
Alternatively, an insulating coating 16 ′ may be used to insulate selected metal traces 28 and 30 , or components 32 and 34 , mounted on or to a ceramic substrate 14 ′ of a hybrid integrated circuit 12 ′, while other components, such as electrode 36 , or some portions of the surface of the substrate 14 ′, are not coated or encapsulated, as illustrated in FIG. 2A . In FIG. 2A , those components or surface areas not to be coated with the layer 16 ′ may be masked using conventional techniques at the time the coating 16 ′ is applied.
In general terms, and for applications where a hybrid circuit, an IC chip, or other device is to be coated with alumina in accordance with the encapsulation/coating process of the present invention, the steps followed by the invention are illustrated in FIG. 3 and may be summarized as:
(1) Atomically cleaning an insulating substrate or IC chip (if necessary) with a plasma cleaning, or equivalent, process (block 102 of FIG. 3 ). Note: if an IC chip is being coated by itself, and if the IC chip has not yet left its clean fabrication environment, this step may not be needed. The insulating substrate, when used, may be made from, or already coated with, successive layers of alumina or other suitable insulating material, such as magnesium oxide or zirconia.
(2) Depositing metallized patterns of a suitable conductive material on one or more of the exposed surfaces of the substrate (block 104 ). The metallized patterns are preferably deposited or etched on the substrate using conventional thin film deposition, painting or metallized etching techniques, as are common in the printed circuit board and integrated circuit fabrication arts. These patterns are used to make desired electrical connections between components of the circuit.
(3) Depositing a layer of titanium on the metallized portions of alumina substrate (block 106 ). Typically, such layer of titantium will be about 300 Å thick.
(4) Depositing additional layers of alumina, using an ion-enhanced evaporative sputtering technique, or ion beam deposition (IBD) technique, over the entire surface of the substrate including the metallized traces. Using an IBD technique, for example, one application of alumina may lay down a layer of alumina that is only 1–2 microns thick. Through application of several such layers, an alumina coating may thus be formed of sufficient thickness to provide the desired insulative (leakage current) and encapsulation (hermeticity) properties. Advantageously, the deposited alumina coating (comprising a plurality of deposited layers) need only be 5–10 microns thick.
Various techniques may be used to apply the alumina insulation over the device or component that is to be insulated. A preferred technique, for example, is to use an ion beam deposition (IBD) technique. IBD techniques are known in the art, as taught, e.g. in U.S. Pat. No. 4,474,827 or 5,508,368, incorporated herein by reference.
Using such IBD techniques, or similar techniques, the desired alumina layer may be deposited on all sides of an object 15 as illustrated in FIG. 4 . As seen in FIG. 4 , the object 15 is placed on a suitable working surface 40 that is rotatable at a controlled speed. The working surface 40 , with the object 15 thereon, is rotated while a beam 42 of ions exposes the rotating surface. Assuming the object 15 has six sides, five of the six sides are exposed to the beam 42 as it rotates, thereby facilitating application of the desired layer of alumina onto the five exposed sides of the object. After sufficient exposure, the object is turned over, thereby exposing the previously unexposed side of the object to the beam, and the process is repeated. In this manner, four of the sides of the object 15 may be double exposed, but such double exposure is not harmful. Rather, the double exposure simply results in a thicker coating of alumina on the double-exposed sides.
Other techniques, as are known in the art, may also be used to apply the alumina coating to the object.
The steps typically followed in applying a coating of alumina to an object are illustrated in the flow chart of FIG. 5 . As seen in FIG. 5 , these steps include:
(a) Sputtering a layer of titanium of about 300 Å thick over any metal conductor or other object that is to be coated with the alumina (block 110 of FIG. 4 ).
(b) If selective application of the alumina to the object is to be made (YES branch of block 112 ), spinning a photosensitive polyamide onto a ceramic hybrid substrate, or other component to be encapsulated with the alumina or other substance (block 114 ).
(c) Applying a mask that exposes those areas where Alumina is not to be applied (block 116 ).
(d) Shining ultra violet (UV) light through the mask to polymerize the polyamide (block 118 ). Where the UV light illuminates the polyamide is where aluminum oxide will not be deposited. Thus, the polymerization of the polyamide is, in effect, a negatively acting resist.
(e) Developing the photoresist by washing off the unpolymerized polyamide with xylene (block 120 ), or an equivalent substance. Once the unpolymerized polyamide has been washed off, the ceramic (or other component) is ready for aluminum oxide deposition.
(f) If selective application of the alumina is not to be made (NO branch of block 112 ), i.e., if alumina is to be applied everywhere, or after washing off the unpolymerized polyamide (block 120 ), depositing aluminum oxide to a prescribed thickness, e.g., between 4 and 10 microns, e.g., 6 microns, over the object using ion enhanced evaporation (or sputtering), IBD, or other suitable application techniques (block 122 ).
(g) During application of the coating, rotate and/or reposition the object as required (block 124 ) in order to coat all sides of the object, e.g., as shown in FIG. 4 , with a coating of sufficient thickness. This step may require several iterations, e.g., incrementally depositing a thin layer of alumina (block 126 ), checking the layer for the desired thickness or properties (block 127 ), and repeating the repositioning (block 124 ), depositing (block 126 ), and checking (block 127 ) steps as required until a desired thickness is achieved, or until the coating exhibits desired insulative and/or hermeticity properties.
(h) Breaking or scribing the aluminum oxide that resides over the polyamide, if present, with a diamond scribe, or laser, controlled by a computerized milling machine (block 128 ). This permits a pyrana solution, explained below, to set under the oxide for subsequent lift off of the aluminum oxide.
(i) Lifting off the polyamide and unwanted aluminum oxide after soaking the substrate in pyrana solution (H 2 SO 4 ×4+H 2 O 2 ×2 heated to 60° C.) (block 130 ). Soaking should occur for 30 to 60 minutes, depending on the thickness of the polyamide layer.
For some applications, the device to be coated may comprise an entire IC chip or a permanent magnet, e.g., a small ceramic magnet. When an IC chip or a magnet is to be coated with alumina, a similar process to that described above is followed, except that there are no metal traces or pads that need to be deposited or covered. Rather, the entire chip or magnet is coated with one or more layers of alumina.
Leakage tests and voltage breakdown tests, when applicable, may also be performed in conventional manner in order to determine the insulative and/or sealing properties of the coating. Typically, the device or component is immersed in a saline solution representative of living body tissue. Next, a voltage is applied between a metal trace covered by the alumina and a platinum black electrode, or other reference electrode, positioned proximate the covered device. The voltage is slowly increased while watching/monitoring the current drain. The voltage increase is stopped and measured at the point where breakdown occurs. Leakage current is measured by keeping the applied voltage at a constant value and monitoring the current drain.
A useful test for determining how thick the alumina coating must be to eliminate micro-holes, or pinholes, is shown in the flow diagram of FIG. 6 . As seen in FIG. 6 , a first step is to apply a layer of pure aluminum to a test object (block 140 ). This layer of pure aluminum serves as a base layer. Then, n layers of a suitable oxide, such as alumina, are applied over the base layer, where n is an integer of from e.g., 1 to 5. Each of these n oxide layers are applied in a controlled manner, using, e.g., IBD techniques, so that each deposited layer has a thickness that is more or less consistent, e.g., 1–2 microns. After application of n layers of alumina (or other ceramic), the coated device is dipped in an acid (block 143 ). If any pinholes are present in the coating, then the acid immediately starts to react with the aluminum base layer, leaving a very detectable ring. Thus, by performing a simple visual inspection of the device (block 144 ), one can easily determine whether there is any evidence of pinholes (block 146 ). If evidence of pinholes is seen (YES branch of block 146 ), then that is evidence that the n layers of alumina that were deposited did not create a sufficiently thick coating (block 150 ). Thus, the value of n is increased (block 152 ), and the test is repeated. If no evidence of pinholes is seen (NO branch of block 146 ), then that is evidence that the alumina coating is sufficiently thick.
Generally, 4–6 layers of alumina, creating a total coating thickness of 5–10 microns, is sufficient to reduce leakage current to less than about 6 pa. For desired hermeticity, at least about 6 layers of alumina are typically required.
It is to be emphasized that while using alumina in an implanted device is not new, depositing extremely thin layers of alumina, e.g., 5 to 10 microns thick, over components or devices to be implanted, and then relying on such thin layer of alumina to act as an insulative layer or coating, is new, and has produced surprising and unexpected results relative to its insulative properties.
EXAMPLE
A test specimen that included a plurality of 75 mil by 25 mil and 75 mil by 5 mil metallized pads deposited on an alumina substrate was constructed using conventional techniques. The plurality of metallized pads are separated from one another by a distance of about 2.0–2.5 mils. A layer of alumina insulator approximately 5–6 microns thick was deposited on and between the metallized pads using an ion-enhanced evaporative sputtering technique. The ion-enhanced evaporative sputtering was performed in an evacuated chamber at a moderate temperature of about 60–100° C., and allowed to cure for approximately 0.5–4 hours. The test specimen was subsequently submersed in a saline solution at 87° C. for three months. Leakage current between the metallized pads and the saline solution was measured and did not exceed 10 pA across the 6 micron size insulating layer. In addition leakage current between each metallized pads did not exceed 10 pA across the 2.0–2.5 mil spacings.
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A protective, biocompatible coating or encapsulation material protects and insulates a component or device intended to be implanted in living tissue. The coating or encapsulation material comprises a thin layer or layers of alumina, zerconia, or other ceramic, less than 25 microns thick, e.g., 5–10 microns thick. The alumina layer(s) may be applied at relatively low temperature. Once applied, the layer provides excellent hermeticity, and prevents electrical leakage. Even though very thin, the alumina layer retains excellent insulating characteristics. In one embodiment, an alumina layer less than about 6 microns thick provides an insulative coating that exhibits less than 10 pA of leakage current over an area 75 mils by 25 mils area while soaking in a saline solution at temperatures up to 80° C. over a three month period.
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TECHNICAL FIELD
[0001] The present invention relates to an oil clearing apparatus for a bowling ball, which can clear oil on a surface of a bowling ball by using high-temperature heat, thereby preventing the bowling ball from sliding due to the oil applied to a lane of a bowling alley, and can be utilized for the purpose of keeping the bowling ball warm and heating the bowling ball, as well as storing the bowling ball.
BACKGROUND ART
[0002] In general, bowling is one of indoor sports in which a bowling ball of a predetermined weight is rolled along a lane to throw down pins arranged at an end of the lane, and is being recently spotlighted since the game rule of the bowling is relatively simple and a high exercising effect can be achieved.
[0003] Relatively heavy bowling balls designed to be held by inserting fingers are used in bowling games, and oil on lanes or other foreign substances are often attached to the bowling balls during use of the bowling balls. Thus, if the contaminants are not cleared, the bowling balls may have bad outer appearances and may be slid and separated from the hand as well, also badly influencing the game records due to inferior rolling characteristics thereof.
[0004] Thus, according to the related art, a bowling player has to wipe a contaminated bowling ball with towel personally before and after the game or during the game.
[0005] However, the process of manually wiping a contaminated bowling ball is very troublesome and considerably laborious, and does not exhibit a sufficient washing effect, demanding advent of a mechanical washing apparatus.
[0006] As an example of related technologies, Korean Patent Pre-registration No. 1995-0008098 discloses a bowling ball washing apparatus as shown in FIG. 1 . The bowling ball washing apparatus includes a housing 20 defined by a bottom plate 22 , a vertical wall 24 and a ceiling plate 26 , and a horizontal baffle plate 28 is disposed in the housing 20 . A bowling ball introduction opening 30 having a diameter slightly larger than that of the bowling ball is formed in the ceiling plate 26 of the housing 20 , and a user can input the bowling ball into the washing apparatus through the bowling ball introduction opening 30 .
[0007] A coin insertion slot 32 is arranged on the vertical wall 24 of the housing 20 and a bowling ball support body 34 is arranged below the bowling ball insertion opening 30 to be spaced apart from the bowling ball introduction opening 30 , and a soft washing cloth 36 formed of an water absorbing material is detachably attached onto an inner curved surface of the bowling ball support body 34 .
[0008] A driving roller 38 is supported by an arm at an upper side of the bowling ball support body 34 to be rotated about an axis of rotation thereof by an electric motor 42 , an output shaft of the electric motor 42 is connected to an axis of rotation of the driving roller 38 by a belt 44 in conjunction with the driving roller 38 , and a driven roller 46 is installed at an opposite side of the driving roller 38 to be rotated about an axis of rotation thereof while maintaining an interval by which the bowling ball can be accommodated.
[0009] However, the bowling ball washing apparatus washes the bowling ball with the washing cloth 36 while rotating the bowling ball with the driven roller 46 and the driving roller 38 , and the washing cloth is repeatedly reused, so the oil attached to the bowling ball cannot be perfectly eliminated.
DISCLOSURE
Technical Problem
[0010] The present invention has been made in an effort to solve the above-described problems, and an object of the present invention is to provide an oil clearing apparatus for a bowling ball, which can naturally clear oil from a surface of a bowling ball due to gravity by using properties of the oil which is melted when heated, simultaneously clear the oil and foreign substances, serve as a keeping box for the bowling ball while clearing the oil of the bowling ball, keep the temperature of the bowling ball and heat the bowling ball while preventing the bowling ball from sliding.
Technical Solution
[0011] In order to accomplish the object, according to an aspect of the present invention, there is provided an oil clearing apparatus for a bowling ball including a housing having an upper body and a lower body installed separately from the upper body, a heating unit provided in at least one of the upper body and the lower body, and casing installed inside the upper and lower bodies of the housing to support the bowling ball while the bowling ball is heated by the heating unit, wherein a drain unit is connected to the casing located in the lower body.
[0012] The oil clearing apparatus may further include a locking unit and a knob in the housing, and a control box is provided at one side of the heating unit to control an operation and a temperature of the heating unit.
[0013] The oil clearing apparatus may further include a support unit 210 supporting the bowling ball and provided inside the casing 200 and a positioning boss fixing the bowling ball 300 and provided at a lower portion of the casing.
[0014] The oil clearing apparatus may further include a drain unit including a drain hole and a collection box installed to close the drain hole and coupled to the support unit serving as a screw coupling unit through a sealing member.
[0015] The heating unit may include a heating coil installed at an inner periphery of the housing and a control box including a microcomputer connected to the heating coil to control the heating temperature and time.
[0016] The heating unit may have a heating coil, a blower fan, and a plurality of air holes through which external air flows by the blower fan.
Advantageous Effects
[0017] As described above, the oil clearing apparatus for a bowling ball according to the present invention can naturally clear oil from a surface of a bowling ball by using properties of the oil which is melted when heated, naturally remove foreign substances from a surface of the bowling ball when the oil is cleared, serve as a keeping box while clearing the oil of the bowling ball, store the bowling ball while maintaining the temperature of the bowling ball and heat the bowling ball while preventing the bowling ball from sliding.
DESCRIPTION OF DRAWINGS
[0018] FIG. 1 is a sectional view showing a bowling ball washing apparatus according to the related art;
[0019] FIGS. 2 to 4 are a perspective view, a disassembled view, and an assembled sectional view showing an oil clearing apparatus according to the present invention, respectively;
[0020] FIG. 5 is a perspective view showing an oil clearing apparatus according to another embodiment of the present invention;
[0021] FIG. 6 is an exploded perspective view showing an oil clearing apparatus according to the present invention;
[0022] FIGS. 7A and 7B are sectional views showing a heating unit provided in the oil clearing apparatus according to the present invention, respectively;
[0023] FIG. 8 is a sectional view showing an oil clearing apparatus including a heating unit according to another embodiment of the present invention;
[0024] FIGS. 9A and 9B are sectional views showing mounted states of heating units according to other embodiments of the present invention, respectively;
[0025] FIGS. 10 and 11 are perspective views showing oil clearing apparatus of the present invention, respectively;
[0026] FIG. 12 is a perspective view showing a keeping state of the oil clearing apparatus according to the present invention; and
[0027] FIGS. 13A and 13B are a perspective view and a sectional view showing an oil clearing apparatus according to another embodiment of the present invention, respectively.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0028] Hereinafter, exemplary embodiments of the present invention will be described with reference to the accompanying drawings.
[0029] FIGS. 2 to 4 are a perspective view, a disassembled view, and an assembled sectional view showing an oil clearing apparatus according to the present invention, respectively, FIG. 5 is a perspective view showing an oil clearing apparatus according to another embodiment of the present invention, FIG. 6 is an exploded perspective view showing an oil clearing apparatus according to the present invention, FIGS. 7A and 7B are sectional views showing a heating unit provided in the oil clearing apparatus according to the present invention, respectively, FIG. 8 is a sectional view showing an oil clearing apparatus including a heating unit according to another embodiment of the present invention, FIGS. 9A and 9B are sectional views showing mounted states of heating units according to other embodiments of the present invention, respectively, FIGS. 10 and 11 are perspective views showing oil clearing apparatus of the present invention, respectively, FIG. 12 is a perspective view showing a keeping state of the oil clearing apparatus according to the present invention, and FIGS. 13A and 13B are a perspective view and a sectional view showing an oil clearing apparatus according to another embodiment of the present invention, respectively.
[0030] The oil clearing apparatus C of the present invention has an assembly structure of a housing 100 having supports 140 for preventing rolling and a casing 200 provided inside the housing 100 .
[0031] The housing 100 of the present invention may be fixed to a box-shaped outer casing (not shown) without an additional support.
[0032] A heating unit 110 is provided inside the housing 100 and a locking unit 120 is provided at a connecting portion of the housing 100 to prevent the housing 100 having upper and lower separable structures from being separated.
[0033] The housing 100 may have a separable structure without using the separate locking unit 120 .
[0034] A control unit 150 having a combination of a temperature adjustor 151 , a timer 153 , and a microcomputer 155 connected to the temperature adjuster 151 and the timer 153 is further provided such that the control unit 150 can be exposed to the outside at one side of the housing 100 .
[0035] Then, the control unit 150 may be integrally or separately provided at one side of the housing 100 , and may be installed to supply an external power through a connector 157 .
[0036] The casing 200 is integrally installed at an inner side of the housing 100 to support the bowling ball 300 and the drain unit 170 is connected to the casing 200 .
[0037] The housing 100 may not include the drain unit 170 separately.
[0038] A knob 180 is further installed at an outer side of the housing 100 for transportation.
[0039] A support unit 210 for supporting the bowling ball 300 is further provided inside the casing 200 , and a positioning boss 230 for fixing the bowling ball 300 is further provided at a lower portion of the casing 200 .
[0040] The positioning boss 230 includes a plurality of support bosses 231 corresponding to finger insertion portions 310 of the bowling ball 300 and fixing blocks 235 connected to the support bosses 231 via springs 233 and coupled to the casing 200 .
[0041] The drain unit 170 includes a drain hole 171 , an L-shaped guide groove 173 to close the drain hole 171 and a collection box 175 having a fixing boss 175 a corresponding to the guide groove 173 and coupled to the guide groove 173 through vertical movement and rotation thereof.
[0042] As shown in FIGS. 7A and 7B , the heating unit 110 includes a first heating coil 111 installed at an inner periphery of the housing 100 , and a set of first heating coils may be separately installed at inner sides of the upper and lower casings or may be integrally connected to each other.
[0043] As shown in FIGS. 9A and 9B , the heating unit 110 includes a heating chamber 113 , a second heating coil 115 provided at an inner side of the heating chamber 113 , a blower fan 114 provided in the heating chamber 113 , and a vent hole 117 .
[0044] The vent hole 117 may be formed in the upper body 101 and the lower body 103 prepared as a set in the housing 100 , respectively, or one vent hole may be formed such that air can flow through a separate vent hole formed at a connecting portion of the upper body 101 and the lower body 103 coupled with each other.
[0045] The heating unit 110 may employ a surface heater instead of a coil.
[0046] Meanwhile, a plurality of stoppers 270 protrude from a side surface of the casing 200 while forming the same plane to prevent interference with the bowling ball 300 received in the casing 200 such that a support shelf 275 can be positioned thereon.
[0047] The oil clearing apparatus C and the bowling ball 300 are kept in a bowling ball bag 400 having a support plate 410 .
[0048] As shown in FIGS. 13A and 13B , in the oil clearing apparatus C of the present invention, after the upper body 101 and the lower body 103 of the housing 100 are separately installed, the support unit 105 is formed in the lower body 103 to accommodate one end of the upper body 101 and a flexible cable 290 is connected to sides of the upper and lower bodies 101 and 103 to supply an electric power to the heating coil 111 of the heating unit 110 .
[0049] In the present invention, an adiabatic member 500 is provided into the housing 100 to prevent loss of heat of the heating unit 110 .
[0050] In the present invention, as shown in FIG. 8 , the upper body 101 of the housing 100 has a height smaller than a height of the lower body 103 so that the center of weight of the housing 100 is located in the lower body 103 .
[0051] Hereinafter, the operation of the present invention will be described.
[0052] As shown in FIGS. 2 to 13 , the present invention has the housing 100 including the combination of the upper body 101 and the lower body 103 and the casing 200 installed to correspond to the shape of the bowling ball 300 when connected to the upper and lower bodies 103 of the housing 100 while forming a closed space inside the housing 100 so that the bowling ball 300 can be kept inside the housing 100 to which the casing 200 are integrally coupled.
[0053] Then, the housing 100 is connected by a hinge at one side thereof and is provided with the locking unit 120 at the other side thereof, so that the bowling ball 300 can be safely kept if the housing 100 is closed and movement of the housing 100 is minimized by the supports 140 provided on a bottom surface of the housing 100 when the housing 100 is received in a keeping bag 400 .
[0054] Further, the oil clearing apparatus C of the present invention performs a function of a keeping container even without a bowling ball bag 400 and can be carried by using the knob 180 .
[0055] Moreover, the heating unit 110 for heating an inner side of the casing 200 is provided at one side of the casing 200 mounted to an inner side of the housing 100 , that is, the closed space 200 to heat an inner side of the casing 200 during an operation thereof, thereby melting the oil attached to the bowling ball 300 and separating the oil from the bowling ball.
[0056] Then, the heating unit 110 is connected to the control unit 150 including a temperature adjustor 151 , a timer 153 , and a microcomputer 155 connected to the temperature adjuster 151 and the timer 153 to adjust the temperature of the bowling ball 130 to a desired temperature, making it possible to safely adjust temperature while preventing overheating by using a program input to the microcomputer 155 in advance.
[0057] Further, in the present invention, the adiabatic member 500 is filled at one side of the heating unit 110 so that the heat generated by the heating unit 110 can be transferred only to an inner side of the casing, minimizing loss of heat to the outside of the housing 100 .
[0058] The heating unit 110 includes the first heating coil installed at an inner periphery of the upper housing 100 and attached to the casing 200 , the heating chamber 113 , the second heating coil 115 provided inside the heating chamber 113 , the blower fan 115 provided in the heating chamber 113 , and the vent hole 117 , so that when the blower fan 115 is operated, the air heated in the heating chamber 113 flows through the vent hole 117 via the blower fan 115 to heat the closed space while transferring heat to the casing 200 to heat an inner side of the casing 200 .
[0059] Meanwhile, the heating unit 110 of the present invention may not have a coil shape but may use a surface heater.
[0060] Further, the heating unit 110 easily connects the melted and dropped oil through the drain unit 170 connected to the casing 200 .
[0061] The support unit 210 for supporting the bowling ball 300 is provided at an inner side of the casing 200 and the positioning bosses 230 for fixing the bowling ball 300 is provided at a lower portion of the casing 200 to safely support and keep the bowling ball 300 received in the casing 200 .
[0062] Then, the support unit 210 includes a support plate 211 and a resilient support portion 213 , and the positioning boss 230 includes a plurality of support bosses 231 corresponding to the finger insertion portions 310 of the bowling ball 300 and the fixing blocks 235 connected to the support bosses 231 via springs 233 and coupled to the casing 200 , so that the bowling ball can be safely supported by easily absorbing an impact of the bowling ball.
[0063] The drain unit 170 includes the drain hole 171 , the L-shaped guide groove 173 configured to close the drain hole 171 and the collection box 175 having the fixing boss 175 a corresponding to the guide groove 173 and coupled to the guide groove 173 through vertical movement and rotation thereof, so that the drain unit 170 can be promptly coupled and separated and the melted and dropped oil can be easily collected and then removed.
[0064] Meanwhile, the stoppers 270 protrude from a side surface of the casing 200 while forming the same plane to prevent interference with the bowling ball 300 received in the casing 200 such that the support shelf 275 can be positioned thereon, so that the oil clearing apparatus C can be utilized as a keeping container when the oil clearing apparatus C is not used to clear oil by using the heated casing.
[0065] As shown in FIGS. 13A and 13B , the oil clearing apparatus C of the present invention includes the lower body having the support unit by which one end of the upper body is accommodated and attached to the lower body, and when the oil clearing apparatus C is kept, the upper body and the lower body can be separated to reduce a keeping space.
[0066] Further, as shown in FIG. 8 , the upper body 101 of the housing has a height smaller than a height of the lower body 103 so that the center of weight of the housing 100 is located in the lower body 103 . Thus, the housing 100 is prevented from being overturned when stored.
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Disclosed is an oil clearing apparatus for a bowling ball which clears oil on a surface of a bowling ball by using high-temperature heat, thereby preventing the bowling ball from sliding due to the oil applied to a lane of a bowling alley, and is utilized for the purpose of keeping the bowling ball warm and heating the bowling ball, as well as storing the bowling ball.
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BACKGROUND OF THE INVENTION
The present invention relates generally to devices for cellular telephone transmission equipment and more particularly to a self-contained cellular antenna site adapted to be small in footprint, quickly assembled without the use of heavy equipment, and easily disassembled for transporting.
The continued proliferation and widespread use of wireless telecommunications equipment has brought with it the need for more self-contained cellular antenna sites. Typical methods of deploying cellular antennas are on permanent structures such as towers or monopoles, or on rooftops. When based on the ground, the permanent structures are normally supported on conventional foundations such as reinforced concrete slabs or pads, and often the concentrated weight of a tall antenna tower has required a relatively substantial and separate foundation member such as a deep reinforced concrete pier. Therefore, these structures often require special zoning and permitting, soil core sampling, engineering, excavation, and the use of heavy equipment and cranes to perform installation, all of which may be costly and time consuming. In addition, the time required to pour and cure a concrete foundation may delay the erection of an antenna and ultimately the operation of the cellular site. Further, such a permanent tower or monopole is not readily removed and redeployed at another site, and even if the tower or monopole itself is removed, the permanent foundation remains.
U.S. Pat. No. 6,131,349 [Hill] illustrates an attempt in the prior art to eliminate the need for construction of a separate foundation to support a cellular antenna tower. However, the apparatus disclosed utilizes the supporting foundation of the adjacent telecommunications equipment enclosure to provide load bearing support for the cellular antenna tower and therefore this design is not self-contained, is integrally connected to a permanent foundation, and cannot be quickly assembled or easily removed and relocated.
Developments in the newer generations of wireless systems have allowed both the antenna systems and the signal processing electronics packages to become smaller. A smaller antenna atop a pole of approximately 6 to 12 inches in diameter and a total height of 30 feet to 60 feet can now provide reasonable cellular coverage, enabling the design of cellular sites with decreased visual impact and decreased wind loading requirements. The present invention is designed to take advantage of these developments to provide a cellular antenna site which is much more flexible in its deployment than sites presently available.
Therefore, it is an object of the present invention to provide a cellular antenna site that is modular and inexpensive, and can be easily and quickly assembled, disassembled, and moved by hand without the use of heavy equipment. It is another object of the present invention to provide a cellular antenna site that is sufficiently anchored to support a small diameter 60 foot tall antenna pole under the sufficient loading to meet a 100 mile per hour wind speed rating. It is a further object of the present invention to provide a cellular antenna site that requires only a small footprint and can be situated on any relatively level and flat piece of ground.
It is yet another object of the present invention to provide a cellular antenna site that creates minimal environmental and visual impact in order to potentially ease zoning and permitting requirements and in order to allow for deployment in environmentally sensitive areas. It is still a further object of the present invention to provide a cellular antenna site that can accommodate an electrical cabinet and other required equipment, enclosures, or shelters, within a fenced and secure area.
Other objects will appear hereinafter.
SUMMARY OF THE INVENTION
The present invention overcomes the disadvantages inherent in the types of cellular antenna sites known in the prior art. The cellular antenna site of the present invention is of a modular construction that can be assembled from components and pre-fabricated sub-structures that are small and light enough to be manipulated by a team of two people. The cellular antenna site does not penetrate the ground on which it rests and can be situated on any relatively level and flat piece of ground, including a parking lot, a gravel lot, or a patch of grass or undeveloped land.
The base of the cellular antenna site of the present invention does not require any excavation or permanent foundation, but is instead anchored to the ground by a ballast comprising either concrete blocks, crushed gravel, poured concrete, or an equivalent material. Except in the case of poured concrete ballast, the entire cellular antenna site can be completely disassembled into its original component parts and removed from the location without leaving a trace of its having been installed. In the case of poured concrete ballast, the cellular antenna site may still be removed but it may require the removal of the entire base as one piece instead of disassembling the base into its component modules. The ballast material, when placed in the base modules, will form a substantially flat, level decking surface regardless of which of the ballast materials is actually used.
The cellular antenna site of the present invention, when assembled with three base modules each measuring 10 feet long by 3 feet 4 inches wide by 1 foot high and outfitted with a 6 to 12 inch diameter antenna pole ranging in overall height between 30 and 60 feet, has a nominal weight of approximately 2000 to 3000 pounds and a nominal footprint of 10 feet by 10 feet. When loaded with a ballast of concrete blocks, the site increases to a weight of about 10,000 pounds and is capable of achieving a 75 mile per hour wind speed rating. When loaded with a ballast of poured concrete, the site increases to a weight of about 15,000 pounds and is capable of achieving a 100 mile per hour wind speed rating.
In view of the preceding example, it is noted that due to the modular construction of the base, the site can be assembled into a wide variety of configurations and footprint dimensions, depending on the requirements of the specific deployed location. Expansion of the cellular antenna site base can be achieved by bolting additional base modules to any of the four sides of the base. It is also noted that the design concept of the cellular antenna site of the present invention can be applied using base modules of any nominal dimensions. It is further noted that the base modules need not be of rectangular shape and could in fact be of any geometric shape with straight edges to allow for interconnecting and mating with other base modules, including cooperating triangular and hexagonal shapes.
The base of the cellular antenna site of the present invention provides integral means for securing an electrical cabinet which houses the required telecommunications electronics, as well as means for mounting any other auxiliary enclosures, cabinets, or shelters. The base also includes integral means for mounting the hinged antenna base, so that the antenna may be first attached in a horizontal position and then erected by simply hoisting it into a vertical position about a hinge, avoiding any need for a crane. Once erected, the hinged antenna base can be secured to maintain the antenna in the vertical position. A simple weatherproof wiring harness electrically connects the antenna to the electrical cabinet. Additionally, the base of the cellular antenna site provides means for connection of a grounding stake to ensure that the entire apparatus of the present invention is properly grounded.
The base of the cellular antenna site further provides integral means for the mounting of fence posts to support a fence, e.g., wire mesh or wooden post, encircling the base and surrounding the antenna, electrical cabinet, and any auxiliary equipment, in addition to a hinged gate allowing easy access to the site while providing a measure of security, personnel safety, and protection of the wireless telecommunications equipment.
BRIEF DESCRIPTION OF THE DRAWINGS
For the purpose of illustrating the invention, there is shown in the drawings forms which are presently preferred; it being understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown.
FIG. 1 is a perspective view of the temporary cellular antenna site of the present invention.
FIG. 2 is a top view of the temporary cellular antenna site of the present invention shown with concrete block used as the anchoring ballast.
FIG. 2A is a top view of the temporary cellular antenna site of the present invention shown with poured concrete used as the anchoring ballast.
FIG. 2B is a top view of the temporary cellular antenna site of the present invention shown with gravel used as the anchoring ballast.
FIG. 3 is a side view of the temporary cellular antenna site of the present invention.
FIG. 4 is a front view of the temporary cellular antenna site of the present invention.
FIG. 5 is a perspective view of a partially assembled base of the temporary cellular site comprising a number of base modules attached to one another by fastening means in a predetermined configuration.
FIG. 6 is a perspective view of a base assembly of a second embodiment of the temporary cellular site comprising a number of base modules having a trapezoidal configuration arrayed around a smaller number of base modules having a diamond configuration attached to one another by fastening means in the arrangement shown.
FIG 7 is a partial perspective view of the temporary cellular site of the present invention showing the hinge between the lower and upper portions of the antenna.
FIG 8 is a side view of the temporary cellular site of the present invention showing the hinge between the lower and upper portions of the antenna.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following detailed description is of the best presently contemplated mode of carrying out the invention. The description is not intended in a limiting sense, and is made solely for the purpose of illustrating the general principles of the invention. The various features and advantages of the present invention may be more readily understood with reference to the following detailed description taken in conjunction with the accompanying drawings.
Referring now to the drawings in detail, where like numerals refer to like parts or elements, there is shown in FIG. 1 a perspective view of the temporary cellular antenna site apparatus 10 . The apparatus 10 is of modular construction comprising a base 16 , an antenna system 18 , an electrical cabinet 12 , fencing 38 , and a grounding means (not shown). An additional component required for the functioning of the apparatus 10 is anchoring ballast, which may be in the form of concrete blocks 40 , poured concrete 40 a , crushed gravel 40 b , or another equivalent material, as shown in FIGS. 2 , 2 A, and 2 B, respectively.
The apparatus 10 is fabricated as a set of components, some of which are pre-assembled into sub-structures to facilitate onsite deployment. The apparatus 10 is easily transported to a required location and can be fully assembled and commissioned by two workers in a single day. Each base module 20 is approximately 10 feet long by 3 feet 4 inches wide by 1 foot high. The dimensions of a base module 20 are constrained to keep within a manageable weight and size, noting that many other sizes, shapes, and aspect ratios could be fabricated within the same weight range. The antenna pole 14 is available in lengths from 30 feet to 60 feet. Although a single length is preferred, the antenna pole 14 may be comprised of one or more segments. The antenna pole, or elongated support means 14 , may be manufactured of metal, fiberglass, or composite materials and may be configured as either a monopole or as a lattice work tower, however for descriptive purposes, a monopole type antenna support 14 will serve as a model encompassing all of the other configurations.
Prior to assembly of the apparatus 10 , a location should be selected that is relatively flat and level. Acceptable site locations include a parking lot, a gravel lot, a flat rooftop capable of supporting the required weight, and a relatively flat and level patch of grass or undeveloped ground. A temporary and non-damaging installation may be achieved by using an anchoring ballast of concrete blocks 40 or gravel 40 b. A slightly more permanent installation may be achieved by using an anchoring ballast of poured concrete 40 a. When using the concrete block ballast 40 or the gravel ballast 40 b, a 60 foot antenna pole 14 is capable of achieving a 75 mile per hour wind speed rating. When using the poured concrete ballast 40 b, the wind speed rating for a 60 foot antenna pole 14 is increased to 100 miles per hour.
The detailed construction of the base 16 is best described in reference to FIG. 1 and the top view shown in FIG. 2 . The base 16 is assembled from a combination of similar base modules 20 . Each rectangular base module 20 comes pre-assembled and is formed by joining the ends of two side rails 22 with the ends of two end rails 24 . The rails are joined by bolting, welding, or other equivalent joining means. Each side rail 22 and each end rail 24 is a galvanized steel C-channel member, although a similar lightweight and strong form such as a rectangular tube or I-beam may be used. When assembled to form the frame of a base module 20 , a side rail 22 thereof is capable of being butted up against and bolted to the side rail 22 or the end rail 24 of another base module 20 ; likewise an end rail 24 thereof is capable of being butted up against and bolted to the end rail 24 or the side rail 22 of another base module 20 . In this manner, base modules 20 may be interconnected to create a base 16 of various sizes, shapes, and aspect ratios. See FIG. 5 .
Further comprising each base module 20 is an expanded metal grating or screen 26 which is rigidly attached along all four of its edges to the underside of the side rails 22 and the end rails 24 thereof to form a lightweight mesh bottom of the base module 20 . The mesh bottom formed by the metal grating 26 is capable of supporting and retaining the ballast material 40 , 40 a, or 40 b . The ballast material of concrete blocks 40 , poured concrete 40 a or crushed stone or gravel 40 b , when placed in the base modules 20 , will form a substantially flat, level decking surface 50 between the plurality of perimeter rails 22 , 24 of each base module 20 of the antenna base 16 of the present invention. In each case the ballast material 40 , 40 a or 40 b will extend upward to approximately the height of the perimeter rails 22 , 24 of the base modules 20 as shown in FIGS. 1 , 2 , 2 A and 2 B. In this fashion a flat, level decking surface 50 is formed using the ballast material instead of having to construct such a deck using either prefabricated materials or other materials fabricated on site.
Fence post sleeves 28 , integrally secured along the inner edges of the side rails 22 and the end rails 24 of the base 16 , provide a means for mounting the perimeter fencing 38 . Pre-drilled mounting holes at various positions along the side rails 22 are adapted for bolting the base plate 46 and hinged antenna base 44 and the electrical cabinet support members 42 . Optional mounting support members 48 may be connected across any base module 20 between the side rails 22 thereof, also utilizing the mounting holes, to provide additional structural integrity and to provide means to mount auxiliary equipment cabinets, enclosures, or shelters as desired.
Thus, each base module 20 is a rectangular frame comprising the two side rails 22 , the two end rails 24 , the metal grating 26 across the bottom thereof, the fence post sleeves 28 facing vertically upward, and the mounting means to attach the hinged antenna base 44 , the electrical cabinet support members 48 , and the optional support members 42 , as required. Once each base module 20 is positioned where desired on the ground, multiple base modules 20 are interconnected to form the base 16 . The base may be of various configurations. For example, in FIG. 1 , four base modules 20 are connected side-to-side to form the base 16 . In another example, in FIG. 2 , six base modules 20 are interconnected in a three by two configuration with two sets of three base modules 20 each connected side-to-side and then the two sets of three connected to each other end-to-end to form the base 16 . See also, FIG. 5 . Other similar, and different geometric configurations may be conceived.
Before continuing with a further description of the base assembly 16 of the temporary cellular site, a second arrangement of interconnected base modules can be assembled. This arrangement of base modules 120 in a hexagonal base 116 is shown in FIG. 6 . There are two types of base modules in this arrangement, a trapezoidal base module 120 a and a diamond base module 120 b. The trapezoidal base modules 120 a are arrayed around three central diamond base modules 120 b. The diamond base modules 120 b are shown having like triangular sections of equal length legs with a support member 142 extending along the common base of the triangular sections. The dimensional relationship of this base assembly 116 is similar to the rectangular base assembly 16 in that the overall dimension across the hexagonal shape is a similar twenty (20) feet taken along a line directly through the center of the hexagon from an interconnection point between two adjacent trapezoidal base modules 120 a to the same interconnection point between two adjacent trapezoidal base modules 120 a on the opposite side of the hexagon. In this way the dimensional footprint of the temporary cellular antenna site remains substantially the same regardless of the base assembly configuration.
Each triangular section of the diamond base modules 120 b has an external sidewall 122 for interconnecting to the outer ring of trapezoidal base modules 120 a and to the other diamond base modules 120 b. Likewise, each of the trapezoidal base modules 120 a has an external sidewall 122 for interconnecting to the other trapezoidal base modules 120 a and to the diamond base modules 120 b. The trapezoidal base modules 120 a also have an external sidewall 122 facing outward forming one base of the trapezoid shape. The other base of the trapezoid shape is dimensioned to be of equal length to one of the legs of a triangular section of the diamond base modules 120 b such that the external sidewalls 122 of the base modules 120 a, 120 b fit tightly together. The interconnecting sidewalls 122 are held together by fastening means as described in connection with the other base assembly 16 .
At the center of the interconnected diamond base modules 120 b are three segmented antenna base members 144 a, b, c, each such segment being mounted to one of the three diamond base modules 120 b. The three segments of the antenna base 144 a, b , and c cooperatively engage to form a hexagonal base member 144 to which the antenna pole 14 is bolted through the respective mounting holes. To support the antenna base 144 and to keep the base from tilting from the horizontal position, support arms 150 are arranged to extend adjacent to and beneath the edges of the antenna base member 144 . The support arms 150 extend between interconnecting sidewalls 122 of adjacent triangular sections of each diamond base module 120 b, supported at their respective approximate midpoints by the support members 142 extending across the diamond base modules 120 b. At the center of the antenna base member 144 is a triangular reinforcing member 145 to provide added stabilization to the base connection for support of the antenna tower 14 .
Extending across the distance between the bases of the trapezoidal base modules 120 a are support members 142 to provide substantial rigidity to the sidewalls 122 of the base modules. This strengthening of the base 116 provides the rigidity to withstand deformation or distortion of the base from wind forces against the elongated support member 14 and the antenna 15 . Along the downward facing edges of the sidewalls 122 of the base modules 120 a, 120 b metal grating 126 is attached to retain anchoring ballast to provide a sufficient weight factor to withstand the wind or shear forces exerted against the antenna tower.
Although this embodiment has a different configuration than that of FIGS. 1–5 , the similar elements permit for the assembly of the base systems along with the peripheral elements described more fully below in connection with the first embodiment. It is to be understood that each of the elements described below can be fitted to be used with the hexagonal base assembly 116 in a similar fashion and being attached or mounted in a similar way as that described below.
The next step in assembly of the temporary cellular antenna site apparatus 10 is to anchor the base 16 at its desired location. A temporary and easily removable anchoring ballast of concrete blocks 40 or crushed gravel 40 b may be used. A more permanent but still removable ballast of poured concrete 40 a may be used, since the metal grating 26 creates a floor for the poured concrete form that prevents the concrete from binding to the surface below.
As described above, the ballast material of concrete blocks 40 , poured concrete 40 a or crushed stone or gravel 40 b , when placed in the base modules 20 , will form a substantially flat, level decking surface 50 between the plurality of perimeter rails 22 , 24 of each base module 20 of the antenna base 16 of the present invention. The ballast material 40 , 40 a or 40 b will extend upward to approximately the height of the perimeter rails 22 , 24 of the base modules 20 as shown in FIGS. 1 , 2 , 2 A and 28 creating a flat, level decking surface 50 using the ballast material instead of having to construct the decking using either prefabricated materials or other materials fabricated on site.
Once the base 16 is constructed and anchored with the ballast material 40 , 40 a, or 40 b, the electrical cabinet 12 is mounted. The electrical cabinet support members 42 are connected across a base module 20 and secured between the side rails 22 thereof using predrilled mounting holes, at the position on the base 16 where the electrical cabinet 12 will be located. The members 42 provide structural support for mounting the electrical cabinet 12 within the perimeter fencing 38 surrounding the base 16 . The cabinet 12 may also be free standing outside of the perimeter fencing 38 , if the size of the electrical cabinet 12 and the physical constraints of the mounting location on the base 16 are exceeded. The electrical cabinet 12 is secured to the cabinet support members 42 . A grounding stake (not shown), electrically connected to the electrical cabinet 12 , is used to provide an earth ground for the electrical cabinet 12 as well as for the entire apparatus 10 . External wiring 52 connects the electrical cabinet components to the antenna 15 as described below.
Prior to installing the perimeter fencing 38 , the antenna system 18 is installed. First, the base plate 46 is positioned in a desired location on the base 16 and secured to the side rails 22 at the base module 20 at that location using the predrilled mounting holes. The bottom portion of the hinged antenna base 44 is mounted to the base plate 46 using appropriately sized mounting hardware. The tapered aluminum antenna pole 14 , or the bottom segment 14 C of the antenna pole, is attached in a horizontal position to the top pivoting portion of the hinged antenna base 44 . A hinge 50 , extending along an entire side, connects the top pivoting portion and the bottom portion of the hinged antenna base 44 . Additional antenna pole segments 14 B and 14 A are then added and secured to the previously mounted segment, if a segmented antenna pole is being utilized, and the antenna 15 is positioned at the top of the assembly. The assembled antenna system 18 is then erected to its standing position by being hoisted in a pivoting motion about the hinge 50 of the antenna base 44 . See, FIGS. 7 and 8 . Once erected the antenna pole 14 is secured in a vertical position by bolting, clamping, or equivalent removable securing means. Signal connections are accomplished between the antenna 15 , along the antenna pole 14 and into the electrical cabinet 12 by means of a waterproof electrical wiring harness 52 .
Perimeter fencing 38 may be erected by inserting the fence posts 30 into the fence post sleeves 28 and securing the desired fencing material 32 to the fence posts 30 around the perimeter of the base 16 . The fencing may be of wire mesh, wooden post, or any similar fencing material providing securable access to the antenna system on the temporary cellular antenna system 18 , etc. A hinged access gate 36 is provided to fit between one pair of fence posts 30 to provide for personnel access to the antenna system 18 , to the electrical cabinet 12 if it is inside the perimeter fencing 38 , and to the interior of the fenced space of the apparatus 10 .
After assembling the base 16 from the base modules 20 , anchoring the base 16 with the ballast material 40 , 40 a, or 40 b, mounting the electrical cabinet 12 , erecting the antenna system 18 , connecting the wiring harness 52 between the antenna 15 and the electrical cabinet 12 , and erecting the fencing 38 around the perimeter of the base 16 , the temporary cellular antenna site apparatus 10 is ready for use. The only external connections required are the power and communication links. The apparatus 10 can be operated for as long as is required. If and when it is desired to remove the apparatus 10 for use in another location or in favor of a more permanent cellular antenna site, the apparatus 10 may be disassembled into its component parts and removed.
Disassembly of the apparatus 10 is the reverse of assembly. The perimeter fencing 38 is removed by detaching the fence 32 and the hinged access gate 36 from the fence posts 30 and by removing the fence posts 30 from the fence post sleeves 28 . The wiring harness 52 is detached from the antenna 15 and the electrical cabinet 12 . The antenna pole 14 is lowered by pivoting about the hinge of the hinged antenna base 44 and is disconnected from the antenna base 44 and disassembled from the hinged base 44 . The antenna base 44 is then removed from the side rails 22 of the base module 20 to which it was mounted. The electrical cabinet 12 is removed from its support members 42 , and the support members 42 are disconnected from the side rails 22 of the base module 20 to which they were mounted. The grounding stake (not shown) disconnected from the electrical cabinet 12 and is pulled from the ground.
If a temporary ballast such as concrete blocks 40 or gravel 40 b was used, this ballast is removed and the base modules 20 are disconnected from each other. If a more permanent ballast such as poured concrete 40 a was used, removal of the ballast and disconnection of the base modules 20 from each other may not be possible and the base 16 may need to be removed as one piece. The components of the apparatus 10 may be relocated and reassembled as described previously.
The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof and, accordingly, the described embodiments are to be considered in all respects as being illustrative and not restrictive, with the scope of the invention being indicated by the appended claims, rather than the foregoing detailed description, as indicating the scope of the invention as well as all modifications which may fall within a range of equivalency which are also intended to be embraced therein.
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A small-footprint portable modular cellular antenna site capable of being deployed on any substantially level, flat piece of ground, the cellular antenna site being easily assembled, disassembled, and moved without the aid of heavy equipment. The cellular antenna site does not require a permanent foundation, but instead is anchored by weighting with a non-damaging ballast material sufficient to support a small diameter 30 to 60 foot high antenna pole at wind speed ratings up to 100 miles per hour. The cellular antenna site includes a modular base configurable in different geometric arrangements that retains the ballast material and supports a segmented monopole antenna, an electrical cabinet, perimeter fencing with an access gate, and any auxiliary cabinets, enclosure, or shelters as may be required.
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BACKGROUND OF THE INVENTION
Industrial processes frequently require raising the temperature of large numbers of billets of metal in a continuing operation. The usual billet furnace is essentially a long passageway heated to high temperatures, and traversed by a conveyor. The billets are usually round blocks of metal of essentially the same size, and move down the conveyor in closely-spaced relationship as the temperature is increased to the desired level. Heat is usually supplied by a series of torch-like burners spaced along the passageway closely enough so that temperature variation along the path traveled by the billets can be held close to the desired level or gradient. Since the object of these furnaces is to produce perdetermined temperature conditions within the billets, it has become standard practice to check and control the operation of the furnace by thermocouple probes that are periodically projected into the furnace to engage a particular billet to sense its temperature. Installations of this type are common in connection with aluminum extrusion processes, where it is necessary to raise the billets to a temperature sufficient to allow the extrusion, without the raising the plasticity of the billets to the point where they cannot be handled by the associated automated equipment. It is also obvious that the temperature-sensing function has the effect of preserving the integrity of the furnace itself, as an excess in temperature will usually cause the damage to the lining, housing, or conveyor of the furnace.
A common maintenance problem is encountered in connection with the probe rods. Repeated exposure to the high temperatures of the furnace can produce oxidation of the tips of the probes, which injects an unknown variable to the electrical resistence. Since the probes are usually shoved into the billet hard enough to penetrate the surface slightly, repeated cycles of this action also tend to dull the sharpened points of the probe. A thermocouple produces a small electrical sensing signal as a function of the effect of temperature on probe rods of different material; and minor variations of the resistence at the point of contact will have a serious effect on the magnitude of this signal, resulting in serious problems as the signal is used for the control of the furnace temperature. Maintenance of acceptable conditions at the points of the probes requires repeated sharpening of the probe tips, and ultimately a replacement of the entire probe rods after a relatively short decrease in its length. The conventional practice requires sufficient disassembly of the probe system to get at the rods, followed by either re-grinding the tips, or by the replacement of the entire rods.
The usual arrangement for providing access to the interior of the furnace for the probe assembly is to surround a trap door in the furnace structure with a box-like chamber that can be pressurized to match or coordinate with the pressure conditions within the furnace. The box provides an opening large enough to accommodate the outer cantilever housing of the probe assembly, which is extended through this opening into the chamber, and then through the trap door into the furnace to engage one of the billets. Protection of the equipment associated with the probe assembly requires that the escape of hot gases around the probe assembly housing be kept to a minimum, but practical considerations limit the closeness of the fit that it is possible to maintain at this point. The problems outlined above have generated a maintenance nuisance that is capable of seriously interferring with the operation of the entire system.
SUMMARY OF THE INVENTION
The thermocouple probe assembly has probe rods constructed with a replaceable tip detachably secured to the remaining length of the rod at a position fully surrounded by insulating material to isolate the junction from heat and exposure to air. In the active position of the probe assembly, the entrance of the cantilever portion into the pressure-control box of the furnace is covered to prevent outflow of high temperature gases through the opening surrounding the probe assembly housing. In the preferred form of the invention, two pairs of probes are used within the same insulator, each pair associated with an independent control system for backup.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top view of the probe assembly.
FIG. 2 is a side elevation of the probe assembly illustrated in FIG. 1.
FIG. 3 is a side elevation of the carriage body of the probe assembly.
FIG. 4 is an end view with respect to FIG. 3.
FIG. 5 is a side elevation of the insulating end-plug.
FIG. 6 is an end view with respect to FIG. 5.
FIG. 7 is a side elevation of a complete probe rod.
FIG. 8 is an enlarged view with respect to FIG. 7, showing the junction of the shank and tip of the probe rod.
FIG. 9 is a side elevation of the principal insulator of the probe assembly.
FIG. 10 is an end view with respect to FIG. 9.
FIG. 11 is a side elevation of one of the probe couplings.
FIG. 12 is a side elevation showing another of the probe couplings, FIGS. 11 and 12 representing the couplings of a particular pair of probes.
FIG. 13 is an end view of the heat shield.
FIG. 14 is a side elevation with respect to FIG. 13.
FIG. 15 is a perspective view showing the installation of the probe assembly in conjunction with a billet furnace.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings, the illustrated probe assembly is shown in FIG. 15 installed in conjunction with the furnace 20. A floor-mounted structure includes the square tube 21 inclined away from the furnace at an angle of forty-five degrees to the horizontal. This arrangement permits billets of various sizes to be engaged near their center. The bracket directly supporting the probe assembly includes the square tube 22 received in telescoping relationship within the exterior tube 21, with the degree of extension adjustably secured by the cross bolt 23 engaging a selected one of the holes 24 in the tube 21. The supporting bracket also includes the horizontal member 25 welded to the end of the tube 22, and providing a platform receiving the probe assembly. The plate 26 forms a base for the assembly; and the left portion of it, as viewed in FIGS. 1 and 2, forms a guideway receiving the rollers 27 and 28 mounted on the carriage body 29 connected solidly by the coupling 30 to the piston rod associated with the cylinder 31. The cylinder end 32 has a base flange bolted to the plate 26 as shown at 33, and the opposite cylinder end member 34 is bolted to the plate 26 as shown at 35. The position of this assembly along the support bracket member 25 is secured by bolts as shown at 36 disposed at any convenient location. The cylinder 31 and its associated components are of standard design, with tie rods as indicated at 37 serving to transfer the pressure-generated forces, and hold the end members 32 and 34 in engagement with the cylinder 31. A valve control 38 is also standard, with pressure conditions being communicated to the left end of the cylinder, as shown in FIGS. 1 and 2, by the conduit 39.
Referring to FIGS. 3 and 4, the carriage 29 includes a central vertical block 40 containing the holes 41 for receiving the coupling 30, and 42 for receiving the shaft 43 carrying the rollers 27 and 28. The carriage also includes the sleeve 44 secured to the central member 40, which receives the inner housing tube 45. An end plug 46 of insulating material is slipped into the end of the inner housing tube 45, and the assembled relationship of these components is maintained by the cross-pin 47 traversing the sleeve 44, the inner housing tube 45, and the end plug 46. A cylindrical ceramic insulator 48 is received within the inner housing 45. Referring to FIG. 10, holes as shown at 49-51 extend throughout the length of the insulator for accommodating the two pairs of probe rods, which appear at 52-54 in FIGS. 1 and 2. These rods also traverse the holes 55-58 in the end plug 46, which also has the transverse hole 59 receiving the cross-pin 47.
Setscrew collars as shown at 60-62 in FIGS. 1 and 2 are installed on each of the probe rods, and serve a dual purpose. They serve as abutments for the compression springs 64-66 extending between these collars and the end of the plug 46 to bias the probe rods to the left, as shown in FIGS. 1 and 2. As the carriage 29 is shoved to the left under the action of the cylinder 31, the cantilever inner housing 45 carrying the insulator 48 and the probe rods is shoved into the opening 67 of the pressurized box 68 surrounding an access door (not shown) in the furnace 20. The pressure control within the box prevents the opening of the door from interferring with the conditions within the furnace, and also prevents the outflow of hot gases and flame. The movement of the carriage ultimately results in the engagement of a hot billet in the furnace with the tips of the probe rods, and a consequent detection of the temperature conditions in that billet. Just prior to the final extended position of the probe assembly, the heat shield 69 bears against the outer face of the pressurized box 68 to seal off the space between the opening 67 and the inner housing 45. The heat shield 69 has a collar 70 secured in any convenient fashion to the outer housing 71, which is a tubular sleeve in sliding engagement with the outer surface of the inner housing 45, and biased to the left by the spring 72. A cross bolt 73 traverses the outer housing and also the insulator 48, and is received within elongated slots in the outer housing as shown at 74 in FIG. 2. The freedom of axial sliding movement of the outer housing with respect to the inner housing is thus determined by the presence of the ends of the bolt 73 within the slots 74. This interengagement also prevents relative rotation between the inner and outer housings.
Referring to FIGS. 7 and 8, the probes are a two-piece assembly. The tip section 75 with the sharpened point 76 is detachably secured to the shank 77 at the junction 78 by the engagement of the threaded extension 79 on the shank engaging a corresponding threaded opening in the tip section 75. This junction is well within the protective confines of a insulator 48 at all times. The tip section 75 may be unscrewed from the left end of the probe assembly during periods in which it is withdrawn from the furnace, without any further disassembly being required. The tip may then be reground, or replaced. The cost of the material represented by the length of the shank 77 (which is of a material selected for thermocouple characteristics) is thus saved, together with a very considerable amount of time involved in performing this operation. The shanks of the probes have a portion of reduced diameter as indicated at 80 in FIG. 7 for engagement with the bore 81 or 82 of the couplings 83 or 84 shown in FIGS. 11 and 12, respectively. These couplings are provided with threaded holes as shown at 85 and 86 for receiving setscrews to secure the couplings on the ends 80 of the probe shanks. At the opposite ends of the couplings, the holes 87 and 88 are coaxial with the holes 81 and 82, and of larger diameter. The holes 87 and 88 are of different diameters, and are adapted to receive the ends of wire connectors of diameters selected to fit the holes 87 and 88 closely enough to distinguish one from the other, and thus to preserve the polarity of the electrical connections. The electrical harnesses associated with these connections are shown generally at 89 in FIG. 15.
During the extension and retraction of the probe assembly by the cylinder 31, these harnesses are formed in a loop suspended by the resilient arm 90, the base of which is clamped to the plate 26 as shown at 91. A portion of the length of the arm 90 is formed by the coil spring 92, permitting substantial deflection during the extremes of movement of the carriage 29, without inducing sharp bends in the electrical harnesses, and without dragging them over the surrounding structure. In these cycles of movement, the retracted position of the probe assembly shown in FIGS. 1 and 2 is controlled by the engagement of the actuator 93 bolted to the carriage 29, and extending to a point where it can engage the operating point of the switch 94 mounted on the bracket 95 bolted to the plate 26 as shown at 96. The switch 94 will control appropriate valves in the structure 34, which determines the pressure conditions within the cylinder 31. The conventional electrical connections between these points are not shown.
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A thermocouple probe assembly for a billet furnace is provided with replaceable contact tips joined to the shanks of the probe rods within a surrounding insulator to inhibit oxidation of the junctions. Two pairs of probes are used, each pair being associated with an independent control circuit as a safety backup system. The assembly is preferably mounted on a bracket that is extendable on an angle forty-five degrees to the horizontal to provide correct probe positioning for various sizes of billets, and has a heat shield correspondingly adjustable along the probe assembly to accommodate various degrees of penetration of the probe assembly into the furnace.
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BACKGROUND OF THE INVENTION
This invention is directed to a process and apparatus for filling tires with nitrogen gas (N 2 ). More particularly, this invention is directed to a process and apparatus for efficiently filling large size vehicle tires such as truck and bus tires with nitrogen gas.
When compressed air is introduced into a tire, via a compressor open to the ambient atmosphere, water vapor and other impurities are introduced into the tire. With moisture and other impurities present, the air volume in the tire, fluctuates fairly widely with temperature, particularly due to moisture changing from liquid to vapor form and vis-versa as temperatures in the tire change. As a rule of thumb, tires inflated with compressed ambient air will change about 1psi for every 10 degree Fahrenheit change in temperature. Thus, a tire inflated at 60 degrees Fahrenheit will be substantially under inflated at 20 degrees due to the combined effects of temperature in reducing gas pressure and moisture condensing out of the air within the tire. Conversely, as temperatures increase to 90 degrees Fahrenheit, the tire will be substantially overinflated due to the water being vaporized and the attendant increase in air pressure due to temperature. Those under or over inflation conditions can adversely affect rolling friction of tires on pavement, thus decreasing gas mileage. Tire wear is also increased when the tires are not inflated to the manufacturer's recommendations. Water vapor within tires may also induce rust within steel belted radials, which further reduces tire life.
In order to reduce or eliminate these problems, race cars, earthmoving and mining equipment, and commercial and military aircraft often utilize tires inflated with compressed nitrogen. Nitrogen is an ideal gas for such a purpose since it is chemically inert, non-combustible, non-flammable and non-corrosive, and when dry, is relatively stable in volume through a wide range of temperatures. For example, the specific volume of a quantity of dry nitrogen gas at 1 atmosphere of pressure varies less than 13% in a range of −10 degrees F. to +116 degrees F. Thus, the use of nitrogen to inflate a pneumatic tire offers a reduction in fluctuations of internal tire pressure due to temperature variations over those which occur when moisture laden compressed ambient air is used.
In view of the above, it is believed that filling a tire with N 2 gas may help the degradation of rubber and the like. Known systems of providing N 2 gas for tire inflation include a method wherein N 2 gas is separated and purified from air using industrial activated carbon, a method of using a gas separation membrane wherein O 2 and N 2 are separated from air by utilizing different permeation rates, and by simply using an N 2 filled canister.
SUMMARY OF THE INVENTION
While these several known systems for providing N 2 gas for tire inflation provide benefits, each also demonstrates certain drawbacks. For example, N 2 gas canister storage requires significant physical space to maintain a sufficient supply. Furthermore, transporting canisters to a filling station is both inconvenient and costly. The carbon or membrane separation apparatus can be problematic because of low N 2 separation rates, resulting in long filling times. In a commercial operation, extended filling times can render the process undesirable to consumers. This problem can be particularly severe when the system is used with large tire vehicles such as bus or truck. Accordingly, an improved system/process for N 2 tire inflation would be desirable.
According to one embodiment of the invention, a method of inflating a tire is provided. The method involves the use of an apparatus including a membrane and a storage tank and includes the steps of separating N 2 gas from air using the membrane and providing the N 2 gas to a storage tank having capacity for storing at least 40 cubic feet of N 2 gas at 18° centigrade. Preferably, the storage tank is separately transportable from the membrane, i.e., they are independent units. Thereafter, N 2 gas is provided from the storage tank to a hose, the hose including a pressure gauge, a stop valve, and a fitting suited for mating with a tire inflation valve stem. The fitting is secured to the tire inflation valve stem and the stop valve opened to initiate introduction of the N 2 gas into the tire. Preferably, the storage tank will include the capacity for between 50 and 600 cubic feet of N 2 gas at 18° centigrade. Preferably, the storage tank is able to accommodate said N 2 gas up to at least 100 psig, more preferably at least 200 psig. Preferably, the N 2 gas will be provided to the tire at a pressure of at least 110 psig.
According to another embodiment of the invention, an apparatus for inflating a tire with N 2 gas is provided. The apparatus includes a mechanism supplying compressed air to a membrane which separates N 2 and O 2 gas. The apparatus further includes a fluid path providing the N 2 gas to a storage tank having capacity for storing at least 40 cubic feet of N 2 gas at 18° centigrade. A hose, including a pressure gauge, a stop valve, and a fitting suited for mating with a tire inflation valve stem is provided in fluid communication with the storage tank.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described with reference to the accompanying drawing wherein:
FIG. 1 is a schematic illustration of an apparatus for filling N 2 gas according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention provides an apparatus and process for providing N 2 gas to fill a tire. As recognized, tires filled with nitrogen gas provide many benefits including generally enhanced performance and longer life. These benefits may be most significant in association with high use vehicles such as trucks and buses, which can generally be categorized as large tire vehicles. The present invention provides an apparatus and process for tire inflation, particularly large tires, over a short time span thereby providing a commercially viable system of N 2 tire inflation. The method involves separating N 2 gas from air in a location proximate the tire inflation location. In this context, proximate is intended to reflect at the site of tire servicing, e.g., the service center, a vehicle manufacturing facility, an airport, etc. More preferably, proximate will mean within about 500 meters, more preferably 100 meters, of the tire(s) being inflated.
Referring now to FIG. 1, the nitrogen inflation system 1 , includes air compressor 3 , providing pressurized air into line 5 . Air compressor 3 , for large tire vehicles, preferably is capable of providing air from the atmosphere at a pressure of at least 110 psi, and more preferably, at least 140 psi. Air compressor 3 can be any available type, and preferably is provided with an internal shut off mechanism at approximately 140 psi in the event of a down stream pressure increase.
Line 5 includes stop valve 7 , to facilitate opening and closing flow of pressurized air into nitrogen filter membrane module 9 . Membrane module 9 may be any type known in the art useful for the separation of nitrogen from air. Examples include separation membranes formed of polyimide or activated carbon. By utilizing a difference of permeation rate produced when pressurized air is passed through such a membrane, O 2 gas is removed while a high concentration of N 2 gas is retained. O 2 gas can be removed via discharge line 11 , including noise reduction muffler 13 at the base of N 2 membrane module 9 . A muffler and exhaust outlet 14 is also provided for expulsion of N 2 system gas. Furthermore, membrane module 9 will also preferably include a nitrogen sensor 16 for monitoring the quality of gas established by the membrane.
Pressurized nitrogen gas is discharged from membrane module 9 into line 15 secured to membrane module 9 via a quick disconnect mechanism 17 . Line 15 includes stop valve 19 to regulate the flow of nitrogen gas into a storage tank 21 .
Storage tank 21 is preferably comprised of a high strength material capable of storing nitrogen gas up to a pressure of 150 psig, more preferably 200 psig and most preferably 250 psig. Storage tank 21 is equipped for safety purposes with a top off valve 23 set to a value commensurate to the pressure rating of the tank, e.g. 150, 200 or 250 psig. Storage tank 21 also preferably includes a pressure gauge 25 to facilitate monitoring of the system to assure readiness for prompt tire inflation.
Secured to storage tank 21 via a quick disconnect element 27 , is hose 29 . Hose 29 is preferably of a length which facilitates easy access to vehicle tires, particularly, bus and truck tires. Accordingly, the preferred length is at least 10 meters, more preferably, 25 meters.
Hose 29 is equipped with a pressure regulation valve 31 which facilitates introduction of nitrogen gas at the desired pressure. In addition, line 29 will include a pressure gauge with stop valve 33 to allow pressure to be monitored and the system to be closed as desired. Line 29 is completed with the inclusion of a fitting 35 suited to mate with a tire inflation valve stem.
Nitrogen inflation system 1 also includes additional hose 37 , equipped with a tire inflation gauge 39 for monitoring tire pressure inflation. Although not shown, line 37 is preferably secured to line 15 via a check off valve. Stop-valve 41 allows back flow of N 2 gas from the tire into the nitrogen filter membrane module 9 , allowing use of nitrogen sensor 16 to determine quality of N 2 gas tire fill.
It should be noted, that several aspects of the nitrogen inflation system 1 can be modified. For example, the entirety of the system depicted upstream of storage tank 21 can be comprised of a nitrogen-apparatus as depicted in U.S. Pat. No. 6,234,217 herein incorporated by reference. The N 2 flow stabilizer provided in the present invention serves as a buffer that allows for easy inflation of multiple tires with minimal difficulty.
A general method of operating the subject nitrogen inflation system 1 is to maintain storage tank 21 in a filled N 2 condition, i.e., up to about the maximum pressure of the apparatus. Pressure regulation valve 31 is then set to a pressure commensurate with the designated inflation pressure of a tire to be filled. Stop valve 33 is opened and fitting 35 secured to the tire inflation valve stem. Advantageously, because of the large volume high pressure nitrogen gas capacity of storage tank 21 the tires of a multiple axle vehicle such as bus or truck can be inflated rapidly. For example, the apparatus allows inflation of the tire in three to four minutes to achieve a minimum 93%, preferably 95% N 2 density. In contrast, the nitrogen generating apparatus depicted in U.S. Pat. No. 6,234,217 has been demonstrated to give approximately 23 minutes to inflate one tire.
Storage tank 21 can be maintained in a suitable pressurized condition via operation of air compressor 5 in conjunction with an open position of stop valves 7 and 19 . It is desirable that compressor 3 provide pressurized air at a pressure sufficiently high to account for a pressure drop over the membrane 9 and still provide storage tank 21 with a pressure in accord with desired levels. A preferred storage tank provides capacity for between about 40 and 300 cubic feet of N 2 gas between about 100 and 200 psig and 18° C.
Examples have been performed wherein the device depicted in FIG. 1 was utilized with an air compressor generating 140 lbs. per square inch air and an 80 gallon storage tank with a 200 psig top off valve. In three tests, the results of the following table were achieved. These examples are provided to further explain the invention but are not intended to limit the scope thereof.
Tire
Air Tank
Nitrogen Density In
Test #
Inflation Time
Pressure
Pressure
the Tire
1
1 min. 45 secs.
82
psi
109 psi
96%
3 min. 53 secs.
113
psi
117 psi
98.14%
2
0
0
120 psi
1 min. 45 secs.
83
psi
106 psi
N/A
3 min. 52 secs.
110
psi
116 psi
96.8%
3
0
0
125 psi
1 min. 45 secs.
87
psi
106 psi
2 min. 45 secs.
103
psi
112 psi
96.3%
3 min. 45 secs.
111
psi
116 psi
98.4%
4
0
0
125 psi
1 min. 45 secs.
87
psi
106 psi
2 min. 45 secs.
104
psi
111 psi
96.3%
3 min. 45 secs.
112
psi
115 psi
98.1%
Accordingly, it can be seen that the apparatus of the present invention and the method associated therewith provide a rapid mechanism for N 2 gas filling of large tires.
The invention has been described with reference to one exemplary figure and several exemplary embodiments. Modifications and alterations will be apparent to others upon reading and understanding the specification. The invention is intended to include such modifications and alterations insofar as they come within the scope of the appended claims.
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A method of inflating a tire comprising separating N 2 gas from air using a membrane; providing the N 2 gas to a storage tank having capacity for at least 40 cubic feet of N 2 gas at 18° Centigrade, providing the N 2 gas from the storage tank to a hose, the hose including a stop valve and a fitting suited to mate with a tire inflation stem; securing the fitting to a tire inflation valve, and opening a stop valve to initiate the introduction of N 2 gas into the tire.
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BACKGROUND
[0001] Storage arrays built from a group of drives in a rack have been designed to provide fresh air for the drives, thereby ensuring reliable operation and maximum performance for the drives. FIG. 1 illustrates such a storage array in a rack 100 , having a plurality of drives 102 at the front of the rack, and a plurality of fans 104 at the rear of the rack. Airflow 106 cools the drives during use. Note, however, that in such an arrangement, a significant portion of the center of the rack is unused.
[0002] Additional designs for storage arrays have aimed to utilize more of the rack depth. As shown in FIG. 2 , the rack 100 is filled with four rows of disk drives 102 , and a row of fans 104 to cool the drives 102 . As a result of such a rack layout, disks toward the rear of the rack reside in a higher temperature environment (i.e., the higher temperature drives 110 ) than the drives at the front of the rack (i.e., the lower temperature drives 108 ), because the drives towards the front of the rack 108 preheat the air. As such, higher airflow fans are needed to move the air. Additionally, the added rows of drives add airflow resistance, and thus the fans with higher static pressure abilities are needed. Despite the fans for cooling, the drives towards the rear of the rack will necessarily run hotter, and have higher failure rates.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] For a detailed description of exemplary embodiments of the invention, reference will now be made to the accompanying drawings in which:
[0004] FIG. 1 shows a top view block diagram of a prior art storage array rack layout;
[0005] FIG. 2 illustrates a top view block diagram of another prior art storage array rack layout;
[0006] FIG. 3 shows a top view block diagram of a storage array rack layout in accordance with the present disclosure;
[0007] FIG. 4 shows a block diagram of various system storage units in the order in which data is stored, based on priority or frequency of access in accordance with the present disclosure;
[0008] FIG. 5 illustrates a flowchart of a method for dynamic hierarchical storage based on performance throttling in accordance with the present disclosure; and
[0009] FIG. 6 illustrates a flowchart of another method for dynamic hierarchical storage based on performance throttling in accordance with the present disclosure.
NOTATION AND NOMENCLATURE
[0010] Certain terms are used throughout the following description and claims to refer to particular system components. As one skilled in the art will appreciate, computer companies may refer to a component by different names. This document does not intend to distinguish between components that differ in name but not function. In the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to . . . .” Also, the term “couple” or “couples” is intended to mean either an indirect, direct, optical or wireless electrical connection. Thus, if a first device couples to a second device, that connection may be through a direct electrical connection, through an indirect electrical connection via other devices and connections, through an optical electrical connection, or through a wireless electrical connection.
DETAILED DESCRIPTION
[0011] The following discussion is directed to various embodiments of the invention. Although one or more of these embodiments may be preferred, the embodiments disclosed should not be interpreted, or otherwise used, as limiting the scope of the disclosure, including the claims. In addition, one skilled in the art will understand that the following description has broad application, and the discussion of any embodiment is meant only to be exemplary of that embodiment, and not intended to intimate that the scope of the disclosure, including the claims, is limited to that embodiment.
[0012] The present disclosure is directed to methods and systems wherein disk drives (or other similarly functioning physical memory devices) are throttled, and data may be mapped to throttled disk drives according to the frequency access to the data. Specifically, for disk drives in a rack comprising a system storage array, the spindle speed of each disk drive may be throttled, or decreased, row by row across the depth of the rack, which may be a result of external environmental effects or exceeding certain thresholds, including temperature or power. Each throttled row of drives thus has slower access times than the previous row. Data that is accessed frequently is then stored in the drives that are not throttled, or drives that are throttled less than other drives, while data that is accessed relatively infrequently may be stored in the most, or more, throttled disk drives. Whether, or the degree to which a disk drive is throttled, may be predetermined and set statically by design, or alternatively, the disk drive may employ sensors so as to be self-aware of certain system conditions and environment, such as temperature, power, or reliability. In various embodiments, a rack or system wide processor may synchronize and monitor the various drives, and dynamically set storage priorities. A further advantage of the present disclosure is enabling the use of less powerful, less noisy fans to cool the devices in the rack.
[0013] As shown in FIG. 3 , the devices in the rack may be organized according to their location relative to fresh air access, or the front of rear of the rack. As shown in FIG. 3 , the drives are arranged in rows, specifically in four rows in the embodiment of FIG. 3 , but a rack could contain as many rows as feasible based on physical limitations, temperature limitations, the power of fans, and the like. As shown, the drives 112 in row 1 ( 102 A) are maintained as full speed drives, being physically closest to the front of the rack and with access to fresh air in the form of airflow 106 . The drives 114 in row 4 ( 102 D) may be throttled down to a lower speed, being physically closest to the rear of the rack and the fans 104 . Devices in rows 2 and 3 ( 102 B and C) respectively may be throttled to some degree greater than no throttling at all, as with row 1 ( 102 A) and to some degree less than the greatest degree of throttling found in disk drives of row 4 ( 102 D), or throttled to the same degree as row 4 ( 102 D), depending on various system conditions and programming. In some embodiments, the back row 102 D could be throttled while the other rows remain at full speed. Likewise, in some embodiments, the particular disk drives that are throttled could be in any geometric configuration (as viewed from above, as with the figures herein) or a single disk drive anywhere in the array. In some embodiments, the disk drive or drives that are throttled could be selected for throttling at random.
[0014] Alternatively, the selection of drives for throttling may be performed, and then less frequently accessed data may be mapped to the throttled drives. By selecting and throttling drives ahead of time, conditions that could be dangerous to system function (such as overheating or exceeding a power cap) may be avoided proactively.
[0015] In some embodiments, drives 102 are throttled based on a configuration of predetermined protocols, while in other embodiments, the drives 102 are each self-aware of system conditions, such as temperature. In racks of self-aware drives, in lightly loaded configurations, the drives may not be as likely to overheat, and thus can opt to operate at higher spindle speeds.
[0016] In well controlled environments (such as, for example, a well cooled computer room), there may be no need to throttle any, or as many, drives, and thus the decision of whether or not to throttle may be made dynamically (either by a drive individually, or the system overall monitoring the drives) in order to achieve increased performance and/or reliability. For example, drives may be throttled dynamically upon the occurrence of exceeding a predetermined threshold for, for example, power or temperature. Alternatively, settings for throttling may be set statically when there are known problem locations in rack, the environment of which often indicates that throttling is advisable to avoid overheating. Such static settings could be set at time of assembly.
[0017] FIG. 4 shows a block diagram of various system storage units in the order in which data is stored, based on priority or frequency of access. A computer system 118 operating in conjunction with the rack 100 stores data that is most frequently accessed in storage that is most quickly accessed, and data that is least often accessed in storage that is slower. Thus, as shown in FIG. 4 , the preference for storing data is ordered according to the following: L1 Cache, L2 Cache, L3 Cache, L4 Cache, System memory, and the memory external to the computer system, namely Storage Array—Row 1 , Storage Array—Row 2 , Storage Array—Row 3 , Storage Array—Row 4 , and finally tape storage. As is known in the art, cache memory often has the fastest access time, thus data used most frequently is prioritized and stored therein. In accordance with the present disclosure, Storage Array—Row 1 , operating at full speed and not being throttled to a lower speed, provides fastest access to data, at least with respect to the other rows in the same rack, and Storage Array—Row 2 offers slightly less fast access, Storage Array—Row 3 slightly less fast access than Row 2 , and so on, although as discussed above, the various rows may be throttled to the same degree or differing degrees as needed.
[0018] Referring now to FIG. 5 , a flowchart is shown of a method for dynamic hierarchical storage based on performance throttling. The method begins with throttling the speed of at least one or more disk drives in a bank of drives based on a system condition (block 500 ). A system condition may include, for example, ambient temperature, a power cap, or a failure rate of drives in the system. In some embodiments, the drive (or drives) that is throttled is physically located in a specific region of the configuration, such as in the warmest region of a physical arrangement such as a rack. In some embodiments, the drives are self-aware, and adjust the speed based on the system condition without direction from any system logic. For example, a disk drive may be programmed with a threshold temperature, and upon operating at a temperature above the threshold, the disk drive automatically adjusts its spindle speed to a lower speed in order to accommodate the ambient temperature and ensure continued operation and reliability. As another example, a disk drive may be programmed to operate within a power cap, and upon exceeding the power cap, the disk drive is programmed to automatically reduce its spindle speed in order to reduce its power consumption.
[0019] At block 502 , system logic determines which of the disk drives in the rack may be likely, based on characteristics known about the configuration, to be throttled, even if not currently throttled. For example, a particular row of disk drives or a particular single disk may be currently operating at acceptable temperatures, but based on location near the rear of the rack, such drives are likely to be throttled upon exceeding a threshold temperature.
[0020] At block 504 , system logic controls mapping of data to external storage such as a storage array comprising rows of disk drives and determines the relative frequency of access to data. Data that is accessed relatively less frequently may be logically mapped to less fast access storage, such as a throttled drive, or drive that is likely to be throttled based on its location , while data that is accessed relatively more frequently may be logically mapped to more fast access storage, such as a non-throttled, full speed disk drive. At block 506 , the system logic that controls mapping of data to external storage optimized the mapping of least access data to a throttled disk drive or disk drive likely to be throttled, and most accessed data to full speed memory, as necessary. In some embodiments, throttled drives or drives likely to be throttled may be used for storing data as full speed drives become too full and, thus, unavailable.
[0021] FIG. 6 shows a flowchart of another method for dynamic hierarchical storage based on performance throttling. The method begins with a determination of whether throttling is needed, based on a system condition (block 600 ). In some embodiments, a system condition may include ambient temperature or a failure rate of memory drives in the system. The determination of whether throttling is even needed may be carried out by system logic or by each individual disk drive. In various embodiments, system conditions may be well controlled and ambient temperature may not indicate that any throttling is necessary, and in such situations, no disk drives are throttled (block 601 ). The determination at block 600 is repeated periodically to reassess the system condition.
[0022] If throttling is determined to be needed at block 600 , then the method continues with throttling the speed of at least some drives in the bank of disk drives based on the system condition (block 602 ). The determination of which particular drive or drives in the bank of drives is throttled may be based on the physical location in a specific region of the configuration, such as in the warmest region of a physical arrangement such as a rack. By comparison to the discussion of self-aware drives above, in some embodiments, the system is self-aware and monitors the system conditions for each drive, and adjusts the speed of each drive individually based on the system condition with direction from the system logic. For example, the system logic may be programmed with a threshold temperature, and upon any disk drive within the system operating at a temperature above the threshold, the system adjusts the spindle speed of the particular drive (and as necessary, other drives in the vicinity, as logically, drives near an overheated drive are also susceptible to overheating) in the bank to a lower speed in order to accommodate the ambient temperature and ensure continued operation and reliability across the bank of drives.
[0023] The drives that are throttled may be some or all of the drives in the bank, though preferably, the drives are organized into rows, and the degree to which any particular drive is throttled is based on which row in the bank the drive resides in.
[0024] At block 604 , system logic controls mapping of data to external storage such as a storage array comprising rows of disk drives and determines the relative frequency of access to data. Data that is accessed relatively less frequently may be logically mapped to less fast access storage, such as throttled drives, while data that is accessed relatively more frequently may be logically mapped to more fast access storage, such as non-throttled, full speed drives. At block 606 , the system logic that controls mapping of data to external storage optimized the mapping of least access data to throttled drives and most accessed data to full speed drives, as necessary. In some embodiments, throttled drives are used for storing data as full speed drives become too full and thus unavailable.
[0025] In various embodiments, drives may be throttled to result in a constant temperature, power rating, or a preferred degree of reliability. In various embodiments, disk drives may be throttled based on configuration either by predetermined protocols or by self-awareness of system condition such as temperature or power consumption. In lightly loaded configurations, drives may not become as hot, and thus, may be permitted to operate at higher spindle speeds.
[0026] In various embodiments, in well controlled and/or lower temperature environments, drives may be operated at full speed for increased performance, as throttling is determined to be unnecessary.
[0027] The degree of throttling (e.g., spindle speed) may be set one time statically, periodically, or dynamically in real time. For embodiments wherein throttling is applied dynamically, the system monitors disk temperatures throughout the bank of disk drives and applies throttling according to predetermined algorithms and geometries configured to permit the most reliable performance.
[0028] In various embodiments, the disk drives may have a set of predetermined speeds, just as processors have a predetermined set of p-states, and “throttling” refers to switching from a first predetermined speed to a second predetermined speed that is slower than the first predetermined speed.
[0029] The above discussion is meant to be illustrative of the principles and various embodiments of the present invention. Numerous variations and modifications will become apparent to those skilled in the art once the above disclosure is fully appreciated. It is intended that the following claims be interpreted to embrace all such variations and modifications.
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A system and method for dynamic storage based on performance throttling. The method comprises providing an array of storage devices coupled to a computing device. The method comprises determining a status of a system condition, such as ambient temperature. The method comprises throttling the operating speed of one or more storage devices in the array based on the status of the system condition. The method comprises determining relative frequency of access to data to be stored by the computing device in the array of storage devices. The method comprises optimizing storage of data by the computing device in the array of storage devices based at least in part on 1) relative frequency of access to data and 2) which of the one or more storage devices are throttled.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a control of automobile internal combustion engines, and is particularly concerned with an automatic control apparatus for an engine throttle valve which is capable of minimizing loads of a motor for controlling a position of the throttle valve.
2. Description of the Prior Art
As a control apparatus for internal combustion engine throttle valves, there known hitherto, for example, are "Control Apparatus for Internal Combustion Engine Throttle Valves" disclosed in Japanese Patent Publication No. 25853/1983 dated May 30, 1983 and "Valve Driving Device" disclosed in Japanese Patent Laid-Open No. 145867/1980 dated Nov. 13, 1980.
In such conventional apparatuses, a throttle valve is supported rotatably on a pipeline. A motor for driving the throttle valve is coupled direct to the throttle valve or connected thereto through a reduction gear. A return spring is provided on the throttle valve, and thus when a current is not carried to the motor, it is returned invariably to a position whereat an engine comes to idling. A position sensor for detecting an opening is provided on the throttle valve, and information on a current position of the throttle valve is obtained from the position sensor, thereby applying a correction to a position control of the motor.
Generally in an automobile internal combustion engine for which a fuel injection is carried out downstream of the throttle valve, viscous deposits stick on the throttle valve due to a fuel scum return, a backfire and the like, which are capable of clogging the throttle valve at a full-open position. In the conventional apparatuses, a torque of the return spring is loaded in addition to a torque for relieving the throttle valve from such a clogged state, and thus a heavy torque is required for the motor. To obtain a heavy torque, a reduction ratio will be increased normally; however, such a measure is defective to deteriorate an answerability. To provide an enlarged motor therefor is to increase the weight of the apparatus inevitably, which is, needless to say, inadvisable.
SUMMARY OF THE INVENTION
An object of the invention is to provide an automatic control apparatus for an engine throttle valve operating on a small-sized motor wherein the throttle valve is prevented from being clogged at a full-open position without deteriorating an answerability.
The throttle valve is so clogged by deposits being hardened from leaving the throttle valve close for a long time after the engine is shut down. The valve will not be clogged if it is kept open as far as a certain position after shutdown of the engine, accordingly.
In the invention, an improvement is therefore such that an actuator operating at the time of engine shutdown is provided on the throttle valve, thus forcing the throttle valve to open as predetermined according to an operation of the actuator when the engine is shut down.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 represents one embodiment of the invention.
FIG. 2 represents another embodiment of the invention.
FIG. 3 is a drawing for illustrating in detail a magnetic coupling of FIG. 2.
FIG. 4 is a drawing representing a further embodiment of the invention.
FIG. 5 is a drawing representing an even further embodiment of the invention.
FIG. 6 is a drawing for illustrating in detail a lever of FIG. 5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, a throttle valve 1 is supported rotatably on a pipeline, and a lever 11 is fixed on one end thereof. An actuator 12 pushes the lever 11 to open the throttle valve. The actuator 12 comprises a diaphragm 14 and a retainer 15 for holding the diaphragm 14, a shaft 13 fixed on the retainer 15, and a case 17 for supporting the shaft slidably, the case 17 holding down the diaphragm 14 to form an airtight chamber on the side counter to the shaft 13.
There is provided a spring 16 for extruding the shaft on the airtight chamber side. The airtight chamber is connected to a check valve 18. The check valve 18 grows to a large orifice when stepping down on air pressure of the airtight chamber, but to a small orifice when stepping up the air pressure to the contrary, thus checking the air pressure from rising sharply. The check valve 18 communicates with the downstream of the throttle valve 1. A in FIG. 1 indicates the direction in which air flows, and E indicates the engine side. When the engine starts, a suction negative pressure is present and passes the check value 18, an air pressure of the airtight chamber of the actuator 12 drops, the diaphragm 14 is pulled, the spring 16 is compressed, the shaft 13 is also drawn in, and thus the throttle valve is closed.
The size of the spring 16 and that of the diaphragm 13 are so set as for them to operate even at the time of cranking.
When the engine stops, the suction negative pressure downstream of the throttle valve 1 is turned to an atmospheric pressure to step up the air pressure of the actuator 12; however, the air pressure does not rise quickly owing to the check valve 18 present therefor, the shaft 13 will not come out so suddenly, and thus the throttle valve is not opened right off after the engine stops. The check valve thus provided is effective enough to suppress a hunting.
FIG. 2 represents another embodiment. The throttle valve 1, a pipeline 2 and the lever 11 are disposed likewise as in the case of FIG. 1. A lever 21 is so disposed as to come in contact with the lever 11, and thus the throttle valve can be opened on a tensile force of a spring 22. A wire 23 is mounted on the lever 21, and thus when the wire 23 is pulled, the lever 21 is detached from the lever 11. The wire 23 is wound on a drum 24. The drum 24 has a stopper 25, which prevents the lever 21 from being overdrawn. The drum 24 is connected to an engine shaft 27 through a magnetic coupling 26. A structure of the magnetic coupling 26 is shown in FIG. 3. The drum 24 is rotatable with respect to the engine shaft 27 through a bearing 28. A magnet 30 is fixed on the drum 24. The magnetic coupling 26 is fixed on the engine shaft 27, and an iron plate 29 is fixed further thereon. A magnetic flux from the magnet 30 comes in the iron plate 29, and a torque is generated so as to rotate the drum in the same direction as that of engine rotation. The torque is generated in the direction R of FIG. 2, and the wire 23 is pulled thereby. The lever 21 is thus detached from the lever 11, and no action compes to exert on the throttle valve.
When the engine stops, the torque is not generated, a tensile force of the wire 23 is removed, and the lever 21 pushes the lever 11 by a force of the spring 22 to open the throttle valve.
In FIG. 4, the same construction is given as in the case of FIG. 2; however, the spring is not provided direct on the lever 21, and a spring 31 is provided on the drum 24 of FIG. 2. Quite different from that of FIG. 2, the lever 21 extrudes the lever 11 when the wire 23 is pulled. The drum 24 generates a torque during rotation of the engine, moves in the direction losing a tensile force of the wire against the spring 31 and then stops on the stopper 25. The wire has the tensile force removed as above, therefore the lever 21 does not work on the lever 11. When the engine stops, the drum 24 loses the torque, and thus the drum 24 pulls the wire 23 on a torque of the spring 31. The lever 21 works on the lever 11 to open the throttle valve.
In the example of FIG. 4, when the wire 23 is cut, no action can be exerted on the throttle valve, and hence a car or engine can be prevented from running away.
In FIG. 5, a return spring 4 and an actuator 41 for keeping the return spring 4 from operating at the time of motor actuation are provided against the construction of FIG. 1. As in the case of the actuator 12, the actuator 41 operates on a suction negative pressure. A three-way solenoid valve 42 is provided halfway of the line connecting the actuator 41 and a suction pipe, a suction negative pressure is introduced to the actuator 41 when a solenoid is turned on, and an atmospheric pressure is introduced to the actuator 41 when the three-way solenoid valve 42 is turned off. The three-way solenoid valve 42 is turned on whenever the engine starts. However, when something is wrong with the motor to bring about an uncontrollable state, it is turned off upon decision of a controller 6, the atmosphere pressure is introduced to the actuator 41, the return spring 4 works on the throttle valve, and thus the throttle valve is closed as far as a position of idling frequency.
The return spring 4 of FIG. 5 and its periphery are shown in detail in FIG. 6. A drum 51 is rotatable with respect to a throttle valve shaft 50. An adjusting screw 52 is provided on the drum 51, which comes in contact with a lever 53 fixed on the throttle valve shaft 50, and thus the throttle valve 1 is closed by a torque of the return spring 4 mounted on the drum 51. A wire 54 is mounted on the drum 51, and when it is pulled, the adjusting screw 52 is detached from the lever 53, and the torque of the return spring will not work on the throttle valve. The actuator 12 operates on the lever 53 likewise as in the case of FIG. 1. According to the embodiment, a load of the motor is limited to a frictional force and a torque generated on the throttle valve according to an air stream.
As described above, according to the invention, since the throttle valve is never clogged at an idling position, it is not necessary to take an escape torque into consideration as a load of the motor for position control of the throttle valve, the load can be decreased accordingly, thus a gear with a large reduction ratio is unnecessary, and further the motor can be miniaturized reasonably.
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A throttle valve is supported rotatably on a pipeline. The throttle valve is driven by a motor. A downstream side of the throttle valve is connected to an engine. A means for opening the throttle valve forcedly is provided so as not to allow a tar component in the fuel for driving the engine to stick on the throttle valve at an outer peripheral portion when the engine is shut down.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present patent application is a continuation of U.S. Ser. No. 10/827,014, (U.S. Pat. No. 6,855,922), filed on Apr. 19, 2004, which is a divisional patent application of U.S. Ser. No. 09/659,100, (U.S. Pat. No. 6,815,652) filed on Sep. 11, 2000, the entire content of both applications are hereby expressly incorporated by reference.
BACKGROUND OF THE INVENTION
The present invention relates to the field of auto-darkening eye protection devices, such as welding helmets having a shutter (or lens) assembly that automatically darkens upon the detection of a welding arc. A photosensitive device such as a photodiode or a phototransistor may be used to sense the intensity of light incident on the area of the shutter assembly so as to provide an indication to the circuitry controlling the shutter assembly that the shutter assembly needs to be driven to either a dark state or a clear state. If a welding arc is present, the welding helmet protects the eyes of the welder from any danger caused by the intensity of the welding arc by driving the shutter assembly to a dark state, thereby decreasing the amount of energy passing through the lens to the welder's eyes. U.S. Pat. Nos. 4,385,806, 4,436,376, 4,540,243, Re. 32,521, 5,248,880, 5,252,817, 5,347,383, 5,533,206, 5,751,258, 5,959,705, 6,067,129, and 6,070,264 each disclose various shutter assemblies and liquid crystal driver electronics that can be used in conjunction with the present invention. The disclosures of these above-mentioned patents are hereby incorporated in their entireties by reference.
Commonly-owned U.S. Pat. No. 5,347,383 discloses a driving circuit for a liquid crystal shutter. The sensor circuitry of this invention utilizes a photodiode to detect the occurrence of welding. This sensor circuitry also utilizes a comparator to compare the sensed light signal with a threshold value to determine whether the shutter assembly should be driven to a dark or clear state. Additionally, the '383 patent discloses the use of a 9 V supply.
While the invention disclosed in this patent functioned for its intended purpose, a need was felt for an improvement in the power consumption by the sensor circuit. As incident light increases on a photodiode, the voltage across the photodiode will begin to saturate. To prevent the photodiode from saturating, a steadily increasing load must be put on the photodiode which leads to excessive power consumption.
To alleviate the excessive power consumption inherent in a photodiode-based sensor circuit, a phototransistor has been utilized as a weld sensor. The use of a phototransistor allows the use of feedback to bias the phototransistor so that less current is needed to keep the phototransistor in its operational mode. Commonly-owned U.S. Pat. Nos. 5,252,817, 5,248,880, 5,751,258, and 6,070,264 are illustrative of sensor circuits using phototransistors as weld sensors. Each of these patents discloses a sensor circuit wherein the output of the phototransistor is fed into a comparator. The comparator compares the phototransistor output with a threshold level. If the phototransistor output exceeds the threshold level, the drive circuitry is activated to darken the shutter assembly. If the phototransistor output does not exceed the threshold level, the drive circuitry operates the shutter assembly in a clear state. While the circuits disclosed in these patents utilize feedback to bias the phototransistor and avoid the excessive drawing of current, heavy loads were still needed. The circuits implementing such designs used voltage supplies ranging from 5.6 V to 9 V. Therefore, a need was still felt for a sensor circuit having improved power consumption characteristics.
Moreover, the phototransistors used in the prior art designs were metal can phototransistors. Metal can phototransistors are relatively big and bulky. Their size, height and relative difficulty in mounting serves as a limiting factor in the ability of designers to reduce the size of the units in which the sensor circuit is implemented. Thus, a need was felt to use a smaller and more compact phototransistor that is more easily mountable to a circuit board to produce a smaller, sleeker unit while still having the ability to maintain a constant signal level without excessive loading or the drawing of excessive current.
Additionally, the sensor circuits of the prior art produced an output voltage from the phototransistor in response to incident light intensity as seen in FIG. 3 of the '880 and '817 patents. As can be seen, low light intensities produce a steep rise in output of the phototransistor. Because of the power drain caused by the response of the phototransistor to low intensity incident light, it is desirable that the phototransistor be configured to minimize the phototransistor output signal when the sensor circuit is exposed to low intensity incident light. Thus, a need existed for a sensor circuit that provided greater attenuation in the response of the phototransistor to low intensity incident light.
While it is desirable to minimize the phototransistor output when the sensor circuit is exposed to low intensity incident light, the phototransistor still must be able to quickly increase its output in response to a transition from low intensity light to high intensity light, such as the light provided by a welding arc. Thus, an ever present need exists within the art to sharpen the rise provided by the phototransistor in response to sharp increases in light intensity.
Also, the sensor circuitry of the prior art used a comparator to correlate the sensed light signal with the desired shade level. The comparator compared the output of the phototransistor with a threshold voltage signal to determine whether the shutter assembly should be driven to a dark state or a clear state. This design required additional circuitry to set the threshold voltage level. This additional circuitry not only complicated circuit design, but also increased the drain on the power supply. Thus, a need was felt to simplify the sensor circuitry to provide a more power-efficient way of correlating the phototransistor output to the proper shade setting of the shutter assembly.
BRIEF SUMMARY OF THE INVENTION
In order to solve these and other problems in the prior art, the inventor herein has succeeded in designing and developing an improved welding detection circuit utilizing a novel phototransistor-based sensor circuit. This sensor circuit comprises a phototransistor biased via a feedback circuit and having an output connected to an amplifier. The sensor circuit can be connected to a power supply and a control circuit to drive a shutter assembly to either a dark state or a clear state depending upon the intensity of incident light.
One feature of the present invention is the use of a resistor coupled between the base and emitter of the phototransistor. This resistor helps reduce the current produced by the sensor during low ambient light conditions, thereby attenuating the phototransistor output in response to low intensity light signals, and helps produce a sharply rising voltage from the phototransistor in response to high intensity light signals. Preferably, the feedback circuit also includes a second resistor coupled between the emitter of a feedback transistor and ground to further attenuate phototransistor output in the presence of low intensity ambient light.
Another feature of the present invention is its use of a planar phototransistor. Because of the planar phototransistor's small size, as compared to the metal can phototransistors used in the prior art, and because of the planar transistor's ability to maintain a constant signal level without excessive loading or the drawing of excessive current, the use of a planar phototransistor not only performs as well as metal can phototransistors, but also allows a reduction in the size of the unit in which the circuit is implemented. Preferably, the planar phototransistor is configured for a surface mount to further simplify construction of the circuit.
Another feature of the present invention is its use of a closed loop noninverting amplifier to provide a gain for the phototransistor output. The gain of the amplifier is preferably set so that a sufficient output voltage will be generated to activate the shutter assembly when the phototransistor produces an output indicative of the presence of a welding arc. Preferably, a capacitor is coupled between the phototransistor output and noninverting input of the amplifier to block the DC portion of the phototransistor output.
Another feature of the present invention is its use of the energy saved by an improved and efficient circuit design to recharge a rechargeable battery. By recharging the battery, the present invention extends the battery life of the invention's power supply.
Another feature of the present invention is its use of a solar cell to reduce the circuit's power consumption. By using a solar cell to power various components of the circuit, the present invention prevent those components from acting as a drain on the power supply when the invention is left unexposed to light. Often, while not in use, a welding helmet will be left in a dark room or left face down on a table. When in these conditions, it is undesirable for the circuit to operate as a drain on the power supply. When, the welding helmet is in use, it will be either outdoors, in a lighted room, or in a dark environment with the presence of welding arc. In such conditions, it is desirable to use the light incident on the welding helmet to power the circuitry therewithin.
The present invention uses the solar cell to power the phototransistor and the amplifier that is coupled to the output of the phototransistor, thus preventing those two components from draining the power supply when the welding helmet is left unexposed to light.
The present invention also uses the solar cell to power an activation circuit, the activation circuit functioning to activate a signal generator. The signal generator, once activated, generates the voltage level and frequency signal to be used to drive the shutter assembly to a dark state. The generation of this signal acts as a drain on the power supply. By using the solar cell to power the activation circuit, the present invention improves the circuit's power consumption by triggering the signal generator when light is incident on the welding helmet.
Yet another feature of the present invention is its use of a selector circuit for selecting the drive signal that will be delivered to the shutter assembly. If the sensor circuit indicates to the selector circuit that a welding arc is present, the selector circuit will cause a dark state drive signal to be delivered to the shutter assembly. If the sensor circuit indicates to the selector circuit that no welding arc is present, the selector circuit will cause a “clear state” drive signal to be delivered to the shutter assembly. The selector circuit uses a transistor as a switch to control the selection of the drive signal. An RC circuit is part of the selector circuit. The RC circuit utilizes its RC time constant to delay the transition of the “dark state” drive signal to the “clear state” drive signal, thus preventing the shutter assembly from switching to a clear state during brief “off” periods in the weld pulsations that exist with various weld types.
While the principal advantages and features employed are explained above, a fuller understanding of the invention may be attained by referring to the drawings and description of the preferred embodiment which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of the circuit of the present invention;
FIG. 2 is a schematic diagram of the circuit of the present invention;
FIG. 3 a is a schematic diagram of an equivalent circuit for the sensor circuit when both the phototransistor and feedback transistor are “off.”
FIG. 3 b is a schematic diagram of an equivalent circuit for the sensor circuit when the phototransistor is “on” and the feedback transistor is “off.”
FIG. 3 c is a schematic diagram of an equivalent circuit for the sensor circuit when both the phototransistor and the feedback transistor are “on.”
FIG. 4 is a graph depicting the voltage from the phototransistor as a function of incident light intensity.
FIG. 5 is a perspective view of a surface mount phototransistor utilized in the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A block diagram of the circuit of the present invention is depicted in FIG. 1 . As can be seen, a power supply 250 is connected via power lines 251 , 252 , 253 , 254 , and 255 to the sensor circuit 200 , activation circuit 326 , selector circuit 316 , signal generator 325 , and delivery circuit 315 . The power supply 250 furnishes the circuit with the power necessary for operation. Activation circuit 326 , selector circuit 316 , signal generator 325 , and delivery circuit 315 function together to control the shutter assembly 400 depending upon the signals received from power supply 250 and sensor circuit 200 .
Activation circuit 326 receives power from the power supply 250 and sends an activation signal to the signal generator 325 . Upon activation by the activation circuit, the signal generator 325 generates a frequency signal 102 and a voltage signal 104 and sends the two signals 102 and 104 to the delivery circuit 315 . The delivery circuit 315 uses the frequency signal 102 and the voltage signal 104 to assemble a “dark state” drive signal for the shutter assembly 400 .
The sensor circuit 200 senses incident light 256 and produces an output signal representative of the amount of incident light sensed. This output signal 211 is sent to selector circuit 316 . Depending upon the sensor circuit output, the selector circuit delivers a selection signal 107 to the delivery circuit 315 . If the sensor circuit 200 produces an output representative of the presence of high intensity light, such as the light produced by a welding arc, the selector circuit will send a selection signal 107 to the delivery circuit indicating that a “dark state” drive signal should be delivered to the shutter assembly 400 . If the sensor circuit 200 produces an output representative of the presence of low intensity light (i.e., no welding arc is present), the selector circuit will send a selection signal 107 to the delivery circuit indicating that a “clear state” drive signal should be delivered to the shutter assembly 400 . The delivery circuit 315 uses the selection signal 107 to determine the voltage level for the drive signals. If the selection signal 315 indicates that a “dark state” drive signal is needed, the delivery circuit will assemble a drive signal having a frequency set by the frequency signal 102 and voltage levels transitioning between the voltage signal 104 and the voltage of the power signal 253 . If the selection signal 315 indicates that a “clear state” drive signal is needed, the delivery circuit will assemble a drive signal having a constant voltage level set by the voltage of the power signal 253 . The delivery circuit 315 delivers this drive signal to the shutter assembly 400 via drive signal lines 110 and 112 . If the drive signal is a “dark state” drive signal, the shutter assembly 400 will be driven to a dark state. If the drive signal is a “clear state” drive signal, the shutter assembly 400 will be driven to a clear state.
Referring to FIG. 2 , a detailed schematic of the circuit depicted in the block diagram of FIG. 1 is shown. Preferably, power supply 250 includes a rechargeable 3 V supply and a solar cell 257 . However, a single power source, either a battery or a solar cell, can be used without dramatically altering the operation of the circuit. It is also preferable that the solar cell serve as the circuit's primary power source, with the 3 V supply functioning to provide additional power to various circuit components when the solar cell voltage falls below the battery voltage. The solar cell power supply supplemented by the 3 V rechargeable supply is seen on line 100 (the signal on this line will be referred to as the 3 V signal). The solar cell power supply that is not supplemented by the 3 V rechargeable supply is seen on line 150 . Because of the improved power efficiency of the present invention, the circuit can utilize unused energy to recharge the 3 V supply.
To implement these preferences, the 3 V supply is coupled to diode D 5 as shown, with the output of D 5 fed back to its input. Also, diode D 6 is coupled between the output of D 5 and V SOL+ as shown. Capacitor C 11 is coupled between V SOL+ and ground as shown. C 11 , preferably 0.1 μF, serves as a filter for V SOL+ . Capacitors C 10 and C 13 , coupled between the 3 V supply and ground, function to filter and smoothen the 3 V supply on line 100 . Preferably, C 10 and C 13 are each 3.3 μF. When light 256 reaches the solar cell, the voltage V SOL+ will increase until the solar cell reaches approximately 3.3 V (depending on the amount of incident light). The solar cell also functions to recharge the 3 V supply.
The power supply 250 delivers a 3 V signal along line 100 to the V CC pin of the 4060 chip 310 , to the V CC pin of the 4053 chip 320 , to the X 1 pin of the 320 (through R 16 ), to the Y 1 pin of 320 , to the Z 0 pin of 320 and to the collector of transistor Q 3 (through resistor R 15 ). The power supply delivers V SOL+ along line 150 to the collector of the phototransistor S 1 , to the supply for amplifier 210 , and to the base of transistor Q 1 (through resistor R 5 ).
When light incident on the solar cell increases, thereby causing an increase in voltage on line 150 , the voltage at the base of control transistor Q 1 will increase. Once the voltage at the base of Q 1 reaches approximately 0.6 V, Q 1 will turn “on” to activate the signal generator 325 . By only activating the signal generator when there is light incident on the solar cell, the power drain on the circuit is reduced because the signal generator will only be active when the welding helmet is likely to be in use. When the welding helmet is not in use, it is typically left in either a dark room or with its solar cell face down, which in either case would prevent the solar cell from triggering Q 1 . With Q 1 “off,” the signal generator will not drain the power supply. When the welding helmet is in use, it will be exposed to outdoor light, indoor light, or weld light. In these situations, the solar cell will trigger Q 1 to activate the signal generator.
The voltage at the base of Q 1 is set by the resistor divider circuit formed by the junction 101 of R 5 and R 7 as shown. Preferably, R 5 is 2 MΩ and R 7 is 1 MΩ. The emitter of Q 1 is grounded. The collector of Q 1 is connected to the 3 V supply through R 12 . The collector of Q 1 is also connected to the RESET pin of 310 via line 105 . The signal on line 105 serves to activate the signal generator 325 . Once Q 1 is turned “on,” the voltage at the collector of Q 1 will change from 3 V to substantially 0 V as a path to ground is created. This transition causes the signal on line 105 to go from high to low, which removes the reset signal from 310 . With the reset signal low, 310 begins toggling C IN and C OUT . The two C OUT pins and the C IN pin of 310 are connected to a charge pump 324 as shown. Charge pump 324 comprises capacitors C 2 , C 3 , C 4 , C 5 , C 6 , and C 7 and diodes D 1 , D 2 , D 3 , and D 4 as shown. The charge pump 324 functions to generate the signal used to set the voltage level of the “dark state” drive signal. This voltage level is sent to the delivery circuit 315 via line 104 . Preferably, this voltage level is set to be approximately −15 V using charge pump capacitors C 2 through C 7 of 0.1 μF apiece. The −15 V signal on line 104 is stored in capacitor C 8 , which is preferably 6.8 μF. RC circuit 327 sets the frequency of the charge pump. Preferably, the RC circuit is designed to produce a frequency of approximately 550 Hz using an R 1 of 2 MΩ, an R 2 of 1 MΩ, and a C 1 of 680 μF. This frequency can be passed through a binary counter in chip 310 to divide the frequency to about 0.5 Hz. The 0.5 Hz signal exits 310 through line 102 at pin Q 10 as shown. Line 102 delivers this frequency signal to pins B and C of the 4053 chip 320 . This frequency serves as the frequency for the “dark state” drive signal.
The output of the sensor circuit on line 211 is coupled to the base of control transistor Q 3 . The collector of Q 3 is connected to a 3 V power supply through R 15 . The collector of Q 13 is also coupled to the ground through capacitor C 14 . The collector of Q 3 is also coupled to pin A of the 4053 chip 320 via line 107 .
Pins B and C of the chip 320 receive the frequency signal 102 from signal generator 325 . Thus, pins B and C toggle at the frequency of frequency signal 102 , which is preferably 0.5 Hz. Pin A controls the selection of pins X 0 and X 1 . When pin A is “high,” pin X 1 is selected. When pin A is “low,” pin X 0 is selected. Pin B controls the selection of pins Y 0 and Y 1 . When pin B is “high,” pin Y 1 is selected. When pin B is “low,” pin Y 0 is selected. Pin C controls the selection of pins Z 0 and Z 1 . When pin C is “high,” pin Z 1 is selected. When pin C is “low,” pin Z 0 is selected. The selection of a particular pin means that the signal on the selected pin will be passed on to the output associated with the pair. For example, when pin A is “high,” pin X 1 is selected and the signal at pin X 1 is passed through to output pin X. When pin B is“low,” pin Y 0 is selected and the signal at pin Y 0 is passed through to output pin Y.
Pin X 0 is connected to the B 15 V voltage signal supplied on line 104 by signal generator 325 . Pin X 1 is connected to the 3 V power supply via R 16 . Thus, the status of the signal at pin A determines whether a B 15 V signal or a 3 V signal is passed through to output pin X. Pin Y 0 is connected to output pin X via line 106 . Thus, whatever signal is passed to X will be received at Y 0 . Pin Y 1 is connected to the 3 V supply. Pin Z 0 is also connected to the 3 V supply. Pin Z 1 , like pin Y 0 , is connected to output pin X via line 106 . Output pins Y and Z are connected to the shutter assembly 400 .
The signal on line 211 at the output of the sensor circuit 200 controls whether Q 3 is turned “off” or “on.” Q 3 needs a signal on line 211 of about 0.6 V to turn “on.” The sensor circuit 200 is configured to produce an output of at least 0.6 V when a welding arc is present. If no welding arc is present, Q 3 will not receive a sufficient voltage on line 211 to turn “on.”
When in the “off” state, the voltage on line 107 will be “high,” that is, substantially equal to the 3V supply. While pin A is “high,” the signal at pin X 1 is passed through to output pin X. Since pin X 1 is substantially 3 V, this signal will be passed to input pins Y 0 and Z 1 . Thus, when pin A is “high” (which corresponds to no welding arc being present), pins Y 0 , Y 1 , Z 0 , and Z 1 will all receive a substantially 3 V signal. Thus, as pins B and C alternate from “high” to “low” at 0.5 Hz (the frequency of signal 102 ) and pins Y 0 and Z 0 , and pins Y 1 and Z 1 are alternately passed through to output pins Y and Z, the resultant signal on lines 110 and 112 will be a substantially steady 3 V signal. This steady 3 V signal on lines 110 and 112 corresponds to a “clear state” drive signal, that is, the drive signal which will transition the shutter assembly to a clear state.
When the output of the sensor circuit 200 is sufficient to turn “on” Q 3 (indicating the presence of a welding arc), the signal on line 107 will quickly go from 3 V to 0 V as a path to ground is created through Q 3 . Thus, pin A will go “low.” When pin A is “low,” the signal at pin X 0 is passed through to output pin X. Since pin X 0 is B 15 V, this B 15 V signal will be received at pins Y 0 and Z 1 . As pins B and C alternate from “high” to “low” at 0.5 Hz (the frequency of signal 102 ), the value of Y will be 3 V when the value of Z is B 15 V and vice versa. The signal on line 110 will alternate between 3 V and B 15 V at 0.5 Hz. The signal on line 112 will alternate between 3 V and B 15 V at 0.5 Hz out of phase with the signal on line 110 . Thus, the resultant signal delivered to the shutter assembly 400 will be an 18 V square wave having a 0.5 Hz frequency. This 18 V, 0.5 Hz, square wave corresponds to a “dark state” drive signal, that is, the drive signal which will transition the shutter assembly to a dark state.
When the welding arc ceases, the voltage on line 211 will be insufficient to maintain Q 3 in an “on” state. Once Q 3 turns “off,” the signal on line 107 will return to a “high” state. However, this transition will not be instantaneous due to the RC circuit formed by R 15 and C 14 . The transition of 107 from “low” to “high” will be delayed as C 14 charges. By selecting the RC time constant for R 15 and C 14 , the delay can be set to accommodate brief “off” periods in the “on/off” pulsating light of various welding conditions. Before C 14 recharges, the light pulse of the weld arc will pass through the sensor circuit 200 and reactivate Q 3 to cause a quick transition on line 107 back to “low.” Preferably R 15 is 2 MΩ and C 14 is 0.1 μF. The “low-to-high” transition on line 107 will be about 0.25 seconds in a circuit with those parameters.
Sensor circuit 200 includes a phototransistor S 1 coupled to a feedback circuit 249 . Additionally, resistor R 13 is coupled between the base and emitter of the phototransistor. The output of phototransistor S 1 is sent to line 208 . A load resistor R 6 is connected between line 208 and ground. Additionally, a capacitor C 9 couples line 208 to line 209 . Resistor R 4 is connected between line 209 and ground. Line 209 is also connected to the noninverting input of amplifier 210 . Amplifier 210 is preferably configured as closed loop noninverting amplifier wherein the R 9 and R 3 feedback loop is connected to the inverting input of amplifier 210 as shown. The output of amplifier 210 on line 211 serves as the sensor circuit output. Line 211 is connected to the input of selector circuit 316 .
The solar cell 257 powers phototransistor S 1 and amplifier 210 via line 150 . Thus, if the solar cell is left unexposed to incident light, phototransistor S 1 and amplifier 210 will not receive power, thus preventing the phototransistor and amplifier from draining the power supply when the welding helmet is not in use (when not in use, the welding helmet is typically not exposed to light).
The feedback circuit 249 for the phototransistor S 1 comprises a resistor capacitor circuit 248 connected between the emitter of the phototransistor and ground, and a feedback transistor Q 2 having a base coupled to line 205 of the resistor capacitor circuit 248 , a collector coupled to the base of the phototransistor, and an emitter coupled to the ground via resistor R 10 .
Phototransistor S 1 serves as the weld sensor. It receives an input of incident light 256 and produces an output on line 208 representative of the intensity of the incident light. The phototransistor S 1 used in the present invention is preferably a planar phototransistor configured for a surface mount. The planar phototransistor is smaller than conventional metal can phototransistors, thus allowing a reduction in size of the unit in which the sensor circuit is implemented. While the metal can phototransistors used in the sensor circuits of the prior art had a thickness of about ½ inch, the planar phototransistors with a surface mount used in the present invention have a thickness of only about ¼ inch. This reduction is thickness allows the sensor circuit to be implemented into a smaller and sleeker unit. Further, the surface mount configuration of the phototransistor S 1 allows the phototransistor to be easily affixed to a circuit board. The inventor herein has found that the TEMT4700 silicon npn phototransistor manufactured by Vishay-Telefunken is an excellent phototransistor for the present invention as it has a smaller size than conventional metal can phototransistors and allows the sensor circuit to maintain a constant signal level without excessive loading or the drawing of excessive current.
The resistor capacitor circuit 248 and the feedback transistor Q 2 in the phototransistor feedback circuit 249 function to adjust the sensitivity of the phototransistor S 1 . The resistors R 8 and R 11 and capacitor C 12 are chosen to be of a size to provide a relatively large time constant, and therefore a relatively slow response to changes in voltage on line 208 . The delay exists because of the time it takes for the voltage on line 205 to charge to an amount sufficiently large to activate Q 2 . Exemplary values for R 8 and R 11 are 1 MΩ and 2 MΩ respectively. An exemplary value for C 12 is 0.1 μF. A detailed description of the operation of the resistor capacitor circuit 248 and feedback transistor Q 2 can be found in prior U.S. Pat. Nos. 5,248,880 and 5,252,817, the disclosures of which have been incorporated by reference.
R 13 functions to attenuate phototransistor output in response to low intensity incident light by essentially shutting down the phototransistor when low intensity light is present. R 13 further aids the response of the phototransistor by enabling the phototransistor to sharply increase its output when high intensity light is detected. R 10 , connected between the emitter of Q 2 and ground further improves the sensor circuit by attenuating phototransistor output in response to low intensity light signals. Load resistor R 6 is coupled between phototransistor output 208 and ground helps to further attenuate phototransistor output when low intensity light is incident upon the phototransistor. An exemplary value for R 10 is 20 kΩ. An exemplary value for R 6 is 1 MΩ.
Referring to FIGS. 3 a , 3 b , and 3 c , the operation of the sensor circuit 200 will be described. First, the phototransistor has operational characteristics similar to a photodiode whose output is fed into the base of a conventional npn transistor. The equivalent circuit for a phototransistor is depicted in FIGS. 3 a , 3 b , and 3 c . Photodiode 221 is connected between the base and collector of npn transistor 222 . Incident light will produce a photocurrent, I PHOTO , from the photodiode 221 . I PHOTO serves to feed the base of the transistor 222 . However, in the sensor circuit of the present invention, resistor R 13 is also coupled between the base and emitter of the phototransistor. Thus, in the equivalent circuit model, R 13 is connected between the base and emitter of transistor 222 as shown.
When light 256 first reaches the phototransistor, the phototransistor S 1 is in the “off” state. Additionally, feedback transistor Q 2 is in the “off” state. FIG. 3 a depicts the equivalent circuit model for the sensor circuit 200 in this mode of operation. In the equivalent circuit model, the photocurrent, I PHOTO , sees an essentially open circuit in the path to the base of transistor 222 because transistor 222 is “off.” Thus, I PHOTO passes through R 13 as shown in FIG. 3 a . The voltage drop across R 13 caused by I PHOTO will be equal to the base-emitter voltage drop across transistor 222 because R 13 is coupled between the base and emitter of 222 . To turn “on” the transistor 222 , the voltage drop across the base and emitter of transistor 222 needs to be about 0.47 V to 0.53 V. By selecting a value of R 13 that will keep the voltage drop across R 13 below 0.47 V to 0.53 V in response to a photocurrent that corresponds with low intensity incident light, R 13 can attenuate the phototransistor's output in response to low intensity incident light. An exemplary value for R 13 is 10 MΩ. Because the phototransistor is not turned “on,” the photocurrent is kept away from the base, preventing amplification of the photocurrent (the base of the transistor 222 drives the gain of the phototransistor S 1 ). When transistor 222 is turned “on,” photocurrent will feed the base of transistor 222 , and the output of the phototransistor will be amplified accordingly. Once on line 208 , the photocurrent will be further diverted to ground through R 6 , through the resistor capacitor circuit 248 , and through R 4 (via C 9 ). The current passing through the resistor capacitor circuit 248 will begin the charging of capacitor C 12 at line 205 .
As more light reaches the phototransistor, I PHOTO will increase. When I PHOTO is sufficiently large to create a voltage drop across R 13 of about 0.47 V to 0.53 V, the transistor 222 will turn “on.” Also, if intense incident light, such as light from a welding arc, reaches the phototransistor, a large photocurrent will be produced. The large photocurrent passing through R 13 will quickly create a voltage drop across R 13 that is sufficient to turn “on” transistor 222 , thus achieving a sharp increase in phototransistor output in response to high intensity light. While in the preferred embodiment R 13 is a resistor, it is conceivable that any nonreactive element providing a quick voltage drop in response to a current may be used in the invention.
When transistor 222 first activates, the feedback transistor Q 2 will still be in the “off” state while it waits for the voltage on line 205 to charge through capacitor C 12 . FIG. 3 b depicts the equivalent circuit model for the sensor circuit in this mode of operation. Part of I PHOTO will be fed into the base of transistor 222 and part of I PHOTO will be diverted through R 13 . The current fed into the base of 222 will drive the gain for the phototransistor. The output of the phototransistor on line 208 will be the sum of the emitter current of transistor 222 and the current diverted through R 13 . Once on line 208 , the current will be further diverted to ground through R 6 , through the resistor capacitor circuit 248 , and through R 4 (via C 9 ).
As previously explained, the current passing through the resistor capacitor circuit 248 will cause the capacitor C 12 to charge. As C 12 charges, the voltage on line 205 will begin to increase toward 0.6 V. Once the voltage on line 205 reaches about 0.6 V, the feedback transistor Q 2 is turned “on.” Once Q 2 is activated, it drains some of the photocurrent away from the base of the transistor 222 as shown in FIG. 3 c . By diverting photocurrent from the base of the phototransistor, the feedback transistor Q 2 decreases the gain provided by the phototransistor, thereby causing a drop in the phototransistor output despite an incident light level that remains essentially constant. This biasing operation allows the phototransistor to maintain a constant signal level for a steady light intensity.
The signal on line 208 if fed into an amplifier 210 . The signal is first passed through a capacitor C 9 to block the DC component of the detected signal. Line 209 contains the DC blocked detected signal. The current on line 209 is diverted to ground via resistor R 4 .
The sensor circuit operates in the presence of both AC welds and DC welds. In an AC weld (also known as a MIG weld), the welding light is pulsating. Thus, the phototransistor will detect a pulsating light signal. The frequency of the pulsations is often 120 Hz. In a DC weld (also known as a TIG weld), the welding light is substantially continuous, with the exception of a small AC component. When an AC weld is present, the phototransistor will produce a pulsating output on line 208 . The variations in the voltage signal due to the pulses will be passed through the capacitor to line 209 and fed into the amplifier. The amplifier will then provide gain for the signal on line 209 which is sufficient to trigger the delivery of a “dark state” drive signal to the shutter assembly 400 . The slow charge time of capacitor C 14 in selector circuit 316 will prevent the transition from a dark state to a clear state during brief interruptions in the AC weld pulses. Before C 14 recharges, the next AC pulse will cause the capacitor to discharge before a “clear state” drive signal is triggered.
When a DC weld is present, the phototransistor will quickly produce an output on line 208 catching the rising edge of the DC weld. This sudden rise in voltage on line 208 will be passed through to the amplifier 210 causing a signal on line 211 sufficient to trigger the delivery of a “dark state” drive signal to the shutter assembly 400 . Thereafter, capacitor C 9 will block the DC component of the DC weld, allowing only the AC variations in the DC weld to pass through to the amplifier. The amplifier 210 must have a gain sufficient to keep the shutter assembly in the dark state when the AC variations in the DC weld reach the amplifier.
The amplifier 210 is a closed loop, noninverting amplifier as described above. The output of the amplifier is fed into a selector circuit 316 . The selector circuit 316 uses a phototransistor to send a selection signal to the delivery circuit 315 via line 107 . As previously explained, for the selector circuit 316 to send a signal indicating that a “dark state” drive signal should be delivered to the shutter assembly, a 0.6 V signal needs to be applied to the base of control transistor Q 3 on line 211 . Thus, it can be seen that amplifier 210 must produce a signal of about 0.6 V on line 211 when the phototransistor produces a signal on line 208 indicative of the presence of a welding arc. The gain of amplifier 210 must therefore be set such that it will sufficiently amplify its input voltage to produce an output voltage of about 0.6 V when the input signal on line 209 indicates the presence of a welding arc. The gain of the amplifier 210 is set by resistors R 9 and R 3 in the feedback loop. The gain of the amplifier having this configuration is:
Gain=( R 9 / R 3 )+1
The inventor herein has noted that a gain of about 3.67 will be sufficient for the amplifier to trigger the “dark state” drive signal when a welding arc is lit. Exemplary values for R 9 and R 3 would be 1 MΩ and 374 kΩ respectively.
Referring to FIG. 4 , the output of the phototransistor will be described in relation to the amount of incident light. The curve of FIG. 4 depicts the output of the phototransistor on line 208 (on the vertical axis) as a function of the intensity of incident light (on the horizontal axis). The curve has a relatively steep portion 241 for lower intensity incident light and a less steep portion 242 for higher intensity incident light. The operation of the phototransistor in these portions of the curve are discussed in detail in prior U.S. Pat. Nos. 5,248,880 and 5,252,817, the disclosures of which have been incorporated by reference. Of note for the present invention is curve portion 243 which represents an extremely low voltage response from the phototransistor when the incident light has low intensity. This gap in the voltage response of the phototransistor is due to the effect of R 13 whereby it prevents the activation of the phototransistor in the presence of low intensity light. However, the invention still provides a sharp increase in phototransistor output when the light intensity increases as can be seen by the steep slope of curve portion 241 .
The invention has been disclosed herein in the context of the inventor's preferred embodiment. However, changes and modifications thereto as would be apparent to one of ordinary skill in the art are intended to be included by the inventor and the invention should be limited only by the scope of the claims appended hereto, and their equivalents.
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An auto darkening eye protection device including a shutter assembly, a light sensing circuit, a control circuit and a power supply source. The shutter assembly is adjustable to a plurality of shade levels. The phototransistor of the light sensing circuit senses light from a welding arc and provides an output of the light sensing circuit indicative of the shade level at which the shutter assembly should be operated. The phototransistor is configured for surface mount and has an external base connection connected to the base of the phototransistor. The control circuit is configured to receive the output from the light sensing circuit and provide a drive signal to the shutter assembly responsive to said output, drives the shutter assembly to one of said plurality of shade levels. The present invention provides reduced power consumption, improved attenuation of low intensity light signals, a sharp rise time from the phototransistor in response to high intensity light, and allows implementation into a smaller sleeker eye protection device.
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FIELD OF THE INVENTION
[0001] The present invention relates to the regulation of the expression of the high affinity IgE receptor γ-chain and more particularly relates to transcriptional control of the high affinity IgE receptor γ-chain gene and to the utilization of this transcriptional control.
BACKGROUND
[0002] The high affinity IgE receptor (referred to below as FcεRI) expressed on the cell membrane of mast cells and basophils is known to be a key glycoprotein in the type I allergic reaction. When antigen-specific IgE's bonded to FcεRI are crosslinked by the corresponding polyvalent antigen (for example, cedar pollen antigen for individuals suffering from cedar pollen allergy, dust mite antigen for individuals suffering from dust mite allergies), the FcεRI's are clustered, the signal transduction mechanism operates, and the mast cells undergo initial activation. As a result, various chemical transmitters that evoke allergic inflammation, i.e., most prominently the histamine preliminarily stored in cell granules, are released and the new synthesis and release of leukotriene, prostaglandin, and so forth, which are intracellular metabolites, is explosively induced, evoking a type I allergic reaction.
[0003] In addition, cytokine secretion from mast cells is promoted by the clustering of FcεRI's on the mast cells, inducing the expression of various adhesion molecules in the neighboring vascular endothelial cells. Eosinophils and lymphocytes in the blood aggregate by binding via these adhesion molecules to the vascular endothelial cells at the site of inflammation. The late allergic reaction is evoked as a result. Moreover, the FcεRI expressed by the Langerhans cells of the skin is presumed to contribute to the pathogenesis of atopic dermatitis by antigen presentation and cytokine production.
[0004] Based on the preceding, a promising strategy for the development of agents for allergy prophylaxis treatment is to target the FcεRI that specifically mediates type I allergy and thereby block signal transduction from this receptor at the point of origin.
[0005] FcεRI is also known to participate in platelet activation and glomerulonephritis, and given this it is also promising to carry out the development of thrombosis and glomerulonephiritis by targeting FcεRI.
[0006] In humans, human FcεRI functions expressed on the cell surface as a tetramer of an α-chain, a β-chain, and 2 γ-chains or as a trimer of an α-chain and 2 γ-chains. The extracellular region of the α-chain binds-directly to IgE while the β-chain γ-chain participate in signal transduction into the cell. The γ-chain assembles with the other molecules, which have a ligand binding site, to form a receptor on the cell surface. When ligand binds to the receptor's ligand binding site, the γ-chain transduces the signal into the cell.
[0007] For example, the γ-chain has been reported to perform the function of transmitting an activation signal into the cell in the FcεRI-mediated induction of allergic reactions (refer, for example, to Non-Patent documents 1 to 3). In addition, the γ-chain has been reported to induce the platelet activation reaction by associating with the collagen receptor GP VI on the platelet (refer, for example, to Non-Patent document 4).
[0008] The γ-chain is also a constituent element of the IgG receptors FcγRIII and FcγRI and the IgA receptor FcαR, and the suggestion has also been made these FcR's participate in glomerulonephritis-(refer, for example, to Non-Patent document 5).
[0000] Non-Patent document 1 Ra C et al., Nature, 341:752-754 (1989);
Non-Patent document 2 Blank U et al., Nature, 337; 187-189 (1989);
Non-Patent document 3 Kinet J P, Annual Review of Immunology, 17:931-972 (1999);
Non-Patent document 4 Konishi H et al., Circulation, 105(8):912-916 (2002);
Non-Patent document 5 Suzuki Y et al., Kidney Int., 54(4):1166-1174 (1998)
[0009] However, on the subject of transcriptional regulatory regions for the high affinity human IgE receptor γ-chain, only the analysis by Brini A T et al., in 1993 has been carried out, and to date no detailed analysis that precisely identifies transcriptional regulatory elements and/or transcriptional regulatory factors has been performed.
[0010] As a result of intensive investigations, the present inventors succeeded in identifying, from within previously unanalyzed regions, regions that participate in the transcriptional regulation of the human FcεRI γ-chain gene and in identifying transcription factors that bind to these regions and were thereby able to achieve the present invention.
SUMMARY
[0011] That is, the present invention provides (1) a DNA comprising the full length or a portion of the base sequence shown in SEQ ID NO:1, that regulates transcription of the human high affinity IgE receptor (FCεRI) γ-chain gene; (2) a method of regulating transcription of the FcεRI γ-chain gene, that regulates the binding of Sp1 with an FcεRI γ-chain gene transcriptional regulatory region comprising the full length or a portion of the base sequence shown in SEQ ID NO:1; (3) a method of screening for a compound, or salt thereof, that regulates the binding of Sp1 with an FcεRI γ-chain gene transcriptional regulatory region comprising the full length or a portion of the base sequence shown in SEQ ID NO:1; (4) a DNA comprising the full length or a portion of the base sequence shown in SEQ ID NO:2, that regulates transcription of the human high affinity IgE receptor (FcεRI) γ-chain gene; (5) a method of regulating transcription of the FcεRI γ-chain gene, that regulates the binding of Elf-1 or GABP α/β heterodimer with an FcεRI γ-chain gene transcriptional regulatory region comprising the full length or a portion of the base sequence shown in SEQ ID NO:2; (6) a method of screening for a compound, or salt thereof, that regulates the binding of Elf-1 or GABP α/β heterodimer with an FcεRI γ-chain gene transcriptional regulatory region comprising the full length or a portion of the base sequence shown in SEQ ID NO:2; (7) a DNA comprising the full length or a portion of the base sequence shown in SEQ ID NO:3, that regulates transcription of the human high affinity IgE receptor (FcεRI) γ-chain gene; (8) a method of regulating transcription of the FcεRI γ-chain gene, that regulates the binding of C/EBP with an FcεRI γ-chain gene transcriptional regulatory region comprising the full length or a portion of the base sequence shown in SEQ ID NO:3; (9) a method of screening for a compound, or salt thereof, that regulates the binding of C/EBP with an FcεRI γ-chain gene transcriptional regulatory region comprising the full length or a portion of the base sequence shown in SEQ ID NO:3. (10) a method of regulating transcription of the human high affinity IgE receptor (FcεRI) γ-chain gene by controlling functional regulation by at least one transcription factor selected from Sp1, Elf-1, GABP α/β heterodimer, and C/EBP or by controlling the interaction between or among transcription factors; (11) a vector that incorporates the full length or a portion of the base sequence shown in SEQ ID NO:1, SEQ ID NO:2, or SEQ ID NO:3; (12) a screening kit used in the screening method according to the preceding (3), (6), or (9); (13) a drug containing a compound, or salt thereof, that regulates transcription of the FcεRI γ-chain gene and is obtained using the screening method according to the preceding (3), (6), or (9) or the transcriptional regulatory method according to the preceding (10); (14) the drug described in the preceding (13), that is a prophylactic/therapeutic agent for allergic diseases or autoimmune diseases; (15) the drug described in the preceding (13), that is a prophylactic/therapeutic agent for thrombosis; and (16) the drug described in the preceding (13), that is a prophylactic/therapeutic agent for glomerulonephritis or lupus nephritis.
[0012] Thus, the present inventors cloned the human γ-chain gene and using a human cell line carried out a reporter assay on the region upstream from the translation initiation point. The presence of two enhancer elements in the nt-103/-75 region (here and in the following, the translation initiation point is designated as base number +1) was elucidated as a result, i.e., the region shown by SEQ ID NO:1, containing nt-98 to -96, and the region shown by SEQ ID NO:2, containing nt-84 to -82. With regard to these elements, it was found by EMSA that Sp1 binds to the former and that Elf-1 or GABP α/β heterodimer binds to the latter.
[0013] In addition, the region of SEQ ID NO:3, which contains nt-65 to -61 and exhibits homology with the C/EBP binding sequence, was found to contribute to activation of the γ-chain promoter. On the occasion of carrying out reporter assays while inducing overexpression of various combinations of these transcription factors, it was shown that transcription activation was synergistically increased and that the use of a plurality of the transcription factors resulted in cooperative activation of the γ-chain promoter.
[0014] Moreover, in view of the following facts as cited in the preceding: the γ-chain functions to transmit the activation signal into the cell during induction of the FcεRI-mediated allergic reaction, the γ-chain induces the platelet activation reaction by associating with the collagen receptor GP VI on the platelet, and the γ-chain is a constituent element of the IgG receptors FcγRIII and FcγRI and the IgA receptor FcαR and these FcR's participate in the pathogenesis of glomerulonephritis, the expression regulatory regions and control factors identified by the present inventors for the γ-chain gene are useful as targets for the development of prophylactic/therapeutic agents for, inter alia, allergic diseases, autoimmune diseases, thrombosis, glomerulonephritis, and lupus nephritis. The present invention is also useful for genetic analysis in personalized medicine.
[0015] The genomic structure and base sequence of the human FcεRI γ-chain gene have already been elucidated (GenBank, accession number M33196, SEQ ID NO:4). The phrase, “comprising the full length or a portion of the base sequence shown in SEQ ID NO:1”, used in the present invention means comprising the main portion essential for transcriptional regulation of the FcεRI γ-chain gene and in particular comprising a sequence based on nt-98 to -96 (the translation initiation point is designated as base number +1).
[0016] The phrase, “comprising the full length or a portion of the base sequence shown in SEQ ID NO:2”, used in the present invention means comprising the main portion essential for transcriptional regulation of the FcεRI γ-chain gene and in particular comprising a sequence based on nt-84 to -82 (the translation initiation point is designated as base number +1).
[0017] The phrase, “comprising the full length or a portion of the base sequence shown in SEQ ID NO:3”, used in the present invention means comprising the main portion essential for transcriptional regulation of the FcεRI γ-chain gene and in particular comprising a sequence based on nt-65 to -61 (the translation initiation point is designated as base number +1).
[0018] The “high affinity IgE receptor γ-chain” referenced in the present invention was discovered as a high affinity IgE receptor γ-chain, but subsequent findings have shown that, inter alia, other immunoglobulin Fc receptors also contain it in common as a constituent element, and at the present time it is also known as “immunoglobulin receptor γ-chain”.
[0019] The present invention provides base sequences that participate in transcriptional regulation of the human FcεRI γ-chain gene and establishes a method of screening for compounds and salts thereof that inhibit γ-chain expression and also establishes a kit for use in this screening method.
DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 shows the transcriptional regulatory activity according to a reporter assay of the 5′ region of the human FcεRI γ-chain gene;
[0021] FIG. 2 shows the identification of binding factors by a gel shift assay, wherein (A) is a competitive test using unlabeled double-stranded oligoDNA (the added unlabeled double-stranded DNA was as follows: lanes 3, 4; sequence identical to probe, lanes 5, 6; three bases substituted in the probe sequence) and (B) is a test using antibody;
[0022] FIG. 3 shows the identification of binding factors by a gel shift assay, wherein (A) is a competitive test using unlabeled double-stranded oligoDNA (the added unlabeled double-stranded DNA was as follows: lanes 3, 4: sequence identical to probe, lanes 5, 6: three bases substituted in the probe sequence) and (B) is a test using antibody;
[0023] FIG. 4 shows the effect of site-directed mutagenesis on human FcεRI γ-chain gene promoter activity; and
[0024] FIG. 5 shows the effect of the overexpression of the different transcription factors on human FcεRI γ-chain gene promoter activity in HeLa cells.
DETAILED DESCRIPTION
[0025] Embodiments of the present invention will now be described. The following embodiments are examples for the purpose of explaining the present invention, but the present invention should not be construed as limited only to these embodiments. The present invention can be implemented using various modalities while preserving the essential features of the present invention.
[0026] The present invention, based on the determination of DNA regions that participate in regulating transcription of the FcεRI γ-chain gene and the identification of transcriptional regulatory factors that bind to these regions, enables the construction of a method of screening for compounds and salts thereof that inhibit expression of the FcεRI γ-chain and of a kit for use in this screening. The present invention thereby contributes to the development of agents for the prophylaxis or treatment of allergic diseases, autoimmune diseases, thrombosis, glomerulonephritis, and lupus nephritis. For example, the development of compounds or salts thereof that inhibit γ-chain expression is possible based on the strategy of searching for substances that inhibit the binding of the identified transcriptional regulatory factor Sp1 with the specified gene region.
[0027] The aforementioned salt of a compound denotes, inter alia, a salt with a physiologically acceptable acid (for example, an inorganic acid or an organic acid) or a salt with a physiologically acceptable base (for example, an alkali metal). Physiologically acceptable acid-adduct salts are particularly preferred. Specific examples are salts with hydrochloric acid, phosphoric acid, hydrobromic acid, and sulfuric acid within the realm of inorganic acids and salts with acetic acid, formic acid, propionic acid, fumaric acid, maleic acid, succinic acid, tartaric acid, citric acid, malic acid, oxalic acid, benzoic acid, methanesulfonic acid, benzenesulfonic acid, and so forth within the realm of organic acids.
[0028] An FcεRI γ-chain gene transcription-regulating compound or salt thereof that is obtained using the screening method and screening kit according to the present invention is useful as an agent for the prophylaxis/treatment of allergic diseases, autoimmune diseases, thrombosis, glomerulonephritis, and lupus nephritis.
[0029] A compound or salt thereof obtained by means of the present invention can be used via the oral route as, for example, a tablet or pill, possibly sugar coated, a capsule, or a microcapsule, or can be used via a parenteral route in the form of an injectable, for example, a sterile solution or suspension with water or with a pharmaceutically acceptable liquid other than water. For example, production can be carried out by mixing a compound or salt thereof obtained by means of the present invention, in the unit dose form required for the elaboration of a generally recognized formulation, with, for example, a physiologically acceptable carrier, flavorant, filler, vehicle, preservative, stabilizer, binder, and so forth.
[0030] The amount of effective component in these formulations is an amount that provides an appropriate dose in the indicated range. Additives that can be incorporated into, for example, a tablet or capsule, can be exemplified by binders such as gelatin, corn starch, tragacanth, gum arabic, and so forth; fillers such as crystalline cellulose; swelling agents such as corn starch, gelatin, alginic acid, and so forth; lubricants such as magnesium stearate and so forth; sweeteners such as sucrose, lactose, saccharin and so forth; and flavorants such as peppermint, Japanese wintergreen ( Gaultheria adenothrix ) oil, and cherry. When the unit formulation takes the form of a capsule, starting material of the aforementioned type may also include a liquid carrier such as an oil or fat. Sterile compositions for injection can be formulated by the usual methods for producing a formulation, such as dissolving or suspending a natural vegetable oil or the like, such as sesame oil or coconut oil, and the active ingredient in a vehicle such as injection-grade water.
[0031] Examples of aqueous solutions for use as injection-grade water include physiological saline, isotonic solutions containing glucose and/or other adjuvants (such as D-sorbitol, D-mannitol, sodium chloride, and so forth), and suitable dissolution auxiliaries such as alcohols (e.g., ethanol), polyalcohols (e.g., propylene glycol, polyethylene glycol, and so forth), and nonionic surfactants (e.g., Polysorbate 80™, HCO-50, and so forth) can be used in combination therewith. Sesame oil and soy oil are examples of dissolution auxiliaries, and, for example, benzyl benzoate, benzyl alcohol, and so forth can be used in combination therewith as dissolution auxiliaries. Buffers (e.g., phosphate buffers, sodium acetate buffers, and so forth), analgesics (e.g., benzalkonium chloride, procaine chloride, and so forth), stabilizers (e.g., human serum albumin, polyethylene glycol, and so forth), preservatives (e.g., benzyl alcohol, phenol, and so forth), antioxidants, and the like may also be incorporated. The formulated injectable is usually filled into a suitable ampule.
[0032] A formulation obtained as described in the preceding is safe and exhibits low toxicity and can therefore be administered to, for example, mammals and warm-blooded animals (for example, human, rat, mouse, guinea pig, rabbit). The administered dose of a compound or salt obtained by means of the present invention will vary as a function of, inter alia, the targeted disease, the recipient of the administration, and the route of administration. As an example, when a compound or salt thereof obtained by means of the present invention is administered orally for the purpose of treating hay fever, 0.1 mg to 1.0 g and preferably about 1.0 mg to 50 mg of the compound or salt thereof is generally administered per day to an adult (60 kg).
EXAMPLES
[0033] The present invention is described in additional detail in the following using examples, but the present invention is not limited to these examples. The individual skilled in the art will be able to implement not only the examples given in the following, but will also be able to add various modifications; these modifications are also encompassed in the claims provided herein.
Example 1
Measurement of the Transcriptional Regulatory Activity of the 5′ region of the human FcεRI γ-Chain Gene
[0034] nt-103 to -1 and nt-74 to -1 at the 5′ region of the human FcεRI γ-chain gene were each incorporated upstream from the luciferase gene in the pGL3Basic Vector (Promega), a plasmid that contains the firefly luciferase gene as a reporter gene, to construct the respective reporter plasmids. 5 μg of the particular reporter plasmid and 0.1 μg pRL-CMV Vector (Promega), a plasmid encoding the Renilla luciferase gene under CMV promoter control, as the control were transfected into each of four γ-chain-expressing human cell lines (Jurkat, KU812, THP1, U937) by electroporation (300 V, 950 μF).
[0035] After cultivation for 20 to 24 hours at 37° C./5% CO 2 , the cells were recovered and cell lysis and measurement of the luciferase activity were carried out using a Dual Luciferase Assay Kit (Promega). At the time of measurement, the value of firefly luciferase activity/ Renilla luciferase activity was calculated for each sample and the plasmid transfection efficiency and cell lysis efficiency were corrected.
[0036] The relative activity is shown in FIG. 1 , where a value of 1 was assigned to the luciferase activity for transfection with a reporter plasmid containing only the firefly luciferase gene. As shown in FIG. 1 , in all of the γ-chain-expressing cell lines used, the -103 to -1 region caused a major enhancement in luciferase activity, while the -74 to -1 region showed almost no enhancement effect of this nature. This example demonstrated that a transcription activating element with a common function in the four cell lines is present in the -103 to -75 region.
Example 2
Identification of Factors Binding to nt-102 to -88
[0037] Gel shift assays were carried out using a nuclear extract prepared from KU812 cells and the FITC-labeled double-stranded synthetic oligoDNA probe 5′-ATGGGGGAAGGCGTG-3′ (corresponds to nt-102/-88 of the γ-chain gene).
[0038] Two unlabeled double-stranded synthetic oligoDNA's were used as the competitors: one having the same base sequence as the probe (comp) and one in which the three bases at nt-98 to -96 were changed (mut-comp).
[0039] 30 μl of the aforementioned nuclear extract and 5 pmol of the aforementioned probe and 25 or 250 pmol of the competitor were mixed in a 10 mM HEPES buffer (pH 7.9) containing 400 ng poly(dl-dC), 1 mM MgCl 2 , 30 mM KCl, 1 mM DTT, and 5% glycerol and this was allowed to stand for 20 minutes at room temperature. This was followed by submission to 4% polyacrylamide gel electrophoresis using 0.5×TBE buffer (45 mM Tris, 45 mM boric acid, 1 mM EDTA). After phoresis for 2 to 3 hours at 120 V, the FITC fluorescence was detected using a FluorImager 595 (Amersham Bioscience). The results are shown in FIG. 2(A) .
[0040] As shown in FIG. 2(A) , several bands were observed (lane 2) that were shifted to positions of lower mobility than the band for the probe by itself. Among these, the band indicated by the arrow was extinguished in a competitor concentration-dependent manner when comp was added at 25 and 250 pmol (lanes 3 and 4), while extinction of this band did not occur in the case of the addition of mut-comp at 25 and 250 pmol (lanes 5 and 6). This showed that this band was a band in which nuclear protein was bound with specific recognition of the sequence based on nt-98 to -96.
[0041] The same results were obtained for the use of nuclear extracts prepared from Jurkat, THP1, and U937.
[0042] In order to identify this nuclear protein, 2 μg antibody (Santa Cruz Biotechnology, Inc.) against each of the transcription factors USF-1, USF-2, Sp1, and Ikaros was added. As shown in FIG. 2(B) , the band indicated by the arrow was extinguished only for the addition of anti-Sp1 antibody. The same results were obtained for the use of nuclear extracts prepared from Jurkat, THP1, and U937. It was thus confirmed that the transcription factor Sp1 binds to the sequence based on nt-98 to -96.
Example 3
Identification of Factors Binding to nt-93 to -76
[0043] In order to identify factors binding to nt-93 to -76 of the human FcεRI γ-chain gene, a gel shift assay was carried out as in Example 2, but in this case using the double-stranded synthetic oligoDNA probe 5′GGCGTGGCAGGAAGAGGG-3′ as the probe and using, as the competitors, two unlabeled double-stranded synthetic oligo's, one having the same base sequence as the probe (comp) and one in which the three bases at nt-84 to -82 were changed (mut-comp). The results are shown in FIG. 3(A) .
[0044] As shown in FIG. 3(A) , the two bands indicated by the arrows underwent a competitor concentration-dependent extinction in the case of the addition of 25 and 250 pmol comp (lanes 3 and 4), but were not extinguished in the case of the addition of 25 and 250 pmol mut-comp (lanes 5 and 6). This showed that these bands were bands in which nuclear protein was bound with specific recognition of the sequence based on nt-84 to -82. The same results were obtained for the use of nuclear extracts prepared from Jurkat, THP1, and U937.
[0045] In order to identify this nuclear protein, 2 μg antibody (Santa Cruz Biotechnology, Inc.) against each of the transcription factors PU.1, Fli1, Elf-1, GABP α, and GABP β was added. As shown in FIG. 3(B) , of the two bands indicated by the arrows, the lower band was extinguished when anti-GABP α antibody and anti-GABP β antibody were added, while the upper band was extinguished by the addition of anti-Elf-1 antibody. The same results were obtained for the use of nuclear extracts prepared from Jurkat, THP1, and U937. It was thus confirmed that GABP α/β heterodimer and Elf-1 bound to the sequence based on nt-84 to -82.
Example 4
Influence of Base Substitution by Site-Directed Mutagenesis on γ-Chain Promoter Activity
[0046] The nt-177 to -1 fragment of the human FcεRI γ-chain gene was inserted upstream from the firefly luciferase gene in the pGL3Basic Vector (Promega), and the γ-chain gene fragment in the resulting plasmid was subjected to site-directed mutagenesis to construct four reporter plasmids. Thus, using a Quick Change Site-Directed Mutagenesis Kit (Stratagene), four reporter plasmids were obtained by replacing the following three or four bases, respectively: nt-98 to -96 (mut1), -84 to -82 (mut2), -77/-75/-74 (mut3), and -65/-64/-62/-61 (mut4). Proceeding as in Example 1, expression testing was carried out by transfecting the obtained reporter plasmids into human cell lines (Jurkat, KU812, THP1, U937). The relative activity is shown in FIG. 4 , where a value of 1 was assigned to the luciferase activity for transfection with the reporter plasmid in which mutation had not been induced. As shown in FIG. 4 , a decline in luciferase activity was observed for base substitution at nt-98 to -96, -84 to -82, and -65/-64/-62/-61, while the luciferase activity was unchanged for base substitution at -77/-75/-74.
[0047] The regions based on nt-98 to -96 and -84 to -82, which were shown in accordance with the preceding Examples 2 and 3 to bind, respectively, Sp-1 and GABP α/β or Elf-1, were confirmed in accordance with this example to function as transcription activation elements. In addition, the region based on nt-65 to -61, which is downstream from the preceding, was also shown to function as a transcription activation element. The region based on nt-65 to -61 is homologous with the binding motif of the C/EBP transcription factor. Moreover, when these results are considered in combination with the results of Example 1, the conclusion is drawn that this element has almost no transcription activating capacity by itself and functions cooperatively with the other two transcription activation elements.
Example 5
Influence of the Overexpression of Various Transcription Factors on γ-Chain Promoter Activity
[0048] Expression tests were carried out as in Example 1 by transfecting HeLa cells with 5 μg of a reporter plasmid prepared by inserting the nt-177 to -1 region of the human FcεRI γ-chain gene upstream from the firefly luciferase gene in the pGL3-Basic Vector (Promega) and with 3 μg of an expression plasmid for GABP α, GASP β, Elf-1, Sp1, and/or C/EBP α.
[0049] The relative activity is shown in FIG. 5 , where a value of 1 is assigned to the luciferase activity for transfection with only the reporter plasmid. The black bar in the graph in FIG. 5 shows the relative activity for transfection with the expression plasmid(s) for the particular transcription factor(s), while the white bar shows the relative activity for transfection with the same amount of the corresponding empty vector. As shown in FIG. 5 , the luciferase activity was increased several fold by the expression of GASP α/β only, or Elf-1 only, or Sp1 only, or C/EBP a only, in comparison to transfection with the empty vector, thus confirming that these transcription factors in fact activate the γ-chain promoter. In addition, a synergistic activation of the γ-chain promoter was shown for GABP α/β+Sp1+C/EBP α and for Elf−1+Sp1+C/EBP α.
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Transcriptional regulatory regions and transcriptional regulatory factors for the human high affinity IgE receptor (FcεRI) γ-chain gene are specified and are targets for the development of transcriptional regulatory agents for the FcεRI γ-chain gene. The following are provided: DNA comprising the full length or a portion of the base sequence shown in SEQ ID NO:1, that regulates transcription of the human high affinity IgE receptor (FcεRI) γ-chain gene; and DNA comprising the full length or a portion of the base sequence shown in SEQ ID NO:2, that regulates transcription of the human high affinity IgE receptor (FcεRI) γ-chain gene. The present invention is promising for the development of novel agents for the prophylaxis/treatment of allergic diseases, autoimmune diseases, thrombosis, glomerulonephritis, and lupus nephritis.
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BACKGROUND OF THE INVENTION
The present invention relates to a dielectric ceramic used in the microwave frequency region and a multilayer microwave device employing the dielectric ceramic.
In response to recent development of communications utilizing electromagnetic wave in the microwave frequency region, for example, a mobile phone, a portable phone and satellite broadcasting, there is a keen demand for compact equipments. To this end, each of components constituting each equipment should be made compact. In these equipments, dielectric material is incorporated, as a dielectric resonator, in a filter element or an oscillator element. In case an identical resonance mode is employed, size of the dielectric resonator is inversely proportional to square root of a dielectric constant of the dielectric material. Therefore, material having high dielectric constant is required for producing a compact dielectric resonator. In addition, in order to put a dielectric resonator to practical use, the dielectric loss should be low in the microwave frequency region, namely, the Q value should be high. Furthermore, change of resonant frequency with temperature should be small.
A number of ceramics for dielectric resonators have been developed so far. For example, U.S. Pat. No. 4,330,631 discloses BaO-TiO 2 -Sm 2 O 3 type ceramic as a ceramic having an especially high dielectric constant. This ceramic has a dielectic constant of about 80, a high Q value of about 3000 at 2 to 4 GHz and a small temperature coefficient of resonant frequency. Meanwhile, BaO-PbO-TiO 2 -Nd 2 O 3 type ceramic is reported as a ceramic having a dielectric constant of not less than 90 in Journal of American Ceramic Society, Vol. 67 (1984), p. 278-281.
Meanwhile, if conductive material and dielectric ceramic are of multilayer construction, the dielectric resonator can be made compact and have high functions. Conductive material for multilayer devices is required to have high conductivity for use at high frequency and therefore, should be Cu, Au, Ag or their alloy. On the other hand, dielectric ceramic for multilayer devices is required to be co-fired with the conductive metal and thus, should be fired under conditions in which the conductive metal is neither molten nor oxidized. Namely, dielectric material for multilayer devices should be sintered densely at low temperatures of not more than 1050° C. Furthermore, when Cu is used as the conductive metal, characteristics of dielectric material for multilayer devices should not deteriorate even in the case of firing at low partial pressure of oxygen.
However, known ceramics for microwave, including the above mentioned dielectric ceramic have a high firing temperature of about 1300° C. and thus, cannot be co-fired with the conductive metal having high conductivity, thereby resulting in failure in production of multilayer devices. Bi-based material is known as a dielectric ceramic suitable for low-temperature sintering. Especially, Bi 2 (ZnNb 2 )O 6 -Bi 3 (Ni 2 Nb)O 9 disclosed in U.S. Pat. No. 4,638,401 is a dielectric material for a multilayer capacitor and can be sintered at about 950° C. Furthermore, this dielectric material has a high dielectric constant of 90 and excellent temperature characteristics of the dielectric constant. However, not to mention this dielectric material, no dielectric ceramic having high dielectric constant is known which can be used at high frequency of not less than 100 MHz and sintered at low temperatures.
SUMMARY OF THE INVENTION
Accordingly, an essential object of the present invention is to provide not only a dielectric ceramic composition which can be co-fired with Cu, Ag, Au or their alloy and has excellent characteristics in the microwave frequency region but a multilayer microwave device employing the dielectric ceramic.
In order to accomplish this object of the present invention, a dielectric ceramic composition according to the present invention consists essentially of bismuth oxide, calcium oxide and niobium oxide, wherein when the dielectric ceramic composition is expressed by a formula xBiO 3/2 -yCaO-zNbO 5/2 and the x, y and z are plotted in a ternary system diagram so as to total 1.0, the x, y and z fall in a region enclosed by a pentagon having the following vertexes A, B, C, D and E,
A: (x, y, z)=(0.55, 0.16, 0.29)
B: (x, y, z)=(0.5, 0.21, 0.29)
C: (x, y, z)=(0.44, 0.24, 0.32)
D: (x, y, z)=(0.44, 0.2, 0.36) and
E: (x, y, z)=(0.5, 0.175, 0.325).
Furthermore, by employing the dielectric ceramic composition as a dielectric layer, the present invention provides a multilayer device in which Cu, Ag, Au or their alloy is used as a conductor.
The above mentioned dielectric ceramic is sintered densely even in the case of firing in air or N 2 of not more than 1050° C. and under low partial pressure of oxygen, e.g in N 2 and exhibits in the microwave frequency region of 2 to 6 GHz, excellent characteristics such as a dielectric constant of not less than 50, a Q value of not less than 300 and an absolute value of temperature coefficient of resonant frequency of not more than 50 ppm/°C.
Furthermore, by using the above mentioned dielectric ceramic, it becomes possible to produce a multilayer device employing a metal having high conductivity, for example, Cu, Ag, Au or their alloy as conductive material.
BRIEF DESCRIPTION OF THE DRAWINGS
This object and features of the present invention will become apparent from the following description taken in conjunction with the preferred embodiments thereof with reference to the accompanying drawings, in which:
FIG. 1 is a diagram showing composition of a dielectric ceramic consisting of ternary system, according to the present invention;
FIG. 2 is a longitudinal sectional view of a 10 multilayer dielectric resonator including the dielectric ceramic of FIG. 1;
FIG. 3 is a transverse sectional view of the multilayer dielectric resonator of FIG. 2;
FIG. 4 is a perspective view of the multilayer dielectric resonator of FIG. 2; and
FIGS. 5(a) to 5(c) are diagrams showing printing patterns of inner conductive layers of the multilayer dielectric resonator of FIG. 2 as observed in the directions of the arrows Va, Vb and Vc in FIG. 2, respectively.
Before the description of the present invention proceeds, it is to be noted that like parts are designated by like reference numerals throughout several views of the accompanying drawings.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1, the hatched pentagon A, B, C, D and E in an equilateral triangle shows composition of a dielectric ceramic composed of bismuth oxide, calcium oxide and niobium oxide, according to the present invention.
Initially, a first embodiment of the present invention is described. Bi 2 O 3 , CaCO 3 and Nb 2 O 5 which are highly pure chemically are employed as starting materials for the dielectric ceramic and purity of each of the starting materials is corrected. Then, the starting materials are measured such that the dielectric ceramic has a composition expressed by a formula xBiO 3/2 -yCaO-zNbO 5/2 where x, y and z assume values shown in Table 1 below so as to total 1.0, namely, x+y+z=1.0. Subsequently, powders of these starting materials are put into a ball mill made of polyethylene. Thereafter, stabilized zirconia balls and pure water are added to the powders and mixed with the powders for 17 hours. Then, the slurry is dried and put into a crucible made of alumina so as to be calcined at 800° C. for 2 hours. The calcined powder is ground by as same method as mixing and dried, so that raw material powder is obtained. Subsequently, 6% by weight of aqueous solution of polyvinyl alcohol having a concentration of 5% is mixed with the raw material powder as a binder and then, is passed through a sieve having a 32-mesh so as to be granulated. Then, the granulated powder is pressed into a cylinder of 13 mm in diameter and about 5 mm in thickness at 100 MPa. The pressed body is heated at 650° C. for 2 hours such that the binder is burned out. Then, after the body has been put into a vessel made of magnesia, a lid is placed on the vessel. The vessel is held in air at 850 to 1100° C. on 2 hours so as to fire the body. Dielectric characteristics are measured about the sintered body which is fired at a temperature giving a maximum density. Results are shown in Table 1 below.
In Table 1, sample Nos. having the symbol "#" denote comparative examples falling out of the scope of the present invention.
TABLE 1______________________________________ Firing Di-Sample Composition temp. electric Q .sup.τ fNo. x y z (°C.) constant value (ppm/°C.)______________________________________ 1# 0.55 0.165 0.285 950 67 270 +57 2 0.55 0.16 0.29 950 70 310 +48 3# 0.55 0.155 0.295 1000 72 250 +40 4# 0.525 0.19 0.285 925 59 260 +41 5 0.525 0.175 0.30 950 66 340 +41 6# 0.525 0.165 0.31 975 72 280 +33 7# 0.5 0.215 0.285 925 55 220 +20 8 0.5 0.21 0.29 950 57 320 +21 9 0.5 0.19 0.31 975 65 480 +2910 0.5 0.175 0.325 1025 71 330 +3011# 0.5 0.165 0.335 1075 81 110 +512 0.49 0.2 0.31 975 60 590 +2613 0.475 0.2 0.325 1000 62 630 +1514# 0.46 0.235 0.305 975 59 270 +2615 0.46 0.215 0.325 1000 58 930 +2116# 0.46 0.185 0.355 1100 73 150 -2017 0.45 0.215 0.335 1025 58 460 +1618 0.44 0.24 0.32 1000 63 300 +2819 0.44 0.2 0.36 1025 70 310 -1520# 0.435 0.215 0.35 1025 68 270 -19______________________________________
In Table 1, the resonant frequency and the Q value are determined by dielectric resonator method. The dielectric constant is calculated from dimensions of the sintered body and the resonant frequency. The resonant frequency is 3 to 5 GHz. Meanwhile, by measuring the resonant frequency at -25° C., 20° C. and 85° C., temperature coefficient of resonant frequency τ f is obtained by method of least squares as shown in Table 1.
As will be seen from Table 1, the dielectric ceramic of the present invention is sintered densely at a low temperature of not more than 1050° C. and exhibits a dielectric constant of not less than 50, a Q value of not less than 300 and a small absolute value of not more than 50 ppm/°C. of temperature coefficient of resonant frequency. Meanwhile, also in the case of firing in N 2 , there is characteristics. The samples of the comparative examples have a Q value of not more than 300 and therefore, are not suitable for practical use.
Hereinbelow, a second embodiment of the present invention is described with reference to Table 2 below. In Table 2, sample Nos. having the symbol "#" denote comparative examples falling out of the scope of the present invention, while character c represents a value of {(Cu/(Bi+Ca+Nb)}. As shown in Table 2 below, two kinds of compositions are selected as main compositions of the dielectric ceramic and various amounts of CuO are added to the compositions as Cu components.
TABLE 2______________________________________ Di-Sam- Firing electric .sup.τ fple Composition temp. con- Q (ppm/No. x y z c (°C.) stant value °C.)______________________________________1 0.49 0.20 0.31 0 975 60 590 +262 0.49 0.20 0.31 0.01 925 61 580 +233 0.49 0.20 0.31 0.04 900 59 370 +214# 0.49 0.20 0.31 0.05 900 57 190 +205 0.45 0.215 0.335 0 1025 58 460 +166 0.45 0.215 0.335 0.005 950 59 490 +147 0.45 0.215 0.335 0.04 925 57 330 +128# 0.45 0.215 0.335 0.05 900 56 130 +10______________________________________
Preparation of the sintered body and evaluation of dielectric characteristics of the sintered body are performed in the same manner as in the first embodiment of the present invention.
It will be understood from Table 2 that addition of Cu in the samples of the present invention do not deteriorate microwave characteristics of the dielectric ceramic. On the other hand, addition of Cu in the samples of the comparative examples lowers the Q value in microwave characteristics of the dielectric ceramic. Consequently, it is desirable that the value c of {Cu/(Bi+Ca+Nb)} is not more than 0.04, i.e., {Cu/(Bi+Ca+Nb)}≦0.04.
Furthermore, a third embodiment of the present invention is described with reference to FIGS. 2 to 4 showing a dielectric resonator. As a multilayer microwave device, the dielectric resonator includes a dielectric layer 1, inner conductive layers 2, 3 and 4 embedded in the dielectric layer 1 and an outer electrode 5. A capacitor for an input is formed between the inner conductive layers 3 and 4 so as to act as a built-in capacitor. The dielectric layer 1 is made of the dielectric ceramic according to the second embodiment of the present invention. Firstly, production of the dielectric resonator is described. Initially, calcined dielectric powder is prepared in which 0.1% by weight of CuO is added to the composition of the sample No. 12 of Table 1. Organic binder, solvent and plasticizer are added to and mixed with the calcined powder so as to obtain slurry. The slurry is formed into a sheet by doctor blade method. By selecting one from various metals shown in Table 3 below as a conductive metal, the metal is kneaded with vehicle so as to obtain paste.
TABLE 3______________________________________ ResonantConductive frequency Unloadedmetal (MHz) Q value______________________________________Cu 855 170Ag 850 19099Ag--1Pt 845 18095Ag--5Pd 845 170Au 860 180______________________________________
If the conductive metal is Cu, paste of CuO is employed. FIGS. 5(a) to 5(c) show printing patterns of the inner conductive layers 2, 3 and 4 of the dielectric resonator, respectively. In FIG. 5, the inner conductive layer 3 is set to a length of 13 mm. After a plurality of sheets have been laminated, the conductive pattern of the inner conductive layer 2 is formed by screen printing method. Moreover, after a plurality of sheets have been laminated thereon, the conductive pattern of the inner conductive layer 3 is printed. In addition, a plurality of sheets have been laminated on the inner conductive layer 3, a conductive pattern of the inner conductive layer 4 is printed. Subsequently, a plurality of sheets are laminated thereon and then, the lamination body is thermal pressed. After the product has been cut into individual chips, the chips are heat treated in air such that the binder is burned out. In case paste of CuO is employed, the chips are heat treated in H 2 so as to reduce the conductor to Cu and then, are fired in N 2 . When other metals than CuO are used as the conductive metal, the chips are fired in air at 900° C. Then, commercially available paste of Cu is fired as the outer electrode 5 in air. As a result, a multilayer dielectric resonator is obtained. After firing, length of the inner conductive layer 3 ranges from 11.4 to 12.5 mm. For each of the conductive metals of Table 3, 10 chips are produced and dielectric characteristics are determined by using their average. Thus, resonant frequency and unloaded Q value of the dielectric resonator are obtained as shown in Table 3.
As shown in Table 3, since resonant frequency is 850 MHz or so and unloaded Q value is higher than 100 when any one of Cu, Au, Ag and their alloy is employed as the conductive metal, the dielectric resonator has excellent dielectric characteristics.
It is to be noted that dielectric constant of conventional low-temperature firing material for a substrate is about 8. Therefore, if a resonant frequency identical with that of the present invention should be obtained in the same construction as that of the third embodiment by using the conventional low-temperature firing material for a substrate, the inner conductive layer 3 needs to have a length of 31.5 mm. On the other hand, since dielectric constant of the dielectric material of the present invention is as high as 60, length of the inner conductive layer 3 is as short as 11.5 mm and thus, the dielectric resonator having a resonant frequency of 850 MHz can be made compact remarkably.
Meanwhile, if the inner conductive layer 3 is formed into a curved shape or a stepped shape, the dielectric resonator can also be made further compact. By combining a plurality of these inner conductive layers 3 with a capacitor, etc., a band-pass filter or the like can also be obtained.
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A dielectric ceramic composition which consists essentially of bismuth oxide, calcium oxide and niobium oxide, wherein when the dielectric ceramic composition is expressed by a formula xBiO 3/2 -yCaO-zNbO 5/2 and the x, y and z are plotted in a ternary system diagram so as to total 1.0, the x, y and z fall in a region enclosed by a pentagon having the following vertexes A, B, C, D and E,
A: (x, y, z)=(0.55, 0.16, 0.29)
B: (x, y, z)=(0.5, 0.21, 0.29)
C: (x, y, z)=(0.44, 0.24, 0.32)
D: (x, y, z)=(0.44, 0.2, 0.36) and
E: (x, y, z)=(0.5, 0.175, 0.325); and
a multilayer microwave device including a dielectric layer formed by the dielectric ceramic composition.
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CROSS REFERENCE TO RELATED APPLICATION
The present application is a continuation of U.S. patent application Ser. No. 07/471,859 now abandoned, filed Jan. 29, 1990, which was a continuation-in-part of U.S. application Ser. No. 07/266,399 filed Jul. 29, 1988, now U.S. Pat. No. 4,896,833.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to salt, pepper and granular, powdery, or other particle condiment dispensers. More particularly, the present invention relates to sprayers utilizing air pressure within a container to eject particles stored within the container to form a spray of air and suspended particles.
2. Description of the Prior Art
The common and readily available salt and pepper shaker, as well as similar structures for other condiments, are well known. The salt and pepper, hereinafter referred to generally as particulate material, are stored within a container and poured from the container onto food through a pattern of holes in a top of the container. The principal drawback to the common device is the inability to measure even reasonably precisely the amount of particulate material to be deposited onto the food. In addition, material is easily spilled if the common devices are turned over or upset for any reason.
U.S. Pat. No. 2,609,971 to M. Vivolo shows a salt dispenser in which salt flows by gravity into an air passage in a small but uncontrolled accumulation. Squeezing a bulb generates a pulse of compressed air, which flows through the passage and carries the salt out of the dispenser. Vivolo incorporates a storage area with a convex bottom having a hole at the lowermost position for the feeding of the particulate material through the hole and into the passage. The passage communicates with the bulb to receive compressed air to force the particulate material through a projecting nipple for dispensing onto the food.
The difficulty with Vivolo, as well as all of the prior art using air pressure to force particulate material along a passage, is that the air which flows along the passage must force the material directly from the dispenser. This process has three drawbacks. Firstly, the passage is more likely to be clogged by the particulate material as some material is pushed by air pressure, while other material is moved by collisions with the material directly influenced by air pressure. Secondly, the particulate material is not necessarily dispersed evenly into the spray of air by the pulse of air generated. Thirdly, it is not likely that any preselected amount of particulate material will be dispensed, since the volume of the passage available for a pulse of air is not controlled nor controllable.
Italian Patent No. 449,894 is also a sprayer utilizing a piston and bellows to eject particulate material from the device. As in Vivolo the material is deposited into a passage and then air pressure is used to eject the material. A linkage meters the particulate material into the passage tube.
U.S. Pat. No. 3,785,568 to E. Pfingsten passes a gaseous fluid at pressure through a tube which intersects and communicates with a second depending tube. The depending tube extends into a reservoir of material. The passage of the gaseous fluid develops a low pressure area in the depending tube which causes the material to be elevated into the gaseous fluid stream and carried away. Pfingsten does not use direct air pressure to move particulate material and therefore defines a more evenly dispersed spray. However, Pfingsten still moves material with direct air pressure down a common feed tube, which is more likely to be clogged.
U.S. Pat. No. 2,126,924 to W. Rose is a dust sprayer utilizing a manually operated plunger to force air through openings over one end of a tube. The other end of the tube communicates with a dust filled zone above powder stored in a container. The air flow generated by the plunger over the openings generates a low pressure zone, which draws dust up the tube. The same plunger action forces air down another tube and through a powder body to enhance the efficiency of the sprayer by creating a dust cloud into which the first tube depends. Rose is similar to Pfingsten in using high velocity air, created by a plunger, to draw powder into a tube by creating a low pressure zone.
U.S. Pat. No. 4,120,427 to J. McRoskey, et al. shows a powder container including an annular air channel through which air is forced by the action of a diaphragm. This action reduces the volume of the container. Venturi openings connect the interior of the container with a channel which allows powder to be drawn into the channel and exhausted through a discharge nozzle.
U.S. Pat. No. 1,554,991 to J. Crowley forces air through a nozzle to draw powder from a reservoir. Crowley uses gravity in combination with air pressure to move the powder.
U.S. Pat. No. 2,202,079 to W. Ayres shows a dispenser for powder which employs air flow through tubes to generate suction at venturi locations, drawing powder into the air flow for transport out of the dispenser. Again, positive air pressure, rather than negative or low pressure, is used to move the material.
U.S. Pat. No. 2,358,329 to E. Houghton compresses air in a chamfer by depression of a member, forcing air through a tube, past a slot and to a tube exit. The slot communicates with powder in a container. The passage of the high pressure air over the slot draws powder into the air stream under the influence of the low pressure thereby created.
U.S. Pat. No. 3,904,087 to J. McRoskey, et al. uses a longitudinally extending tube with spaced venturi openings to pull powder into an air stream passing vertically upward through the tube. Squeezing and releasing an outer container forces the material from an inner container into the tube, through a nozzle, ejecting the material from the device.
My copending patent, U.S. Pat. No. 4,896,833, is similar to the present invention. However, that patent does not control air flow after a piston has been activated to spray the particulate material.
OBJECTS AND SUMMARY OF THE INVENTION
It is the principal object of the present invention to provide an air powered dispenser for spraying particulate material using positive air flow to create a low pressure area to draw particulate material from the bottom of the dispenser and to then eject the particulate material in an evenly dispersed spray, while preventing negative air flow from establishing a back pressure drawing the particulate material into an air compartment of the dispenser.
In accordance with the object of the invention, a particulate material sprayer includes a container divided into an upper air compartment and a lower storage compartment. The air compartment is separated from the storage compartment by a mid portion bulkhead. A piston or air moving means is slidably mounted in the air compartment and is biased away from the bulkhead by a spring. Manual downward displacement of the piston forces air from the air compartment through an air passageway creating a positive air flow out of the sprayer.
A vertical tube extends downwardly into the storage compartment, which storage compartment holds salt, pepper or other condiments, hereinafter referred to as particulate material. The vertical tube is in air flow communication with the air passageway. A venturi opening is located in the air passageway at the intersection of the vertical tube and the air passageway. High pressure or compressed air in the air passageway results from downward movement of the piston in the air compartment. The air flows in a positive flow direction past the venturi opening at an increased velocity and creates a low pressure area or zone at the top of the vertical tube. The low pressure zone draws particulate material from the storage compartment via the vertical tube. The material is dispersed into the air ejecting from the sprayer through an outlet, creating a spray of air dispersed with suspended material. The creation of a low pressure area by a venturi opening removed from the particulate material minimizes the chances of clogging the air passageway or the vertical tube. Each actuation of the piston disperses a spray having an amount of material which is directly proportional to the extent that the piston is depressed.
After the piston has been compressed, it is released and moves upwardly in the air compartment under the influence of the spring. This upward movement of the piston in the air compartment establishes an air flow in a negative flow direction over the vertical tube. A low pressure area is again created that tends to draw particulate material from the storage compartment. Were particulate material drawn up the vertical tube and into the air passageway, there is a likelihood that some particulate material would enter the air compartment and interfere with the operation of the piston. Means for controlling air flow include a relief passageway and a one-way or non-return valve formed in the sprayer. Air flow communication between the air compartment and the outside ambient air is established through the relief passageway. The one-way valve prevents positive air flow from exiting the sprayer through the relief passageway when the sprayer is actuated. The release of the piston, and the creation of a negative air flow, allows the relief passageway and associated one-way valve to draw air into the air compartment of the dispenser, preventing negative air flow from raising any particulate material from the storage compartment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a particle sprayer of the present invention.
FIG. 2 is a fragmentary sectional view taken along line 2--2 of FIG. 1, the sprayer shown spraying particulate material and creating a positive air flow exiting the sprayer.
FIG. 3 is a fragmentary sectional view similar to FIG. 2, the sprayer shown creating a negative air flow entering the sprayer.
FIG. 4 is an enlarged fragmentary sectional view taken in the plane of line 4--4 of FIG. 3.
FIG. 5 is an enlarged fragmentary sectional view taken in the plane of line 5--5 of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIG. 1, a particle sprayer 10 is used to dispense a spray 11 (FIG. 2) of air and salt, pepper or other condiment, hereinafter referred to as particulate material 12. (FIG. 3). The sprayer 10 is particularly useful to dispense, in the spray 11 of air and suspended particulate material 12, a predetermined amount of the material 12. The spray 11 dispenses the material 12 at the predetermined amount by manually pressing a button 14 to the limit of its downward motion. Lesser amounts can be measured by depressing the button 14 over lesser downward motions.
As seen in FIGS. 2 and 3, the button 14 is integrally connected to a circular piston 16, comprising air moving means, which slides along an inner surface of a main body 18 of the sprayer 10. The movement of the piston 16 creates a positive air flow out of the sprayer 10 and along an air passageway 20 of essentially constant cross sectional area and past an outlet orifice 22 of a vertical discharge tube 24. The tube 24 extends into the air passageway 20 to provide air flow communication between the tube 24 and the air passageway 20. The tube 24 partially closes the air passageway 20, forming a restriction in the cross sectional area of the air passageway 20, hereinafter referred to as a venturi opening 64.
The other end of the tube 24 is inserted into the particulate material 12. Low pressure developed at the outlet orifice 22, located immediately adjacent the venturi opening 64, draws the particulate material 12 up the discharge tube 24, where the material 12 is mixed with the air in the passageway 20. An outlet 26 formed in the main body 18 is immediately downstream of the outlet orifice 22 and registers with the air passageway 20. The material 12 is dispersed into the air and ejected from the sprayer 10 through the outlet 26. The result is an even dispersion of the particulate material 12 with the air. The chance of blocking either the air passageway 20 or the discharge tube 24 is significantly reduced.
To further reduce the chance of blocking the air passageway 20, or even drawing material into an air compartment 52 within which the piston 16 slides, an air relief passageway 27 and one-way or non-return valve 29 (FIGS. 4 and 5) formed interiorly of the main body 18. The relief passageway 27 provides air flow communication between the air compartment 52 and the exterior of the sprayer 10. Blockage of the air passageway 20 is prevented by controlling the air flow path out of the sprayer 10, the positive air flow (FIG. 5), as well as the air flow path into the sprayer 10, negative air flow (FIG. 4). The one way valve 24 insures that during positive air flow, as the piston 16 is depressed, all of the air in the air compartment 52 is directed along the passageway 20. Similarly, upon release of the button 14 and the raising of the piston 16, at least some air flows into the sprayer 10 along relief passageway 27 and past the one-way valve 29, rather than principally along the air passageway 20 and past the venturi 64 in a manner which might raise some of the material 12 in the tube 24 and deposit it in the air passageway 20. It is important to keep the air passageway 20 clear of particulate material so that there is a minimal chance of any of the particulate material entering the air compartment 52 and possibly damaging the seal between the piston 16 and an inner surface 50 of the air compartment 52.
The main body 18 is of generally cylindrical shape and of a suitable size to be grasped easily by the human hand. The body 18 includes a top end 28 and a bottom end 30. The top end 28 includes a raised portion 32 integrally connected to a land portion 34 through an arcuate surface 36. The button 14 projects through a slot 38 formed in the land portion 34 and the arcuate surface 36.
The bottom end 30 of the main body 18 includes a circular opening 40 through which opening 40 the particulate material 12 is deposited into a storage compartment 42 formed interiorly of the main body 18. An end cap 44 threadably connects to the bottom end 30 to close the circular opening 40 and maintain the material 12 in the sprayer 10. (FIG. 2).
The button 14 and the piston 16 are integrally formed as by plastic injection molding or similar conventional manufacturing process. The button 14 is biased by spring 46 to a position wherein a finger pad 48 of the button is essentially flush with and coplanar with the raised portion 32 of the main body 18. The integral piston 16 is of disc shape and extends radially from a longitudinal axis of the main body 18 to sealingly contact the inner surface 50. The air compartment 52 defined by the inner surface 50 of the main body 18 extends downwardly from the top end 28 a predetermined distance equal to the stroke of the piston 16 as established by manually depressing the button 14.
A bulkhead or middle portion 54 separates the air compartment 52 from the storage compartment 42. The bulkhead 54 is separately formed, as by injection molding. During assembly of the sprayer 10, the bulkhead 54 is inserted through the circular opening 40 into the main body 18 and connected to the inner surface 50 at a preselected location in any conventional manner. The bulkhead 54 includes a cavity 55 into which the one-way valve 29 is seated. The one-way valve 29 is made of flexible material like rubber or a polymer. As shown, the valve 29 is a "beak" valve, but could be of other non-return valve designs.
The piston 16 includes an integral central post 56 lying along the longitudinal axis of the sprayer 10 and projecting downwardly from the piston 16 directly under the finger pad 48 of the button 14. The spring 46 is coaxial with the central post 56, which post 56 is inserted into the spring 46. The bulkhead 54 includes an upward sleeve or guide 58 which is circumscribed by the spring 46.
Manually actuating the button 14 causes the piston 16 to descend into the air compartment 52 and compresses the spring 46 about the central post 56 and the sleeve or guide 58. (FIG. 2). As the piston 16 descends in the air compartment 52, positive air flow from the air compartment 52 enters the air passageway 20. Air flow out of the sprayer 10 along the relief passageway 27 is prevented by the one-way valve 29. (FIG. 5). The air passageway 20 includes an inlet 60 formed by drilling, molding or similar process in a top planar surface 62 of the bulkhead 54. From the inlet 60, the air passageway 20 turns through an elbow to extend radially away from the longitudinal axis of the sprayer 10 toward the vertical discharge tube 24 and the outlet 26. The vertical discharge tube 24 frictionally fits into a bore 61 formed in the bulkhead 54. The outlet orifice 22 of the discharge tube 24 extends into the air passageway 20 and restricts the cross-sectional area of the air passageway 20 through which air flows, defining the venturi opening 64.
A low pressure area 66 is defined adjacent to the outlet orifice 22 of the discharge tube 24. The low pressure area 66 acts with the discharge tube 24 to pull the particulate material 12 from the storage compartment 42 and out the outlet 26.
The end cap 44 includes a raised central portion 68 which directs the material 12 downwardly to a peripheral feed trough 70 adjacent to an input orifice 72 of the discharge tube 24.
In operation, the button 14 and integral piston 16 are depressed into the air compartment 52. (FIG. 2). Air under pressure is forced into the inlet 60 and directed along the air passageway 20. The venturi opening 64 increases the velocity of the positive air flow in the air passageway 20, creating the low pressure area 66. The particulate material 12, which is directed into the feed trough 70, and/or is located in the discharge tube 24, is drawn up the discharge tube 24-and dispersed into air exiting through the outlet 26 as the spray 11. The particulate material 12 is deposited in an amount depending on the extent to which the piston 16 is depressed. Release of the piston 16 creates some back pressure along the air passageway 20. Any of the particulate material 12 deposited in the air passageway 20 downstream of the venturi opening 64, and not discharged, might be drawn back into the air passageway 20, or even the air compartment 52. This is undesirable and might ultimately cause corrosion, blockage or deterioration of the seal between the piston 16 and the interior surface 50. To help control this problem, the outlet orifice 22 of the discharge tube 24 extends partially across the passageway 20 and the one-way valve and relief passageway 27 are operative during negative air flow to prevent air flow in the passageway 20.
Any back pressure along the air passageway 20 will draw the material 12 toward the outlet orifice 22 where the material 12 will be physically blocked from further travel up the air passageway 20 by the outlet orifice 22. The orifice 22 includes a chamfer surface 65, which angles downwardly from the venturi opening 64 to a position flush with the air passageway 20. The orifice 22 is of substantially the same diameter as the air passageway 20, so that any material 12 suspended in a back flow will strike the discharge tube 24, and because of the chamfer surface 65, drop down the tube 24 and remain in the tube 24 until discharged, or will drop into the storage compartment 42.
During a negative air flow situation (FIGS. 3 and 4), the one-way valve 29 opens under the negative pressure created in the air compartment 52 relative to air pressure outside the sprayer 10. The one-way valve 29 must open at a relatively low pressure differential between the pressure in the air compartment 52 and that in the cavity 55 so that the majority of negative air flow into the air compartment 52 occurs along the relief passageway 27 and through the return valve 29, rather than along air passageway 20. Whatever negative air flow occurs along the air passageway 20 will be less than what occurs during positive air flow. This reduces the likelihood that the low pressure area 66 will develop a sufficient low pressure to draw any particulate material 12 into the passageway 20 during negative air flow.
Although the present invention has been described with a certain degree of particularity, it is understood that the present disclosure has been made by way of example, and changes in detail or structure may be made without departing from the spirit of the invention, as defined in the appended claims.
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A particle sprayer includes a hollow body divided into an air compartment and a storage compartment for particulate material. The air compartment receives a piston which is manually slidable along the length of the air compartment to create air pressure within the air compartment. An air passageway provides air flow communication between the air compartment and the exterior of the sprayer. A discharge tube extends into the material in the storage compartment at one end and at the other end intersects the air passageway near a restriction in the air passageway defining a venturi opeing. Depression of the piston creates increased positive air flow exiting the sprayer the venturi opening and the resultant low pressure area draws material up the discharge tube from the storage compartment to be dispersed in a uniform amount into the air in the air passageway and ejected from the sprayer as a spray. Air flow control means lowers the pressure in the down pressure area during negative air flow into the sprayer as the piston raises in the air compartment.
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BACKGROUND OF THE INVENTION
This invention relates to the field of drying racks for use in the home, specifically for portable placement over a baseboard heater.
Dealing with wet outdoor clothing in the home has long been a problem. Shelf-type racks, with latticework shelves for the free passage of air, hold articles of wet clothing and may also serve as convenient general-purpose shelves. Drying is accelerated when warm air is supplied to the rack, and a common source of such air is the home heating system.
Prior art shows an evolution of adaptations for dealing with contemporary types of home heating systems, but few anticipate today's baseboard heaters. U.S. Pat. No. 5,692,316 to Antal (1996) discloses a shaped wire rack which may be placed over a baseboard heater. U.S. Pat. No. 5,127,529 to Martinez et al. reveals a wire rack adapted to rest on the floor over, and to fit under the edges of, a floor register used in the era of stove-type heating. U.S. Pat. No. 4,596,078 to McCartney teaches a plenum with tubes adapted to hold gloves and the like, also to fit over a floor register.
None of these provide shelf space for general use during good weather.
BRIEF SUMMARY OF THE INVENTION
To provide an attractive and useful shelf unit for drying wet clothing articles, our invention uses latticework horizontal shelves held by upright supports adapted for portable placement over baseboard heating units.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 provides an overall view of the preferred embodiment of our drying rack.
FIG. 2 shows an end view of the preferred embodiment.
FIG. 3 illustrates an overall view of an alternate embodiment.
FIG. 4 gives a detailed view of an alternative extension.
REFERENCE NUMERALS USED IN DRAWINGS
11 shelf
12 support
13 floor
14 wall
15 baseboard heater
16 extension
17 protrusion
18 adjustable fastener
DETAILED DESCRIPTION OF THE INVENTION
Where a rack stands freely on an unobstructed floor, legs of equal length serve well for support, but where the rack must be placed against a wall over a wall-mounted baseboard heater, the supports must be modified.
FIG. 1 depicts an overall view of the preferred embodiment of our drying rack. Two horizontal shelves 11 are each attached at their edges to four upright supports 12 using conventional fasteners, dowels, adhesive cement or the like, and the drying rack is placed on the floor against a wall 14 and over a baseboard heater 15.
FIG. 2 views the preferred embodiment of the drying rack from one end, showing that two of the four supports 12 are resting on the floor 13 while the other two supports 12 are shortened to rest above the baseboard heater 15. Extensions 16 are attached by bolts, screws, adhesive cement or the like, to the shortened supports 12 and extend downward behind the baseboard heater 15, between it and the wall 14, to prevent the drying rack from moving away from the wall.
In the alternative embodiment shown at FIG. 3, one horizontal shelf 11 is shown attached to one of two upright supports 12 using conventional fasteners, dowels, adhesive cement or the like, and the drying rack is shown placed as in FIG. 1. In this embodiment, supports 12 are relieved in contour to clear the baseboard heater 15, and extensions 16 are attached by adjustable fasteners 18 such as bolts and wingnuts, or the like, to the edges of supports 12 nearest the wall 14.
It may be understood that heated air from the baseboard heater 15 will rise by convection, and because in the preferred embodiment the shelf or shelves 11 are open as with latticework, perforated metal, screening or the like, the air will pass freely upward through the shelves, drying any articles placed thereon. When not used for drying, these horizontal shelves may be alternatively used for such general purposes as holding books or plants. Indeed the drying rack will function, though much less effectively, even if the shelves are solid, because rising air will generally circulate around the articles on the shelves.
Since friction between the supports 12 and the floor 13 may vary greatly from one installation to another, extensions 16 are used in the preferred embodiment to prevent motion away from the wall 14 or to carry weight to the top of the baseboard heater 15, whose height may vary from one type or from one installation to another. To help in transferring weight to the top of a variety of baseboard heaters 15, extension 16 may be provided with a protrusion 17, best seen in FIG. 4, extending perpendicularly thereto which may be adjusted with extension 16 to rest on the baseboard heater 15. As shown in FIG. 4, protrusion 17 is an integral lanced portion of extension 16, but protrusion 17 could as well be a separate part such as a welded bracket, through-bolt, or the like. Where friction on the floor is adequate, extensions 16 may be omitted.
Though the above description is necessarily specific, many alternatives to materials and structure may be used to accomplish the same results. The scope of our invention should be determined by the appended claims rather than by the specific embodiments recited above.
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A drying rack for placement over a baseboard heater provides convenient shelves for drying a variety of objects. The rack is provided with supports adapted to fit over and behind the baseboard heater.
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BACKGROUND
[0001] 1. Field
[0002] The present invention relates to broadcast communications, otherwise known as point-to-multipoint, in a wireline or a wireless communication system. More particularly, the present invention relates to a system and method for a handoff in such a broadcast communication system.
[0003] 2. Background
[0004] Communication systems have been developed to allow transmission of information signals from an origination station to a physically distinct destination station. In transmitting information signal from the origination station over a communication channel, the information signal is first converted into a form suitable for efficient transmission over the communication channel. Conversion, or modulation, of the information signal involves varying a parameter of a carrier wave in accordance with the information signal in such a way that the spectrum of the resulting modulated carrier is confined within the communication channel bandwidth. At the destination station the original information signal is replicated from the modulated carrier wave received over the communication channel. Such a replication is generally achieved by using an inverse of the modulation process employed by the origination station.
[0005] Modulation also facilitates multiple-access, i.e., simultaneous transmission and/or reception, of several signals over a common communication channel. Multiple-access communication systems often include a plurality of subscriber units requiring intermittent service of relatively short duration rather than continuous access to the common communication channel. Several multiple-access techniques are known in the art, such as time division multiple-access (TDMA), frequency division multiple-access (FDMA), and amplitude modulation multiple-access (AM). Another type of a multiple-access technique is a code division multiple-access (CDMA) spread spectrum system that conforms to the “TIA/EIA/IS-95 Mobile Station-Base Station Compatibility Standard for Dual-Mode Wide-Band Spread Spectrum Cellular System,” hereinafter referred to as the IS-95 standard. The use of CDMA techniques in a multiple-access communication system is disclosed in U.S. Pat. No. 4,901,307, entitled “SPREAD SPECTRUM MULTIPLE-ACCESS COMMUNICATION SYSTEM USING SATELLITE OR TERRESTRIAL REPEATERS,” and U.S. Pat. No. 5,103,459, entitled “SYSTEM AND METHOD FOR GENERATING WAVEFORMS IN A CDMA CELLULAR TELEPHONE SYSTEM,” both assigned to the assignee of the present invention.
[0006] A multiple-access communication system may be a wireless or wireline and may carry voice and/or data. An example of a communication system carrying both voice and data is a system in accordance with the IS-95 standard, which specifies transmitting voice and data over the communication channel. A method for transmitting data in code channel frames of fixed size is described in detail in U.S. Pat. No. 5,504,773, entitled “METHOD AND APPARATUS FOR THE FORMATTING OF DATA FOR TRANSMISSION”, assigned to the assignee of the present invention. In accordance with the IS-95 standard, the data or voice is partitioned into code channel frames that are 20 milliseconds wide with data rates as high as 14.4 Kbps. Additional examples of a communication systems carrying both voice and data comprise communication systems conforming to the “3rd Generation Partnership Project” (3GPP), embodied in a set of documents including Document Nos. 3G TS 25.211, 3G TS 25.212, 3G TS 25.213, and 3G TS 25.214 (the W-CDMA standard), or “TR-45.5 Physical Layer Standard for cdma2000 Spread Spectrum Systems” (the IS-2000 standard).
[0007] An example of a data only communication system is a high data rate (HDR) communication system that conforms to the TIA/EIA/IS-856 industry standard, hereinafter referred to as the IS-856 standard. This HDR system is based on a communication system disclosed in co-pending application Ser. No. 08/963,386, entitled “METHOD AND APPARATUS FOR HIGH RATE PACKET DATA TRANSMISSION,” filed Nov. 3 , 1997 , assigned to the assignee of the present invention. The HDR communication system defines a set of data rates, ranging from 38.4 kbps to 2.4 Mbps, at which an access point (AP) may send data to a subscriber station (access terminal, AT). Because the AP is analogous to a base station, the terminology with respect to cells and sectors is the same as with respect to voice systems.
[0008] In a multiple-access communication system, communications between users are conducted through one or more base stations. A first user on one subscriber station communicates to a second user on a second subscriber station by transmitting data on a reverse link to a base station. The base station receives the data and can route the data to another base station. The data is transmitted on a forward link of the same base station, or the other base station, to the second subscriber station. The forward link refers to transmission from a base station to a subscriber station and the reverse link refers to transmission from a subscriber station to a base station. Likewise, the communication can be conducted between a first user on one subscriber station and a second user on a landline station. A base station receives the data from the user on a reverse link, and routes the data through a public switched telephone network (PSTN) to the second user. In many communication systems, e.g., IS-95, W-CDMA, IS-2000, the forward link and the reverse link are allocated separate frequencies.
[0009] When a subscriber station travels outside the boundary of the base station with which the subscriber station currently communicates, it is desirable to maintain the communication link by transferring the call to a different subscriber station. The method and system for providing a communication with a subscriber station through more than one base station during the soft hand-off process are disclosed in U.S. Pat. No. 5,267,261, entitled “MOBILE ASSISTED SOFT HAND-OFF IN A CDMA CELLULAR TELEPHONE SYSTEM,” assigned to the assignee of the present invention. The method and system for providing a softer hand-off is described in detail in U.S. Pat. No. 5 , 933 , 787 , entitled “METHOD AND APPARATUS FOR PERFORMING HANDOFF BETWEEN SECTORS OF A COMMON BASE STATION”, assigned to the assignee of the present invention. Using these methods, communication between the subscriber stations is uninterrupted by the eventual handoff from an original base station to a subsequent base station. This type of handoff may be considered a “soft” handoff in that communication with the subsequent base station is established before communication with the original base station is terminated. When the subscriber unit is in communication with two base stations, the subscriber unit combines the signals received from each base station in the same manner that multipath signals from a common base station are combined.
[0010] In accordance with the above-cited inventions, each base station transmits a pilot signal of a common PN spreading code offset in code phase from pilot signals of other base stations. A subscriber station assisted soft handoff operates based on the pilot signal strength detected by the subscriber station. To streamline the process of searching for pilots, four distinct sets of pilot offsets are defined: the Active Set, the Candidate Set, the Neighbor Set, and the Remaining Set. The Active Set identifies the base station(s) or sector(s) through which the subscriber station is communicating. The Candidate Set identifies the base station(s) or sector(s) for which the pilots have been received at the subscriber station with sufficient signal strength to make them members of the Active Set, but have not been placed in the Active Set by the base station(s). The Neighbor Set identifies the base station(s) or sector(s), which are likely candidates for the establishment of communication with the subscriber station. The Remaining Set identifies the base station(s) or sector(s) having all other possible pilot offsets in the current system, excluding those pilot offsets currently in the Active, the Candidate and Neighbor sets.
[0011] The subscriber station is provided with a list of PN offsets corresponding to base stations of neighboring cells. In addition, the subscriber station is provided with a message which identifies at least one pilot corresponding to a base station to which the subscriber station is to communicate through. These lists are stored at the subscriber station as a Neighbor Set and an Active Set of pilots, and are updated as conditions change.
[0012] When communication is initially established, a subscriber unit communicates through a first base station and the Active Set contains only a pilot signal of the first base station. The subscriber unit monitors pilot signal strength of the base stations of the Active Set, the Candidate Set, the Neighbor Set, and the Remaining Set. When a pilot signal of a base station in the Neighbor Set or Remaining Set exceeds a predetermined threshold level (T_ADD), the pilot signal identifier is added to the Candidate Set. The subscriber unit communicates a Power Strength Measurement Message (PSMM) to the first base station identifying the new base station. A system controller decides whether to establish communication between the new base station and the subscriber unit, and communicates the decision in a Handoff Direction Message (HDM). The message identifies the pilots of the Active Set which correspond to base stations through which the subscriber station is to communicate. The system controller also communicates information to each base station corresponding to a new pilot in the Active Set which instructs each of these base stations to establish communications with the subscriber station. The subscriber station communications are thus routed through all base stations identified by pilots in the subscriber station Active Set.
[0013] When the subscriber unit is communicating through multiple base stations, it continues to monitor the signal strength of the base stations of the Active Set, the Candidate Set, the Neighbor Set, and the Remaining Set. Should the signal strength corresponding to a base station of the Active Set drop below a predetermined threshold (T_DROP) for a predetermined period of time (T_TDROP), the subscriber unit generates and transmits a message to report the event. The system controller receives this message through at least one of the base stations with which the subscriber unit is communicating. The system controller may then decide to terminate communications through the base station whose pilot signal strength as measured at the subscriber station is below the T_DROP.
[0014] The system controller upon deciding to terminate communications through a base station generates a new message identifying the pilots of the Active Set to which the subscriber station is to communicate through. In this message, which identifies pilots of the Active Set, the pilot of the base station to which communications with the subscriber station are to be terminated is not identified. The system controller also communicates information to the base station not identified in the Active Set to terminate communications with the subscriber station. The subscriber station, upon receiving the message identifying pilots of the Active Set, discontinues processing signals from the base station whose pilot is no longer in the Active Set. The subscriber station communications are thus routed only through base stations identified by pilots in the subscriber station Active Set. In the case where there were previously more than one pilot identified in the Active Set and now only one, the subscriber station communicates only to the one base station corresponding to the pilot identified in the subscriber station Active Set.
[0015] The above described wireless communication service is an example of a point-to-point communication service. In contrast, broadcast services provide central station-to-multipoint communication service. The basic model of a broadcast system consists of a broadcast net of users served by one or more central stations, which transmit information with a certain contents, e.g., news, movies, sports events and the like to the users. Each broadcast net user's subscriber station monitors a common broadcast forward link signal. Because the central station fixedly determines the content, the users are generally not communicating back. Examples of common usage of broadcast services communication systems are TV broadcast, radio broadcast, and the like. Such communication systems are generally highly specialized purpose-build communication systems. With the recent, advancements in wireless cellular telephone systems there has been an interest of utilizing the existing infrastructure of the—mainly point-to-point cellular telephone systems for broadcast services. (As used herein, the term “cellular” systems encompasses communication system utilizing both cellular and PCS frequencies.)
[0016] Although the described handoff method for subscriber units acting as point-to-point units described above could be applied to broadcast systems, because in a broadcast system, large number of subscribers monitor a common broadcast forward channel, a handoff based on base station-subscriber station signaling message exchange would result in a high signaling load. Furthermore, as described in the above-cited U.S. Pat. Nos. 5,267,261, and 5,933,787, the transmissions received simultaneously by a subscriber station during handoff are synchronized at the transmitting base stations. Because broadcast transmission is intended for many subscriber stations, the base station cannot synchronize transmission for each subscriber station desiring to handoff. Based on the foregoing, there is a need in the art for a system and method for handoff in such a broadcast communication system.
SUMMARY
[0017] Embodiments disclosed herein address the above stated needs by providing a method for autonomous handoff in a broadcast communication system, by receiving at a subscriber station a broadcast channel transmitted through a first sector, measuring at the subscriber station a quality metric of a forward link transmitted by sectors, identifying at the subscriber station at least one sector, different from the first sector, for which said measured quality metric exceeds a first pre-determined threshold; and combining at the subscriber station broadcast channels received from the first sector and said at least one identified sector.
[0018] In another aspect, the above stated needs are addressed by providing method for a set management in a broadcast communication system, comprising providing to a subscriber station a first list identifying a first set of sectors; measuring at the subscriber station a quality metric of a forward link transmitted by each identified sector; removing from said first list at the subscriber station an identifier of a sector said measured quality metric of which exceeds a first predetermined level; and placing the identifier of the sector into a second list at the subscriber station.
[0019] In another aspect, the above stated needs are addressed by providing method for method for transitioning a subscriber station from an area covered by a first sector into an area covered by a different sector in a broadcast communication system, comprising determining at the subscriber station a configuration of a broadcast channel transmitted by a second sector; and transitioning from the coverage area covered by the first sector in accordance with said determined configuration of the broadcast channel transmitted by the second sector.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] [0020]FIG. 1 illustrates conceptual block diagram of a High-Speed Broadcast Service communication system;
[0021] [0021]FIG. 2 illustrates concept of soft-handoff groups in a broadcast communication system;
[0022] [0022]FIG. 3 illustrates an embodiment of signaling pertaining to the changes in a pilot's strength and the pilot's membership in the various sets for subscriber assisted handoff;
[0023] [0023]FIG. 4 illustrates an embodiment of signaling pertaining to the changes in a pilot's strength and the pilot's membership in the various sets in autonomous handoff; and
[0024] [0024]FIG. 5 illustrates an alternative mode, in which a pilot may be added to the Active Set for subscriber assisted handoff.
DETAILED DESCRIPTION
[0025] Definitions
[0026] The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any embodiment described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments.
[0027] The terms point-to-point communication is used herein to mean a communication between two subscriber stations over a dedicated communication channel.
[0028] The terms group service, point-to-multipoint communication, push-to-talk, or dispatch service are used herein to mean a communication wherein a plurality of subscriber stations are receiving communication from—typically—one subscriber station.
[0029] The term packet is used herein to mean a group of bits, including data (payload) and control elements, arranged into a specific format. The control elements comprise, e.g., a preamble, a quality metric, and others known to one skilled in the art. Quality metric comprises, e.g., a cyclical redundancy check (CRC), a parity bit, and others known to one skilled in the art.
[0030] The term access network is used herein to mean a collection of base stations (BS) and one or more base stations' controllers. The access network transports data packets between multiple subscriber stations. The access network may be further connected to additional networks outside the access network, such as a corporate intranet or the Internet, and may transport data packets between each access terminal and such outside networks.
[0031] The term base station is used herein to mean the hardware with which subscriber stations communicate. Cell refers to the hardware or a geographic coverage area, depending on the context in which the term is used. A sector is a partition of a cell. Because a sector has the attributes of a cell, the teachings described in terms of cells are readily extended to sectors.
[0032] The term subscriber station is used herein to mean the hardware with which an access network communicates. A subscriber station may be mobile or stationary. A subscriber station may be any data device that communicates through a wireless channel or through a wired channel, for example using fiber optic or coaxial cables. A subscriber station may further be any of a number of types of devices including but not limited to PC card, compact flash, external or internal modem, or wireless or wireline phone. A subscriber station that is in the process of establishing an active traffic channel connection with a base station is said to be in a connection setup state. A subscriber station that has established an active traffic channel connection with a base station is called an active subscriber station, and is said to be in a traffic state.
[0033] The term physical channel is used herein to mean a communication route over which a signal propagates described in terms of modulation characteristics and coding.
[0034] The term logical channel is used herein to mean a communication route within the protocol layers of either the base station or the subscriber station.
[0035] The term communication channel/link is used herein to mean a physical channel or a logical channel in accordance with the context.
[0036] The term reverse channel/link is used herein to mean a communication channel/link through which the subscriber station sends signals to the base station.
[0037] A forward channel/link is used herein to mean a communication channel/link through which a base station sends signals to an subscriber station.
[0038] The term soft hand-off is used herein to mean a communication between a subscriber station and two or more sectors, wherein each sector belongs to a different cell. The reverse link communication is received by both sectors, and the forward link communication is simultaneously carried on the two or more sectors' forward links.
[0039] The term softer hand-off is used herein to mean a communication between a subscriber station and two or more sectors, wherein each sector belongs to the same cell. The reverse link communication is received by both sectors, and the forward link communication is simultaneously carried on one of the two or more sectors' forward links.
[0040] The term erasure is used herein to mean failure to recognize a message.
[0041] The term dedicated channel is used herein to mean a channel modulated by information specific to an individual subscriber station.
[0042] The term common channel is used herein to mean a channel modulated by information shared among all subscriber stations.
[0043] Description
[0044] As discussed a basic model of a broadcast system comprises a broadcast net of users, served by one or more central stations, which transmit information with a certain contents, e.g., news, movies, sports events and the like to the users. Each broadcast net user's subscriber station monitors a common broadcast forward link signal. FIG. 1 illustrates conceptual block diagram of a communication system 100 , capable of performing High-Speed Broadcast Service (HSBS) in accordance with embodiments of the present invention.
[0045] The broadcast content originates at a content server (CS) 102 . The content server may be located within the carrier network (not shown) or outside Internet (IP) 104 . The content is delivered in a form of packets to a broadcast packet data-serving node (BPDSN) 106 . The term BPSDN is used because although the BPDSN may be physically co-located or be identical to the regular PDSN (not shown), the BPSDN may be logically different from a regular PDSN. The BPDSN 106 delivers the packets according to the packet's destination to a packet control function (PCF) 108 . The PCF is a control entity controlling function of base stations 110 for the HSBS and any general packet data services, as a base station controller is for regular voice services. To illustrate the connection of the high level concept of the HSBS with the physical access network, FIG. 1 shows that the PCF is physically co-located or even identical, but logically different from a base station controller (BSC). One of ordinary skills in the art understands that this is for a pedagogical purposes only. The BSC/PCF 108 provides the packets to base stations 110 . The communication system 100 enables the HSBS by introducing a forward broadcast shared channel 112 (F-BSCH) transmitted by base stations 110 . The F-BSCH 112 need not be transmitted from every base station 110 . A F-SBCH is capable of high data rates that can be received by a large number of subscriber stations. The term forward broadcast shared channel is used.
[0046] The F-BSCH may be monitored by a large number of subscribers 114 . Consequently, the base station-subscriber station signaling message based handoff is not efficient in a HSBS because such a handoff results in a high signaling load and may not be feasible since it is a fixed broadcast transmission not tailored for a particular subscriber station. On the other hand, because of the high power demand for transmission of the common broadcast forward channel, there are only few common broadcast forward channel on a given CDMA carrier, which makes autonomous soft and softer handoff without the base station-subscriber station signaling message exchange practical.
[0047] Therefore, instead of exchanging messages between a base station and a subscriber station desiring to handoff, the information regarding broadcast transmission in neighbor base stations is announced by overhead messages on each channel F-BSCH in each base station. Because a subscriber may soft combine the only synchronous transmissions, a Broadcast Service Parameters Message transmitted in each base station will list the identities of base stations that are part of this sector's soft handoff (SHO) group for each supported FBSCH. The method and system for signaling, including both mentioned embodiments is described in detail in co-pending U.S. patent application Ser. No. ______ entitled “A METHOD AND APPARATUS FOR SIGNALING IN BROADCAST COMMUNICATION SYSTEM”, filed Aug. 20, 2001, assigned to the assignee of the present invention. As used herein a SHO group means a group of all base station transmitting the Common Broadcast Forward Link synchronously. FIG. 2 illustrates two SHO groups, SHO Group 1 202 comprising BS 1 , BS 2 , and BS 3 , and SHO Group 2 202 comprising BS 4 , BS 5 , BS 6 , and BS 7 .
[0048] Referring to FIG. 2, if a subscriber station crosses boundaries from a coverage area of SHO Group 1 202 to a coverage area of SHO Group 2 202 , a hard handoff is required. The term hard handoff as used here means that monitoring of a first channel is discontinued before monitoring of the second channel begins (“break before make”). On the other hand, if a subscriber station monitors transmissions from a BS 7 and enters a coverage area of a new base station, e.g., BS 6 , because both base stations are in the same SHO group the subscriber can monitor the F-BSCH transmission from the base stations before stop listening to the F-BSCH transmission from the BS 7 .
[0049] Autonomous Soft Handoff
[0050] In one embodiment of the current invention, a subscriber station uses a quality metric of a forward link for decision, which F-BSCH to monitor. The quality metric may comprise, e.g., pilot signal strength, bit-error-rate, packet-error-rate, and other quality metrics known to one of ordinary skills in the art. To streamline the decision process, several distinct sets of pilot offsets and rules from transitioning among the sets are defined as discussed in detail below. For the ease of explanation of essential concepts of the various embodiments, the following discussion uses all sets, i.e., Active Set, the Candidate Set, and the Neighbor Set, and the Remaining Set. When the subscriber stations subscribed to HSBS services acquires a sector, it decodes a message, which provides the subscriber station with a list of identities of sectors that are part of the sector's SHO group for each supported F-BSCH. In accordance with one embodiment, the list is provided in a Broadcast Service Parameters Message transmitted in each sector. In accordance with another embodiment, the list is provided in existing overhead messages. The subscriber station initially assigns identifiers of sectors in the provided list into a Neighbor Set. The subscriber station monitors the signal strength of the sectors in the Neighbor Set, and assigns identifiers of the pilot signal into the Active Set, the Candidate Set, the Neighbor Set, in accordance with the monitored signal strength. As the subscriber station moves around, the subscriber station may update the overhead parameters of the BS 6 simultaneously. The Broadcast Service Parameters Message from the new sector may indicate additional members and delete some members of the SHO groups relative to the information in the old sector Broadcast Service Parameters Message. Therefore, while the Broadcast Service Parameters Message from the BS 6 (BSPM 6 ) contained members {BS 4 , BS 5 , BS 7 }, the Broadcast Service Parameters Message from the BS 7 (BSPM 7 ) contains only members {BS 4 , BS 6 }. The subscriber station thus places certain sectors to a Remaining Set.
[0051] The advantage of a soft handoff is that a subscriber station may combine synchronous transmission of multiple sectors, subject to subscriber station capabilities, e.g., number of receiver fingers, processing power, and other known to one of ordinary skills in the art. Consequently, when the subscriber station decides to monitor an HSBS channel modulating a F-BSCH, assuming that the Active Set contains more than one pilot signal identifiers, the subscriber station may select to combine the F-BSCH from the sectors, the pilot signal identifiers of which belong to the Active Set, and have the highest signal strength. The subscriber station then tunes to the frequency transmitted by the sectors, modulated by the selected F-BSCH that is modulated by the HSBS channel. The subscriber station continues monitoring pilot signal strength of the sectors in the Active Set, the Candidate Set, the Neighbor Set, and the Remaining Set. When a pilot signal of a second sector in the Neighbor Set or Remaining Set qualifies for transition to the Active Set, the subscriber station adds the pilot signal's identifier to the Active Set. Thus, the subscriber station monitors the F-BSCH transmitted by only the sectors identified by pilots in the subscriber station Active Set.
[0052] While the subscriber station is monitoring the F-BSCH transmitted by multiple sectors, the subscriber station continues to measure the signal strength of the sectors of the Active Set, the Candidate Set, the Neighbor Set, and the Remaining Set. Should the signal strength of a pilot signal corresponding to a sector of the Active Set disqualify the pilot signal from being a member of the Active Set, the subscriber station may decide to remove the pilot signal identifier from the Active Set. If the subscriber station monitors the F-BSCH transmitted through the sector, the subscriber station then terminates monitoring the FBSCH transmitted. In the case where there were previously more than one pilot identified in the Active Set and now only one, the subscriber station monitors only the one sector corresponding to the pilot signal, and identifier of which belongs to the Active Set.
[0053] Pilot Set Management
[0054] As discussed above, as the subscriber station assisted soft and softer handoff as described in the above-referenced U.S. Pat. Nos. 5,267,261, and 5,933,787, the autonomous soft handoff of the present invention utilizes a concept of pilot sets. In accordance with the above-referenced U.S. Pat. Nos. 5,267,261, and 5,933,787, the sector-subscriber station signaling assisted with pilot Set management. However, the autonomous soft handoff in accordance with embodiments of the invention does not utilize such a signaling, therefore, a different method of set management is needed. To better understand concepts of set management, the set management in accordance with the above-referenced U.S. Pat. Nos. 5,267,261, and 5,933,787 is reviewed, and then embodiments in accordance with the present invention are described.
[0055] [0055]FIG. 3 illustrates an embodiment of the signaling pertaining to the changes in a pilot's strength and the pilot's membership in the various sets during a subscriber assisted handoff. In FIG. 3, before time to, the pilot P A is in the Neighbor Set with a rising signal strength as measured by the subscriber station's searcher receiver. However, the pilot signal strength is below the threshold T_ADD, which would qualify the pilot to enter the Candidate Set. The subscriber station control processor makes a decision to place a non-Active or non-Candidate Set member in the Candidate Set when the measured pilot exceeds the threshold value T_ADD, an event to which the subscriber station control processor generates and transmits a PSMM.
[0056] At time to the pilot P A signal strength as measured by the searcher receiver exceeds the value T_ADD. The subscriber station control processor compares the measured value with the T_ADD value and determines that the T_ADD value has been exceeded. The subscriber station control processor thus generates and transmits a corresponding PSMM.
[0057] It should be noted that the searcher may detect several multipath versions of pilot P A , which may be time-shifted from one another by several chips. The sum of all detected usable multipath versions of the pilot may be used for identifying the strength of the pilot.
[0058] The decision for placing a Candidate Set member into the Active Set is made by the system controller. For example, when the measured Candidate pilot is of a signal strength which exceeds the signal strength of one other Active Set member pilot by a predetermined value it may join the Active Set. However there may be limits placed on the number of Active Set members. Should the addition of a pilot to the Active Set exceed the Active Set limit, the weakest Active Set pilot may be removed to another set.
[0059] Once a decision is made by the system controller that a pilot should enter the Active Set, a Handoff Direction Message is sent to the subscriber station, all sectors that have a traffic channel assigned to the subscriber station, which includes the pilot P A in the Active Set. In FIG. 3 at time t 1 the Handoff Direction Message is received at the subscriber station where the identified pilots, including pilot P A , are used to demodulate received signals from the sector from which pilot P A was transmitted and/or from another sector. Once a pilot is identified in the Handoff Direction Message, one version or multipath versions of the information signals if present corresponding to the identified pilot from the same sector may be demodulated. The signals ultimately demodulated may therefore be transmitted from one or more sector and may be multipath versions thereof. During the soft handoff the subscriber station diversity combines at the received signals at the symbol level. Therefore, all sectors participating in the soft handoff must transmit identical symbols, except for closed loop power control subchannel data as discussed later herein.
[0060] In FIG. 3 between the times t 1 and t 2 the pilot P A falls in signal strength to where at time t 2 the signal strength drops below a predetermined threshold value T_DROP. When the signal strength of a pilot drops the value T_DROP for a predetermined period of time, the subscriber station control processor again generates and transmits, at time t 3 , a PSMM.
[0061] In response to this PSMM, the system controller generates a Handoff Direction Message that is sent to the subscriber station, by all sectors having a traffic channel assigned to the subscriber station, which no longer includes the pilot P A in the Active Set. At time t 4 the Handoff Direction Message is received at the subscriber station for removing the pilot P A from the Active Set, for example to the Neighbor Set. Once removed from the Active Set this pilot is no longer used for signal demodulation.
[0062] As well known to one of ordinary skills in the art, a spread spectrum communication system is interference limited. In subscriber station assisted handoff, the Candidate Set serves the purpose of keeping the pilot signal identifier in a convenient place for quick access, and the search frequency for the pilot signals in the Candidate Set is higher than the search frequency for the pilot signals in the Neighbor Set. Therefore, the effect of a delay between the PSMM and the HDM was minimized because upon receiving the HDM, the subscriber could quickly place the pilot signal into Active Set and start traffic channel combining, which improved signal-to-interference-and-noise-ratio (SINR). However, in autonomous handoff, the subscriber can change the search frequency and start traffic channel combining without the delay. Consequently, in one embodiment of the present invention, the Candidate Set is eliminated from the four distinct sets of pilot offsets. Thus, if a pilot strength exceeds a first threshold T_ADD 1 at time to, the pilot is promoted from the Neighbor Set directly to the Active Set. One of ordinary skills in the art recognizes methods of promoting a pilot from a Neighbor Set are equally applicable for promoting a member form the Remaining set.
[0063] In accordance with another embodiment of the present invention, the Candidate Set is retained. Referring to FIG. 4, the transition from a Neighbor Set to a Candidate Set occurs at time to, when a pilot strength exceeds a first threshold T_ADD 1 . The pilot signal is then observed, and in accordance with one embodiment promoted from the Candidate Set to the Active Set when the pilot strength exceeds a second threshold T_ADD 2 at time t 1 . In accordance with another embodiment, a timer for the pilot is started at time to. If the pilot remains in the Candidate Set for the timer interval (T_TADD), the pilot is promoted to the Active Set. If the pilot is removed from the Candidate Set before the T_TADD, the timer is stopped. Thus, the pilot signal is promoted only if the pilot signal strength increases or is stable.
[0064] An alternative mode, in which a pilot may be added to the Active Set, is illustrated in reference to FIG. 5. Referring to FIG. 5, the strength of a pilot signal rises above members of the Active Set. When the signal strength of a pilot signal exceeds pilot signal strength of a pilot of an Active Set by at least T_COMP dB, the subscriber reports that event to the sector. In FIG. 5, pilots P 1 , P 2 and P 3 are members of the Active Set while pilot P 3 is initially a member of another set such as the Neighbor Set.
[0065] Generally the number of Active Set members correspond to the number of data receivers available, however the Active Set may be of a greater number of pilots. The subscriber station is therefore permitted to select from the Active Set member pilots those of greatest signal strength for demodulation of the corresponding data signals. One of ordinary skills in the art understends that one or more pilots of the Active sets may have multipath propagations of the same sector or sector transmitted pilot as received at the subscriber station. In the case of multipath propagations, the subscriber station again selects signals for demodulation corresponding to those multipath versions of the pilots identified in the Active Set pilots of greatest signal strength. Therefore the actual sector signals demodulated by the subscriber station may be from different sectors or from a same sector.
[0066] At time to the pilot P 0 as measured by the searcher receiver and compared with the value T_ADD by the subscriber station control processor is determined to be greater than the value T_ADD. As discussed above, this event results in the subscriber station control processor generating a PSMM, which is transmitted by the subscriber station to a sector for relay to the system control processor. The subscriber station also adds the pilot P 0 to the Candidate Set.
[0067] At time t 1 the pilot P 0 exceeds pilot P 1 by a value greater than the value T_COMP. The subscriber station control processor generates another PSMM, which is transmitted by the subscriber station to a sector for relay to the system control processor. It should be noted that only pilots that are already members of the Candidate Set are compared to Active Set members using the T_COMP criteria. Since the pilot P 0 has exceed the pilot P 1 by the value T_COMP, the system controller may begin setting up a modem at another sector or sector for communicating with the subscriber station. However if the pilot is not of another sector or sector no setup is necessary. In either case the system controller would then communicate a Handoff Direction Message to the subscriber station including the pilot if not already an Active Set member.
[0068] The procedure is similar as pilot P 0 grows stronger. At time t 2 the pilot P 0 has grown stronger than the next strongest pilot P 2 by a value greater than the value T_COMP. Consequently, the subscriber station control processor generates another PSMM, which is transmitted by the subscriber station to a sector for relay to the system control processor. Since the pilot P 0 has exceed the pilot P 2 by the value T_COMP, the system controller may add the pilot to the Active Set as discussed above if not yet already done.
[0069] In subscriber assisted handoff, the addition of strong pilot to the Active Set via the T_COMP method served the purpose to quickly add a pilot with a fact increasing signal strength to the Active Set. As discussed, a base station controller had discretion to promote a pilot from a Candidate Set to the Active Set. If the sector decided not to promote the pilot to the Active Set, and the pilot signal strength kept rising, the sector transmitting the pilot signal became an interferer. To prompt the base station controller to act, the new PSMM in accordance with the T_COMP method was generated. However, in autonomous handoff, when the subscriber station identifies a pilot with a fast increasing signal strength, the subscriber station can change the search frequency and start channel combining immediately. Consequently, in accordance with one embodiment of the present invention, the T_COMP method of adding pilot identifiers to an Active Set is not utilized.
[0070] The size of the Active Set is limited. Therefore, a subscriber station may refuse to add an identifier of a pilot signal with sufficient signal strength into an Active Set when the Active Set is already full. If the pilot signal strength keeps rising, a sector transmitting the pilot signal became an interferer, and it may be advantageous to remove an identifier of a weaker pilot signal from the Active Set, add the identifier of the fast raising pilot, and start combining a signal from the sector. Therefore, in accordance with another embodiment of the present invention, the alternative mode of adding a pilot to the Active Set is retained. The method must be modified in accordance with the above-described embodiments of the present invention.
[0071] Consequently, in accordance with the embodiment, in which the Candidate Set is eliminated, the subscriber station monitors whether a signal strength of a pilot, an identifier of which is not a member of an Active Set, exceeds a pilot strength of a pilot an identifier of which is a member of the Active Set by a value of T_COMP a . Upon identifying such a pilot, the subscriber station makes a decision whether to add an identifier of the pilot to the Active Set.
[0072] In accordance with the embodiment, in which the Candidate Set is retained, if the transition method to a Candidate Set utilizes the two thresholds T_ADD 1 , and T_ADD 2 , the identifier of a pilot will be added to the Candidate Set when the pilot signal strength exceeds T_ADD 2 as dicussed. The subscriber station monitors whether a signal strength of a pilot, an identifier of which is a member of a Candidate Set, exceeds a pilot strength of a pilot an identifier of which is a member of the Active Set by a value of T_COMP a . Upon identifying such a pilot, the subscriber station makes a decision whether to add an identifier of the pilot to the Active Set.
[0073] If the transition method to a Candidate Set utilizes the threshold T_ADD 1 , and an expiration of timer interval T_TADD, the subscriber station may decide to add the pilot to the Active Set, once the pilot signal strength exceeds the signal strength of a pilot with the weakest signal strength already in an Active set by the value of T_COMP, regardless of whether the timer interval T_TADD expired or not.
[0074] The pilot is removed from the Active Set whenever the signal strength of the pilot is determined to be below T_DROP a a period exceeding T_TDROP a .
[0075] Broadcast Service Handoff Control & Signaling
[0076] Because of the potential mobility of subscriber stations or changing conditions of the F-BSCH, the subscriber station may need to handoff form a coverage area of a original sector to a coverage area of a second sector. The method of performing the handoff depends on a state of the subscriber station in the coverage area of the original sector and the configuration of the original and the second sectors.
[0077] Upon a power-up, a subscriber station enters a system determination substate, in which the system upon which to perform an acquisition attempt is selected. In one embodiment, after having selected a system for system determination, the subscriber station transitions into a pilot acquisition sub-state, in which the subscriber station attempts to demodulate a pilot signal based on the acquisition parameters retrieved in the system determination sub-state. The subscriber station attempts to acquire a CDMA pilot signal in accordance with the acquisition parameters. When the subscriber station detects a pilot signal with energy above a predetermined threshold value, the subscriber station transitions into a Sync channel acquisition sub-state and attempts acquisition of the Sync channel. Typically, the Sync channel as broadcasted by the sectors includes basic system information such as the system identification (SID) and the network identification (NID), but most importantly provides timing information to the subscriber station. The subscriber station adjusts the subscriber's station timing in accordance with the Sync channel information and then enters the subscriber station idle state. The subscriber station begins the idle state processing by receiving a channel provided by the system for overhead messages identified in the Sync channel message, and if a sector, which the subscriber station acquired supports multiple frequencies, both the subscriber station and the sector use a hash function to determine, which frequency to use for communication. The subscriber and sector then use the hash function to determine a paging channel, which the subscriber monitors. In one embodiment, the hashing function accepts number of entities to hash, e.g., frequencies, paging channels, and the like and an international subscriber station identifier (IMSI) and outputs one entity.
[0078] In the idle state the subscriber station can receive messages, receive an incoming call, initiate a call, initiate registration, or initiate message transmission. Furthermore, a subscriber subscribed to an HSBS service may monitor an HSBS channel modulating a F-BSCH. The frequency determined by the hash function may or may not be modulated by F-BSCH. Consequently, if a subscriber station desires to monitor an HSBS channel modulating a F-BSCH on a frequency different form the frequency determined by the hash function, it must re-tune to the frequency modulated by the F-BSCH.
[0079] Based on the foregoing the subscriber station may be in the following states at the original sector:
[0080] State 1: not monitoring F-BSCH, and tuned to the frequency determined by the hash function; −State 2: not monitoring F-BSCH, and tuned to the frequency modulated by the F-BSCH different form the frequency determined by the hash function; and −State 3: monitoring F-BSCH and, therefore, tuned to in the frequency modulated by the F-BSCH.
[0081] In accordance with one embodiment, the subscriber station determines the configuration of the second sector in accordance with a value of an HSBS neighbor configuration indicator (NGHBR_CONFIG_HSBS) transmitted by the current sector. Specific values of NGHBR_CONFIG_HSBS indicate, e.g., whether a HSBS configuration of the neighbor sector is known, whether the neighbor sector is transmitting the F-BSCH, whether the F-BSCH of the neighbor sector is being transmitted on the same frequency, whether the HSBS channels are synchronized, whether the same set of HSBS channels are being multiplexed in the same manner into the F-BSCH being transmitted in the neighbor sector, whether autonomous soft-handoff is allowed, and other configuration information known to one skilled in the art. In accordance with one embodiment, the NGHBR_CONFIG_HSBS is included in the Broadcast Service Parameters Message transmitted in the current sector.
[0082] When the subscriber station makes a decision to handoff to a second sector, the subscriber station ascertains the NGHBR_CONFIG_HSBS for the second sector. The subscriber station then takes action in accordance with the value of the NGHBR_CONFIG_HSBS. Several scenarios in accordance with above-listed examples of NGHBR_CONFIG_HSBS values are discussed. One of ordinary skills in the art recognizes that the scenarios discussed are communication system implementation dependent.
[0083] When the subscriber station is in state 1 or 2, the subscriber station is not concerned with the status of the F-BSCH. Consequently, the subscriber station receives a NGHBR_CONFIG_HSBS, and determines configuration parameters for the second sector. The subscriber station then performs idle handoff in accordance with an idle handoff method implemented in the communication system. In one embodiment, the idle handoff method uses the above-disclosed hashing methods to determine a frequency, the subscriber station tunes to and a paging channel the subscriber station starts monitoring. Alternatively, the subscriber station may choose to tune to the frequency modulated by the F-BSCH, even if the subscriber station is not interested in monitoring a HSBS channel at present, if sufficient information about the neighbor HSBS channels is available in the Broadcast Service Parameter Message of the current sector.
[0084] The NGHBR_CONFIG_HSBS received by the subscriber station in state 1 or 2 may indicate that configuration of the second subscriber station is unknown. In one embodiment, the subscriber station handoffs to a sector, for which NGHBR_CONFIG_HSBS indicates that a configuration is known. Alternatively, the subscriber station attempts to find non-broadcast related neighbor information. For example, communication systems in accordance with IS-95 and IS-2000 standards provide a neighbor configuration identifier (NGHBR_CONFIG), which indicates neighbor information, e.g., number of frequency assignment and paging channels. One of ordinary skills in the art recognizes that other communication systems may provide similar information. Consequently, the subscriber station need not initiate the full initialization process as described above, but acquires a frequency and a paging channel of the neighbor sector using the above-described hashing method in accordance with the neighbor information. If such information is not found or is inconclusive, the subscriber station must enter initialization process.
[0085] When a subscriber station in state 3 receives a NGHBR_CONFIG_HSBS indicating that a soft-handoff with the F-BSCH of the second sector is allowed, the subscriber station performs autonomous soft handoff if the subscriber station supports it. A soft handoff is allowed if both sectors belong to the same SHO group, the F-BSCH is being transmitted on the same frequency through both sectors, the same set of HSBS channels are being multiplexed identically onto the F-BSCH, and F-BSCH transmissions are synchronized. Alternatively, the subscriber station performs hard handoff in accordance with the described embodiments, acquires a new sector, and resumes monitoring the HSBS channel.
[0086] When a subscriber station in state 3 receives a NGHBR_CONFIG_HSBS indicating that the HSBS channel is available in the second sector but the transmissions are not synchronized among the sector, the subscriber station performs hard handoff. Because the two broadcast channels are identical, the subscriber station transitions directly to the HSBS channel frequency of the second sector and resumes monitoring HSBS channel. If the subscriber station failed to acquire all necessary parameters from the NGHBR_CONFIG_HSBS, the subscriber station performs a hard handoff, to the second sector, acquires a frequency and a paging channel of the second sector using the above-described hashing method in accordance with the neighbor information, determines information about the HSBS channel from the Broadcast Service Parameters Message, tunes to the HSBS channel frequency, and resumes receiving the HSBS channel.
[0087] The subscriber station in state 3 receives a NGHBR_CONFIG_HSBS indicating that the HSBS channel is available in the second sector, but the configuration parameters of the F-BSCH are different, e.g., the F-BSCH of the second sector is being transmitted on different frequency, set of HSBS channels multiplexed onto the F-BSCH channel is not identical or is not multiplexed in the same manner. The subscriber station performs a hard handoff to the second sector, acquires a frequency and a paging channel of the second sector using the above-described hashing method in accordance with the neighbor information, determines information about the HSBS channel from the Broadcast Service Parameters Message, tunes to the HSBS channel frequency, and resumes receiving the HSBS channel. Alternatively, if the subscriber station can determine the difference, which can be remedied by an action of the subscriber station, e.g., all parameters are identical, except the frequency, the subscriber station may transition directly to the HSBS channel frequency of the second sector and resume monitoring HSBS channel.
[0088] When a subscriber station in state 3 receives a NGHBR_CONFIG_HSBS indicating that the second sector is not transmitting a F-BSCH, in one embodiment, the subscriber station handoff to a sector transmitting a F-BSCH with a weaker, but acceptable, pilot signal. Alternatively, the subscriber station discontinues reception of the F-BSCH and performs idle handoff to the second sector in accordance with an idle handoff method implemented in the communication system. In one embodiment, the idle handoff method uses the above-disclosed hashing methods to determine a frequency the subscriber station tunes to and a paging channel the subscriber station starts monitoring.
[0089] Subscriber station is in state 3, NGHBR_CONFIG_HSBS indicates that configuration of the second sector is unknown. In one embodiment, the subscriber station handoffs to a sector, for which NGHBR_CONFIG_HSBS indicates that a configuration is known, regardless of whether a F-BSCH is transmitted or not. Alternatively, the subscriber station attempts to find non-broadcast related neighbor information. For example, communication system in accordance with IS-95 and IS-2000 standards provide a NGHBR_CONFIG, which indicates neighbor information, e.g., number of frequency assignment and paging channels. One of ordinary skills in the art recognizes that other communication systems may provide similar information. Consequently, the subscriber station need not initiate the full initialization process as described above, but acquires a frequency and a paging channel of the neighbor sector using the above-described hashing method in accordance with the neighbor information. If such information is not found or is inconclusive, e.g., unknown neighbors' configuration, the subscriber station must enter initialization process. Once the subscriber station acquires a new sector, the subscriber station can receive the Broadcast Service Parameter Message to determine availability of HSBS channels in that sector and tune to the appropriate frequency carrying the HSBS channel and resume receiving the HSBS channel.
[0090] Traffic Channel Handoff
[0091] Unlike the above-described embodiments, this embodiment contemplates a handoff for a subscriber station in the dedicated mode (e.g., in a voice call) on a traffic channel, while also monitoring a F-BSCH. In accordance with one embodiment of the present invention, the base station-subscriber station signaling assisted handoff is performed for the call. Furthermore, the handoff methods disclosed in the embodiments of the present invention are performed for the F-BSCH. The base station provides the subscriber station with a new pilot sets for the handoff on a traffic channel via a handoff direction messages. As discussed, the subscriber receives information about the pilot Sets via the Broadcast Service Parameter Message in accordance to one embodiment. However, the subscriber station is able to receives the Broadcast Service Parameter Message only in an idle state.
[0092] Consequently, in accordance with one embodiment, the handoff direction message indicates the pilot sets for both the traffic channel and the FBSCH. As discussed, SHO groups determine the Active Set for a F-BSCH.
[0093] In accordance with another embodiment, no information pertaining to the F-BSCH is sent in the handoff direction message because the F-BSCH is not a dedicated channel. Rather, the F-BSCH SHO groups for each sector are sent via dedicated mode counterparts to overhead messages.
[0094] Note that whether the F-BSCH is soft-combined or not depends on the SHO groups involved (as advertised by the Broadcast Service Parameters Message) and is not related to whether the dedicated traffic channel is being soft-combined or not.
[0095] One skilled in the art will appreciate that although the flowchart diagrams are drawn in sequential order for comprehension, certain steps can be carried out in parallel in an actual implementation. Furthermore, unless indicate otherwise, method steps can me interchanged without departing form the scope of the invention.
[0096] Those of skill in the art would understand that information and signals may be represented using any of a variety of different technologies and techniques. For example, data, instructions, commands, information, signals, bits, symbols, and chips that may be referenced throughout the above description may be represented by voltages, currents, electromagnetic waves, magnetic fields or particles, optical fields or particles, or any combination thereof.
[0097] Those of skill would further appreciate that the various illustrative logical blocks, modules, circuits, and algorithm steps described in connection with the embodiments disclosed herein may be implemented as electronic hardware, computer software, or combinations of both. To clearly illustrate this interchangeability of hardware and software, various illustrative components, blocks, modules, circuits, and steps have been described above generally in terms of their functionality. Whether such functionality is implemented as hardware or software depends upon the particular application and design constraints imposed on the overall system. Skilled artisans may implement the described functionality in varying ways for each particular application, but such implementation decisions should not be interpreted as causing a departure from the scope of the present invention.
[0098] The various illustrative logical blocks, modules, and circuits described in connection with the embodiments disclosed herein may be implemented or performed with a general purpose processor, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA) or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed to perform the functions described herein. A general purpose processor may be a microprocessor, but in the alternative, the processor may be any conventional processor, controller, microcontroller, or state machine. A processor may also be implemented as a combination of computing devices, e.g., a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core, or any other such configuration.
[0099] The steps of a method or algorithm described in connection with the embodiments disclosed herein may be embodied directly in hardware, in a software module executed by a processor, or in a combination of the two. A software module may reside in RAM memory, flash memory, ROM memory, EPROM memory, EEPROM memory, registers, hard disk, a removable disk, a CD-ROM, or any other form of storage medium known in the art. An exemplary storage medium is coupled to the processor such the processor can read information from, and write information to, the storage medium. In the alternative, the storage medium may be integral to the processor. The processor and the storage medium may reside in an ASIC. The ASIC may reside in a user terminal. In the alternative, the processor and the storage medium may reside as discrete components in a user terminal.
[0100] The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
[0101] 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.
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A method and system for a handoff in a broadcast communication system is disclosed. A subscriber assisted handoff is impractical in a broadcast communication system due to e.g., a high signaling load, a difficulty to synchronize the broadcast transmission. On the other hand, the small number of broadcast channels enables the subscriber station to perform the handoff autonomously. To streamline the autonomous handoff decision process, several distinct sets of pilot identifiers and rules for transitioning among the sets are defined. To fully integrate broadcast services with the services provided by the cellular telephone systems in a subscriber environment, a methods for various handoff scenarios are analyzed.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of Swiss Patent Application No. 00928/09, filed Jun. 15, 2009, which is incorporated herein by reference as if fully set forth.
BACKGROUND
The invention is directed to a placement device and a method for placing decorative elements on a textile or non-textile sheet material.
Articles of clothing, as well as other textile and non-textile sheet materials can be embellished by applying decorative elements, such as sequins, rhinestones, rivets, and the like. Such applications are realized conventionally by industrial machines constructed especially for each task. Rhinestones are normally covered on the back side with a hot-melt layer. For the industrial production of motifs or arrangements of rhinestones on articles of clothing, the individual rhinestones are typically separated from bulk supplies, arranged, and placed onto the article of clothing. The fixing or connecting process to the article of clothing is performed immediately after the setting process, wherein the hot-melt adhesive is activated, e.g., by supplying energy by an ultrasonic sonotrode. It is also known to apply industrially prefabricated motifs in mirror-inverted representation on transfer films. Here, the rhinestones are placed on this transfer film with the visible side directed toward the self-adhesive transfer film and then covered with an additional protective film. Such arrangements of rhinestones produced as unfinished products can then be purchased and bonded on surfaces in the desired way or connected rigidly to these surfaces by means of conventional flat irons or presses. For guaranteeing high quality, the most uniform possible supply of a certain quantity of energy to each of the rhinestones is advantageous.
Alternatively, rhinestones could also be applied at home, e.g., individually by tweezers onto a transfer film. Or the rhinestones are held and placed directly onto the article of clothing. Then, through a piston-like applicator with an electrical heating device or an ultrasonic sonotrode, the required energy is fed for heating the adhesive for connecting the rhinestone to the article of clothing. Such applicators can be adapted, e.g., by adapters to different sizes and shapes of the rhinestones.
Conventionally, the efficient application of individually shaped rhinestone arrangements on articles of clothing is possible only by expensive machines designed for commercial use. These machines are constructed only for the application of rhinestones and are not suitable for other decorative elements.
SUMMARY
Therefore, the objective of the present invention is to create a device and a method that allow, also in the home, a simple and efficient production of individual rhinestone applications. An additional task of the invention lies in constructing the device and the method so that, as an alternative or addition to rhinestones, other decorative elements, such as, e.g., rivets, sequins, stones, films, stamps, etc., can also be applied onto a sheet material.
These tasks are achieved by a placement device that can be connected to a sewing machine and by a placement method for textile and non-textile sheet materials according to the invention.
The invention uses the knowledge that the placement of decorative elements at certain positions of an sheet material has similarities with the construction of sewing stitches by a sewing machine during sewing or embroidery, and that functions of a sewing machine—be it now functions of the electronic sewing machine control or mechanical movement sequences—can be used for the arrangement of decorative elements at certain positions of an sheet material. The placement device according to the invention is connected to a household sewing machine and uses functions of this sewing machine for applying or setting decorative elements at positions that are or can be specified in advance on a textile or non-textile sheet material. For an advantageous construction of the invention, instead of a conventional presser foot, the placement device can be attached to the presser foot bar of the sewing machine. The placement device comprises a placement head that can be controlled by the control of the sewing machine for the sequential application of decorative elements at positions that can be or are specified in advance on the sheet material. For this purpose, the sheet material can be moved relative to the placement device selectively, e.g., by hand or by an embroidery hoop or by a different positioning or transport device, such as, e.g., the feed dog of the sewing machine. Alternatively, the placement device or the sewing machine with the placement device could also be moved equivalently relative to the sheet material.
The individual set positions can be stored, e.g., analogous to the embroidery positions when embroidering with an embroidery program and can be called up by the sewing machine control.
According to the construction of the invention, the term “control” can comprise only the sewing machine control itself or also one or more additional control devices interacting with the sewing machine control, for example, control electronics of the placement device or an embroidery hoop or a computer with a higher rank than the sewing machine. The decorative elements are ready-to-use and—in contrast to bulk goods—are stored in a defined way in a storage medium or magazine. Such a magazine could have a different construction. Through the use of a corresponding feeder device, the magazine or parts of this can be moved in a controlled way by the control, such that decorative elements stored in the magazine can be relocated by the placement head from the magazine to the desired positions on the sheet material. Alternatively, the feeder device could also move the decorative elements directly, in order to bring these into a suitable transfer position. The application of the decorative elements can be performed selectively by hand or individually (e.g., triggered by a foot switch) or controlled by a program or automatically (analogous to an embroidery program).
The placement head can be constructed and act differently consistent with the magazines being used and each feeding device. It could comprise, for example, a shuttle or a collet chuck with which the decorative element is moved in a suitable way to the corresponding support position and then released again at the set position on the sheet material. The placement head can also comprise an element for pressing decorative elements out from a hold of the magazine and/or for pressing decorative elements onto the sheet material, wherein the contact force advantageously can be set or adjusted or controlled. In particular, the placement head could be arranged and constructed so that it can be activated by movements or by the application of force by the needle bar. Alternatively or additionally, other movements of the sewing machine, such as, e.g., those of the sewing foot presser bar or the feed dog (in or perpendicular to the sewing direction) or the application of forces from additional drives (e.g., step motors, magnets, pneumatic suction devices) could also be used to move the placement head so that it takes decorative elements from the magazine and arranges them in the desired way on the sheet material.
For an advantageous construction of the invention, the magazine is constructed like a kind of cartridge or a parts dispenser. This is lowered at each of the set positions by the movement of the needle bar in the direction of the sheet material. Shortly before reaching the lowermost position, e.g., an activation lever constructed on the magazine contacts a step of the placement device or on the sheet material. For the further lowering of the magazine, a slide or a flap is opened on the magazine, so that an individual decorative element falls from the magazine directly on the sheet material at the provided position. If the placement device is constructed accordingly, the decorative element can also be pressed onto a transfer film. Therefore, a better fixing on the sheet material is possible. Due to the small distance to the sheet material and optionally, e.g., a funnel-like guide constructed on the placement device, the decorative element comes to lie exactly on the desired position or set position on the sheet material. Alternatively, the decorative element could also be transferred in an analogous way to a moving arm or lever or placement device and fed indirectly from this to the provided position.
Advantageously, the magazines have supporting positions adapted to the geometry of the corresponding decorative elements. These supporting positions can be arranged or lined up relative to each other, e.g., at specified constant or standardized distances. An example here is a transport tape or carrier tape with tubs in an equidistant arrangement as supporting positions. Feeding devices for such magazines could be constructed very easily, because the carrier tape must be advanced by only a given distance between two adjacent supporting positions. For this purpose, for example, the sewing movement (up-and-down movement) or the zigzag movement of the needle bar can be used, wherein, e.g., one or more pins connected to the needle bar engage in a regular perforation arrangement along the carrier tape. For alternative embodiments of the placement device, differently constructed magazines, such as, e.g., revolvers or rotary plates, and/or other drives, such as, e.g., step motors or pneumatic parts operating with an overpressure and/or negative pressure can be used for moving magazines and/or parts of magazines and/or decorative elements supported in magazines. There is also the ability for the magazines to have a refillable construction, such that these can be loaded individually with a desired combination of identical or different decorative elements. For placement, the decorative elements are placed in the specified sequence of support positions at the provided set positions on the sheet material.
As an alternative to supporting positions lined up in one dimension, magazines could also comprise supporting positions arranged in a defined way like an array in several rows or in a different way. If necessary, additional parameters could be set for individual supporting positions of the magazines or for groups of supporting positions, wherein these parameters can be taken into account by the control for setting the decorative elements. Such parameters can comprise, for example, information on the type, size, color, desired connection technique, etc., of the decorative elements supported at these support positions and/or information on the support positions themselves, e.g., information on their shape, size, arrangement, orientation, and the like. Such parameters can be reported to the control, e.g., by an input terminal and stored in a storage medium. Alternatively, sensors could also be provided for detecting individual, multiple, or all of the parameters to be detected. In particular, for this purpose, an image sensor or a camera could be used in connection with an image-processing device. As an alternative to the direct detection of such parameters, these could also be detected in advance during production or during the filling of the magazines and stored in a suitable storage medium on each magazine. Such storage media are, e.g., stitch codes or RFID tags. They could be detected by a corresponding reading device of the placement device and processed by the control.
The consideration of such information detected and stored in advance makes the placement process significantly more flexible: with reference to stored parameter values, e.g., a targeted access to supporting positions of difference decorative elements is possible. In this case, it is not necessary to access adjacent supporting positions in a specified sequence.
The orientation of a decorative element or its positional angle relative to the sheet material can be, according to the construction of the invention, e.g., random or defined by a forced or specified position of the decorative element at or in the supporting positions of the magazine. Thus, the supporting positions could comprise, e.g., springs or other elastically flexible parts, such as coverings that are made from silicon rubber and that hold the decorative elements in a defined position. As an alternative or addition, the placement head could comprise a rotating device that could be used for orienting the decorative element. In connection with a camera, the control can automatically recognize the position and situation of decorative elements at the supporting positions of the magazines and can place the decorative elements in the specified orientation on the sheet material. The invention comprises magazines and feeding devices in different constructions. Advantageously, for moving the feeding device and/or the placement head, drives of the sewing machine are used (e.g., drive for the needle bar movement, the zigzag movement of the needle bar, feed dog drive, lifting movement of the sewing presser foot bar). Alternatively or additionally, motors of an embroidery module (x-y table) connected to the sewing machine or other external actuators that can be controlled by the sewing machine, such as, e.g., magnets or step motors could also be used for this purpose. Suitable magazines are, e.g., carrier tapes, belts, cassettes, cartridges, parts dispensers, capsules connected flexibly or rigidly to each other, rotary plates, and the like.
With the placement device according to the invention, decorative elements can be placed selectively on textile or non-textile sheet materials. In particular, decorative elements could also be applied to transfer films and later connected to the desired surfaces.
In addition to setting or arranging the decorative elements, the placement device can also comprise a joining or connecting device for the temporary or permanent connection of the decorative elements to the sheet materials. This connecting device can be constructed for performing one or more different joining techniques. Examples here are hot melt adhesive, gluing, welding, sewing, rivets. The individual decorative elements are advantageously connected to the sheet material during or immediately after the setting, so that they maintain the desired positioning. For this purpose, the connecting device could be formed completely or partially on the placement head.
For activating a hot-melt adhesive on the decorative element, the required thermal energy can be supplied locally to this element, e.g., in a non-contact method by a laser or through contact with an applied ultrasonic sonotrode or an electrical heating device.
For bonding decorative elements by other adhesives, the placement device can advantageously comprise a glue dispenser on the placement head. Before placing and pressing a decorative element on the sheet material, a small dose of adhesive is deposited either on the bottom side of the decorative element or on the provided placement site of the sheet material. Alternatively, the bottom sides of the decorative elements could also be equipped with micro-encapsulated adhesive. During placement, these decorative elements are pressed with sufficient force onto the sheet material. In this way, the micro-capsules burst. The released adhesive connects the decorative elements to the sheet material.
Certain decorative elements, such as, e.g., rivets or deformable foil or stamp parts, can be attached on the sheet material by shaping techniques, such as, riveting or crimping. Perforated decorative elements, such as, e.g., sequins or buttons, could also be sewn tightly on the sheet material. This obviously also applies for textile or other parts that can be pierced by a sewing needle or for fitted parts or parts to be sewn on in some other way. Because the sewing machine is already constructed for this connection technique, it is not necessary to also construct a corresponding connecting device on the placement device. If the placement device is to be used in connection with a sewing process for attaching the decorative elements, then they must be constructed and attached to the sewing machine, so that the sewing process is not hindered. Decorative elements can be sewn tight, e.g., immediately after being set. Alternatively, the decorative elements could also be placed in a first processing step temporarily, e.g., by means of a replaceable double-sided adhesive non-woven material on the sheet material and then sewn tight in a second processing step. Such non-woven materials can also contain adhesives for a permanent connection that can be activated, e.g., by pressure.
The placement device or parts of this can be connected as described to the sewing machine in the region of the sewing machine head above the sheet material to be processed or alternatively in the region of the bottom arm of the sewing machine underneath the sheet material to be processed. Combinations with interacting, active and/or passive parts on both sides of the sheet material to be processed are also possible. Thus, for example, the placement head could be attached to the sewing foot pressure bar above the sheet material and activated by the movement of the needle bar. The stitch plate of the sewing machine can be replaced, e.g., by a passive work plate that comprises contact zones corresponding to the placement head for pressing the decorative elements. In addition, in the region of the bottom arm or the work plate, templates needed, e.g., for crimping, stamping, or riveting for the shaping or some other processing of the decorative elements could be constructed. Instead of or in addition to such passive elements or connection means, active elements for connecting the decorative elements to the sheet material could also be provided. Examples here are heating devices, ultrasonic sonotrodes, or UV light sources for activating or hardening the adhesive. For alternative embodiments of the placement device, decorative elements could also be placed on the sheet material from the bottom side or on both sides.
BRIEF DESCRIPTION OF THE DRAWINGS
Two example embodiments of the invention are described in detail with reference to the drawing figures. Shown here are
FIG. 1 is a schematic representation of a placement device attached to the sewing foot presser bar in a first embodiment.
FIG. 2 is a schematic representation of a placement device attached to the sewing foot presser bar in a second embodiment for the removal of a rhinestone from a cartridge-like magazine.
FIG. 3 is a view of the placement device from FIG. 2 , wherein the rhinestone is relocated by a lever mechanism into a position suitable for placement on a transfer film.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In a schematic representation, FIG. 1 shows a first embodiment of a placement device 3 that is used for decorative elements 5 and that is attached analogously to a presser foot to a material pressure foot or presser foot 1 of a sewing machine. In the illustrated example, these decorative elements 5 are rhinestones 5 a that are held detachably at regular or identical intervals A on a tape-shaped, rolled-up carrier tape 7 a . The carrier tape 7 a is a special construction of a magazine 7 that is constructed for the ordered storage of decorative elements 5 and for feeding these decorative elements 5 to a part of the placement device 3 designated, in general, as placement head 9 . The placement device 3 comprises a base part 11 with a sewing presser foot shaft 13 for holding the normally conical lower end of the sewing pressure foot bar 1 . The base part 11 is connected rigidly to the sewing presser foot bar 1 analogous to a sewing presser foot by a retaining clip 15 . On the base part 11 , a replaceable supply roll 17 and a take-up roll 19 are each supported so that they can rotate. The carrier tape 7 a with the rhinestones 5 a is rolled up on the supply roll 17 . The front end of the carrier tape 7 a is connected to the take-up roll 19 so that the carrier tape 7 a can be unwound from the supply roll 17 onto the take-up roll 19 . Between the supply roll 17 and the take-up roll 19 , the carrier tape 7 a is guided by a convexly curved guide web 21 constructed on the bottom side of the base part 11 under the needle bar 23 of the sewing machine. Advantageously, the carrier tape 7 a is held slightly in tension between the supply roll 17 and the take-up roll 19 , so that it contacts the guide web 21 in a defined way. In the region of the lowest-lying position of the guide web 21 , a continuous borehole 25 is defined coaxial to the needle bar axis, wherein a pin or press plunger 27 is supported so that it can be moved in this borehole in the axial direction. The press plunger 27 is loaded by a restoring spring 28 and held on the guide web 21 or, in general, on the base part 11 , such that its lower-lying contact face 29 does not project beyond the borehole 25 without the action of additional forces. An advantageously impact-damping contact plate 31 is formed on the upper end of the press plunger 27 .
For performing a lowering movement of the needle bar 23 in the direction of arrow B 1 , as it is otherwise constructed for sewing or embroidering, a feeding device 35 (shown only symbolically by a rectangle for the sake of better clarity) transports the carrier tape 7 a forward by an advance length that corresponds to the distance A between adjacent bearing positions of the carrier tape 7 a . The downward movement of the needle bar 23 is used for driving the feeding device 35 . For this purpose, e.g., a catch (not shown) can extend on the needle bar 23 , wherein this catch comes in contact with a corresponding activation lever (not shown) on the base part 11 for the downward movement of the needle bar 23 . The activation lever is moved at least on one section of the downward movement of the needle bar 23 by the catch and thus drives the feeding device 35 . The feeding device 35 can comprise, e.g., a latch mechanism (not shown) that moves the carrier tape 7 a forward exactly by the desired advance length in the provided feeding direction. Alternatively or additionally, the movement of the needle bar 23 could also be used to rotate the take-up roll 19 and/or the supply roll 17 in a corresponding way or to tension a spring drive (not shown) that keeps the carrier tape 7 a slightly tensioned between the supply roll 17 and the take-up roll 19 . In this position, the decorative element 5 located under the press plunger 27 has a small distance H 1 to the sheet material 39 of, for example, 2 to 4 mm. Advantageously, this distance H 1 is somewhat larger than twice the maximum height H 2 of that of the decorative element 5 to be placed, with the height of this element typically lying, in the case of rhinestones 5 a , on the order of magnitude of approximately one to two millimeters. In this way it is achieved that the sheet material 3 can still be moved freely in a horizontal placement plane even for decorative elements 5 that have been already placed. Alternatively, the feeding device 35 could also be driven by upward movements or by zigzag movements of the needle bar constructed perpendicular to these upward movements. By advancing the carrier tape 7 a , the next support position with the next decorative element 5 to be placed comes to lie directly under the press plunger 27 . In agreement with the advancement of the carrier tape 7 a , the take-up roll 19 and the supply roll 17 rotate in rotational directions specified by the arrows B 2 and B 3 .
After the decorative element 5 to be placed has been brought into the correct transfer position under the press plunger 27 through the advancing of the carrier tape 7 a , for further lowering of the needle bar 23 , its lower end or the needle holder 33 arranged there contacts the contact plate 31 shortly before reaching the reversing point. For the further downwards movement, the needle bar 23 presses the press plunger 27 downward against the force of the restoring spring 28 . The contact face 29 presses from the back side against the carrier tape 7 a , and, indeed, exactly at the support position with the decorative element 5 to be placed. In this way, the decorative element 5 is released from the carrier tape 7 a and falls onto the sheet material 39 that is located at a small distance underneath and that is tensioned in an embroidery hoop 37 . In the shown example, the sheet material 39 is a self-adhesive transfer film. The flexible carrier tape 7 a comprises an adhesive layer or advantageously isolated adhesive spots at the individual bearing positions on the side facing the sheet material 39 . The back sides of the rhinestones 5 a that are opposite the visible sides and that coated with activatable adhesive are attached in a detachable way on the carrier tape 7 a at their adhesive positions. As an alternative to attaching the rhinestones 5 a by adhesive, the supporting positions of the carrier tape 7 a can also comprise, e.g., receptacles made from silicone or a different elastically spring-like material that surround the decorative elements 5 in a non-positive fit and hold them in a defined position on the carrier tape 7 a . For the back-side pressure of the press plunger 27 , the decorative elements 5 are released from the hold and placed on the sheet material 39 .
As an alternative to letting the decorative elements 5 fall from a low height, the carrier tape 7 a could also be pressed downward by the stroke of the press plunger 27 (due to the movement of the needle bar 23 up to its lower reversing point) and/or optionally by the vertical lifting movement of the sewing foot presser bar 1 . The lowering movement of the sewing foot presser bar 1 with the base part 11 attached to it is shown in FIG. 1 by the arrow B 4 . The decorative elements 5 are pressed by the press plunger 27 onto the sheet material 39 . If the lowering movement of the spring-mounted sewing foot presser bar 1 is used for pressing the decorative element 5 onto the sheet material 39 , then the decorative elements 5 can be pressed onto the sheet material 39 in a simple way with a contact pressure force that is or can be specified. The sheet material 39 is here supported on a work plate 41 . As the work plate 41 , for simple constructions of the invention, the stitch plate of the sewing machine can be used. In this case, the axes of the needle bar 23 and the press plunger 27 are advantageously arranged slightly offset relative to each other, so that a suitable contact face of the stitch plate without openings or other interfering elements lies directly underneath the press plunger 27 . For alternative constructions, the work plate 41 could also comprise passive or active parts that have a certain function for setting and optionally for connecting the decorative elements 5 to the sheet material 39 . Such parts are passive anvils that are, e.g., flat or adapted to the shape of the decorative elements 5 and to the corresponding connection technique or active stop elements that are formed, e.g., for heating the connection point between the pressed decorative element 5 and the sheet material 39 . Heating can be performed, e.g., by electrical heating elements, laser light, or ultrasound.
When placing on a transfer film, normally no active parts are required on the side of the work plate 41 . For a corresponding stroke of the press plunger 27 and the sewing foot presser bar 1 , the decorative elements 5 could also be pressed onto the adhesive layer of the transfer film with a specified force. If the decorative elements 5 are likewise attached with adhesive on the carrier tape 7 a , then the adhesion there should be lower than for the adhesive of the transfer film. For contact with the transfer film, the decorative elements thus remain bonded to the transfer film, if the needle bar 23 and thus also the press plunger 27 moves upward again.
The sewing machine control or a computer with a higher rank than this control controls the embroidery module connected to the sewing machine with the movable embroidery hoop 37 and the sheet material 39 tensioned in this hoop and the placement device 3 analogous to an embroidery program in the way that, instead of sewing stitches, decorative elements 5 are placed on the sheet material 39 and temporarily or finally connected to this. In the case of sheet materials 39 in the form of transfer films, mirror-inverted patterns or arrangements of decorative elements 5 can be created that are then transferred in an additional processing step that is independent of the placement, e.g., through fusing by means of heat as a whole onto an article of clothing or onto a different sheet material 39 and attached to this clothing or material.
Alternatively, decorative elements 5 , such as, e.g., rhinestones 5 a , could be arranged and attached with the placement device 3 according to the invention also directly on the final sheet material 39 —for example, on an article of clothing. In this case, the individual rhinestones 5 a are placed on the sheet material 39 directly with the back side opposite the visible side. The attachment on the sheet material 39 is realized directly after setting each rhinestone 5 a , wherein, e.g., micro-adhesive capsules on the back side of the rhinestones 5 a are crushed by the pressure of the press plunger 27 . In this way, the adhesive is released and the rhinestones 5 a are finally bonded with the sheet material 39 . Alternatively, adhesives can be activated, e.g., also through the supply of thermal energy or through light, in order to connect the decorative elements 5 to the sheet material 39 . In particular, there is also the ability to deposit an adhesive only directly before the application of each decorative element 5 onto this element or onto the corresponding connection point on the sheet material 39 . For this purpose, an adhesive cartridge (not shown) could be arranged, e.g., on the placement device 3 . Prior to setting the decorative element 5 , the control can trigger the dosing of a specified amount of adhesive from the adhesive cartridge onto the desired position, e.g., through a zigzag pivoting motion of the needle bar 23 . If necessary, for depositing the adhesive, the sheet materials 39 tensioned in the embroidery hoop 37 can be temporarily shifted into a different position corresponding to the adhesive cartridge and then shifted back again.
The placement device 3 according to the invention can also be constructed for feeding and attaching decorative elements 5 to sheet materials 39 by means of other connection techniques, such as, e.g., sewing, riveting, stamping, crimping, etc. (not shown).
For an additional embodiment of the invention, as shown in FIG. 2 , the magazine 7 is constructed as a cartridge 7 b or frame and is placed detachably on the base part 11 or is connected to this part in some other way. A first leg 11 a of the base part 11 is attached like in the embodiment according to FIG. 1 to the sewing foot presser bar 1 . The cartridge 7 b is attached to a second leg 11 b of the base part 11 , wherein the two legs 11 a , 11 b enclose an obtuse angle α of, e.g., 120°.
Rhinestones 5 a or other decorative elements 5 are stacked in an ordered way in a holding sleeve 43 of the cartridge 7 b adapted to the size of these decorative elements 5 . The schematic representation in FIG. 2 shows, for the sake of better clarity, only a few of the stacked rhinestones 5 a . A front-side removal opening 45 of the holding sleeve 43 can be covered by a closing mechanism. Advantageously, this closing mechanism comprises closing flaps 47 that are held by spring force in a closed position. On the back, a magazine spring 49 presses the stacked decorative elements 5 in the receiving sleeve 43 forward, wherein the front-most decorative element 5 is queued at the closed closing flaps 47 . Alternatively—for sufficient inclination of the second leg 11 b —instead of a magazine spring 49 , the force of gravity of the decorative element 5 can be used for its advance within the magazine 7 . In an arrangement according to FIG. 2 , the placement head 9 comprises angled transport lever 51 that can pivot about a first pivot axis Z 1 on the base part 11 with a take-up device 53 for transferring the front-most decorative element 5 from the cartridge 7 b and for transporting this element to the placement position on the sheet material 39 . In the representation in FIG. 2 , the transport lever 51 is in a loading position, wherein the take-up device 53 is arranged under the removal opening 45 of the cartridge 7 b . By lowering the needle bar 23 , first the closing flaps 47 are opened against the closing spring force. As a drive, here the needle bar movement is used in connection with a feeding device 35 shown schematically only as a rectangle for the sake of simplicity. In this way and through the application of force of the magazine spring 49 , the lowermost decorative element 5 is transferred from the cartridge 7 b to the take-up device 53 . It is held tight there predominantly, e.g., pneumatically, by negative pressure or with a spring-mounted clamp (not shown). For further downward movement of the needle bar 23 , the feeding device 35 closes the closing flaps 47 again. Through further downward movement of the needle bar 23 up to the lower reversing point, the placement head 9 is activated and here pivots the transport lever 51 with the decorative element 5 held on this lever into a placement position, as shown in FIG. 3 .
In FIGS. 2 and 3 , the arrows designated with B 1 show the lowering movement of the needle bar 23 , the arrows designated with B 5 show the pivoting movement of the transport lever 51 about the first pivot axis Z 1 , and the arrows designated with B 6 show the pivoting movement of a guide rod 55 that is held on the base part 11 so that it can pivot about a second pivot axis Z 2 . When the needle bar 23 is lowered and raised, its movement is transferred by a coupling element 57 to the guide rod 55 . This realizes a pivoting movement about the second pivot axis Z 2 . This movement is in turn transmitted by one or more hinges 59 supported on the transport lever 51 so that they can move, such that the placement head 9 rotates from the loading position according to FIG. 2 to the placement position according to FIG. 3 or vice versa. In the placement position, the decorative element 5 —similar to the embodiment according to FIG. 1 —is placed at the desired position on the sheet material 39 and attached to this material. For the subsequent raising of the needle bar 23 , the placement head 9 pivots back into the loading position, in order to receive the next decorative element 5 from the magazine 7 .
In addition to these two precisely described embodiments, the invention comprises a plurality of additional placement devices 3 that can be mounted on a sewing machine and that can be used in connection with the control of the sewing machine or a control with a higher rank than or interacting with this control for setting and optionally for fixing decorative elements 5 on sheet materials 39 . Advantageously, this sheet material 39 is tensioned in an embroidery hoop 37 or a different tensioning device and can be oriented relative to the placement head 9 in a way controlled by the control. In this way, functions (control functions and/or mechanical functions) of the sewing machine and/or accessory parts of the sewing machine can be used for placing decorative elements 5 . In particular, control functions of embroidery programs and movements of parts of the sewing machine can be used, in order to arrange decorative elements 5 or, in general, arbitrary individual parts on the sheet material 39 .
LEGEND OF THE REFERENCE SYMBOLS
1 Sewing foot presser bar
3 Placement device
5 Decorative elements
5 a Rhinestones
7 Magazine
7 a Carrier tape
7 b Cartridge
9 Placement head
11 Base part
13 Sewing foot shaft
15 Retaining clip
17 Supply roll
19 Take-up roll
21 Guide web
23 Needle bar
25 Borehole
27 Press plunger
28 Restoring spring
29 Contact face
31 Contact plate
33 Needle holder
35 Feeding device
37 Embroidery hoop
39 Sheet material
41 Work plate
43 Take-up sleeve
45 Removal opening
47 Closing flaps
49 Magazine spring
51 Transport lever
53 Take-up device
55 Guide rod
57 Coupling element
59 Hinge
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A placement device ( 3 ) for placing decorative elements ( 5 ) on a textile or non-textile sheet material is connected to a sewing machine. The decorative elements ( 5 ) are stored in an ordered way in magazines ( 7 ) and are fed in a controlled way by the control of the sewing machine to the appropriate set positions on the sheet material ( 39 ) and are connected to this material.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of prior U.S. Provisional Application No. 61/348,629 filed on May 26, 2010, which is incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field
[0003] This invention relates generally to the production of natural fiber textiles, including those made from naturally-occurring materials such as silk cocoons.
[0004] 2. Background and Relevant Art
[0005] Silk is a natural fiber, made of protein, and produced by insects and spiders. For example, the earliest silk was thread obtained from the silk moth Antheraea , and in particular Antheraea mylitta . More recently, workers obtain silk from silkworm species, such as the domesticated silkworm, Bombyx mori ( B. mori ), or the wild silkworm Borocera madagascariensis ( B. madagascariensis ).
[0006] In the case of the domesticated silkworm, B. mori , a worker can obtain silk thread by unwinding a cocoon. (The process of unwinding the silk filaments from the cocoon and combining them together to make a thread of raw silk can be termed “reeling.”) In other cases, such as silkworm species like B. madagascariensis , the silk thread cannot be reeled or unwound, and so a worker may boil the cocoon until it breaks down into its component fiber. After boiling, the worker can spin the silk fiber much like wool, cotton, flax, linen or other fibers that can be bundled into a yarn. Either reeled/unwound silk or spun silk can be transformed into area-covering textiles using warp-weft weaving.
[0007] Unfortunately, silk production can require a substantial farmer financial investment by the farmer in both silkworm seed stock, in larval food plants, and silkworm and plant rearing and growing technology. Similarly, silk thread and textile production can require a substantial, additional investment in spinning and weaving equipment. The initial investment required for silk production, especially with the domesticated silkworm, can make it inaccessible to subsistence farmers without significant, additional, financial resources.
BRIEF SUMMARY OF THE INVENTION
[0008] A new type of non-spun, silk textile can be made with indigenous species of silkworms that feed on indigenous plants. The textile can provide a low-cost alternative to traditional silk production. Instead of decomposing the cocoons into fibers that can be spun or reeled, the cocoons can be used “as is” and assembled into an area-covering fabric. Because the method uses only indigenous plant and animal species, the method may not adversely affect ecologically sensitive sites, and may assist in benefiting ecologically sensitive sites by promoting re-establishment of the native food plants of the indigenous silk moths. At least one embodiment relates to heat treatment used to flatten the cocoons prior to textile production, during assembly, and to construct the textile into three-dimensional forms.
[0009] In one aspect, a textile can include a non-spun silk component. A non-spun silk component can include silk fibers obtained from a silk source. A silk source can be a cocoon, more specifically, a single cocoon. A cocoon can be a silkworm cocoon. The silk fibers may not be reeled, unwound or spun.
[0010] In some embodiments, a non-spun silk component can consist essentially of silk fibers obtained from a single cocoon or silk fibers obtained from a single layer of a cocoon. In other words, a non-spun silk component can be free of a glue, a polymer, a plastic or other binder.
[0011] In some embodiments, a textile can include a plurality of non-spun silk components. A plurality can be any number greater than one, for example, a plurality can be greater than 10, greater than 25, greater than 50, greater than 100, greater than 200, greater than 300, greater than 400 or greater than 500. In some embodiments, each non-spun silk component can consist essentially of silk fibers obtained from a single cocoon or silk fibers obtained from a single layer of a cocoon. Each non-spun silk component can be free of a glue, a polymer, a plastic or other binder.
[0012] In some embodiments, a cocoon can include a plurality of layers. In a preferred embodiment, a cocoon can include an inner layer and an outer layer. In some embodiments, a non-spun silk component can include an inner layer and/or an outer layer.
[0013] In some embodiments, a textile can further include one or more threads. In some embodiments, one or more threads can attach a first non-spun silk component to a second non-spun silk component. In some embodiments, one or more threads can attach a first subset of non-spun silk components to a second subset of non-spun silk components, where a subset can include one or more non-spun silk components.
[0014] In some embodiments, a textile can further include one or more attachment devices. In some embodiments, one or more attachment devices can attach a first non-spun silk component to a second non-spun silk component. In some embodiments, one or more attachment devices can attach a first subset of non-spun silk components to a second subset of non-spun silk components, where a subset can include one or more non-spun silk components. An attachment device can include an adhesive, a clasp, a button, a VELCRO™, a snap, or a zipper.
[0015] In some embodiments, a textile can include a shaped non-spun silk component, wherein the shaped non-spun silk component has been manipulated to obtain its shape. In some embodiments, a component can be manipulated by flattening, cutting, folding or texturizing.
[0016] In some embodiments, a non-spun silk component can include sericin. In some embodiments, the sericin has been redistributed, for example by, heating the sericin.
[0017] In another aspect, a method of preparing a textile can include obtaining one or more non-spun silk components from a silk source. A non-silk component can include silk fibers obtained from a silk source. A silk source can be a cocoon. A cocoon can be a silk worm cocoon. The silk fibers may not be reeled, unwound or spun.
[0018] In some embodiments, a non-spun silk component can consist essentially of silk fibers obtained from a single cocoon or silk fibers obtained from a single layer of a cocoon. In other words, a non-spun silk component can be free of a glue, a polymer, a plastic or other binder.
[0019] In some embodiments, a cocoon can include a plurality of layers. In some embodiments, a cocoon can include an inner layer and an outer layer. In some embodiments, a non-spun silk component can include an inner layer and/or an outer layer.
[0020] In some embodiments, obtaining the one or more silk components can include removing a live, insect pupa and chrysalis from a cocoon. In some embodiments, obtaining one or more silk components can include washing the cocoon, for example, in soap and water. In some embodiments, obtaining one or more silk components can include drying the cocoon. A cocoon can be dried by air drying or drying the cocoon with the assistance of heat. Drying the cocoon with the assistance of heat can be performed with an oven, an iron or a blow dryer, for example. Drying the cocoon with the assistance of heat can also be performed by placing the cocoon in a location which receives sunshine.
[0021] In some embodiments, a method can further include assembling the one or more non-spun silk components.
[0022] In some embodiments, one or more non-spun silk components can be assembled from the cocoon without reeling, unwinding, or spinning.
[0023] In some embodiments, the one or more non-spun silk components can be assembled from the cocoon without reeling, unwinding, or spinning. In some embodiments, assembling the non-spun silk components can include selecting non-spun silk components based on color, quality or size. In some embodiments, assembling the non-spun silk components can include manipulating a non-spun silk component. A non-spun silk component can be manipulated by, for example, flattening, cutting, folding, tinting, dyeing or texturizing. In some embodiments, assembling the non-spun silk components can include positioning the one or more non-spun silk components into a pattern. In some embodiments, assembling the non-spun silk components can include attaching or sewing the one or more non-spun silk components together.
[0024] In some embodiments, assembling the non-spun silk components can include heat treating a non-spun silk component. For example, a non-spun silk component can be ironed.
[0025] In some embodiments, a method can further include ironing the cocoon as a double layer. In some embodiments, a method can further include separating the two layers of the cocoon into two independent components and ironing the separated independent components.
[0026] In some embodiments, a method can include finalizing the one or more non-spun silk components. Finalizing the one or more non-spun silk components can include finalizing the one or more non-spun silk components into a shape.
[0027] In some embodiments, finalizing the assembled non-spun silk components can include forming the assembled non-spun silk components into the shape.
[0028] In some embodiments, finalizing the assembled non-spun silk components can further include heat treating the shaped non-spun silk components.
[0029] In some embodiments, heating the shaped non-spun silk components by use of a heating apparatus can include heating a heating apparatus and/or non-spun silk component to between about 200° F. to about 500° F., preferably about 350° F. In some embodiments, heating the shaped non-spun silk components by use of a heating apparatus can include maintaining the assembled non-spun silk components in or in contact with the heated heating apparatus for between about 2 minutes to about 20 minutes, preferably about 8 minutes.
[0030] In some embodiments, a method can include heat treating. Obtaining one or more non-spun silk components from a silk source, assembling the one or more non-spun silk components and/or finalizing the one or more non-spun silk components can include heat treating.
[0031] In some embodiments, heat-treating the shaped components can include heating the one or more shaped non-spun silk components using a heating apparatus. Heat treating can include heating a heating apparatus and/or a non-spun silk component to a temperature greater than 150° F., greater than 200° F., greater than 250° F., greater than 300° F., greater than 350° F., greater than 400° F. or greater than 450° F. A heat treatment can last for at least 2 minutes, at least 5 minutes, at least 10 minutes, at least 15 minutes, at least 20 minutes or at least 30 minutes. A heat treatment can last for at most 1 hour, at most 45 minutes, at most 30 minutes, at most 15 minutes, or at most 10 minutes. In a preferred embodiment, a heat treatment can last between 2 and 20 minutes, even more preferable, between 5 and 15 minutes.
[0032] One will appreciate that such apparatus can comprise virtually any appropriate heating apparatus such, including but not limited to a convection or conventional heating apparatus (or even a microwave heating apparatus) including a conventional oven, a convection oven, an iron or a microwave oven. A heating apparatus can include vacuum ovens and autoclaves. Heating can include using fire, steam, electricity or irradiation.
[0033] In some embodiments, using a heating apparatus can include one or more of heating the shaped non-spun silk components with an iron, or heating the shaped non-spun silk components by use of an oven.
[0034] Additional features and advantages of exemplary implementations of the invention will be set forth in the description which follows, and in part will be understood from the description, or may be learned by the practice of such exemplary implementations. The features and advantages of such implementations may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. These and other features will become more fully apparent from the following description and appended claims, or may be learned by the practice of such exemplary implementations as set forth hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] In order to describe the manner in which the above-recited and other advantages and features of the invention can be obtained, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof, which are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
[0036] FIG. 1 is a photograph illustrating a cocoon recently spun by a silkworm A. suraka , with caterpillar visible inside;
[0037] FIG. 2 is a photograph illustrating a top view of an inner layer of a cocoon (such as shown in FIG. 1 ), in which an inner layer has been separated from an outer layer;
[0038] FIG. 3 is a photographic depiction of a production team as the members cut and pin cocoons to a patter, and as they sew cocoon components in textile assembly;
[0039] FIG. 4 is a photograph illustrating a textile, such as after the production shown in FIG. 3 ;
[0040] FIG. 5 is a photographic depiction of pendant made from heat-treated wild silk;
[0041] FIG. 6 is a photograph illustrating a close-up view of a non-spun, needled textile assembled from silk cocoons;
[0042] FIG. 7 is another photograph illustrating a close-up view of a non-spun, needled textile assembled from silk cocoons; and
[0043] FIGS. 8 through 10 are photographs illustrating various sequences in one implementation of a disclosed method.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0044] In one aspect, a textile can be a natural textile, for example, silk. A textile may not be or include paper. A textile can be free from a glue, a polymer or other binder. A textile can consist essentially of silk. A silk or silk textile can include non-spun silk. A silk can be made by silkworms.
[0045] In an exemplary embodiment, a silk textile can be made with a species of silkworm indigenous (i.e. native or grown in the region where the textile is made). Preferably, an indigenous silkworm can be fed on indigenous plants (i.e. plants which can be native or can be grown in the region where the silkworm is raised and/or where the textile is made). The textile can provide a low-cost alternative to textile production, for example, when compared to traditional silk production. Instead of decomposing the cocoons into fibers that are spun or reeled, cocoons can be used “as is” and can be assembled into a textile or an area-covering fabric. Decomposing the cocoons into fibers can include removing a fiber from the cocoon to be used as a single fiber or thread. This can be performed by unraveling a fiber from a cocoon. Because the method can use only indigenous plant and animal species, the method may not adversely affect ecologically sensitive sites, and may assist in benefiting an ecologically sensitive site by promoting re-establishment of the native food plants of the indigenous insects, for example, silk worms or silk moths. A method can include heat treatments. Heat treatments can be used to flatten the cocoons prior to textile production, during assembly, and/or to construct the textile into three-dimensional forms.
[0046] For example, assembling flattened, silk cocoons into an area-covering textile or sheet can make a non-spun fabric. A non-spun silk component created can be a textile or can be assembled into a textile including multiple non-spun silk components. This method of constructing a silk textile/fabric can have an added advantage of avoiding the substantial equipment and training costs that can be needed to make spun silk and woven textiles. This method can also take advantage of the fact that cocoons that can be used (e.g. silk cocoons spun by the silk moths in the family Saturniidae) can be coated with a heavy layer of sericin or protein glue that can make the thread difficult to spin and can make the thread almost impossible to reel. Nevertheless, when the cocoon is heated (including by oven-heating or ironing), the sericin can softens and can spread over the fibers to flatten and stiffen them. Upon cooling, the flattened cocoon can be easy to sew into fabric or form into a three-dimensional shape.
Silk Preparation
[0047] A non-spun silk component can be obtained from a silk source, for example, a cocoon, more specifically, a silkworm cocoon. The silk fibers may not be reeled, unwound or spun.
[0048] Obtaining a non-spun silk component can include silk preparation. A silk preparation process can start by removing the live, insect pupa or the chrysalis from the cocoon, exemplified by FIG. 1 . The insect pupae and/or chrysalis can be removed from a cocoon by a number of methods, including, but not limited to, physical extraction (e.g. cutting the pupa and chrysalis from the cocoon). In the alternate, an insect pupae and/or chrysalis can be removed from a cocoon by other physical extraction methods (e.g. crushing the pupa and chrysalis, heat liquefying the pupa and chrysalis) or chemical extraction (e.g. dissolving the pupa and chrysalis in a chemical). The cocoon can then be washed. Washing can include any process for cleaning the cocoon, for example, washing the cocoon in water or washing the cocoon in soap and water. The cocoon can also be dried. Drying can include air drying, blow drying or drying with heat.
[0049] A cocoon can be of a variety of colors, properties (e.g. fiber properties) or qualities. For example, a cocoon can be darker or lighter. A cocoon can include a thick fiber or a thin fiber. The fiber of a cocoon may have a sheen or a gloss. Some cocoons can have fiber that can have a more consistent fiber texture, fiber size, or color. In some embodiments, a cocoon can be selected based on a color, property or quality of a cocoon.
Cocoon Preparation and Assembly
[0050] A method can include a heat treatment. Heat treatments can be a critical component of textile preparation. A heat treatment can be performed during multiple steps, for instance, during the preparation step (e.g. during washing or drying of a cocoon), after drying a cocoon, during the manipulation of a non-spun silk component, or after the manipulation of a non-spun silk component. Heat treatment can include heating to a temperature greater than 150° F., greater than 200° F., greater than 250° F., greater than 300° F., greater than 350° F., greater than 400° F. or greater than 450° F. A heat treatment can last for at least 2 minutes, at least 5 minutes, at least 10 minutes, at least 15 minutes, at least 20 minutes or at least 30 minutes. A heat treatment can last for at most 1 hour, at most 45 minutes, at most 30 minutes, at most 15 minutes, or at most 10 minutes. In a preferred embodiment, a heat treatment lasts between 2 and 20 minutes, even more preferable, between 5 and 15 minutes.
[0051] One will appreciate that such apparatus can comprise virtually any appropriate heat such, including but not limited to a convection or conventional heating apparatus (or even a microwave heating apparatus) including a conventional oven, a convection oven, an iron or a microwave oven. A heating apparatus can include vacuum ovens and autoclaves. Heating can include using fire, steam, electricity or irradiation.
[0052] For example, after drying, the cocoon can be heat-treated as part of assembling the non-spun silk components. The cocoon can be heat treated as a particular layer, such as ironed as a double layer. Alternatively, the layers of the cocoon can be separated into independent components and heat treated (e.g. ironed), such as shown in FIG. 2 . A cocoon can have a plurality of layers. In other words, the cocoon can have more than one layer, for example, two, three, four or more layers. In a preferred embodiment, the cocoon can have two layers, an inner layer and an outer layer. In some embodiments, for example, a worker can iron cocoon as a double layer or a single layer component.
[0053] Heat treatments can be used to soften sericin or protein glue of a cocoon or to change a quality or property of a silk fiber (e.g. soften or stiffen a silk fiber).
[0054] A worker can assemble the non-spun silk components. A non-spun silk component can be a textile. A non-spun silk component can be a cocoon that has been prepared. A heat treatment can include flattening or otherwise shaping a cocoon. A worker can attach or sew the component to make a textile or a textile including multiple non-spun silk components. (For example, FIG. 3 illustrates a team performing various assemblies from the double or single layer components.)
[0055] The non-spun silk components can also be manipulated. For example, a non-spun silk component can be cut, shaped, tinted, dyed, folded or texturized. In some embodiments, a non-spun silk component can be cut into different shapes and/or sizes. A non-spun silk component can be pinned into a pre-designed pattern. This modular approach to fabric assembly and production can allow textiles of any size to be made (e.g., FIG. 4 ). It can also allow the textile to be easily transported, for example, from remote areas to market centers.
[0056] After a fabric or textile has been produced, the fabric or textile can be heat-treated (e.g., ironed and/or oven-heated) to stiffen it once again. If the textile has been formed into a three-dimensional shape, it can be placed in a heating apparatus of sufficient temperature and for sufficient duration.
[0057] For example, in one implementation, the heating apparatus temperature can be between about 200° F. and about 500° F., preferably between about 300° F. to about 400° F. Similarly, the worker can heat the shaped textile in the heating apparatus from about 2 minutes to about 20 minutes, preferably from about 5 minutes to about 15 minutes. In at least one implementation, the worker can heat the shaped silk textile in a heating apparatus that has been heated to about 350° F. for about 8 minutes. After cooling, the textile shape can be retained essentially permanently. Along these lines, FIG. 5 is a photograph illustrating a shaped silk textile that has undergone this additional heating and cooling sequence.
Thread And Stitching
[0058] In at least one implementation, the type of thread used to sew the non-spun silk components into a fabric or textile can be critical to the final design of the fabric. Where it is desired that the thread not be seen, the fabric can be sewn with transparent or “invisible” thread, for example, 100%, polyester and made by SULKY. The thread can be tinted or un-tinted depending on the cocoon color and desired effect. For example, FIG. 6 illustrates a textile made using a translucent/transparent, smoky thread. Of course, one will appreciate that the stitching can be done as part of the macro-pattern of the textile, and a variety of threads and embroidery techniques can be used thereby. In these cases, the thread may be selected to contrast with the cocoon and may be chosen from any type of fiber whether synthetic, natural or mixed synthetic natural.
[0059] FIG. 6 illustrates a textile made using a zig-zag pattern. In one implementation, the illustrated zig-zag stitch can mimic the irregular, fractal-like spinning of the silk moth. One will appreciate that the zig-zag stitch can be sewn by hand or machine. Hence, the micro-design of the resulting fabric can be simply as it appears in nature, but instead of a 2 inch silk fragment (or cocoon) the textile can be extended to any desired size. Furthermore, one will appreciate that the resulting textile can be light-weight, and can be easily shipped in modules.
[0060] Additionally or alternatively, individual cocoon components may also be cut into shapes that are laid in either geometric designs, or non-geometric patterns. For example, FIG. 7 is a photograph illustrating a sequence of standard square or rectangle patterns. Regardless of the textile pattern, the preferred stitching can include a zig-zag stitch, such as exemplified in FIGS. 6 and 7 . Other stitch styles or patterns other than zig-zag can be appropriate in some cases, and such stitching can affect not only style but strength of the end product. In particular, there will be some cases where the stitching forms part of the design, whereas, in other cases, the stitching will not form part of the design, but will provide primarily attachment support between non-spun silk components or components. Furthermore, other attachment means may be useful in some cases beyond stitching or sewing, including attachment methods for example, adhesives (e.g. glues), VELCRO™, snaps, buttons or tapes. It is important to differentiate an adhesive or binder as a means of attaching components from an adhesive or binder used to form a non-spun silk component. An adhesive or binder as an attachment means can be present only on a portion of a non-spun silk component for the purpose of attaching one non-spun silk component to another. An adhesive or binder used to form a non-spun silk component can be present throughout the entirety of a single non-spun silk component for the purpose of creating or stabilizing the non-spun silk component.
[0061] Once the worker has completed assembling and attaching the raw non-spun silk components, the worker can then finalize the textile. In at least one implementation, this finalization can involve heating treating the sewn/attached components. The finalization can, for example, include ironing. The finalization can include ironing and another form of heat treatment. The result can be an aesthetically pleasing textile comprising non-spun silk. The non-spun silk can be light-weight and easily usable in a wide range applications, including jewelry and textiles
[0062] The textile can be free of dye and/or tint. Alternatively, the textile can be dyed or tinted.
[0063] FIGS. 8 through 10 are photographs illustrating various sequences in one implementation of the inventive production process. For example, FIGS. 8 , 9 and 12 illustrate positioning sewn non-spun silk components on a pattern −/− grid. FIGS. 10 and 11 show workers sewing various non-spun silk components that have previously been extracted and cut from cocoons. FIG. 13 shows a large section of nearly finalized textile that has been assembled and shown in a pattern corresponding to the paper grid shown underneath. FIG. 14 is a photograph showing a worker sewing extracted and cut non-spun silk components.
[0064] In describing some embodiments, the term “worker”, “member”, “team” or “team member” has been used to refer to a person. However, it should be understood that a “worker”, “member”, “team” or “team member” can also be a machine or automated device, such that a method or a step of a method can be performed or completed by an automated device or machine. As a non-limiting example, a worker performing a step of sewing silk textile should also be understood to encompass a machine or automated device performing a step of sewing a silk textile.
EXAMPLES
Example 1
[0065] In a series of experiments, cocoons were assembled into two-dimensional textiles. The silk textile can be unique because it is not woven from spun fibers. Instead, the cocoons were treated, assembled and sewn to make a fabric. The preparation process involved removing the insect pupae before emergence, cleaning the cocoon and separating it into its two component layers. The silk was then heat-treated (ironed). The cocoons were used in either their natural form or cut into geometric shapes, such as squares, rectangles and circles. The shapes were sewn together with different types of threads. In the first case, cotton thread whose color matched the cocoons was used. The textile was sewn by hand using a zigzag stitch.
Example 2
[0066] In a second series of experiments, the cocoons were stitched together using 100% polyester, “invisible” thread purchased from Speed Stitch, S.C. Both clear “invisible thread” as well as smoke-tinted, “invisible thread” was used. The cocoons were stitched together using a zigzag stitch by hand or machine. The result was a textile that does not appear to be sewn but the silk pieces appear to be fused. Textiles were made using the natural shape of the cocoon, as well as geometric shapes.
[0067] The invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated also by the appended claims rather than by the foregoing description alone.
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A method for preparing a textile can include obtaining silk components, such as non-spun silk components, from a cocoon. The method can also involve assembling the obtained silk components obtained from the cocoon into a pattern, and attaching the non-spun silk components together. The method can still further involve shaping the attached non-spun silk components, and finalizing the shape through heat-treatment. In one implementation, heat-treatment of the shaped components comprises heating the components with a heating apparatus (e.g., iron, or oven, etc.) for an appropriate time and at an appropriate temperature. A variety of end products, including jewelry, and textiles for further processing generally, can be made from the silk prepared in accordance with an implementation of the invention.
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BACKGROUND OF THE INVENTION
1. Field of Invention
The present invention relates generally to gas heaters and, more particularly, to unvented gas heaters.
2. Description of the Related Art
Gas heaters include one or more heating elements. The heating elements are typically in the form of ceramic plaques. A gaseous air/fuel mixture is burned on the surface of the ceramic plaques which, in turn, radiate heat. Examples of such gas heaters include the GLO-WARM unvented propane gas heater and the GLO-WARM blue flame unvented natural gas heater, both of which are manufactured UNIVERSAL HEATING, INC., located at 3830 Prospect Avenue, Yorba Linda, Calif. 92686, and the assignee of the present application. Unvented gas heaters are designed to be used indoors without pipes or other conduit to vent the heater's exhaust to the atmosphere.
The level of oxygen in the air is typically about 20.9%. It is important that the oxygen level in a room in which an unvented heater is used remain at or near 20.9%, both for proper combustion and safety purposes. An adequate supply of fresh air will maintain the oxygen level at or near the desired level. In buildings with loose structures, such as houses made of wood, an adequate supply of fresh air will enter via wall spaces as well as door and window frames. Other buildings are more tightly sealed. Here, steps should be taken to insure that fresh air is supplied.
Heater users sometimes operate unvented gas heaters in rooms which do not receive an adequate supply of fresh air. Thus, for safety purposes, many unvented heaters include an oxygen depletion sensor (ODS) system which will shut off the heater when the oxygen level in the air drops below a predetermined "unsafe" level (typically about 18%). More specifically, when the oxygen level drops to 18%, the flow of gas to the pilot and burner of the heater will be automatically shut off.
Although unvented heaters with ODS systems are generally quite useful, the inventor herein has determined that there are many disadvantages associated with their use and installation. For example, ODS systems of the type presently know in the art simply turn off the pilot and burner when the oxygen level drops below the predetermined "unsafe" level. If the user fails to properly adjust the doors and windows, the first indication that the ODS system has caused the heater to stop producing heat is typically the cold sensation caused by a drop in room temperature. Other disadvantages are associated with improper installation, which often results in fuel leakage and other unsafe conditions. Combustible gas leaks pose severe hazards to persons and property. Unfortunately, such leakage normally goes undiscovered until the user of the heater, or another person, smells gas. Another disadvantage associated with unvented gas heaters is the production of carbon monoxide gas. The level of carbon monoxide in the air can rise to dangerous levels in environments that do not receive an adequate supply of fresh air.
SUMMARY OF THE INVENTION
The general object of the present invention is to provide a gas heater which substantially obviates, for practical purposes, the aforementioned problems in the art.
More specifically, one object of the present invention is to provide a gas heater which will provide a warning before it stops producing heat in response to a drop in oxygen level. In accordance with one embodiment of the present invention, this objective is accomplished by providing a heater which is capable of determining when the oxygen level has dropped to a level that is below normal, but above the "unsafe" level. The present heater is also capable of conveying this information to the user before the oxygen level reaches the "unsafe" level. The oxygen level information may be conveyed audibly, visibly, both audibly and visibly, or by other means. This embodiment of the present invention provides a number of advantages over presently known gas heaters. For example, the early warning provided by this embodiment of the invention will allow the user to take any necessary steps, such as slightly opening a widow, to insure that there is a proper supply of fresh air and that the oxygen level will remain at an acceptable level.
Another object of the present invention is provide a heater which is less likely than prior heaters to remain in an improperly installed state or in any other state that results in fuel leakage. In accordance with another embodiment of the invention, this objective is accomplished by providing a heater that is capable of sensing fuel leaks and conveying this information to the user. The fuel leak information may be conveyed audibly, visibly, both audibly and visibly, or by other means. As a result, this embodiment is capable of warning the user when a fuel leak occurs, whether the fuel leak is due to improper installation, jolting of the heater, normal wear and tear, or any other circumstances that could result in a leak.
Still another object of the present invention is to prevent the level of carbon monoxide in the room in which a heater is operating from reaching an unacceptable level. In accordance with still another embodiment of the invention, this objective is accomplished by providing a heater which is capable of determining when the carbon monoxide level has reached an unacceptable level. The present heater is also capable of conveying this information to the user. The carbon monoxide level information may be conveyed audibly, visibly, both audibly and visibly, or by other means. This aspect of the present invention provides a number of advantages over prior heaters. For example, it will allow the user to take the necessary steps, such as slightly opening a widow, to insure that the carbon monoxide in the air will remain at an acceptable level.
The above described and many other features and attendant advantages of the present invention will become apparent as the invention becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Detailed description of the preferred embodiments of the invention will be made with reference to the accompanying drawings.
FIG. 1 is a perspective view of the housing of an unvented heater in accordance with a preferred embodiment of the present invention.
FIG. 2a is a partially exploded view of a propane gas heating assembly that may be used in conjunction with the housing shown in FIG. 1.
FIG. 2b is a partially exploded view of a blue-flame type natural gas heating assembly that may be used in conjunction with the housing shown in FIG. 1.
FIG. 3a is a side view of a pilot and oxygen level detection system in accordance with one embodiment of the present invention.
FIG. 3b is a side view of a pilot and oxygen level detection system in accordance with another embodiment of the present invention.
FIGS. 4a-4c are representations of flame progression in accordance with the pilot and oxygen level detection system shown in FIGS. 3a and 3b.
FIG. 5 is a partially exploded perspective view of the unvented heater shown in FIG. 1.
FIG. 6 is a front view of an exemplary display panel.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following is a detailed description of the best presently known mode of carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention. The scope of the invention is defined by the appended claims.
An exemplary heater in accordance with a preferred embodiment of the present invention is shown in FIG. 1. Such a heater may be fueled by natural gas, propane gas or other appropriate fuels. Although the exemplary embodiments shown in FIGS. 1-6 relate to unvented gas heaters, it is to be understood that the present invention need not be limited to this variety of heater. Referring to the numbered elements in FIG. 1, the exemplary unvented heater 10 includes a heating assembly housing 12 mounted on a base 14. The housing 12 includes a heating chamber 16. The heating chamber 16, which contains a plurality of heat emitting infrared burner plaques, is covered by a grill 18. The housing 12 also includes a plurality of air circulation vents 20, 21 (see FIG. 5) and 22, as well as a pair of handles 24. Air enters the housing through vents 20 and 21 and exits through the heating chamber grill 18 and the vent 22.
The heater controls are located on the top portion of the housing 12. In the exemplary embodiment, these controls include an ignition knob 26, a temperature setting knob 28 that is used when the heater is in the thermostatic control mode, and a burner control knob 30 that is used to select the number of burners to which fuel will be supplied. The exemplary ignition knob 26 includes OFF, IGNITE, PILOT and ON settings. The temperature setting knob 28 includes a plurality of numbered settings, each corresponding to a desired amount of heat output. The housing 12 also includes various warning indicators. The exemplary warning indicators consist of a display panel 32 and a loud speaker 34. The display panel 32 includes three lights (numbered 36, 38 and 40), a test/reset button 42 and a numerical display 44. The respective functions and operations of the speaker, lights, test/reset button and numerical display are discussed in greater detail below.
As shown by way of example in FIG. 2a, a propane gas-fueled heating assembly that may be used in conjunction with the housing 12 shown in FIG. 1 includes five burners 46, each of which consists of an infrared ceramic plaque 48 that is secured to a corresponding burner box 50. The number of burners may, however, be increased or decreased to suit particular applications. An upper burner deflector 52 and lower burner deflector bracket 54 are also shown. Propane gas is supplied to the burners and to a pilot system in the following manner. The gas enters the heating assembly through a pressure regulator 56 and an inlet pipe 58. From there, it enters a thermostat control valve 60 such as, for example, the control valve sold under model number GV30-B3A2A8C, by Mertik Maxitrol, located in Quedlinburg, Germany. No gas will pass beyond the control valve 60 when the ignition knob 26 is set to the OFF mode. To place the heater in the pilot mode, the ignition knob 26 is moved from the from the OFF position, past the IGNITE position to the PILOT position. The thermostat control valve 60 will allow gas to pass through a gas line 62 to a pilot 64. The longitudinal end surface of the pilot includes a small nozzle. An ignitor 66, which is connected to the control valve 60 by a wire 67, ignites the gas and a pilot flame is formed. The pilot and ignitor are discussed in greater detail below in conjunction with the present invention's oxygen level detecting capabilities.
After the pilot flame is lit, the thermostat control valve 60 will supply gas to the burners through a gas line 68 and a gas control valve 70. The amount of gas supplied to the burners is mechanically regulated by the thermostat control valve 60 and is equal to that necessary to maintain the temperature specified by the temperature setting knob 28. The temperature is monitored by a thermocouple 72 which is connected to the thermostat control valve 60 by a line 74. The burner control knob 30 in the exemplary embodiment has five settings, OFF, PILOT/IGNITE, LOW, MEDIUM and HIGH, each of which corresponds to a control valve 70 state. No gas is supplied to the burners by the control valve 70 when the control knob 30 is set to OFF or PILOT/IGNITE. When the control knob 30 is set to LOW, MEDIUM or HIGH, gas will be supplied to one, three or five of the burners, respectively, through gas lines 76, 78 and 80.
It should be noted that if, for example, a three burner design is employed, then the corresponding progression could be one, two or three burners. It should also be noted that heaters in accordance with the present invention may also be configured in such a manner that the burner control knob 30 and control valve 70 are both eliminated. When such a configuration is employed, all of the burners will be used whenever the heater is in operation and the amount of gas supplied to the burners will be controlled by the thermostat control valve. Ignition functions may be handled by an ignition switch.
An exemplary natural gas-fueled heating assembly is shown in FIG. 2b. More specifically, a blue-flame type heating assembly has been used as the exemplary natural gas heating assembly. The natural gas heating assembly may be used in conjunction with a slightly modified version of the housing shown in FIG. 1. Such modifications are well within the purview of those of ordinary skill in the art and, therefore, will not be discussed here. The exemplary natural gas-fueled assembly is similar to the propane gas-fueled assembly described above in that it includes a thermostat control valve 60' which receives gas from an inlet pipe 58' and pressure regulator 56'. The desired temperature may be set with a control knob 28' and the actual temperature may be monitored by a thermocouple 72'. The thermocouple 72' is connected to the thermostat control valve 60' by a wire 74'. The thermostat control valve 60' will, in turn, regulate the flow of gas to the natural gas burner 46' through pipe 68'. Gas is also supplied through a pipe 62' to a pilot 64'. The pilot flame is lit by an ignitor 66'.
Oxygen Level Detecting
Referring now to FIG. 3a, a propane gas pilot system 82 in accordance with the present invention includes the aforementioned pilot 64, having a nozzle 71, and the ignitor 66. The ignitor includes an L-shaped electrode 69. An oxygen level detection system is also provided. The present oxygen level detection system includes a first thermocouple 84 which is used to determine when the oxygen level reaches a "low" level (19.0 to 19.2%). The first thermocouple 84 supplies a predetermined voltage to an early warning device (described in detail below with respect to FIG. 5) via a wire 86 when in contact with, or substantially close to, the pilot flame. The early warning device will cause an audible and/or visible "low" oxygen level signal to be produced if this voltage drops. The present oxygen detection system may also include a second thermocouple 88 which is connected to the thermostat control valve 60 by a wire 90. The second thermocouple 88 is used to determine when the oxygen level reaches an "unsafe" level (18.5 to 18.7%) or below. When in contact with or substantially close to the pilot flame, the second thermocouple 88 supplies a predetermined voltage to the thermostat control valve 60. If this voltage is not supplied, the supply of gas to the burners and pilot will be shut off. The effect of dropping oxygen levels and the corresponding operation of the present oxygen detection system will now be described with reference to FIGS. 4a-4c.
In FIG. 4a, the propane gas pilot system 82 is shown operating under "normal" oxygen level conditions (oxygen level greater than or equal to 21%). Here, the flame 92 extends from the pilot 64 through the L-shaped electrode 69 and is in contact with the first thermocouple 84 and the second thermocouple 88. Sufficient voltage will be supplied to both the thermostat control valve 60 and the early warning device. As a result, the early warning device will not cause a "low" oxygen level signal to be produced and the thermostat control valve 60 will not shut off the supply of gas to the burners and pilot.
When the oxygen level drops to a "low" level (19.0 to 19.2%), the flame 92 will move to the position in contact with, or just above, the L-shaped electrode 69 shown in FIG. 4b. The flame 92 is no longer in contact with or substantially close to the first thermocouple 84 and, as a result, the temperature of first thermocouple will drop, as does the voltage produced thereby. When the voltage drops to a predetermined level (such as 3 mV), the early warning device will initiate the "low" oxygen level signal. Users will be warned in the manner described below that the oxygen level has dropped and, if this continues, that the heater will turn itself off. The flame 92 will continue to contact the second thermocouple 88, thereby preventing fuel shut-off by the thermostat control valve 60. Under normal conditions in a typically-sized room, the flame will remain in this location for approximately 8-15 minutes and the user will have plenty of time to take appropriate action, such as opening a window, to raise the oxygen level.
The shape and location of the L-shaped electrode 69 plays a substantial role in maintaining a steady flame in the location shown in FIG. 4b. This electrode reduces the speed of gas flow and increases the duration of gas/air mixing, as well as the effectiveness of the mixing. When prior electrodes, such as those which are substantially S-shaped, are used and the oxygen level is "low," the flame tends to jump around, from the position shown in FIG. 4a to the position shown in FIG. 4b. Such flame movement prevents accurate "low" oxygen level detection.
Once the oxygen level drops to an "unsafe" level (18.5 to 18.7%) or below, the flame 92 will move to location shown in FIG. 4c. Here, the flame is not in contact with or substantially close to either thermocouple and, as a result, the temperature of the second thermocouple 88 will also drop, as will the voltage produced thereby. The supply of gas to the burners and the pilot will then be cut off by the thermostat control valve 60.
The progression described above should be distinguished from those instances where the heater is merely turned off. When the heater is turned off, the flame will move through the sequence shown in FIGS. 4a to 4c and then completely disappear in a matter of seconds. No "low" oxygen level signals will be provided when the heater is merely turned off.
In order to insure that the flame 92 moves in the manner described above with respect to FIGS. 4a -4c, the preferred embodiments rely on a predetermined relationship between the nozzle diameter of the pilot 64, the fuel pressure, the distance of the electrode 69 from the pilot nozzle as well as the location of the L-shaped electrode relative to the nozzle centerline, and the level of oxygen in the air. Referring first to the preferred pilot and oxygen level detection system shown in FIG. 3a, which may be used in conjunction with a propane gas heater, the diameter of the pilot nozzle 71 is approximately 0.23 mm (±0.005 mm) and the gas pressure is between 8 and 11 inches of mercury. The downwardly extending portion of the L-shaped electrode 69 is offset with respect to the centerline CL of the pilot nozzle 71 by 3.00 mm and is spaced approximately 3.50 mm from the nozzle. The second thermocouple 88 is positioned such that its tip is approximately 18.25 mm from the nozzle. With respect to the position of the first thermocouple 84 relative to the electrode 69, distance "a" is approximately 4.00 mm and distance "b" is approximately 2.60 mm. So configured, the propane gas embodiment will provide a warning time of approximately 8-15 minutes in a typical room. In other words, the flame 92 will remain in the position shown in FIG. 4b for approximately 8-15 minutes.
The second preferred pilot and oxygen detection system, which is shown in FIG. 3b, may be used in conjunction with a natural gas heater (see the exemplary natural gas heater shown in FIG. 2b). The embodiment shown in FIG. 3b is substantially similar to that shown in FIG. 3a. However, there are a few differences necessitated by the differences in the manners in which the respective fuels burn and the properties thereof. For example, natural gas has a lower caloric value and its flame length is longer than propane. In the natural gas embodiment, the pilot 64' has a nozzle 71' diameter of approximately 0.46 mm (±0.01 mm) and the gas pressure is approximately 3 inches of mercury. The downwardly extending portion of the electrode 69' is centered with respect to the nozzle of pilot 64' and is spaced approximately 4.20 mm from the nozzle. In addition, distance "a" is approximately 4.25 mm. So configured, the natural gas embodiment will provide the same warning time (approximately 8-15 minutes) as the propane gas embodiment.
Carbon Monoxide and Combustible Gas Leakage Detecting
As illustrated in FIG. 5, an exemplary early warning device 94 may include a carbon monoxide sensor 96 and a gas detection sensor 98. If so desired, the sensors may be protected by an insulating material which will not substantially effect their sensing capabilities. Turning first to the carbon monoxide sensor 96, a suitable sensor is the QM-B thick film gas sensor produced by the Hefei Institute of Intelligent Machines in Hefei, China. The exemplary carbon monoxide sensor 96 sensor will produce an alert signal in response to one or more of the following situations: (1) the level of carbon monoxide in the air remains between 100 ppm and 200 ppm for 60 minutes; (2) the level of carbon monoxide in the air remains between 200 ppm and 300 ppm for 30 minutes; and (3) the level of carbon monoxide in the air reaches or exceeds 300 ppm. After the alert signal is produced, the early warning device 94 will apply a 5 V clear signal to the sensor to return it to its normal state. The carbon monoxide sensor also produces a signal indicative of the level of carbon monoxide in the air (measured in ppm).
A suitable gas detection sensor 98 is the QM-B2 thick film gas sensor produced by the Hefei Institute. Such a sensor will detect most combustible gases, such as natural gas, propane gas, smoke, and oil gas, and produce an alert signal in response thereto. As discussed above, gas leaks may result from a variety of circumstances including, but not limited to, improper installation and use.
The location of the carbon monoxide sensor 96 and gas detection sensor 98 within the housing 12 is also noteworthy. As shown in FIG. 5, these sensors are mounted within a lower compartment 100 that is associated with the air inlet vents 20 and 21. The lower compartment 100 is substantially separated from the heating chamber 16 by a burner deflector plate 101. The deflector plate 101 is spaced apart from the burners in such a manner that a passage for letting air flow from the lower compartment 100 to the heating chamber 16 is formed. Although not visible here, an upper deflector plate is also included and is spaced from the burners so that heat will be able to escape from the housing through the vent 22.
There are a number of advantages associated with this configuration. For example, the temperature within this compartment will normally remain close to room temperature. Note that the temperature sensing thermocouple 72 is also located here.! This is important because the environment in which the sensors are used should remain between -10° C. and 40° C. In addition, by virtue of their close proximity to the inlet vents 20 and 21, the sensors will be sampling air which is representative of that within the room.
Finally, although the respective lower portions of the heating assemblies shown in FIGS. 2a and 2b could, in some instances, be visible in FIG. 5, they have not been shown in order to expose other aspects of the present invention.
Early Warning Indicators
As shown in FIG. 5, the early warning device 94 may, in addition to having the carbon monoxide sensor 96 and the gas detection sensor 98 mounted thereon, also be connected to the first thermocouple 84 by a wire 86. Suitable circuitry is provided so that the early warning device 94 will transmit a number of signals via a ribbon cable 102 to the display panel 32 and to the loud speaker 34, both of which are mounted on a panel 104. Referring to the exemplary display panel 32 shown in FIG. 6, the display panel includes a green light 36 which is indicative of normal operation, a yellow light 38 which is indicative of a "low" oxygen level in the room, and a red light 40 which is indicative of a gas leak. The display panel 32 may also include a test/reset button 42 and a numerical display 44 which displays the carbon monoxide level in ppm. The test/reset button may be used to test or reset the early warning device, as well as the lights, speaker and numerical display.
With respect to "low" oxygen indications, the early warning device is configured such that "low" oxygen level indications will not be produced when the heater is turned off or when the heater is in the process of being turned off or on.
The early warning device 94 and speaker 34 may be configured such that the speaker acts as a simple buzzer in the event of a "low" oxygen level, high carbon monoxide level or gas leak. A voice simulation chip may also be included in the early warning device. Here, the speaker 34 could be used to emit phrases such as "the oxygen level is low," "the carbon monoxide level is high" and "there is a gas leak."
Although the present invention has been described in terms of the preferred embodiment above, numerous modifications and/or additions to the above-described preferred embodiments would be readily apparent to one skilled in the art. By way of example, but not limitation, the present invention may be incorporated in heaters which do not have a thermostatic control system. The "unsafe," "low" and "normal" oxygen level percentages discussed above may be varied if desired. It is intended that the scope of the present invention extends to all such modifications and/or additions and that the scope of the present invention is limited solely by the claims set forth below.
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A heater including a housing, a heating assembly having a burner, and at least one of an oxygen level detection assembly adapted to distinguish between a relatively normal oxygen level, a relatively low oxygen level and relatively unsafe oxygen, a carbon monoxide sensor and a combustible gas sensor. The heater may also include an indicator adapted to produce at least one of an audible indication and a visible indication in response to a detection of a relatively low oxygen level, a detection of a predetermined level of carbon monoxide, or a detection of combustible gas.
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This application is a continuation of U.S. application Ser. No. 14/103,704, filed Dec. 11, 2013, now issued as U.S. Pat. No. 8,894,170 which is a continuation of U.S. application Ser. No. 13/748,355 filed Jan. 23, 2013, now issued as U.S. Pat. No. 8,632,148 which is a Continuation of U.S. application Ser. No. 12/821,324, filed Jun. 23, 2010, now issued as U.S. Pat. No. 8,382,224 which claims priority to Japanese Application No. 2009-151230, filed Jun. 25, 2009. The foregoing patent applications are incorporated herein by reference.
BACKGROUND
1. Technical Field
The present invention relates to a fluid ejection device in which a drive signal is applied to an actuator to eject fluid, and is suitable for a fluid ejection printer adapted to, for example, eject small droplets from a nozzle of a fluid ejection head to form fine particles (dots) on a print medium, thereby printing a predetermined character, image, or the like.
2. Related Art
In the fluid ejection printer, there is provided an actuator such as a piezoelectric element in order for ejecting a droplet from the nozzle of the fluid ejection head, and it is required to apply a predetermined drive signal on the actuator. Since the drive signal has a relatively high voltage, it is required to power-amplify a drive waveform signal forming a basis of the drive signal with a power amplifier circuit. Therefore, in JP-A-2007-168172 (Document 1), there is used a digital power amplifier circuit, which has a smaller power loss compared to an analog power amplifier circuit and can be made smaller in size, a modulator executes pulse modulation on the drive waveform signal to obtain a modulated signal, the digital power amplifier circuit performs power amplification on the modulated signal to obtain a power-amplified modulated signal, and a low pass filter smoothes the power amplified modulated signal to obtain the drive signal.
In the fluid ejection printer described in the Document 1 mentioned above, the digital power amplifier circuit continues to operate even in the case in which the voltage of the drive signal does not change. Since the piezoelectric element used as the actuator of the fluid ejection printer is a capacitive load, even in the case in which the current supply to the actuator is stopped, the voltage of the actuator is kept at the voltage applied immediately before the stoppage. In other words, since the drive signal applied to the actuator or the drive waveform signal forming a basis thereof has a portion (period) with a voltage kept constant, it is not necessary to supply the actuator with a current when the voltage of the drive signal does not change. However, in the fluid ejection printer described in the Document 1 mentioned above, there arises a problem that the digital power amplifier circuit continues to operate, and therefore, the power is consumed in the digital amplifier circuit and the low pass filter even when the voltage of the drive signal does not change.
SUMMARY
An advantage of some aspects of the invention is to provide a fluid ejection device capable of reducing power consumption and a fluid ejection printer using the fluid ejection device.
A fluid ejection device according to an aspect of the invention includes a modulator adapted to pulse-modulate a drive waveform signal forming a basis of a drive signal of an actuator to obtain a modulated signal, a digital power amplifier circuit adapted to power-amplify the modulated signal to obtain a power-amplified modulated signal, a low pass filter adapted to smooth the power-amplified modulated signal to obtain the drive signal, and a power amplification stopping section operating when holding a voltage of the actuator constant.
According to the fluid ejection device of this aspect of the invention, since the operation of the digital power amplifier circuit is stopped when keeping the voltage of the actuator constant, or in other words, keeping the voltage of the drive waveform signal constant, power consumption in the digital power amplifier circuit and in the low pass filter is reduced.
Further, the digital power amplifier circuit has a switching element, and the power amplification stopping section stops the operation of the digital power amplifier circuit by setting all of the switching elements of the digital power amplifier off.
According to the fluid ejection device of this aspect of the invention, since all of the switching elements of the digital power amplifier circuit are off, these switching elements become to be in the high-impedance state, thus the discharge from the actuator (a capacitive load) is prevented.
Further, the modulator stops an output of the modulated signal when the operation of the digital power amplifier circuit is stopped by the power amplification stopping section.
According to the fluid ejection device of this aspect of the invention, since the output of the modulated signal itself is stopped, the power consumption of the modulator and the digital power amplifier circuit is reduced.
Further, the modulator pulse-modulates the drive waveform signal using a first modulation frequency, and the modulator increases the modulation frequency of the pulse modulation from the first modulation frequency when a voltage applied to the drive waveform signal changes from varying to constant.
According to the fluid ejection device of this aspect of the invention, a ripple voltage that causes distortion in the drive waveform signal when stopping the operation of the digital power amplifier circuit is suppressed to enable a waveform of the drive signal to become closer to a desired form.
The modulator pulse-modulates the drive waveform signal using a first modulation frequency, and the modulator increases the modulation frequency of the pulse modulation from the first modulation frequency when a voltage applied to the drive waveform signal changes from constant to varying.
According to the fluid ejection device of this aspect of the invention, a ripple voltage that causes distortion of the drive waveform signal when resuming the operation of the digital power amplifier circuit is suppressed.
When, for the purpose of explaining, a period in which the modulated signal is in a high level is referred to as a first period, and a period in which the modulated signal is in a low level is referred to as a second period, the modulator sets the modulated signal to be at the high level (or the low level) for a half the time of the first period (or the second period) immediately after the voltage of the drive waveform signal changes from constant to varying.
According to the fluid ejection device of this aspect of the invention, a ripple voltage that causes distortion of the drive waveform signal when the voltage of the drive waveform signal changes from constant to varying is suppressed.
Further, the power amplification stopping section temporarily resumes the operation of the digital power amplifier circuit during a stoppage of the operation of the digital power amplifier circuit.
According to the fluid ejection device of this aspect of the invention, a voltage drop by self-discharge in the actuator due to being a capacitive load.
A memory adapted to store the drive waveform signal is further provided, and the memory stores drive waveform voltage difference data.
According to the fluid ejection device of this aspect of the invention, whether the voltage applied to the drive waveform signal is varying or not may be easily determined.
A memory adapted to store the drive waveform signal is further provided, and the memory stores drive waveform voltage data and information regarding whether the voltage of the drive waveform signal is varying or not.
According to the fluid ejection device of this aspect of the invention, determining whether the voltage applied to the drive waveform signal is varying or not is no longer required.
A memory adapted to store the drive waveform signal is further provided, and the memory stores drive waveform voltage data, and the power amplification stopping section calculates a difference between the drive waveform voltage data retrieved from the memory, and stops the operation of the digital power amplifier circuit when the difference indicates a 0.
According to the fluid ejection device of this aspect of the invention, the memory with small capacity can be adopted.
Further, the memory stores a modulation frequency by the modulator.
According to the fluid ejection device of this aspect of the invention, it becomes possible to flexibly set the modulation frequency.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described with reference to the accompanying drawings, wherein like numbers reference like elements.
FIG. 1 is a front view of a schematic configuration showing a fluid ejection printer using a fluid ejection device as an embodiment of the invention.
FIG. 2 is a plan view of the vicinity of fluid ejection heads used in the fluid ejection printer shown in FIG. 1 .
FIG. 3 is a block diagram of a control device of the fluid ejection printer shown in FIG. 1 .
FIG. 4 is an explanatory diagram of a drive signal for driving actuators in each of the fluid ejection heads.
FIG. 5 is a block diagram of a switching controller.
FIG. 6 is a block diagram of a drive circuit of the actuators.
FIGS. 7A and 7B are detailed block diagrams showing an example of the drive circuit shown in FIG. 6 .
FIG. 8 is an explanatory diagram of a modulated signal, a gate-source signal, and an output signal in the drive circuit shown in FIGS. 7A and 7B .
FIGS. 9A and 9B are detailed explanatory diagrams of the modulated signal shown in FIG. 8 .
FIG. 10 is a detailed explanatory diagram of the modulated signal shown in FIGS. 9A and 9B .
FIG. 11 is a waveform chart showing an example of a drive waveform signal.
FIG. 12 is an explanatory diagram of the memory contents showing a first embodiment of the invention.
FIG. 13 is a flow chart of arithmetic processing performed by the controller shown in FIG. 7A in accordance with the memory contents shown in FIG. 12 .
FIG. 14 is an explanatory diagram of the memory contents showing a second embodiment of the invention.
FIG. 15 is a flow chart of arithmetic processing performed by the controller shown in FIG. 7A in accordance with the memory contents shown in FIG. 14 .
FIG. 16 is an explanatory diagram of the memory contents showing a third embodiment of the invention.
FIG. 17 is a flow chart of arithmetic processing performed by the controller shown in FIG. 7A in accordance with the memory contents shown in FIG. 16 .
FIGS. 18A and 18B are detailed block diagrams showing another example of the drive circuit shown in FIG. 6 .
DESCRIPTION OF EXEMPLARY EMBODIMENTS
Then, as a first embodiment of the invention, a fluid ejection device applied to a fluid ejection printer will be explained.
FIG. 1 is a schematic configuration diagram of the fluid ejection printer according to the first embodiment, and in the drawing, the fluid ejection printer is a line head printer in which a print medium 1 is conveyed in the arrow direction from the left to the right of the drawing, and printed in a printing area midway of conveying.
The reference numeral 2 shown in FIG. 1 denotes a plurality of fluid ejection heads disposed above a conveying line of the print medium 1 , which are fixed individually to a head fixing plate 11 in such a manner as to form two lines in the print medium conveying direction and to be arranged in a direction intersecting with the print medium conveying direction. The fluid ejection head 2 is provided with a number of nozzles on the lowermost surface thereof, and the surface is called a nozzle surface. As shown in FIG. 2 , the nozzles are arranged to form lines in a direction intersecting with the print medium conveying direction color by color in accordance with the colors of the fluid to be ejected, and the lines are called nozzle lines, and the direction of the lines is called a nozzle line direction. Further, the nozzle lines of all of the fluid ejection heads 2 arranged in a direction intersecting with the print medium conveying direction constitute a line head covering the overall width of the print medium in a direction intersecting with the conveying direction of the print medium 1 . When the print medium 1 passes through under the nozzle surface of the fluid ejection head 2 , the fluid is ejected from a number of nozzles provided to the nozzle surface to thereby perform printing on the print medium 1 .
The fluid ejection head 2 is supplied with fluids such as ink of four colors of yellow (Y), magenta (M), cyan (C), and black (K) from fluid tanks not shown via fluid supply tubes. Then, a necessary amount of fluid is ejected simultaneously from the nozzles provided to the fluid ejection heads 2 to necessary positions, thereby forming fine dots on the print medium 1 . By executing the above for each of the colors, one-pass printing can be performed only by making the print medium 1 to be conveyed by a conveying section 4 pass through once.
As a method of ejecting a fluid from the nozzles of the fluid ejection head 2 , there can be cited an electrostatic driving method, a piezoelectric driving method, a film boiling fluid ejection method, and so on, and in the first embodiment there is used the piezoelectric driving method. In the piezoelectric driving method, when a drive signal is applied to a piezoelectric element as an actuator, a diaphragm in a cavity is displaced to cause pressure variation in the cavity, and the fluid is ejected from the nozzle due to the pressure variation. Further, by controlling the wave height and the voltage variation gradient of the drive signal, it becomes possible to control the ejection amount of the fluid. It should be noted that the invention can also be applied to fluid ejection methods other than the piezoelectric driving method in a similar manner.
Under the fluid ejection head 2 , there is disposed the conveying section 4 for conveying the print medium 1 in the conveying direction. The conveying section 4 is configured by winding a conveying belt 6 around a drive roller 8 and a driven roller 9 , and an electric motor not shown is coupled to the drive roller 8 . Further, in the inside of the conveying belt 6 , there is disposed an adsorption device, not shown, for adsorbing the print medium 1 on the surface of the conveying belt 6 . For the adsorption device there is used, for example, an air suction device for adsorbing the print medium 1 to the conveying belt 6 with negative pressure, or an electrostatic adsorption device for adsorbing the print medium 1 to the conveying belt 6 with electrostatic force. Therefore, when a feed roller 5 feeds just one sheet of the print medium 1 on the conveying belt 6 from a feeder section 3 , and then the electric motor rotationally drives the drive roller 8 , the conveying belt 6 is rotated in the print medium conveying direction, and the print medium 1 is conveyed while being adsorbed to the conveying belt 6 by the adsorption device. While conveying the print medium 1 , printing is performed by ejecting the fluid from the fluid ejection heads 2 . The print medium 1 on which printing has been performed is ejected to a catch tray 10 disposed on the downstream side in the conveying direction. It should be noted that a print reference signal output device formed of, for example, a linear encoder is attached to the conveying belt 6 . Focusing attention on the fact that the conveying belt 6 and the print medium 1 conveyed by the conveying belt 6 while being adsorbed by the conveying belt 6 are moved in sync with each other, the print reference signal output device outputs a pulse signal corresponding to the print resolution required in conjunction with the movement of the conveying belt 6 after the print medium 1 passes through a predetermined position on the conveying path, and a drive circuit described later outputs a drive signal to the actuator in accordance with this pulse signal to thereby eject the fluid of a predetermined color at a predetermined position on the print medium 1 , thus a predetermined image is drawn on the print medium 1 with the dots of the fluid.
Inside the fluid ejection printer using the fluid ejection device according to the first embodiment, there is provided a control device for controlling the fluid ejection printer. As shown in FIG. 3 , the control device is configured including an input interface 61 for reading print data input from a host computer 60 , a control section 62 configured with a microcomputer for executing arithmetic processing such as a printing process in accordance with the print data input from the input interface 61 , a feed roller motor driver 63 for controlling driving of a feed roller motor 17 coupled to the feed roller 5 , a head driver 65 for controlling driving of the fluid ejection heads 2 , and an electric motor driver 66 for controlling driving of an electric motor 7 coupled to the drive roller 8 , and further including an interface 67 for connecting the feed roller motor driver 63 , the head driver 65 , and the electric motor driver 66 , to the feed roller motor 17 , the fluid ejection heads 2 , and the electric motor 7 , respectively.
The control section 62 is provided with a central processing unit (CPU) 62 a , a random access memory (RAM) 62 c , and a read-only memory (ROM) 62 d . The CPU 62 a executes various processes such as a printing process. The random access memory (RAM) 62 c temporarily stores the print data input via the input interface 61 or data for executing, for example, the printing process of the print data, and temporarily develops a program of, for example, the printing process. The read-only memory (ROM) 62 d is formed of a nonvolatile semiconductor memory for storing the control program and so on executed by the CPU 62 a . The control section 62 obtains the print data (image data) from the host computer 60 via the input interface 61 . Then, the CPU 62 a executes a predetermined process on the print data to obtain nozzle selection data (drive pulse selection data) representing which nozzle the fluid is ejected from or how much fluid is ejected. Based on the print data, the drive pulse selection data, and input data from various sensors, drive signals and control signals are output to the feed roller motor driver 63 , the head driver 65 , and the electric motor driver 66 . In accordance with these drive signals and control signals, the feed roller motor 17 , the electric motor 7 , actuators 22 inside the fluid ejection head 2 , and so on operate individually, thus feeding, conveying, and ejection of the print medium 1 , and the printing process to the print medium 1 are executed. It should be noted that the constituents inside the control section 62 are electrically connected to each other via a bus not shown in the drawings.
FIG. 4 shows an example of a drive signal COM supplied from the control device of the fluid ejection printer using the fluid ejection device according to the first embodiment to the fluid ejection heads 2 , and for driving the actuators 22 each formed of a piezoelectric element. In the first embodiment, it is assumed that the signal has the electric potential varying around a midpoint potential. The drive signal COM is obtained by connecting drive pulses PCOM, each of which is a unit drive signal for driving the actuator 22 to eject the fluid, in a time-series manner. The rising portion of a drive pulse PCOM corresponds to a stage of expanding the volume of the cavity (a pressure chamber) communicating with the nozzle to pull-in (in other words, to pull-in the meniscus, in view of the ejection surface of the fluid) the fluid. The falling portion of the drive pulse PCOM corresponds to a stage of shrinking the volume of the cavity to push-out (in other words, to push-out the meniscus, in view of the ejection surface of the fluid) the fluid, and as a result of pushing out the fluid, the fluid is ejected from the nozzle.
By variously modifying the gradient of increase and decrease in voltage and the wave height of the drive pulse PCOM formed of trapezoidal voltage waves, the pull-in amount and the pull-in speed of the fluid, and the push-out amount and the push-out speed of the fluid can be modified, thus the ejection amount of the fluid can be varied to obtain the dots with different sizes. Therefore, even in the case in which a plurality of drive pulses PCOM are joined in a time-series manner, it is possible to select the single drive pulse PCOM from the drive pulses, and to supply the actuator 22 with the drive pulse PCOM to eject the fluid, or to select two or more drive pulses PCOM, and to supply them to the actuator 22 to eject the fluid two or more times, thereby obtaining the dots with various sizes. In other words, when the two or more droplets land on the same position before the droplets are dried, it brings substantially the same result as in the case of ejecting a larger amount of droplet, thus it is possible to increase the size of the dot. By a combination of such technologies, it becomes possible to achieve multiple tone printing. It should be noted that the drive pulse PCOM1 shown in the left end of FIG. 4 is only for pulling in the fluid without pushing it out. This is called a fine vibration, and is used for, for example, preventing thickening in the nozzle without ejecting the fluid.
Besides the drive signal COM described above, the drive pulse selection data SI&SP, a latch signal LAT, channel signal CH, and a clock signal SCK are input to the fluid ejection head 2 from the control device shown in FIG. 3 as the control signals. The drive pulse selection data SI&SP is used for selecting the nozzle ejecting the fluid based on the print data, and at the same time, determining the connection timing of the actuators 22 such as piezoelectric elements to the drive signal COM. The latch signal LAT and the channel signal CH connects the drive signal COM and the actuator 22 of the fluid ejection head 2 based on the drive pulse selection data SI&SP after the nozzle selection data is input to all of the nozzles. The clock signal SCK is used for transferring the drive pulse selection data SI&SP to the fluid ejection head 2 as a serial signal. It should be noted that it is hereinafter assumed that the minimum unit of the drive signal for driving the actuator 22 is the drive pulse PCOM, and the entire signal having the drive pulses PCOM joined with each other in a time-series manner is described as the drive signal COM. In other words, output of a string of drive signal COM is started in response to the latch signal LAT, and the drive pulse PCOM is output in response to each channel signal CH.
FIG. 5 shows a configuration of a switching controller, which is built inside the fluid ejection head 2 in order for supplying the actuator 22 with the drive signal COM (the drive pulses PCOM). The switching controller is provided with a shift register 211 , a latch circuit 212 , and a level shifter 213 . The shift register 211 stores the drive pulse selection data SI&SP for designating the actuators 22 such as piezoelectric elements corresponding to the nozzles for ejecting the fluid. The latch circuit 212 temporarily stores the data of the shift register 211 . The level shifter 213 performs level conversion on the output of the latch circuit 212 , and then supplies the result to a selection switch 201 , thereby connecting the drive signal COM to the actuators 22 such as piezoelectric elements.
The drive pulse selection data SI&SP is sequentially input to the shift register 211 , and at the same time, the storage area thereof is sequentially shifted from the first stage to the subsequent stage in accordance with the input pulse of the clock signal SCK. The latch circuit 212 latches the output signals of the shift register 211 in accordance with the latch signal LAT input thereto after the drive pulse selection data SI&SP corresponding to the number of nozzles has been stored in the shift register 211 . The signals stored in the latch circuit 212 are converted by the level shifter 213 so as to have the voltage levels capable of switching on and off the selection switches 201 on the subsequent stage. This is because the drive signal COM has a relatively high voltage compared to the output voltage of the latch circuit 212 , and the operating voltage range of the selection switches 201 is also set to be high in accordance therewith. Therefore, the actuator 22 such as a piezoelectric element, the selection switch 201 of which is closed by the level shifter 213 , is coupled to the drive signal COM (the drive pulses PCOM) (switched on) at the coupling timing of the drive pulse selection data SI&SP. Further, after the drive pulse selection data SI&SP of the shift register 211 is stored in the latch circuit 212 , the subsequent print information is input to the shift register 211 , and the stored data in the latch circuit 212 is sequentially updated in sync with the fluid ejection timing. It should be noted that the reference symbol HGND in the drawing denotes the ground terminal for the actuators 22 such as piezoelectric elements. Further, even after the actuator 22 such as a piezoelectric element is separated from the drive signal COM (the drive pulses PCOM) (switched off), the selection switch 201 maintains the input voltage of the actuator 22 at the voltage applied thereto immediately before the separation.
FIG. 6 shows a schematic configuration of the drive circuit for the actuators 22 . The actuator drive circuit is built inside the control section 62 and the head driver 65 included in the control circuit. The drive circuit of the first embodiment is configured including a drive waveform generator 25 , a modulator 26 , a digital power amplifier circuit 28 , and a low pass filter 29 . The drive waveform generation circuit 25 generates a basis of the drive signal COM (the drive pulses PCOM), namely a drive waveform signal WCOM forming a basis of the signal for controlling the drive of the actuator 22 . The modulator 26 performs pulse modulation on the drive waveform signal WCOM generated by the drive waveform generator 25 . The digital power amplifier circuit 28 power-amplifies the modulated signal pulse-modulated by the modulator 26 . The low pass filter 29 smoothes the power-amplified modulated signal power-amplified by the digital power amplifier circuit 28 , and then supplies the result to the fluid ejection heads 2 as the drive signal COM (the drive pulses PCOM). The drive signal COM (the drive pulses PCOM) is supplied from the selection switches 201 to the actuators 22 .
FIGS. 7A and 7B show a configuration of the actuator drive circuit. FIG. 7A shows the drive waveform generator 25 and the modulator 26 , and FIG. 7B shows the digital power amplifier circuit 28 , the low pass filter 29 , and the fluid ejection heads 2 . The drive waveform generator 25 is configured including a memory 31 , a controller 32 , and a D/A converter 33 . The memory 31 stores drive waveform data of the drive waveform signal formed of digital voltage data or the like. The controller 32 converts the drive waveform data read from the memory 31 into a voltage signal, and then holds the result corresponding to a predetermined sampling period, and at the same time, instructs a triangular wave oscillator described later in a frequency and a waveform of a triangular wave signal, or a waveform output timing. The D/A converter 33 performs analog conversion on the voltage signal output from the controller 32 , and outputs the result as the drive waveform signal WCOM. It should be noted that the controller 32 also outputs an operation stop signal/Disable for stopping the operation of the digital power amplifier circuit 28 to a gate drive circuit 30 described later in the digital power amplifier circuit 28 . It is assumed that the operation of the digital power amplifier circuit 28 is stopped when the operation stop signal/Disable takes a low level.
Further, as the modulator 26 , there is used a known pulse width modulator (PWM). The modulator 26 is provided with the triangular wave oscillator 34 for outputting the triangular wave signal forming a base signal in accordance with the frequency, the waveform, and the waveform output timing instructed from the controller 32 described above. A comparator 35 compares the drive waveform signal WCOM output from the D/A converter 33 with the triangular wave signal output from the triangular wave oscillator 34 , and then outputs the modulated signal with a pulse duty cycle in which the on-duty represents that the drive waveform signal WCOM is higher than the triangular wave signal. It should be noted that the frequency of the triangular wave signal (the base signal) is defined as a modulation frequency (called, in general, a carrier frequency, for example). Further, as the modulator 26 , there can be used a well-known pulse modulator such as a pulse density modulator (PDM) besides the above.
The digital power amplifier circuit 28 is configured including a half-bridge output stage 21 and the gate drive circuit 30 . The half-bridge output stage 21 is composed of a high-side switching element Q1 and a low-side switching element Q2 for substantially amplifying the power. The gate drive circuit 30 controls the gate-source signals GH, GL of the high-side switching element Q1 and the low-side switching element Q2 based on the modulated signal from the modulator 26 . In the digital power amplifier circuit 28 , when the modulated signal is in the high level, the gate-source signal GH of the high-side switching element Q1 becomes in the high level, while the gate-source signal GL of the low-side switching element Q2 becomes in the low level. In other words, since the high-side switching element Q1 is set to be in a connected state (“ON”) and the low-side switching element Q2 is set to be in an unconnected state (“OFF”), as a result, the output Va of the half-bridge output stage 21 becomes equal to a supply voltage VDD. On the other hand, when the modulated signal is in the low level, the gate-source signal GH of the high-side switching element Q1 becomes in the low level, while the gate-source signal GL of the low-side switching element Q2 becomes in the high level. In other words, since the high-side switching element Q1 is OFF and the low-side switching element Q2 is ON, as a result, the output Va of the half-bridge output stage 21 becomes 0.
In the case in which the high-side switching element Q1 and low-side switching element Q2 are driven digitally as described above, although a current flows through the switching element that is ON, the resistance value between the drain and the source is small, and therefore, the loss is hardly caused. Further, since no current flows in the switching element that is OFF, no loss is caused. Therefore, the loss itself of the digital power amplifier circuit 28 is extremely small, and therefore, it is possible to use small-sized switching elements such as MOSFETs.
It should be noted that when the operation stop signal/Disable output from the controller 32 is in the low level, the gate drive circuit 30 sets both of the high-side switching element Q1 and the low-side switching element Q2 OFF. As described above, when the digital power amplifier circuit 28 is in operation, either one of the high-side switching element Q1 and the low-side switching element Q2 is ON. Setting both of the high-side switching element Q1 and the low-side switching element Q2 OFF is equivalent to stopping the operation of the digital power amplifier circuit 28 , which leads that the actuators 22 each formed of a piezoelectric element, the capacitive load from an electrical point of view, are kept in a high-impedance state. If the actuators 22 are kept in the high-impedance state, the charge stored in the actuators 22 as capacitive loads is held, and the charge/discharge state is maintained or restricted to a slight self-discharge state.
As the low pass filter 29 , there is used a quadratic filter composed of one capacitor C and a coil L. The modulation frequency generated by the modulator 26 , namely the frequency component of the pulse modulation, is attenuated to be removed by the low pass filter 29 , and then the drive signal COM (the drive pulses PCOM) having the waveform characteristic described above is output. It should be noted that although FIGS. 7A and 7B show a form of a circuit for the sake of easiness of understanding, the drive waveform generator 25 and the modulator 26 can also be constituted by a program executed inside the control section 62 shown in FIG. 3 . The low pass filter 29 can be configured using a stray inductance or a stray capacitance generated in the circuit wiring, the actuator, or the like, and is therefore not necessarily required to be formed as a circuit. Further, the memory 31 can also be formed inside the ROM 62 d.
FIG. 8 shows a control condition of the digital power amplification performed in the first embodiment. The upper part of FIG. 8 shows the condition of ordinary digital power amplification as a related art example, while the lower part of FIG. 8 shows a specific example of the digital power amplification control of the first embodiment. In the ordinary digital power amplification having been performed from the past, the digital power amplifier circuit is made to continue to operate constantly irrespective of whether or not the voltage of the drive signal COM varies. For example, since the digital power amplifier circuit used in the field of the audio engineering is premised on the fact that the input is varied constantly, there is no chance to stop the operation. On the other hand, since the actuator 22 such as a piezoelectric element is a capacitive load, there is no need to apply electrical current when the voltage of the drive signal COM does not vary. Despite the circumstance described above, if the high-side switching element Q1 and the low-side switching element Q2 of the digital power amplifier circuit 28 continues to be switched on/off, the power is consumed in the high-side switching element Q1, the low-side switching element Q2, and the coil L of the low pass filter 29 .
Therefore, in the first embodiment, as shown in the truth table of Table 1 described below, when the voltage of the drive signal COM (the same can be applied to the drive waveform signal WCOM, which has not yet been power-amplified) does not vary, the operation stop signal/Disable is set to be in the low level to stop the operation of the digital power amplifier circuit 28 , and further both of the high-side switching element Q1 and the low-side switching element Q2 are OFF. When setting both of the high-side switching element Q1 and the low-side switching element Q2 OFF, the actuators 22 as the capacitive loads are kept in the high-impedance state, and hence there is little of the self-discharge. Further, in the first embodiment, in the case of stopping the operation of the digital power amplifier circuit 28 , namely when the voltage of the drive signal COM (the drive waveform signal WCOM) does not vary, output of the modulated signal PWM is also stopped (kept in the low level). Thus, the power consumption in the modulator 26 and the gate drive circuit 30 can also be reduced.
TABLE 1
Pulse Modulation
Signal
/Disable
Q1
Q2
Power Amplifier
0
1
OFF
ON
Operating
1
ON
OFF
0
0
OFF
Stopped
1
Incidentally, it is not possible to set both of the high-side switching element Q1 and the low-side switching element Q2 of the digital power amplifier circuit 28 OFF only by stopping the output of the modulated signal PWM (keeping the modulated signal PWM in the low level). This is because, when the modulated signal PWM is in the low level, the gate-source signal GH of the high-side switching element Q1 becomes in the low level, but the gate-source signal GL of the low-side switching element Q2 becomes in the high level, and consequently, the high-side switching element Q1 becomes OFF, but the low-side switching element Q2 becomes ON. Therefore, the gate drive circuit 30 sets both of the gate-source signal GH of the high-side switching element Q1 and the gate-source signal GL of the low-side switching element Q2 to be in the low level when the operation stop signal/Disable is in the low level, thereby setting both of the high-side switching element Q1 and the low-side switching element Q2 OFF.
FIGS. 9A and 9B show the details of the PWM modulation performed in the modulator 26 . FIG. 9A shows the state in which the voltage of the drive waveform signal WCOM gradually increases, and is then held constant, and then decreases gradually. Further, FIG. 9B shows the state in which the voltage of the drive waveform signal WCOM gradually decreases, and is then held constant, and then increases gradually. In the first embodiment, in both of the case in which the drive waveform signal WCOM increases and the case in which the drive waveform signal WCOM decreases, the modulation frequency (the frequency of the triangular wave signal TRI) of the pulse modulation is increased when the voltage of the drive waveform signal WCOM changes from varying to constant. Similarly, in both of the case in which the drive waveform signal WCOM increases and the case in which the drive waveform signal WCOM decreases, the modulation frequency (the frequency of the triangular wave signal TRI) of the pulse modulation is also increased when the voltage of the drive waveform signal WCOM changes from constant to varying. Specifically, the modulation frequency (the frequency of the triangular wave signal TRI) of the usual pulse modulation is set to be 500 kHz, and the modulation frequency (the frequency of the triangular wave signal TRI) of the pulse modulation when the voltage of the drive waveform signal WCOM changes from varying to constant or from constant to varying is set to be 1,000 kHz. According to the configuration described above, the ripple voltage of the drive signal COM in each of the transition periods can be prevented, and it becomes possible to match the voltage of the drive signal with no particular variation with the target value. It should be noted that the switching of the modulation frequency is not limited to two levels, it is also possible to increase the number of levels of the switching, or to vary the modulation frequency gradually.
Further, in the first embodiment, the period with the modulated signal PWM in either of the high level and the low level immediately after the voltage of the drive waveform signal WCOM changes from constant to varying is set to be a half of the period of the original modulated signal PWM. Specifically, since it is arranged that the modulated signal PWM becomes in the high level when the drive waveform signal WCOM is higher than the triangular wave signal TRI, and the modulated signal PWM becomes in the low level when the drive waveform signal WCOM is lower than the triangular wave signal TRI as shown in FIG. 10 , by arranging that the output of the modulated signal PWM is started from the lower apexes of the triangular wave signal TRI, the period with the high level halves. Further, by arranging that the output of the modulated signal PWM is started from the upper apexes of the triangular wave signal TRI, the period with the low level halves. For example, in FIG. 9A , the controller 32 instructs the triangular wave oscillator 34 in the wave form and the waveform output timing of the triangular wave signal TRI so that the triangular wave signal TRI is started from the upper apex simultaneously with when the voltage of the drive waveform signal WCOM starts to decrease from a constant state. In contrast, in FIG. 9B , the controller 32 instructs the triangular wave oscillator 34 in the wave form and the waveform output timing of the triangular wave signal TRI so that the triangular wave signal TRI is started from the lower apex simultaneously with when the voltage of the drive waveform signal WCOM starts to increase from a constant state. Further, according to the process described above, the ripple voltage of the drive signal COM in each of the transition periods can be prevented.
Further, in the first embodiment, in the period in which the digital power amplifier circuit 28 stops the operation thereof, the operation of the digital power amplifier circuit is temporarily resumed. Specifically, the operation stop signal/Disable is set to be in the high level to resume the operation of the gate drive circuit 30 , and at the same time, the modulated signal PWM is output from the modulator 26 to perform on/off control of the high-side switching element Q1 and the low-side switching element Q2 of the digital power amplifier circuit 28 . Since the operation of the digital power amplifier circuit 28 is stopped when the voltage of the drive waveform signal WCOM does not vary, the voltage of the drive signal COM supplied to the actuators 22 is also the same as the voltage before and after the operation of the digital power amplifier circuit 28 is stopped. According to the process described above, it becomes possible to prevent the voltage drop due to the self-discharge of the actuators 22 made of capacitive loads.
For example, in the case in which the drive waveform signal WCOM takes the voltage of 0V in the periods 0 through 2, the voltage of 2V in the period 3, the voltage of 4V in the period 4, the voltage of 6V in the period 5, the voltage of 8V in the period 6, the voltage of 10V in the periods 7 through 11, the voltage of 8V in the period 12, the voltage of 6V in the period 13, the voltage of 4V in the period 14, the voltage of 2V in the period 15, and the voltage of 0V in the periods 16 through 18 as shown in FIG. 11 , the memory 31 stores the data shown in FIG. 12 , for example. In the first embodiment, the voltage difference between the adjacent periods is stored as an output voltage difference value Vd, and at the same time, the modulation frequency (the PWM frequency in the drawing) fpwm in each of the periods is also stored.
FIG. 13 is a flowchart of an arithmetic processing performed in the controller 32 using the data stored in the memory 31 shown in FIG. 12 . In the arithmetic processing, firstly, a previous voltage value Vs is cleared in the step S 1 .
Then, the process proceeds to the step S 2 , and a memory address counter N is cleared.
Subsequently, the process proceeds to the step S 3 , and the waveform data (the output voltage difference value) Vd is retrieved from the memory 31 .
Then, the process proceeds to the step S 4 , and whether or not the waveform data (the output voltage difference value) Vd retrieved in the step S 3 is the waveform termination data is determined. If it is the waveform termination data, the arithmetic processing is terminated, and otherwise the process proceeds to the step S 5 .
In the step S 5 , determination of the waveform data (the output voltage difference value) Vd retrieved in the step S 3 is performed. In this case, if the previous output voltage difference value Vd is 0, and the output voltage difference value Vd retrieved presently is also 0, the process proceeds to the step S 6 on the ground that the voltage of the drive waveform signal WCOM is constant. Further, if the previous output voltage difference value Vd is not 0, and the output voltage difference value Vd retrieved presently is 0, the process proceeds to the step S 11 on the ground that the voltage of the drive waveform signal WCOM changes to constant. If the previous output voltage difference value Vd is 0, and the output voltage difference value Vd retrieved presently takes a positive value, the process proceeds to the step S 13 on the ground that the voltage of the drive waveform signal WCOM does not vary to the state of increasing the voltage occurs. Further, if the previous output voltage difference value Vd is 0, and the output voltage difference value Vd retrieved presently takes a negative value, the process proceeds to the step S 14 on the ground that the voltage of the drive waveform signal WCOM changes from varying to constant. In other cases such as the case in which the previously-output voltage difference value Vd is not 0, and the output voltage difference value Vd last retrieved is not 0, the process proceeds to the step S 15 .
In the step S 6 , determination of the modulation frequency fpwm retrieved from the memory 31 is performed. In this case, if the previous modulation frequency fpwm is 0, and the modulation frequency fpwm retrieved presently is not 0, the process proceeds to the step S 7 on the ground that the operation of the digital power amplifier circuit 28 is to be resumed temporarily. Further, if the previous modulation frequency fpwm is not 0, and the modulation frequency fpwm retrieved presently is 0, the process proceeds to the step S 8 on the ground that the operation of the digital power amplifier circuit 28 is to be stopped. Further, if the previous modulation frequency fpwm is 0, and the modulation frequency fpwm retrieved presently is also 0, the process proceeds to the step S 10 on the ground that the operation of the digital power amplifier circuit 28 continues to be stopped.
In the step S 7 , the on-duty period of the modulated signal PWM is reduced to half, and is then output, and the process proceeds to the step S 9 .
In the step S 9 , the operation stop signal/Disable is set to be in the high level to make the digital power amplifier circuit 28 and the modulator 26 operate, and the process proceeds to the step S 12 .
Further, in the step S 8 , the process waits until the end of the modulation period, and then proceeds to the step S 10 .
Further, also in the step S 11 , the process waits until the end of the modulation period, and then proceeds to the step S 10 .
In the step S 10 , the operation stop signal/Disable is set to be in the low level, and the operations of the digital power amplifier circuit 28 and the modulator 26 are stopped, and the process proceeds to the step S 12 .
Incidentally, in the step S 13 , by controlling the waveform and the waveform output timing of the triangular wave signal TRI as described above, the period in which the modulated signal PWM is kept in the high level is reduced to half of the period in which the original modulated signal is kept in the high level, and is then output, and the process proceeds to the step S 15 .
Further, in the step S 14 , by controlling the waveform and the waveform output timing of the triangular wave signal TRI as described above, the period in which the modulated signal PWM is kept in the low level is reduced to half of the period in which the original modulated signal is kept in the low level, and is then output, and the process proceeds to the step S 15 .
In the step S 15 , the output voltage difference value Vd is added to the previous voltage value Vs to thereby obtain a present voltage value V, and the process proceeds to the step S 16 .
In the step S 16 , the present voltage value V obtained in the step S 15 is output to the D/A converter 33 , and the process proceeds to the step S 17 .
In the step S 17 , the modulation frequency fpwm retrieved from the memory 31 is output to the modulator 26 (the triangular wave oscillator 34 ), and the process proceeds to the step S 18 .
In the step S 18 , the operation stop signal/Disable is set to be in the high level, and at the same time, the digital power amplifier circuit 28 and the modulator 26 are made to operate, and the process proceeds to the step S 19 .
In the step S 19 , the present voltage value V is stored as an update of the previous voltage value Vs, and then the process proceeds to the step S 12 .
In the step S 12 , the process waits until the read timing of the memory 31 , and then proceeds to the step S 20 .
In the step S 20 , the memory address counter N is incremented, and then the process proceeds to the step S 3 .
According to this arithmetic processing, the operation of the digital power amplifier circuit 28 is stopped when the voltage of the drive signal COM does not vary, and consequently, there is no need to supply the actuators 22 with the current, namely when the voltage of the drive waveform signal WCOM does not vary, thereby making it possible to reduce an amount of power consumption in the high-side switching element Q1 and the low-side switching element Q2 constituting the digital power amplifier circuit 28 , and the coil L inside the low pass filter 29 .
Further, by setting both of the high-side switching element Q1 and the low-side switching element Q2 of the digital power amplifier circuit 28 OFF, it becomes possible to set the high-side switching element Q1 and the low-side switching element Q2 to be in the high-impedance state, thus it becomes possible to prevent the discharge from the actuators 22 as capacitive loads.
Further, by stopping the output of the modulated signal PWM itself in the case in which the operation of the digital power amplifier circuit 28 is stopped, the power consumption in the modulator 26 and the gate drive circuit 30 of the digital power amplifier circuit 28 can be reduced.
When the voltage of the drive waveform signal WCOM changes from varying to constant, the ripple voltage caused when stopping the operation of the digital power amplifier circuit 28 is preventable by increasing the modulation frequency fpwm of the pulse modulation, so as to match the voltage of the drive signal COM having no variation with the target value.
When the voltage of the drive waveform signal WCOM changes from constant to varying, the ripple voltage caused when resuming the operation of the digital power amplifier circuit 28 is preventable by increasing the modulation frequency fpwm of the pulse modulation.
Further, the period in which the modulated signal PWM is in the high level, immediately after the voltage of the drive waveform signal WCOM has changed from constant to increasing, is set to be a half of the period in which the original modulated signal PWM is in the high level, thus the ripple voltage can be prevented.
Further, the period in which the modulated signal PWM is in the low level, immediately after the voltage of the drive waveform signal WCOM has changed from constant to decreasing, is set to be a half of the period in which the original modulated signal PWM is in the low level, thus the ripple voltage can be prevented.
Further, by temporarily resuming the operation of the digital power amplifier circuit 28 while stopping the operation of the digital power amplifier circuit 28 , it becomes possible to prevent the voltage drop due to the self-discharge of the actuators 22 formed of capacitive loads.
Further, since the drive waveform signal WCOM is stored in the memory 31 as the data of the output voltage difference value Vd, it becomes easy to determine whether or not the voltage of the drive waveform signal WCOM varies.
Further, since the modulation frequency fpwm by the modulator 26 is also stored in the memory 31 , it becomes possible to flexibly set the modulation frequency fpwm.
Then, a fluid ejection device according to a second embodiment of the invention will be explained. The fluid ejection device according to the present embodiment is applied to the fluid ejection printer similarly to the first embodiment described above, and the schematic configuration, the vicinity of the fluid ejection head, the control device, the drive signal, the switching controller, the actuator drive circuit, the modulated signal, the gate-source signals, and the output signal are substantially the same as those of the first embodiment described above. The second embodiment is different therefrom in the contents of the data stored in the memory 31 , and the arithmetic processing performed by the controller 32 using the stored data.
For example, assuming that the waveform of the drive waveform signal is substantially the same as shown in FIG. 11 of the first embodiment, the data having the contents shown in FIG. 14 is stored in the memory 31 in the second embodiment. In the second embodiment, the output voltage value (drive waveform voltage data) V of the drive waveform signal WCOM in each of the periods, drive waveform states D0, D2 in each of the periods, and the modulation frequency (PWM frequency in FIG. 14 ) fpwm in each of the periods are stored in the memory 31 . The drive waveform states D0, D2 are expressed with 3 bit data, wherein [000] represents that the voltage of the drive waveform signal WCOM is constant, [011] represents the voltage of the drive waveform signal WCOM changes from constant to increasing, [111] represents that the voltage of the drive waveform signal WCOM continues to vary, [010] represents a change in the voltage of the drive waveform signal WCOM from varying to constant,
represents that the operation of the digital power amplifier circuit 28 is temporarily resumed, [100] represents that the operation of the digital power amplifier circuit 28 is stopped, and [001] represents that that the voltage of the drive waveform signal WCOM changes from constant to decreasing.
FIG. 15 is a flowchart of an arithmetic processing performed in the controller 32 using the data stored in the memory 31 shown in FIG. 14 . In the arithmetic processing, firstly, the previous voltage value Vs is cleared in the step S 101 .
Then, the process proceeds to the step S 102 , and the memory address counter N is cleared.
Subsequently, the process proceeds to the step S 103 , and the waveform data (the output voltage value) V is retrieved from the memory 31 .
Then, the process proceeds to the step S 104 to determine whether or not the waveform data (the output voltage value) V retrieved in the step S 103 is the waveform termination data, and if it is the waveform termination data, the arithmetic processing is terminated, and otherwise the process proceeds to the step S 105 .
In the step S 105 , determination of the waveform states D0, D2 retrieved in the step S 103 is performed. In this case, if the drive waveform states D0, D2 are [101], the process proceeds to the step S 107 on the ground that the operation of the digital power amplifier circuit 28 is to be resumed temporarily. Further, if the drive waveform states D0, D2 are [100], the process proceeds to the step S 108 on the ground that the operation of the digital power amplifier circuit 28 is to be stopped. Further, if the drive waveform states D0, D2 are [000], the process proceeds to the step S 110 on the ground that the operation of the digital power amplifier circuit 28 continues to be stopped. If the drive waveform states D0, D2 are [010], the process proceeds to the step S 111 on the ground that a change in the voltage of the drive waveform signal WCOM from varying to constant occurs. If the drive waveform states D0, D2 are [011], the process proceeds to the step S 113 on the ground that a change in the voltage of the drive waveform signal WCOM changes from constant to increasing occurs. If the drive waveform states D0, D2 are [001], the process proceeds to the step S 114 on the ground that a change in the voltage of the drive waveform signal WCOM from constant to decreasing occurs. Further, if the drive waveform states D0, D2 are [11*] (* represents either one of 0 and 1), the process proceeds to the step S 116 as other states.
In the step S 107 , the on-duty period of the modulated signal PWM is reduced to half, and is then output, and the process proceeds to the step S 109 .
In the step S 109 , the operation stop signal/Disable is set to be in the high level to make the digital power amplifier circuit 28 and the modulator 26 operate, and the process proceeds to the step S 112 .
Further, in the step S 108 , the process waits until the end of the modulation period, and then proceeds to the step S 110 .
Further, also in the step S 111 , the process waits until the end of the modulation period, and then proceeds to the step S 110 .
In the step S 110 , the operation stop signal/Disable is set to be in the low level, and the operations of the digital power amplifier circuit 28 and the modulator 26 are stopped, and the process proceeds to the step S 112 .
Incidentally, in the step S 113 , by controlling the waveform and the waveform output timing of the triangular wave signal TRI as described above, the period in which the modulated signal PWM is kept in the high level is reduced to half of the period in which the original modulated signal is kept in the high level, and is then output, and the process proceeds to the step S 116 .
Further, in the step S 114 , by controlling the waveform and the waveform output timing of the triangular wave signal TRI as described above, the period in which the modulated signal PWM is kept in the low level is reduced to half of the period in which the original modulated signal is kept in the low level, and is then output, and the process proceeds to the step S 116 .
In the step S 116 , the output voltage value V retrieved in the step S 103 is output to the D/A converter 33 , and the process proceeds to the step S 117 .
In the step S 117 , the modulation frequency fpwm retrieved from the memory 31 is output to the modulator 26 (the triangular wave oscillator 34 ), and the process proceeds to the step S 118 .
In the step S 118 , the operation stop signal/Disable is set to be in the high level, and at the same time, the digital power amplifier circuit 28 and the modulator 26 are made to operate, and the process proceeds to the step S 112 .
In the step S 112 , the process waits until the read timing of the memory 31 , and then proceeds to the step S 120 .
In the step S 120 , the memory address counter N is incremented, and then the process proceeds to the step S 103 .
According to this arithmetic processing, since the drive waveform signal WCOM is stored in the memory 31 as the output voltage value (the drive waveform voltage data) V, and the memory 31 also stores the drive waveform states (information regarding whether or not the voltage of the drive waveform signal varies) D0, D2, it becomes possible to eliminate the determination itself on whether or not the voltage of the drive waveform signal WCOM varies in addition to the advantage of the first embodiment described above.
Then, a fluid ejection device according to a third embodiment of the invention will be explained. The fluid ejection device according to the third embodiment is applied to the fluid ejection printer similarly to the first embodiment described above, and the schematic configuration, the vicinity of the fluid ejection head, the control device, the drive signal, the switching controller, the actuator drive circuit, the modulated signal, the gate-source signals, and the output signal are substantially the same as those of the first embodiment described above. The third embodiment is different therefrom in the contents of the data stored in the memory 31 , and the arithmetic processing performed by the controller 32 using the stored data. For example, assuming that the waveform of the drive waveform signal is substantially the same as shown in FIG. 11 of the first embodiment, the data having the contents shown in FIG. 16 is stored in the memory 31 in the third embodiment. In the third embodiment, the output voltage value (drive waveform voltage data) V of the drive waveform signal WCOM in each of the periods, and the modulation frequency (PWM frequency in FIG. 16 ) fpwm in each of the periods are stored in the memory 31 .
FIG. 17 is a flowchart of an arithmetic processing performed in the controller 32 using the data stored in the memory 31 shown in FIG. 16 . In the arithmetic processing, firstly, the previous voltage value Vs is cleared in the step S 201 .
Then, the process proceeds to the step S 202 , and the memory address counter N is cleared.
Subsequently, the process proceeds to the step S 203 , and the waveform data (the output voltage value) V is retrieved from the memory 31 .
Then, the process proceeds to the step S 204 to determine whether or not the waveform data (the output voltage value) V retrieved in the step S 203 is the waveform termination data, and if it is the waveform termination data, the arithmetic processing is terminated, and otherwise the process proceeds to the step S 205 .
In the step S 205 , determination of the waveform data (the output voltage value) V retrieved in the step S 203 is performed. In this case, if the value obtained by subtracting the last-but-one output voltage value V from the last output voltage value V is 0, and the value obtained by subtracting the last output voltage value V from the output voltage value V retrieved presently is also 0, the process proceeds to the step S 206 on the ground that the voltage of the drive waveform signal WCOM stays constant. If the value obtained by subtracting the last-but-one output voltage value V from the last output voltage value V is not 0, and the value obtained by subtracting the last output voltage value V from the output voltage value V retrieved presently is 0, the process proceeds to the step S 211 on the ground that the drive waveform signal WCOM has become constant. If the value obtained by subtracting the last-but-one output voltage value V from the last output voltage value V is 0, and the value obtained by subtracting the last output voltage value V from the output voltage value V retrieved presently is a positive value, the process proceeds to the step S 213 on the ground that a change in the voltage of the drive waveform signal WCOM from constant to increasing occurs. Further, if the value obtained by subtracting the last-but-one output voltage value V from the last output voltage value V is 0, and the value obtained by subtracting the last output voltage value V from the output voltage value V retrieved presently is a negative value, the process proceeds to the step S 214 on the ground that there a change in the voltage of the drive waveform signal WCOM from constant to decreasing. Otherwise the process proceeds to the step S 216 .
In the step S 206 , determination of the modulation frequency fpwm retrieved from the memory 31 is performed. In this case, if the previous modulation frequency fpwm is 0, and the modulation frequency fpwm retrieved presently is not 0, the process proceeds to the step S 207 on the ground that the operation of the digital power amplifier circuit 28 is to be resumed temporarily. Further, if the previous modulation frequency fpwm is not 0, and the modulation frequency fpwm retrieved presently is 0, the process proceeds to the step S 208 on the ground that the operation of the digital power amplifier circuit 28 is to be stopped. Further, if the previous modulation frequency fpwm is 0, and the modulation frequency fpwm retrieved presently is also 0, the process proceeds to the step S 210 on the ground that the operation of the digital power amplifier circuit 28 continues to be stopped.
In the step S 207 , the on-duty period of the modulation signal PWM is reduced to half, and is then output, and the process proceeds to the step S 209 .
In the step S 209 , the operation stop signal/Disable is set to be in the high level to make the digital power amplifier circuit 28 and the modulator 26 operate, and the process proceeds to the step S 212 .
Further, in the step S 208 , the process waits until the end of the modulation period, and then proceeds to the step S 210 .
Further, also in the step S 211 , the process waits until the end of the modulation period, and then proceeds to the step S 210 .
In the step S 210 , the operation stop signal/Disable is set to be in the low level, and at the same time, the operations of the digital power amplifier circuit 28 and the modulator 26 are stopped, and the process proceeds to the step S 212 .
Incidentally, in the step S 213 , by controlling the waveform and the waveform output timing of the triangular wave signal TRI as described above, the period in which the modulated signal PWM is kept in the high level is reduced to half of the period in which the original modulated signal is kept in the high level, and is then output, and the process proceeds to the step S 216 .
Further, in the step S 214 , by controlling the waveform and the waveform output timing of the triangular wave signal TRI as described above, the period in which the modulated signal PWM is kept in the low level is reduced to half of the period in which the original modulated signal is kept in the low level, and is then output, and the process proceeds to the step S 216 .
In the step S 216 , the output voltage value V retrieved in the step S 203 is output to the D/A converter 33 , and the process proceeds to the step S 217 .
In the step S 217 , the modulation frequency fpwm retrieved from the memory 31 is output to the modulator 26 (the triangular wave oscillator 34 ), and the process proceeds to the step S 218 .
In the step S 218 , the operation stop signal/Disable is set to be in the high level, and at the same time, the digital power amplifier circuit 28 and the modulator 26 are made to operate, and the process proceeds to the step S 212 .
In the step S 212 , the process waits until the read timing of the memory 31 , and then proceeds to the step S 220 .
In the step S 220 , the memory address counter N is incremented, and then the process proceeds to the step S 203 .
According to the arithmetic processing, since it is arranged that the drive waveform signal WCOM is stored in the memory 31 as the output voltage value (the drive waveform voltage data) V, the controller 32 calculates the difference of the output voltage value (the drive waveform voltage data) V retrieved from the memory 31 , and the operation of the digital power amplifier circuit 28 is stopped if the difference in the output voltage value (the drive waveform voltage data) V is 0, the memory 31 with small capacity can be adopted in addition to the advantages of the first and second embodiments described above.
Then, a modified example of the actuator drive circuit described above will be explained. FIGS. 18A and 18B are block diagrams showing another example of the actuator drive circuit. This actuator drive circuit is similar to the actuator drive circuit shown in FIGS. 7A and 7B described above, and the equivalent constituents are denoted by the equivalent reference numerals, and detailed explanation thereof will be omitted. In the actuator drive circuit shown in FIGS. 7A and 7B described above, the controller 32 outputs the operation stop signal/Disable to the gate drive circuit 30 , and when the operation stop signal/Disable is in the low level, both of the high-side switching element Q1 and the low-side switching element Q2 of the digital power amplifier circuit 28 are OFF to thereby stop the operation of the digital power amplifier circuit 28 . This is because, as described above, in the case in which only one gate drive circuit 30 is provided, and, for example, the gate-source signal GL to the low-side switching element Q2 is obtained by inverting the gate-source signal GH to the high-side switching element Q1, and is then output, it is not achievable to set both of the gate-source signals GH, GL to the high-side switching element Q1 and the low-side switching element Q2 to be in the low level.
Therefore, in the present modified example, the gate drive circuit 30 is provided to each of the high-side switching element Q1 and the low-side switching element Q2. Further, it is arranged that the comparator 35 outputs a pulse-modulated signal PWMP taking the high level when the drive waveform signal WCOM is higher than the triangular wave signal TRI, and an inverted pulse-modulated signal PWMN, so that the pulse-modulated signal PWMP is output to the gate drive circuit 30 for the high-side switching element Q1, and the inverted pulse-modulated signal PWMN is output to the gate drive circuit 30 for the low-side switching element Q2. When stopping the digital power amplifier circuit 28 , namely in the case in which the voltage of the drive waveform signal WCOM does not change, the controller 32 holds both of the modulated signals PWMP, PWMN output from the comparator 35 in the low level. Thus, the gate-source signals GH, GL output from the respective two gate drive circuits 30 are set to be in the low level, and both of the high-side switching element Q1 and the low-side switching element Q2 are OFF. The operation and the stop of the operation of the digital power amplifier circuit 28 are as shown in the truth table shown in Table 2 below.
TABLE 2
Pulse Modulation
Pulse Modulation
Signal P
Signal N
Q1
Q2
Power Amplifier
0
0
OFF
OFF
Stopped
1
0
ON
OFF
Operating
0
1
OFF
ON
1
1
ON
ON
It should be noted that although in the first through third embodiments described above only the case in which the fluid ejection device according to an aspect of the invention is applied to the line head-type printer is described in detail, the fluid ejection device according to an aspect of the invention can also be applied to multi-pass type printer in a similar manner.
Further, the fluid ejection device according to an aspect of the invention can also be embodied as a fluid ejection device for ejecting a fluid (including a fluid like member dispersing particles of functional materials, and a fluid such as a gel besides fluids) other than the ink, or a fluid (e.g., a solid substance capable of flowing as a fluid and being ejected) other than fluids. The fluid ejection device can be, for example, a fluid like member ejection device for ejecting a fluid like member including a material such as an electrode material or a color material used for manufacturing a fluid crystal display, an electroluminescence (EL) display, a plane emission display, or a color filter in a form of a dispersion or a solution, a fluid ejection device for ejecting a living organic material used for manufacturing a biochip, or a fluid ejection device used as a precision pipette for ejecting a fluid to be a sample. Further, the fluid ejection device can be a fluid ejection device for ejecting lubricating oil to a precision machine such as a timepiece or a camera in a pinpoint manner, a fluid ejection device for ejecting on a substrate a fluid of transparent resin such as ultraviolet curing resin for forming a fine hemispherical lens (an optical lens) used for an optical communication device, a fluid ejection device for ejecting an etching fluid of an acid or an alkali for etching a substrate or the like, a fluid ejection device for ejecting a gel, or a fluid ejection recording apparatus for ejecting a solid substance including fine particles such as a toner as an example. Further, an aspect of the invention can be applied to either one of these ejection devices.
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A fluid ejection device includes: a modulator adapted to pulse-modulate a drive waveform signal forming a basis of a drive signal of an actuator to obtain a modulated signal; a digital power amplifier circuit adapted to power-amplify the modulated signal to obtain a power-amplified modulated signal; a low pass filter adapted to smooth the power-amplified modulated signal to obtain the drive signal; and a power amplification stopping section operating when holding a voltage of the actuator constant.
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This is a continuation of application Ser. No. 07/487,546 filed 2 Mar. 1990 now abandoned.
FIELD OF THE INVENTION
This invention is directed to devices and methods for the percutaneous administration of physostigmine and its closely related chemical analogs.
BACKGROUND OF THE INVENTION
Acetylcholine (ACh), an essential neurotransmitter, occurs both within the brain and in the peripheral parasympathetic nervous system. Impulses conducted along muscle fibers or axons depend upon the formation of ACh at the synaptic junction for transmission of the impulse to other fibers or axons. Acetylcholine's function as a transmitter is terminated (switched off) when it is converted to choline and acetic acid by the enzyme acetylcholinesterase (AChE). Modern biophysical methods have revealed that the amount of time consumed for the process of conversion of ACh to choline and acetic acid is less than one thousandth of a second. Drugs that have the ability to inhibit or inactivate AChE are called anticholinesterases or AChE inhibitors. As a result of AChE inhibition, acetylcholine accumulates in the synaptic cleft; since ACh is not Switched off, impulses are transmitted to the affected site for a longer period of time than would otherwise occur and results in a stronger or more prolonged neuromuscular action. Since these ACh parasympathetic synapses are widely distributed in the brain and peripheral nervous syslem, it is not surprising that AChE inhibitors produce a wide variety of effects on both the brain and body.
Physostigmine is one of the naturally occurring acetylcholinesterase inhibitorsl It has been isolated from the dry, ripe seed of the calabar or ordeal bean, a perennial plant (Physostigma venenosum), found in the Calabar region of Nigeria, West Africa. Also called Esre nut, chop nut or bean of Etu Esre, calabar bean was used as an ordeal poison. As a test of guilt, the suspect was forced to ingest a quantity of calabar beans. If he died, his guilt was proved. If the accused was confident of his innocence and ate the beans rapidly, the chances were high that he would regurgitate the beans and survive the ordeal. (It is reported that proof of guilt or innocence was not always left to chance. Apparently, a placebo was given to those prejudged to be innocent by the tribal elders in order to avoid any potential miscarriages of tribal justice), see Plants in the Development on Modern Medicine, Swain, T. ed., Harvard University Press, p. 303-360 (1972). Physostigmine, isolated from the calabar bean, was introduced into medicine for the treatment of wide angle glaucoma in 1877 by Laqueur.
Glaucoma is a disease characterized by an increase in intraocular pressure that, if sufficiently high and persistent, can lead to damage to the optic disc and result in permanent blindness. Wide angle glaucoma, or chronic, simple glaucoma occurs when the meshwork of pores of small diameter involved in the outflow of the aqueous humor lose their tone. Wide angle glaucoma has a gradual, insidious onset and is generally not amenable to surgical improvement. In this type of glaucoma, control of ocular pressure is only possible with continuous and permanent drug therapy.
Myasthenia gravis is a neuromuscular disease characterized by weakness and marked fatigability of skeletal muscles. Its clinical manifestations were described before the turn of the century, but it was not until the early 1930s that physostigmine was used in the management of this disease. The observation that physostigmine gave rise to increased strength of muscular contraction and the similarity between the symptoms of myasthenia gravis and curare poisoning in animals, suggested that physostigmine, an agent then known to antagonize curare, might be of therapeutic value for this disease. This observation led to the use of physostigmine in the treatment of myasthenia gravis.
Tardive dyskinesia is a disease characterized by abnormal, involuntary movements, usually of oral and facial musculature but often involving the trunk and extremities. Typical of oral and facial movements are puffing of the cheeks, grimacing, protrusion and licking of the tongue, and incessant blinking of the eyes. The abnormal movements are rhythmic and repetitive and may interfere with speech, salivation, chewing, and swallowing. Patients, many times, are not aware of the symptoms. Tardive dyskinesia is usually irreversible and considered to be incurable at the present time. Therefore, prevention of the manifestations of this disease is considered to be the only known effective method for dealing with the problem. Tardive dyskinesia is most frequently found in geriatric patients who have been taking neuroleptic drugs. All neuroleptic drugs may cause tardive dyskinesia. However, the low-dose, high potency drugs which produce the greatest degree of blockage, and thus a greater degree of pyramidal side effects are the most likely to cause tardive dyskinesia. Such high potency drugs include the phenothiazines, the thioxanthenes, the butyrophenones, the benxodiazepines and the dihydroindolones. In recent years, the greater use of psychotropic drugs has aggravated the incidence of tardive dyskinesia. The increasing use of neuroleptic drugs in geriatric care facilities has resulted in dramatic increase in the incidence of tardive dyskinesia. See Geriatrics, Volume 34, Number 7, pages 59-66, July 1979, by Harcourt Brace Jovanovich, Inc. An investigation in the use of anticholinergic drugs reported in American Journal of Psychiatry, Volume 134, Number 7, July 1979, pages 769-774 indicates that the use of physostigmind and choline have positive therapeutic effects on tardive dyskinesia. Although the data presented is not unequivocal, tests have shown that physostigmine injections reduce tardive dyskinesia in from 20% to 80% of the patients suffering from tardive dyskinesia. Continuous and permanent drug therapy is necessary to control tardive dyskinesia.
Senile dementia of the Alzheimer's type (SDAT) is a progressive, incurable, and irreversible disease characterized by long term memory impairment. Studies in humans and animals have implicated cholinergic processes in memory functioning. Investigations with anticholinergics and cholinomimetics indicate that fluctuations in cholinergic activity can profoundly affect storage and retrieval of information in memory. Davis, et al. in a study by reported in Science, Volume 201, p.272 (1978) concluded that physostigmine significantly enhanced storage of information into long-term memory. This study moreover indicates that retrieval of information from long-term memory was also improved by physostigmine therapy.
Treatment of tardive dyskinesia, wide angle glaucoma, SDAT, and the like, by injection of physostigmine is not practical therapy. Physostigmine exhibits a short half-life (about 1 to 2 hours) due to rapid metabolism following systemic administration. Thus, treatment would require injections of physostigmine every 30 minutes to 1 hour at a minimum, to maintain efficacious blood levels. Additionally, physostigmine has a narrow therapeutic window which necessitates constant patient monitoring for safety in order to avoid side effects which limit physostigmine's systemic use. Recently, physostigmine has been formulated into tablets for oral dosage. Determination of drug blood levels for multiple oral doses show typical variations in blood concentration ranging from a maxima above the required level (and possibly in the toxic range) to a minima which may be below the effective dose. The dysfunctions mentioned above, as well as many others, are more prevalent among the elderly. This population group endures more memory impairment and physical disability than other age groups and consistent therapy is necessarily more difficult to attain. Percutaneous administration of physostigmine has many advantages over systemic therapy. It is well known that patient compliance is improved where therapy can be attained with fewer numbers of drug applications within a twenty-four hour period. Transdermal administration offers the possibility that application of an appropriate device need occur but once in a twenty four hour period. Therapy can be terminated by removal of the transdermal device. Stable blood levels can be obtained using dose-controlled devices, thus limiting the toxic side effects caused by overdosing and the lack of effect due to underdosing. Pharmacologically active agents with short metabolic lifetimes are particularly suited to transdermal methods of drug delivery.
The literature is filled with descriptions of transdermal devices for the slow or sustained or controlled release of medicaments. These devices may take the form of monolithic reservoir devices, osmotically driven devices, membrane controlled devices, enhancer controlled devices, microencapsulated drugs, bioerodable devices and almost every conceivable combination of the above. For a general review of the art see, "Controlled Release of Biologically Active Agents", R. W. Baker, John Wiley and Sons, 1987. All of the dosing methods and devices used in drug therapy carry an implicit and many times unstated assumption, that the drug released has not been altered upon storage in any way to significantly decrease its efficacy or accumulate undesirable or unacceptable break-down products. It is well known that most free base alkaloids are not stable against air oxidation, actinic radiation, heat etc. Physostigmine free base is a particularly labile compound because its two basic tertiary amine groups facilitate hydrolysis of its phenolic carbanilide group. Once hydrolysis has taken place, contact with atmospheric oxygen will rapidly oxidize the phenolic hydroxyl group to the highly colored ortho-quinone, rubreserine, see, Studies on Physostigmine and related substances, IV Chemical Studies on Physostigmine Breakdown Products and Related Epinephrine Derivatives, S. Ellis, J. Pharmacol. Exp. Ther., 79 (1943) pp 364-372. See Reaction I. Consequently, chemicals of this class are commonly stored and administered as their salts. For example, because physostigmine is difficult to store as its free base, the salicylate salt is sold as a commercial preparation with the admonition that solutions should be kept well closed in light-resistant, alkali-free glass containers and used within a week of opening. The practitioner is cautioned to discard the preparation if it is discolored. In almost all cases, the free base is preferred for transdermal permeation because the free base will quickly cross the stratum corneum skin barrier while the salt form is poorly, if at all, transported and absorbed. Many approaches have been tried to solve this conflicting problem of storage vs permeability. For example, Banerje, in U.S. Pat. No. 4,692,462, binds the free base of drug on an ion exchange resin and relies upon the absorption of an equilibrium concentration of the free base form of the drug by the skin for utility. Lee and Yum in U.S. Pat. No. 4,781,924, store a variety of basic drugs in their salt form in combination with a dry basic compound. Upon moisture absorption, a solution is formed which permits the reaction between the alkaline compound and the salt form of the organic base, liberating the free base. The free base migrates through the device to the skin surface where it rapidly permeates the skin barrier. These inventions serve to illustrate the lengths to which those skilled in the art have gone in order to contain the therapeutic agent in its stable form as the salt, and administer the drug in its most biologically useful form, the free base. The foregoing discussion illustrates the need and value of a device or method that contains the target drug in its most active and bioavailable form (free base) while maintaining adequate storage stability.
Conventional wisdom has indicated that effective protection against the deleterious effects of oxygen and moisture could not be achieved by employing the various polymers as monolithic matrices for sensitive drugs. Diffusion of atmospheric oxygen and water vapor are thought to be so high that drugs sensitive to hydrolysis or oxidation, stored for any significant length of time under ambidnt conditions, would be quickly converted to the expected degradation products. Comequently, past efforts toward dealing with the problem of drug instability have been dedicated to converting the target drug into a chemical form that has adequate storage stability.
OBJECTS OF THE INVENTION
It is the object of this invention to disclose a novel means for increasing the storage lifetime of drugs.
It is another object of this invention to disclose a novel means for increasing the storage lifetime of physostigmine free base and its closely related analogs.
It is another object of this invention to disclose novel transdermal devices for the release of physostigmine free base and its closely related analogs.
It is another object of this invention to disclose devices and methods for controlled release of compounds effective in the treatment of memory impairment, glaucoma, tardive dyskinesia and myasthenia gravis.
It is another object of this invention to provide a means for treatment of disorders resulting from a deficiency of acetylcholine.
It is a further object of this invention to provide a means for symptomatic treatment of disorders resulting from a deficiency of acetylcholine.
Further objects of the invention will be apparent from the description of the invention to those skilled in the art.
SUMMARY OF THE INVENTION
The present invention stabilizes compounds containing chemically labile functional groups, such as physostigmine free base, by incorporating them into a monolithic polymer matrix.
The effective compounds include physostigmine free base and physostigmine derivatives. Physostigmine free base and physostigmine free base derivatives may be represented by formula I as follows: ##STR1## In formula I, R1, R2, R3 and R4 independently represent H or lower alkyl groups.
Chemically similar functional groups are defined as hydrolytically, oxidatively or hydrolytically and oxidatively unstable moieties.
"Monolith" as used herein means a single-phase combination of chemical and polymeric carrier.
DETAILED DESCRIPTION OF THE INVENTION
Physostigmine free base is known to be hydrolytically and oxidatively unstable. It has been discovered that when physostigmine free base is contained in a polymer matrix, its stability is markedly increased. A number of techniques may be used to obtain a drug in polymer matrix, including extrusion of blends of polymer and drug (where temperature and shear stability permit), powder compaction, solution methods and the like. In a most elementary embodiment, preparation of a drug loaded matrix is achieved by first dissolving both physostigmine free base and a polymer in an appropriate solvent followed by solution casting. When a clear solution is obtained, the preparation can be cast onto a protective backing by any of the known techniques for casting solvent based polymer films, and the solvent allowed to evaporate. After evaporation, a thin adhesive film is cast onto the matrix, or double-sided medical adhesive tape is attached. The adhesive is covered by a release liner, and patches are cut out by punching. The finished patches may be heat sealed into foil pouches, and stored until needed. The physostigmine free base matrix comprises solid physostigmine free base dispersed in a polymer matrix. The inventors offer the following interpretation of the observed phenomenon for the purposes of explanation without intending to be bound. Since the degradation of physostigmine like compounds require reaction with water and oxygen, polymers with low moisture absorption and low oxygen and moisture transmission prevent degradation by exclusion of an essential reagent for the degradation reaction. Preferably, the polymer should have moisture absorption of less than 5 wt % at 100% relative humidity at 20° C. In order to prevent premature degradation caused by processing and not the result of polymer matrix control, oxygen and moisture should be excluded during the processing of the free base into the finished patch including thorough drying of the polymer before use, conducting the manufacturing operations under and inert atmosphere and sealing the finished patches under an inert atmosphere. One of the preferred polymers is of the polyurethane type. Polyurethanes are usually synthesized using polyisocyanates (hard segment) and polyols (soft segment) of various types. Many of the physical and chemical properties of a polyurethane are determined by the ratio of hard to soft segments as well as the choice of polyol and polyisocyanate reactants. Linear polyurethanes are typically made by the prepolymer route, reacting a hydroxy-terminated compound with a diisocyanate according to the reaction:
(X)HO--R--OH+(X+1)OCN--R.sub.1 --NCO→OCN--R.sub.1 --[NHCOO--R--OOCHN-R.sub.1 ]X--NCO
where R is a polyether, polyester, polycarbonate or hydrocarbon.
The product of this reaction is an isocyanate terminated prepolymer. This prepolymer is then further reacted (two shot process) with a lower molecular weight diol (chain extender) such as 1,4-butane diol to produce linear, thermoplastic and solvent soluble elastomers. Alternatively, all the reactants can be combined in a single step (one shot process) to produce the desired product. Polyether soft segmented polyurethanes have better hydrolysis resistance than polyester based polyurethanes but have less oxidative resistance and lower tensile strength; polycarbonate based soft segmented polyurethanes normally occupy a middle ground in physical and chemical properties between the polyether and polyester types. Hydrocarbon based polyols are available and can be used to prepare polyurethanes with superior oxidative and hydrolysis resistance. Aromatic, aliphatic and alicyclic polyisocyanates offer differing degrees of ultra-violet and moisture resistance biocompatibility. Thus, one of ordinary skill in the art of polyurethane synthesis can select appropriate monomers for synthesis to overcome specific application problems. Polyether, polycarbonate and hydrocarbon type polyurethanes are preferred for biomedical use, because, in general, they are more inert than polyester types. Polyurethane polymers are available in grades approved for medical use from Dow Chemical, Midland, Mich. under the trade name Pellethane™ 2363 and from Thermedics Corporation, Woburn, Massa. under the name of Teccoflex™ EG-80A and Teccoflex™ EG-60D. Different hardnesses are available; the softer grades are generally preferred in the context of the present invention, because they are easier to dissolve.
Other polymers that can be used as the polymer matrix material include ethylene vinyl acetate copolymers. These polymers are commercially available (Elvax®, DuPont Corporation; Ultrathene®, USI Chemicals, etc.) in a wide variety of grades from 2% to more than 50% vinyl acetate content. Generally, the permeability of the polymer is increased with increasing vinyl acetate content, see Controlled Release of Biologically Active Agents, Baker, R. W., John Wiley & Sons, pp 161-165. Thus, by choosing the appropriate vinyl acetate content and film thickness, an appropriate release characteristic may be obtained. Other useful matrix materials include polyether polyamide block copolymers such as those available from Atochem Inc. under the trade name Pebax®. Also useful are silicone based polymers of the types available from Dow Corning, General Electric, etc. In general, rubbery polymers are preferred for this application, although glassy polymers such as polyvinyl chloride or ethyl cellulose could be used if supplied as plasticized by the drug or an added pharmacologically acceptable plasticizer such as dioctyl phthalate, polyethyleneglycol, butyl sebacate or the like. The patch may be assembled by any of the techniques known in the art for laminating patches. Typically the first step in preparation of the patch is to prepare a solution of the polymer matrix material. Solvents that may be used to dissolve polyurethane include tetrahydrofuran (THF), Fischer Scientific, Springfield, N.J., dimethylsulfoxide (DMSO), and dimethylformamide (DMF). Tetrahydrofuran is the preferred solvent, because it has been approved for use with medical materials so long as the residue remaining in the material after drying does not exceed 1.5%. Typically the percentage by weight of polyurethane in the solution will be in the range 5% to about 35%, depending on the solvent and the polyurethane grade. Using THF, it is possible to prepare casting solutions with relatively high concentrations, typically around 20 to 25%, of a soft grade polyurethane. The harder grades are more difficult to dissolve. It is usually desirable to make the concentration of polyurethane as high as possible. The solution as cast is closer in thickness to the finished film. Also, concentrated solutions are more viscous, and it has been found that, in general, better containment of physostigmine free base is achieved with films cast from viscous solutions. Solid physostigmine free base is added to the polymer solution, and the mixture is stirred until complete solution is achieved. The percentage of physostigmine free base in the solution may be varied according to the desired loading of the finished matrix. The physostigmine free base content of the finished matrix may vary widely, from around 3% to about 30%. Loading above 30% may be achieved, but because of the potency and toxicity of physostigmine, highly concentrated matrices do not offer advantages that outweigh the hazards associated with potential for accidentally overdosing physostigmine.
Physostigmine free base in polyurethane was chosen as a model compound for the examples given, but one of ordinary skill in the art can apply the general principles and methods to other analogous chemicals.
EXAMPLE 1
Stability of Physostigmine Free Base in Aqueous Solution
Relative stability of physostigmine free base in neutral or alkaline solution was determined as follows. Methanolic solution of physostigmine free base was acidified with a few drops of hydrochloric acid to lower the pH to about 3-6. Aliquots of this solution were analyzed immediately and after one or two hours when the solution became pink due to accumulation of the degradation product rubreserine. Analysis was performed using HPLC Nova Pak 4-C18 column and a mobile phase consisting of:
348.0 g Water
650.0 g Methanol
12.0 g Citric Acid
0.63 g 85% Phosphorous Acid
0.96 g Sodium pentasulphonate
BRIEF DESCRIPTION OF THE DRAWINGS
The chromatogram of physostigmine free base immediately before significant degradation is shown in FIG. 1a, the appearance of degradation products of the pink solution that appear after one or two hours is shown in FIG. 1b.
In the same manner, stability of physostigmine free base in neutral or slightly acidified water was determined and is shown in FIG. 2. At room temperature, pH 3, the drug is more stable, and slightly pink; however, the drug in neutral solution degrades rapidly with more than half of the initial drug gone within 30 days under the same storage conditions. Repetition of these experiments using ethanol and isopropyl myristate as solvents showed the rate of degradation to be slower than with unbuffered water but faster than with acidified water. In ethanol solution, 5% of the physostigmine free base was lost after 7 days and 10% after 27 days. At this rate of degradation, a patch would have lost 72% of its active ingredient in one year and 92% in two years.
EXAMPLE 2
Stability of Physostigmine Free Base in Polymer Matrix
Increased stability of physostigmine free base in polymer matrices over solutions is shown in the following experiments. Patches containing physostigmine free base in a polymer matrix were prepared by dissolving 18 g of a polyether based polyurethane produced by Dow under the name Pellethane™ grade 2363-80AE, 2.0 g physostigmine free base and 2.0 g isopropyl myristate in 80 g THF. The solution was allowed to stand until clear. A second identical lot of polymer/drug solution was prepared containing 0.02 g of acetyl cystine. Clear solutions were cast onto the reverse side of a polyester-based release liner available from 3M Company of Minneapolis under the trade name Scotch™ 1002. After evaporation of the THF solvent, the liquid cast film of 2000 μm produced a dry matrix film 200-230 μm thick. Patches with an area of 7.9 cm 2 were cut from these laminated structures, packaged in polyethylene foil pouches and stored at room temperature and at 45° C.
Three patches from each lot were tested for physostigmine free base content immediately after manufacture and after 7 and 25 days of storage at room temperature and at 45° C. Once the backing was removed from the patch, the drug-containing film was weighed and then dissolved in 25 g of THF, followed by dilution with 25 g on methanol. Precipitated Pellethane™ was filtered from the solution before injection into the HPLC. Average amounts of physostigmine free base recovered from the patches, with and without acetyl cysteine, are given in Table I. Theoretical drug loadings were 17.2 and 16.2 mg for the stabilized and unstabilized patches, respectively. Scatter in the weight data can be attributed to variation in film weights and analytical errors amounting to as much as ±10%.
TABLE I______________________________________Stability of Physostigmine Free Base Patches with andwithout Preservatives (n = 3)Weight of Physostigmine free base Recovered (mg)Storage No Preservative With PreservativeTime Room Room(days) Temperature 45° C. Temperature 45° C.______________________________________Theoretical 17.2 17.2 16.2 16.2Loading0 15.0 15.0 15.1 15.17 16.5 16.8 17.3 16.825 16.8 18.5 16.8 16.8______________________________________
Within the limits of error, there was no measurable physostigmine free base loss during these tests either at room temperature or at 45° C. Patches stored for 25 days at 45° C. appeared slightly discolored; however, no additional peaks were observed in the HPLC analysis of these patches.
EXAMPLE 3
In Vivo Test of Physostigmine Free Base Patches
Pellethane™ 2363-80AE (24.4 g) was added to a solution of 101.3 g of THF containing 2.903 g of physostigmine free base and 2.951 g of isopropyl myristate and stirred until a clear solution was formed. After evaporation of the THF solvent, the liquid cast film of 2000 μm produced a dry matrix film 180-230 μm thick. A solution of Avery adhesive 460, containing 10 wt % isopropyl myristate was cast on the drug/polymer matrix film to produce an adhesive layer approximately 801 μm thick. The film was finally overlaid with a release liner film 1022 available from 3M Company and patches with an area of 7.92 cm 2 were cut from the laminated structure. These patches were weighed, heat sealed into polyethylene-foil pouches and stored until use.
The patches were then placed on the skin of rabbits from which the hair had been carefully clipped, after 23 hours, the patches were removed and the in vivo skin fluxes determined and summarized in Table II.
TABLE II__________________________________________________________________________Rabbit Test Results Drug AveragePatch Film Calculated Remaining Drug Delivered ΔMass Total DeliveryWeight Weight Drug Load in Patch* ΔMass ΔMass time FluxPatch(mg) (mg) (mg) (mg) (mg) (%) (mg/hr) (μg/cm.sup.2 · hr)__________________________________________________________________________1 408 229 22.0 6.8 15.2 69 0.66 832 412 233 22.4 7.4 15.0 67 0.65 823 396 217 20.8 6.8 14.0 67 0.61 774 417 238 22.8 7.1 15.7 69 0.68 865 359 180 17.2 5.2 12.0 70 0.52 666 415 236 22.7 6.7 16.0 70 0.70 887 367 188 18.0 5.2 12.8 71 0.56 718 393 214 20.5 6.2 14.3 70 0.62 789 390 211 20.2 6.5 13.7 68 0.60 7510 411 232 22.3 7.1 15.2 68 0.66 8311 371 192 18.4 5.7 12.7 69 0.55 7012 353 174 16.7 4.9 11.8 71 0.51 64Average391 212 20.3 6.3 14.0 69 0.61 77Std. Dev.22 22 2.1 0.8 1.4 1 0.06 8% CV 5.6 10.4 10.5 12.9 9.8 1.9 9.8 9.8__________________________________________________________________________ *Measured by HPLC. Average weight of backing, adhesive, and liner = 0.179 g Patch area = 7.9 cm.sup.2
Over the 23 hour period the average total drug flux to the rabbits was 0.77±8 μg/cm 2 ·h with approximately 70% of the drug delivered. Average Physostigmine free base flux was 160 μg/cm 2 ·h.
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This patent relates a method for increasing the storage stability of physostigmine free base and physostigmine analogs by incorporating the free base into a polymer matrix. Chemically compatible enhancers and adjuvants do not interfere with the stabilization of the free bases.
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This application is a continuation application of international patent application No. PCT/SE95/01333, filed on Nov. 10, 1995, and claims priority Swedish patent application No. 9403978-1 filed on Nov. 15, 1994, the complete disclosures of which are incorporated herein by reference.
1. TECHNICAL FIELD
The present invention provides a novel method for continuously cooking cellulose-containing fiber material in a digester. The present invention also provides a novel digester.
2. BACKGROUND OF THE INVENTION
In conventional Kraft digesters, black liquor is used only in a limited amount, for example, in amounts substantially less than 50% of the total liquid content in the impregnation zone of the digester. The remainder of the externally added liquid usually consists of white liquor. It has now been found that this large addition of white liquor at such an early stage in the cooking process may have an adverse effect on the tear resistance of the fully cooked fibers. Thus, there is a need for a method of digesting pulp which utilizes substantially less amounts of white liquor.
U.S. Pat. No. 3,303,088 (Gessner) discloses a method for continuously cooking cellulose-containing fiber material in a single-vessel system in which:
(1) chips are fed in at a first end of the digester,
(2) white liquor is added at a position at the first end,
(3) the chips are impregnated in a concurrent impregnation zone,
(4) the chips are cooked in a cooking zone downstream of the impregnation zone,
(5) hot black liquor is extracted from at least one screen section,
(6) black liquor is added to the impregnation zone, and
(7) cooked pulp is discharged at the other end of the digester.
This patent also discloses that the extracted liquor from the first screen section, which is arranged downstream of the position of the addition of the black liquor, is returned to the digester by first being conveyed to a container in which white liquor and the extracted impregnation and cooking liquids are mixed. Due to this recirculation, a high content of volatile sulphur and terpene compounds in the impregnation and cooking liquid can build up. Furthermore, the method disclosed in Gessner does not permit sufficiently rapid heating of the cooking liquid to achieve optimal process conditions. It is also evident that the method of Gessner does not include process parameters which are necessary to achieve optimal conditions, such as, the correct liquor-to-wood ratio for obtaining the desire movement of the chip column in the digester.
SUMMARY OF THE INVENTION
An objective of the present invention is to provide an improved method for continuously cooking fiber containing cellulose material which solves the problems associated with using a large amount of white liquor.
Another objective of the present invention is to provide a novel digester suitable for practicing the method.
Surprisingly, the above objectives and other objectives can be obtained by a method for continuously cooking kraft pulp in a digester comprising the steps of:
feeding chips into an inlet of a digester;
supplying black liquor to an impregnation zone of the digester in an amount such that the black liquor makes up greater than 40% by volume of the total volume of liquid present in said impregnation zone;
extracting liquor from a screen girdle downstream of where said black liquor is added to the digester, in the direction the wood chips flow through the digester, in an amount greater than 50% by volume of the total volume of liquor present at the location of the screen girdle;
maintaining a liquor:wood ratio in the impregnation zone of greater than 3:1; and
discharging cooked pulp from the digester.
The present invention also provides a novel digester for continuously cooking kraft pulp. The digester comprises:
an interior chamber defined by a walled structure;
a chip inlet to the interior chamber for supplying chips to the interior chamber;
an impregnation zone in the interior chamber which is connected to the chip inlet, for impregnating the chips;
at least one screen girdle connected to the impregnation zone for extracting liquor from the impregnation zone, the screen girdle being constructed and arranged to extract an amount of liquor exceeding 50% by volume of the total volume of liquor present at the location of the screen girdle;
a cooking zone in the interior chamber for cooking the impregnated chips;
a black liquor recirculation loop constructed and arranged for recirculating the extracted black liquor to the impregnation zone such that black liquor present in the impregnation zone exceeds 40% by volume of the total volume of liquid present in the impregnation zone, the black liquor recirculation loop comprising an extraction screen in the interior chamber, which is connected to the cooking zone, for extracting black liquor from the cooking zone, and means for supplying the extracted black liquor to a location in the impregnation zone such that there is a dwell time of at least 20 minutes for the chips to move from the location the extracted black liquor is supplied to the impregnation zone to the extraction screen; and
at least one cooking liquor recirculation loop comprising a digester screen downstream of the impregnation zone and upstream of the cooking zone for extracting cooking liquor from the digester, a heater connected to the disgester screen for heating cooking liquor extracted by the digester screen, and means for supplying the heated cooking liquor to the digester at a location downstream of said impregnation zone and within 5 meters upstream of the digester screen.
BRIEF DESCRIPTION OF THE DRAWING
The drawing illustrates an embodiment of the digester and method according to the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In the method according to the present invention, black liquor is added to an impregnation zone of a digester such that the amount of black liquor present in the impregnation zone is greater than 40% by volume based on the total volume of liquid present in the impregnation zone, in combination with maintaining a liquor:wood ratio of in the impregnation zone exceeding 3:1.
Preferably, the amount of black liquor present in the impregnation zone is greater than 50%, and more preferably greater than 60%, based on the total volume of liquid present in the impregnation zone.
Preferably, the liquor:wood ratio in the impregnation zone is maintained at a value exceeding 3.5:1, and more preferably is equal to or greater than 4:1.
Liquor extracted from the first screen girdle, which is arranged downstream of the position of addition of the black liquor, is largely removed from the digester. For example, the liquor is removed to an extent in excess of 50%, preferably in excess of 70%, and more preferably in excess of 90%, based on the total volume of liquor present at the first screen girdle.
A further aspect of the present invention is that at least one cooking circulation loop is arranged downstream of the first extraction screen, as a result of which a predetermined heating of the recirculated cooking liquid is obtained, and preferably also a predetermined addition of white liquor, so that optimal preconditions for the cooking can be achieved.
Another aspect according to the invention is to ensure that the distance between the lower edge of the screen girdle and the upper edge of the next screen girdle, included in a cooking circulation, in the direction of the feeding of the chips, is less than 5 meters, preferably less than 3 meters, and most preferably less than 1.5 meters, so that it is possible to quickly establish optimal conditions for the cooking.
The present invention will now be explained with reference to the attached drawing. The drawing is a diagrammatic representation of a preferred flow plan for continuous cooking of fiber material in accordance with the present invention.
The drawing illustrates a chip bin, shown at A, a horizontal steaming vessel, shown at B, and a digester, shown at 1. The broken-up fiber material, which preferably comprises wood chips, is fed from the chip bin A through the steaming vessel B to a high-pressure feeder C. The high-pressure feeder C forces the chips through line 2 up to the digester top, shown at 3. An example is shown in Swedish patent no. SE-B-468053. At the digester top 3, there is a screen for separating off a selected quantity of the liquid with which the chips are transported up to the top 3. This liquid can be returned and recirculated via the high-pressure feeder.
The preferred embodiment according to the present invention shown in the drawing includes the use of a hydraulic digester. In contrast to a steam/liquor phase digester, the hydraulic digester is filled hydraulically with liquid and therefore uses a downward feeding screw in the top screen for discharging the chips. After passing through the screw, the chips move slowly downward in the chip column. The chip column has a liquid:wood ratio which is approximately 2.0:1 to 4.5:1, preferably between 3:1 and 4:1.
The temperature in the upper part of the digester, shown at 3, is usually approximately 110 to 120° C., but can sometimes be up towards 135° C. In this upper part, the liquid moves in concurrent in relation to the chip column passing through the digester. After some time, the chips have moved with the chip column down to a level at which a first central pipe, shown at 11, opens out, shown at 11A. The central pipe 11 is connected to a circulation loop, shown at 8A, 7, 12 and 11. This circulation loop extracts hot black liquor from the extraction screen section shown at 8A and 8B, some of which is fed via the line 7 to a first flash cyclone, shown at 18, and the remainder of which is fed with the aid of pump 12 onwards to the central pipe 11. Hot black liquor is therefore supplied in concurrent with the chip column. The black liquor has a temperature of approximately 155 to 165° C. and is supplied in such an amount that the liquor:wood ratio preferably increases by at least 1/2 a unit, preferably by 1 unit, and in some cases by as much as 11/2 units.
According to a most preferred embodiment of the present invention, a sufficiently large addition of hot black liquor is made to obtain a liquor:wood ratio of between 4:1 to 5:1. At 4:1, the liquid comprises just under one part white liquor, one part wood liquor, and just over two parts black liquor.
The temperature which is obtained in this case in the impregnation zone is approximately 120 to 140° C. At a certain distance from the pipe mouth, shown at 11A, of the central pipe 11, viewed in the direction of the chip flow, there is a first extraction screen girdle, shown at 14. The screen 14 is placed, in the preferred case, sufficiently far from the mouth 11A to obtain a dwell time at least in excess of 20 minutes for the chips to move from the level of the mouth 11A to the upper edge of the screen 14. This means in practice that the distance is preferably in excess of 4 meters, preferably in excess of 5 meters, and more preferably in excess of 6 meters. At this first screen girdle 14, such an amount of impregnation liquor is extracted liquor 13 that the desired liquor:wood ratio after addition of white liquor is obtained. In order to fully to minimize the build-up of released material, all this extracted liquor 13 is led off, according to the preferred embodiment shown, to a second flash cyclone, shown at 20, from which the liquor 21 is taken to the recovery. The steam from the second flash cyclone 20 can be used at another point in the system.
After having passed the first screen girdle 14, the chip column continues down and encounters, immediately below this first screen-girdle 14, a first cooking circulation 15. The purpose of the cooking circulation 15 is to increase the temperature of the cooking liquid up to a suitable cooking temperature, i.e. preferably in excess of 150° C., more preferably in excess of approximately 155° C. Preferably, the cooking circulation increases the temperature of the cooking liquor by at least 10° C. In most cases, it is necessary to have at least two such cooking circulations, shown at 15 and 16, in order to achieve, with sufficiently good distribution, the desire temperature in the chip column. The first cooking circulation 15 is placed quite near, i.e. immediately below, the first extraction screen girdle 14. The distance between the lower edge 14 of the extraction screen and the upper edge of the digester screen should be less than 5 meters, more preferably 3 meters, and even more preferably 1.5 meters, in order to attain the desired temperature sufficiently quickly.
The extracted liquor from the digester screen 15 is recirculated by means of a pump, shown at 15A, pumping the cooking liquid through a heat exchanger, shown at 15B, where the desired heating is obtained, and is reintroduced into the digester preferably together with newly added white liquor by means of a central pipe whose mouth 15C opens out approximately level with the actual screen girdle 15. The second cooking circulation, shown at 16, 16A, 16B, and 16C, functions in a corresponding manner to the first cooking circulation. In the preferred case which is shown in the drawing, two digester screens have been used. The chip column and its surrounding liquid have then reached the desired cooking temperature, whereupon it enters a cooking zone 16 and continues to move downwards. After a fairly long distance, corresponding to a dwell time of approximately two hours, the chips have moved down to be level with a second set of extraction screens, which have already been mentioned above. These extraction screens correspond to the sort of extraction screen which is normally always found on a continuous digester. The greater part of this extracted liquor is thus conveyed to the first flash cyclone 18 and is thereafter conveyed onwards to recovery. Below the level of the extraction screens 8A and 8B, the chip column enters a countercurrent cooking zone. The chips here encounter cooking liquid which has been extracted at the lower screen 17, heated in a lower heat exchanger, shown at 17B, and with the aid of a pump, shown at 17A, has been recirculated via a central pipe whose mouth 17C opens out level with the screen 17.
According to a preferred embodiment of the present invention, white liquor can be added in at least two positions, on the one hand at the digester top 3, and on the other hand in the cooking circulation. In the case where there are two cooking circulations, it can be added to the one cooking circulation or to both cooking circulations. It is of course also possible to add white liquor in the lower circulation 17, so that the alkali concentration is increased in the counter-current zone, and approximately the same temperature is expediently maintained in all the cooking zones so that the patented method ITC™ is used.
Wash liquor is added at the lower end 10 of the digester, which wash liquor thus moves in a conventional manner in countercurrent and displaces hot liquor from the fiber material, which permits a subsequent cold blow. The pulp is then fed through a feeding arrangement known per se and is conveyed out through a line for further treatment, shown at 9.
The person skilled in the art will appreciate that the invention is not limited by what has been shown in detail above, but can instead be varied within the scope and spirit of the claimed invention. Thus, for example, it is possible to equip a digester according to the method prescribed above with a further circulation down a the bottom, for example a so-called ITC™ circulation, in order to cook to an even lower kappa number, if so desired. An example of a suitable method is disclosed in published Swedish patent application SE 9203462. An MCC design is also conceivable to the person skilled in the art. In addition, the person skilled in the art will appreciate that a number of modifications can be made within the scope of the invention, such as, for example, the choice of the exact temperatures and alkali concentrations, etc.
Also, instead of pumping hot black liquor directly from the extraction screen 8 to the impregnation zone 5, it is possible to pump the hot black liquor which is collected from the first flash cyclone 18 up to the impregnation zone 5. The temperature of the black liquor is then lower, but the advantage obtained is that the black liquor contains less air, which can be a great advantage in connection with elimination foaming problems in the digester. In addition, it is possible, in certain existing digesters, to use the existing screen arrangement and to lead off only some of the extracted liquor from the upper screen girdle and, in the same way as in a conventional cooking circulation, to recirculate the remainder and a the same time also expediently to heat and add white liquor. It is of course also possible for this last-mentioned principle to be used in connection with the erection of new digesters. A single-vessel steam phase digester can also be used.
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The present invention relates to a digester and a method for continuously cooking kraft pulp in a single-vessel system (1), preferably a single-vessel hydraulic digester, with chips (2) being fed in at a first end (3) of the digester (1), white liquor (4) being added at at least one position at or near the said first end (3), the chips being impregnated in a cocurrent impregnation zone (5), the chips being cooked in a cooking zone (6) downstream of the impregnation zone, hot black liquor (7) being extracted from at least one extraction strainer section (8), and cooked pulp being discharged (9) at the other end of the digester, and hot black liquor (7) being added (11), (12) to the said impregnation zone (5), and the extract (13) from the first strainer section (14), which is arranged downstream of the position of addition (11a) of the said hot black liquor (7), being largely removed from the digester.
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FIELD OF THE INVENTION
The present invention is in the field of immunology, relating more specifically to methods of modifying the immune system of a mammal for suppressing the functioning population of immunocompetent cells (lymphocytes) the invention can be used for therapy of human and animal diseases, including certain oncological diseases (leukoses, cutaneous T-cell lymphomas, etc.), and auto-immune diseases (hepatitis B, rheumatoid arthritis, etc.).
BACKGROUND OF THE INVENTION
For treatment of diseases associated with functional disturbances in the immune system, there are known methods operating by suppression of lymphocytes.
There is known a method for producing a therapeutic effect upon the organism, disclosed in PCT/GB88/00951, which comprises withdrawal of lymph from the thoracic duct of a patient, irradiating the lymph withdrawn by ultraviolet light, and returning the irradiated lymph to the lymphatic system of the patient.
When exposed to ultraviolet radiation, lymphocytes undergo direct degradation leading, in the final analysis, to their death. Considering the fact that most of the lymphocytes are pathologic cells, it is pathologic lymphocytes that are mainly destroyed. Thence the therapeutic effect.
However the lymphocytes so irradiated are not sufficiently immunogenic. That is to say, when these are introduced into the lymphatic system, the healthy immunocompetent cells of the lymphoid tissue are not capable of effecting a reaction when in contact with irradiated lymphocytes, such that would originate an immune response aimed at degradation or suppression of the functional and metabolic activities of such pathologic cells by the organism itself.
To achieve effective suppression of the pathologic lymphocytes by the organism itself, there is added to the biological fluid enriched with lymphocytes a photo-active chemical agent which has a specific affinity for the receptor sites in or on the constituents of said biological fluid, which is activated by ultraviolet radiation, and which is capable, when activated by said ultraviolet radiation, of forming photo-adducts with receptor sites of the constituents of said biological fluid, thereby assuring chemical linkage between said photo-active chemical agent and said receptor sites.
Added to the biological fluid enriched with lymphocytes, the photo-active chemical agent is adsorbed on the cell membranes, cell nucleus membranes, and cell and nucleus contents, as well as on the constituents of the intracellular fluid. Affected by ultraviolet radiation, the photo-active chemical agent passes into an active state and becomes highly reactive. In such a state, some photo-active chemical agents, e.g. of the furocoumarin class, form covalent linkages between the pyrimidines of the complementary DNA chains in a cell's nucleus, thereby preventing the possibility of divergence of DNA chains when the cell divided. In this manner, lymphocyte proliferation is prevented.
At the same time, affected by ultraviolet radiation, the photo-active chemical agent adsorbed at the receptor sites in or on the biological fluid constituents will either considerably intensify the photochemical reactions occurring under the effect of ultraviolet radiation (oxygen-dependent free radical reactions of cellular membrane lipids), which leads to changes in the receptor field of the membranes and their antigenic determinants, or increase the agent's specific effect level (when this agent is a carrier-photo-active group complex, and the carrier is a biologically active moiety having a specific suppressive effect upon immunocompetent cells, e.g. antibodies, cortisone, etc.). Thus, in said processes, the therapeutic effect is achieved by directly destroying or suppressing the functional and metabolic activities of the treated cells, which leads to a decrease in the cell concentration in the treated fluid, while, on the other hand, introduction into the organism of treated cells and fragments thereof with heavily changed antigenic structures (this being due to the formation-owing to the effect of ultraviolet irradiation-of photo-adducts comprising cellular components and photo-active chemical agent molecules) leads to the formation of an immune response by the organism, which is purposed to suppress the population of pathologic cells. Since the concentration of pathologic cells essentially exceeds that of healthy ones and also because it is in these that metabolic processes are most active, the photochemical effect is primarily upon pathologic cells, and it is these cells that are capable of causing-following the formation of covalent bonded stable photo-adducts and introduction of these into the organism-a systemic immune response aimed thereagainst.
U.S. Pat. No. 4,613,322 discloses a method for producing therapeutic effect upon the organism, comprising withdrawal of blood from a patient, centrifuging the blood drawn to separate red blood cells and most of the plasma, and obtaining a fraction, in which lymphocytes make the predominant cellular constituent. Said lymphocyte-rich fraction is then exposed to irradiation by ultraviolet light in the presence of a dissolved photo-active chemical agent which is introduced into the organism of the patient 2 hours before blood withdrawal. The blood fraction so irradiated is then returned to the blood supply system of the patient.
When said irradiated blood fraction is returned to the blood channel, the immunogenic photo-adducts formed by exposure to ultraviolet radiation with the participation of constituents of the treated fluid and molecules of the photo-active chemical agent and present in said blood fraction, are not in a position to interact with healthy intact lymphocytes circulating with the blood because, firstly, to provide for said therapeutic effect, the major part (up to 75%) of the immunocompetent cells (lymphocytes) available in the blood supply system of the patient must be exposed to radiation, and, secondly, the presence of other cellular elements in the blood, primarily erythrocytes, hinders direct contact between immunogenic photo-adducts and healthy cells. As regard the main immune response initiated by the emergence in the organism of changed antigenic structures as a result of photo adducts being introduced into the blood supply system, it is mainly localized within the spleen. But even the spleen receives but a limited portion of these immunogenic photo-adducts. This is due to the fact that a substantial part of these immunoreagents to be found in the blood gets attached to the surfaces of macrophages, and since the entire blood passes through the liver where a large number of macrophages is to be found, the major part of the immunogenic adducts introduced into the blood becomes concentrated in the liver, as well as in the kidneys and lungs, and only the remaining portion (up to 10% of the total quantity) falls to the share of the spleen.
This is what reduces the therapeutic effect provided by exposure to radiation.
SUMMARY OF THE INVENTION
It is an object of the present invention to enhance the therapeutic effect upon a living organism with a lymphatic system.
Another object of the invention is to provide a method for producing a therapeutic effect upon the organism, such that would ensure more active suppression of pathologic cells and their proliferation.
A further object of the invention is to provide a method for producing a therapeutic effect upon the organism, such as would ensure a more powerful immune response by the organism to the introduction therein of immunogenic photo-adducts.
In accordance with the invention, the method of producing a therapeutic effect upon a living organism provides for obtaining from said organism a biological fluid, wherein lymphocytes make the predominant cellular constituent, and for exposing said fluid to ultraviolet radiation. Prior to irradiation, said biological fluid has a fluid-soluble photo-active chemical agent added to it. On completion of the irradiation, the biological fluid is returned to the lymphatic system of the organism.
In this method of producing a therapeutic effect upon the organism, the immunogenic photo-adducts formed by exposure to ultraviolet radiation with the participation of constituents of the treated fluid and molecules of the photo-active chemical agent, will find their way into a medium with a significant concentration of healthy intact lymphocytes and, in consequence thereof, they will be enabled to actively interact therewith. This will lead immediately to initiation of a response at the level of the population of lymph-circulated healthy immunocompetent cells. As a result, there occurs a much more effective suppression of pathologic lymphocytes circulating in the organism than provided in the prototype, leading to a considerably enhanced therapeutic effect. Moreover, while moving with the lymph into the thoracic duct and further on into the blood, the photo-adducts pass through a whole series of lymphonodi which form, in response to such a stimulus, a generalized immune response involving the entire lymphoid system. This also contributes to more active suppression of pathologic cells, and the efficiency of the therapeutic effect upon the organism is thereby enhanced.
For biological fluids, wherein lymphocytes prevail as a cellular constituent, use may be made of lymph directly originating from the lymphatic system of a patient or of a lymph fraction enriched with lymphocytes or of a blood fraction enriched with lymphocytes.
In another embodiment of the invention, irradiation is effected directly in one of the vessels of the lymphatic system of a living organism.
A photo-active chemical agent to be used may be: (1) some one of the active furocoumarins as such or a combination of furocoumarins, also, ethylene blue, pyrene, cholesteryloleate, protoporphyrin, porphyrin, acridine, fluoroscein, rodamine, 16-diazocortisone, ethidium, a transition metal complex of bleomycin, a transition metal complex of deglycobleomycin, or an organoplatinum complexes; (2) a polypeptide selected from the group consisting of interleukin, transferrin, thyopoietin, insulin, antibodies, and monoclonal antibodies, and covalently linked with a photo-active cytotoxic agent; or (3) a liposoma linked with a polypeptide which comprises a photo-active cytotoxic chemical agent selected from the group consisting of furocoumarins, pyrene, cholesteryloleate, protoporphyrin, porphyrin, acridine, fluoroscein, rodamine, 16-diazocortisone, ethidium, a transition metal complex of bleomycin, a transition metal complex of deglycobleomycin, or organoplatinum complexes.
DETAILED DESCRIPTION OF THE INVENTION
The inventive therapeutic effect is realized as follows. A biological fluid, with lymphocytes as the main cellular component, is withdrawn from the organism. To this end, blood may be drawn from a patient, and centrifuged in a conventional manner to separate a fraction containing lymphocytes as the main constituent, with lymphocyte-free fractions to be returned to the blood supply system of the patient. This done, the blood fraction rich in lymphocytes is placed in a cuvette, and a photo-active chemical agent is added thereto. As disclosed in U.S. Pat. No. 4,613,322, this agent may be selected from: (1) some one of the active furocoumarins, or a combination of furocoumarins, methyl blue, pyrene, cholesteryloleate, acridine, porphyrin and protoporphyrin, fluorescein, rodamine, 16-diazocortisone, ethidium, transition metal complexes of bleomycin, transition metal complexes of deglycobleomycin, organoplatinum complexes; (2) a polypeptide selected from the group consisting of interleukin, transferrin, thymopoietin, insulin, antibodies, and monoclonal antibodies, and covalently linked with a photo-active cytotoxic agent; or (3) a liposoma linked with a polypeptide which comprises a photo active cytotoxic chemical agent selected from the group consisting of furocoumarins, pyrene, cholesteryloleate, protoporphyrin, porphyrin, acridine, fluorescein, rodamine, 16-diazocortisone, ethidium, a transition metal complex of bleomycin, a transition metal complex of deglycobleomycin, or organoplatinum complexes. Introduction of an agent into the biological fluid may be also provided by way of administering of directly onto the organism of a patient prior to blood withdrawal.
Following the addition of a photo-active chemical agent to the lymphocyte-rich biological fluid and a short period of mixing, the agent is adsorbed on the surfaces of cellular membranes and cellular elements and also on DNA sections, assuming that the agent is capable of penetrating into the cell's nucleus and has affinity towards DNA.
Then the biological fluid (blood fraction) in the cuvette is irradiated using ultraviolet light with wavelength of 200 to 800 nm, the wavelength being varied in relation to the photo active chemical agent employed. Mercury-vapour lamps, xenon lamps, or lasers may be used for purposes of irradiation.
In the case of agents intercalating in darkness between pairs of DNA pyrimidines, the radiation effect results in irreversible DNA degradation or in covalent linkage being formed between pyrimidines from complementary DNA chains, with the photo-active chemical agent participating therein.
As a result, stable complexes are formed, with clearly pronounced modified stable antigenic properties. The use of known natural compounds and pharmaceuticals linked with photo-active chemical groups, antibodies, natural polypeptides, including interleukin, transferrin, etc., cortisone, and the like, for which there are appropriate receptor sites on cellular membranes, leads to a more powerful manifestation of their biological activity aimed at direct degradation or suppression of the functional end metabolic activity of the target cells, the result being formation in the irradiated fluid or photo-altered non-viable cells and fragments thereof which are capable, when introduced into the lymphatic system, of causing a reaction from the healthy constituents of the lymphoid tissue. In consequence of the fact that the metabolic processes characteristic of a living cell are considerably more active in pathologic cells than in healthy ones, it is pathologic cells that are subjected primarily to degradation and loss of functional activity. In the event of the biological fluid being exposed to ultraviolet radiation in the presence of a photo-active chemical agent having the properties of a photosensitizer, such as a psoralen, and in a medium with an insignificant oxygen content (specifically, when the biological fluid sample is slightly vacuumized prior to exposure), the photochemical reactions in the fluid become oriented towards formation of diadducts of psoralen and DNA filament and, alongside with inhibition of the division processes of the treated cells. Formation of artificial homogeneous structures capable of provoking in healthy immunocompetent cells a strong reaction against said homogeneous antigenic structures.
Should there be need for initiating a be polyvalent immune response from the organism, the biological fluid may be conveniently treated in the presence of an elevated oxygen content so that the oxygen-dependent reactions of the photo-active chemical agents in the biological substrate might be intensified. This can be easily achieved by irradiating the fluid, with 8-methoxy psoralen or some other photosensitizer dissolved therein, in a vessel where oxygen is supplied under pressure. With this arrangement. reactions of a radical nature occuring in the fluid will cause degradation of many cellular structures and modification of the cellular surfaces of a considerable number of immunocompetent cells, as well as formation of numerous cellular fragments covalently linked with photo-active agent molecules and possessing immunogenic properties.
Next, the treated blood fraction is introduced into the lymphatic system. To this end, a lymphatic vessel is catheterized in a conventional manner. It is convenient to choose for the purpose one of the lower extremities.
A clearly pronounced immune response is to be observed when the treated fluid is introduced into the lymphatic system. The possibility of contact between the immunogenic photo-adducts and certain groups of cells of the lymphoid organs depends on the anatomic position of these cells. Where the immunogenic photo-adduct is introduced endolymphatically (or into the fatty surrounding lymphonodi or into lymphonodi, which is technically more difficult). this immunoreagent is delivered with the lymph to the lymphonodi responsible for draining of a given area, where it interacts with the macrophages of the medullar region and the dendritic cells of the lymphoid follicles and passes nearly in its entirety through the regional lymphatic nodi. This causes a powerful generalized immune response from the entire system. There are no constituents in the lymph that could screen the healthy intact lymphocytes present therein from interaction with the immunogenic photo-adduct, and for this reason direct interaction is possible between the healthy intact lymphocytes and the immunogenic photo-adducts with the result that a reaction is initiated on the part of the healthy intact lymphocytes, aimed at suppression of pathologic cells. An essential therapeutic effect can be obtained here, using but slight quantities of the immunoreagent.
Considering the fact that in malignant lymphoproliferative diseases and in auto-immune diseases the pathologic cells are considerably more numerous than healthy ones, they can form - on their return to the organism after said treatment and formation of immunogenic photo-adducts- that critical mass of immunoreagents which causes the formation of an immune response by the system. When introducing the treated cells into the organism endolymphatically, there is a possibility of direct interaction between immunogenic photo-adducts and healthy immunocompetent cells, e.g. based on anti-idiotypic reactions. Besides, it is quite possible that a strong immune response may be associated with a mixed lymphocyte culture reaction being initiated right in the lymphatic system, more particularly when the cell treated has been performed at an elevated oxygen concentration.
We have discovered in our in vitro experiments that co-cultivation of intact lymphocytes and autologic lymphocytes irradiated in the presence of a photo-active chemical agent leads to higher activity in the DNA synthesis in the cells of the culture as a whole. It may be assumed in this connection that ultraviolet irradiation leads to changes in the histocompatibility antigens in the HLAF region while the subsequent re-infusion of irradiated cells into the organism initiates mixed culture reactions. The biological effect at the organism level may thus be associated with the mixed culture reaction being induced throughout the circulating lymph and manifested as blast transformation of T-lymphocytes and formation of cytotoxic T-lymphocytes which may have a toxic effect upon target lymphocytes.
Said biological fluid may be lymph enriched with lymphocytes. To be used as such, lymph is withdrawn from a patient, centrifuged, and a fraction enriched with lymphocytes is isolated. Although lymph withdrawal is a more complicated procedure than blood withdrawal, the vessels of the lymphatic system being narrower, yet a much lower quantity of fluid is to be withdrawn and treated in this case in order to obtain a clearly pronounced immune response.
Lymph can also be used as a biological fluid as such, without being fractionated.
As a matter of principle, cerebro-spinal fluid which contains immunocompetent cells may also be used as a biological fluid, but its use is less preferable, considering the risk of a trauma to the patient incident to its withdrawal, as well as the relatively low concentration (up to 10%) of immunocompetent cells therein.
For forced saturated of the biological fluid with oxygen before irradiation, the biological fluid is placed into a container capable of withstanding a pressure of 2 to 3 atm. This container should either have one of the walls made quartz and allow of an extended radiation source to be arranged above it or have a fibre-optic light guide secured in one of the walls and connected optically via a focusing system with a radiation source. Connected to the container via a connecting hose is a compressed oxygen vessel equipped with a reducing valve.
For pre-irradiation vacuumization, the biological fluid is placed into a container which also has one of the walls made of quartz or a fibre-optic light guide in one of the walls. Connected to this container via a connecting hose is a pump placed over a special pipe stub provided on the container.
In accordance with another embodiment of the invention, irradiation is effected endolymphatically. A thin catheter is introduced into a lymphatic vessel, and a fibre optic light guide is inserted down the entire depth of the catheter, the light guide being optically connected via a lens system to a point ultraviolet radiation sirocco. A photo-active chemical agent is either administered to the patient per os 4 to 8 hours before the treatment or supplied endolymphatically at regular intervals in small portions in the course of treatment. In intracorporeal lymph treatment, some of the known means may conveniently be used to accelerate lymph flow through the vasal channel. The processes incident to intracorporeal lymph treatment are similar to these occuring in extracorporeal treatment. Intracorporeal irradiation will greatly reduce the risk of traumatism involved in the procedure and provides better opportunities for interaction between immunogenic photo-adducts and healthy cells. Also, with this arrangement, immunogenic photo-adducts are supplied to the lymphatic system at a constant rate, i.e. the load on the lymphonodi is distributed more informly, and this provides for more stable functioning of the immune system.
Puncturing points in lymphatic vessels may conveniently be chosen on a lower extremity because, considering the anatomic structure of the lymphatic system, an immunogenic photo-adduct fragment introduced thereinto will inevitably pass-before entering the blood supply system--through the entire system of regional lymphonodi, of which there will be quite a number to be encountered in its path, with the result that a powerful immune response will be provoked and the probability and period of interaction of healthy cells therewith will be considerably increased to further enhance the immune response.
The proposed method may be illustrated with the following specific examples of its implementation.
EXAMPLE 1
A cow, breed black-mottled, diagnosed as having acute lymphoid leukosis accompanied with a considerable increase in the total number of leucocytes in the blood--to 35,000 per microliter.
A syringe of 300 ml capacity was used to withdraw 250 ml of blood from the cow's jugular vein. The withdrawn blood was established with heparin, 15 units per milliliter. Then it was fractionated by centrifuging for 20 minutes at a centrifuge rotor speed of 2000 rev/min. The fraction enriched with lymphocytes, in the amount of 25 ml. was collected in a sterile flask. The remaining plasma and erythrocyte mass were mixed together and introduced back into the cow's blood supply system by means of a syringe through the original puncture point. The blood withdrawal and separation procedure was repeated 7 more times, so that 200 ml of lymphocyte-in-plasma suspension was collected in the flask in the long run.
Then 40 mg of psoberane (preparation comprising a mixture of 8-methoxy psoralen and bergaptene) was added to the suspension-containing vessel, and the contents were mixed in a special shaker. Next, the suspension was irradiated while passed through a cuvette sized 140×25×1 mm and providing a luminous energy intensity of 2 mw/cm 2 in the cuvette plane. The suspension flow rate through the cuvette was 20 ml/min. Nearly 90% of the luminous energy intensity in the cuvette plane was provided by ultraviolet radiation with a maximum near 350 nm.
Then a lymphatic vessel in a rear extremity was drained, and a catheter installed, enrich catheter was used to introduce the irradiated suspension at the rate of 1,5 ml per minute.
The same procedure was repeated 5 more times at intervals of 10 to 15 days. Already after the third procedure the animal showed an improved clinical picture. On completion of the course of treatment the concentration of leucocytes in the blood was 800 per microliter. This value continued practically unchanged an observation period of 11 months.
EXAMPLE 2
Patient K., male, age 16, delivered with a diagnosis of acute T-cell leukosis in the exacerbation phase. By the time of delivery the patient has suffered from the disease for 2 years, during which period he had undergone 3 courses of treatment based on conventional chemotherapy. The concentration of blast cells in the blood was up to 30%.
Five hours before the commencement of the procedure, the patient was administered intravenously a solution containing 30 mg of 8-methoxy psoralene. The lymphatic duct was drained in the left leg, in the groin area, and a catheter was installed. A fibre-optic light guide was inserted throughout the length of the catheter, having a high transmission coefficient in the UVA region and connected optically via a focusing lens system to a point source based on the use of a xenon lamp and providing a luminous energy intensity at outlet from the light guide of 1 mW in the UVA region (fibre optic conductor diameter being 0.8 mm). The radiation time per procedure was up to 120 minutes. The intervals between procedures were 7 to 14 days. A total of 6 procedures were carried out. For several days after each procedure the patient received up to 200 mg of allopurinol daily.
On completion of the course of treatment, no blast cells were to be found in the peripheral blood. The concentration of various forms of leucocytes was typical for patient suffering from leukosis in the remission phase.
EXAMPLE 3
Patient T., male, age 39, delivered with a diagnosis of bronchial asthma in the abating exacerbation phase and respiratory deficiency.
Four hours before the commencement of the procedures, the patient was administered per os 30 mg of beroxane (preparation comprising a mixture of 8-methoxy psoralen and bergaptene). The lymphatic duct in the leg in the groin area at left was catheterised. A light guide connected to an U.V. source was introduced throughout the length of the catheter. The luminous energy intensity at outlet from the light guide was 2 mW (the diameter of the fibre optic light conductor being 0.8 mm). The irradiation time per procedure was 40 to 60 minutes. The procedure were carried out at intervals of 10 days. A total of 5 procedures were carried out.
Already after the first procedure, rhinocleisis and rhinorrhea were no longer to be observed. Asphyxia fits became much less frequent, and the quantity of secreted sputum was decreased. On completion of the treatment, stable remission was to be observed, as well as improved endurance of physical strains.
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A method of producing a therapeutic effect upon a living organism endowed with a lymphatic system, comprising the steps of with drawing from said organism a biological fluid, wherein lymphocytes prevail as the cellular constituents, and introducing into said biological fluid a photo-active chemical agent soluble therein. The chemical agent has a specific affinity for the receptor sites in or on the fluid constituents, and is capable of being activated by ultraviolet radiation, and, when activated by said ultraviolet radiation, of forming photo-adducts with receptor sites of the fluid constituents, thereby ensuring chemical linkage between said photo-active chemical agent and said receptor sites. The method further includes irradiating the biological fluid, with the photo-active chemical agent introduced thereinto, by ultraviolet light, and introducing said biological fluid after said irradiation back into said lymphatic system. Irradiation may be effected endolymphatically.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to management of power in blade computing systems.
[0003] 2. Description of the Related Art
[0004] In the past, information handling systems, e.g., workstations, servers, etc. were essentially self-contained systems within an appropriate housing. For example, a desktop PC would consist of user interface elements (keyboard, mouse, and display) and a tower or desktop housing containing the CPU, power supply, communications components and the like. However, as demands on server systems and PC systems increased and with the increasing spread of networks and the services available through networks, alternate technologies have been proposed and implemented.
[0005] Blade computing is one such technology. A blade server provides functionality comparable to or beyond that previously available in a “free standing” or self-contained server, by housing a plurality of information handling systems in a compact space and a common housing. Each server system is configured to be present in a compact package known as a blade, which can be inserted in a chassis along with a number of other blades. At least some services for the blades, typically including power supply, are consolidated so that the services can be shared among the blades housed in common. As blade technology has advanced, blade architecture has been developed whereby servers are packaged as single boards and designed to be housed in chassis that provide access to all shared services. In other words, blade servers today are single board units that slide into a slot in a housing in which other like boards are also housed.
[0006] Similar to blade servers, desktop blades involve the configuration of the major components of a PC onto a single card, and then storing/housing many such cards in a single chassis or housing. As with server blades, the use of desktop blades allows centralized management and maintenance of power shared among the various blades.
[0007] In an IBM BladeCenter® and other blade/chassis systems, there are advantages to allowing the maximum possible density of blades within the chassis. Other than the size of the chassis itself, the only limitation on blade density is the amount of power consumed by the blades in the chassis. In a typical blade center system there are two power domains, each supported by two power supplies running in a shared, fully redundant mode. This two-supply system is considered fully redundant because if one of the supplies (the “non-redundant” or primary supply) fails, the other supply (the “redundant” or secondary supply) is of a size that allows it to provide sufficient power to fulfill the power demands of the entire domain. In other words, the “nominal power” of a single supply is sufficient to provide power for the entire domain. In practice, the power allocation is typically shared between the multiple supplies when all are functioning properly. When one of the power supplies fails, the portion of the power that it was providing is automatically shifted to the remaining supply.
[0008] As CPUs and other devices have increased their speed, their power demands have also increased. The aggregation of blades constructed with newer, more powerful and power-demanding CPUs may exceed the capacity of power provided by a single (non-redundant) power supply system, i.e., they may exceed the nominal power that can be provided by a single power supply; meanwhile the nominal power available by existing power supplies has not increased in a corresponding manner. While larger capacity power supplies could be utilized, space limitations within the chassis can be prohibitive. Thus, there is either a limit to the number of blades that can be used, or other power management strategies must be applied.
[0009] One solution has been to “oversubscribe” the number of blades available within the chassis, and utilize some of the spare capacity of the shared redundant power supplies for normal operations. Oversubscribing is the term used to describe the situation where aggregate power demand is greater than the non-redundant supply capacity (e.g., at nominal value of the power supply in a “1+1” redundant system, i.e., a system having one supply that can handle the complete load, plus one additional supply also capable of handling the complete load). In an oversubscription situation, the power needed to supply the subscribed blades will exceed the capacity of the non-redundant power supply and thus the power system is no longer fully redundant. This can threaten the overall operation of the system, since if a power supply failure occurs, the remaining supply may be overloaded and thus an entire domain of blades may not be able to remain operational.
[0010] Besides implementing a fully redundant policy, multiple levels of oversubscription can be defined. Recoverable-oversubscription is where the limit of power with redundant power supplies (recoverable-oversubscription limit) is greater than the power supply nominal value, but where recoverable action (e.g., throttling of blades) can be taken when a redundant supply is lost, such that the remaining power supply will not shut down. Non-recoverable-oversubscription is where the limit of power with redundant power supplies (non-recoverable-oversubscription limit) is greater than the power supply nominal value, but where sufficient recoverable action (e.g., throttling of blades) cannot be taken in a manner that will assure that the remaining power supply will not shut down.
[0011] When in oversubscription mode and a redundant power supply is lost, action must be taken very quickly to reduce the power demand or the power system will fail. One possible action is to power off one or more blades to thereby reduce the power demand. However, some blades are designed with programmable throttling such that their power consumption can be reduced, albeit with some loss of performance. It would be desirable to use this programmable throttling function for power reduction in the above-described situation when a redundant power supply is lost while operating in oversubscription. However, the chassis management entity in the prior art is not configured with sufficient information to enable power reduction via the programmable throttling. Different blades can have different mechanisms with different power reduction characteristics, and new blades may be released with new mechanisms and characteristics which would require an update to the chassis power management functions for them to be utilized by the chassis management entity when effecting power reduction.
[0012] Accordingly, it would be desirable to have a blade power management system whereby the amount of power reduction that a blade can withstand and still function was determined by the blade and utilized when determining which blades to reduce in power and by how much. Additionally, it would be desirable to provide a mechanism whereby the power is reduced within a very short window where the remaining power supply (or remaining power supplies) will provide the excess power needed for only this short period of time.
SUMMARY OF THE INVENTION
[0013] The present invention provides a method, system, and computer program product to enable and control power reduction in a blade/chassis system. A “maximum power reduction” attribute is stored in the VPD of the blade (or can otherwise be input to or retrieved or calculated by the management entity). The management module of the chassis in which the blades and power supplies are located uses this information to manage the power reduction of blades when the system is operating in an over-subscription mode and a power supply fails. If throttling is required, the system knows the amount of power reduction available for each blade and controls the throttling by spreading it out among the blades in the system so that, ideally, no blade will cease operation altogether. Mechanisms for rapid reduction of power are provided for situations in which redundant power is lost.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 illustrates an exemplary blade environment;
[0015] FIG. 2 is a block diagram that illustrates the allocation of power in a 1+1 redundant system as used in the present invention;
[0016] FIG. 3 illustrates the chassis illustrated in FIG. 2 , with MPR values for each blade included; and
[0017] FIG. 4 is a flowchart illustrating the basic steps performed in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] While the present invention will be described more fully hereinafter with reference to the accompanying drawings, in which a preferred embodiment of the present invention is shown, it is to be understood at the outset of the description which follows that persons of skill in the appropriate arts may modify the invention here described while still achieving the favorable results of the invention. Accordingly, the description which follows is to be understood as being a broad, teaching disclosure directed to persons of skill in the appropriate arts, and not as limiting upon the present invention.
[0019] Referring now more particularly to the drawings, FIG. 1 illustrates an exemplary blade rack housing 102 . While the view is simplified and certain elements to be described herein are not visible in FIG. 1 , the rack housing 102 includes a plurality of chassis 104 , 106 , 108 , and 110 . Within the chassis, multiple blades, e.g., blades 112 , 114 , and 116 , can be mounted. For example, in FIG. 1 , blade 112 is illustrated as being mounted in chassis 106 ; blade 114 is shown as being mounted in chassis 108 , and blade 116 is shown being mounted in chassis 110 . A power supply 118 is shown being mounted in chassis 104 . Although not shown, typically a Management Module is also included in the rack housing 102 and, in a known manner, manages the operations performed by the blade system.
[0020] FIG. 2 is a block diagram that illustrates the allocation of power in a 1+1 redundant system as used in the present invention. The values given in FIG. 2 for the maximum power of each blade and the nominal capacity of the power supplies is given for the purpose of example only and it is understood that the present invention is not limited to the values illustrated in FIG. 2 . Referring to FIG. 2 , a simplified example of a rack 200 containing blades 202 - 216 is shown. Power supplies 218 and 220 provide power to the blades in rack 200 on a shared-allocation basis.
[0021] In the example of FIG. 2 , blades 202 and 204 each are allocated 300 watts of power (maximum); blade 206 is allocated 290 watts of power (maximum); blade 208 is allocated 310 watts of power (maximum); and blades 210 - 216 are each allocated 250 watts of power (maximum). The maximum values are calculated based on the various options that may be installed on each blade. At any given time any of the blades may be drawing the maximum values; however, it is understood that there will also be times when they are drawing less power. In the example of FIG. 2 , if all of the blades are subscribed simultaneously, 2200 watts of power would have to be allocated to run the blades at maximum power. This is 200 watts above the nominal power of either of the power supplies 218 or 220 individually, which means that the system is running in an oversubscription mode where additional power is being provided by the excess capacity of the redundant power supplies.
[0022] In accordance with the present invention, a maximum power reduction (MPR) attribute for each blade is identified and is utilized by the management module of the system to manage the amount of throttling performed when a throttle condition exists. As noted above, in the example of FIG. 2 the blade system is oversubscribed by 200 watts. In other words, if one of the power supplies 218 or 220 were to fail, the overall power being drawn by the blades in the aggregate would have to be reduced by 200 watts to enable the power supply to continue powering the blade system. As noted above, a method in the prior art for quickly reducing the power would be to completely shut down a sufficient number of blades to reduce the power requirement of the remaining functioning supply. In the example of FIG. 2 , since each of the blades has a maximum power draw that exceeds the 200 watt oversubscription value, in the prior art systems, any one of the blades would be shut down and the remaining blades could be powered by the functioning power supply. This is problematic, however, in that the entire functionality of one of the blades is lost.
[0023] The present invention allows one or more of the blades to be throttled back by an amount that does not exceed the “maximum power reduction” value. This is a value that has been determined in advance at which a particular blade can continue to function and perform its primary duties while drawing a reduced amount of power.
[0024] FIG. 3 illustrates the chassis illustrated in FIG. 2 , but with the MPR values for each blade included. As can be seen, the MPR value for blades 202 and 204 is 100 watts for each blade; the MPR value for blade 206 is 50 watts; the MPR value for blade 208 is 150 watts; and the MPR values for blades 210 - 216 is 0 watts. In other words, blades 202 and 204 can reduce their power by 100 watts each and still continue to perform their functions; blade 206 can reduce its power draw by 50 watts and still continue to perform its functions; and blade 208 can reduce its power draw by 150 watts and still continue to perform its functions. Blades 210 - 216 cannot have their power reduced below their maximum value. This indicates that they are incapable of throttling or are performing important functions or are fully loaded, i.e., they cannot reduce their power. The MPR attributes can be provided in the VPD of each blade. This value can be static (set in manufacturing) or dynamically calculated by the blade based on installed blade options. For dynamic calculation, tables and algorithms for this calculation are self-contained within the blade. The blades can dynamically calculate their maximum power requirement by detecting the installed blade options, determining the options' power requirements from the table stored on the blade, and summing all the individual power requirements, thereby arriving at the total power requirement for the blade.
[0025] FIG. 4 is a flowchart illustrating steps performed in accordance with the present invention. Referring to FIG. 4 , at step 402 the maximum power (P max ) value for each blade in the chassis is obtained. As noted above, this information can be obtained from the VPD of the blade or could be dynamically calculated by the blade based on the installed blade options. At step 404 , the total maximum power for all blades in the chassis is calculated by totaling up the maximum power value of the individual blades. In the example of FIG. 3 , the total maximum power value for all blades in the chassis is 2200 watts.
[0026] At step 406 , the MPR for each blade in the chassis is identified. Again, this can be obtained from the VPD of the blade or dynamically calculated by the blade based on installed blade options. At step 408 , the total MPR value for all blades in the chassis is calculated. This is simply an addition step wherein all MPR's for all blades in the chassis are added. In the example of FIG. 3 , the total MPR value for the blades in chassis 300 is 400 watts.
[0027] At step 410 , the non-redundant power available (NRPA) value is identified. This is essentially the value of, in the example of FIG. 3 , one of the power supplies, i.e., it is the value of power available if redundancy is lost.
[0028] At step 412 , the amount of oversubscription is calculated. This is determined by subtracting the NRPA value from the total P max value for the blades in the chassis. In the example of FIG. 3 , this calculation is 2200 watts−2000 watts=200 watts. At step 414 , the throttling power reduction (TPR) value for each blade is calculated. One example of how to perform the calculation is to divide the MPR value of a blade by the Total MPR (TMPR) value for all blades, and then multiply that result by the amount of oversubscription. Thus, for example, for blade 302 , the TPR value is: 100 watts (the MPR value of blade 302 )−400 watts (the TMPR value for all blades)=0.25 watts, multiplied by 200 watts (the amount of oversubscription). The TPR value for blade 302 is thus 50 watts. The same calculation holds true for blade 304 , since the values of blade 304 are identical to the values of blade 302 . Alternative calculations exist and could be customer selectable. For example, the throttle for blades could be calculated by subtracting the average non-redundant power available per blade (250 W in FIG. 3 ) from the Pmax (assuming that this value is not greater than the blade MPR).
[0029] For blade 306 , the calculation is 50 watts÷400 watts=0.125 watts, multiplied by 200=25 watts. For blade 308 , the calculation is 150 watts÷400 watts=0.375 watts×200=75 watts. The TPR value for blades 310 - 316 is 0 watts.
[0030] At step 420 , the blade system is monitored for the occurrence of a throttle condition, that is, for example, a problem in power supply 320 that causes it to shut down. Upon this occurrence being sensed at step 420 , the process proceeds to step 422 , and the blades are throttled using the TPR values for each. The throttle level of each blade must minimally meet the TPR. This brings the total power draw of the blades down to the nominal value of the remaining power supply so that the system does not shut down altogether.
[0031] If, at step 420 , a throttle condition has not been sensed, the process proceeds back to step 418 where monitoring takes place to sense throttle conditions.
[0032] Once throttling levels have been determined, a “performance percentage” can be derived, which is a numeric indication of the percentage of performance at which a particular blade is operating, after throttling. This can easily be done by configuring the blades with the appropriate algorithms and tables to calculate the performance percentage based upon the throttle amount needed to meet the TPR value. This will give an overall indication of the throttled performance as compared to the performance without throttling. This information can also be communicated to the management module so that the information will be available to a system user. Based on these performance numbers a system user may take appropriate action to insure that application(s) are performing at the required level.
[0033] There is a need to insure that when in oversubscription, the blades are quickly throttled independent of the chassis management entity (management module of MM). This can be accomplished by the MM pre-setting the TPR values in each blade. The blades then detect the loss of redundant power and automatically throttle to meet the preset TPR value. Once redundant power is returned, a blade remains in the throttled condition until the chassis management entity issues a command for it to unthrottle. This ensures that viability of the power system has been validated by the chassis management entity prior to the unthrottling of the throttled blades.
[0034] Alternatively, for systems where the blades are not capable of detecting the loss of redundant power, the chassis management module may be used to trigger the blades to throttle. However, when this is done it is prudent to insure that a loss of the chassis management module will not cause a power failure when there is a loss of redundant power. To protect the power domain during periods of loss of the power monitoring management system itself (e.g., if the management module ceases operation), the blades can be configured to dynamically monitor for the loss of the management entity function, and in such a case, automatically throttle to meet the pre-set TPR values until such time as the management module can be brought back into operation. One configuration to enable this function would be to provide a “watchdog timer” between the management module and the blades. The timer will monitor communications between the management module and the blades, and if there has been no communication from the management module for a predetermined period of time, it can be presumed that the management module is experiencing difficulty and the blades can automatically then be put into a throttling mode. The management module could be configured to send the command out at a frequency such that, without a failure, the timer would be reset multiple times within a timer window. A dummy command could be sent if a normal command was not ready to be sent within the given time period. Thus, a loss of a single command (or response) would not be sufficient for triggering the timer. Once the loss is detected, the action for power reduction (e.g., throttling) is initiated, just as in the case of a loss of redundant power. The notification of the power reduction would be continued and forwarded when the management module is again functional. Further, while the management module is in the non-operational state, the blades can be configured to perform a periodic test to determine if the management entity has returned to operation. Exit from the throttled state and reinitiation of the watchdog timer can be accomplished by configuring the management module to issue an explicit command to each blade to “unthrottle”.
[0035] The present invention can also be implemented using hardware throttling techniques. For example, some Intel devices utilize a “FORCEPR#” pin, and driving this pin can throttle the processors when a power loss is detected which necessitates prompt throttling. The Early Power Off Warning (EPOW) from the system power supplies can be used to determine that the amount of available power is decreasing, and the warning can drive the FORCEPR# pin (or similar pin on a non-Intel processor) and thereby trigger the throttling of each processor by the TPR value. The system can be configured to issue a high priority interrupt to the BMC when the EPOW event occurs. This allows the FORCEPR# action to be asserted quickly, within the short window provided by EPOW.
[0036] Although the descriptions herein refer to the use of the present invention with blade computers (server blades, desktop blades, etc.), the present invention as claimed is not so limited. The present invention may be used with other components, including “blade-like” devices that are not generally considered servers in the IT sense, drop-insert routing of telecom circuits, voice processing blades, blades that packetize voice from telecom circuits to a packet network, as well as switch modules, integrated switches and the like.
[0037] 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 of some type, such as permanent storage on a disk drive located in a rack housing. 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.
[0038] 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.
[0039] 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, this disclosure supports 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.
[0040] 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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A method and system are disclosed to enable and control power reduction in a blade/chassis system. A “maximum power reduction” attribute is stored in the VPD of the blade (or can otherwise be input to or retrieved or calculated by the management entity). The management module of the chassis in which the blades and power supplies are located uses this information to manage the power reduction of blades when the system is operating in an over-subscription mode and a power supply fails. If throttling is required, the system knows the amount of power reduction available for each blade and controls the throttling by spreading it out among the blades in the system so that, ideally, no blade will cease operation altogether.
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RELATED APPLICATIONS
[0001] The present application is a divisional application of U.S. patent application Ser. No. 13/050,805, by Gene Y. Fridman, filed Mar. 17, 2011, which is a divisional application of U.S. patent application Ser. No. 11/096,402, by Gene Y. Fridman, filed Apr. 1, 2005, now issued as U.S. Pat. No. 7,953,490, which claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application No. 60/559,296 by Gene Y. Fridman, filed Apr. 2, 2004 and entitled “Methods and Apparatus For Cochlear Implant Signal Processing,” the contents of which are hereby incorporated by reference in their entirety.
BACKGROUND INFORMATION
[0002] Cochlear implant systems provide the sensation of sound to those who are profoundly deaf. Unfortunately, the clarity of the sound that is perceived is not always as good as desired.
[0003] U.S. Pat. No. 5,626,629, and U.S. Pat. No. 5,601,617, both of which patents are incorporated herein by reference, teach or use some speech processing and stimulation strategies that may be used by a cochlear implant system, such as the CLARION or C-II cochlear stimulation systems available from Advanced Bionics Corporation, of Sylmar, Calif. One common speech processing strategy used in the prior art is a simultaneous analog stimulation (SAS) strategy, wherein more than one channel may provide stimulation at the same time. Another common speech processing strategy used and known in the art is continuous interleaved sampling (CIS) strategy. U.S. Pat. No. 6,289,247, also incorporated herein by reference, teaches other types of speech processing and stimulation strategies that may be used by a cochlear implant system. U.S. Pat. No. 5,597,380, and U.S. Pat. No. 5,271,397 are likewise incorporated herein by reference.
SUMMARY
[0004] Dynamic selection of the number of channels to stimulate can provide greater sound clarity. Once a selection of the channels to stimulate has been made, stimulation can be removed from the other channels. Stimulation can be applied to the selected channels only, if desired.
[0005] In one configuration, the selected channels are the ones on which the spectral power is above the mean of all the available channels. In this example, few channels get stimulated at any one time for a given frame, and the contrast of the stimulation is enhanced. The contrast is improved further because the perceived loudness on the fewer number of channels will increase due to faster presentation rate. Also, the temporal resolution will increase as the number of stimulated channels is decreased.
[0006] Further, because the selected channels are the ones on which the spectral power is above a threshold, e.g., above the mean, or above the average, or above some other measure of the spectral power on all of the channels, the selection of channels often is not static. Rather, the selection can be dynamic based on the spectral power in the channels.
[0007] One configuration of a stimulation system applies stimulation to the areas of the cochlea which correspond in the desired way to spectral power, such as the selected spectral power. Stimulation may be removed from all other locations along the cochlea corresponding to channels having a low spectral power, for example below the selected spectral power.
[0008] Cochlear implants having one or more of the characteristics described above may offer increased speech clarity and higher temporal performance. They may also offer increased speech clarity without consuming excessive power.
[0009] The present invention advantageously provides an increase in perceived SNR (signal-to-noise ratio) by removing stimulation from low power channels. Further, the invention provides an increase in spectral contrast since fewer channels receive a higher pulse rate. Additionally, the invention provides an increase in temporal resolution since the integration frame is shorter for a smaller number of channels.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The above and other aspects of the present inventions will be more apparent from the following more particular description thereof, presented in conjunction with the following drawings wherein:
[0011] FIG. 1 shows a cochlear stimulation system;
[0012] FIG. 2 shows a typical biphasic stimulation waveform generated by an implantable cochlear stimulator (ICS);
[0013] FIG. 3 illustrates the signal flow through a cochlear stimulation system in accordance with the present inventions;
[0014] FIG. 3A is a schematic of a processor assembly used on a platform for the stimulation system; and
[0015] FIG. 4 depicts an illustration of how the present inventions may process signals to provide stimulation only on those channels of high spectral power.
[0016] Corresponding reference characters indicate corresponding components throughout the several views of the drawings.
DETAILED DESCRIPTION
[0017] The following description is of the best mode presently contemplated for carrying out one or more aspects of the present inventions. This description is not to be taken in a limiting sense, but is made merely for the purpose of describing the general principles of the invention. The scope of the invention should be determined with reference to the claims.
[0018] In one exemplary apparatus and methods, improved speech clarity can be achieved by only stimulating the locations of the cochlea which correspond to high spectral power, namely spectral power above a defined spectral power. Additionally, stimulation can be removed from all other locations along the cochlea with low spectral power, namely spectral power below the selected spectral power. “Low spectral power” and “High spectral power” are defined here as being that spectral power that is below and above the selected spectral power, respectively. In one aspect of the inventions, the selected spectral power is estimated by the signal average. In the examples described herein, the “signal average” is the sum of the channel signals divided by the total number of channels.
[0019] A representative cochlear stimulation system with which the present invention may be used is described in U.S. Pat. No. 5,603,726, which patent is incorporated herein by reference. Other cochlear stimulation systems with which the present invention may be used are found in U.S. Pat. Nos. 6,308,101; 6,219,580; and 6,272,382; which patents are also incorporated herein by reference.
[0020] FIG. 1 shows a typical cochlear stimulation system 10 comprising a speech processor portion 12 and a cochlear stimulation portion 14 . The cochlear stimulation portion 12 is usually implanted, and includes an implantable cochlear stimulator (ICS) 16 and a cochlear lead 18 . The lead 18 includes a multiplicity of electrode contacts thereon (not visible in FIG. 1 ) through which electrical stimulation pulses, generated by the ICS 16 , are applied to selected locations or areas of the cochlea.
[0021] The speech processor portion 12 includes a speech processor (SP) 20 and a microphone 22 . The microphone 22 may be physically connected to the SP 22 , or connected through an appropriate wireless link 21 . The microphone 22 senses acoustic sound and transduces it to an electrical signal. The electrical signal from the microphone has different intensities as a function of the loudness of the audio signal that is sensed. The electrical signal from the microphone 22 is then processed by the SP 20 in accordance with a selected speech processing strategy. Based on the type of processing strategy employed, appropriate control signals are generated and sent to the ICS 16 over link 24 . The ICS 16 responds to these control signals by generating appropriate stimulation signals that are applied to tissue at various locations along the inside of the cochlea through the electrode contacts located near the distal end of the lead 18 .
[0022] Typically, the speech processor portion 12 of the cochlear stimulation system 10 is external (not implanted), and the link 24 between the SP 20 and the IPG 16 is a transcutaneous link. However, it is to be understood that parts of the speech processor portion 12 may also be implanted. In a fully-implantable cochlear stimulation system, such as is described in the U.S. Pat. No. 6,308,101, all of the speech processor portion 12 is implanted. When both the SP portion 12 and the cochlear stimulation portion 14 are implanted, the SP 20 and the ICS 16 may reside in respective housings, as shown in FIG. 1 , or the circuitry associated with both the SC 20 and the ICS 16 may be combined into a single housing.
[0023] A biphasic pulse of the type that is generated by the ICS 16 in response to the control signals received from the SP 20 is shown in FIG. 2 . In general, the amplitude and/or pulse width (PW) of the pulses may be varied to adjust the magnitude of the stimulus. Also, the frequency, or stimulation rate, at which the pulses are generated may be controlled, as needed.
[0024] A preferred platform for launching the present invention is shown in U.S. Pat. No. 6,219,580, previously incorporated herein by reference. Some features associated with that platform are shown in the signal flow diagram of FIG. 3 . Additionally, a schematic of a processor assembly used on the platform is shown in FIG. 3A , showing a physical partitioning of the ICS2 portion of the platform described and illustrated in FIG. 14 of U.S. Pat. No. 6,219,580. The ICS2 consists of electronic circuitry that fits inside a hermetically sealed, U-shaped ceramic case 300 , e.g., of the type disclosed in U.S. Pat. No. 4,991,582, incorporated herein by reference. The package design may be the same as is used by the ICS described in the '726 patent, previously referenced. The power and telemetry coils 302 , and the back telemetry coil 304 , and all circuitry are mounted on a ceramic hybrid 306 inside of the case 300 . The majority of the circuitry is integrated into custom integrated circuits (ICs). Two IC's are employed—one analog IC 308 and one digital IC 310 . Discrete components are used as necessary, e.g. coupling capacitors Cc. Attachment of the circuitry to the sixteen external electrodes and one indifferent (reference) electrode is through a bulkhead connector 312 at one end of the case. (Note that Electrodes are numbered 1 through 16, with 1 the most apical and 16 the most basal.) Provision for an additional indifferent electrode and two stapedius electrodes are also made in the ICs.
[0025] As seen in FIG. 3 , the signal generated by the microphone 22 is split into frequency bands by a bank of bandpass filters 40 - 0 , 40 - 1 , . . . 40 - k connected in parallel. Each bandpass filter 40 receives the microphone signal. Each bandpass filter 40 has a center frequency that allows signal frequencies within a specified band to pass therethrough. The bandpass filter 40 - 0 , for example, allows relatively low frequency signals to pass through. The bandpass filter 40 - k , on the other hand, allows only high frequency signals to pass through. The bank of bandpass filters is an example of apparatus that can divide an incoming audio signal into channels.
[0026] The signals in each frequency band are then subjected to envelope detectors 50 - 0 , 50 - 1 . . . 50 - k . Each of these envelope detectors 50 senses the spectral power component of the signal in its respective frequency band. This spectral power component is represented in FIG. 3 as the signals E 0 , E 1 , . . . E K . The average of these signals E 0 , E 1 , . . . E K is dynamically determined. The average of the power of the spectral channels can be determined through appropriate processing carried out on the ICS2 ( FIG. 3A ). This average allows selection of a selected spectral power, which can then be used to select which of the signals E 0 , E 1 , . . . E K represents “low” spectral power, and which of the signals represents “high” spectral power. The envelope detector is an example of apparatus that can determine the spectral power of a signal. The selected spectral power is an example of a threshold that can be used to differentiate between high and low spectral power signals, and the threshold can be determined through appropriate processing carried out on the ICS2 ( FIG. 3A ). A selector circuit 60 allows only those signals having “high” spectral power to be sent on to the ICS for stimulus generation. The channels having “low” spectral power are de-selected, i.e., removed so that stimulation pulses corresponding to the channels having “low” spectral power is effectively turned off. These low spectral power channels will be effectively zero channels, because they will be turned off, or those channels will be set at zero or have no pulses applied for those channels. The selector circuit 60 is an example of an apparatus for selecting channels having spectral power above a threshold value. The selector circuit can be implemented in the ICS2 ( FIG. 3A ).
[0027] Further, the signals of “high” spectral power that pass through the selector circuit 60 are sequenced using sequencer 64 so that the stimuli generated by the ICS 16 are applied sequentially only on the non-zero (spectral power) channels. Acoustic-to-electrical mapping of the signals is further carried out with mapping circuits 70 - 0 , 70 - 1 , . . . 70 - k , which mapping further conditions the signals that are applied to the electrodes on the lead 18 . A biphasic stimulus pulse is then applied on the non-zero channels in sequence as controlled by the sequencer 64 and as conditioned by appropriate mapping circuits 70 . The mapping circuits are an example of an apparatus for sequentially applying electrical stimuli only to the electrodes of channels having a spectral power above a threshold value.
[0028] Because the spectral power in each channel changes dynamically as a function of the acoustic signals sensed through the microphone 22 , the non-zero channels through which a stimulus, or stimuli, are applied also changes dynamically. However, for any cycle of the sequencer 64 , there will be some zero channels on which no stimulus will be provided, and some non-zero channels on which a biphasic stimulus pulse is applied. The biphasic stimulus provides a loudness associated with the various parameters of the stimulation pulse train, such as the amplitude, pulse width of the pulses, and the time between pulses.—We refer to the perceived loudness on a given channel as intensity. Intensity is controlled by the spectral power of that channel. The intensity in some applications will be the combination of the amplitude and the pulse width and number of pulses per unit time, but it should be understood that intensity for purposes of the present discussion may be manifested in other ways, for example amplitude only with relatively constant pulse width, or pulse width with relatively constant amplitude. For the example illustrated in FIG. 3 , the spectral power is non-zero only in the 0th channel and the kth channel. All of the other channels are zero. Thus, a biphasic pulse 72 is applied to electrode 0 on lead 18 , and a biphasic pulse 74 is applied to electrode k on the lead 18 . Electrode 0, corresponding to channel 0, which represents the channel having the lowest frequency components, is located distally near the end of the lead 18 so that when the lead is inserted into the cochlea this electrode 0 is close to those nerve cells deep in the cochlea that recognize lower frequency signals. Electrode k, corresponding to channel k, which represents a channel having higher frequency components, is located more proximally on the lead 18 so that when the lead is inserted into the cochlea this electrode k is close to those nerve cells closer to the entrance of the cochlea that recognize higher frequency signals.
[0029] The operation of the invention is depicted in signal processing illustration of FIG. 4 . Note that FIG. 4 is divided into five rows, labeled (A), (B), (C), (D), and (E). Each row represents a different example of a signal processing condition.
[0030] In row (A) of FIG. 4 , the speech power spectrum has peaks at about 800 and 2500 Hz, as seen in the Speech Power Spectrum graph 80 A. However, these peaks are not sharp peaks, meaning that the spectral power is spread over many of the channels. This creates a power spectral spread in each of eight channels as illustrated in “Envelope Output” chart 82 A. This is basically a chart of the signals E 0 , E 1 , . . . E K , (see FIG. 3 ), where k=8 in this example. The average of these signals E 0 , E 1 , . . . E K is determined and is used as a threshold. The average is taken as equal to Sum(Ej)/K, where Sum is the conventional sum of elements (Ej), “j” is the channel number, and “K” is the total number of channels, or “k” in this example, where k=8. This threshold, or “threshold value” 83 A, is then used as the selected spectral power, and used to identify those channels above the threshold value and those channels below the threshold value. For the example of this row (A), five of the eight channels—channels 2, 3, 4, 5 and 6—have spectral power signals above the threshold 83 A. Hence, these five channels are selected, as seen in the Dynamic Peak Selection Output chart 88 A, and biphasic pulses are applied sequentially to these five channels, as illustrated in the Stimulation Pattern chart 90 A.
[0031] The speech power spectrum in rows (B), (C), (D) and (E) of FIG. 4 shows that the spectral peaks, all of which are at approximately 800 and 2500 Hz, become increasingly sharper. Thus, for example, in Row (E), only two of the eight channels—channels 3 and 6—have spectral power above the average 83 E. Hence, only these two channels are selected, as seen in the Dynamic Peak Selection Output chart 88 (E), and biphasic pulses are applied sequentially to just these two channels, as illustrated in the Stimulation Pattern chart 90 (E). Note also the rate at which the pulses are applied to these two channels is faster than the rate would be if more channels were selected. This increases the temporal resolution for the stimulated channels since the time between stimuli is shorter. Thus, in general, the temporal resolution increases since the integration frame is shorter for a smaller numbers of channels.
[0032] Thus, it is seen that in operation for one aspect of the present signal processing method, the speech processing strategy operates by splitting the incoming signal (obtained from the microphone 22 , or equivalent) into k frequency bands or channels. The spectral power component of the signal present in each frequency band is determined. The average (or mean, or other suitable collective measure) of these spectral power components, E 0 , E 1 , . . . E K , is determined and is used as a threshold value. Only those channels having a spectral power component above the threshold value is selected for stimulation as a non-zero channel. The other channels are de-selected, as zero spectral power channels, and no stimulus is applied on these zero channels. The stimuli are then applied sequentially only on the selected channels.
[0033] While the mean is one example of a criterion for identifying a selected spectral power to use, for example as a threshold value, other criteria may be used as well. Other examples include other statistical methods, such as using variance to determine a threshold value or a combination of the average and variance to determine a threshold value. Other examples include using a weighted average, such as where the weight may be dynamically assigned or where it is assigned as a function of known speech spectra. Dynamic assignment of a weighting factor may include weighting based on relative or absolute amplitude, based on noise level as may be determined dynamically, for example, or other weighting methods. Additionally, weighting may be applied to incoming signals before they are analyzed or they may be applied to the threshold value or other determinant before calculating which channels will be non-zero and which will be assigned zero values. Other examples for identifying a spectral power to use include identification of the median, or identification of the median with a weight factor applied. Therefore, identification of the selected spectral power may be considered to be based on some function, f(E 0 , E 1 , E 2 , E 3 , . . . E K ), hereafter f(E), as desired, which function is then used to select the non-zero channels. The function may also be a function of time, which will be designated as f(Et), indicating that the function is based preferably on both the spectral power but also on time “t”. The function f(E) will be used when indicating that the spectral power is based on the channel energies regardless of any dependence on time.
[0034] The function f(Et) can be used or applied dynamically, as a function of on-going speech patterns, and need not be static for a given time period or static for a given user. For example, the mean in the example discussed herein can be determined for the channels on a frame-by-frame basis or on some other basis selected by the designer or technician. The mean (or other criterion) can be determined at regular intervals, or when a selected event occurs, such as when signal levels rise or fall beyond a set level. For present purposes, using a function to select a selected spectral power, different than a previously selected spectral power, more than once during the lifetime of the device will be considered dynamically determining the selected spectral power. Therefore, “t” in f(Et) can be as large as the device lifetime, and as small as a frame or less. Additionally, the number of channels selected for stimulation can be varied. The selection criteria may be the same as described herein, for example, and such selection will allow the number of channels that are stimulated to be changed as a function of time as well. Therefore, the number of channels for stimulation may be selected. At a later time, one or more channel signals may be evaluated, such as by applying a suitable function to the spectral power values for the channel (or each channel desired), and thereafter identifying those channels with spectral power values that exceed a selected value. The number of channels may then be increased or decreased as desired. The number of channels may be decreased or increased dynamically based on the desired criteria or criterion.
[0035] Advantageously, the present apparatus and methods can be used to increase the perceived signal-to-noise ratio (SNR) because the stimulation from the low spectral power channels can be identified and removed. Moreover, the spectral contrast increases since fewer channels receive a higher pulse rate. Additionally, the temporal resolution increases since the integration frame can be made shorter for smaller number of channels. As a further advantage, the power consumption of the cochlear stimulation system can be less than when using simultaneous speech processing strategies, such as SAS.
[0036] Because the present invention may operate using less power than an SAS strategy, SAS users who choose the present strategy would have the option of using a behind-the-ear (BTE) speech processor, which consumes less power than the body-worn speech processors.
[0037] While the invention herein disclosed has been described by means of specific embodiments and applications thereof, numerous modifications and variations could be made thereto by those skilled in the art without departing from the scope of the invention set forth in the claims.
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An exemplary speech processor configured to be used in a cochlear implant system includes signal processing circuitry that 1) separates an incoming audio signal into a plurality of channels, wherein each channel included in the plurality of channels includes a channel signal included in a plurality of channel signals and representing a portion of the audio signal, 2) selects one or more channel signals from the plurality of channel signals that have a spectral power that exceeds a predetermined threshold value, the selected one or more channel signals corresponding to one or more channels included in the plurality of channels, and 3) designates only the one or more channels that correspond to the selected one or more channel signals to be used for stimulation representative of the incoming audio signal.
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This is a continuation of application Ser. No. 08/012,035 filed on Feb. 1, 1993 now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to ophthalmic analgesic agents and in particular to topical ophthalmic agents which are generally used for alleviation of pain sensation in the cornea and conjunctiva due to disease or injury.
Currently, local ophthalmic analgesia is achieved using various anesthetic agents. The anesthetic agents used include topical application of tetracaine hydrochloride, procaine hydrochloride, benoxinate hydrochloride, and proparacaine hydrochloride. Tetracaine, a derivative of para-aminobenzoic acid, is generally applied as a 2.5% solution or by ointment. Procaine is available in concentrations of 1% solution, 2% solution, or 10% solution. Benoxinate, a benzoic acid and related to procaine, is used in a 0.4% solution prior to intraocular pressure measurement. Alcaine, a benzoate, is available in a 0.5% solution. Another drug which has been used as a local ophthalmic anesthetic is cocaine, which is one of the first agents discovered and has been used since the beginning of this century. Extensive pharmacological studies have shown that these drugs when used at therapeutic doses of 5,000 to 20,000 ug/ml exhibit an anesthetic property by completely blocking the neuronal conduction.
Unfortunately, repeated or prolonged application of topical ophthalmic anesthetics has been shown to exert deleterious effects on corneal epithelium, lacrimal glands, mucous production, and cell motility. Furthermore, recent studies have demonstrated that even a single dose of topical anesthetic can cause severe toxicity to the corneal epithelium. Major toxic effects of these drugs include: 1) inhibition of corneal regeneration or re-epithelialization that may result in sloughing of the corneal epithelium, which then exposes the corneal stroma to subsequent destructive effects of pathogenic microorganisms, causing corneal ulcers; 2) alteration in lacrimation and mucous adherence causing decrease in stability of the precorneal tear film; 3) increase in corneal permeability and swelling which results in loss of corneal transparency; and 4) altering corneal epithelial cytoskeletal elements (actin, myosin), which causes disruption of cell motility. Other adverse effects include allergic dermatitis which is seen in sensitive patients. Thus, the profound anesthetic property exhibited by these drugs severely limits their application as topical ophthalmic analgesics. In fact, following application of these topical anesthetics the loss of corneal sensitivity is so profound that some patients inadvertently injure their corneas without being aware of the extent of the self-injury. From the therapeutic standpoint, the outcome of such therapy seems as painful as giving no drug at all. Clearly, it seems that local analgesia can not be achieved by these anesthetics without impairing the normal function of the eye. Collectively, these inherent problems have limited the use of topical ophthalmic anesthetics for pain relief following corneal abrasion and/or injury.
The need for a truly useful ophthalmic analgesic is even more pressing in that numerous ocular conditions, diseases, and injuries would be treated if a safer formulation was available. An ideal formulation should be composed of an effective analgesic which does not cause any adverse effects or permanent damage to ocular structures. The ideal formulation could be prescribed by physicians for the following ocular conditions: 1) any injury to the eye causing damage to the corneal epithelium and conjunctiva, such as traumatic corneal abrasion, penetration, perforation, acid and alkali burn, or any other chemical burn; 2) any disease causing dry eye syndrome and the subsequent loss of localized or diffused corneal-epithelial cell damages, such as keratoconjunctivitis scica, vitamin A deficiency, abnormalities of the eye lids and eye lashes; 3) eye diseases causing cicatricial changes of the conjunctiva and cornea, such as traucoma; 4) viral infection affecting corneal epithelium and/or stroma, such as Herpes viruses and others; 5) bacterial and fungal infections causing corneal ulcers; and 6) any disease affecting lacrimal glands causing lower tear production. These medications could also permit removal of foreign bodies from the conjunctiva, cornea, and those which are dislodged under the superior lid.
The application of this ideal formulation or analgesic agent may eliminate the unnecessary use of local anesthetics or general anesthesia for the examination of sensitive eyes in some patients. Furthermore, the use of this ideal formulation could facilitate general ophthalmic examinations, such as the use of fundus contact lenses for evaluation of the background of the eye or the angle of the anterior chamber. It could also be used prior to the measurement of intraocular pressure. Additionally, an ideal formulation of an ophthalmic analgesic preparation must not irritate or cause any permanent damage to the ocular structures.
For all these reasons, development of a safe, effective topical fommulation for ophthalmic analgesic is warranted. If a topical formulation exhibits an effective analgesia without damaging the corneal epithelium and without having a profound anesthetic property, it may permit normal regrowth of the epithelial cells without any delay over the denuded areas of the cornea. Such a local analgesic can be used for temporary relief of pains in patients having corneal and conjunctival diseases or injuries, without experiencing the deleterious toxic effects of currently used local anesthetics.
SUMMARY OF THE INVENTION
An ophthalmic formulation for topical treatment of an eye comprises an opioid analgesic solution. The ophthalmic formulation comprises an aqueous solution of an opiate agonist, such as morphine, in the range of about 0.01 to about 5 mg/ml (0.01-0.5% by weight), having a physiologic pH close to 7.4 and osmolarity of about 300 milliosmol. The preferred concentration of the opiate agonist in the ophthalmic formulation is in the range of about 0.5 to about 0.8 mg/ml.
Accordingly, it is an object of the invention to provide a topical ophthalmic analgesic formulation which does not impair or damage the corneal epithelial cells or other ocular structures.
It is a further object of the present invention to provide a local ophthalmic analgesic formulation which does not exhibit a profound anesthetic property.
It is a still further object of the present invention to provide a local ophthalmic analgesic formulation for use in treating various corneal and conjunctival injuries and diseases.
It is another object of the present invention to provide a local ophthalmic analgesic formulation to be used prior to the measurement of intraocular pressure.
These and other objects and advantages of the present invention will become apparent to those skilled in the art after considering the following detailed specification in conjunction with the accompanying drawing, wherein:
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a graph of the relationship between wound surface area healing versus days after corneal abrasion for three different treatment groups.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As described above, ophthalmic anesthetics can provide corneal and conjunctival analgesia, but their observed toxicities at therapeutic levels (0.5% to 2% by volume) have limited their use as topical analgesics.
As a result of recent investigations, the applicants herein have found that topical application of opiates, such as morphine sulphate, at low concentration results in effective analgesia in patients with corneal abrasion or after a surgical refractive procedure as early as 10 minutes following application. Furthermore, it has been found that this analgesic formulation does not exhibit any adverse effects, as examined in an abrasion and healing model, on corneal epithelial cells regeneration, migration, and permeability. To our knowledge, the effects of ophthalmic formulations of containing morphine or other opiates as a topical or local analgesic medication for a corneal and conjunctival pain therapy have never been described. The present invention is based upon the above findings.
In the past, the use of morphine or other opiates as analgesic agents have been by systemic routes including oral, subcutaneous (SC), intramuscular (IM) or intravenous administration (IV). The analgesic response experienced following the use of opiates is believed to be the result of opioid receptor activation in the central nervous system. This theory that opiates produce their effects by interacting with receptors developed from observations that specific structural and stereochemical requirements are necessary for their analgesic action. Recently, the existence of multiple opioid receptor types and subtypes have been suggested based on the relationship between the molecular structure of opiate drugs and their analgesic effect. Thus, the discovery of opiate receptors in the central nervous system reinforced the search for identification of endogenous opioids, as well as demonstration of opiate receptors in the peripheral nerve terminals (Stein et al., J. Pharmacol. Exp. Ther. 248,1269-75 (1989)). Several recent studies have demonstrated that opiate agonists exhibit peripheral analgesic effects in inflamed tissue of animals (Joris et al., Anesth. Analg. 66,1277-1281 (1987); Stein et al., J. Neurosci. 10,1292-1298 (1990)), and that the antinociceptive effects of opiate mu- and kapa agonists are enhanced by peripheral opioid receptor-specific mechanism (Stein et al., Eur. J. Pharmacol. 155,255-264 (1988)). Furthermore, in a double-blind, clinical trial study, the analgesic efficacy of a low dose, aqueous morphine solution was investigated. When morphine was applied locally inside the joints following knee surgery, it significantly reduced pain scores, more likely due to local activation of opioid receptors that reached maximal effect in 3 to 6 hours (Stein et al., New Engl. J. Med. 325,1123-1126 (1991)).
The only indication that opiates may have receptors and perhaps a physiologic role in the surface structures of the eye comes from a Fanciullacci et al. observation (Eur. J. Pharmacol. 61,319-320 (1980)). Fanciullacci et al have shown that when an opiate antagonist, such as naloxone, is applied topically to one eye of a morphine-dependent subject (a conjunctival-test model for morphine addiction), it causes pupillary dilation in the same eye. Numerous other studies have examined the effects of opiates on pupillary diameter following IM, IV, SC, or oral administration. Miosis or pupillary constriction is a consistent effect of opiates and since there is an excellent agreement between the potency of analgesics in producing miosis and generalized analgesia, the miosis phenomenon has been utilized as a bioassay test for studying the time course and relative potency of opiate analgesic drugs in man. However, the effects of an ophthalmic formulation of morphine or other opiates as a topical/local analgesic medication for the corneal and conjunctival therapy have not been reported.
The primary component of the analgesic formulation will be an opioid drug of endogenous or synthetic origin. The ophthalmic solution can be formulated to include one or more drugs at therapeutically effective concentrations to be applied topically. Any pharmacologically active opioid with an analgesic property may be used in the formulation. The drug may be an endogenous opioid or a synthetic analgesic from the agonist, partial agonist, or agonist-antagonist group, preferably with less addictive or abuse potential. Also, antiprostaglandins and antiprostacyclins may be employed, in combination with opioids, in the topical analgesic formulation. Desirably, the drug will be sufficiently soluble in the physiological solution to be formulated at a therapeutically effective analgesic dose.
Drugs of particular interest include opiate agonists, such as buprenorphine, codeine, dextrorphan, dynorphins, endorphins, fentanyl, hydrocodone, hydromorphone, ketocyclazocine, levorphanol, meperidine, methadone, normorphine, oxymorphone, profadol, propoxyphene, and propiram; and agonist-antagonists, such as butorphanol, cyclazocine, ethylketocyclazocine, diprenorphine, nalbuphine, nalorphine, normetazocine, and pentazocine.
Other drugs of interest include anti-cyclooxygenases, such as aspirin-like anti-inflammatory agents including: aspirin, indomethacin, ibuprofen, fenoprofen, flurbiprofen, phenylbutazone, ketorolac tromethamine, sulindac, apazone, mefenamic, tolemtin, naproxen, piroxicam, suprofen, voltaren, and zomepirac; and steroids, particularly anti-inflammatory drugs, such as cortisone (or its acetate salt), hydrocortisone (or its acetate, cypionate, succinate, sodium phosphate salts), prednisone, prednisolone (or its acetate, tebutate, sodium phosphate salts), 6 alpha-methyl-prednisolone (or its acetate, succinate salts), fludrocortisone, fluorometholone, beclomethasone, betamethasone (or its acetate, benzoate, dipropionate, valerate, sodium phosphate salts), dexamethasone (or its acetate, sodium phosphate salt), medrysone, paramthasone (or its acetate salt), and triamcinolone (or its acetonide, diacetate, hexacetonide salts).
Other pharmacologic agents may be employed in the formulation for a variety of purposes. In addition to the active ingredient, diluents, buffering agents and preservatives may be employed. The water soluble preservatives include benzalkonium chloride, antioxidants, such as ascorbic acid, sodium bisulfite, parabens, benzyl alcohol and with or without essential vitamins. The essential vitamins include vitamin A and/or vitamin E. The formulation may contain sodium chloride, glucose, calcium, magnesium, glycerin, hydrochloric acid and/or sodium hydroxide to adjust osmolarity and pH. These agents may be added in amounts of from 0.001 to 5%. The pH of the formulation will be maintained between 6 to 8, preferably in the range of about 7 to about 7.4.
The formulation may be supplied in a single use plastic bag or regular ophthalmic drug bottles or may be in the form of an ointment preparation.
The following describes the preparation of a preferred embodiment of a topical ophthalmic analgesic formulation. An amount of morphine sulphate was dissolved in a normal saline solution to form a concentrated stock solution. Then, appropriate dilutions were made from the stock solution in order to prepare a morphine concentration of 0.5 milligram/millileter (0.05% by volume). This concentration of analgesic preparation was chosen because previous observations had shown that this dose of morphine was sufficient to cause suppression of pain pressure in animals and humans. The pH of the solution was adjusted to 7.2 with addition of a hydrochloric acid and/or a sodium hydroxide solution. The osmolarity was also adjusted to 300 milliosmol with addition of sucrose or glucose. Immediately before each study, the analgesic preparation was sterilized by filtering through a 0.2 micrometer filter into a sterilized test tube. The solution was withdrawn into a syringe and used as needed. The stability results indicated that there was no detectable changes in color or amounts of morphine degradation when the solution was protected from light and stored at −20° C. or 4° C. for over a month.
The following describes analgesic tests which were performed on patients following topical application of the prepared and previously described topical ophthalmic analgesic formulation. This study was designed to examine the analgesic efficacy of the morphine formulation, the time to exhibit response, and dose proportionality in subjects with corneal abrasion or after a refractive procedure, when the drug is applied topically to the eye. Five patients were selected to participate in this study. In all cases, three measurements were made in the following fashion: First, a baseline response (corneal sensitivity) was established by determining the response of the patient eye to a standard pain pressure using a Cochet Bonnet Aesthesiometer instrument and without applying any drug. Measurements were made by beginning with the nylon monofilament (0.12 mm diameter) fully extended. The tip was applied perpendicularly to the corneal surface and gently pressed until the fiber's first visible bending. The length of the fiber was gradually decreased until a blink reflex and/or a verbal pain response were observed. The length was then recorded in units of mm. Second, a saline solution (2 drops) were instilled in the eye and at 10 and 20 minutes later the response of the patient's cornea to pain pressure was determined as described above. These repeated measurements served as a placebo effect for comparison purposes. Finally, 2 drops of the morphine formulation were instilled in the eye and the analgesic effect on the cornea was assessed. It is important to point out the clinician responsible for evaluating the ophthalmic solutions was not informed of the nature of the drugs being tested. Results of these tests are shown in the following table designated as Table 1.
TABLE 1
Analgesic Effects of Morphine (0.5 mg/ml) on
Corneal Sensitivity of Patients
Expressed as Pressures in grm/sq. mm
Dose
Time after topical drug treatment
Drug
(drops)
0
10 min
20 min
None
Baseline
1.95 ± 0.20
—
—
Saline
2
1.73 ± 0.42
1.68 ± 0.72
(0.9% by volume)
Morphine
2
7.69 ± 2.16
9.84 ± 1.00
(0.5% by volume)
The values in the above Table 1 are the mean pressures±SEM (standard error of the mean). Again, an Aesthesiometer, based upon the principle of pressure transmitted axially by a nylon monofilament of known diameter but of variable length for a given bending stress, was applied to the corneal surface. By decreasing the length and exerting slight pressure on the tip of the monofilament, the patient reacts to the pain pressure. The distance, in millimeters (mm) of the nylon monofilament is recorded and then converted to pressure in gram/square millimeter.
As shown in Table 1, application of saline eye drops had no analgesic effects as expected. The analgesic response (corneal sensitivity) to saline solution at 10 and 20 min. was very similar to the baseline response. On the contrary, topical application of two drops of the morphine formulation (0.05% by weight solution) exhibited a dramatic analgesic effect as early as 10 minutes after administration. The magnitude of pain suppression by the morphine solution was such that much greater pressures in gram/sq.mm were required to obtain a corneal sensitivity response. As such, the present morphine formulation exhibited an analgesic efficacy of 4.3 and 5.5-fold greater than the baseline or saline responses at 10 and 20 minutes, respectively. Interestingly, the analgesic response observed at 20 minute is greater than the response observed at 10 minute, indicative of time-dependent analgesic effect by morphine. It seems that the maximal analgesic effect of the morphine formulation may not occur until after 20 minutes following topical application.
The following describes toxicity tests which were performed on animals following topical application of the prepared and previously described topical ophthalmic analgesic formulation. Healthy pigmented rabbits weighing about 1.5-2.2 kg were anesthetized and then corneal epithelial cells were scraped and removed using a blade under direct view of a microscope. The basal lamina was left intact while thorough de-epithelialization was performed and confirmed by staining the surface of the cornea with 1% fluorescein. All eyes were thoroughly washed with saline and randomly divided into three treatment groups as follows: 1) saline solution (control), 2) morphine formulation, and 3) proparacaine HCl (positive control). Eyes in each group were instilled with two drops of the corresponding solution at 4 hourly intervals for 6 consecutive days. Wound healing (corneal re-epithelialization) was assessed on days 2, 3, 4, 5, 6, 7, and 8 following corneal abrasion using fluorescein staining with Fluor-I-Strip, and epithelial regeneration and migration were monitored by clinical examinations as well as wound surface area measurements. The results of these tests are shown in FIG. 1 and Table 2.
In FIG. 1, the line with open circles indicates saline effects on corneal re-epithelialization, the line with closed circles indicate when morphine (0.5% by volume) was applied to the cornea, and the line with closed triangles indicates when Alcaine (0.5% by volume) was applied.
As show in FIG. 1 and Table 2, repeated topical application of the morphine formulation had no adverse effect on the corneal epithelial cell regeneration and migration. In fact, rates of wound closure were similar in both saline and morphine treated groups. Eyes treated with the morphine formulation began to show epithelial regeneration on the second day and complete regeneration by 4 days following corneal abrasion. The progression of wound closure was normal since by 4 days (1 eye), 5 days (3 eyes), and 7 days (5 eyes) completed regeneration. Only 1 eye did not show complete wound closure due to infection. On the contrary, repeated application of Alcaine significantly prevented regeneration of the corneal epithelial cells. Eyes treated with the Alcaine formulation began to show corneal regeneration on the third day and complete wound healing by 8 days following corneal abrasion. The time-course study showed that only 2 eyes out of 6 in the Alcaine group had completed regeneration of the corneal epithelium by 8 days, the last time point observed. Interestingly, only 1 eye of the remaining 4 eyes with incomplete epithelial regeneration developed infection in the Alcaine treated group.
TABLE 2
Progression of Corneal Epithelial
Regeneration Following Mechanical Epithelial
Cells Removal
Days after drug treatment
Drug
1
2
3
4
5
6
7
8
Saline
0/4
0/4
0/4
1/4
1/4
2/4
2/4
—
2 drops
Morphine
0/6
0/6
0/6
1/6
3/6
4/6
5/6
5/6
2 drops
(0.5%
by volume)
Alcaine
0/6
0/6
0/6
0/6
0/6
0/6
0/6
2/6
2 drops
(0.5%
by volume)
In Table 2 above, the first number represents the number of animals which exhibited complete healing of the cornea and the second number represents the total number of animals per group. For example, 0/4 under day 1 for Saline represents zero animals exhibited complete healing of the cornea out of a total of four animals for this group.
There has thus been shown and described a novel topical ophthalmic analgesic formulation which fulfills all of the objects and advantages sought therefor. It will be apparent to those skilled in the art, however, that many changes, modifications, variations, and other uses and applications of the subject topical ophthalmic analgesic formulation are possible and contemplated. All such changes, modifications, variations, and other uses and applications which do not depart from the spirit and scope of this invention are deemed to be covered by the invention, which is limited only by the claims which follow.
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A method of alleviating pain sensations in a denuded eye comprising the step of applying topically to the eye an analgesic solution with the analgesic solution comprising an opioid analgesic is disclosed.
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BACKGROUND
[0001] The present invention relates to a steering device that includes a steering control, which is pivoted on an axis and is designed for operation by an occupant of the vehicle, especially in the form of a steering wheel; a transmission arrangement, by means of which a rotational movement of the steering control can be translated into a movement of an elongate steering element (for example, a steering spindle) arranged outside the axis of rotation;
[0002] together with an elongate mount, which defines the axis of rotation of the steering control and which is fastened to a fixed structure of the motor vehicle.
[0003] The elongate steering element is here taken to mean a steering element which extends from the steering control to the track rods of the relevant vehicle, where it is coupled to the so-called steering gear. Steering shafts and steering spindles, in particular, are used as elongate steering elements. In the present case, however, the actual design of the elongate steering element is of no importance (with regard to the so-called “drive by wire”, for instance).
[0004] A fixed structure of the vehicle is taken to mean a component or sub-assembly of the vehicle, which in its spatial position is unaffected by operation of the steering device. It therefore does not move together with a moveable element of the steering device, such as the steering control (steering wheel) or the elongate steering element (steering spindle), for example.
[0005] Steering devices of the type are disclosed, for example by DE 21 31 902 A1, DE 21 36 593 A1 and DE 89 05 457 U1 (all incorporated by reference herein).
[0006] In such steering devices the mount, which is generally designed as support column, defines an axis of rotation for the steering wheel, the steering wheel being pivoted by its hub on the support column. The support column itself is fixed and can therefore serve for the fixed mounting of other functional assemblies of a motor vehicle, such as a safety device (airbag module) or electrical units or control elements, for example.
[0007] In addition, DE 30 07 726 C2 and FR 2 633 239 A3 (both incorporated by reference herein) disclose steering devices with a fixed central sub-assembly, in which the steering wheel is in each case axially displaceable and rake-adjustable for adopting a position comfortable for the respective driver.
[0008] The object of the invention is to further improve a steering device of the type described above.
SUMMARY OF THE INVENTION
[0009] According to the present invention an apparatus or device for steering a motor vehicle is provide. The device includes a steering control or steering device that is rotatable about an axis of rotation and is configured to be operated by an occupant of the vehicle. The apparatus further includes a transmission arrangement or mechanism for transferring the rotational movement of the steering control to a steering element positioned away from the axis of rotation of the steering control.
[0010] According to the present invention, the apparatus includes a mount for supporting the steering control. The mount includes at least one element, which in the event of an impact by a vehicle occupant against the steering control causes shortening and/or tilting of the mount. This is taken to mean any element, which in the event of an impact by a vehicle occupant against the steering control facilitates a defined shortening of the elongate mount along its longitudinal axis and/or a defined tilting of the mount in a predetermined direction.
[0011] The shortening of the mount distances it from the impinging vehicle occupant.
[0012] Through a specific tilting of the mount the steering control (steering wheel) and a safety device (airbag module) regularly arranged in the area of the steering control can be purposely brought into a defined position in relation to the body of the impinging vehicle occupant. The biomechanical interaction of the body of the occupant with the steering control and possibly the safety device can thereby be optimized. In particular, it is possible to achieve a parallel movement of the body of the occupant on the one hand and a deploying airbag of an airbag module on the other.
[0013] Owing to the eccentric arrangement of the steering control in relation to the longitudinal axis of the steering element, the longitudinal axis of the steering element and a transmission element supported thereon can at the same time define a pivot point, about which the mount and hence the steering control tilts, as represented in more detail below in the explanation of preferred embodiments of the invention.
[0014] The shortening of the mount need not necessarily result in an adjustment of the absolute length of the mount (due, for example, to compression or telescoping). It is also feasible for the mount to be shifted away from the vehicle occupant; with a constant, actual length of the mount, this leads to a shortening of its effective length, that is the length measured from the point at which the mount was originally connected to the structure fixed to the vehicle (prior to displacement).
[0015] The mount is preferably tilted in such a way that, in relation to the state of the steering device as installed in a vehicle, in the event of a frontal impact of a vehicle occupant against the steering control, the mount tilts downwards so that the end section of the mount facing the steering control extends essentially parallel to the longitudinal direction of the vehicle, and so that a steering wheel supported on this mount extends with its steering wheel rim in a plane essentially perpendicular to the longitudinal direction of the vehicle. The plane defined by the steering wheel rim thereby lies essentially parallel to the plane of the upper body of an impinging occupant.
[0016] Tilting of the mount can be achieved, in that at least one section of the mount is capable of swiveling about an axis. Alternatively, the mount may be deformable, and in particular bendable, for performing the tilting movement.
[0017] In order to ensure adequate deformability of the mount for this purpose, it may have weakened areas, especially in the form of notches, which are arranged and formed so as to define a preferred direction of the tilting movement.
[0018] For the shortening of the mount, it may be of compressible design. The mount may include weakened areas, which permit a defined compression of the mount by an impinging occupant.
[0019] According to another embodiment, the mount is of telescopic design, it being possible, in particular, to provide a hydraulic or pneumatic telescopic device, so that the mount is capable of telescoping against the action of a fluid.
[0020] The mount is preferably formed by a column, which has an end section (where necessary angled for adaptation to the spatial conditions in the area of the steering wheel), which forms the axis of rotation of the steering control.
[0021] At its end section facing the steering control, the mount preferably has at least one fixed sub-assembly, to which a non-steering function attaches, for example as a safety device (in the form of an airbag module) and/or as an electrical unit or electrical operating device for other functional assemblies (audio system, horn, etc.) of a motor vehicle.
[0022] The fixed arrangement of the safety device in the form of an airbag module in the area of the steering control, in which the positioning of the airbag module is unaffected in operation of the steering control, means that the airbag module, by means of an asymmetrical design in relation to the axis of the steering control, can be specifically optimized with a view to an optimum protection of a vehicle occupant, even in a so-called out-of-position (OOP) situation (in which the corresponding vehicle occupant is situated outside their normal seated position, too close to the steering control). The apparatus may include provisions for an asymmetric folding of the inflatable airbag contained in the airbag module. Since the position of the airbag module is unaffected in operation of the steering control, the airbag module and hence also the airbag arranged in the airbag module always remains in the required position in relation to the corresponding vehicle occupant.
[0023] For immovable fixing of the mount, the mount may be fixed, for example, to a steering column cladding enclosing the steering element or to a cross-member running in the area of the dashboard.
[0024] The transmission arrangement, which serves to translate a rotational movement of the steering control into a movement of the associated steering element, may be designed, for example, as toothed gearing. It may also consist, however, of an endless member, especially in the form of a chain or a toothed belt, which is coupled on the driving side to the steering control and on the driven side to the elongate steering element. In any event, the coupling between the steering control and the elongate steering element must be designed in such a way that it does not prevent a tilting or shortening of the mount and an associated movement of the steering control relative to the elongate steering element. In the case of a toothed gearing this can be achieved, for example, in that the corresponding toothed gear elements are deformable by the forces occurring in the event of a crash, in such a way that the gears on the steering control side and those on the steering element side disengage. By contrast, a belt or chain mechanism can be arranged in such a way that the belt or the chain slips off the assigned driving and/or driven elements under the effect of the crash forces.
[0025] The support column is preferably arranged in such a way in relation to the elongate steering element that in the event of an impact of a vehicle occupant the steering control tilts about a transmission element of the transmission arrangement arranged on the longitudinal axis of the elongate steering element, the transmission arrangement acting as a lever, which extends from the longitudinal axis of the elongate steering element to the axis of rotation of the steering control.
[0026] The transmission arrangement is furthermore designed in such a way that transmission elements of the transmission arrangement on the steering control side and on the steering element side can be ultimately disengaged by the forces acting on the steering device in the event of an impact of a vehicle occupant (for example, through a belt slipping off or deformation of toothed gear elements), so as not to prevent the desired deformation or movement of the mount.
[0027] If the transmission arrangement is arranged at least partially in a housing, this is preferably destroyed in the tilting or shortening of the mount. This is intended to ensure that the housing does not oppose a movement of the mount relative to the steering element. For this purpose the housing may be provided with weakened areas, which may be predefined breaking points, for example.
[0028] The mount, the steering control and the transmission arrangement may be combined into one pre-assembled module using a suitable accommodation for the transmission arrangement, the module being mounted as a whole on a conventional steering element in the form of a steering spindle or steering shaft. The module may also be incorporated into an additional sub-assembly fixed to the mount, such as an airbag module and/or operating devices for electrical units in a motor vehicle.
[0029] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only, and are not restrictive of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] These and other features, aspects and advantages of the present invention will become apparent from the following description, appended claims, and the accompanying exemplary embodiments shown in the drawings, which are briefly described below.
[0031] [0031]FIG. 1 shows a side view of a first embodiment of a steering device with a steering spindle arranged outside the axis of rotation of the steering wheel and with a separate support column for the rotatable mounting of the steering wheel;
[0032] [0032]FIG. 2 shows a side view of an alternative embodiment of a steering device according to the present invention.
DETAILED DESCRIPTION
[0033] [0033]FIG. 1 represents a steering device for a motor vehicle with a steering control in the form of a steering wheel 1 . The steering wheel 1 has a steering wheel rim 11 and spokes 12 , which extend from the steering wheel rim 11 to a steering wheel hub 15 . The hub 15 is pivoted on an end section 41 a of a support column 4 , which thereby defines an axis of rotation A of the steering wheel 1 .
[0034] An elongate steering element in the form of a steering shaft or steering spindle 3 , by means of which a rotational movement of the steering wheel 1 and hence of the steering wheel hub 15 can be transmitted to a steering gear and ultimately to the track rod of a motor vehicle, is pivoted outside the axis of rotation A.
[0035] A transmission arrangement or mechanism 2 is provided for coupling the steering wheel hub 15 to the steering shaft or steering spindle 3 . The arrangement comprises an external toothing 21 arranged on the circumference of the steering wheel hub 15 , together with a gear 22 , concentrically connected and rotationally fixed to the steering wheel spindle 3 , the external toothing 23 of which gear meshes with the external toothing 21 of the steering wheel hub 15 . A rotational movement of the steering wheel hub 15 about the axis of rotation A of the steering wheel 1 is thereby translated directly into a rotational movement of the steering spindle about its longitudinal axis L.
[0036] A housing 20 may be provided to protect the transmission arrangement 2 . The wall of the housing 2 may be provided with weakened areas in the form of predefined breaking points 20 a, which permit a destruction or damage of the housing under the effect of a defined external force. The steering spindle 3 is furthermore surrounded by a steering column tube 30 , which is immovably fixed in the relevant motor vehicle (that is to say it does not turn with the steering spindle 3 ) and on which a sleeve 31 is fastened by means of suitable fasteners 32 . The sleeve 31 at the same time forms the end of the support column 4 remote from the steering wheel 1 and the steering wheel hub 15 .
[0037] The support column is therefore fixed to a component (steering column tube 30 ), secured to the vehicle, by the sleeve 31 .
[0038] The support column 4 extends from the sleeve 31 to an end section 41 a, which on the one hand defines an axis of rotation of the steering wheel hub 15 and hence of the steering wheel 1 , and on the other hand serves for the fixed (non-rotatable) accommodation of an additional sub-assembly 6 .
[0039] The end section 41 a at the same time forms the steering wheel-end of a first section 41 of the support column 4 , which is aligned parallel to the axis of rotation A of the steering wheel 1 . This first section 41 of the support column 4 extends outwards at an angle from a second section 42 which extends from the first section of the support column 4 to the sleeve 31 on the steering column tube 30 . The additional sub-assembly 6 , fixed to the steering wheel-end section 41 a of the support column 4 , comprises in particular an airbag module 7 with a housing 70 , a cover 71 , a gas generator 72 and an airbag 73 that can be inflated by the gas generator 72 . In the event of a strong vehicle deceleration caused by a crash and detectable by a suitable sensor, the airbag 73 is automatically inflated by means of the gas generator 72 and in so doing opens the cover 71 of the airbag module 7 , so that it can deploy out of its housing 70 , in order to form a protective cushion for a vehicle occupant seated behind the steering wheel.
[0040] Since the airbag module 7 is firmly arranged in the area surrounded by the steering wheel rim 11 , it can be specifically optimized with a view to an optimal crash behavior, also taking particular account of so-called out-of-position (OOP) situations, in which the driver at the instant of vehicle deceleration is situated outside their normal seated position, very close to the steering wheel. Such an optimization of the airbag module 7 always requires an asymmetrical design of major parts of the module, such as the housing 70 , the cover 71 , the gas generator 72 and the folding of the airbag 73 , cf. DE 199 27 024 A1. The spatially fixed position of the airbag module 7 (not turning with the steering wheel 1 ) ensures that the advantages of an asymmetrical design of the component parts of the airbag module, optimized to take account of the body shape of a vehicle occupant in a crash, are always retained regardless of the current angular position of the steering wheel 1 . For the airbag module 7 is firmly arranged between the steering wheel rim 11 and therefore always remains in its original position fixed by the fastening to the support column 4 , regardless of the current steering angle.
[0041] Through a suitable design of the housing 70 , cover 71 , gas generator 72 and airbag 73 it can be ensured, in particular, that in an OOP situation, detectable by means of a suitable sensor 75 , the airbag preferably initially deploys in the lower area of the airbag module 7 facing the thighs of a vehicle occupant. For this purpose, provision can be made for the gas flow G to be initially directed by means of a diffuser 74 into the lower area of the airbag module 7 , cf. the arrows G shown in FIG. 1, which run in the lower area of the airbag module 7 . In an OOP situation this prevents the airbag as it deploys during inflation, from already exerting excessive pressure on the upper body or head of an occupant at an early stage, cf. DE 199 27 024 A1. Instead the deployment initially occurs in the area of the lower part of the body and the thighs of a vehicle occupant, the filling and deployment of those sections of the airbag 73 assigned to the chest and head area of the occupant (driver) being delayed until subsequently.
[0042] In addition to the airbag module 7 the additional sub-assembly 6 may also have electrical operating devices 61 (switches) for electrical units of the motor vehicle, such as an audio system or horn, for example, together with electrical instruments, in the form of display devices, for example.
[0043] A special feature of the steering device represented in FIG. 1 resides in the fact that in a crash-induced interaction with an occupant, who impinges frontally against the steering wheel 1 or the deploying airbag 73 , the support column 4 shortens in a defined manner and also tilts. This shortening or tilting may be already initiated by the recoil action of the deploying airbag 73 .
[0044] In the exemplary embodiment of FIG. 1, the shortening of the support column 4 is achieved in that in its second sleeve end-section 42 , which runs essentially in the vehicle longitudinal direction x, the support column 4 has a weakened area 43 , which causes a compression of the support column 4 due to the force F occurring in the interaction with an occupant. The weakened area 43 is therefore designed as a deformation area, which permits a compression and hence a shortening of the support column 4 .
[0045] In order to permit a defined tilting of the steering wheel-end, first section 41 of the support column 4 and hence also of the steering wheel 1 and the additional sub-assembly 6 with the airbag module 7 in a pre-determinable direction K, the support column 4 , in the area of the transition from the first section 41 to the second section 42 , has a notch 47 and an expansion-compression area 47 arranged opposite the notch 47 , which is formed by an especially expandable and compressible section of material. This combination of a notch 47 with an expansion-compression area means that in a frontal impact of an occupant against the steering wheel 1 or the airbag 73 deploying out of the module 7 , the first section 41 of the support column tilts in such a way that the steering wheel rim 11 extends in a plane lying essentially perpendicular to the vehicle longitudinal direction x. In other words, the steering wheel rim 11 , which is initially situated in a plane running obliquely to the vehicle longitudinal direction x, tilts into a plane that lies essentially perpendicular to the vehicle longitudinal direction x.
[0046] Owing to the arrangement of the axis of rotation A of the steering wheel 1 outside the longitudinal axis L of the steering spindle 3 , the tilting of the support column 4 and hence of the steering wheel 1 under the force F of an impinging occupant initially occurs about a pivot point situated on the longitudinal axis L of the steering spindle 3 and defined by the gear 22 situated on this longitudinal axis L, the pivot point being fixed by a sufficiently firm, rigid arrangement and design of steering spindle 3 and steering column tube 30 . As a result, the transmission arrangement 2 acts as a lever, which initiates the tilting movement of support column 4 and steering wheel 1 , in which the steering wheel 1 moves towards the sleeve 32 . (In this process the hub 15 , gear 22 and sleeve 31 form a type of “ternaryjoint”). As the movement progresses, the hub 15 and the gear 22 then disengage due, for example, to a deformation of the toothed areas 21 , 23 as a result of the crash induced forces F or corresponding torsional forces, in order to permit the desired movement and deformation of the mount 4 . At the same time the housing 20 of the transmission arrangement 2 is destroyed.
[0047] In FIG. 1, the plane E lying perpendicular to the vehicle longitudinal direction x and into which the steering wheel rim 11 is shifted by a combined tilting and shortening of the support column 4 , is indicated by dashed line. It can be seen that owing to the combined shortening and tilting of the support column 4 , the steering wheel rim 4 and hence also the airbag module 7 have on the one hand been distanced from the body of an occupant (driver) situated behind the steering wheel 1 , and that the steering wheel rim 11 and the cover 71 of the airbag module 7 now lie in a plane E, which lies essentially perpendicular to the vehicle longitudinal direction x and thereby essentially parallel to the upper body of an occupant sitting upright.
[0048] The compression or shortening of the support column 4 cushions the impact of an occupant against the deploying airbag 73 . Owing to the simultaneous tilting of the steering wheel 1 and hence also of the airbag module 7 into a perpendicular position, the airbag 73 deploys out of the module housing essentially in the vehicle longitudinal direction x. As a result, the main direction of deployment of the airbag 73 (in the vehicle longitudinal direction x) is adjusted to the direction of movement of the impinging occupant, who in a head-on collision essentially moves in precisely the opposite direction to the main direction of deployment of the airbag 73 . The interaction of the occupant with the airbag is thereby optimized from the biomechanical standpoint.
[0049] Also of importance for the present invention is the fact that, due to the arrangement of the steering shaft or steering spindle 3 outside the axis of rotation A (which is defined by the support column 4 ), the steering spindle 3 does not adversely affect the tilting and shortening of the support column 4 .
[0050] The steering wheel 1 and the airbag module 7 can therefore be brought into their desired final position by a suitable, defined tilting and shortening of the support column 4 , unimpeded by the steering spindle 3 .
[0051] As an alternative to the weakened area 43 in the second section 42 of the support column 4 provided for in FIG. 1, a shortening of the support column 4 might also be brought about, for example, through displacement of the support column 4 on the steering column tube 30 in a direction away from the occupant. For this purpose the connection between the sleeve 31 supported on the steering column tube 30 and the steering column tube 30 would have to be designed in such a way that it is released when a vehicle occupant impinges on the steering wheel 1 or on the deploying airbag 73 and permits a displacement of the sleeve 31 and thereby of the support column 4 along the steering column tube 30 . This also shortens the effective length of the support column 4 , since the support column 4 is telescopically displaceable on the steering column tube 30 .
[0052] In another exemplary embodiment of the invention represented in FIG. 2 the support column 4 is telescopic. In particular, the second section 42 of the support column is telescopic, therefore forming a telescopic device 45 . In this embodiment, the tilting of the support column 4 is facilitated by a plurality of notches 48 .
[0053] In order that the telescopic device 45 becomes operative only once a defined force (impact of a vehicle occupant) is exerted on the steering wheel 1 or the airbag module 7 , a fluid or other means (elastic elements, for example), which counteract a shortening of the support column 4 and can be overcome only by a pre-determinable minimum force, may be provided in the telescopic device 45 .
[0054] A further difference between the exemplary embodiment of FIG. 2 and the steering device represented in FIG. 1 is that the support column 4 of FIG. 2 is fixed by means of a flange 51 to a cross-member 50 of the vehicle structure 5 running in the area of the dashboard 55 .
[0055] Furthermore, of FIG. 2 an endless member in the form of a plastic toothed belt 25 , which is driven by an external toothing 26 of the steering wheel hub 15 , serves to transmit the rotational movement of the steering wheel 1 to the steering shaft or steering spindle 3 . For this purpose the toothed belt 25 engages with the external toothing 28 of a gear 27 arranged concentrically on and rotationally fixed to the steering spindle 3 .
[0056] Coupling the steering wheel 1 to the steering spindle 3 by way of a toothed belt 25 has the advantage that a crash-induced movement of the support column 4 in relation to the steering spindle 3 can thereby easily be compensated for, if the toothed belt 25 slips off the assigned transmission elements 15 , 27 owing to the forces F acting in the event of a crash.
[0057] Furthermore, the use of such a toothed belt 25 permits great flexibility with regard to the spatial arrangement of the steering spindle 3 on the one hand and the support column 4 on the other. A number of different arrangements of the steering spindle 3 in relation to the support column 4 are represented by dashed lines in FIG. 1, the dashed lines identified by 3 ′ each denoting possible alternative arrangements of the steering spindle 3 or of its longitudinal axis L.
[0058] In this instance the support column 4 is arranged in relation to the steering spindle 3 in such a way that the desired tilting movement K of the steering wheel 1 cannot occur about the gear 27 supported on the steering spindle 3 as pivot point. The arrangement of steering spindle 3 and support column 4 chosen here would rather impede the desired tilting movement. Means must therefore be provided, which in a crash will permit deflection of the steering spindle 3 (by tiling down, for example), in order to allow the desired movement of the support column 4 .
[0059] The problem described above might also be overcome by arranging the steering spindle along a line 3 ′ indicated by a dashed line in FIG. 2, where space in the relevant vehicle permits. The arrangement of steering spindle 3 and support column 4 would then essentially correspond to that shown in FIG. 1.
[0060] The exemplary embodiment of FIG. 2 otherwise matches the exemplary embodiment of FIG. 1, so that for other details reference may be made to the descriptions above.
[0061] Germany Priority Application 100 59 928.1, filed Nov. 23, 2000 including the specification, drawings, claims and abstract, is incorporated herein by reference in its entirety.
[0062] Given the disclosure of the present invention, one versed in the art would appreciate that there may be other embodiments and modifications within the scope and spirit of the invention. Accordingly, all modifications attainable by one versed in the art from the present disclosure within the scope and spirit of the present invention are to be included as further embodiments of the present invention. The scope of the present invention is to be defined as set forth in the following claims.
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An apparatus for steering a motor vehicle that includes a steering control device which rotates on an axis and is designed for operation by an occupant of the vehicle. the apparatus includes a transmission mechanism for translating the rotational movement of the steering control device into a movement of an elongate steering element arranged outside the axis of rotation of the steering control device. The apparatus also includes an elongate mount which defines the axis of rotation of the steering control and which is fastened to a fixed structure of the motor vehicle. The mount is configured to be shortened or tilt downward in the event of an impact by a vehicle occupant against the steering control device.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 09/256,259, filed Feb. 23, 1999, now U.S. Pat. No. 6,131,521 which is a continuation-in-part of U.S. patent application Ser. No. 09/193,910, filed on Nov. 17, 1998 now abandoned.
TECHNICAL FIELD
The present invention relates to decorative surfacing such as worktops, and specifically to modular decorative surfacing. The present invention has further relation to worktops that are easy to install and have removable components that may be replaced permanently or periodically for aesthetic reasons.
BACKGROUND OF THE INVENTION
Worktops, vanity tops, and the like are traditionally made of decorative laminate bonded to a substrate, such as particle board. They are also made of solid polymeric surfacing, wood, metal, and various combinations thereof. Typically, a worktop has a front edge and a backsplash that are permanently fixed to the worktop or are formed integrally to the worktop. Various types of worktops and their construction are well known to those skilled in the art.
When backsplashes and front edges are formed integrally to the worktop, they inherently are of the same decorative surfacing material as the rest of the article; the resulting aesthetic effect is uniform. When backsplashes and front edges of a different aesthetic effect and/or different decorative surfacing material are used in conjunction with a worktop, they are typically permanently fixed to the top either during fabrication of the top or during installation of the top in a home, office, business, or the like. This work is typically done by trained fabricators and is beyond the skill of the average consumer. Additionally, if a consumer eventually decides that he or she does not like the aesthetic combination of front edge, backsplash, and counter surface that were initially chosen, the typical option is to tear out the whole worktop and start over again. Other options include resurfacing by installing new laminate over existing laminate, and routing out the old front edge and installing a new one. The result is a tremendous waste in terms of time, effort, and money. For example, if a consumer contracts with a fabricator for the installation of a white worktop with a white backsplash and blue front edge, then later decides a red front edge would be preferable, the whole worktop must be replaced, or the front edge must be routed out so that a new one may be installed.
There exists a need then for a modular worktop that is easily assembled from components of differing sizes and decorative surfacing options, so that a consumer may assemble and install the worktop, as well as “mix and match” various types and styles of components. There also exists a need for an easy way to assemble these components that is within the realm of the skill of the average consumer. There also exists a need for components that are replaceable at the discretion of the consumer. The objects of the present invention are to fill these unmet needs, and these and other objects of the invention will become apparent through the specification, claims, and drawings provided herein.
SUMMARY OF THE INVENTION
Disclosed is a worktop including a surface member, a front edge, and a backsplash, the front edge and backsplash being attached to the surface member, and at least the front edge being removably attached to the surface member. The removable attachment device may be a centric sphere connector. Each of the surface member, front edge, and backsplash are selected from a predetermined group of decorative surfacing options. At least one of the front edge and backsplash may be a different decorative surfacing option from the surface member.
Also disclosed is a method of assembling a worktop including the steps of selecting a surface member from a predetermined group of surface member decorative surfacing options, selecting a front edge from a predetermined group of front edge decorative surfacing options, selecting a backsplash from a predetermined group of backsplash decorative surfacing options, and attaching the backsplash and the front edge to the surface member to form a worktop. At least the front edge is removably attached to the surface member, for example with a centric sphere connector.
The disclosed worktop may be thought of as a multi-component surfacing unit, some or all of the components thereof being removably attached to each other to form a custom selected decorative surfacing unit that is aesthetically pleasing to the consumer or person selecting the components. Some or all of the components may be removably attached to each other with centric sphere connectors, or other attachment means known in the art. Each component may be selected from a predetermined group of decorative surfacing options. At least one component may be a different decorative surfacing option from the remaining components.
Additionally disclosed is a method of using a worktop with a changeable front edge, the method comprising the steps of supplying a plurality of front edge decorative surfacing options, selecting a desired decorative surfacing option from the plurality of options, and removably attaching the selected option to the worktop. The removable attachment member may be a centric sphere connector, or other attachment means known in the art. The front edge decorative surfacing options may include designs that conform to seasons of the year, designs that conform to holidays, or the like.
Also disclosed is a method of assembling a worktop including the steps of providing a plurality of surface member modules of varying lengths, a plurality of backsplashes of varying lengths, and a plurality of front edges of varying lengths, and selecting and assembling components of a size necessary to produce the desired sized worktop. A sink module may also be provided for installation with the surface member modules if a sink is desired in the worktop. The components may be provided already cut to size or may be provided in a few sizes that may need to be cut to size upon assembly and installation.
The components are ideally removably attached to each other for ease of changeover when desired. Removable attachment members such as concentric sphere connectors may be used to attach the components to each other. Where the worktop extends around a ninety-degree corner the components may need to be mitered at the corner. Exposed side edges may be covered with edging that is mitered into the front edge at the corners. The backsplash may be provided with a location for decorative indicia. Each of the components may be provided in a variety of aesthetic designs.
The backsplash may include a sealing member extending the length of the backsplash and located on the back surface proximate to the top surface, a portion of the sealing member extending from the back surface so that upon installation of the backsplash against a wall, the sealing member will come into contact with the wall to fill any gap between the backsplash and the wall to eliminate the necessity for scribing the backsplash into the wall. The joint between the backsplash and the surface member may include a sealing member attached to the worktop at the joint to substantially prevent liquids from penetrating the joint. The joint between the front edge and the surface member may also include a sealing member attached to the worktop at the joint to substantially prevent liquids from penetrating the joint.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is an elevational side view of an embodiment of a backsplash in accordance with the present invention.
FIG. 1B is an elevational side view of an embodiment of a surface member in accordance with the present invention.
FIG. 1C is an elevational side view of an embodiment of a front edge in accordance with the present invention.
FIG. 2 is an elevational side view of an embodiment of a worktop in accordance with the present invention.
FIG. 3 is a partial perspective view of the underside of the components of a worktop in accordance with the present invention.
FIG. 4 is an elevational sectional view of an exemplary means for attaching a surface member to a front edge in accordance with the present invention.
FIG. 5A is an exploded view of the exemplary means for attachment shown in FIG. 4 in the unlocked position.
FIG. 5B is an exploded view of the exemplary means for attachment shown in FIG. 4 in the locked position.
FIG. 6 is a plan view of a worktop installation in accordance with the present invention.
FIG. 7 is an elevational side view of an embodiment of a worktop in accordance with the present invention, showing a finished end.
FIG. 8 is an alternative plan view of a worktop installation in accordance with the present invention.
FIG. 9 is an elevational side view of a finished end in accordance with the worktop installation of FIG. 8 .
FIG. 10 is an exploded perspective view of a modular worktop in accordance with the present invention, showing a sink module.
FIG. 11 is an exploded perspective view of a modular worktop in accordance with the present invention, showing various component parts.
FIG. 12 is an exploded perspective view of a modular worktop in accordance with the present invention, showing module attachment means on the underside of the worktop.
FIG. 13 is an exploded perspective view of a backsplash in accordance with the present invention.
FIG. 14 is an exploded perspective view of a front edge in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Detailed embodiments of the present invention are now disclosed. It should be understood, however, that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, the details disclosed herein are not to be interpreted as limiting, but merely as the basis for the claims and as a basis for teaching one skilled in the art how to make and/or use the invention.
FIGS. 1A, 1 B, and 1 C show the typical component parts of a worktop 10 , or a countertop, as exemplary of the present invention. FIG. 1A shows a backsplash 12 , FIG. 1B shows a surface member 14 , and FIG. 1C shows a front edge 16 . These components are constructed of typical decorative surfacing materials known in the art, such as high pressure decorative laminate, solid surfacing, solid surfacing veneer, natural and artificial stone compositions, low or direct pressure laminates, metal foils, wood veneers, and the like. These materials may or may not require use of a substrate in conjunction with the decorative layer; such substrates known to the art are fiberboard, particleboard, foamed polymers, wood, and the like. The presently described embodiment, as exemplary, consists of particle board substrate 18 a , 18 b , and 18 c , affixed to a high pressure decorative laminate (HPDL) surface layer 20 a , 20 b , and 20 c.
Each of components 12 , 14 , and 16 may be supplied in a variety of different colors, materials, surface textures, etc., backsplash 12 and front edge 16 may be supplied in various profile configurations, and the components may be supplied in a variety of lengths. For example, a consumer may have a need for a worktop ten feet in length to install in the consumer's home. The consumer may want, for example, a surface member 14 with white HPDL along with a backsplash 12 and front edge 16 with blue HPDL. The consumer would then purchase each of components 12 and 16 in blue and in ten foot lengths, and component 14 in white and in a ten foot length, for subsequent assembly and installation in the home. The decorative combinations of components 12 , 14 , and 16 could just as easily be HPDL and wood, solid surfacing veneer and metal, etc.
The components may then be removably attached together with any removable attachment means known to the art. An exemplary attachment means is a centric sphere connector, described in detail below, and supplied by Häfele America Co., of Archdale, N.C. Other such removable attachment means include nuts and bolts, screws, and the like. For example, backsplash 12 and front edge 16 may be attached to surface member 14 via tongue and groove joints. Screws, or other means of securing, may then be inserted through the tongue and groove joint to secure the assembly together.
Typical use of centric sphere connectors in the present invention would include fixing pins 22 into backsplash 12 and front edge 16 as shown in FIGS. 1 through 4, and providing vertical cavities 24 and horizontal cavities 26 in surface member 14 . Pins 22 must be fixed into backsplash 12 and front edge 16 so as to withstand tensile stresses on pins 22 during use. Means for fixing pins 22 into a substrate are generally known in the art, and include screw threads in the case of a wood-based substrate, drilling holes and using a bonding agent in conjunction with screw threads in the case of polymeric substrates, and other means known in the art. The locations of pins 22 and cavities 24 and 26 , and the size of cavities 24 and 26 , must be accurate per the hardware supplier's instructions to insure proper and secure attachment of the components.
Referring now to FIGS. 3 and 4, pins 22 are inserted into cavities 26 such that their heads 28 are approximately centrally located within cavities 24 . This allows insertion of locking cams 30 into cavities 24 over heads 28 . Referring to FIG. 5A, locking cam 30 is provided with a vertical opening that allows it to slide over and encompass head 28 . Cam 30 is also provided with a horizontal opening around a portion of its circumference. Referring to FIG. 5B, this horizontal opening allows cam 30 , when rotated to the lock position, to grab onto pin 22 and put it into a state of tension. This causes backsplash 12 and front edge 16 to be tightly secured to surface member 14 . The positioning of pins 22 and cavities 24 and 26 along the length of the components must be precise and frequent enough to insure accurate and quality assembly of the components.
Referring now to FIG. 6, a typical worktop installation is shown from above; cabinetry is typically located below and supports the worktop, which may be attached to the cabinetry by any method known in the art. A typical miter joint 32 is used where the worktop takes a 90-degree turn; backsplash 12 and front edge 16 would be mitered accordingly, as shown. The miter joint may be connected via concentric sphere connectors.
FIG. 7 shows finished end 34 of FIG. 6 . End 34 is typically covered with a piece of HPDL cut to fit the shape of end 34 . Because backsplash 12 would generally not be readily removable, the piece of HPDL covering end 34 may include integral coverage for backsplash 12 and surface member 14 . Front edge end 36 , however, would need to be covered with a separate piece of HPDL so as to facilitate any subsequent removal of front edge 16 .
Because front edge 16 is removably attached to surface member 14 , front edge 16 may be easily replaced or changed periodically. For example, if the consumer desires a red front edge rather than an existing blue one, a new red front edge may be purchased and installed with minimal cost and effort. Also, a variety of front edges, each with a different design, may be made available to the consumer. If the consumer, for example, wishes to change worktop front edge designs for each holiday season, replaceable front edges may be supplied with Halloween designs, Christmas designs, Fourth of July designs, etc. Alternatively, a set of front edges with summer, winter, spring, and fall designs may be supplied. The removability of the front edge of the present invention facilitates easy changeover for use of such designs by the consumer.
Another embodiment of the present invention contemplates a set of modular components, or a “kit”, the assembly and installation of which are within the skill of the average consumer. As shown in FIG. 8, the component parts include lengths of backsplash 50 and 52 , lengths of front edge 54 and 56 , lengths of side edge 58 and 60 , first surface member module 62 , second surface member module 64 , third surface member module 66 , and sink module 68 .
The thickness of the backsplash 50 and 52 is standard, as is the depth of surface member modules 62 , 64 , 66 , and 68 . This allows for a predetermined standard length of side edges 58 and 60 , which may also be supplied pre-mitered for left and right-hand worktop sides. Backsplashes 50 and 52 , front edges 54 and 56 , and modules 62 , 64 , and 66 may be supplied in a wide variety of lengths and with pre-mitered ends to facilitate assembly and installation without the need for cutting. Alternatively, these components may be supplied in a few different sizes, thereby requiring the consumer to select sizes slightly longer than necessary for the installation in question and subsequently cutting the individual components to size. Naturally, it is preferable to supply these components in a wide enough variety of lengths to eliminate any need for cutting by the consumer.
Sink module 68 , better shown in FIG. 10, may also be supplied in a wide variety of sizes to accommodate various sink sizes and designs. The present invention contemplates the use of drop-in sinks, such as sink 70 , to be inserted into sink module 68 . Alternatively, sink module 68 may be supplied as a preformed module with integral sink.
Note the use of connectors 72 in sink module 68 which provide for the width dimension of the hole for sink 70 , and also for a means of connecting sink module 68 to adjacent surface member modules 62 and 64 . Surface member and sink modules 62 , 64 , 66 , and 68 are provided with channels 74 which correspond to vertical and horizontal channels 24 and 26 as shown in FIGS. 1-3. Channels 74 are equally spaced around the perimeter of the surface members 62 , 64 , 66 , and sink module 68 , so as to provide means for necessary and sufficient connection of the component parts to each other. It is contemplated that concentric sphere connectors, such as those shown in FIGS. 1-5 may be used in conjunction with channels 74 to provide for an easy to assemble and easy to disassemble worktop.
If the surface member modules do need to be cut, connecting member 76 , shown in FIG. 11, must be supplied to provide means for connecting other component parts of the worktop onto cut end 78 . The length of connecting member 76 is standard, as it is dependent upon the standard depth of the surface members. Connecting member 76 may be ideally attached in place with glue and wood screws, or any other means of providing attachment secure enough to withstand the forces exerted upon it through attachment to another component with concentric sphere connectors.
FIG. 12 shows the underside of surface member modules 64 and 66 , and the use of concentric sphere connectors, as explained above, to connect the two components. FIGS. 13 and 14 show backsplash 50 and front edge 54 respectively. A plurality of pins 80 may be slidably engaged into slots 82 for ease of alignment between pins 80 and channels 74 . Sealing members 84 may be inserted into slots 86 to provide for a liquid-tight joint between the components if necessary. Also, sealing member 88 may be inserted into slot 90 so as to fill any gaps between backsplash 50 and the wall. Sealing members 84 and 88 may be caulking compound, rubber gasket strips, or any other similar sealing material.
Sealing member 88 extends beyond the plane of the back of backsplash 50 in order to eliminate the need for scribing backsplash 50 into the wall behind it. Scribing is a process by which a worktop fabricator cuts the contour of the wall into a backsplash to eliminate gaps between the backsplash and the wall. An alternative method is to fill any such gaps with caulking compound, usually a very messy process. Provision of sealing member 88 provides for a quick, clean, and easy method of eliminating gaps between a backsplash and a wall.
Finally, decorative indicia 92 may be supplied for insertion into location 94 on backsplash 50 . As discussed above, backsplash 50 may be supplied in a variety of colors and styles. A variety of decorative indicia 92 may also be supplied so that consumers can “mix and match” indicia 92 with backsplashes 50 to their liking. Such indicia 92 may be of the peel and stick type, the glue on type, etc. Once the worktop is installed, decorative indicia 92 may be changed as desired by peeling off the old indicia, and selecting and installing new indicia.
The present invention may also be used in conjunction with an “island” countertop installation. In such an application, no backsplashes are used. Typically, one large surface member is used along with a plurality of edge moldings.
Additional advantages and modifications will be readily apparent to one skilled in the art, while falling within the spirit and scope of the claimed invention. The claimed invention in its broader aspects is not, therefore, limited to the specific examples and structures described above and claimed below. Any such advantages and modifications, while not specifically described herein, are deemed to be within the spirit and scope of the presently disclosed and claimed invention.
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Disclosed is a modular worktop, and method of assembly, including a surface member, a front edge, and a backsplash, the components preferably being removably attached to each other. Each of the surface member, front edge, and backsplash may be selected from a predetermined group of decorative surfacing options, resulting in a worktop that is aesthetically pleasing to the consumer or person selecting the components. Additionally, each of the components is sized and configured so as to bring assembly and installation within the skill range of the average consumer. Because the front edge is removably attached, the front edge is changeable at the discretion of the consumer, for example, for aesthetic reasons.
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This is a continuation of application No. PCT/AU00/01495, filed Dec. 4, 2000.
FIELD OF THE INVENTION
This invention relates to micromachines and an improved rotor for micromachinery. The term micromachine is used to embrace many types of very small turbines or compressors. These machines can be as small as 12 mm in diameter with rotors of 4 mm in diameter.
BACKGROUND
Micromachines such as micro-gas turbines, combustion power generators, pumps and compressors are described in U.S. Pat. No. 5,932,940 (the M.I.T. patent), the disclosure of which is incorporated herein by reference. All of these machines contain a rotor comprising a disc or discs defining either a centrifugal compressor/pump or a radial inflow turbine. The material of construction is characterised by a strength to density ratio enabling a rotor speed of at least 500,000 rotations per minute. The machines are constructed using microfabrication techniques including vapour deposition and bulk wafer etching, the material of construction being common to all the structural elements.
The compressor and the turbine rotors of the devices described in the M.I.T. patent utilise a plurality of radial flow vanes. It is considered that this arrangement of blades is not desirable in micromachines for the following reasons:
(a) because the nature of construction involves planar fabrication techniques, fillets on corners are difficult to achieve and, in the absence of adequate fillets, high stress concentration at the blade root attachment decreases the fracture strength of these microelements;
(b) the placement of blades around the periphery of the discs increases the mass of the structure at the place where centrifugal stresses have the greatest effect;
(c) the plurality of blades tends to set up undesirable turbulence and pulsations in the working fluids, and the cyclic nature of the reaction between fluids & blades results in cyclic stress fluctuations (fatigue stresses) that limit the durability (fatigue life) of the rotor assembly;
(d) the maximum rotor speed is limited in part by the allowable mechanical and thermal stresses that may be imposed on the rotor structure by the plurality of radial flow vanes;
(e) the degree of rotor balance obtainable is affected by the requirement for a plurality of radial flow vanes; and
(f) the rotor disc employs blades only on one side and is subject to a bending moment, caused by centrifugal blade loading.
It is these problems that have brought about the present invention to use a bladeless or vaneless rotor in micromachines.
The use of bladeless rotors has been suggested in the context of “large scale” turbines. Thus, a method for driving turbines by means of viscous drag was taught by Tesla in U.S. Pat. No. 1,061,206 and for fluid propulsion in U.S. Pat. No. 1,061,142. In both disclosures the rotor comprises a stack of flat circular discs with openings in the central portions, with the discs being set slightly apart. In the turbine embodiment the rotor is set in motion by the adhesive and viscous action of the working fluid, which enters the system tangentially at the periphery and leaves it at the center. In the fluid propulsion embodiment, fluid enters the system at the center of the rotating discs and is transferred by means of viscous drag to the periphery where it is discharged tangentially.
For fluid propulsion applications such as pumps and compressors, the fluid is forced into vortex circulation around a central point where a pressure gradient is created. This pressure gradient is such that an increasing radial distance from the center of rotation leads to an increase in pressure, with the density of the fluid and the speed of rotation determining the rate of pressure rise. If an outwardly radial flow is superimposed on the vortex circulation an increasing pressure is imposed on the fluid as it flows outwardly.
To preserve the vortex circulation, an external force must act upon the fluid, and this force must accelerate the fluid in the tangential direction as the fluid moves outwardly in order to maintain its angular velocity. This function is simply a transfer of momentum from the impeller to the fluid, and with a centrifugal compressor it may be achieved in one of two ways. A first method is to confine the fluid within a fixed boundary channel and then accelerate the channel. In an impeller of the type utilized in prior art microturbomachinery, the vanes and rotor walls form such a channel, and acceleration occurs as the fluid moves outwardly towards regions of higher impeller velocity. A second method of momentum transfer is by viscous drag and this is the principle underlying the Tesla arrangement described in the two US patents referred to above. Viscous drag always acts to reduce the velocity difference, so that in the case of a compressor where the channel walls are moving relative and parallel to the fluid, the fluid will accelerate in the direction of the channel motion. Conversely, where the fluid is moving relative and parallel to the channel walls, the channel walls will accelerate in the direction of the fluid motion.
Known bladeless or vaneless rotors have had limited success in large scale turbines. The relatively large number of parts required for their construction and the distortion of the discs that occur under high thermal and mechanical stress conditions have restricted their adoption.
It is these issues that have brought about the present invention.
SUMMARY OF THE INVENTION
According to one aspect of the present invention there is provided a micromachine including at least one bladeless rotor, said rotor being adapted to impart energy to or derive energy from a fluid.
For the micromachine, the rotor of the invention may have a disc of diameter no greater than 20 mm.
Preferably the rotor includes a shaft centrally supporting at least two closely spaced planar discs, the discs having opposed surfaces defining a fluid passageway. At least one of the discs may have one or more apertures to allow fluid to pass into or out of the fluid passageway. The apertures preferably are close to a central region of the disc. There may be two or more apertured discs, with the apertures of each disc being aligned with those of the other disc. Preferably the discs are separated by spacers.
The rotor of the invention may have a backing disc supporting a plurality of annular discs in a closely spaced coaxial array. In that arrangement, each annular disc may be mounted to the backing disc or an adjacent disc by an array of spacers. The backing disc preferably is mounted coaxially on a shaft.
The micromachine, including its rotor, preferably has a vaned stator positioned around the periphery of the bladeless rotor.
The micromachine preferably is made of material capable of operating at temperature greater than 1000° C. The rotor most preferably is made of a material having a tensile strength to allow the rotor to run at speeds greater than 500,000 rpm at elevated temperatures associated with combustion. The rotor may be made of a single crystal material. The rotor may, for example, be formed at least in part from a material selected from silicon, silicon carbide, silicon coated with silicon carbide, and silicon coated with silicon nitride.
The rotor preferably is formed by a microfabrication technique, such as photolithography or vapour deposition.
According to a further aspect of the present invention there is provided a rotor for a micromachine, wherein the rotor includes at least a pair of closely spaced co-axially aligned discs defining opposed planar surfaces, at least one disc having at least one aperture whereby a fluid passageway is defined between the aperture, the planar surfaces and the periphery of the rotor, and wherein the rotor is bladeless and is formed of a single crystal material.
In accordance with a still further aspect of the present invention there is provided a rotor for a micromachine, wherein the rotor includes at least a pair of closely spaced co-axially aligned discs defining opposed planar surfaces, at least one disc having at least one aperture whereby a fluid passageway is defined between the aperture, the planar surfaces and the periphery of the rotor, and wherein the rotor is bladeless and manufactured of a material having a tensile strength to allow the rotor to run at speeds greater than 500,000 rpm at elevated temperatures associated with combustion.
In accordance with a still further aspect of the present invention there is provided a rotor, wherein the rotor includes a backing disc and at least one coaxially spaced annular disc supported on the backing disc by a central hub defining at least one aperture, wherein the rotor is bladeless and the annular disc defines an unimpeded fluid passage between the aperture and the periphery of the disc.
The rotor of the invention most preferably is of unitary construction. The rotor preferably is formed by a microfabrication technique, such as photolithography or vapour deposition.
DESCRIPTION OF THE DRAWINGS
Embodiments of the invention will now be described by way of example only with reference to the accompanying drawings in which:
FIG. 1 is a front elevational view of a first embodiment of a bladeless rotor for use in a micromachine,
FIG. 2 is a side elevational view of the bladeless rotor of FIG. 1,
FIG. 3 is a cross sectional view taken along the lines III—III of FIG. 1,
FIG. 4 is a front elevational view of a second embodiment of a bladeless rotor,
FIG. 5 is a sectional view of the rotor, taken through the lines V—V of FIG. 4,
FIG. 6 is a sectional view of the rotor, taken through the lines VI—VI of FIG. 4,
FIG. 7 is a three dimensional view illustrating two bladeless rotors mounted coaxially on a common shaft,
FIG. 8 is a front elevational view of a bladeless rotor in accordance with a third embodiment,
FIG. 9 is a side elevational view of the rotor of FIG. 8,
FIG. 10 is a sectional view of the rotor taken through the lines X—X of FIG. 9,
FIG. 11 is a front elevational view of a test rig illustrating operation of a radial flow turbine utilising a bladeless rotor,
FIG. 12 is a cross sectional view taken along the lines XII—XII of FIG. 11,
FIG. 13 is a front elevational view of a test rig illustrating operation of a radial flow turbine utilising a rotor with blades,
FIG. 14 is a cross sectional view taken along the lines XIV—XIV of FIG. 13,
FIG. 15 is a graph of rotor speed against plenum chamber pressure utilising the test rigs of FIGS. 11 and 13, and
FIG. 16 is a graph of rotor speed against mass flow in grams per second.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In U.S. Pat. No. 5,932,940 (the M.I.T. patent) there is disclosure of micromachinery in the form of micro-gas turbines and associated microcomponentry. The components such as the compressor, diffusers, combustion chambers, turbine rotors and stators are all disclosed as being manufactured using microfabrication techniques in a material that is common to all the elements. Suitable materials include a range of ceramics used in the semiconductor art or in the microelectronic fields, such materials include silicon, silicon carbide and silicon nitride. Other suitable materials include refractory metals and alloys based on nickel, tantalum, iridium and rhenium. Composite materials such as molybdenum silicide are also envisaged. The materials can also vary depending on whether they are used in the hot and cold regions of the micromachines. Such techniques and materials are suitable for use with a rotor and a micromachine according to the invention.
Regardless of whether the engine is a turbine or compressor it includes at least one rotor usually mounted on a shaft. In one embodiment the engine could include a common shaft driving a compressor disc at one end, defining a centrifugal compressor and a turbine disc at the opposite end defining a radially inflow turbine. The componentry is very small with the whole assembly being less that 20 mm in diameter. The micromachines are designed to run at very high speeds with a rotational speed of at least 500,000 rotations per minute being typical. In a preferred embodiment the dimensions of the machine embraces compressor and turbine discs of diameters between 1 and 20 mm with a combustion chamber having a height of between 2 to 10 mm and the axial length of the combustion chamber being between 0.5 mm and 12 mm. The materials that are used to produce the componentry should preferably be able to withstand temperature of at least 1,000° C. in the case of turbines. Again, these considerations apply similarly to a rotor and a micromachine according to the present invention, as will be evident from the following.
The micromachine disclosed in the M.I.T. patent utilises bladed or vaned rotors. As discussed in the introduction of the present specification, it is considered that the use of a bladed or vaned rotor in micromachinery causes a series of problems, many of which can be solved by the use of bladeless or vaneless rotors.
In the embodiment shown in FIGS. 1 to 3 , a suggested construction of a bladeless rotor 10 is illustrated. The bladeless or vaneless rotor 10 shown in FIGS. 1 to 3 includes two substantially smooth and planar annular discs or rings 12 and 13 co-axially supported in a close parallel array by a star shaped hub 14 which is attached to a backing disc 16 . The hub 14 is provided with openings/apertures 18 that communicate with the space 20 between backing disc 16 and the ring 12 and with the space 21 between ring 12 and ring 13 . In the example shown the rotor has a diameter of about 4 mm and a width of about 0.6 mm. The rotor is constructed from material such as silicon, silicon carbide or other suitable material and is manufactured preferably as a sub assembly of prior art microturbomachinery and by means compatible with the manufacture of associated microturbomachine components.
The spaces 20 and 21 form fluid passageways from opening 18 to the periphery of the rings 12 and 13 . The fluid passageways are defined by four surfaces 22 , 23 , 24 and 25 over which the fluid flows, namely opposing surfaces 23 and 24 of the rings 12 and 13 and the opposing surfaces 22 and 25 of the ring 12 and backing disc 16 .
In FIGS. 4 to 6 , a second embodiment of a micromachine rotor 30 is illustrated. In rotor 30 , a backing disc 32 , supports a cross shaped hub 34 upon which are supported in close parallel array two smooth and substantially planar annular discs or rings 36 and 37 . The hub 34 is provided with openings 38 that are in fluid connection with the space 40 between backing disc 32 and ring 36 and with space 41 between ring 36 and ring 37 . The spaces 40 and 41 form fluid passageways from openings 38 , to the periphery of the rings 36 and 37 . The fluid passageways are defined by four surfaces 42 , 43 , 44 and 45 , namely opposing surfaces 43 and 44 of the rings 36 and 37 , and the opposing surfaces 42 and 45 of the ring 36 and the backing disc 32 . The inner diameter 46 of the spaces 40 and 41 , is smaller than the outer diameter 48 of the openings 38 . This arrangement allows an unimpeded flow of the vortex circulation of the fluid within the fluid passageways formed by the spaces 40 and 41 and within the openings 38 . In this embodiment the rotor has a diameter of about 4 mm and a width of about 0.6 mm.
Construction of the rotor 10 of FIGS. 1 to 3 and rotor 41 of FIGS. 4 to 6 may be accomplished by means of microfabrication techniques in common usage such as photolithography and masking layers. In the case where silicon is the material of construction, deep trench etch processes employing anistropic plasma etching steps alternating with polymerizing steps may also be employed. Such a process is described in U.S. Pat. No. 5,501,893 and is available from Surface Technology Systems Ltd. of Imperial Park, Newport U.K. However, other etching techniques can be employed, and preferably the etchant and chemistry employed are capable of producing deep trench geometries having high aspect ratios. Other manufacturing techniques may also be employed, particularly when the material of construction is silicon carbide, in which case components may be molded by vapor deposition of the selected material into a pre-etched mold formed in for instance a silicon wafer. The resulting molded components are then removed from their molds and may be bonded together with other components to produce the finished rotor.
The rotor 10 shown in FIGS. 1 to 3 may operate either as a compressor/pump or a turbine. In the case where the rotor is defined as the compressor/pump in a microturbomachine, the rotor is driven up to speed within a suitable housing by either electrical or mechanical means (not shown). It should be noted that the rotor 10 will operate with equal efficiency when driven in either a clock-wise or counter clockwise direction. Fluid upon entering inlet openings 18 and coming into contact with discs 12 and 13 is subjected to two forces, one acting tangentially in the direction of rotation, and the other radially outwardly. The combined effect of these tangential and radial forces is to propel the fluid with increasing velocity in a spiral path until it reaches the perimeter of the rotor where it is ejected. In the case where the rotor is operating as a turbine in a microturbomachine the operation described above is reversed. Thus, if fluid under pressure is admitted tangentially to the perimeter of the rotor disc, the rotor 10 will be set in motion by the viscous drag properties of the fluid which, travelling in a spiral path and with continuously diminishing velocity reaches the openings 18 from where it escapes.
Although a rotor 10 having two discs 12 , 13 is depicted in FIGS. 1 to 3 , it is to be understood that a plurality of more than two discs suitably serving particular operating requirements may be utilized. Similarly, rotor 30 of FIGS. 4 to 6 may have at least one further disc or ring additional to rings 36 , 37 .
As may be appreciated from FIGS. 1 to 3 , stresses set up by centrifugal forces are supported radially by the star shaped hub 14 thus preventing a bending moment on the backing disc 16 . Also, as illustrated in FIGS. 1 to 3 , ends 26 of the star shaped hub 14 extending into the space 20 between the backing plate 16 , and disc 12 , and the space 21 between discs 12 and 13 in order to provide lateral support to the discs 12 and 13 .
In contrast, in the second embodiment illustrated in FIGS. 4 to 6 , the ends of the cross shaped hub 34 terminate below the outer diameter 48 of openings 38 thereby forming inner diameter 46 of spaces 40 and 41 . The benefits with this embodiment are that disturbed fluid flow, caused by the ends 26 of the hub 14 of rotor 10 of the first embodiment, is able to be eliminated and the viscous drag flow is permitted to continue unimpeded to the openings 38 .
A preferred material of construction for the rotor of the invention is silicon carbide. This material possesses the properties of high strength and dimensional stability (creep-resistance) at elevated temperatures and a high strength to density ratio. In the particular case of prior art bladeless turbine rotors where the major problems have always related to internal vibration, high temperatures, high speeds and high pressures it has been impractical to construct the rotor from silicon carbide thus limiting the high performance potential of turbine rotors operating on the principles of fluid viscous drag. The use of silicon carbide in a micro-gas turbine rotor of the present invention minimizes disc distortion and allows higher speeds and therefore improved performance. In addition, because the rotor is made by microfabrication techniques, an advantage is gained from the particular batch production methods available. In the case where microturbomachine rotors may operate at lower temperatures than micro-gas turbines the preferred material of construction may be silicon. This material is already in wide usage in microelectronic componentry and the fabrication techniques are well understood. Ceramics are excellent materials for microfabrication of highly stressed components because they demonstrate high tensile strength at very high temperatures.
In some applications of micromachinery, a relatively low level of thermal or mechanical stress may apply in which case the means of supporting the rings 12 and 13 as shown for rotor 10 in FIGS. 1 to 3 may be modified. The same may apply to rings 36 and 37 of rotor 30 shown in FIGS. 4 to 6 .
FIG. 7 is a perspective view of a micro-gas turbine rotor 50 of the present invention constructed according to Brayton cycle gas turbine practice. Rotor 50 has a radial outflow compressor unit 51 and a radial inflow turbine unit 52 each of which operates on the principles of fluid viscous drag. Units 51 and 52 are mounted by their respective support discs 53 and 54 to a respective end of a connecting shaft 55 .
Each of the units 51 and 52 of rotor 50 of FIG. 7 has a general form similar to that of rotor 10 of FIGS. 1 to 3 and of rotor 30 of FIGS. 4 to 6 . Detailed description of units 51 and 52 therefore is not necessary. However, as shown, the respective support discs 53 and 54 face each other along shaft 55 . Thus, the rings 56 and 57 of unit 51 are adjacent to the surface of disc 53 which is remote from unit 52 , while rings 58 and 59 are adjacent to the surface of disc 54 which is remote from unit 51 .
In FIGS. 8 to 10 there is shown an embodiment in which a micromachine rotor 70 comprises a support disc 72 upon which is mounted an array of spacers 73 . Each of the spacers 73 is attached by a first face to support disc 72 and by the opposite face to ring 74 . On the opposite face of ring 74 is mounted a further array of spacers 75 and these spacers attach to the inner face of ring 76 . Although six spacers 73 and six spacers 75 of a particular size and shape are shown in the drawings it is to be understood that other numbers, sizes and shapes may be effective. In this particular embodiment of the invention of FIGS. 8 to 10 , the advantage of the radial support given to the rings by the star shaped hub as shown in FIGS. 1 to 3 or a cross shaped hub as shown in FIGS. 4 to 6 , respectively, is exchanged for the advantage of an unrestricted opening 78 . This embodiment of FIGS. 8 to 10 , like the first embodiment of FIGS. 1 to 3 and second embodiment of FIGS. 4 to 6 , defines fluid passageways between the opening 78 and periphery of the rings 74 and 76 .
The dimensions of rotor 70 as a whole, and the spacings of the disc 72 and rings 74 and 76 , for any given machine will be determined by the conditions and requirements of the particular application of the micromachine, as with rotor 10 of FIGS. 1 to 3 , rotor 30 of FIGS. 4 to 6 and rotor 50 of FIG. 7 . In general, greater disc spacing is required for larger disc diameters, longer fluid spiral path and greater fluid viscosity. For instance, when the machine is configured as a turbine the torque is directly proportional to the square of the velocity of the fluid relative to the rotor and to the effective area of the discs, and inversely, to the distance separating them. The size and shape of the disc openings will also be determined dependent on application and rotor construction. In a multiple disc rotor, the disc furthest from the backing disc may have larger openings to not only accommodate the fluid out flow through the passage adjacent that disc, but also the fluid outflow from all other discs between the backing disc and furthest disc. Further, the surface finish of the discs is sufficiently smooth to adhere at least one layer of fluid particles to the disc thereby creating a boundary layer in the fluid vortex.
In its preferred forms, the present invention may provide the following advantages over the prior art-use of radial flow vanes in microturbomachines:
(a) reduced corner stress concentration;
(b) reduced turbulence and pulsation in the working fluids;
(c) higher rotational speeds within the limits of the tensile strength and elastic modulus of the material due to plain radial loading and absence of sharp section changes;
(d) an improved rotor balance;
(e) a reduction of the bending moment caused by centrifugal blade loading;
and in the case of prior art use of large scale bladeless rotors:
(f) no requirement for a multiplicity of parts; and
(g) minimized disc distortion due to a preferred material of construction giving high strength and dimensional stability at high temperatures e.g. silicon carbide or silicon.
The reduction or elimination of cyclic stresses that arise from reaction between blades and working fluids in prior art microturbine rotors, has the effect of achieving the advantages outlined in paragraph (b) above and, effectively, extending the fatigue life, or durability of the rotor in the present bladeless configuration.
FIGS. 11 and 12 show a first test rig 80 for use in testing a bladeless rotor 10 as shown in FIGS. 1 to 3 . FIGS. 13 and 14 show a second test rig 80 , used in testing a bladed rotor 100 having blades 102 . The respective rigs 80 of FIGS. 11 and 12 and of FIGS. 13 and 14 are identical, and they therefore have the same reference numerals and are described with reference to either one of them. The rotor 100 shown in FIGS. 13 and 14 has a construction modelled as closely as possible on the turbine rotors described in the M.I.T. patent.
The respective rigs 80 were used to demonstrate the efficiency of using a bladeless or vaneless rotor in a micromachine represented by a test rig 80 as shown in FIGS. 11 and 12 and, using a bladed rotor 100 , in a test rig 80 as shown in FIGS. 13 and 14. That is, the purpose of rigs 80 was to demonstrate the performance of such machinery when used with a bladeless rotor 10 of the kind described above, as shown in FIGS. 11 and 12, compared with performance with a conventional bladed rotor 100 , having blades 102 shown in FIGS. 13 and 14. For practical reasons a decision was made to construct a turbine with 18 mm diameter rotors 10 and 100 to be driven by compressed air. The use of compressed air meant that the turbine did not require the capacity to embrace high combustion temperatures and thus did not have to be made in high temperature resistant ceramic materials. Thus, the componentry was constructed of a readily available metal that has excellent qualities of machineability. An aluminium alloy 2011 was selected due to its characteristics of machineability and its high tensile strength. The choice of an 18 mm diameter rotor was selected also for ease of manufacture and to ensure that the rig can still be classed as a micromachine.
The rotor design follows the embodiment of rotor 30 as illustrated in FIGS. 4 to 6 but with all dimensions scaled in the ratio of 1:4.5. The spacing between the backing disc 32 , and the disc 36 , and between the discs 36 and 37 , was 0.375 mm, whilst the thickness of the discs 36 and 37 , was 0.375 mm. The distance between the working surfaces 44 and 45 was 1.125 mm.
As shown in FIGS. 11 to 14 , each test rig 50 comprises a housing block 81 having a front face 82 with an annular recess 83 . A cylindrical throughway 84 extends through the center of the block 81 from the center of the annular recess 83 to the rear face 85 of the block 81 . The throughway 84 supports spaced bearings 86 . In FIGS. 11 and 12, bladeless rotor 10 is shown as mounted at one end of a shaft 87 that is supported within the throughway 84 by the bearings 86 for axial rotation. The rear end 85 of the block 81 is closed off by an end plate 88 which is secured to the block by cap head screws 89 . The annular recess 83 at the front of the block 81 supports an annular backing plate 90 that is positioned in close proximity to the rear of the bladeless rotor 10 in FIGS. 11 and 12 and the bladed rotor 100 in FIGS. 13 and 14. The bearing plate 89 supports an annular stator 91 having profiled blades 92 . The respective stator 91 is positioned outside but close to the periphery of the rotor 10 or rotor 100 to direct incoming air to the rotor periphery. A front cover 93 is secured over the front of the housing by six cap head screws 94 . Compressed air is used to drive the turbine and the air inlet 95 is positioned at the lower right hand side of the block as shown in each of FIGS. 11 and 13. The air initially fills the annular cavity around the periphery of the respective rotor 10 and 100 and then in the case of the bladeless rotor 10 flows through the fluid passageway defined by the rotor discs to impart viscous drag to rotate the rotor and then to escape via the apertures at the center of the rotor. The annular space exterior of each rotor is also coupled via a plenum chamber to a pressure sensor (not shown) via a bleed passageway 96 shown in FIGS. 11 and 13 in the top right hand corner of the block 81 .
The radial inflow rotor 10 , 100 mounted on the respective shaft 87 is supported by a respective high speed (140,000 rpm) ball bearing race, of each bearing 86 , precisely located with identical preloads in both test rigs. The air is fed tangentially to the rotor by the air inlet 95 . It is also fed to the plenum chamber that includes the pressure sensor. The respective multi-vaned stator 91 directs the air onto the rotor 10 , 100 and each stator 91 also is modelled on the stator disclosed in the M.I.T. patent. The rigs 80 have identical exhaust apertures and the shaft 87 includes a bicoloured disc that allows the rotational speed of the shaft 87 to be read using an optical tachometer. The compressed air was regulated with coarse and fine needle valves to ensure fine flow control.
Every care was taken to ensure that the two test rigs 80 operated on identical parameters. In one test, the revolutions per minute were measured against the plenum chamber pressure at precise change points to retrieve repeatable data. The pressure was increased slowly to ensure measurements represented stable conditions of air flow and rotor speed. Pressure was progressively increased until the ball bearing rpm specification limit for each bearing 86 was exceeded. The results of these test, namely rotor speed against supply pressure were plotted on the graph shown in FIG. 15 .
The test rigs 80 were then used to conduct mass flow tests where rpm were measured against exhaust air speed. The pressure was increased slowly to ensure measurements represented stable conditions of air flow and rotor speed. Pressure was progressively increased until the ball bearing rpm specification limit was exceeded. The mass flow in grams per second was then derived from volume per second of exhaust air and a graph was plotted as shown in FIG. 16 .
It can be seen from the graphs of FIG. 16 there is a clear performance advantage in using the bladeless rotor 10 , compared with the bladed rotor 100 . The mass flow graphs diverged from approximately 40,000 rpm showing a strong trend to proportionately lower values, for bladeless rotor 10 compared to bladed rotor 100 , at increasing rpm. The bladed rotor 100 registered a Mass Flow figure of 30% higher than the bladeless rotor 10 at 100,000 rpm. At maximum test Mass Flow, the bladeless rotor achieved approximately 35% higher rpm than the bladed rotor 100 . The plenum pressure against rpm graph showed a similar strong trend favouring the bladeless rotor 10 . From approximately 50,000 rpm the bladeless rotor 10 achieved higher speeds than the bladed rotor 100 and this divergence increased until 140,400 rpm which was just over the specification limit of the bearings. This speed was reached at only 2.75 pounds force per square inch (psi) an improvement of 18.5% over the bladed rotor 100 . Additionally, a 27% higher pressure was required in order for the bladed rotor 100 to reach 100,000 rpm. The divergent trends of both the graphs are indicative of major performance benefits that would be expected to increase proportionally at higher rpm's.
A further advantage that was noted in using the two test rigs 80 was that the bladeless rotor 10 was considerably quieter than the bladed rotor 100 .
It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the invention as shown in the specific embodiments without departing from the spirit or scope of the invention as broadly described. The present embodiments are, therefore, to be considered in all aspects as illustrative and not restrictive.
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A micromachine including at least one bladeless rotor, said rotor being adapted to impart energy to device energy to or derive energy from a fluid. A rotor for a micromachine comprising at least a pair of closely spaced co-axially aligned discs defining opposed planar surfaces, at least one disc having at least one aperture whereby a fluid passageway is defined between the aperture, the planar surfaces and the periphery of the rotor, the rotor being formed of a single crystal material.
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RELATED APPLICATIONS
[0001] This application is a Divisional of U.S. Ser. No. 09/031,960 filed on Feb. 26, 1998, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention concerns integrated circuits that include field-effect transistors, particularly metal-oxide-semiconductor field-effect transistors.
[0003] Integrated circuits, the key components in thousands of electronic and computer products, are interconnected networks of electrical components fabricated on a common foundation, or substrate. Fabricators typically use various techniques, such as layering, doping, masking, and etching, to build thousands and even millions of microscopic transistors, resistors, and other electrical components on a silicon substrate, known as a wafer. The components are then “wired,” or interconnected, together to define a specific electric circuit, such as a computer memory.
[0004] Many integrated circuits include a common type of transistor known as a metal-oxide-semiconductor, field-effect transistor, or “mosfet” for short. A mosfet has four electrodes, or contacts—specifically, a gate, source, drain, and body. In digital integrated circuits, such as logic circuits, memories, and microprocessors which operate with electrical signals representing ones and zeroes, each mosfet behaves primarily as a switch, with its gate serving to open and close a channel connecting its source and drain. Closing the switch requires applying a certain threshold voltage to the gate, and opening it requires either decreasing or increasing the gate voltage (relative the threshold voltage), depending on whether the channel is made of negatively or positively doped semiconductive material.
[0005] Mosfets are the most common transistors used in integrated-circuit memories, because of their small size and low power requirements. Integrated-circuit memories typically include millions of mosfets operating simultaneously, to store millions of bits of data. With so many mosfets operating simultaneously, the power consumption of each mosfet is an important concern to memory fabricators. Moreover, as fabricators continually strive to pack more and more mosfets into memory circuits to increase data capacity, the need for even lower power and lower voltage mosfets compounds.
[0006] Conventional mosfets operate with power supply voltages as low as two volts. Although lower supply voltages are desirable, fabricators have reached a technical impasse based on their inability to make millions of mosfets with perfectly identical threshold voltages. Hence, each of the mosfets has its own unique threshold voltage, with some deviating only slightly from the fabricator's intended threshold voltage and others deviating significantly. The typical range of threshold voltages in memory circuits extends from 0.2 volts above to 0.2 volts below the intended threshold voltage.
[0007] Thus, for example, if fabricators build mosfets with an intended threshold of one-quarter volt to accommodate half-volt power supplies, some mosfets will actually have a threshold around 0.4 volts and others around 0.05 volts. In practice, these deviant mosfets are prone not only to turn on and off randomly because of inevitable power-supply fluctuations or electrical noise affecting their gate voltages, but also to turn on and off at widely variant rates. Therefore, to avoid random operation and promote uniform switching rates, fabricators raise the intended threshold to a higher level, which, in turn, forecloses the option of using lower power-supply voltages.
[0008] Recently, three approaches involving the concept of a dynamic, or variable threshold voltage, have emerged as potential solutions to this problem. But, unfortunately none has proven very practical. One dynamic-threshold approach directly connects, or shorts, the gate of a mosfet to its body, causing the mosfet to have a lower effective threshold during switching and higher threshold during non-switching periods. (See, Tsuneaki Fuse et al., A 0.5V 200 MHZ 32b ALU Using Body Bias Controlled SOI Pass-Gate Logic, IEEE International Solid State Circuits Conference, San Francisco, pp. 292-93, 1997.) However, this approach forces the mosfet to draw significant power even when turned off, in other words, to run continuously. This poses a particularly serious limitation for battery-powered applications, such as portable computers, data organizers, cellular phones, etc.
[0009] Louis Wong et al. disclose another dynamic-threshold approach which capacitively couples an n-channel mosfet's gate to its body. (See Louis Wong et al., A 1V CMOS Digital Circuits with Double-Gate Driven MOSFET, IEEE International Solid State Circuits Conference, San Francisco, pp. 292-93, 1997.) Implementing this approach requires adding a gate-to-body coupling capacitor to every mosfet in a memory circuit. Unfortunately, conventional integrated-circuit capacitors are planar or horizontal capacitors that consume great amounts of surface area on an integrated-circuit memory, ultimately reducing its data capacity.
[0010] The third dynamic-threshold approach, referred to as a synchronous-body bias, applies a voltage pulse to the body of a mosfet at the same time, that is, synchronous, with the application of a voltage to the gate, thereby reducing its effective threshold voltage. (See Kenichi Shimomuro et al., A 1V 46 ns 16 Mb SOI-DRAM with Body Control Technique, Digest of the IEEE International Solid-State Circuits Conference, San Francisco, pp. 68-69, 1997.) Unfortunately, implementing the circuitry to apply the synchronous voltage pulse requires adding extra conductors to carry the voltage pulses and possibly even built-in timing circuits to memory circuits. Thus, like the previous approach, this approach also consumes significant surface area and reduces data capacity.
[0011] Accordingly, there is a need to develop space-and-power efficient implementations of the dynamic threshold concept and thus enable the practical use of lower power-supply voltages.
SUMMARY OF THE INVENTION
[0012] To address these and other needs, embodiments of the present invention provide a space-saving structure and fabrication method for achieving gate-to-body capacitive coupling in n- and p-channel field-effect transistors. Specifically, one embodiment of the invention uses at least one vertical, that is, non-horizontal, capacitive structure, to achieve the gate-to-body capacitive coupling. In contrast to conventional horizontal capacitor structures, the vertical structure requires much less surface area. Moreover, for further space savings, another embodiment not only uses a lateral semiconductive surface of the transistor as a conductive plate of the gate-to-body coupling capacitor, but also places the other conductive plate in a normally empty isolation region between neighboring transistors. The space-saving gate-to-body capacitive coupling of the invention yields practical transistors with superior switching rates at low-operating voltages, ultimately enabling practical half-volt inverters, buffers, sense amplifiers, memory circuits, etc.
[0013] Another aspect of the invention concerns a method for making a field-effect transistor having gate-to-body capacitive coupling. One embodiment entails forming an NMOS or PMOS device island and then growing dielectric sidewalls on two opposing sidewalls of the NMOS or PMOS device island. Afterward, the method forms conductive sidewalls on the dielectric sidewalls. This method yields two vertical gate-to-body coupling capacitors, one on each of the two opposing sidewalls of the device island. In other embodiments, the method isolates the device island from an underlying substrate to form a silicon-on-insulator structure and forms self-aligned source and drain regions.
[0014] Still other aspects of the invention include circuits for half-volt inverters, voltage-sense amplifiers, and memories. Each incorporates a field-effect transistor having vertical gate-to-body capacitive coupling and thus offers not only space savings but also superior switching rate at low voltages.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] [0015]FIG. 1A is a perspective view of an integrated-circuit assembly for complementary field-effect transistors having gate-to-body capacitive coupling;
[0016] [0016]FIG. 1B is a top view of the FIG. 1A assembly;
[0017] [0017]FIG. 1C is a front view of the FIG. 1A assembly;
[0018] [0018]FIG. 1D is a schematic diagram showing an equivalent circuit for a portion of the FIG. 1A assembly.
[0019] [0019]FIG. 2 is a cross-sectional view of an integrated-circuit assembly after formation of an n-well;
[0020] [0020]FIG. 3 is a cross-sectional view of the FIG. 2 assembly after formation of NMOS and PMOS device islands;
[0021] [0021]FIG. 4 is a cross-sectional view of the FIG. 3 assembly after isolating the device islands from underlying substrate;
[0022] [0022]FIG. 5 is a cross-sectional view of the FIG. 4 assembly after formation of vertical sidewall capacitors on the NMOS and PMOS device islands;
[0023] [0023]FIG. 6 is a cross-sectional view of the FIG. 5 assembly after formation of metal gate layers;
[0024] [0024]FIG. 7 is a perspective view of the FIG. 6 assembly after definition of metal gate members;
[0025] [0025]FIG. 8 is a perspective view of the FIG. 7 assembly after formation of the source and drain regions;
[0026] [0026]FIG. 9 is a schematic diagram of an inverter circuit incorporating the integrated-circuit structures of FIGS. 1 A- 1 D and 8 ; and
[0027] [0027]FIG. 10 is a schematic diagram of a memory circuit incorporating the inverter circuit of FIG. 9 as part of a voltage-sense amplifier.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] The following detailed description, which references and incorporates FIGS. 1 - 10 , describes and illustrates specific embodiments of the invention. These embodiments, offered not to limit but only to exemplify and teach the invention, are shown and described in sufficient detail to enable those skilled in the art to practice the invention. Thus, where appropriate to avoid obscuring the invention, the description may omit certain information known to those of skill in the art.
[0029] More specifically, this description includes four sections, a definition section that defines certain terms used throughout the description and three sections actually describing the invention. The first section describes a preferred embodiment of new structures for n-and p-type dynamic threshold transistors. The second section describes a preferred method of making these structures, and the third section describes several integrated-circuit applications for complementary dynamic threshold transistors.
Definitions
[0030] The description includes many terms with meanings derived from their usage in the art or from their use within the context of the description. As a further aid, the following term definitions are presented.
[0031] The term “substrate,” as used herein, encompasses semiconductor wafers as well as structures having one or more insulative, semi-insulative, conductive, or semiconductive layers and materials. Thus, for example, the term embraces not only the silicon-on-insulator structure of this preferred embodiment, but also silicon-on-sapphire and other advanced structures. “Horizontal,” as used herein, refers to a direction substantially parallel to a supporting surface of the substrate, regardless of substrate orientation. “Vertical,” as used herein, generally refers to any direction that is not horizontal.
[0032] Preferred Structure for Complementary Dynamic Threshold Transistors
[0033] [0033]FIGS. 1A, 1B, and 1 C respectively show perspective, top, and side views of a preferred integrated-circuit assembly 10 comprising complementary n- and p-type dynamic threshold transistors 14 N and 14 P. Both transistors feature gate-to-body capacitive coupling implemented through transistor sidewall capacitors 26 b and 26 c (highlighted in FIG. 1C.) In the preferred embodiment, the capacitance of each sidewall capacitor is approximately equal to the transistor gate capacitance.
[0034] More specifically, assembly 10 includes a substrate 12 having two stacked, or superimposed, layers: a p-doped silicon layer 12 a and a silicon dioxide insulative layer 12 b . Supported on substrate 12 are respective NMOS and PMOS dynamic threshold transistors 14 N and 14 P. The transistors are separated on substrate 12 by isolation region 15 , best illustrated in FIGS. 1B and 1C. Transistor 14 N, which differs from transistor 14 P only in terms of semiconductor doping, includes three layers of semiconductive material. The first layer, a p-type semiconductive body (or bulk) 16 , contacts substrate 12 , specifically insulative layer 12 b . Atop p-type body 16 is a second layer 18 of lightly doped, p-type semiconductive material (P−), and atop layer 18 is a third layer 20 of heavily doped n-type semiconductive material (N+). Layer 20 has two regions 20 d and 20 s , which respectively serve as drain and source regions of transistor 14 N. The drain and source regions are also shown in the top view of FIG. 1B.
[0035] Transistor 14 N also includes an insulative saddle structure 22 atop layer 20 . Saddle structure 22 , shown best in the side view of FIG. 1C, has a middle region 22 a that connects insulative sidewall regions 22 b and 22 c . Middle region (or section) 22 a contacts a region of layer 20 , the channel region, between drain and source regions 20 d . And insulative sidewall regions 22 b and 22 c contact opposing lateral semiconductive surfaces of layers 16 , 18 , and 20 . Middle region 22 a functions as a gate insulator. In the preferred embodiment, insulative saddle structure 22 consists essentially of silicon dioxide or another electrical insulator.
[0036] Atop insulative saddle structure 22 is a conductive saddle structure 24 , preferably formed of polysilicon. FIG. 1C shows that, like insulative saddle structure 22 , conductive saddle structure 24 has a conductive middle region 24 a connecting conductive sidewalls 24 b and 24 c . Conductive middle region 24 a , which forms a gate region 24 a of transistor 14 , contacts middle region 22 a of insulative saddle structure 22 . Conductive sidewalls 24 b and 24 c contact respective insulative sidewalls 22 b and 22 c which space the conductive sidewalls from adjacent lateral surfaces of semiconductive layers 16 , 18 and 20 .
[0037] Conductive sidewalls 24 b and 24 c , together with corresponding insulative sidewalls 22 b and 22 c and the opposing lateral semiconductive surfaces of layers 16 , 18 , and 20 form respective twin vertical sidewall capacitors 26 b and 26 c . (In geometric terms, the vertical sidewalls define respective planes that intersect or are non-parallel to the supporting surface of substrate 12 .) In the preferred embodiment, the sidewalls are substantially perpendicular, or normal, to the supporting surface. The conductive sidewalls 24 b and 24 c and semiconductive lateral surfaces of layers 16 , 18 , and 20 serve not only as parallel conductive plates of the twin vertical sidewall capacitors 26 b and 26 c , but also as conductive leads, connecting the vertical sidewall capacitors to gate region 24 a , and thereby capacitively coupling gate region 24 a of transistor 14 N to its body layer 16 . (Gate region 24 a , gate insulator 22 a , and semiconductive layer 20 also provide a gate capacitance.)
[0038] One advantage of the vertical sidewall construction of capacitor 26 is its use of space in the normally unused isolation region 15 between transistors 14 N and 14 P. Sidewall conductors 24 b and 24 c and respective insulative, or dielectric, layers 22 b and 22 c extend outwardly, or widthwise, from the lateral surfaces of the transistors into the isolation region. This arrangement, which essentially affixes or attaches the vertical capacitors to the sides of the transistors, consumes a minimum of substrate surface area. In contrast, a conventional integrated-circuit capacitor lies horizontally with its two conductive plates essentially parallel to a supporting substrate, and thus typically occupies a greater surface area to provide similar capacitance. Moreover, instead of requiring parallel plates separate from other features of the integrated circuit assembly, the present invention uses the existing lateral semiconductive surfaces of the transistor itself as a plate, providing not only further space savings but also fabrication savings.
[0039] [0039]FIG. 1D shows an equivalent circuit for the dynamic threshold transistors 14 N and 14 P. Notably, the gate-to-body coupling capacitance is shown as twin capacitors 26 b and 26 c to denote the preferred space-saving structure of the present invention. In operation, capacitors 26 b and 26 c appear as short circuits to a switching signal level at gate 24 a and as open circuits when the signal reaches its steady-state level. As short circuits, the capacitors enable concurrent forward biasing of both the gate 24 a (the frontgate) and the backgate formed by layers 18 and 16 . Concurrent forward biasing of the frontgate and backgate effectively lowers threshold voltage relative to input voltage and thus accelerates activation of the transistor. In a sense, concurrent forward biasing forms the conductive channel region from front and back directions, thereby amplifying or accelerating the effect of a given gate voltage. Thus, in keeping with the dynamic threshold concept, the transistors 14 N and 14 P provide effectively lower thresholds during switching episodes and higher thresholds, based on conventional doping techniques, during steady state.
The Preferred Method of Making
Complementary Dynamic Threshold Transistors
[0040] FIGS. 2 - 8 show a number of preferred integrated-circuit assemblies, which taken collectively and sequentially, illustrate a preferred method of making an integrated-circuit assembly substantially similar to space-saving assembly 10 . Although the preferred method conforms to 0.2-micron CMOS technology, the exemplary dimensions are scalable, both upwardly and downwardly.
[0041] The first steps of the method form the integrated-circuit assembly of FIG. 2. These steps, which entail defining NMOS and PMOS device regions in a semiconductor substrate, start with a positively doped silicon substrate or wafer 30 , form a thermal screen layer 32 , preferably a 10-nanometer-thick layer of silicon dioxide on substrate 30 , and then implant a p-type dopant into substrate 30 to a depth of about 0.4 microns. The implantation defines a retrograde doping profile, with dopant concentrations increasing with distance from the upper substrate surface. Next, the method defines an N-well device region 36 on p-doped silicon substrate 30 by applying photo resist mask 34 on thermal screen layer 32 and etching according to conventional techniques. The method then forms an n-well 38 within device region 36 by implanting an n-type dopant, again achieving a retrograde doping profile.
[0042] The next steps yield the integrated-circuit assembly of FIG. 3, which includes N-channel and P-channel device islands 47 and 48 . Specifically, the method strips away mask 34 and screen layer 32 , exposing n-well 38 . The method next forms a gate isolation (or insulation) layer 40 , preferably consisting of silicon dioxide. Subsequently, the method forms a heavily positively doped p-type (P+) gate region 42 P and heavily positively doped n-type (N+) gate region 42 N on respective regions 40 N and 40 P of gate isolation layer 40 . Forming the gate regions entails forming a 0.1-micron-thick polysilicon layer over both the device regions, masking and doping gate region 42 P and then masking and doping gate region 42 N. A cap layer 44 of silicon nitride, approximately 0.1 micron thick, is then formed on the gate regions 42 N and 42 P, to protect them during subsequent steps.
[0043] Finally, to form device islands 47 and 48 , which have respective pairs of opposing vertical sidewalls, the method applies an etch-resistant mask (not shown) defining the perimeter of the islands and then etches through cap layer 44 , polysilicon gate regions 42 P and 42 N, gate oxide layer 40 , and into substrate 30 approximately as deep as n-well 38 . As FIG. 3 shows, device islands 47 and 48 are separated by an isolation region 49 (similar to region 15 shown in FIG. 1C.)
[0044] [0044]FIG. 4 shows the results of the next steps which isolate NMOS and PMOS device islands 47 and 48 from underlying substrate 30 with an insulative layer 50 of silicon dioxide. Although there are a variety of techniques for achieving this isolation, the inventors prefer the Noble method disclosed in co-pending U.S. patent application Ser. No. 08/745,708 entitled “Silicon-on-Insulator Islands and Methods for Their Formation” filed on Nov. 12, 1996. Another method is disclosed in U.S. Pat. No. 5,691,230 entitled Technique for Producing Small Islands of Silicon on Insulator” issued Nov. 11, 1997 to Leonard Forbes. Both the application and the patent are assigned to the assignee of the present invention and incorporated herein by reference. A by-product of the Noble method is the formation of silicon nitride sidewalls 51 on device islands 47 and 48 .
[0045] As shown in FIG. 5, dielectric (or insulative) sidewalls 52 a - 52 d are then formed on the device islands. In the preferred embodiment, forming the dielectric sidewalls entails first removing silicon nitride sidewalls 51 from the device islands and then growing silicon dioxide or other dielectric material on the sidewalls of the device islands. The preferred thickness of the dielectric sidewalls is the same as gate insulation layer 40 , which is 5-10 nanometers.
[0046] After forming the dielectric sidewalls, the method forms respective conductive vertical sidewalls 54 a - 54 d on corresponding dielectric sidewalls 52 a - 52 d In the preferred method, making the vertical sidewalls entails depositing doped polysilicon and directionally etching the doped polysilicon to remove it from undesired areas, thereby leaving it only on the sidewalls of device islands 47 and 48 .
[0047] The regions between and around device islands 47 and 48 are then filled with a preferentially etchable material 56 , such as intrinsic polysilicon, and subsequently planarized through chemical-mechanical planarization. After planarization, the method removes cap layer 44 to expose polysilicon gates 42 P and 42 N and top inside edges of vertical conductive sidewalls 54 a - 54 d . In other words, removing cap layer 44 also entails removing the top most portion of the dielectric sidewalls to allow contact with the inside edges of the conductive sidewalls. Next, FIG. 6 shows that the method fills the resulting depressions over gates 42 N and 42 P with a refractory metal, preferably tungsten, to form contacts 58 a and 58 b.
[0048] Following removal of excess refractory metal, the method defines drain and source region pairs 60 a - 60 b and 60 c - 60 d for respective device islands 47 and 48 . This entails masking and etching through metal layer 58 , through polysilicon gate regions 42 P and 42 N, through underlying gate insulation layer 40 , and intrinsic polysilicon 56 . After this, the method removes, preferably by gallic acid wet etching, remaining intrinsic polysilicon. The resulting structure is shown in the perspective of FIG. 7, which for sake of clarity omits intrinsic polysilicon 56 .
[0049] [0049]FIG. 8 shows the results of forming source and drain region pairs 60 a - 60 b and 60 c - 60 d in self-alignment with respective gates 42 P and 42 N, according to conventional procedures. Although not shown, further processing would entail conventional passivation and formation of contact holes and wiring to form a full integrated circuit, such as one or more of those described below.
Preferred Circuits For Dynamic Threshold Transistors
[0050] The structure and/or method described above may be used to implement the circuits shown in FIGS. 9 and 10. FIG. 9 shows a logic inverter or buffer circuit 70 useful for pass-gate transistor logic or complementary pass-gate transistor logic, as an output driver or driver for an integrated circuit. Circuit 70 comprises respective input and output nodes 72 and 73 and voltage supply nodes 74 and 75 . In the preferred embodiment, voltage supply node 74 provides a nominal voltage of one-half volt, and voltage supply node 75 provides a nominal voltage of zero volts.
[0051] Circuit 70 also includes respective NMOS and PMOS dynamic threshold transistors 76 and 78 , which are preferably consistent with the space-saving structures and operating principles of integrated-circuit assembly 10 described above with the aid of FIGS. 1 A- 1 D. Transistor 76 includes a field-effect transistor 76 a having a gate, drain, source, and body, and twin gate-to-body coupling capacitors 76 b and 76 c . Similarly, transistor 78 comprises a field-effect transistor 78 a and twin gate-to-body coupling capacitors 78 b and 78 c . The gates of transistors 76 a and 78 a are connected together to form input 72 ; and their drains are connected together to form output 73 . The source of transistor 76 a connects to supply node 74 and the source of transistor 78 a connects to supply node 75 .
[0052] In operation, circuit 70 performs as an inverter, providing a nominal half-volt output at output 73 in response to a nominal zero-volt input at input 72 and a zero-volt output in response to a half-volt input. However, gate-to-body coupling capacitors 76 b - 76 c and 78 b - 78 c play a significant role during input-voltage transitions.
[0053] More precisely, during positive input transitions (that is, from low to high), these capacitors approximate short circuits between the gates and bodies of transistors 76 a and 78 a , thereby forward biasing the backgate of (n-channel) transistor 78 a , and reverse biasing the backgate of (p-channel) transistor 76 a . Forward biasing the backgate of transistor 78 a effectively lowers its threshold voltage relative the input voltage, and thus accelerates activation, or turn on, of transistor 78 a . Consequently, the voltage at output 73 begins decreasing more rapidly toward the voltage at supply node 75 , zero volts in the preferred embodiment. After switching, the gate-to-body capacitance discharges, thereby reverse biasing the backgate and restoring the threshold voltage. Similarly, a negative voltage transition at input 72 temporarily forward biases the backgate of (p-channel) transistor 76 a and thus accelerates its activation and the associated increase in the output voltage toward the voltage at upper supply node 74 , one-half volt in the preferred embodiment.
[0054] Estimates are that the gate-to-body capacitive coupling in circuit 70 will yield peak switching currents about five times larger than conventional low-voltage circuits lacking gate-to-body capacitive coupling. Ultimately, such peak-current increases translate into a three-fold increase in switching rates. Moreover, unlike previous efforts that directly shorted the gate and body to permanently forward bias the backgate junctions and thus drew current continuously, circuit 70 only forward biases the backgate junctions temporarily.
[0055] [0055]FIG. 10 illustrates a dynamic-random-access-memory (DRAM) circuit 80 suitable for one-half-volt (or lower) power-supply voltages. In addition to conventional DRAM features, such as a memory array 82 which comprises a number of memory cells 83 , a column address decoder 84 , and a row address decoder 85 , and associated bit lines 86 and word lines 87 , DRAM circuit 80 includes a novel voltage-sense-amplifier circuit 90 coupled in conventional fashion to bit lines 86 .
[0056] Voltage-sense-amplifier circuit 90 includes two cross-coupled inverters 70 A and 70 B, each similar to circuit 70 shown in FIG. 9. Thus, the backgates or bodies of each inverter transistor are capacitively coupled to its input, thereby providing the circuit 80 with the peak switching current and switching rates advantages of circuit 70 .
[0057] More specifically, circuit 90 further includes a bit-line node 92 coupled to a first bit-line 86 a , and a bit-line node 94 coupled to a second bit line 86 b , and two power supply nodes 96 and 97 . Bit-line node 92 connects to input node 72 A of circuit 70 A, and output node 73 B of circuit 70 B. Bit-line node 94 connects to input node 72 B of circuit 70 B, and output node 73 A of circuit 70 A. Power supply nodes 96 and 97 , which preferably provide respective nominal voltages of one-half and zero volts, are coupled to corresponding supply nodes 74 A- 74 B and 75 A- 75 B. With the exception of its dynamic thresholding which provides superior switching current and switching rate at low operating voltages, circuit 90 operates according to well-known and understood principles to sense data stored in memory cells 83 .
Conclusions
[0058] The present invention provides a space-saving structure and fabrication method for achieving gate-to-body capacitive coupling in n- and p-channel transistors. Instead of using common horizontal capacitor structures to achieve the capacitive coupling, the invention uses vertical, that is, non-horizontal, capacitors, which require less substrate area. Moreover, the invention places these vertical capacitors in the isolation region between adjacent transistors. And, for even greater savings, the invention uses a lateral semiconductive surface (or sidewall) of the transistor as a conductive plate of the gate-to-body coupling capacitor. Furthermore, transistors incorporating gate-to-body capacitive coupling provide superior switching speed with low-operating voltages, ultimately enabling practical half-volt inverters, buffers, sense amplifiers, memory circuits, etc.
[0059] The embodiments described above are intended only to illustrate and teach one or more ways of implementing or practicing the present invention, not to restrict its breadth or scope. The actual scope of the invention, which includes all ways of implementing or practicing the invention, is defined only by the following claims and their equivalents.
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Many integrated circuits, particularly digital memories, include millions of field-effect transistors which operate simultaneously and thus consume considerable power. One way to reduce power consumption is to lower transistor threshold, or turn-on, voltage, and then use lower-voltage power supplies. Although conventional techniques of lowering threshold voltage have enabled use of 2-volt power supplies, even lower voltages are needed. Several proposals involving a dynamic threshold concept have been promising, but have failed, primarily because of circuit-space considerations, to yield practical devices. Accordingly, the present invention provides a space-saving structure for a field-effect transistor having a dynamic threshold voltage. One embodiment includes a vertical gate-to-body coupling capacitor that reduces the surface area required to realize the dynamic threshold concept. Other embodiments include an inverter, voltage sense amplifier, and a memory. Ultimately, the invention facilitates use of half-volt (or lower) power supplies.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a Division of U.S. patent application Ser. No. 11/367,330, filed on Mar. 6, 2006, now U.S. Pat. No. 7,267,129, which is a Division of U.S. patent application Ser. No. 10/632,962 filed on Aug. 4, 2003, now U.S. Pat. No. 7,007,702, which is a division of application Ser. No. 10/164,424 filed on Jun. 10, 2002, now U.S. Pat. No. 6,858,092. Application Ser. No. 10/164,424 is a Division of U.S. patent application Ser. No. 09/556,426 filed on Apr. 24, 2000, now U.S. Pat. No. 6,435,200. The entire contents of the above-identified applications are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
The invention relates to a device and a process for liquid treatment of a defined section of wafer-shaped article, a section near the edge, especially of a wafer.
The reason for treatment of a defined section of wafer-shaped article near the edge, especially of a wafer, will be described below.
A wafer, for example a silicon wafer, can for example have a silicon dioxide coating on all sides. For subsequent processes (if for example a layer of gold or a layer of polysilicon (polycrystalline silicon) is to be applied), it can be necessary to remove the existing coating from the wafer at least in the edge area of the main surface, but optionally also in the area of its peripheral surface and/or the second main surface. This is done by etching processes which can be divided mainly into dry etching processes and wet etching processes.
Another application is the cleaning of wafers. Here it can be necessary to clean a wafer at least in the edge area of a main surface, but optionally also in the area of its peripheral surface and/or the second main surface, i.e. to remove particles and/or other contamination. This is done by wet cleaning processes.
The invention is aimed at wet etching and wet cleaning (combined under the concept of liquid treatment). In doing so the surface area of the wafer to be treated is wetted with the treatment liquid and the layer which is to be removed or the impurities are carried off.
A device for executing this liquid treatment is described for example in U.S. Pat. No. 4,903,717. In this device the wafer-shaped article (wafer) is mounted on a spin chuck. The treatment liquid, for example, an etching liquid, is applied to the wafer surface to be treated, the liquid is distributed as a result of the rotational motion of the wafer over its surface and is flung off laterally over the edge of the wafer.
To prevent the treatment liquid from reaching the surface which is not be to treated in an uncontrolled manner, in U.S. Pat. No. 4,903,717 a chuck is proposed which flushes the surface which faces the chuck and which is not to be treated with a gas. In doing so the gas emerges between the wafer edge and the chuck.
JP 09-181026 A describes a chuck for semiconductor wafers which outside of an annular nozzle has a special shape, for example an annular step which falls away to the outside or a bevelling of its edge. In addition, a suction opening is proposed. This shaping of the intake opening is designed to influence (reduce) the flow velocity in the edge area. This is intended to serve such that the treatment liquid which has been applied from overhead flows beyond the edge of the wafer onto the side facing the chuck and treats the edge area there.
Regardless of whether a means to hold the wafer-shaped article (chuck) is used as claimed in U.S. Pat. No. 4,903,717 or JP 09-181026 A, an edge area of 1.5 mm (measured from the outer edge of the wafer) at most can be treated on the main surface facing the chuck. The liquid afterwards flows back in the direction of the wafer edge and is flung off by it.
SUMMARY OF THE INVENTION
Accordingly the object of the invention is to demonstrate one possibility for treating a defined, edge-side area with a liquid on one surface of a wafer-shaped article and it is also to be possible to treat an edge area of more than 2 mm (measured from the outside edge of the wafer).
Accordingly, the invention in its general embodiment proposes a device for liquid treatment of a defined section of a wafer-shaped article, especially a wafer, near the edge, with a means for holding the wafer-shaped article, with a gas feed means for at least partial gas flushing of the surface of the wafer-shaped article which faces the means, in which on the peripheral side there is a gas guide device which routes most of the flushing gas in the edge area of the wafer-shaped article away from the latter.
The holding means (chuck) is used to hold the wafer for this purpose. Here holding can be done using a vacuum or the wafer floats on an air cushion and is prevented from sliding off sideways by lateral guide elements.
The wafer can also be held by the gas which flows past on the bottom of the wafer forming a negative pressure (also called the Bernoulli effect) by which the wafer experiences a force in the direction of the chuck. The wafer is touched by an elevated part of the chuck within the gas feed device, by which the wafer is prevented from sliding off sideways.
Via the gas feed line the gas can be routed onto the bottom (the surface which faces the chuck) of the wafer-shaped article (wafer) in order to prevent the liquid from reaching this bottom and thus executing unwanted treatment. The gas used for this purpose should be inert to the surface onto which it is flowing; for example, nitrogen or extremely pure air are suited.
The gas feed means can consist of one or more nozzles or an annular nozzle. These nozzles should be attached symmetrically to the center of the chuck in order to enable uniform gas flow over the entire periphery.
The gas guide device is used to route the gas which flows from the middle part of the chuck in the direction of the edge of the wafer away from the edge area. The gas now flows past the side of the gas guide device which faces away from the wafer-shaped article. The farther inside (towards the center of the chuck) this gas guide device is attached, the larger the edge area is at this point.
Since in the section of the bottom of the wafer near the edge essentially gas can no longer flow to the outside, in treatment with the liquid the latter can flow around the wafer edge onto the bottom and thus can wet the section of the wafer bottom near the edge.
The advantage of the invention over the prior art is that the size of the section near the edge can be any size desired by means of suitable selection of the gas guide device.
The gas stream which flows past the gap between the gas guide device and the wafer can produce a negative pressure within the gap by suitable shaping of the gas guide, by which in addition in the edge area the gas flows from the vicinity of the wafer edge to the inside. During liquid treatment the liquid is thus sucked into the edge area.
In one embodiment the gas guide device has the shape of a ring. This ring can be attached to the base body of the chuck using for example three or more spacers. But it can also be machined out of the base body by corresponding milling.
The ring in one embodiment has an inside diameter which is smaller than the outside diameter of the wafer-shaped article and an outside diameter which is at least the same size as the outside diameter of the wafer-shaped article.
In this way the liquid which flows around the peripheral-side edge of the wafer-shaped article (around the wafer edge) can be captured by the ring and delivered to the inside.
The gas guide device can also be formed by an annular groove which is concentric to the periphery of the means and from which the gas is discharged to the outside. This can be ensured by simple holes which lead to the outside from the bottom of the groove in the base body of the chuck.
In another embodiment the gas guide device on its inner periphery has a sharp edge (edge angle less than 60°). In this way almost all the gas can be routed away in the edge area from the wafer.
In one embodiment the part of the means which is located between the gas feed means and the gas guide device (base body) is located at a greater distance to the wafer-shaped article (wafer) than the gas guide device to the wafer-shaped article. In this way more gas can flow between the wafer and this part (base body) than between the wafer and the gas guide device. Most of the gas on the side of the gas guide device facing away from the wafer must therefore flow past this device.
Advantageously the gas guide device is configured such that if there is a wafer-shaped article (wafer) on the chuck the gas guide device does not touch the wafer-shaped article (wafer), i.e. a gap remains between the wafer and the ring.
This gap between the gas guide device and the wafer-shaped article in one embodiment is 0.05 to 1 mm, advantageously 0.1 to 0.5 mm. In this way, between the wafer and the gas guide device a type of capillary forms, from which the liquid which has flowed around the wafer edge is sucked. The inside diameter of the surface which faces the gas guide device and which is wetted by the liquid is smaller than the inside diameter of the annular surface of the gas guide device.
It is advantageous if the surface of the gas guide device facing the wafer-shaped article is parallel to the main surfaces of the wafer-shaped article. The gap between the wafer-shaped article (wafer) and the gas guide device is thus the same size in the entire edge area.
One embodiment calls for the chuck being able to be caused to rotate. This is advantageous, even if not necessary, since the treatment liquid can be flung off both from the chuck and also the wafer edge. If the chuck is not in rotation during liquid treatment, the liquid is entrained or blown off by the gas flow.
Another part of the invention is a process for liquid treatment of a defined area of a wafer-shaped article, especially of a wafer, near the edge. In this process the liquid is applied to a first surface facing the liquid source. The liquid flows essentially radially to the outside to the peripheral-side edge of the wafer-shaped article (wafer edge) and around this edge onto the second surface which faces away from the liquid source. The liquid wets a defined section near the edge on the second surface and is thereupon removed from the wafer-shaped article.
The advantage over the prior art is that in this process the part of the liquid flow which reaches the section of the second surface near the edge also flows on the second surface in a stipulated direction (originating from the edge (wafer edge) in the direction of the wafer middle) and need not flow back again to the edge. Rather the liquid is removed from the inside edge of the section near the edge. This can take place for example with a device as claimed in the invention.
In one embodiment of the process the edge area is chosen to be larger than 2 mm.
In another embodiment of the process the wafer-shaped article during liquid treatment rotates around its axis, by which the treatment liquid is flung off the edge of the wafer-shaped article or the wafer edge.
Advantageously the rotational velocity is at least 100/min in order to effectively fling off the liquid.
BRIEF DESCRIPTION OF THE DRAWINGS
Other details, features and advantages of the invention follow from the description below for the embodiments of the invention which are shown in the drawings.
FIG. 1 schematically shows an axial section of the means (chuck 1 ) including a wafer which is located on it.
FIGS. 2 and 3 schematically show an axial section of the edge area of the chuck. Gas routing is apparent in it. Moreover FIG. 3 shows the motion of the liquid during treatment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The chuck 1 consists essentially of three parts ( 2 , 3 , 4 ), the base body 3 , the cover 2 and the gas guide device 4 . The base body 3 is made annular and is joined to a hollow shaft (not shown) which on the one hand can cause the chuck to rotate (shown by the arrow R) and on the other hand can supply the gas feed means ( 5 , 6 ) with gas G.
The cover 2 is inserted into the base body and is joined to it (not shown) such that between the cover 2 and the base body 3 an annular gas channel 5 is formed which on the top (the side facing the wafer) discharges into an annular gap, the annular nozzle 6 . The diameter of the annular nozzle 6 is smaller than the inside diameter of the gas guide device 4 .
This chuck works according to the “Bernoulli principle”. Outside the annular nozzle 6 (in area 7 ) a gas cushion is formed on which the wafer floats. The wafer is prevented from sliding off sideways by guide elements which are attached on the peripheral side (pins 25 ) and the wafer is entrained by them when the chuck rotates around the axis A. The pins can be moved to rest against the edge of the wafer (compare U.S. Pat. No. 4,903,717).
The gas guide device 4 has the shape of a ring and is attached on the base body 3 on the top (the side facing the wafer) using a plurality of spacers 21 which are distributed regularly on the periphery. The ring 4 has an inside diameter which is smaller than the outside diameter of the wafer W and an outside diameter which is larger than the outside diameter of the wafer W.
The surface 14 of the gas guide device facing the wafer W is a flat annular surface which is parallel to the main surfaces of the wafer. Between the surface 14 and the surface of the wafer facing the chuck, when the wafer is located on the chuck, an annular gap 10 is formed. The depth of the gap c ( FIG. 3 ) corresponds to the difference of the outside radius of the wafer W and the inside radius of the gas guide device 4 . The width a ( FIG. 2 ) is formed by the distance from the surface 14 to the wafer surface facing the chuck.
Between the gas guide device 4 and the base body 3 an annular gas discharge channel 8 is formed into which the gas is discharged by the gas guide device 4 . The total cross section of the gap 10 is much smaller than that of the gas discharge channel 8 , by which the channel can discharge most of the gas.
In the area 7 between the wafer W and the base body 3 or between the annular nozzle 6 and the gas guide device 4 the gas flows directly along the wafer surface facing the chuck. The narrowest cross section in this area is located between the surface 13 (the surface of the base body 3 facing the wafer) and the wafer and is shown in FIG. 2 by b. The distance b of the base body 3 to the wafer is larger than the distance a of the gas guide device to the wafer. The surface 12 of the cover 3 facing the wafer is located essentially in the same plane as the surface 13 of the base body.
If the wafer is located on the chuck, it is held suspended by the gas cushion in area 7 , its touching neither the cover 2 nor the gas guide device 4 . The gas escapes from the annular nozzle 6 (gas flow G 1 ) and is discharged via the gas discharge channel 8 (gas flow G 2 ). A small amount of gas can escape via the gap 10 , but a negative pressure is probably produced by the gas flow G 2 , by which even gas from the vicinity is intaken via the gap 10 and is entrained by the gas flow G 2 .
During liquid treatment the liquid is applied to the surface facing the chuck 1 , the liquid then flows in the direction of the wafer edge (liquid flow F) and around the wafer edge E. When the wafer rotates some of the liquid can be flung off directly from the wafer edge (not shown). Then the liquid flow is divided into two flows F 1 and F 2 . The liquid flow F 1 flows away from the wafer.
The liquid flow F 2 flows into the gap 10 and thus wets the bottom of the wafer. F 2 wets the edge area of this surface somewhat farther than the gas guide device extends to the inside. Therefore the wetted area d is somewhat larger than the depth of the gap c. Here the liquid flow F 2 is deflected by the gas flow G 2 around the inner edge of the gas guide device and the liquid flow F 2 and the gas flow G 2 leave the chuck jointly via the gas discharge channel.
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A device for liquid treatment of a defined area of a wafer-shaped article, especially of a wafer, near the edge, in which the liquid is applied to a first surface, flows essentially radially to the outside to the peripheral-side edge of the wafer-shaped article and around this edge onto the second surface, the liquid wetting a defined section near the edge on the second surface and thereupon being removed from the wafer-shaped article.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the priority benefit of U.S. Provisional Application No. 60/387,637, filed Jun. 11, 2002, the disclosure of which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
The present invention relates generally to processes for the asymmetric synthesis of amino-pyrrolidinones, such pyrrolidinones being useful as intermediates for MMP and TACE inhibitors.
BACKGROUND OF THE INVENTION
Amino-pyrrolidinones of the type shown below are currently being studied as MMP and TACE inhibitors in clinical settings. As one of ordinary skill in the art understands, clinical trials and NDA submissions require practical, large-scale synthesis of the active drug.
Consequently, it is desirable to find new synthetic procedures for making amino-pyrrolidinones.
SUMMARY OF THE INVENTION
Accordingly, the present invention provides a novel intermediate for making an amino-pyrrolidinone.
The present invention provides a novel amino-pyrrolidinone.
The present invention provides a novel process for making amino-pyrrolidinones.
These and other objects, which will become apparent during the following detailed description, have been achieved by the inventors' discovery that novel compounds of formula II can be formed from novel compounds of formula I.
DETAILED DESCRIPTION OF THE INVENTION
Thus, in an embodiment, the present invention provides a novel process of forming a compound of formula II, comprising:
(a) contacting a compound of formula I with a strong base in the presence of a first solvent, wherein the first solvent is an aprotic solvent;
(b) contacting the resulting solution from (a) with an aminating reagent, wherein the aminating reagent is an electrophilic nitrogen source; and,
(c) if necessary, treating the amination product of (b) by reducing, hydrolyzing, or a combination thereof to form a compound of formula II;
wherein:
R f is absent;
R y is selected from H, OH, C 1-6 alkyl, and C 3-12 cycloalkyl;
R z is selected from H, C 1-6 alkyl, and C 3-12 cycloalkyl;
alternatively, R f is O, R z is absent, and R y forms a C 3-12 cycloalkyl group double bonded to the nitrone nitrogen or is a carbon atom double bonded to the nitrone nitrogen and substituted with R 6 and R 7 ;
R 6 is C 1-6 alkyl or C 3-12 cycloalkyl;
R 7 is C 1-6 alkyl or C 3-12 cycloalkyl;
R 1 is Z—U a —X a —Y a —Z a ;
Z is phenyl or pyridyl substituted with 1-5 R b ;
U a is absent or is selected from O and NR a ;
X a is absent or is selected from C 1-10 alkylene, C 2-10 alkenylene, and C 2-10 alkynylene;
Y a is absent or is selected from O and NR a ;
Z a is selected from H, C 3-13 carbocyclic residue substituted with 0-5 R c , and a 5-14 membered heterocyclic system containing from 1-4 heteroatoms selected from the group consisting of N, O, and S, and substituted with 0-5 R c ;
R 2 is H;
R 3 is selected from H, Q, C 1-10 alkylene-Q, C 2-10 alkenylene-Q, C 2-10 alkynylene-Q, (CRR x ) r1 O(CRR x ) r —Q, and (CRR x ) r1 NR a (CRR x ) r —Q;
Q is selected from H and a C 3-13 carbocyclic residue substituted with 0-5 R d ;
R, at each occurrence, is independently selected from H, CH 3 , CH 2 CH 3 , CH═CH 2 , CH═CHCH 3 , and CH 2 CH═CH 2 ;
R x , at each occurrence, is independently selected from H, CH 3 , CH 2 CH 3 , and CH(CH 3 ) 2 ;
R 4 is selected from H, C 1-10 alkylene-H, C 2-10 alkenylene-H, C 2-10 alkynylene-H, (CRR x ) r1 O(CRR x ) r —H, and (CRR x ) r1 NR a (CRR x ) r —H;
alternatively, R 3 and R 4 combine to form a C 3-13 carbocyclic residue substituted with R 4a and 0-3 R b ;
R 4a is U a —X a —Y a —Z a ;
R 5 is selected from H, C 1-6 alkyl, phenyl, and benzyl;
R a , at each occurrence, is independently selected from H, C 1-4 alkyl, phenyl, and benzyl;
R a1 , at each occurrence, is independently selected from H, C 1-4 alkyl, phenyl, and benzyl;
R a2 , at each occurrence, is independently selected from H, C 1-4 alkyl, benzyl, C 3-7 carbocyclic residue, and a 5 to 6 membered heteroaromatic ring containing 1-4 heteroatoms selected from the group consisting of N, O, and S;
alternatively, R a and R a1 taken together with the nitrogen to which they are attached form a 5 or 6 membered ring containing from 0-1 additional heteroatoms selected from the group consisting of N, O, and S;
R b , at each occurrence, is independently selected from C 1-6 alkyl, OR a , Cl, F, Br, I, CN, NR a R a1 , S(O) 2 NR a R a1 , CF 3 , and CF 2 CF 3 ;
R c , at each occurrence, is independently selected from C 1-6 alkyl, OR a , F, NR a R a1 , CF 3 , and CF 2 CF 3 ;
R d , at each occurrence, is independently selected from C 1-6 alkyl, OR a , F, NR a R a1 , S(O) 2 NR a R a1 , CF 3 , and CF 2 CF 3 ;
n is selected from 0, 1, 2, and 3;
r, at each occurrence, is selected from 0, 1, 2, 3, 4, and 5; and,
rl, at each occurrence, is selected from 0, 1, 2, 3, 4, and 5.
In a preferred embodiment, the present invention provides a novel process, wherein (c) is performed by reducing the amination product from (b) to form a compound of formula II, wherein:
R y is selected from H, C 1-6 alkyl, and C 3-12 cycloalkyl; and,
R z is selected from H, C 1-6 alkyl, and C 3-12 cycloalkyl.
In another preferred embodiment, the present invention provides a novel process, wherein (a) is performed in the presence of an inorganic salt selected from a lithium salt, a potassium salt, and a sodium salt; and (c) is performed by contacting the amination product from (b) with a reducing agent and an acid;
the compound of formula I is the compound of formula Ia:
the compound of formula II is a compound of formula IIa:
the strong base is selected from an alkyl lithium, lithium amide, hydride base, and an organometallic base;
the first solvent is selected from an ethereal solvent, a hydrocarbon solvent, and an aromatic hydrocarbon solvent;
the aminating reagent is selected from a chloro-nitroso compound, a sulfonyl azide, a nitroso compound, an azodicarboxylate, a sulfonamide, and an oxaziridine compound;
the reducing agent is selected from zinc and iron;
the acid is selected from formic acid, acetic acid, and methanesulfonic acid;
wherein:
R y is H;
R z is H;
U a is absent or is O;
X a is absent or is C 1-4 alkylene;
Y a is absent;
Z a is selected from H, C 5-6 carbocyclic residue substituted with 0-2 R c , and a 5-10 membered aromatic heterocyclic system containing from 1-4 heteroatoms selected from the group consisting of N, O, and S, and substituted with 0-2 R c ; and,
R b , at each occurrence, is independently selected from C 1-4 alkyl, OR a , Cl, F, NR a R a1 , and CF 3 ;
R c , at each occurrence, is independently selected from C 1-4 alkyl, OR a , F, NR a R a1 , and CF 3 ; and,
R 5 is H or C 1-6 alkyl.
In another preferred embodiment, the present invention provides a novel process, wherein (b) is performed in the presence of a second solvent and the second solvent is an aprotic solvent;
the inorganic salt is selected from lithium chloride, lithium perchlorate, lithium bromide, lithium iodide, potassium chloride, potassium bromide, potassium iodide, sodium chloride, sodium bromide, and sodium iodide;
the strong base is selected from methyl lithium, ethyl lithium, n-propyl lithium, i-propyl lithium, n-butyl lithium, i-butyl lithium, s-butyl lithium, t-butyl lithium, hexyl lithium, lithium bis(trimethylsilyl)amide, lithium diisopropylamide, lithium 2,2,6,6-tetramethylpiperidine, potassium bis(trimethylsilyl)amide, potassium hydride, and sodium hydride;
the first solvent is selected from tetrahydrofuran, 1,2-dimethoxyethane, t-butylmethyl ether, diethyl ether, and dimethoxymethane;
the second solvent is selected from tetrahydrofuran, 1,2-dimethoxyethane, t-butylmethyl ether, diethyl ether, dimethoxymethane, and toluene;
the aminating reagent is selected from 1-chloro-1-nitrosocyclopentane, 1-chloro-1-nitrosocyclohexane, and 2-chloro-2-nitrosopropane;
the reducing agent is zinc;
wherein:
U a is O;
X a is absent or is CH 2 ;
Z a is H or phenyl; and,
R 5 is H or CH 3 .
In another preferred embodiment, the present invention provides a novel process, wherein:
the inorganic salt is selected from lithium chloride and lithium perchlorate;
the strong base is selected from n-butyl lithium and hexyl lithium;
the first solvent is selected from tetrahydrofuran and 1,2-dimethoxyethane;
the second solvent is toluene; and,
the aminating reagent is selected from 1-chloro-1-nitrosocyclopentane and 1-chloro-1-nitrosocyclohexane.
In another preferred embodiment, the present invention provides a novel process, wherein:
the inorganic salt is lithium chloride;
the strong base is n-butyl lithium;
the first solvent is tetrahydrofuran;
the second solvent is toluene;
the aminating reagent is 1-chloro-1-nitrosocyclopentane; and,
the acid is formic acid.
In another preferred embodiment, the present invention provides a novel process, wherein (c) further comprises:
(c 1 ) esterifying the acid product from b 1 , wherein:
R 5 is C 1-6 alkyl.
In another preferred embodiment, the present invention provides a novel process, wherein in (c 1 ) the esterification is performed by contacting the reduced product with an acid in the presence of an alcohol.
In another preferred embodiment, the present invention provides a novel process, wherein the acid is methanesulfonic acid and the alcohol is methyl alcohol.
In another preferred embodiment, the present invention provides a novel process, further comprising:
(d) subjecting the compound from (c) wherein R y is OH to catalytic hydrogenation with a noble metal catalyst to form a compound of formula II wherein R y is H.
In another preferred embodiment, the present invention provides a novel process, wherein the noble metal catalyst is palladium.
In another embodiment, the present invention provides a novel compound of formula IIb:
wherein:
R z is absent and R y forms a C 3-12 cycloalkyl group double bonded to the nitrone nitrogen or is a carbon atom double bonded to the nitrone nitrogen and substituted with R 6 and R 7 ;
R 6 is C 1-6 alkyl or C 3-12 cycloalkyl;
R 7 is C 1-6 alkyl or C 3-12 cycloalkyl;
R 1 is Z—U a —X a —Y a —Z a ;
Z is phenyl or pyridyl substituted with 1-5 R b ;
U a is absent or is selected from O and NR a ;
X a is absent or is selected from C 1-10 alkylene, C 2-10 alkenylene, and C 2-10 alkynylene;
Y a is absent or is selected from O and NR a ;
Z a is selected from H, C 3-13 carbocyclic residue substituted with 0-5 R c , and a 5-14 membered heterocyclic system containing from 1-4 heteroatoms selected from the group consisting of N, O, and S, and substituted with 0-5 R c ;
R 2 is H;
R 3 is selected from H, Q, C 1-10 alkylene-Q, C 2-10 alkenylene-Q, C 2-10 alkynylene-Q, (CRR x ) r1 O(CRR x ) r —Q, and (CRR x ) r1 NR a (CRR x ) r —Q;
Q is selected from H and a C 3-13 carbocyclic residue substituted with 0-5 R d ;
R, at each occurrence, is independently selected from H, CH 3 , CH 2 CH 3 , CH═CH 2 , CH═CHCH 3 , and CH 2 CH═CH 2 ;
R x , at each occurrence, is independently selected from H, CH 3 , CH 2 CH 3 , and CH(CH 3 ) 2 ;
R 4 is selected from H, C 1-10 alkylene-H, C 2-10 alkenylene-H, C 2-10 alkynylene-H, (CRR x ) r1 O(CRR x ) r —H, and (CRR x ) r1 NR a (CRR x ) r —H;
alternatively, R 3 and R 4 combine to form a C 3-13 carbocyclic residue substituted with R 4a and 0-3 R b ;
R 4 a is U a —X a —Y a —Z a ;
R 5 is selected from H, C 1-6 alkyl, phenyl, and benzyl;
R a , at each occurrence, is independently selected from H, C 1-4 alkyl, phenyl, and benzyl;
R a1 , at each occurrence, is independently selected from H, C 1-4 alkyl, phenyl, and benzyl;
R a2 , at each occurrence, is independently selected from H, C 1-4 alkyl, benzyl, C 3-7 carbocyclic residue, and a 5 to 6 membered heteroaromatic ring containing 1-4 heteroatoms selected from the group consisting of N, O, and S;
alternatively, R a and R a1 taken together with the nitrogen to which they are attached form a 5 or 6 membered ring containing from 0-1 additional heteroatoms selected from the group consisting of N, O, and S;
R b , at each occurrence, is independently selected from C 1-6 alkyl, OR a , Cl, F, Br, I, CN, NR a R a1 , S(O) 2 NR a R a1 , CF 3 , and CF 2 CF 3 ;
R c , at each occurrence, is independently selected from C 1-6 alkyl, OR a , F, NR a R a1 , CF 3 , and CF 2 CF 3 ;
R d , at each occurrence, is independently selected from C 1-6 alkyl, OR a , F, NR a R a1 , S(O) 2 NR a R a1 , CF 3 , and CF 2 CF 3 ;
n is selected from 0, 1, 2, and 3;
r, at each occurrence, is selected from 0, 1, 2, 3, 4, and 5; and,
r1, at each occurrence, is selected from 0, 1, 2, 3, 4, and 5.
In another preferred embodiment, the present invention provides a novel compound, wherein the compound is of formula IIc:
wherein:
R z is absent and R y forms a cyclobutyl, cyclopentyl, or cyclohexyl group double bonded to the nitrone nitrogen;
U a is absent or is O;
X a is absent or is C 1-4 alkylene;
Y a is absent;
Z a is selected from H and phenyl; and,
R 5 is H or C 1-6 alkyl.
In another preferred embodiment, the present invention provides a novel compound of formula IId:
In another preferred embodiment, the present invention provides a novel compound of the formula:
wherein the compound is present in its HCl salt form.
In another preferred embodiment, the present invention provides a novel compound of the formula:
DEFINITIONS
The present invention can be practiced on multigram scale, kilogram scale, multikilogram scale, or industrial scale. Multigram scale, as used herein, is preferable in the scale wherein at least one starting material is present in 10 grams or more, more preferable at least 50 grams or more, even more preferably at least 100 grams or more. Multikilogram scale, as used herein, is intended to mean the scale wherein more than one kilo of at least one starting material is used. Industrial scale as used herein is intended to mean a scale which is other than a laboratory sale and which is sufficient to supply product sufficient for either clinical tests or distribution to consumers.
As used herein, the following terms and expressions have the indicated meanings. It will be appreciated that the compounds of the present invention may contain an asymmetrically substituted carbon atom, and may be isolated in optically active or racemic forms. It is well known in the art how to prepare optically active forms, such as by resolution of racemic forms or by synthesis from optically active starting materials. All chiral, diastereomeric, and racemic forms and all geometric isomeric forms of a structure are intended, unless the specific stereochemistry or isomer form is specifically indicated.
As used herein, equivalents are intended to mean molar equivalents unless otherwise specified.
The reactions of the synthetic methods claimed herein are carried out in suitable solvents which may be readily selected by one of skill in the art of organic synthesis, the suitable solvents generally being any solvent which is substantially non-reactive with the starting materials (reactants), the intermediates, or products at the temperatures at which the reactions are carried out, i.e., temperatures which may range from the solvent's freezing temperature to the solvent's boiling temperature. A given reaction may be carried out in one solvent or a mixture of more than one solvent. Depending on the particular reaction step, suitable solvents for a particular reaction step may be selected.
Suitable polar solvents include, but are not limited to, ether and aprotic solvents.
Suitable ether solvents include: dimethoxymethane, tetrahydrofuran, 1,3-dioxane, 1,4-dioxane, furan, diethyl ether, 1,2-dimethoxyethane, diethoxymethane, dimethoxymethane, ethylene glycol dimethyl ether, ethylene glycol diethyl ether, diethylene glycol dimethyl ether, diethylene glycol diethyl ether, triethylene glycol dimethyl ether, or t-butyl methyl ether.
Suitable aprotic solvents may include, by way of example and without limitation, ether solvents, tetrahydrofuran (THF), dimethylformamide (DMF), 1,2-dimethoxyethane, diethoxymethane, dimethoxymethane, dimethylacetamide (DMAC), benzene, toluene, 1,3-dimethyl-3,4,5,6-tetrahydro-2(1H)-pyrimidinone (DMPU), 1,3-dimethyl-2-imidazolidinone (DMI), N-methylpyrrolidinone (NMP), formamide, N-methylacetamide, N-methylformamide, acetonitrile, dimethyl sulfoxide, propionitrile, ethyl formate, methyl acetate, hexachloroacetone, acetone, ethyl methyl ketone, ethyl acetate, sulfolane, N,N-dimethylpropionamide, tetramethylurea, nitromethane, nitrobenzene, or hexamethylphosphoramide.
Suitable hydrocarbon solvents include, but are not limited to, benzene, cyclohexane, pentane, hexane, hexanes, toluene, cycloheptane, methylcyclohexane, heptane, ethylbenzene, m-xylene, o-xylene, p-xylene, octane, indane, nonane, or naphthalene.
As used herein, an alcohol solvent is a hydroxy-substituted compound that is liquid at the desired temperature (e.g., room temperature). Examples of alcohols include, but are not limited to, methyl alcohol, ethyl alcohol, n-propanol, and i-propanol.
As used herein, the term “amino protecting group” (or “N-protected”) refers to any group known in the art of organic synthesis for the protection of amine groups. As used herein, the term “amino protecting group reagent” refers to any reagent known in the art of organic synthesis for the protection of amine groups that may be reacted with an amine to provide an amine protected with an amine-protecting group. Such amine protecting groups include those listed in Greene and Wuts, “Protective Groups in Organic Synthesis” John Wiley & Sons, New York (1991) and “The Peptides: Analysis, Synthesis, Biology, Vol. 3, Academic Press, New York, (1981), the disclosure of which is hereby incorporated by reference. Examples of amine protecting groups include, but are not limited to, the following: 1) acyl types such as formyl, trifluoroacetyl (TFA), phthalyl, and p-toluenesulfonyl; 2) aromatic carbamate types such as benzyloxycarbonyl (cbz) and substituted benzyloxycarbonyls, 2-(p-biphenyl)-1-methylethoxycarbonyl, and 9-fluorenylmethyloxycarbonyl (Fmoc); 3) aliphatic carbamate types such as tert-butyloxycarbonyl (Boc), ethoxycarbonyl, diisopropylmethoxycarbonyl, and allyloxycarbonyl; 4) cyclic alkyl carbamate types such as cyclopentyloxycarbonyl and adamantyloxycarbonyl; 5) alkyl types such as triphenylmethyl and benzyl; 6) trialkylsilane such as trimethylsilane; and 7) thiol containing types such as phenylthiocarbonyl and dithiasuccinoyl.
Amine protecting groups may include, but are not limited to the following: 2,7-di-t-butyl-[9-(10,10-dioxo-10,10,10,10-tetrahydrothio-xanthyl)]methyloxycarbonyl; 2-trimethylsilylethyloxycarbonyl; 2-phenylethyloxycarbonyl; 1,1-dimethyl-2,2-dibromoethyloxycarbonyl; 1-methyl-1-(4-biphenylyl)ethyloxycarbonyl; benzyloxycarbonyl; p-nitrobenzyloxycarbonyl; 2-(p-toluenesulfonyl)ethyloxycarbonyl; m-chloro-p-acyloxybenzyloxycarbonyl; 5-benzyisoxazolylmethyloxycrbonyl; p-(dihydroxyboryl)benzyloxycarbonyl; m-nitrophenyloxycarbonyl; o-nitrobenzyloxycarbonyl; 3,5-dimethoxybenzyloxycrbonyl; 3,4-dimethoxy-6-nitrobenzyloxycarbonyl; N′-p-toluenesulfonylaminocarbonyl; t-amyloxycarbonyl; p-decyloxybenzyloxycarbonyl; diisopropylmethyloxycarbonyl; 2,2-dimethoxycarbonylvinyloxycarbonyl; di(2-pyridyl)methyloxycarbonyl; 2-furanylmethyloxycarbonyl; phthalimide; dithiasuccinimide; 2,5-dimethylpyrrole; benzyl; 5-dibenzylsuberyl; triphenylmethyl; benzylidene; diphenylmethylene; and methanesulfonamide.
As used herein, the term “noble metal catalyst” refers to noble metals, known in the art of organic synthesis, used in catalytic hydrogenation. Examples of noble metal catalysts include, but are not limited to, palladium or platinum.
Preferably, the molecular weight of compounds of the present invention is less than about 500, 550, 600, 650, 700, 750, 800, 850, 900, 950, or 1000 grams per mole. More preferably, the molecular weight is less than about 950 grams per mole. Even more preferably, the molecular weight is less than about 850 grams per mole. Still more preferably, the molecular weight is less than about 750 grams per mole.
The term “substituted,” as used herein, means that any one or more hydrogens on the designated atom is replaced with a selection from the indicated group, provided that the designated atom's normal valency is not exceeded, and that the substitution results in a stable compound. When a substituent is keto (i.e., ═O), then 2 hydrogens on the atom are replaced. Keto substituents are not present on aromatic moieties.
The present invention is intended to include all isotopes of atoms occurring in the present compounds. Isotopes include those atoms having the same atomic number but different mass numbers. By way of general example and without limitation, isotopes of hydrogen include tritium and deuterium. Isotopes of carbon include C-13 and C-14.
When any variable (e.g., R 6 ) occurs more than one time in any constituent or formula for a compound, its definition at each occurrence is independent of its definition at every other occurrence. Thus, for example, if a group is shown to be substituted with 0-2 R 6 , then said group may optionally be substituted with up to two R 6 groups and R 6 at each occurrence is selected independently from the definition of R 6 . Also, combinations of substituents and/or variables are permissible only if such combinations result in stable compounds.
When a bond to a substituent is shown to cross a bond connecting two atoms in a ring, then such substituent may be bonded to any atom on the ring. When a substituent is listed without indicating the atom via which such substituent is bonded to the rest of the compound of a given formula, then such substituent may be bonded via any atom in such substituent. Combinations of substituents and/or variables are permissible only if such combinations result in stable compounds.
As used herein, “alkyl” is intended to include both branched and straight-chain saturated aliphatic hydrocarbon groups having the specified number of carbon atoms. C 1-6 alkyl, is intended to include C 1 , C 2 , C 3 , C 4 , C 5 , and C 6 alkyl groups. Examples of alkyl include, but are not limited to, methyl, ethyl, n-propyl, i-propyl, n-butyl, s-butyl, t-butyl, n-pentyl, and s-pentyl. “Cycloalkyl” is intended to include saturated ring groups, such as cyclopropyl, cyclobutyl, or cyclopentyl. C 3-7 cycloalkyl is intended to include C 3 , C 4 , C 5 , C 6 , and C 7 cycloalkyl groups. Alkenyl” is intended to include hydrocarbon chains of either straight or branched configuration and one or more unsaturated carbon-carbon bonds that may occur in any stable point along the chain, such as ethenyl and propenyl. C 2-6 alkenyl is intended to include C 2 , C 3 , C 4 , C 5 , and C 6 alkenyl groups. “Alkynyl” is intended to include hydrocarbon chains of either straight or branched configuration and one or more triple carbon-carbon bonds that may occur in any stable point along the chain, such as ethynyl and propynyl. C 2-6 Alkynyl is intended to include C 2 , C 3 , C 4 , C 5 , and C 6 alkynyl groups.
“Halo” or “halogen” as used herein refers to fluoro, chloro, bromo, and iodo; “counterion” is used to represent a small, negatively charged species such as chloride, bromide, hydroxide, acetate, and sulfate.
As used herein, “carbocycle” or “carbocyclic residue” is intended to mean any stable 3, 4, 5, 6, or 7-membered monocyclic or bicyclic or 7, 8, 9, 10, 11, 12, or 13-membered bicyclic or tricyclic, any of which may be saturated, partially unsaturated, or aromatic. Examples of such carbocycles include, but are not limited to, cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, adamantyl, cyclooctyl, [3.3.0]bicyclooctane, [4.3.0]bicyclononane, [4.4.0]bicyclodecane, [2.2.2]bicyclooctane, fluorenyl, phenyl, naphthyl, indanyl, adamantyl, and tetrahydronaphthyl.
As used herein, the term “heterocycle” or “heterocyclic system” is intended to mean a stable 5, 6, or 7-membered monocyclic or bicyclic or 7, 8, 9, or 10-membered bicyclic heterocyclic ring which is saturated, partially unsaturated or unsaturated (aromatic), and which consists of carbon atoms and 1, 2, 3, or 4 heteroatoms independently selected from the group consisting of N, NH, O and S and including any bicyclic group in which any of the above-defined heterocyclic rings is fused to a benzene ring. The nitrogen and sulfur heteroatoms may optionally be oxidized. The heterocyclic ring may be attached to its pendant group at any heteroatom or carbon atom that results in a stable structure. The heterocyclic rings described herein may be substituted on carbon or on a nitrogen atom if the resulting compound is stable. A nitrogen in the heterocycle may optionally be quaternized. It is preferred that when the total number of S and O atoms in the heterocycle exceeds 1, then these heteroatoms are not adjacent to one another. It is preferred that the total number of S and O atoms in the heterocycle is not more than 1. As used herein, the term “aromatic heterocyclic system” or “heteroaryl” is intended to mean a stable 5, 6, or 7-membered monocyclic or bicyclic or 7, 8, 9, or 10-membered bicyclic heterocyclic aromatic ring which consists of carbon atoms and 1, 2, 3, or 4 heteroatoms independently selected from the group consisting of N, NH, O and S. It is to be noted that total number of S and O atoms in the aromatic heterocycle is not more than 1.
Examples of heterocycles include, but are not limited to, acridinyl, azocinyl, benzimidazolyl, benzofuranyl, benzothiofuranyl, benzothiophenyl, benzoxazolyl, benzoxazolinyl, benzthiazolyl, benztriazolyl, benztetrazolyl, benzisoxazolyl, benzisothiazolyl, benzimidazolinyl, carbazolyl, 4aH-carbazolyl, carbolinyl, chromanyl, chromenyl, cinnolinyl, decahydroquinolinyl, 2H, 6H-1,5,2-dithiazinyl, dihydrofuro[2,3-b]tetrahydrofuran, furanyl, furazanyl, imidazolidinyl, imidazolinyl, imidazolyl, 1H-indazolyl, indolenyl, indolinyl, indolizinyl, indolyl, 3H-indolyl, isatinoyl, isobenzofuranyl, isochromanyl, isoindazolyl, isoindolinyl, isoindolyl, isoquinolinyl, isothiazolyl, isoxazolyl, methylenedioxyphenyl, morpholinyl, naphthyridinyl, octahydroisoquinolinyl, oxadiazolyl, 1,2,3-oxadiazolyl, 1,2,4-oxadiazolyl, 1,2,5-oxadiazolyl, 1,3,4-oxadiazolyl, oxazolidinyl, oxazolyl, oxindolyl, pyrimidinyl, phenanthridinyl, phenanthrolinyl, phenazinyl, phenothiazinyl, phenoxathinyl, phenoxazinyl, phthalazinyl, piperazinyl, piperidinyl, piperidonyl, 4-piperidonyl, piperonyl, pteridinyl, purinyl, pyranyl, pyrazinyl, pyrazolidinyl, pyrazolinyl, pyrazolyl, pyridazinyl, pyridooxazole, pyridoimidazole, pyridothiazole, pyridinyl, pyridyl, pyrimidinyl, pyrrolidinyl, pyrrolinyl, 2H-pyrrolyl, pyrrolyl, quinazolinyl, quinolinyl, 4H-quinolizinyl, quinoxalinyl, quinuclidinyl, tetrahydrofuranyl, tetrahydroisoquinolinyl, tetrahydroquinolinyl, tetrazolyl, 6H-1,2,5-thiadiazinyl, 1,2,3-thiadiazolyl, 1,2,4-thiadiazolyl, 1,2,5-thiadiazolyl, 1,3,4-thiadiazolyl, thianthrenyl, thiazolyl, thienyl, thienothiazolyl, thienooxazolyl, thienoimidazolyl, thiophenyl, triazinyl, 1,2,3-triazolyl, 1,2,4-triazolyl, 1,2,5-triazolyl, 1,3,4-triazolyl, and xanthenyl. Also included are fused ring and spiro compounds containing, for example, the above heterocycles.
The phrase “pharmaceutically acceptable” is employed herein to refer to those compounds, materials, compositions, and/or dosage forms which are, within the scope of sound medical judgment, suitable for use in contact with the tissues of human beings and animals without excessive toxicity, irritation, allergic response, or other problem or complication, commensurate with a reasonable benefit/risk ratio.
“Stable compound” and “stable structure” are meant to indicate a compound that is sufficiently robust to survive isolation to a useful degree of purity from a reaction mixture, and formulation into an efficacious therapeutic agent.
“Substituted” is intended to indicate that one or more hydrogens on the atom indicated in the expression using “substituted” is replaced with a selection from the indicated group(s), provided that the indicated atom's normal valency is not exceeded, and that the substitution results in a stable compound. When a substituent is keto (i.e., ═O) group, then 2 hydrogens on the atom are replaced.
SYNTHESIS
By way of example and without limitation, the present invention may be further understood by the following schemes and descriptions. Scheme 1 exemplifies how a desired end product can be formed using the presently claimed process and intermediates.
Starting Material: 2-(4-Benzyloxy-phenyl)-pent-4-enoic acid methyl ester can be prepared by alkylating 2-(4-benzyloxy-phenyl)-ethanoic acid methyl ester. The starting ester is deprotonated with a strong base and then alkylated with an allyl alkylating reagent. Preferably, the base is selected from lithium diisopropylamide, lithium hexamethyldisilamide, as well as other lithium bases. More preferably, the base is lithium diisopropylamide or lithium hexamethyldisilamide. Even more preferably, the base is lithium diisopropylamide. Preferably from 0-9 to 1.2 equivalents of base are used, more preferably 1.1. The allyl alkylating agent is preferably allyl bromide or allyl chloride, with allyl bromide being more preferred. Preferably, 0.9 to 2 equivalents of alkylating agent are use, more preferably 1.3. An aprotic solvent is preferably used. Preferred solvents include tetrahydrofuran, dimethylformamide, and diethoxymethane, with tetrahydrofuran being more preferred.
Reaction 1: Compound A can be formed by methods known to those of skill in the art of organic synthesis. For example, it can be formed by subjecting the shown compound to ozonolysis and then quenched. Preferably 1-2 equivalents of ozone are used, more preferably 1. Preferably, the ozonolysis is quenched with Zn. From 1-5 equivalents of Zn are preferred with 2 being more preferred. Generally, an acid is also used to quench the reaction. Preferably, the acid is acetic acid. Other work-ups include using dimethyl sulfide, triphenyl phosphine, and other phosphines known to those of ordinary skill in the art. Solvents including ethyl acetate and methylene chloride can be used. Ethyl acetate is preferred. Compound A need not be a benzyl-protected hydroxy-phenyl moiety. It could be one of numerous starting materials depending on the desired end product, Compound F.
Reaction 2: Lactam B can then be formed by methods known to those of skill in the art of organic synthesis. For example, compound A can be treated with a protected (e.g., methyl ester) amino acid under reductive amination conditions (e.g., NaBH(OAc) 3 ), cyclized to the lactam by heating, and the resulting product deprotected (e.g., LiOH). The protected amino acid used in this sequence will depend in the desired product. One of ordinary skill in the art would recognize that numerous different protected amino acids could be effectively used in this reaction.
Reaction 3: Reaction 3 generally involves two or three reactions: (a) deprotonating compound B, (b) contacting the resulting product with an aminating reagent, and, if desired, (c) converting the resulting intermediate to an amino group (Compound C 2 ) or a hydroxylamine (Compound C 1 ).
Reaction 3(a): Compound B is contacted with a strong base (e.g., n-BuLi) in the presence of a first solvent, wherein the first solvent is an aprotic solvent (e.g., THF). Preferably, the strong base is an alkyl lithium, lithium amide, hydride base, or other organometallic bases. More preferably, the strong base is methyl lithium, ethyl lithium, n-propyl lithium, i-propyl lithium, n-butyl lithium, i-butyl lithium, s-butyl lithium, t-butyl lithium, hexyl lithium, lithium bis(trimethylsilyl)amide, lithium diisopropylamide, lithium 2,2,6,6-tetramethylpiperidine, potassium bis(trimethylsilyl)amide, potassium hydride, or sodium hydride. Even more preferably, the strong base is n-butyl lithium or hexyl lithium. Still more preferably, the strong base is n-butyl lithium.
Preferably, the first solvent, an aprotic solvent, is an ethereal solvent, a hydrocarbon solvent, or an aromatic hydrocarbon solvent. More preferably, the first solvent is tetrahydrofuran, 1,2-dimethoxyethane, t-butylmethyl ether, diethyl ether, or dimethoxymethane. Even more preferably, the first solvent is tetrahydrofuran or 1,2-dimethoxyethane. Most preferably, the first solvent is tetrahydrofuran.
Reaction 3(a) is advantageously performed in the presence of an inorganic salt that is a lithium salt, a potassium salt, or a sodium salt. More preferably, the salt is lithium chloride, lithium perchlorate, lithium bromide, lithium iodide, potassium chloride, potassium bromide, potassium iodide, sodium chloride, sodium bromide, or sodium iodide. Even more preferably, the salt is lithium chloride or lithium perchlorate. Still more preferably, the salt is lithium chloride.
Reaction 3(b): Reaction 3(b) involves the addition of an a chiral aminating reagent diastereoselectively provide the tetra-substituted carbon. The resulting solution from (a) is contacted with an aminating reagent, wherein the aminating reagent is an electrophilic nitrogen source (e.g., 1-chloro-1-nitrosocyclopentane). Preferably, the aminating reagent is a chloro-nitroso compound, a sulfonyl azide, a nitroso compound, an azodicarboxylate, a sulfonamide, or an oxaziridine compound. More preferably, the aminating reagent is 1-chloro-1-nitrosocyclopentane, 1-chloro-1-nitrosocyclohexane, or 2-chloro-2-nitrosopropane. Even more preferably, the aminating reagent is 1-chloro-1-nitrosocyclopentane or 1-chloro-1-nitrosocyclohexane. Still more preferably, the aminating reagent is 1-chloro-1-nitrosocyclopentane.
Reaction 3(b) is preferably performed in the presence of a second solvent, preferably an aprotic solvent. More preferably, the second solvent is tetrahydrofuran, 1,2-dimethoxyethane, t-butylmethyl ether, diethyl ether, dimethoxymethane, benzene, and toluene. Even more preferably, the second solvent is benzene and toluene. Still more preferably, the second solvent is toluene.
The compound resulting from reaction 3(b) has two sterocenters. Preferably, the diastereoselectivity (i.e., de) is 10:1, more preferably 11:1, and even more preferably 13:1.
Reaction 3(c): After amination of Compound B, an aminated product is formed. In a preferred an embodiement the aminated product is a nitrone. The nitrone can be hydrolyzed to a hydroxylamine or reduced to an amino group depending on how it is treated. It is preferable to convert this nitrone to an amino group and esterify the acid group (Compound C 2 ).
The nitrone is reduced to an imine group by the addition of a reducing agent and concomitant hydrolysis and/or alcoholysis affords the amino group (e.g., zinc in the presence of an acid and an alcohol or water). A preferred reducing agent is zinc. Preferred acids used in conjunction with the reducing agent (i.e., zinc) include, but are not limited to, methanesulfonic acid, acetic acid, formic acid, hydrochloric acid, and sulfuric acid. A preferred combination is zinc and formic acid.
Esterification of the amino-acid resulting from nitrone reduction can be accomplished by methods known to those of ordinary skill in the art (i.e., addition of an acid and an alcohol). Esters that can be formed included, but are not limited to, methyl, ethyl, n-propyl, i-propyl, n-butyl, s-butyl, i-butyl, t-butyl, and benzyl. A preferred ester is an alkyl ester. A more preferred ester is methyl ester. Preferably, the methyl ester is formed by the addition of methyl alcohol and methanesulfonic acid. Other acids can be used, such as acetic acid, hydrochloric acid, and sulfuric acid.
The hydroxylamine group is generally obtained by treatment with water and an acid (e.g. methanesulfonic acid, citric acid, or formic acid). It is preferred to conduct this conversion in an alcoholic solvent (e.g., methyl alcohol). The hydroxylamine group can be converted to an amino group by methods known to those of ordinary skill in the art. For example, the hydroxylamine can be reduced to an amino group by the addition of a reducing agent (e.g., zinc in the presence of an acid). A preferred reducing agent is zinc. Preferred acids used in conjunction with the reducing agent (i.e., zinc) include, but are not limited to, methanesulfonic acid, acetic acid, formic acid, hydrochloric acid, and sulfuric acid. A preferred combination is zinc and formic acid.
Reaction 4: Reaction 4 depends on the desired end product, the protecting groups used, and the aminating reagent used. Certain selections of the end product, protecting groups, and aminating reagents can obviate the need for Reaction 4. As shown in Scheme 1, Reaction 4 involves deprotecting the hydroxyl group and, optionally, if the hydroxylamine is present, simultaneously converting it to an amine. The hydroxyl group can be deprotected and the hydroxylamine, if present, simultaneously converted to the amine by methods known to those of ordinary skill in the art. For example, the benzyl group can be removed and the hydroxylamine, if present, can be simultaneously converted to the amine by hydrogenation in the presence of a catalyst (e.g., Pd/C) and a solvent (e.g., methyl alcohol).
Reaction 5: Reaction 5 will depend on the desired end product as well as the protecting groups and aminating agents previously used. As shown in Scheme 1, Reaction 5 can involve treating compound D with a molecule having an appropriate leaving group (e.g., 4-chloromethyl-2-methyl-quinoline). It may also be useful to protect the free amine. For example, Compound D can be treated with an amine protecting agent (e.g., p-tolualdehyde under water removing conditions) and the resulting imine then treated with a molecule having an appropriate leaving group.
Compound E is preferably isolated as a salt. Preferred salts of E include methanesulfonic acid and hydrochloric acid. The hydrochloric acid salt is more preferred.
Reaction 6: Reaction 6 involves replacing the methoxy group with a hydroxylamine group. Suitable hydroxylamines include hydroxylamine hydrochloride and hydroxylamine sulfate. Preferably, hydroxylamine hydrochloride is used. From 1-10 equivalents of hydroxylamine are preferably used. More preferably, 5 equivalents of hydroxylamine are used. Alcohols such as methyl alcohol, t-amyl alcohol, and t-butyl alcohol can be used, methyl alcohol being preferred.
Examples of electrophilic nitrogen sources:
1) Nitrenoids of the type MRN—OR′ (M=metal):
2) Azocarboxylates of the type RCO 2 N═NCO 2 R:
3) Sulfonylazides of the type RSO 2 N 3 :
4) Oxaziridines of the type RCONR 1 :
Alternative methods of making the lactam cores of the present invention are shown below.
The present invention also includes the novel use of a 1-chloro-1-nitrosocyclopentane solution.
Reagents for preparing chloronitroso reagents: Cl 2 , nitrosyl chloride (PhSO 2 NCl 2 ), alkyl-hypochlorite ( t BuOCl), aqueous hypochlorous acid, hypochlorous acid/(1R)-isobornyl ester, NOCl, and N,N′-dichloro-N,N′-dinitro-ethylenediamine.
Solvents for preparing chloronitroso reagents: diethyl ether, benzene, cyclohexane, water, acetic acid, concentrated hydrochloric acid, toluene and ethyl acetate or similar solvents or mixtures thereof.
Halogenated solvents include: CCl 3 F, CH 2 Cl 2 , CHCl 3 , CCl 4 .
Other features of the invention will become apparent in the course of the following descriptions of examplary embodiments which are given for illustration of the invention and are not intended to be limiting thereof.
EXAMPLES
Example 1
Compound A: 2-(4-benzyloxy-phenyl)-4-oxo-butyric acid methyl ester.
Under a nitrogen atmosphere, 2-(4-benzyloxy-phenyl)-pent-4-enoic acid methyl ester (750 g; 2.53 mol) is dissolved in ethyl acetate (7.5 L), and the resulting mixture cooled to −70° C. Ozone is introduced subsurface into the reaction for 3 h causing the reaction mixture to turn blue. The reaction mass is purged subsurface with nitrogen for 0.5 h to displace any residual ozone. At this point HPLC analysis indicates complete consumption of the starting material. The reaction mixture is warmed to −30° C. and held. In a separate vessel, zinc (450 g; 6.88 mol) and aqueous acetic acid (500 mL in 500 mL water) are combined and cooled to 0° C. The contents of the ozonolysis reactor are added to the aqueous acidic zinc mixture at such a rate as to maintain a reaction temperature of ≦0° C. After the addition is complete and the mixture has been held for 2 h, HPLC indicates conversion of intermediates to the desired aldehyde. The reaction mixture is filtered through Celite®, washed with water (2×4.5 L), and water (4.5 L) is added to the organic phase. Sodium bicarbonate (150 g; 1.79 mol) is added to the mixture, and stirring for 0.25 h gives a pH of >7. The aqueous layer is removed, and the volume is reduced to 2.25 L by reduced pressure distillation. The mixture is held at 50° C., and heptane (3L) is added to slowly provide a precipitate. The resulting slurry is cooled to 20° C. over 2 h, the solids are filtered, washed with heptane (3 L), and dried to constant weight at 45° C. and ˜25″ Hg. The title aldehyde, compound A (513 g; 68% isolated yield) is afforded as a tan solid.
IR (KBr pellet) 3441, 2952, 2833, 2727, 1729 cm −1 . 1 H NMR (400 MHz, CDCl 3 ) δ 9.79 (1H, s), 7.46-7.34 (5H, m), 7.22 (2H, d, J=8.8 Hz), 6.96 (2H, d, J=8.8 Hz), 5.07 (2H, s), 4.11 (1H, dd, J=5.0, 9.6 Hz), 3.69 (3H, s), 3.39 (1H, dd, J=9.6, 18.7 Hz), 2.81 (1H, dd, J=5.0, 18.7 Hz). 13 C NMR (100 MHz, CDCl 3 ) δ 199.6, 173.4, 158.1, 136.7, 129.8, 128.7, 128.5, 127.9, 127.3, 115.0, 69.8, 52.2, 47.2, 43.8. HRMS (ESI) calcd for C 18 H 19 O 4 (M + ) 299.128, found 299.128.
Compound B: 1-((R)-2-amino-4-methyl-pentanoic acid)-3-(4-benzyloxy-phenyl)-pyrrolidin-2-one.
Under a nitrogen atmosphere, compound A (1.00 kg; 3.35 mol) is dissolved in diethoxymethane (DEM) (10 L), and D-leucine methyl ester hydrochloride (0.67 kg; 3.7 mol) is added, followed by diisopropylethylamine (0.52 kg; 4.0 mol). The resulting mixture is stirred at 20° C. for 30 min, and treated with sodium triacetoxyborohydride (0.85 kg; 4.0 mol) giving a temperature rise to 31° C. After 1 h, HPLC indicates complete consumption of the starting material. The resulting mixture is washed with water (2×7 L), and heated to reflux. Distillate (5 L) is removed, and at a pot temperature of 80 to 85° C. the reaction is held for 14 h giving complete lactamization by HPLC. The reaction mixture is cooled to 5° C., and aqueous LiOH ((0.1 kg; 4.1 mol) in 1.5 L water) and MeOH (2.0 L) are charged to the reaction. The resulting mixture is warmed to 20° C., and held for 4 h. HPLC indicates >95% conversion to compound B. The pH is adjusted to between 2 to 3 with 1N HCl and EtOAc (5 L) is charged. The aqueous layer is removed and the organic layer is washed with water (2×5 L), concentrated via distillation to 3 L. DEM (7 L) is added and the distillation is continued to remove EtOAc. The reaction volume is reduced to 6 L and cooled to 65° C. After 1 h, the resulting slurry is slowly cooled to 0° C. and held for 3 h. The solids are filtered and washed with cold DEM (1×2 L) and finally with heptane (2×3 L). The product is dried at 50° C. and 25″ Hg for 48 h giving compound B (1.1 kg: 86% overall isolated yield) as a white powder.
IR (KBr pellet) 3449, 2958, 2873, 2583, 1735, 1632 cm −1 . Mixture of diastereomers: 1 H NMR (400 MHz, CDCl 3 ) δ9.40 (1H, bs), 7.46-7.33 (5H, m), 7.22 (1H, d, J=8.6 Hz), 7.17 (1H, d, J=8.6 Hz), 6.96 (2H, d, J=8.6 Hz), 5.07 (1H, s), 5.05 (1H, s), 4.92 (1H, dd, J=8.0, 15.6 Hz), 3.75 (1H, m), 3.62 (1H, m), 3.42, (1H, m), 2.54 (1H, m), 2.12 (1H, m), 1.81 (2H, m), 1.55 (1H, m), 0.99 (6H, m). 13 C NMR (100 MHz, CDCl 3 ) δ176.8, 174.7, 174.4, 157.7, 136.8, 131.9, 131.5, 129.1, 128.8, 128.4, 127.7, 127.3, 114.9, 69.8, 52.4, 47.4, 42.3, 42.0, 37.3, 36.8, 28.5, 28.3, 24.9, 23.0, 21.1, 20.9. HRMS (ESI) calcd for C 23 H 28 NO 4 (M + ) 382.201, found 382.202.
Compound C 1 : (R)-3-aminohydroxy-1-((R)-2-amino-4-methyl-pentanoic acid)-3-(4-benzyloxy-phenyl)-pyrrolidin-2-one.
Under a nitrogen atmosphere, LiCl (30 g; 708 mmol) is charged to a vessel, followed by THF (1.05 L). The resulting mixture is stirred at 20° C. for 0.5 h at which point the mixture is almost homogeneous. Compound B (45 g: 118 mmol) is added, and the mixture cooled to −50° C. 2.5N n-Butyllithium (97.2 mL; 241.83 mmol) in hexanes is added over 0.5 h, and the resulting mixture cooled to −70° C. To the reaction mixture a 23.5 wt % solution of 1-chloro-1-nitrosocyclopentane (113.2 mL; 153.36 mmol) in methyl tert-butyl ether (MTBE) is added over 0.5 h (HPLC indicates>95% conversion and a 9:1 diastereomer ratio), followed by a THF solution of methanesulfonic acid (8 mL; 124 mmol; in 90 mL THF) over 15 min. Trimethylphosphite (12.52 mL; 106.17 mmol) is added to the reaction mixture, followed by warming to 0° C. over 0.5 h, and holding for an additional 0.5 h. An aqueous lithium hydroxide solution (4.3 g; 177 mmol; in 1.35 L of water) is added to the reaction mixture (aqueous pH>12), followed by heptane (400 mL). After vigorous mixing, the phases are separated, and the aqueous phase washed with a further 300 mL of heptane. Ethyl acetate (450 mL) is added to the aqueous phase, and the resulting mixture warmed to 30° C. with vigorous mixing. 10% Aqueous citric acid (250 mL) is added to the mixture until pH 3.6 is reached. After 0.5 h of vigorous mixing, the organic phase is separated, washed with brine (500 mL water+100 mL saturated aqueous brine), and the solvent exchanged for 2-propanol (IPA) via azeotropic distillation (final volume of 400 mL). The reaction mass is held at 60° C., and water (600 mL) is added to the mixture over 2 h inducing precipitation. The resulting slurry is cooled to 20° C. over 2 h, filtered, and washed with 40% IPA/water (2×100 mL). After drying at 70° C. and 25″ Hg to constant weight, the product (32.0 g; 65% isolated yield) is afforded as a light yellow solid, as a single diastereomer. Absolute stereochemistry was confirmed by single crystal X-Ray analysis.
IR (KBr pellet) 3378, 2968, 2878, 1692 cm −1 . Single diastereomer: 1 H NMR (400 MHz, CDCl 3 ) δ 7.61 (1H, s), 7.45-7.37 (5H, m), 7.33 (2H, d, J=8.8 Hz), 6.94 (2H, d, J=8.8 Hz), 5.09 (2H, s), 4.71 (1H, dd, J=4.0, 11.6 Hz), 3.34-3.20 (4H, m), 2.63-2.56 (1H, m), 2.13-2.09 (1H, m), 1.81-1.74 (1H, m), 1.62-1.49 (2H, m), 0.92 (3H, d, J=6.6 Hz), 0.87 (3H, d, J=6.6 Hz). 13 C NMR (100 MHz, CDCl 3 ) δ174.3, 172.6, 157.6, 137.1, 132.3, 128.4, 127.9, 127.7, 127.5, 114.3, 70.5, 69.1, 51.8, 39.0, 36.3, 29.7, 24.1, 23.1, 21.0. HRMS (ESI) calcd for C 23 H 29 N 2 O 5 (M + ) 413.209, found 413.209. [α] D (25° C.) −29.0 (c 1.064, MeOH).
Compound D from Compound C 1 : (R)-3-amino-1-((R)-2-amino-4-methyl-pentanoic acid methyl ester)-3-(4-hydroxy-phenyl)-pyrrolidin-2-one.
Under a nitrogen atmosphere, compound C (10 g; 24.27 mmol) is suspended in MeOH (250 mL) and heated to 40° C. for 0.5 h giving a homogeneous mixture. Palladium on carbon (6.0 g; 54% wet; 8% palladium based on dry weight; 220 mg Pd; Degussa) is charged to the reaction, and the nitrogen replaced with hydrogen. The pressure is increased to 60 PSI and returned to atmospheric pressure three times, and finally held at 60 PSI. After 3.5 h, HPLC indicates complete conversion to the corresponding phenol/primary amine intermediate. The reaction mixture is cooled to 25° C., and filtered through a bed of Celite® over whatman filter paper. The clarified mixture is held at 25° C., and treated with methanesulfonic acid (3.15 mL; 48.54 mmol). After 18 h, HPLC indicates complete conversion to the title ester, compound D. The resulting mixture is neutralized with saturated aqueous sodium bicarbonate, and extracted with dichloromethane (2×500 mL). After drying the organic phase with sodium sulfate, and removing the solvent in vacuo a white solid is obtained. Drying the white solid at 50° C. and 25″ Hg to constant weight affords compound D (7.0 g; 91% isolated yield). The product was recrystallized from EtOAc/heptane to give colorless needles as an EtOAc solvate.
IR (KBr pellet) 3406, 3358, 3298, 3144, 2964, 2874, 1746, 1688 cm −1 . 1 H NMR (400 MHz, CDCl 3 ) δ 7.23 (2H, d, J=8.8 Hz), 6.62 (2H, d, J=8.8 Hz), 5.00-4.96 (1H, m, apparent J=7.6 Hz), 3.98 (3H, bs), 3.70 (3H, s), 3.38-3.29 (2H, m), 2.51-2.46 (1H, m), 2.18-2.10 (1H, m), 1.81-1.77 (2H, m, apparent J=7.6 Hz), 1.56-1.49 (1H, m), 0.99 (3H, d, J=4.5 Hz), 0.97 (3H, d, J=4.5 Hz). 13 C NMR (100 MHz, CDCl 3 ) δ178.0, 171.3, 156.0, 132.5, 126.7, 115.5, 62.8, 52.4, 52.1, 39.6, 36.8, 36.6, 24.6, 23.0, 21.1. HRMS (ESI) calcd for C 17 H 25 N 2 O 4 (M + ) 321.181, found 321.181. [α] D (25° C.) −6.4 (c 0.962, MeOH).
Compound E: (R)-3-amino-1-((R)-2-amino-4-methyl-pentanoic acid methyl ester)-3-[4-(4-methyl alcohol-2-methyl-quinoline)-phenyl]-pyrrolidin-2-one-hydrochloride-monohydrate.
Under a nitrogen atmosphere, compound D (20 g; 62.4 mmol) is dissolved in isopropyl acetate (200 mL), and p-tolualdehyde (8.2 g; 68.6 mmol) is added to the mixture. The mixture is heated to 60° C. for 1 h. A distillation head is attached and the mixture is heated to reflux to allow azeotropic removal of water. After 150 mL of distillate is removed, the reaction mixture is cooled to 60° C. and acetonitrile (150 mL) is added. 4-Chloromethyl-2-methyl-quinoline (13.1 g; 68.6 mmol), potassium carbonate (10.3 g; 74.9 mmol), and tetrabutylammonium iodide (0.9 g; 2.5 mmol) are then charged to the reaction mixture. The temperature is increased to 70° C. After 1.5 h, HPLC indicates a complete conversion to the intermediate imine. The reaction mixture is cooled to 20° C., and water (200 mL) is added. Methane sulfonic acid (13.1 g; 136 mmol) is then charged (pH 1) along with tert-butyl methyl ether (150 mL). After agitation, the layers are allowed to separate and the organic layer is discarded. Ethyl acetate (150 mL) and tert-butyl methyl ether (150 mL) are then added and the pH of the mixture is adjusted to 7 to 8 using a 50 wt % NaOH solution (10.9 g, 136 mmol). After agitation, the layers are allowed to separate and the water layer is discarded. The organic layer is then warmed to 50° C. for salt formation. 6N HCl (10.5 mL; 63 mmol) is then added over 30 min to form a slurry of the desired crystalline product. The mixture is cooled to 20° C. and held for 1 h. The product is then filtered off and washed with ethyl acetate (2×60 mL). The product is dried at 50° C. under vacuum to yield 30.0 g (91%) of the white solid.
1 H NMR (400 MHz, DMSO d 6 ) δ 9.27 (3H, s), 8.13 (1H, d, J=8.1 Hz), 7.98 (1H, d, J=8.1 Hz), 7.76 (1H, t, J=8.1 Hz), 7.58 (1H, s), 7.58 (2H, d, J=8.9 Hz), 7.59 (1H, t, J=7.7 Hz), 7.26 (d, 2H, J=8.9 Hz), 5.67 (s, 2H), 4.79 (dd, 1H, J 1 =3.8 Hz, J 2 =11.3 Hz), 3.61 (s, 3H), 3.52-3.43 (1H, m), 3.39 (2H, s) 3.15-3.25 (1H, m) 2.67 (3H, s,), 2.65-2.50 (2H, m), 1.83 (1H, t, J=10.3 Hz), 1.70-1.52 (2H, m), 0.94 (3H, d, J=6.1 Hz), 0.91 (3H, d, J=5.9 Hz). 13 C NMR (100 MHz, MeOD) δ 173.4, 172.6, 160.9, 148.2, 145.6, 131.6, 129.8, 129.0, 128.8, 128.1, 125.9, 125.0, 121.9, 117.0, 68.1, 64.3, 54.5, 53.4, 41.6, 38.1, 34.1, 26.2, 25.1, 24.0, 22.0. Analysis Calculated for C 18 H 36 ClN 3 O 5 : C, 63.45; H, 6.85; Cl, 6.69; N, 7.93.
Alternate preparation of Compound E: (R)-3-amino-1-((R)-2-amino-4-methyl-pentanoic acid methyl ester)-3-[4-(4-methyl alcohol-2-methyl-quinoline)-phenyl]-pyrrolidin-2-one-hydrochloride-monohydrate.
Under a nitrogen atmosphere, Compound D (10 g; 31.2 mmol), cesium carbonate (11.1 g; 34.1 mmol), 4-chloromethyl-2-methyl-quinoline (6.5 g; 34.0 mmol), tetrabutylammonium iodide (0.6 g; 1.6 mmol), and acetonitrile (100 mL) are combined. The reaction mixture is held at 20° C. for 4 h and then warmed to 40° C. After 4 h, HPLC indicates >95% of Compound D has been consumed. The mixture is cooled to 20° C. and the solids are removed by filtration. Acetonitrile (50 mL) is used to wash the cake and is combined with the original filtrate. While stirring, 6N HCl (2.2 mL, 13.2 mmol) is added dropwise to induce salt formation. Nucleation may be initiated by adding 100 mg of desired product. Once the crystallization has occurred, 6N HCl (2.3 mL, 13.8 mmol) is added dropwise over 15 min. The slurry is held for 1 to 3 h before filtering off the solid product. The white crystalline product is then washed with ethyl acetate (2×20 mL) and dried in a vacuum oven at 50° C. to a constant weight (yield 12.8 g).
Example 2
Compound C 2 : (R)-3-amino-1-((R)-2-amino-4-methyl-pentanoic acid methyl ester)-3-(4-benzyloxy-phenyl)-pyrrolidin-2-one.
Under an N 2 atmosphere, Compound B (1.0 kg; 2.6 mol) and LiCl (110 g; 2.6 mol) are charged to a vessel, followed by THF (10.0 L). The resulting mixture is cooled to −70° C. 2.5N n-Butyllithium (2.6L mL; 6.5 mol.) in hexanes is added over 1 h, while maintaining a temperature below −70° C. To the reaction mixture is added a 20 wt % solution of 1-chloro-1-nitrosocyclopentane (2.3 kg; 3.1 mol) in toluene over 0.5 h, while maintaining a reaction temperature below −70° C. (HPLC indicates >97% conversion and a 11:1 diastereomer ratio). Zinc flake (1.0 kg; 15.7 mol) is added to the reaction mixture followed by neat formic acid (1.0 kg; 20.9 mol). The reaction mass is warmed to 20° C. and held there for 2 h (HPLC indicates >98% conversion). The reaction mass is filtered to remove zinc and the cake is rinsed with THF (1 L).
The filtrate is returned to the vessel and methyl alcohol (10 L) and methanesulfonic acid (1.0 kg; 10.5 mol) were added. The volume of the reaction mass was reduced (25° C. and 130 mmHg) to 10 L. The reaction mass was stirred at 20° C. until HPLC analysis indicated complete conversion (>99%). Toluene (10 L) is added to the reaction mixture followed by a solution of sodium acetate (1.8 kg in 8 L of water). The solution is stirred for 15 min and the phases separated. The organic layer is washed with a solution of sodium acetate (1.8 kg in 8 L of water), a solution of potassium bicarbonate (1.0 kg in 8 L), and water (8 L). The organic layer is concentrated under reduced pressure (27.8° C. @ 30 mmHg) to a volume of 4 L. The reaction mass is warmed to 40° C. and heptane (1 L) is added while maintaining 40° C. The solution is cooled to 20° C. over 1 h and held at 20° C. for an additional 1 h (crystallization occurs during this time). Heptane (7 L) is added and the slurry is stirred for an additional 2 h. The solution is filtered and washed with 2 L of 20% toluene/heptane. The product is dried at 50° C. and 25″ Hg for 24 h giving compound C (600 g: 56% overall isolated yield) as a white to off white powder.
Single diastereomer: 1 H NMR (400 MHz, CDCl 3 ) δ7.43(m, 4H), 7.35(d, 2H, J=6.57 Hz), 7.28(m, 1H), 6.94(d, 2H, J=9.10 Hz), 5.03(s, 2H), 4.98(t, 1H, J=8.08 Hz), 3.65(s, 3H), 3.27(m, 2H), 2.41(m, 1H, apparent J=6.57 Hz), 2.10(m, 1H), 2.01(s, 2H), 1.77(t, 2H, J=7.58 Hz), 1.52(m, 1H, apparent J=6.57 Hz), 0.98(d, 6H, J=7.58 Hz). 13 C NMR (100 MHz, CDCl 3 ) δ 178.04, 171.81, 158.31, 137.19, 135.19, 128.77, 128.13, 127.65, 127.38, 114.90, 70.11, 63.10, 52.57, 52.37, 39.60, 37.48, 37.19; 25.09, 23.47, 21.52. IR (thin film) 3364, 3037, 2948, 2871, 1729, 1684, 1610 cm −1 . MS (ESI+) 412, 394.
Compound D from Compound C2: (R)-3-amino-1-((R)-2-amino-4-methyl-pentanoic acid methyl ester)-3-(4-hydroxy-phenyl)-pyrrolidin-2-one.
Compound C (500 g; 1.22 mol) and activated carbon (100 g) are suspended in EtOAc (7.5 L) at room temperature for 0.5 h. The carbon is filtered off using a pad of Celite®. The solution is charged to an appropriate autoclave and inerted (3×) with nitrogen. Degussa-type E101 palladium on carbon (75.0 g; 50% wet; 10% palladium based on dry weight) is charged to the reactor, and the nitrogen replaced with hydrogen. The pressure is increased to 50 PSI and held at 20-30° C. and 50 PSI. After 3.5 h, HPLC indicates complete conversion (>99%). The reaction mixture is cooled to 25° C., and the catalyst is filtered off using a bag filter. The solution is concentrated to a volume of 1.5 L under reduced pressure while maintaining a maximum pot temperature of 50° C. Heptane (2 L) is added to the warm solution, and then the solution is allowed to cool to 20° C. (crystallization begins at about 30° C.). When the batch reaches 20° C., an additional charge of heptane (3 L) is added. The slurry is filtered and washed with 1 liter of a 5% EtOAc/heptane solution. The solid is dried in a vacuum oven at 50° C. overnight to give the title product (314 g; 81.2% isolated yield).
IR (KBr pellet) 3406, 3358, 3298, 3144, 2964, 2874, 1746, 1688 cm −1 . 1 H NMR (400 MHz, CDCl 3 ) δ 7.19(d, 2H, J=8.59 Hz), 6.60(d, 2H, J=8.59 Hz), 4.90(t, 1H, J=7.58 Hz), 3.61(s, 3H), 3.25(m, 2H), 2.42(m, 1H), 2.09(m, 1H), 1.72(m, 2H), 1.45(m, 1H, apparent J=7.07 Hz), 0.89(t, 6H, J=7.07 Hz). 13 C NMR (100 MHz, CDCl 3 ) δ178.32, 171.62, 156.47, 132.83, 127.03, 115.86, 63.18, 52.73, 52.48, 39.98, 37.08, 36.97, 24.97, 23.38, 21.40. MS (ESI+) 321, 304. HRMS (ESI) calcd for C 17 H 25 N 2 O 4 (M + ) 321.181, found 321.181.
Example 3
Starting Compound: 2-(4-benzyloxy-phenyl)-pent-4-enoic acid methyl ester.
To a 22 L glass flask were charged 0.35 kg (3.5 mol, 1.2 eq) of diisopropylamine and 3.75 L of tetrahydrofuran (THF). The solution was cooled to −70±5° C. and 1.29 L (3.2 mol, 1.1 eq) of 2.5 M n-butyllithium (BuLi) was charged, keeping temperature <−20° C. The reaction was warmed to −5±5° C. to allow the formation of lithium diisopropylamine (LDA). Commercial LDA in THF may be substituted for the previous procedure. The mixture was cooled −70±5° C. while 0.75 kg (2.9 mol, 1 eq) of methyl-4-benzyloxyphenylacetate was dissolved in 2.2 L of THF. The methyl-4-benzyloxyphenylacetate solution was slowly charged to the LDA solution while holding at −70±5° C. After approximately 1 h −70±5° C., during which a light green enolate slurry formed, 0.46 kg (3.8 mol, 1.3 eq) of allyl bromide was charged to the reactor. The reaction was warmed to −40±5° C. and held for about 1 h or until the reaction was deemed complete by HPLC analysis (criteria: >97% conversion of methyl-4-benzyloxyphenylacetate). An aqueous solution of dihydrogen sodium phosphate monohydrate (NaH 2 PO 4 ) was prepared using 0.75 kg (5.4 mol, 1.9 eq) and 8 L water. The phosphate solution was added to the reaction mixture and allow to warm to 20±5° C. Ethyl acetate (EtOAc) was charged and the reaction was held for 5 min. After allowing the layers to separate, the aqueous layer was removed. The organic layer was washed two times with 6 L of water. Using vacuum distillation at <40° C., the solution was concentrated until distillation becomes difficult.
1 H NMR (400 MHz, CDCl 3 ) δ 7.45-7.25 (5H, m), 7.22 (2h, d, J=8.6 Hz), 6.92 (2H, J=8.6 Hz) 5.70 (1H, m), 5.06 (1H, d, J=17.1 Hz), 5.01 (2H, s), 5.01-4.96 (1H, m), 3.62 (3H, s), 3.59 (1H, t, J=8.6 Hz), 2.85-2.73 (1H, m), 2.50-2.45 (1H, m). 13 C NMR (100 MHz, CDCl 3 ) δ 174.4, 158.3, 137.2, 135.6, 131.1, 129.4, 129.2 128.8, 128.2, 127.7, 117.2, 115.2, 70.2, 52.2, 50.8, 37.9.
Compound A: 2-(4-benzyloxy-phenyl)-4-oxo-butyric acid methyl ester.
7.5 L of EtOAc was added to the 2-(4-benzyloxy-phenyl)-pent-4-enoic acid methyl ester concentrate (˜2.9 mol) in a 12 L flask. The reactor was cooled to −50 to −55° C. The introduction of ozone was started below the surface of the liquid with high agitation. When ozone was no longer being consumed and/or the solution turned light gray/blue a sample was submited for HPLC analysis (criteria: >99% conversion of 2-(4-benzyloxy-phenyl)-pent-4-enoic acid methyl ester). The reaction was warmed to −30±5° C. while purging with nitrogen to remove excess ozone from solution. Next, 0.75 L of acetic acid and 0.75 L of water was added. Using a powder addition funnel (screw funnel), the addition of zinc was begun (typical zinc used was ˜325 mesh, 99.9% pure). The temperature was held between −10 and −20° C. during additions. The Zinc (0.37 kg, 5.6 mol, 2 eq) was added over four charges with a minimum of 20 min between additions of zinc to avoid large exotherms. After the zinc additions, the reaction was held at 0 to −10° C. for 30 min. HPLC analysis was used to determine the consumption of the ozonide (criteria: >99.8% conversion of ozonide). The contents, still at 0 to −10° C., were filtered through a 3-inch bed of Celite® (additional Celite® may be added prior to filtration) and the Celite®/Zn cake was washed with 3.0 L of EtOAc. The filtrates were combined and charged back to clean 22 L glass reactor. The ethyl acetate solution was washed two times with 4.5 L of water and 5 L of 4 wt % aqueous sodium bicarbonate (NaHCO 3 ). Using vacuum distillation at <30° C., the volume was reduced to approximately 3 L. 5 L of heptane was added and a sample was removed for GC analysis (criteria: <20% EtOAc by volume using GC standard). If criteria was not met, the EtOAc:Heptane ratio was adjusted by charging heptane and continuing vacuum distillation. The reaction was then cooled to 0 to 10° C. and held for a minimum of 1 h. The resulting slurry was filtered and washed with 3 L of heptane. The wet cake was dried under vacuum to afford 0.93 kg compound A (80% yield).
1 H NMR (400 MHz, CDCl 3 ) δ 9.69 (1H, s), 7.42-7.25 (5H, m), 7.17 (2h, d, J=8.6 Hz), 6.91 (2H, J=8.6 Hz), 4.99 (2H, s), 4.05 (1H, dd, J 1 =5.1 Hz, J 2 =10.1 Hz), 3.61 (3H, s), 3.31 (1H, dd, J 1 =9.6 Hz, J 2 =18.2 Hz), 2.72 (1H, dd, J 1 =5.0, J 2 =18.2 Hz). 13 C NMR (100 MHz, CDCl 3 ) δ 199.6, 173.4, 158.2, 136.8, 129.9, 128.8, 128.6, 128.4, 128.0, 127.4, 127.1, 115.1, 69.9, 52.3, 47.3, 43.9.
Example 4
Compound F: [1(R)]-3-amino-N-hydroxy-alpha-(2-methylpropyl)-3-[4-[(2-methyl-4-quinolinyl)methoxy]phenyl]-2-oxo-1-pyrrolidineacetamide.
To a 50 gallon glass-lined reactor were charged 17.9 kg of hydroxylamine hydrochloride (257 mol, 5 eq) and 22 kg methyl alcohol. The batch temperature was set to 50° C. and 101 kg of a 25 wt % solution of sodium methoxide in methyl alcohol was charged (sodium methoxide: 25 kg, 463 mol, 9 eq) followed by a methyl alcohol rinse of the charging line. The reactor contents were heated to 55° C. and aged for 15 min. The batch was then cooled to 25° C. and filtered through a 36″ nutsch filter using a polypropylene filter bag. The filtrate was collected in a 200 gallon glass-lined reactor and cooled to 10° C. 27.3 kg of Compound E-Hydrochloride ((R)-3-amino-1-((R)-2-amino-4-methyl-pentanoic acid methyl ester)-3-[4-(4-methyl alcohol-2-methyl-quinoline)-phenyl]-pyrrolidin-2-one-hydrochloride-monohydrate) (51.5 mol) was added and the batch was warmed to 25° C. for aged for 1 h. The reactor contents were sampled for reaction completion (HPLC criterion: >99.5 A % conversion). Once the reaction was deemed complete, ˜70 kg of 2N HCl solution was added and the reaction mass was sampled for pH measurement (acceptance criterion: pH ˜7.0). 19 L of purified water was charged and the batch was then heated to 50° C. A 1 L slurry of [1(R)]-3-amino-N-hydroxy-alpha-(2-methylpropyl)-3-[4-[(2-methyl-4-quinolinyl)methoxy]phenyl]-2-oxo-1-pyrrolidineacetamide (150 g) 1:4 methyl alcohol/water (volume ratio) was added. Purified water (126 L) was added uniformly over 1.5 h at 50° C. to induce crystallization. The batch was cooled to 5° C. over a period of 2 h. The contents were filtered and the product washed first with a mixture of methyl alcohol/water (1:4 volume ratio) and then with pure water. The wet cake (˜25 kg) was analyzed to determine the weight % of water and charged to a clean 100 gallon reactor. 2-Propanol (62 kg) was added and the batch was heated to 55° C. Once all the solids were dissolved, purified water was added to adjust the volume ratio to ˜55% water, 45% 2-propanol. At 55° C., 2 L slurry of milled [1(R)]-3-amino-N-hydroxy-alpha-(2-methylpropyl)-3-[4-[(2-methyl-4-quinolinyl)methoxy]phenyl]-2-oxo-1-pyrrolidineacetamide seeds (˜750 g) in 1:4 2-propanol/water (volume ratio) were charged. Purified water (139 kg) was charged through a cartridge filter gradually over a period of 4.5 h. The batch was cooled from 55° C. to 20° C. in 2 h, aged for 30 min and filtered through a 36″ nutsch filter using a dacron filter bag. The filter-cake was washed three times with a mixture of 2-propanol-water (1 st wash: 73 kg water, 14.5 kg 2-propanol; 2 nd and 3 rd washes: 36 kg water, 7 kg 2-propanol). The product was dried in a tray dryer under vacuum at 50° C. to a constant weight to afford 20.9 kg compound F (81% yield).
Numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.
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A novel process for the asymmetric synthesis of an amino-pyrrolidinone of the type shown below from appropriate pyrrolidinones is described.
These compounds are useful as intermediates for MMP and TACE inhibitors.
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PRIORITY
[0001] This is a continuation application of U.S. patent application Ser. No. 14/507,012, filed on Oct. 6, 2014, which is a continuation of U.S. patent application Ser. No. 13/228,713, filed on Sep. 9, 2011, which issued as U.S. Pat. No. 8,855,051 on Oct. 7, 2014, and which claimed the benefit under 35 U.S.C. §119(a) of a Korean patent application filed on Sep. 9, 2010 in the Korean Intellectual Property Office and assigned Serial number 10-2010-0088232, the entire disclosure of each of which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a mobile communication system. More particularly, the present invention relates to a method and apparatus for supporting Non-Access Stratum (NAS) communication between a User Equipment (UE) and a Mobility Management Entity (MME) efficiently by addressing the signaling problems occurring between the UE and MME in a situation where it is necessary for a network node to identify the UE and acquire UE information, if there is any, from another network node to which the UE have been attached after a movement between two different Radio Access Technologies (RATs) such as Evolved Universal Terrestrial Radio Access Network (EUTRAN) and Universal Terrestrial Radio Access Network (UTRAN) or Global System for Mobile Communications (GSM)/Enhanced Data Rates for GSM Evolution (EDGE) Radio Access Network (GERAN).
[0004] 2. Description of the Related Art
[0005] As one of the representative mobile communication standard organizations, the 3 rd Generation Partnership Project (3GPP) has defined Evolved Packet System (EPS) with the introduction of MME.
[0006] The NAS protocols for the 3GPP 3G system have been revised in order to meet the requirements of high-speed data transmission in the next generation mobile communication system. The revision also has included backward compatibility to the 2G and 3G networks of 3GPP. In detail, when attaching to a network or updating a tracking area, the UE identifies the network node which it has accessed before using the node identity information of the UE identifier.
[0007] In a carrier network of the related art, however, the network is configured using even the bit information indicating network node identity information, and thus there is no room to distinguish between the legacy network mobility management node and the MME introduced for supporting the EUTRAN, resulting in a node identification failure problem. There is therefore a need of a method for improving communication service quality by minimizing processing delay with the provision of the information for the UE to discover the network node to which the UE has attached before and the acquisition of the UE information based on the provided information in the communication between the UE and the network through modification of the NAS protocol or a certain procedure of the UE or the mobility management node.
SUMMARY OF THE INVENTION
[0008] Aspects of the present invention are to address at least the above-mentioned problems and/or disadvantages and to provide at least the advantages described below. Accordingly, an aspect of the present invention is to provide a communication method and system for supporting Non-Access Stratum (NAS) communication between a User Equipment (UE) and a network node efficiently in an evolved mobile communication system including 3 rd Generation Partnership Project (3GPP) Evolved Packet System (EPS) supporting Access Stratum (AS) and NAS protocols on layer 2, especially when the UE in idle mode moves or connects to a network or updates the tracking area or performs handover between different Radio Access Technologies (RAT) including Evolved Universal Terrestrial Radio Access Network (EUTRAN) and Universal Terrestrial Radio Access Network (UTRAN) or Global System for Mobile Communications (GSM)/Enhanced Data Rates for GSM Evolution (EDGE) Radio Access Network (GERAN) (UTRAN/GERAN).
[0009] Another aspect of the present invention is to provide a communication method and system that is capable of supporting NAS authentication and NAS communication between a UE and a network entity such as a Mobility Management Entity (MME) without a processing delay by specifying the operations of the UE, MME, and Serving General Packet Radio Service (GPRS) Support Node (SGSN) in the NAS protocol during the roaming of the UE between different technology-based networks including GERAN, UTRAN, EUTRAN, and other equivalent access networks.
[0010] The present invention relates to a method and system for facilitating a UE to discover a best node during or in attempt of communication with a network node using the NAS protocols, and the method for communication between the UE and network based on the NAS protocol messages and operations according to the present invention is implemented with the involvement a UE, an MME, and an old MME or old SGSN to which the UE has previously attached so as to facilitate discovering the best node using the UE information acquired from the old MME or old SGSN during the communication between the UE and the network, resulting in a reduction of communication delay between the UE and network and an improvement of communication efficiency.
[0011] As aforementioned, the present invention is capable of maintaining the communication between UE and network during the handover between two different RATs such as EUTRAN and UTRAN/GERAN, resulting in reduction of communication delay.
[0012] In accordance with an aspect of the present invention, a communication support method of an MME in a mobile communication system is provided. The method includes receiving a Packet-Temporary Mobile Subscriber Identity (P-TMSI) signature from a UE in an access request, and determining an old network node which the UE has accessed previously by analyzing the P-TMSI.
[0013] In accordance with another aspect of the present invention, a communication support apparatus of an MME in a mobile communication system is provided. The apparatus includes a communication unit which receives a P-TMSI signature from a UE in an access request, and a determination unit which determines an old network node which the UE has accessed previously by analyzing the P-TMSI.
[0014] In accordance with another aspect of the present invention, a communication support method of a UE in a mobile communication system is provided. The method includes transmitting a P-TMSI signature to an MME in an access request, and receiving an access response from the MME in response to the access request, wherein the MME analyzes the P-TMSI to determine an old network node which the UE has accessed previously.
[0015] In accordance with still another aspect of the present invention, a communication support apparatus of a UE in a mobile communication system is provided. The apparatus includes a communication unit which is responsible for communication with an MME, and a control unit which transmits a P-TMSI signature to the MME in an access request and receives an access response from the MME in response to the access request, wherein the MME analyzes the P-TMSI to determine an old network node to which the UE has accessed previously.
[0016] Other aspects, advantages, and salient features of the invention will become apparent to those skilled in the art from the following detailed description, which, taken in conjunction with the annexed drawings, discloses exemplary embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The above and other aspects, features, and advantages of certain exemplary embodiments of the present invention will be more apparent from the following description taken in conjunction with the accompanying drawings, in which:
[0018] FIG. 1 is a schematic diagram illustrating communication environment of the mobile communication system according to an exemplary embodiment of the present invention;
[0019] FIG. 2 is a signaling diagram illustrating a network attachment procedure of a User Equipment (UE) according to an exemplary embodiment of the present invention;
[0020] FIG. 3 is a signaling diagram illustrating a tracking area update procedure of a UE according to an exemplary embodiment of the present invention;
[0021] FIG. 4 is a signaling diagram illustrating a network attachment procedure of a UE according to another exemplary embodiment of the present invention;
[0022] FIG. 5 is a signaling diagram illustrating a tracking area update procedure of a UE according to another exemplary embodiment of the present invention;
[0023] FIG. 6 is a flowchart illustrating operations of a Mobility Management Entity (MME) for supporting communication between a UE and a network node according to an exemplary embodiment of the present invention;
[0024] FIG. 7 is a flowchart illustrating operations of a UE for supporting communication between the UE and a network node according to an exemplary embodiment of the present invention; and
[0025] FIG. 8 is a flowchart illustrating operations of an MME for supporting communication between a UE and a network node according to another exemplary embodiment of the present invention.
[0026] Throughout the drawings, it should be noted that like reference numbers are used to depict the same or similar elements, features, and structures.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0027] The following description with reference to the accompanying drawings is provided to assist in a comprehensive understanding of exemplary embodiments of the invention as defined by the claims and their equivalents. It includes various specific details to assist in that understanding but these are to be regarded as merely exemplary. Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the embodiments described herein can be made without departing from the scope and spirit of the invention. In addition, descriptions of well-known functions and constructions may be omitted for clarity and conciseness.
[0028] The terms and words used in the following description and claims are not limited to the bibliographical meanings, but, are merely used by the inventor to enable a clear and consistent understanding of the invention. Accordingly, it should be apparent to those skilled in the art that the following description of exemplary embodiments of the present invention is provided for illustration purpose only and not for the purpose of limiting the invention as defined by the appended claims and their equivalents.
[0029] It is to be understood that the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a component surface” includes reference to one or more of such surfaces.
[0030] The subject matter of the present invention is to provide a method for reducing the delay of Non-Access Stratum (NAS) communication between a User Equipment (UE) and a Mobility Management Entity (MME) by optimizing the operations of the UE, MME, and Serving General Packet Radio Service (GPRS) Support Node (SGSN) in the NAS signaling. Although the description is directed to the 3 rd Generation Partnership Project (3GPP)-based system including Evolved Packet System (EPS), Universal Terrestrial Radio Access Network (UTRAN), and Global System for Mobile Communications (GSM)/Enhanced Data Rates for GSM Evolution (EDGE) Radio Access Network (GERAN), the present invention can be applied to other types of communication systems using NAS.
[0031] In the exemplary embodiment of FIG. 1 , the present invention proposes a communication method between a UE and an MME and operations thereof based on the NAS protocol during the movement of the UE between different Radio Access Technologies (RAT) including Evolved Universal Terrestrial Radio Access Network (EUTRAN) and Universal Terrestrial Radio Access Network (UTRAN), and it will be obvious to those skilled in the art that the disclosed communication method can be applied to other mobile communication systems implemented based on similar or different protocols but operating similarly in similar technological background and channel format with minor changes and modifications without departing from the scope of the present invention.
[0032] FIG. 1 is a schematic diagram illustrating a communication environment of a mobile communication system according to an exemplary embodiment of the present invention. The description is directed to an exemplary 3GPP EPS system. Although the description is directed to the case where the UE connects to a EUTRAN and then moves to another RAT network or connects to an RAT network and then moves to the EUTRAN, the present invention can be applied to other mobile communication systems operating in a similar manner.
[0033] Referring to FIG. 1 , the base stations (referred to as Evolved Node Base Station, E Node B, and eNB, or Radio Network Controller (RNC)) 112 and 133 are responsible for establishing radio links to communicate with the UE 110 within the cell as the service coverage thereof. The UE 110 is a terminal that connects to a packet data network such as the Internet via a Serving Gateway (hereinafter, referred to as Serving GW or S-GW) 116 . In the following description, the Packet Data Network Gateway (hereinafter, referred to as PDN GW) 118 as a significant network entity of the packet data network is responsible for the functions of Home Agent HA. The Mobility Management Entity/Serving GPRS Support Node (MME/SGSN) 135 is responsible for management of mobility, location, and registration of the UE. In order to manage the authentication information of the user or UE, the Home Subscriber Server (HSS) 121 is connected to the MME 114 and MME/SGSN 135 via an interface.
[0034] The eNB/RNC 133 , SGW 116 , and MME/SGSN 135 are connected via data paths with the interface for managing the mobility of UE. The UE 110 and MME/SGSN 135 have an NAS protocol stack to communicate each other for the mobility management and session management. In the described exemplary embodiment, the description is directed to the situation in which the UE 100 connected to an old network (or source network) moves to connect to a new network or updates location. The source network can be one of various RATs including EUTRAN, UTRAN, and GERAN, and it is assumed that the UE moves from the source network to EUTRAN as the new network (or target network). If it moves to the target network, the UE 110 connects to the eNB 112 so as to be served by the eNB 112 , MME 114 , and HSS 121 . The MME 114 of the new network and the MME/SGSN 135 of the old network are connected with each other so as to exchange the information necessary. A description is made of the operations of the UE 110 and MME 114 operating based on the NAS protocol in the above-structured network with reference to FIGS. 2 to 8 . In the mobile communication system according to an exemplary embodiment of the present invention, when a request message is received from the UE, the network node analyzes the request message to check the old network node to which the UE has been attached. The new network node requests the old network node for the information related to the UE. When the UE information is received from the old network node, the new network node sends a response message to the UE using the acquired UE information.
[0035] In the mobile communication system of the present invention, the UE configures the request message. The UE configures the request message in order for the network node to analyze the request message to check the old network node. The UE sends the request message to the network node. Afterward, the UE receives the response message transmitted by the network node in response to the request node.
[0036] Here, the request message includes the connection request message for connection to the network node and the update request message for updating the UE location. The new network node can be an MME, and the old network node can be a SGSN or MME.
[0037] FIG. 2 is a signaling diagram illustrating a network attachment procedure of a UE according to an exemplary embodiment of the present invention.
[0038] Referring to FIG. 2 , the UE 110 requests attachment to the network at step 201 . At this time, the UE sends an access request message, i.e., Attach Request message, including UE identity information which is referred to as Packet-Temporary Mobile Subscriber Identity (P-TMSI) signature. The P-TMSI signature is the information to be used in the attempt of attachment to a network since the UE 110 has successfully connected to an SGSN. The Attach Request message is delivered to the MME 114 via the eNB 112 at step 203 .
[0039] If it is determined that the UE 110 has accessed the old MME/SGSN 135 , the new MME 114 determines the type of the old network node at step 205 . The old network node type is determined by referencing the Most Significant Bit (MSB) of the Local Area Code (LAC) or MME Group Identity (MMEGI) in the Globally Unique Temporary Identity (GUTI) of the UE 110 . Once the old network node type is determined (if the MSB is set to 1, the old network is determined to be EUTRAN, and otherwise the old network is determined to be UTRAN/GERAN), the UE discovers the MME or SGSN in the corresponding network. In the case that the MSB is set to 1 for the UTRAN/GERAN (by some mobile carriers), if the Attach Request message transmitted by the UE 110 includes a valid P-TMSI signature, it can be determined that the UE 110 has accessed the GERAN/UTRAN previously.
[0040] Next, the new MME 114 requests the MME/SGSN 135 , as the old serving network of the UE 110 , for the International Mobile Subscriber Identity (IMSI) and Mobility Management (MM) context at step 207 . The new MME 114 receives the UE information from the old MME/SGSN 135 at step 209 . Next, the authentication and security process is performed at step 211 and then the bearer creation process is performed at step 213 . Next, the new MME 114 sends an Attach Accept message to the new eNB 112 at step 215 , and the new eNB 112 forwards the Attach Accept message to the UE 110 at step 217 so as to complete the attachment procedure.
[0041] FIG. 3 is a signaling diagram illustrating a tracking area update procedure of UE according to an exemplary embodiment of the present invention.
[0042] Referring to FIG. 3 , the UE 110 sends a Tracking Area Update (TAU) Request message to the network through new eNB 112 at step 301 . The TAU Request message includes a P-TMSI signature as UE identity information and a Cipher Key Sequence Number (CKSN) for referencing a cipher key when the UE 110 has accessed a GERAN/UTRAN previously. If there exists a valid CKSN and P-TMSI signature, this means that the UE has successfully connected to an SGSN previously and stored the information for use in the connection or location registration update process afterward. The TAU Request message transmitted by the UE 110 is delivered to the MME 114 via the eNB 112 at step 303 .
[0043] In case that the UE has accessed the MME/SGSN 135 previously, the MME 114 determines the type of the old network node at step 305 . The old network node type is determined by referencing the MSB of the LAC or MMEGI in the GUTI of the UE 110 . Once the old network node type is determined (if the MSB is set to 1, the old network is determined to be EUTRAN, and otherwise the old network is determined to be UTRAN/GERAN), the UE discovers the MME or SGSN in the corresponding network. In case that the MSB is set to 1 for the UTRAN/GERAN (by some mobile carriers), if the Attach Request message transmitted by the UE 110 includes a valid P-TMSI signature, it can be determined that the UE 110 has accessed the GERAN/UTRAN previously.
[0044] Next, the new MME 114 requests the MME/SGSN 135 , as the old serving network of the UE 110 , for the IMSI and MM context at step 307 . The new MME 114 receives the UE information from the old MME/SGSN 135 at step 309 . Next, the authentication and security process is performed at step 311 and then the bearer update process for updating Serving Gateway and UE location information is performed at step 315 . The new MME 114 sends a Context Acknowledge message to the old MME/SGSN 135 for acknowledgment of the receipt of the UE information at step 313 . After the bearer update at step 315 , the new MME 114 sends a TAU Accept message to the UE 110 at step 317 so as to complete the tracking area update procedure.
[0045] According to an exemplary embodiment of the present invention, if an Attach Request or a tracking area update request message is received from the UE, the network node checks the MSB of the MMEGI or the LAC of the GUTI of the UE in the request message. If the MSB is set to 0, this means that the old network node is SGSN. Otherwise if the MSB is set to 1, the new network node determines whether the request message includes at least one of a P-TMSI signature and a CKSN. If the request message includes at least one of the P-TMSI signature and the CKSN, this means that the old network node is SGSN. Otherwise if the request message includes neither the P-TMSI signature nor the CKSN, this means that the old network node is MME. Afterward, the new network node requests the old network node for the UE information and sends a response message to the UE using the UE information received from the old network node.
[0046] FIG. 4 is a signaling diagram illustrating a network attachment procedure of UE according to another exemplary embodiment of the present invention.
[0047] Referring to FIG. 4 , the UE 110 requests attachment to the network at step 401 . The Attach Request message transmitted by the UE includes the capability information on whether the UE 110 is capable of discriminating between the identifier assigned as the result of the connection to an MME and the identifier created based on the P-TMSI or Routing Area Identity (RAI). The capability information can be transmitted in a parameter, i.e., a UE network capability Information Element (IE), or in other ways. The UE 110 can transmit the Attach Request message including the information indicating whether the identifier is assigned as the result of attachment to MME or created from the P-TMSI and/or RAI. The identifier creation information can be transmitted by means of a type of identity (identification type or ID type) or other IE or discriminate between LAC and MMEGI. The Attach Request message transmitted by the UE 110 is delivered to the MME 114 via the eNB 112 at step 403 .
[0048] If it is determined that the UE 110 has accessed the old MME/SGSN 135 , the new MME 114 determines the type of the old network node at step 405 . The old network node type is determined by referencing the MSB of the LAC or MMEGI in the GUTI of the UE 110 . Once the old network node type is determined (if the MSB is set to 1, the old network is determined to be EUTRAN, and otherwise the old network is determined to be UTRAN/GERAN), the UE discovers the MME or SGSN in the corresponding network. In case that the MSB is set to 1 for the UTRAN/GERAN (by some mobile carriers), if the Attach Request message transmitted by the UE 110 includes capability information, this means that the UE 110 has the capability of transmitting identification type along with the GUTI. Accordingly, the MME 114 references an identification type field or the IE related to identification type to determine whether the old network node to which the UE has attached is GERAN/UTRAN or EUTRAN.
[0049] Next, the new MME 114 requests the MME/SGSN 135 , as the old serving network of the UE 110 , for the IMSI and MM context as the UE information at step 407 . The new MME 114 receives the UE information from the old MME/SGSN 135 at step 409 . Next, the authentication and security process is performed at step 411 and the bearer creation process is performed at step 413 . Next, the new MME 114 sends an Attach Accept message to the new eNB 112 at step 415 , and the new eNB 112 forwards the Attach Accept message to the UE 110 at step 417 so as to complete the attachment procedure.
[0050] FIG. 5 is a signaling diagram illustrating a tracking area update procedure of a UE according to another exemplary embodiment of the present invention.
[0051] Referring to FIG. 5 , the UE 110 sends a TAU Request message to the network through new eNB 112 at step 501 . The Attach Request message transmitted by the UE includes the capability information on whether the UE 110 is capable of discriminating between the identifier assigned as the result of the connection to an MME and the identifier created based on the P-TMSI or RAI. The capability information can be transmitted in a parameter, i.e., a UE network capability IE, or in other ways. The UE 110 can transmit the Attach Request message including the information indicating whether the identifier is assigned as the result of attachment to MME or created from the P-TMSI and/or RAI. The identifier creation information can be transmitted by means of a type of identity (identification type or ID type) or other IE or discriminate between LAC and MMEGI. The Attach Request message transmitted by the UE 110 is delivered to the MME 114 via the eNB 112 at step 503 . If it is determined that the UE 110 has accessed the old MME/SGSN 135 , the new MME 114 determines the type of the old network node at step 505 . The old network node type is determined by referencing the MSB of the LAC or MMEGI in the GUTI of the UE 110 . Once the old network node type is determined (if the MSB is set to 1, the old network is determined to be EUTRAN, and otherwise the old network is determined to be UTRAN/GERAN), the UE discovers the MME or SGSN in the corresponding network. In case that the MSB is set to 1 for the UTRAN/GERAN (by some mobile carriers), if the Attach Request message transmitted by the UE 110 includes capability information, this means that the UE 110 has the capability of transmitting identification type along with the GUTI. Accordingly, the MME 114 references an identification type field or the IE related to identification type to determine whether the old network node to which the UE has attached is GERAN/UTRAN or EUTRAN.
[0052] Next, the new MME 114 requests the MME/SGSN 135 , as the old serving network of the UE 110 , for the IMSI and MM context as the UE information at step 507 . The new MME 114 receives the UE information from the old MME/SGSN 135 at step 509 . Next, the authentication and security process is performed at step 511 and the bearer modification process for updating the serving gateway and UE location information is performed at step 515 . The new MME sends a Context Acknowledge message to the old MME/SGSN 135 for acknowledgment of the receipt of the UE information at step 513 . After the bearer modification at step 515 , the new MME 114 sends a TAU Accept message to the UE 110 at step 517 so as to complete the tracking area update procedure.
[0053] According to this exemplary embodiment of the present invention, the UE configures an identification type indicator for discriminating the types of the temporary identifier of the network node which is transmitted in the request message such as the Attach Request and Tracking Area Update Request message. The UE transmits the request message to the network node. Afterward, the UE receives a response message from the network node in response to the request message.
[0054] According to another exemplary embodiment of the present invention, if the request message such as Attach Request or Tracking Area Update Request is received from the UE, the network node determines whether the request message includes the identification type indicator for indicating the type of the old network node based on the temporary identifier. If the request message includes the identification type indicator, the network node identifies the old network node as one of SGSN and MME. At this time, the network node analyzes the identification type indicator related to the temporary identifier corresponding to the old network node to determine the old network node as one of SGSN and MME. Afterward, the network nod receives the UE information from the old network node and sends the response message to the UE using the UE information.
[0055] FIG. 6 is a flowchart illustrating operations of an MME for supporting communication between a UE and a network node according to an exemplary embodiment of the present invention.
[0056] Referring to FIG. 6 , the MME 114 receives the Attach Request/TAU Request message transmitted by the UE 110 at step 701 . Upon receipt of the request message, the MME 114 checks the EPS mobile identity IE in the request message at step 703 . If the MSB of LAC/MMEGI is determined to be set to 0 at step 721 , this means that the old network node to which the UE 110 has been attached is SGSN, and thus the MME 114 discovers the corresponding one among a plurality of SGSNs to request for UE information at step 723 .
[0057] If the MSB of LAC/MEGI is determined to be set to 1 at step 711 , this means that the old network node to which the UE 110 has been attached is MME or SGSN, and thus the MME 114 determines whether the Attach Request message transmitted by the UE 110 includes a valid P-TMSI signature or the TAU Request message transmitted by the UE 110 includes at least one of a CKSN or a P-TMSI signature at step 713 . If it is determined that the request message includes a valid CKSN or a P-TMSI signature, this means that the old network node to which the UE has been attached previously is SGSN, and thus the MME 114 discovers the targeted one of SGSNs to request for the UE information at step 715 . Otherwise, if it is determined that the request message includes neither a valid P-TMSI signature nor a CKSN, this means that the old network node to which the UE has been attached previously is MME, and thus the MME 114 discovers the targeted one among MMEs to request for the UE information at step 717 .
[0058] According to an exemplary embodiment of the present invention, the MME includes a communication unit, a determination unit, and a control unit.
[0059] The communication unit is responsible for communication with the UE. The communication unit can receive the access request message from the UE. Here, the access request message can be one of an Attach Request or a Tracking Area Update Request.
[0060] The determination unit analyzes the access request message transmitted by the UE to determine the type of the old network node. Here, the determination unit analyzes the P-TMSI signature to determine the type of the old network node. The determination unit can include a judging module and an identification module. The determination unit analyzes the P-TMSI signature of the access request message. The identification module judges the old network node as one of MME and SGSN according to the analysis result of P-TMSI signature.
[0061] The control unit requests the old network node for the UE information. Upon receipt of the UE information, the control unit controls such that the network node sends the response message to the UE using the acquired UE information.
[0062] According to an exemplary embodiment of the present invention, the UE includes a communication unit and a control unit. The control unit controls to transmit an access request message to the MME. Here, the control unit controls such that the P-TMSI signature is transmitted in the access request message. The access request message can be one of an Attach Request and a Tracking Area Update Request of the UE. The communication unit is responsible for communication with the MME. At this time, the communication unit receives an Access Response message from the MME in response to the Access Request message.
[0063] FIG. 7 is a flowchart illustrating operations of a UE for supporting communication between the UE and a network node according to an exemplary embodiment of the present invention.
[0064] Referring to FIG. 7 , the UE 110 determines whether the technology release version (hereinafter, referred to as rel) is rel — 8 or post rel — 8, i.e., rel — 9 or rel — 10, at step 801 . The operations can be defined differently according to the technology release version. In case of rel — 8, the UE 110 configures the Attach/TAU Request message with UE network capability or other indication information element indicating GUTI/mapped GUTI or without identifier at step 821 and transmits the Attach/TAU Request message to the network node at step 819 .
[0065] In case of post rel — 8 (i.e., rel — 9 or rel — 10), the UE 110 sets a valid UE network capability at step 811 and determines whether to use the GUTI or mapped GUTI as the identification type information, based on the identification type indication capability of the UE, at step 813 . If it is determined to use GUTI, the UE 110 configures the Attach/TAU Request message with the identification type field or identification type-related IE set to indicate GUTI at step 815 , and otherwise to use mapped GUTI, configures the Attach/TAU Request message with the identification type field or identity-related IE set to indicate mapped GUTI at step 817 . Next, the UE 110 sends the Attach/TAU Request message to the network at step 819 .
[0066] According to an exemplary embodiment of the present invention the UE includes a control unit and a communication unit. The control unit configures the request message with the identification type indicator for notifying the network node of the type of the old network node corresponding to the temporary identifier. The control unit configures the request message with the identification type information of the temporary identifier corresponding to the old network node. The communication unit transmits the request message to the network node under the control of the control unit. The communication unit also receives a response message from the network node in response to the request message.
[0067] FIG. 8 is a flowchart illustrating operations of an MME for supporting communication between a UE and a network node according to another exemplary embodiment of the present invention.
[0068] Referring to FIG. 8 , the MME 114 receives the Attach/TAU Request message transmitted by the UE 110 at step 901 . Upon receipt of the Attach/TAU Request message, the MME 114 analyzes the Attach/TAU Request message to check the UE network capability at step 903 . If the Attach Request message or the TAU Request message includes the identification type indication capability-related information configured, this means that the UE 110 has the identification type indication capability in transmitting GUTI-related information. In this case, the MME 114 checks the identification type field or identification type-related IE of the request message to determine whether the old network node to which the UE has been attached previously is GERAN/UTRAN or EUTRAN at step 911 . If the identification type-related information is determined to be GUTI, this means that the old network node is MME, and thus the MME 114 discovers the targeted one among the MMEs to request for the UE information at step 917 . Otherwise if the identification type-related information is the mapped GUTI, this means that the old network node is SGSN, and thus the MME 114 discovers the targeted one among the SGSNs to request for the UE information at step 913 .
[0069] Returning to step 903 , if the Attach Request message or the TAU Request message does not include identification type discrimination-capability-related information, this means that the UE has no identity indication capability, and thus the MME 114 refers at step 921 to the MSB of the MMEGI or LAC in the GUTI or mapped GUTI so as to select one of the SGSNs as the old network node if the MSB is determined to be set to 0 and one of the MMEs (or one of SGSNs according to the network configuration of the carrier) as the old network node if the MSB is determined to be set to 1. In this case, the MME 114 can determine the SGSN to which the UE 110 has attached previously among a plurality of SGSNs based on the additional information such as a CKSN or a P-TMSI signature.
[0070] According to an exemplary embodiment of the present invention, the MME includes a communication unit, a determination unit, and a control unit.
[0071] The communication unit is responsible for communication with the UE. The communication unit can receive the Access Request message transmitted by the UE. Here, the Access Request message can be one of Attach Request and Tracking Area Update Request of the UE.
[0072] The determination unit analyzes the access request message transmitted by the UE to determine the type of the old network node. The determination unit includes a judging module and an identification module. The judging unit judges whether the identification type indicator for discriminating the type of the old network is configured by the UE in association with the temporary identifier of the UE. If no identification type indicator is configured, the identification module determines the old network node to be one of the SGSNs and MMEs. At this time, the identification module analyzes the information related to the identification type of the temporary identifier corresponding to the old network node in the request message to identify whether the old network node is an SGSN or an MME.
[0073] The control unit requests the old network node for the UE information. If the UE information is received from the old network node, the control unit sends the response message to the UE using the acquired UE information.
[0074] In order to support communication between the UE and the MME as described above with reference to FIGS. 2 to 8 , it is necessary to support the IE in the messages as shown in Table 1. Table 1 shows the IE indicating whether the UE has the capability of informing the network node of the identification type in the message. According to an exemplary embodiment of the present invention, the identification type indication capability is configured in octet 7.
[0000]
TABLE 1
8
7
6
5
4
3
2
1
UE network capability IEI
octet 1
Length of UE network capability contents
octet 2
EEA0
128-EEA1
128-EEA2
EEA3
EEA4
EEA5
EEA6
EEA7
octet 3
EIA0
128-EIA1
128-EIA2
EIA3
EIA4
EIA5
EIA6
EIA7
octet 4
UEA0
UEA1
UEA2
UEA3
UEA4
UEA5
UEA6
UEA7
octet 5*
UCS2
UIA1
UIA2
UIA3
UIA4
UIA5
UIA6
UIA7
octet 6*
0
0
0
ID
LPP
LCS
1xSR
NF
octet 7*
spare
spare
spare
TYPE
VCC
indi-
cation
0
0
0
0
0
0
0
0
octet 8*-
Spare
15*
Identification type indication capability (octet 7, bit 5)
0
Identification type indication mechanisms not supported
1
Identification type indication mechanisms supported
[0075] Although exemplary embodiments of the present invention have been described in detail hereinabove, it should be clearly understood that many variations and/or modifications of the basic inventive concepts herein taught which may appear to those skilled in the present art will still fall within the spirit and scope of the present invention, as defined in the appended claims.
[0076] The present invention achieves the following effects from the above described representative exemplary embodiments.
[0077] The present invention provides a method and system for addressing the problem of delay in NAS protocol-based communication due to a failure of acquiring UE information from a valid network node, especially in a situation where the UE attempts network attachment or Tracking Area Update during the movement between different RATs including EUTRAN and GERAN/UTRAN. The method and system using the NAS protocol message and operations of the UE and MME that are defined according to the present invention are advantageous to facilitate communication between the UE and network node.
[0078] While the invention has been shown and described with reference to certain exemplary embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims and their equivalents.
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A method and apparatus for supporting Non-Access Stratum (NAS) communication between a User Equipment (UE) and a Mobility Management Entity (MME) efficiently by addressing the signaling problems occurring between the UE and the MME in a situation where it is necessary for a network node to identify the UE and acquire UE information, if there is any, from another network node to which the UE has been attached, are provided. The method for communication between the UE and network based on the NAS protocol messages and operations is implemented with the involvement a UE, an MME, and an old MME or an old Serving General Packet Radio Service (GPRS) Support Node (SGSN) to which the UE has been attached before so as to facilitate discovering a best node using the UE information acquired from the old MME or old SGSN during the communication between the UE and the network, resulting in a reduction of a communication delay between the UE and network and an improvement of communication efficiency.
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BACKGROUND
[0001] 1. Technical Field
[0002] Methods and example embodiments described herein are generally directed to interconnect architecture, and more specifically, to network on chip system interconnect architecture.
[0003] 2. Related Art
[0004] The number of components on a chip is rapidly growing due to increasing levels of integration, system complexity and shrinking transistor geometry. Complex System-on-Chips (SoCs) may involve a variety of components e.g., processor cores, DSPs, hardware accelerators, memory and I/O, while Chip Multi-Processors (CMPs) may involve a large number of homogenous processor cores, memory and I/O subsystems. In both systems the on-chip interconnect plays a key role in providing high-performance communication between the various components. Due to scalability limitations of traditional buses and crossbar based interconnects, Network-on-Chip (NoC) has emerged as a paradigm to interconnect a large number of components on the chip. NoC is a global shared communication infrastructure made up of several routing nodes interconnected with each other using point-to-point physical links. Messages are injected by the source and are routed from the source router to the destination over multiple intermediate routers and physical links. The destination router then ejects the message and provides it to the destination. For the remainder of the document, terms ‘components’, ‘blocks’ or ‘cores’ will be used interchangeably to refer to the various system components which are interconnected using a NoC. Without loss of generalization, the system with multiple interconnected components will itself be referred to as ‘multi-core system’.
[0005] There are several possible topologies in which the routers can connect to one another to create the system network. Bi-directional rings (as shown in FIG. 1( a )) and 2-D mesh (as shown in FIG. 1( b )) are examples of topologies in the related art.
[0006] Packets are message transport units for intercommunication between various components. Routing involves identifying a path which is a set of routers and physical links of the network over which packets are sent from a source to a destination. Components are connected to one or multiple ports of one or multiple routers; with each such port having a unique ID. Packets carry the destination's router and port ID for use by the intermediate routers to route the packet to the destination component.
[0007] Examples of routing techniques include deterministic routing, which involves choosing the same path from A to B for every packet. This form of routing is independent of the state of the network and does not load balance across path diversities which might exist in the underlying network. However, deterministic routing is simple to implement in hardware, maintains packet ordering and easy to make free of network level deadlocks. Shortest path routing minimizes the latency as it reduces the number of hops from the source to destination. For this reason, the shortest path is also the lowest power path for communication between the two components. Dimension-order routing is a form of deterministic shortest path routing in 2D mesh networks.
[0008] FIG. 2 illustrates an example of XY routing in a two dimensional mesh. More specifically, FIG. 2 illustrates XY routing from node ‘34’ to node ‘00’. In the example of FIG. 2 , each component is connected to only one port of one router. A packet is first routed in the X dimension till it reaches node ‘04’ where the x dimension is same as destination. The packet is next routed in the Y dimension until it reaches the destination.
[0009] Source routing and routing using tables are other routing options used in NoC. Adaptive routing can dynamically change the path taken between two points on the network based on the state of the network. This form of routing may be complex to analyze and implement and is therefore rarely used in practice.
[0010] Software applications running on large multi-core systems can generate complex inter-communication messages between the various blocks. Such complex, concurrent, multi-hop communication between the blocks can result in deadlock situations on the interconnect. Deadlock occurs in a network when messages are unable to make progress to their destination because they are waiting on one another to free up resources (e.g. at buffers and channels). Deadlocks due to blocked buffers can quickly spread over the entire network, which may paralyze further operation of the system. Deadlocks can broadly be classified into network level deadlocks and protocol level deadlocks.
[0011] Deadlock is possible within a network if there are cyclic dependencies between the channels in the network. FIG. 3 illustrates an example of network level deadlock. In the example of FIG. 3 , starting at a state with all buffers empty, the blocks initiate the message transfer of A→C, B→D, C→A and D→B simultaneously. Each block takes hold of its outgoing channel and transmits the message toward its destination. In the example of FIG. 3 , each channel can hold only one message at a time. From this point on, each channel waits on the next channel to move the message further. There is a cyclic dependency in the wait graph and the network becomes deadlocked. Such network layer deadlock or low-level deadlocks can be avoided by construction using deadlock free routing or virtualization of paths.
[0012] Network end points may not be ideal sinks, i.e. they may not consume all incoming packets until some of the currently outstanding packets are processed. If a new packet needs to be transmitted during the processing of an outstanding packet, a dependency may be created between the NoC ejection and injection channels of the module. The dependency may become cyclic based upon the message sequence, position of components and routes taken by various messages. If the deadlock is caused by dependencies external to the network layer, this is called a high-level, protocol or an application level deadlock. In related art systems, most high level tasks involve a message flow between multiple modules on the NoC in a specific sequence. Such a multi-point sequence of intercommunication may introduce complex dependencies resulting in protocol level deadlock. The underlying cause of deadlock remains the channel dependency cycle introduced by the inter-dependent messages between multiple components. Independent messages from one end point to another on the network will not cause protocol level deadlocks; however, depending on the routing of such messages on the network, network level deadlocks are still possible in the system.
[0013] FIGS. 4( a ), 4 ( b ) and FIGS. 5( a ) to 5 ( c ) illustrate an example of protocol level deadlock. Consider an example of a three central processing unit (CPU) system connected to memory and cache controller through a crossbar. The cache controller's interface to the interconnect has a single First-In-First-Out (FIFO) buffer which can hold a maximum of three messages. Internally, the cache controller can process up to two requests simultaneously (and therefore process up to two outstanding miss requests to the memory).
[0014] At FIG. 4( a ), all three CPUs send read requests to the cache controller.
[0015] At FIG. 4( b ), read requests are queued in an input buffer to the cache controller from the crossbar.
[0016] At FIG. 5( a ), the cache controller accepts two requests ‘1’ and ‘2’ from input buffer while the third request ‘3’ remains in the input buffer. ‘1’ and ‘2’ have a read miss in the cache, which in turn issues miss refill requests ‘m1’, ‘m2’ to the memory
[0017] At FIG. 5( b ), the memory returns refill data ‘d1’, ‘d2’. This data gets queued behind ‘3’ in the cache controller's input buffer.
[0018] At FIG. 5( c ), the cache controller waits for refill data for the outstanding requests before accepting new request ‘3’. However the refill data is blocked behind this request ‘3’. The system is therefore deadlocked.
[0019] In this system, deadlock avoidance can be achieved by provisioning additional buffer space in the system, or using multiple physical or virtual networks for different message types. In general, deadlock is avoided by manually 1) interpreting the intercommunication message sequence and dependencies, 2) then allocating sufficient buffers and virtual and/or physical channels and 3) assigning various messages in the sequence the appropriate channel.
[0020] In large scale networks such as the internet, deadlocks are of a lesser concern. Mechanisms such as congestion detection, timeouts, packet drops, acknowledgment and retransmission provide deadlock resolution. However such complex mechanisms are too expensive in terms of power, area and speed to implement on interconnection networks where the primary demands are low latency and high performance. In such systems, deadlock avoidance becomes a critical architectural requirement.
SUMMARY
[0021] This invention proposes automatic construction of a system interconnect which is free from both network and application level deadlock, based upon the provided specification of intercommunication message pattern amongst various components of the system. An exemplary implementation of the process is also disclosed, wherein deadlock avoidance is achieved while keeping the interconnect resource cost minimal.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIGS. 1( a ) and 1 ( b ) illustrate Bidirectional ring and 2D Mesh NoC Topologies
[0023] FIG. 2 illustrates an example of XY routing in a two dimensional mesh.
[0024] FIG. 3 illustrates an example of network level deadlock.
[0025] FIGS. 4( a ), 4 ( b ) illustrate an example memory subsystem with three CPUs issuing read requests to cache controller.
[0026] FIGS. 5( a ) to 5 ( c ) illustrate message exchange in the memory subsystem causing protocol level deadlock.
[0027] FIG. 6 illustrates an example of communication sequence on a cache read miss in a memory subsystem.
[0028] FIGS. 7( a ) and 7 ( b ) illustrate an example of deadlock in the memory subsystem.
[0029] FIGS. 8( a ) and 8 ( b ) illustrates an example of an implementation of automatic deadlock avoidance in the memory subsystem, in accordance with an example embodiment.
[0030] FIG. 9 illustrates a flowchart for deadlock free traffic mapping on a NoC, in accordance with an example embodiment.
[0031] FIG. 10 illustrates an example computer system on which example embodiments may be implemented.
DETAILED DESCRIPTION
[0032] Complex dependencies introduced by applications running on large multi-core systems can be difficult to analyze manually to ensure deadlock free operation. Example embodiments described herein are based on the concept of automatically constructing deadlock free interconnect for a specified inter-block communication pattern in the system. An example process of the automatic deadlock free interconnect construction is also disclosed.
[0033] Applications running on multi-core systems often generate several sequences of inter-dependent messages between multiple blocks, wherein a message arriving at a block must generate another message for a different block, before it completes processing and releases the resources at the block for new messages. For a hypothetical example, consider a task running on block A which requests an operation to be performed on block B. On receiving the request message, block B completes part of the operation and sends partial results to a third block C which performs another part of the operation and sends the partial results to block D. Block D performs consolidation and sends the final results back to block A. Completion of the operation on block A required a sequence of messages to be generated and exchanged between multiple blocks on the network. There are higher level dependencies between the messages for successful completion of task on the originating block. At the network interface of intermediate blocks there is a dependency of the incoming channel on the outgoing channel of the block. Any cycles in such channel dependencies can result in protocol level deadlock in the system.
[0034] Traditional systems may employ semi-automatic analysis for detecting potential deadlocks in multi-core systems, however the results are manually analyzed and suitable modifications to the interconnect are made to avoid potential deadlocks.
[0035] Communications in the system are specified in its entirety to capture all high level message dependencies. Example embodiments then takes a holistic view of messages on the interconnect, allocates channel resources, and assigns messages to the allocated channel resources to ensure that the generated interconnect is deadlock free at both network and protocol level. The example embodiments remove cyclic resource dependencies in the communication graph through the use of virtual channels. Virtual channels provide logical links over the physical channels connecting two ports. Each virtual channel has an independently allocated and flow controlled flit buffer in the network nodes. Each high level communication in the system needs to be specified in the form of grouped end-to-end sequence of multiple blocks between which the message flows. In the hypothetical example presented above, the sequence would be represented as A→B→C→D→A. Routing paths on the network, between each source-destination pair i.e. sections making up the above sequence, are either made available to the algorithm used in example embodiments, or the algorithm automatically determines to avoid deadlock.
[0036] The flow of the example embodiments begins with the most complex message sequence and uses its routed path on the network to create a channel dependency graph. The example embodiments use the lowest virtual channel ID on the physical links and then pick up progressively less complex message sequences and continue to map their route to the existing global channel dependency graph. When mapping a path between two blocks, if a cycle is detected in the dependency graph, the example embodiments backtrack and re-map the section that contains the dependency by using the next highest virtual channel ID on the path to remove the cycle from the dependency graph. As a rule, example embodiments first attempt to map on to any pre-allocated virtual channels in increasing order of channel ID value and if no other pre-allocated virtual channels remain on the path, allocate free virtual channel IDs also in increasing order of channel ID value. This process continues till network routes of all the specified message sequences are mapped on the global graph without any cycles. The algorithm aborts the effort if a deadlock free mapping of the specified system messages cannot be achieved with the constraint on the number of available virtual channels. Further details are provided in the examples below and in the flowchart of FIG. 9 . Other variations of the scheme are possible. For example, instead of using the same virtual channel for all physical links of a route between end points of a section of a message sequence, it is possible to use different virtual channels on each physical link of a route. It is also possible for the algorithm to attempt to use different routes for various messages in order to reduce the virtual channels usage, or for load balancing while maintaining deadlock avoidance.
[0037] In an example system, the CPU communicates with a memory subsystem that includes a cache and external DRAM memory. The CPU issues a read request which has a read miss in the cache. As a result, the cache controller issues a read refill request to the external memory controller. Refill data returns from the memory to cache controller which in turn issues read response to the CPU.
[0038] FIG. 6 illustrates an example of communication sequence on a cache read miss. The example communication pattern described above is expressed as a sequence as shown in FIG. 6 . In the cache read miss sequence example, a read request 600 is sent from CPU (A) to Cache (B). At Cache (B), a cache read miss occurs and a read refill request 601 is generated which proceeds to Memory (C). At Memory (C), read refill response 602 is generated and sent back to Cache (B). Cache (B) then sends read response 603 back to CPU (A).
[0039] FIGS. 7( a ) and 7 ( b ) illustrate an example of deadlock in the memory subsystem. Specifically, FIG. 7( a ) shows a simple topology in which the CPU, cache and memory are interconnected by physical links. Each physical link on the network is assumed to have a single virtual channel. FIG. 7( b ) illustrates a possible channel dependency graph for the above communication sequence. Specifically, the communication sequence on a cache read miss as depicted in FIG. 6 are illustrated in FIG. 7( b ) based on the physical links of FIG. 7( a ). The graph has a cycle indicating potential application level deadlock. For example, deadlock may occur when CPU (A) sends a subsequent read request message to Cache (B) by physical channel c before Cache (B) receives a response from Memory (C), through the same physical channel for the earlier refill request. Cache (B) thereby becomes deadlocked as it cannot process the subsequent read request message from CPU (A) without first processing its pending refill request, and cannot process the pending refill request as the response to the refill request from Memory (C) is in the queue for physical channel c, behind the subsequent read request message. Similarly, deadlock may occur when Cache (B) attempts to return a response to the message from CPU (A) through physical channel d, but cannot send the message through the channel if Memory (C) has not processed previous messages sent from Cache (B) to Memory (C).
[0040] FIGS. 8( a ) and 8 ( b ) illustrates automatic deadlock avoidance implemented in the example system of FIG. 6 , in accordance with an example embodiment. As shown in FIG. 8( a ), virtual channel ID 0 is utilized on communication sections A→B and B→C without seeing any deadlocks. However, when the subsystem tries to map section C→B on VC ID 0, a loop is detected (e.g., at physical channel c due to the deadlock as described in FIG. 7( b )). The subsystem back tracks and tires to remap C→B path using VC ID 1 (leaving VC ID 0 unused), which does not cause any cycles in the graph. The subsystem proceeds to map path B→A starting with VC ID 0, which creates a cycle in the graph (e.g., at physical channel d due to the deadlock as described in FIG. 7( b )). The subsystem then tries VC ID 1 which maps successfully without cycles in the graph. Thus the subsystem has successfully mapped the entire communication sequence while avoiding potential deadlocks.
[0041] FIG. 9 illustrates a flowchart for deadlock free traffic mapping on a NoC, in accordance with an example embodiment. In the implementation as depicted in FIG. 9 , at 900 , the system selects a user specified message sequence (e.g., receiving a message sequence from the user). At 901 , the system selects network end-points to define a section of the sequence. At 902 , the system selects a route between the section end points based on a routing scheme. At 903 , an internal counter may be set from zero to count how many of the available virtual channels are tested to map the specified traffic. At 904 , the system utilizes the next available virtual channel as indicated by the counter to add a link on the route to the global channel dependency graph. At 905 , the system checks (e.g. automatically) for a cyclic dependency in the current dependency graph. At 906 , if a cycle is detected, then the system proceeds to 907 to remove and reset the current section of the message sequence from the dependency graph. The system proceeds then to 908 to increment the counter to the next available virtual channel, and determines at 909 if all of the available virtual channels have been exhausted. The system proceeds back to 904 if the available virtual channels have not been exhausted. However, if all available virtual channels have been attempted, then the system proceeds to 910 to end the process and to indicate (e.g. message to user) that the specified traffic cannot be mapped with the available virtual channels.
[0042] If no cycle is detected, then the system proceeds to 911 to determine if the current section is fully mapped. If the current section is not fully mapped, then the system proceeds to 904 to utilize the virtual channel (as indicated by the counter) to add the next link on the route.
[0043] If the current section is fully mapped, then the system proceeds to 912 to determine if the current sequence has been fully mapped. If the current sequence has not been fully mapped, then the system proceeds to 901 to select end-points for the next section of the sequence.
[0044] If the current sequence has been fully mapped, then the system proceeds to 913 to determine if all sequences have been fully mapped. If all sequences have not been fully mapped then the system proceeds to 900 to use the next message sequence from the user specification. If all sequences have been fully mapped, the system proceeds to 914 to indicate (e.g., message to the user) a possible deadlock free mapping of the specified traffic.
[0045] FIG. 10 illustrates an example computer system 1000 on which example embodiments may be implemented. The computer system 1000 includes a server 1005 which may involve an I/O unit 1035 , storage 1060 , and a processor 1010 operable to execute one or more units as known to one of skill in the art. The term “computer-readable medium” as used herein refers to any medium that participates in providing instructions to processor 1010 for execution, which may come in the form of computer-readable storage mediums, such as, but not limited to optical disks, magnetic disks, read-only memories, random access memories, solid state devices and drives, or any other types of tangible media suitable for storing electronic information, or computer-readable signal mediums, which can include transitory media such as carrier waves. The I/O unit processes input from user interfaces 1040 and operator interfaces 1045 which may utilize input devices such as a keyboard, mouse, touch device, or verbal command.
[0046] The server 1005 may also be connected to an external storage 1050 , which can contain removable storage such as a portable hard drive, optical media (CD or DVD), disk media or any other medium from which a computer can read executable code. The server may also be connected an output device 1055 , such as a display to output data and other information to a user, as well as request additional information from a user. The connections from the server 1005 to the user interface 1040 , the operator interface 1045 , the external storage 1050 , and the output device 1055 may via wireless protocols, such as the 802.11 standards, Bluetooth® or cellular protocols, or via physical transmission media, such as cables or fiber optics. The output device 1055 may therefore further act as an input device for interacting with a user.
[0047] The processor 1010 may execute one or more modules. The route construction module 1011 is configured to automatically construct a path comprising of physical links of the interconnect for routing messages from a source block to a destination block in the multi-core system. The virtual channel allocation module 1012 may be configured to allocate one of the available virtual channels for a link in the route between endpoints of a section in a message sequence of the multi-core system and add it to the global channel dependency graph. The dependencies module 1013 may be configured to automatically check for cyclic dependencies among the channels by detecting loops in the channel dependency graph.
[0048] The route construction module 1011 , the virtual channel allocation module 1012 , and the dependencies module 1013 may interact with each other in various ways depending on the desired implementation. For example, the route construction module 1011 may select network end-points to define a section of a sequence, and select a route between the section end points based on a routing scheme, based on load balancing, based on resource minimization or other possible factors. The virtual channel allocation module 1012 may set an internal counter may be set from zero to count how many of the available virtual channels are tested to map the specified traffic. The virtual channel allocation module may allocate virtual channels based on resource sharing and minimization, load balancing or other possible factors.
[0049] The route construction module 1011 may instruct the virtual channel allocation module 1012 to utilize the next available virtual channel (e.g. as indicated by the counter in the virtual channel allocation module) to add a link on the route to the global channel dependency graph. Then, the route construction module 1011 may instruct the dependency module 1013 to checks (e.g. automatically) for a cyclic dependency in the current dependency graph. If the dependency module 1013 detects a dependency, the route construction module 1011 may remove and reset the current section of the message sequence from the dependency graph, wherein the virtual channel allocation module 1012 may increment the counter to the next available virtual channel, and check if the available virtual channels are exhausted. If all available virtual channels have been attempted, then the route construction module 1011 may abort and indicate (e.g. message to user) that the specified traffic cannot be mapped with the available virtual channels.
[0050] If no cycle is detected by the dependency module 1013 , then the route construction module 1011 may determine if the current section is fully mapped. If the current section is determined not to be fully mapped, then the route construction module 1011 attempts to utilize the allocated virtual channel to add the next link on the route, and to recheck the dependency.
[0051] If the current section is determined to be fully mapped, then the route construction module 1011 may determine if the current sequence has been fully mapped. If the current sequence is determined not to be fully mapped, then the route construction module 1011 may proceed to select end-points for the next section of the sequence and attempt to select another route between the new end points based on a routing scheme.
[0052] If the current sequence is determined to be fully mapped, then the route construction module determines if all sequences have been fully mapped. If all sequences are determined not to be fully mapped, then the route construction module 1011 selects the next message sequence from the user specification and attempts to map the next message sequence. If all sequences are determined to be fully mapped, then the route construction module 1011 may indicate (e.g., message to the user) a possible deadlock free mapping of the specified traffic.
[0053] The route construction module may also conduct the automatic construction of a map by being configured to receive a specification of the multi-core system containing a deadlock; to instruct the allocation module 1012 to automatically reallocate virtual channels until the deadlock is resolved; and to construct the map based on the reallocation.
[0054] Furthermore, some portions of the detailed description are presented in terms of algorithms and symbolic representations of operations within a computer. These algorithmic descriptions and symbolic representations are the means used by those skilled in the data processing arts to most effectively convey the essence of their innovations to others skilled in the art. An algorithm is a series of defined steps leading to a desired end state or result. In the example embodiments, the steps carried out require physical manipulations of tangible quantities for achieving a tangible result.
[0055] Moreover, other implementations of the example embodiments will be apparent to those skilled in the art from consideration of the specification and practice of the example embodiments disclosed herein. Various aspects and/or components of the described example embodiments may be used singly or in any combination. It is intended that the specification and examples be considered as examples, with a true scope and spirit of the embodiments being indicated by the following claims.
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Systems and methods for automatically building a deadlock free inter-communication network in a multi-core system are described. The example embodiments described herein involve deadlock detection during the mapping of user specified communication pattern amongst blocks of the system. Detected deadlocks are then avoided by re-allocation of channel resources. An example embodiment of the deadlock avoidance scheme is presented on Network-on-chip interconnects for large scale multi-core system-on-chips.
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BACKGROUND OF THE INVENTION
The present invention relates to an armature, and more particularly to a fuel injector armature permitting separate fluid and vapor flow.
In the conventional art, it is known to use a fuel injector in an engine compartment of an automobile, for example. It is also known in the conventional art to use an armature in the fuel injector. Fuel flows from an inlet of the fuel injector, through an opening in the armature, to the outlet of the fuel injector. High engine operating temperatures, engine covers, and crowded engine compartments prevent air flow from cooling the fuel injector, which causes fuel disposed within the fuel injector to change from a liquid to a gaseous state (i.e., vaporize). Vaporization is more likely to occur when the engine has been heated (e.g., operated) and is then turned off, since the fuel injector and fuel remain hot, but cool liquid fuel is not being introduced into the system. Vaporized fuel can block the opening in the armature. When the vaporized fuel blocks the opening in the armature, liquid fuel is prevented from flowing through the fuel injector, and reliable engine restarts can be adversely affected. Thus, the engine must cool, thereby allowing the vaporized fuel to condense into a liquid, before the engine can be reliably restarted.
In the conventional art, it is known to cool the engine using a fan. However, this solution requires additional hardware (e.g., fan components), additional room in the engine compartment (e.g., permit adequate air flow paths, install fan components, etc.), and additional manufacturing and maintenance costs. Thus, it is desirable to have an improved fuel injector that dissipates the effects of vapor fuel flow when the engine has been heated and turned off, thereby allowing the engine to be reliably restarted.
SUMMARY OF THE INVENTION
The present invention provides a fuel injector. The fuel injector comprises a tube assembly having a longitudinal axis extending between a first end and a second end; a seat secured at the second end of the tube assembly, the seat defining an opening; and an armature assembly movable along the longitudinal axis between first and second positions with respect to the seat. The armature assembly is spaced from the seat such that fuel flow through the opening is permitted in the first position and the armature assembly contiguously engages the seat such that fuel flow through the opening is prevented in the second position. The armature includes a first set of passages permitting a first fluid flow in a first direction generally along the longitudinal axis; and a second set of passages permitting a second fluid flow in a second direction generally along the longitudinal axis, the second direction being generally opposite to the first direction.
The present invention also provides an armature assembly for a fuel injector. The armature moves along a longitudinal axis between first and second positions with respect to a seat having an opening. The armature assembly is spaced from the seat such that fuel flow through the opening is permitted in the first position and the armature assembly contiguously engages the seat such that fuel flow through the opening is prevented in the second position. The armature comprises a first set of passages permitting a first fluid flow in a first direction generally along the longitudinal axis; and a second set of passages permitting a second fluid flow in a second direction generally along the longitudinal axis, the second direction being generally opposite to the first direction.
The present invention also provides a method of dissipating fuel vapor in a fuel injector. The fuel injector has a tube assembly extending along a longitudinal axis between a first end and a second end. A seat is secured at the second end of the tube assembly and defines an opening. And an armature assembly that is movable along the longitudinal axis between first and second positions with respect to the seat. The armature assembly is spaced from the seat such that fuel flow through the opening is permitted in the first position and the armature assembly contiguously engages the seat such that fuel flow through the opening is prevented in the second position. The method comprises providing the armature with a first set of passages permitting liquid fuel flow in a first direction generally from the first end toward the second end; and providing the armature with a second set of passages permitting vapor fuel flow in a second direction generally from the second end toward the first end.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated herein and constitute part of this specification, illustrate an embodiment of the invention, and, together with the general description given above and the detailed description given below, serve to explain features of the invention.
FIG. 1 is a cross-sectional view of a fuel injector including an armature assembly according to the present invention.
FIG. 2 is a cross-sectional view of the armature assembly according to the present invention.
FIG. 3 is a bottom view of the armature assembly according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings, FIG. 1 shows a fuel injector 100 including an armature assembly 500 . The fuel injector 100 can be any conventional fuel injector, including top or bottom feeder fuel injectors or the like.
The fuel injector 100 includes a tube assembly having a fuel inlet end portion 110 , a fuel outlet end portion 150 , and the armature assembly 500 . As it is used in connection with the present invention, the term “assembly” can refer to a single homogenous material formation, a construction of multiple components that are generally fixed together, a group of operationally interrelated features, or a combination thereof. The fuel inlet end portion 110 of the fuel injector 100 is adapted to be operatively connected to a fuel rail (not shown). The fuel outlet end portion 150 of the fuel injector 100 is adapted to be operatively associated with a combustion chamber of an internal combustion engine (not shown). The fuel inlet and outlet end portions 110 , 150 define a fuel injector longitudinal axis 101 . The armature assembly 500 includes an armature assembly axis 501 . The armature assembly 500 is disposed between and in fluid communication with both the fuel inlet end portion 110 and the fuel outlet end portion 150 of the fuel injector 100 , such that the armature assembly axis 501 generally coaxial with the fuel injector longitudinal axis 101 .
During operation of the engine, fuel flows from the fuel rail (not shown) into the fuel inlet end portion 110 of the fuel injector 100 . Fuel flow continues from the fuel inlet end portion 110 of the fuel injector 100 , through the armature assembly 500 (to be discussed in detail later), to the fuel outlet end portion 150 of the fuel injector 100 . The fuel then flows from the fuel outlet end portion 150 of the fuel injector 100 to the combustion chamber of the engine (not shown).
The armature assembly 500 will now be discussed in detail. As shown in FIGS. 2 and 3, the armature assembly 500 includes a first portion 510 and a second portion 550 . The first portion 510 of the armature assembly 500 can be disposed proximate the fuel inlet portion end 110 of the fuel injector 100 . The second portion 550 of the armature assembly 500 can be disposed proximate the fuel outlet end portion 150 of the fuel injector 100 .
The first portion 510 includes a first surface 511 and a second surface 513 . The first and second surfaces 511 , 513 can be approximately flat, and can be generally parallel to each other.
An exterior surface 515 and an interior surface 517 are disposed between the first and second surfaces 511 , 513 . The exterior surface 515 defines a maximum radial dimension of the armature assembly 500 . The interior surface 517 defines a first portion of a first passage 521 . The first portion of the first passage 521 is adapted to permit fuel flow through the first portion 510 of the armature assembly 500 . The cross-sectional shapes of the exterior surface and interior surfaces 515 , 517 can be a variety of shapes. For example, each cross-section of the exterior surface 515 and the interior surface 517 can be substantially circular and coaxial with the armature assembly axis 501 such that the exterior and interior surfaces 515 , 517 define an annular wall 519 .
The annular wall 519 includes a second passage 531 . The second passage 531 is adapted to permit liquid fuel flow therethrough. The second passage 531 is in fluid communication with the first passage 521 of the armature 500 and the fuel outlet end portion 150 of the fuel injector 100 . By this arrangement, the second passage 531 can permit liquid fuel flow from the fuel inlet portion 110 to the fuel outlet portion 150 of the fuel injector 100 .
The second passage 531 extends along a second passage axis 532 . The second passage axis 532 can be disposed at an angle relative to the armature assembly axis 501 of the armature 500 . Preferably, the second passage axis 532 of the second passage 531 is disposed at an angle of about 10 degrees to the armature assembly axis 501 of the armature 500 . A cross-section of the second passage 531 can be a variety of shapes, e.g., substantially circular. A diameter of the second passage 531 can be greater than a fuel bore in a conventional armature. According to one example of the invention, the second passage 531 has a diameter of approximately 1.25 inches.
A set of second passages 531 can extend through the annular wall 519 of the armature assembly 500 . As it is used in connection with the present invention, the term “set” can refer to one or more examples of a feature. For example, four second passages 531 can be disposed in the armature assembly 500 . The four second passages 531 can be about equally spaced around the armature assembly axis 501 .
The first portion 510 of the armature 500 further includes a third passage 541 . The third passage 541 is adapted to permit vapor fuel flow therethrough. The third passage 541 is in fluid communication with the outlet end portion 150 and the inlet end portion 110 of the fuel injector 100 . By this arrangement, the third passage 541 is adapted to permit gaseous fuel to flow from generally the fuel outlet end portion 150 toward the fuel inlet end portion 110 of the fuel injector 100 . Thus, the third passage 541 offers an alternate path for fuel vapor to be displaced, thereby allowing liquid fuel to flow through the first and second passages 521 , 532 .
The third passage 541 can extend along a third passage axis 542 . The third passage axis can be generally parallel to the armature assembly axis 501 of the armature 500 . A cross-section of the third passage 541 can be a variety of shapes. For example, the cross-section of the third passage 541 can be a generally rectangular channel with radiuses corners.
A set of third passage 541 can be disposed in the armature assembly 500 . For example, four third passages 541 can be disposed in the armature assembly 500 . The four third passage 541 can be about equally spaced around the armature assembly axis 501 . Moreover, the set of third passages 541 can be angularly offset around the armature assembly axis 501 with respect to the set of second passages 531
The second portion 550 of the armature assembly 500 includes the second surface 513 and a third surface 551 . The second and third surfaces 513 , 551 can be generally flat, and can be generally parallel to each other. Moreover, the first, second, and third surfaces 511 , 513 , 551 can be generally parallel to one another.
An exterior surface 553 and an interior surface 555 are disposed between the second and third surfaces 513 , 551 . The exterior surface 553 defines a maximum radial dimension of the second portion 550 , which can be constricted with respect to the maximum radial dimension of the first portion 510 , as defined by the exterior surface 515 . The interior surface 555 defines a second portion of the first passage 521 . The second portion of the first passage 521 is also adapted to permit liquid fuel flow through the second portion 550 of the armature 500 . Each cross-section of the exterior surface 553 and an interior surface 555 can be of a variety of shapes. Each cross-section of the exterior surface 553 and the interior surface 555 can be substantially circular and coaxial with the armature assembly axis 501 .
While the present invention has been disclosed with reference to certain embodiments, numerous modifications, alterations, and changes to the described embodiments are possible without departing from the sphere and scope of the present invention, as defined in the appended claims. Accordingly, it is intended that the present invention not be limited to the described embodiments, but that it have the full scope defined by the language of the following claims, and equivalents thereof.
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A fuel injector including a tube assembly having a longitudinal axis extending between a first end and a second end, a seat secured at the second end of the tube assembly and defining an opening. An armature assembly is movable along the longitudinal axis between first and second positions with respect to the seat. The armature includes a first set of passages permitting fluid flow therethrough and a second set of passages permitting vapor flow therethrough. Additionally, a method of dissipating fuel vapors in a fuel injector includes providing the armature with a first set of passages permitting fluid flow therethrough and a second set of passages permitting vapor flow therethrough.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a process for the preparation of foams characterized by isocyanurate and urethane linkages, commonly known as urethane-modified polyisocyanurate foams. More particularly, the invention relates to a novel catalyst system for the preparation of these foams.
2. Prior Art
The preparation of foams characterized by isocyanurate and urethane linkages is well known in the art. Generally, these foams are prepared by reacting an organic polyisocyanate with a polyol in the presence of a catalyst which promotes the urethane reaction and a catalyst which promotes the trimerization reaction. The foams may also be prepared by condensing in the presence of a trimerization catalyst, an isocyanate-terminated quasi-prepolymer obtained by the reaction of an organic polyisocyanate with a polyol. Several catalysts are known in the art to promote the trimerization of isocyanate groups. Examples of these catalysts are: (a) organic strong bases, (b) tertiary amine co-catalyst combinations, (c) Friedel-Crafts catalysts, (d) basic salt of carboxylic acids, (e) alkali metal oxides, alkali metal alcoholates, alkali metal phenolates, alkali metal hydroxides and alkali metal carbonates, (f) onium compounds from nitrogen, phosphorous, arsenic, antimony, sulfur and selenium, and (g) monosubstituted monocarbamic esters.
Generally, the use of the above catalysts results in formulations having short cream times, particularly when reactive primary hydroxy-terminated polyols are employed in the formulations. This does not lend the formulations to be of use in pour-in-place and slab stock foaming applications. It is to overcome the aforesaid shortcomings of the prior art operations that the present invention is directed.
SUMMARY OF THE INVENTION
The present invention relates to the use of alkali metal salts of organic sulfinic acids as trimerization catalysts for isocyanate groups. Use of the catalysts of the subject invention offers latent catalytic effect even when using very reactive polyols, i.e., primary hydroxy-terminated polyols in the foam formulation.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The alkali metal salts of organic sulfinic acids, which are of use in the process of the subject invention may be represented by the formula: ##STR1## wherein A is sodium or potassium and R is aryl, alkyl of from 1 to 16 carbon atoms, alkaryl of from 1 to 4 carbon atoms in the alkyl chain, alkoxyaryl having from 1 to 4 carbon atoms in the alkoxy chain, dialkylaminoaryl and dialkylaminoalkyl having from 1 to 4 carbon atoms in the alkyl chains. Representative catalysts include the sodium and potassium salts of the following sulfinic acids: methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, n-hexyl, n-heptyl, n-octyl, n-nonyl, n-decyl, n-undecyl, dichloromethyl, trichloromethyl, benzene, toluene, 2,4-dimethylbenzene, 2,5-dimethylbenzene, 3,4-dimethylbenzene, 2,4,6-trimethylbenzene, 2,4,6-tripropylbenzene, 2,4-diethylbenzene, 2,5-diethylbenzene, 4-methoxybenzene, 4-phenoxybenzene, 2,5-diethoxybenzene, 2-thiophene, 2-naphthalene, 2-dimethylaminobenzene, 2,4-bis(dimethylamino)benzene, 2-(N-methylhydroxyethylamino)benzene, dimethylaminopropyl and diethylaminopropyl. Generally from 0.1 part to 15 parts of catalyst per equivalent of polyisocyanate will be employed in the process of the invention.
The organic polyisocyanate used in the preparation of the foams in the process of the subject invention corresponds to the formula:
R"(NCO).sub.z
wherein R" is a polyvalent organic radical which is either aliphatic, aralkyl, alkaryl, aromatic or mixtures thereof, and z is an integer which corresponds to the valence of R" and is at least two. Representative of the organic polyisocyanates contemplated herein includes, for example, the aromatic diisocyanates such as 2,4-toluene diisocyanate, 2,6-toluene diisocyanate, mixtures of 2,4- and 2,6-toluene diisocyanate, crude toluene diisocyanate, methylene diphenyl diisocyanate, crude methylene diphenyl diisocyanate and the like; the aromatic triisocyanates such as 4,4',4"-triphenylmethane triisocyanate, 2,4,6-toluene triisocyanates; the aromatic tetraisocyanates such as 4,4'-dimethyldiphenylmethane-2,2'-5,5'-tetraisocyanate, and the like; arylalkyl polyisocyanates such as xylylene diisocyanate; aliphatic polyisocyanates such as hexamethylene-1,6-diisocyanate, lysine diisocyanate methylester and the like; and mixtures thereof. Other organic polyisocyanates include polymethylene polyphenylisocyanate, hydrogenated methylene diphenylisocyanate, m-phenylene diisocyanate, naphthylene1,5-diisocyanate, 1-methoxyphenylene-2,4-diisocyanate, 4,4'-biphenylene diisocyanate, 3,3'-dimethoxy-4,4'-biphenyl diisocyanate, 3,3'-dimethyl-4,4'-biphenyl diisocyanate, and 3,3'-dimethyldiphenylmethane-4,4'-diisocyanate. These polyisocyanates are prepared by conventional methods known in the art such as the phosgenation of the corresponding organic amine. Quasi-prepolymers may also be employed in the process of the subject invention. These quasi-prepolymers are prepared by reacting an excess of organic polyisocyanate or mixtures thereof with a minor amount of an active hydrogen-containing compound as determined by the well-known Zerewitinoff test, as described by Kohler in Journal Of The American Chemical Society, 49, 3181 (1927). These compounds and their methods of preparation are well known in the art. The use of any one specific active hydrogen compound is not critical hereto, rather any such compound can be employed herein. Generally, the quasi-prepolymers have a free isocyanate content of from 20% to 40% by weight.
Suitable active hydrogen-containing groups as determined by the Zerewitinoff method which are reactive with an isocyanate group include --OH, --NH--, --COOH, and --SH. Examples of suitable types of organic compounds containing at least two active hydrogen-containing groups which are reactive with an isocyanate group are hydroxy-terminated polyesters, polyalkylene ether polyols, hydroxy-terminated polyurethane polymers, polyhydric polythioethers, alkylene oxide adducts of phosphorus-containing acids, polyacetals, aliphatic polyols, aliphatic thiols including alkane, alkene and alkyne thiols having two or more --SH groups; diamines including both aromatic aliphatic and heterocyclic diamines as well as mixtures thereof. Compounds which contain two or more different groups within the abovedefined classes may also be used in accordance with the process of the present invention such as, for example, amino alcohols which contain an amino group and a hydroxyl group. Also, compounds may be used which contain one --SH group and one --OH group as well as those which contain an amino group and a --SH group.
Any suitable hydroxy-terminated polyester may be used such as are obtained, for example, from polycarboxylic acids and polyhydric alcohols. Any suitable polycarboxylic acid may be used such as oxalic acid, malonic acid, succinic acid, glutaric acid, adipic acid, pimelic acid, suberic acid, azelaic acid, sebacic acid, brassylic acid, thapsic acid, maleic acid, fumaric acid, glutaconic acid, α-hydromuconic acid, β-hydromuconic acid, α-butyl-α-ethyl-glutaric acid, α,β-diethylsuccinic acid, isophthalic acid, terephthalic acid, hemimellitic acid, and 1,4-cyclohexane-dicarboxylic acid. Any suitable polyhydric alcohol, including both aliphatic and aromatic, may be used such as ethylene glycol, 1,3-propylene glycol, 1,2-propylene glycol, 1,4-butylene glycol, 1,3-butylene glycol, 1,2-butylene glycol, 1,5-pentanediol, 1,4-pentanediol, 1,3-pentanediol, 1,6-hexanediol, 1,7-heptanediol, glycerol, 1,1,1-trimethylolpropane, 1,1,1-trimethylolethane, hexane-1,2,6-triol, α-methyl glucoside, pentaerythritol, and sorbitol. Also included within the term "polyhydric alcohol" are compounds derived from phenol such as 2,2-bis(4-hydroxyphenyl)propane, commonly known as Bisphenol A.
The hydroxy-terminated polyester may also be a polyester amide such as is obtained by including some amine or amino alcohol in the reactants for the preparation of the polyesters. Thus, polyester amides may be obtained by condensing an amino alcohol such as ethanolamine with the polycarboxylic acids set forth above, or they may be made using the same components that make up the hydroxy-terminated polyester with only a portion of the components being a diamine such as ethylenediamine.
Any suitable polyalkylene ether may be used such as the polymerization product of an alkylene oxide or of an alkylene oxide with a polyhydric alcohol. Any suitable polyhydric alcohol may be used such as those disclosed above for use in the preparation of the hydroxy-terminated polyesters. Any suitable alkylene oxide may be used such as ethylene oxide, propylene oxide, butylene oxide, amylene oxide, and heteric or block copolymers of these oxides. The polyalkylene polyether polyols may be prepared from other starting materials such as tetrahydrofuran and alkylene oxide-tetrahydrofuran copolymers; epihalohydrins such as epichlorohydrin; as well as aralkylene oxides such as styrene oxide. The polyalkylene polyether polyols may have either primary or secondary hydroxy groups and, preferably, are polyethers prepared from alkylene oxides having from two to six carbon atoms such as polyethylene ether glycols, polypropylene ether glycols, and polybutylene ether glycols. The polyalkylene polyether polyols may be prepared by any known process such as, for example, the process disclosed by Wurtz in 1859 and Encyclopedia Of Chemical Technology, Vol. 7, pp. 257-262, published by Interscience Publishers, Inc. (1951) or in U.S. Pat. No. 1,922,459. Alkylene oxide adducts of Mannich condensation products are also useful in the invention.
Alkylene oxide adducts of acids of phosphorus which may be used include those neutral adducts prepared from the alkylene oxides disclosed above for use in the preparation of polyalkylene polyether polyols. Acids of phosphorus which may be used are acids having a P 2 O 5 equivalency of from about 72% to about 95%. The phosphoric acids are preferred.
Any suitable hydroxy-terminated polyacetal may be used such as, for example, the reaction product of formaldehyde or other suitable aldehyde with a dihydric alcohol or an alkylene oxide such as those disclosed above.
Any suitable aliphatic thiol including alkane thiols containing at least two --SH groups may be used such as 1,2-ethanedithiol, 1,2-propanedithiol, 1,3-propanedithiol, and 1,6-hexanedithiol; alkenethiols such as 2-butene-1,4-dithiol, and alkynethiols such as 3-hexyne-1,6-dithiol.
Any suitable polyamine may be used including aromatic polyamines such as methylene dianiline, polyarylpolyalkylene polyamine (crude methylene dianiline), p-aminoaniline, 1,5-diaminonaphthalene, and 2,4-diaminotoluene; aliphatic polyamines such as ethylenediamine, 1,3-propylenediamine; 1,4-butylenediamine, and 1,3-butylenediamine, as well as substituted secondary derivatives thereof.
In addition to the above hydroxy-containing compounds, other compounds which may be employed include graft polyols. These polyols are prepared by the in situ polymerization product of a vinyl monomer in a reactive polyol medium and in the presence of a free radical initiator. The reaction is generally carried out at a temperature ranging from about 40° C. to 150° C.
The reactive polyol medium generally has a molecular weight of at least about 500 and a hydroxyl number ranging from about 30 to about 600. The graft polyol has a molecular weight of at least about 1500 and a viscosity of less than 40,000 cps. at 10% polymer concentration.
A more comprehensive discussion of the graft polyols and their method of preparation can be found in U.S. Pat. Nos. 3,383,351; 3,304,273; 3,652,639; and 3,823,201, the discosures of which are hereby incorporated by reference.
Also polyols containing ester groups can be employed in the subject invention. These polyols are prepared by the reaction of an alkylene oxide with an organic dicarboxylic acid anhydride and a compound containing a reactive hydrogen atom. A more comprehensive discussion of these polyols and their method of preparation can be found in U.S. Pat. Nos. 3,585,185; 3,639,541; and 3,639,542. As is clear from the above, the particular polyol ingredient employed in the preparation of the quasi-prepolymer is not a critical aspect of the present invention. Any compound containing at least two reactive hydrogen atoms may be so used. Particularly preferred compounds are those having an equivalent weight between 100 and 1500.
As mentioned above, the process of the subject invention can be carried out by condensing an organic polyisocyanate in the presence of a polyol. Any of the organic compounds containing at least two active hydrogen-containing groups reactive with an isocyanate group described above in connection with the preparation of the "quasi-prepolymers" may be employed in the subject invention. Generally, the amount of polyol employed will be from about 0.01 to 0.8 equivalent, preferably from 0.1 to 0.7 equivalent per equivalent of organic polyisocyanate.
When a polyol is employed in the process of the subject invention, a urethane catalyst may also be employed. Urethane catalysts which may be employed are well known in the art and include the metal or organometallic salts of carboxylic acid and tertiary amines. Representative of such compounds are: dibutyltin dilaurate, dibutyltin diacetate, stannous octoate, lead octoate, cobalt naphthenate, and other metal or organometallic salts of carboxylic acids in which the metal is bismuth, titanium, iron, antimony, uranium, cadmium, aluminum, mercury, zinc, or nickel as well as other organometallic compounds such as are disclosed in U.S. Pat. No. 2,846,408. Tertiary amines such as triethylenediamine, triethylamine, diethylcyclohexylamine, dimethylethanolamine, methylmorpholine, trimethylpiperazine, N-ethylmorpholine and diethylethanolamine may also be employed as well as mixtures of any of the above. The preferred urethane-promoting catalyst is dibutyltin diacetate. Generally, the amount of the urethane-promoting catalyst employed will be from 0.01% to 10% by weight based on the weight of organic polyisocyanate.
The foams of the present invention are prepared by mixing together the organic polyisocyanate, the polyol or the quasi-prepolymer, a blowing agent and the catalysts at an initiating temperature which, depending on the catalyst, will range from about 0° C. to 50° C. The present invention also contemplates the incorporation of additional ingredients in the foam formulation to tailor the properties thereof. Thus, plasticizers, surfactants, such as the silicone surfactants, e.g. alkylpolysiloxanes, may be employed in the invention. Further additional ingredients include auxiliary or supplemental trimerization catalysts and carbodiimide-promoting compounds. Also, inorganic fillers, pigments and the like can be used.
In any event, the foams prepared in accordance herewith are rigid cellular products having a density of from about one pound to forty pounds per cubic foot which exhibit excellent strength and flame properties, such as fire resistance, low smoke evolution, and excellent weight retention.
Following are specific, non-limiting examples which are provided to illustrate the enumerated principles described herein. All parts are by weight unless otherwise indicated. In the Examples which follow, the following abbreviations are employed:
Mdi -- crude diphenylmethane diisocyanate
Tdh -- 1,3,5-tris(N,N-dimethylaminopropyl)-s-hexahydrotriazine
Dc-193 -- polyalkylsiloxane-polyoxyalkylene copolymer, a foam stabilizer
F-11b -- trichlorofluoromethane
Sbs -- sodium benzenesulfinate
Sts -- sodium toluenesulfinate
Pbs -- potassium benzenesulfinate
Pa -- potassium acetate
Dbtda -- dibutyltin diacetate
Dbtdl -- dibutyltin dilaurate
Polyol A -- a polyol prepared by the reaction of ethylene oxide with trimethylolpropane, said polyol having an equivalent weight of 250.
Polyol B -- an ester-containing polyol prepared by the reaction of propylene oxide with the product of the reaction of one mole of tetrabromophthalic anhydride with one mole of the propylene oxide adduct of pentaerythritol, said polyol having an equivalent weight of 235.
Polyol C -- an ester-containing polyol prepared by the reaction of propylene oxide with the product of the reaction of equal moles of chlorendic anhydride and propylene glycol, said polyol having an equivalent weight of 290.
Polyol D -- a polyol prepared by the reaction of ethylene oxide with the propylene oxide adduct of sucrose, said polyol having an equivalent weight of 490 and an oxyethylene content of 67% by weight.
Polyol E -- a polyol prepared by the reaction of propylene oxide with sorbitol, said polyol having an equivalent weight of approximately 120.
In addition, the physical properties of the foams were determined in accordance with the following test methods:
Density -- ASTM D - 1622-63
K-factor -- ASTM C - 518
Compression strength -- ASTM D - 1621-3
Tumbling friability -- ASTM C - 421
Flame retardancy -- ASTM D - 3014
Smoke density -- NBS smoke density test
Also, the presence of isocyanurate and urethane linkages in the foams was confirmed by infrared spectroscopic analyses.
EXAMPLE I
A series of foams was prepared by mixing in a vessel at high speed, a stream of polyisocyanate and blowing agent, and a stream containing a polyol, catalyst, and surfactant. Thereafter the resulting mixture was cast in a mold and the foams were allowed to free rise. The ingredients employed, amounts thereof, and reactivity profiles of the formulations are presented in Table I, below.
As the data in the Table indicate, the catalysts of the subject invention offer latent catalytic effect, i.e., longer cream and gel times, yet fully cured foams (tack-free time) in acceptable times.
Table I______________________________________ Parts INGREDIENTS A B C D E______________________________________MDI 100 100 100 100 100F-11B 25 25 25 25 25DC-193 1 1 1 1 1Polyol A 20 20 20 20 20Ethylene Glycol 4 4 3 4 3TDH 2 -- -- -- --DMP-30 -- 2 -- -- --PA -- -- 1 -- --SBS -- -- -- 2 --STS -- -- -- -- 2______________________________________ Foam Reactivity A B C C E______________________________________Cream time,seconds 5 11 13 32 17Gel time,seconds 16 125 20 45 36Rise time,seconds 40 50 38 95 150Tack-free time,seconds 40 240 20 90 145Density, poundsper cubic foot 1.7 Foam 2.0 1.7 2.1 collapsed.______________________________________
EXAMPLES II-IX
A series of foams was prepared in the manner described in Example I. The ingredients employed, amounts thereof, as well as the reactivity profile and physical properties of the resulting foams are presented in Table II, below.
Table II__________________________________________________________________________ Example II III IV V VI VII VIII IX__________________________________________________________________________INGREDIENTS, partsMDI 200 200 200 200 200 200 200 200F-11B 50 50 50 50 50 50 50 50Polyol A 30 30 30 30 30 30 -- --Polyol B 10 10 10 10 10 10 10 10Polyol D -- -- -- -- -- -- 30 30SBS 3.75 4.5 3.75 3.75 3.75 5.6 4.5 4.5Ethylene Glycol 6.25 7.5 6.25 6.25 6.25 9.4 7.5 7.5DC-193 2 2 2 2 2 2 2 2TDH -- -- -- 0.2 -- -- -- --DBTDA -- -- 0.1 -- -- -- -- 0.1DBTDL -- -- -- -- 0.2 -- -- --Reactivity, secondsCream time 35 31 12 20 13 28 30 8Gel time 60 50 30 37 28 51 50 28Rise time 95 90 65 60 50 85 88 50Tack-free time 220 180 120 120 81 90 90 95Physical PropertiesOf Foam Of Example:Density, pounds percubic foot 2.1 2.0 1.9 1.7 1.8 1.9 2.2 1.6K-factor, initial 0.127 0.125 0.125 0.128 0.125 0.117 0.122 0.123Compr. str., 10%Defl., psi. 30 28 26 22 23 10 10 21Friab., Wt. Loss % 24 20 13 22 16 22 23 31Butler Chimney TestWt. Ret., % 82 83 79 80 73 78 84 81Flame Ht., in. 7 9 9 8 9 9 9 8Time to SX, sec. 10 10 12 18 21 10 13 10NBS Smoke Density 120 110 119 69 95 124 116 72__________________________________________________________________________
EXAMPLES X-XVI
A series of foams was prepared in the manner described in Example I. The ingredients employed, amounts thereof, as well as the reactivity profile and physical properties of the resulting foams are presented in Table III, below.
Table III______________________________________ Example X XI XII XIII XIV XV XVI______________________________________INGREDIENTS,parts,MDI 200 200 200 200 200 200 200F-11B 40 40 40 40 40 55 55Polyol A 40 30 40 30 -- -- 30Polyol B -- 10 -- 10 10 10 --Polyol C -- -- -- -- -- -- 30Polyol E -- -- -- -- 30 30 --STS 4 4 4 4 4 4 --PBS -- -- -- -- -- -- 2Ethylene Glycol 6 6 6 6 6 6 2DC-193 2 2 2 2 2 2 4Reactivity, secondsCream time 16 21 20 28 28 95 14Gel time 21 40 38 50 50 150 42Tack-free time 114 115 120 125 165 180 115Rise time 80 105 90 110 115 170 75Physical PropertiesOf Foam OfExample:Density, pounds percubic foot 1.8 2.0 1.8 1.9 2.1 2.0 2.3K-factor, initial 0.146 0.132 0.135 0.129 0.136 0.129 0.110K-factor, aged 10days at 140° F. 0.199 0.154 0.159 0.152 0.165 0.153 0.151Compr. str., 10%Defl., psi. 31 30 27 32 29 31 25Friab., Wt. Loss % 28 22 23 18 27 33 4Butler ChimneyTestWt. Ret., % 77 82 84 82 84 57 75Flame Ht., in. 10 10 10 10 10 10 10Time to SX, sec. 17 11 12 11 11 19 13NBS Smoke Density 64 111 49 93 119 140 98______________________________________
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Foams characterized by isocyanurate and urethane linkages are prepared by condensing: (a) an organic polyisocyanate with a polyol or (b) a quasi-prepolymer in the presence of a blowing agent and a catalytically effective amount of an alkali metal salt of an organic sulfinic acid. The catalysts of the invention offer the advantages of longer cream times and fully cured foams in acceptable times thus finding particular utility in pour-in-place and slab stock foaming applications.
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BACKGROUND OF THE INVENTION
The invention is concerned with benzimidazole derivatives and, in particular, it is concerned with benzimidazol-2-yl pyridinium compounds useful as pharmaceuticals in treating or preventing gastric and duodenal ulcers.
SUMMARY OF THE INVENTION
The present invention is concerned with benzimidazole derivatives, particularly benzimidazol-2-yl pyridinium compounds of formula I hereinbelow, useful as pharmaceuticals in treating or preventing gastric and duodenal ulcers.
These compounds are novel and it has been found that they possess valuable pharmacodynamic properties, namely gastric acid secretion-inhibiting and/or mucosa-protective properties (especially against indomethacin-induced lesions), so that they can be used for the control or prevention of illnesses of the gastro-intestinal tract, especially against gastric ulcers and duodenal ulcers.
The present invention includes the compounds themselves as defined above, as well as pharmaceutical compositions containing such compounds, and the us of such compositions in therapeutic treatment or prevention of gastric and duodenal ulcers.
DETAILED DESCRIPTION OF THE INVENTION
The invention is concerned with benzimidazole derivatives. In particular, it is concerned with benzimidazol-2-yl pyridinium compounds of the formula ##STR2## wherein
R 1 , R 2 , R 3 and R 4 each are hydrogen, fluorine, chlorine, trifluoromethyl, cyano or a residue of the formula ##STR3## or two of R 1 , R 2 , R 3 and R 4 , which are adjacent, together with the carbon atoms to which they are attached are a 5-, 6- or 7-membered ring containing at least one of the structural elements ##STR4## with the proviso that of the symbols R 1 , R 2 , R 3 and R 4 at least one and a maximum of three is/are hydrogen;
R 5 is hydrogen or a negative charge;
R 6 and R 8 each are hydrogen or lower alkyl;
R 7 is lower alkoxy;
R 9 and R 10 each are hydrogen or lower alkyl and R 11 and R 12 each are lower alkyl; or two of the substituents R 9 and R 10 or R 9 and R 11 or R 11 and R 12 together with the carbon atom(s) to which they are attached are a 5-, 6- or 7-membered carbocyclic ring and the remaining two of the substituents R 9 , R 10 , R 11 and R 12 each are hydrogen or lower alkyl; or R 9 and X together are an additional carbon-carbon bond, R 10 is hydrogen or lower alkyl and R 11 and R 12 each are lower alkyl;
R 13 is lower alkyl;
R 14 and R 15 each are hydrogen or lower alkyl or together with the nitrogen atom are a 5-, 6- or 7-membered saturated heterocyclic ring;
R 16 is lower alkyl;
X is chlorine, bromine or a residue of the formula --OR 17 or, as stated above, X and R 9 together are an additional carbon-carbon bond;
R 17 is hydrogen, acyl or a residue of the formula ##STR5##
R 18 is hydrogen or lower alkyl; and
R 19 is hydrogen, lower alkyl, lower alkenyl, lower hydroxyalkyl, lower alkoxy-lower-alkyl, hydroxy-lower-alkoxy-lower-alkyl, lower alkoxy-lower-alkoxy-lower alkyl, hydroxy-lower-alkoxy-lower-alkoxy-lower-alkyl, lower alkoxy-lower-alkoxy-lower-alkoxy-lower-alkyl, hydroxy-lower-alkoxy-lower-alkoxy-lower-alkoxy-lower-alkyl, acyloxy-lower-alkyl or acyloxy-lower-alkoxy-lower-alkyl; whereby the molecule as a whole is non-charged or has a single positive charge and whereby in the latter case an external anion is present.
When the molecule as a whole is non-charged, then the benzimidazol-2-yl pyridinium compounds of formula I are present in the form of internal salts. This is the case when R 5 is a negative charge.
The term "lower" denotes residues or compounds of from 1 to 7, preferably 1 to 4, carbon atoms.
The term "alkyl" denotes straight-chain or branched saturated hydrocarbon residues such as methyl, ethyl, n-propyl, i-propyl, sec-butyl, t-butyl and the like.
The term "alkoxy" denotes alkyl groups as defined above attached via an oxygen atom.
The term "acyl" denotes residues which are derived from organic acids, especially carboxylic acids, by elimination of the hydroxy group, and it primarily embraces lower alkanoyl residues such as acetyl, propionyl and the like.
The 5-, 6- or 7-membered ring which may be formed with two adjacent substituents R 1 , R 2 , R 3 and R 4 and the carbon atoms to which they are attached may be heterocyclic or carbocyclic, it can optionally contain one or more additional double bonds, in which case the ring can be aromatic or non-aromatic, and it can be substituted or unsubstituted. Substituents which may be used include lower alkyl, especially methyl, oxo or the like. For example, R 1 and R 2 or R 2 and R 3 or R 3 and R 4 , taken together, can be a divalent radical of the formula ##STR6##
The 5-, 6- or 7-membered ring which may be formed with R 9 and R 10 or R 9 and R 11 or R 11 and R 12 and the carbon atom(s) to which they are attached is carbocyclic. For example, R 9 and R 10 or R 9 and R 11 or R 11 and R 12 , taken together, can be a divalent radical of the formula --(CH 2 )-- 4 or --(CH 2 ) 5 --.
The 5-, 6- or 6-membered ring which may be formed with R 14 and R 15 and the nitrogen atom to which they are attached is saturated. Examples of such preferred rings include pyrrolidine and piperidine.
The term "external anion" denotes a separated molecule or atom bearing a negative charge.
The term "noncharged" when describing the compounds of the invention denotes that the molecule bears in addition to the compulsory positive charge a negative charge as well.
The term "negative charge" when describing the compounds denotes that there are free electrons in the molecule to the extent that there is one unit of an electric charge is resulting.
The term "intramolecularly" means within the same molecule.
The term "deprotonized" means without a proton.
Conveniently, R 1 and R 4 each are hydrogen and either R 2 and R 3 each are fluorine or each are chlorine or together are a residue of the formula --C(CH 3 ) 2 --CO--C(CH 3 ) 2 -- or R 2 is fluorine or trifluoromethyl and R 3 is hydrogen. Preferably, R 2 is trifluoromethyl and R 1 , R 3 and R 4 each are hydrogen.
Furthermore, conveniently R 6 is hydrogen or methyl, R 7 is methoxy or ethoxy and R 8 is methyl. Methoxy is preferred for R 7 .
Finally, conveniently either R 9 and R 10 each are hydrogen, R 11 and R 12 each are methyl and X is chlorine, hydroxy, methoxy, ethoxy, propoxy, butoxy, acetoxy, 2-hydroxyethoxy, 2-methoxyethoxy, 2-(2-hydroxyethoxy)ethoxy, 2-(2-methoxyethoxy)ethoxy, 2-[2-(2-hydroxyethoxy)ethoxy]ethoxy or 2-[2-(2-methoxyethoxy)ethoxy]ethoxy; or R 9 and X together are an additional carbon-carbon bond, R 10 is hydrogen and R 11 and R 12 each are methyl; or R 9 and R 11 together are tetramethylene, R 10 and R 12 each are hydrogen and X is methoxy. Preferably, R 9 and R 10 each are hydrogen, R 11 and R 12 each are methyl and X is chlorine, hydroxy, methoxy, ethoxy, propoxy, acetoxy, 2-hydroxyethoxy or 2-methoxyethoxy; or R 9 and X together are an additional carbon-carbon bond, R 10 is hydrogen and R 11 and R 12 each are methyl. In an especially preferred embodiment, R 9 and R 10 each are hydrogen, R 11 and R 12 each are methyl and X is ethoxy, acetoxy, 2-hydroxyethoxy or 2-methoxyethoxy.
A particularly preferred compound of formula I is:
2-[[[2-(2-Hydroxyethoxy)-2-methylpropyl]thio]methyl]-4-methoxy-3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium methanesulfonate.
Especially preferred compounds of formula I are:
Intramolecularly deprotonized 2-[[[2-(2-hydroxyethoxy)-2-methylpropyl]thio]methyl]-4-methoxy-3-methyl-1-[-5-(trifluoromethyl)-2-benzimidazolyl]pyridinium cation;
4-methoxy-2-[[[2-(2-methoxyethoxy)-2-methylpropyl]thio]methyl]-3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium methanesulfonate;
Intramolecularly deprotonized 4-methoxy-2-[[[2-(2-methoxyethoxy)-2-methylpropyl]thio]methyl]-3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium cation;
2-[[(2-acetoxy-2-methylpropyl)thio]methyl]-4-methoxy-3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium methanesulfonate;
2-[[(2-acetoxy-2-methylpropyl)thio]methyl]-4-methoxy-3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium chloride;
Intramolecularly deprotonized 2-[[(2-acetoxy-2-methylpropyl)thio]methyl]-4-methoxy-3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium cation;
2-[[(2-ethoxy-2-methylpropyl)thio]methyl]-4-methoxy-3-methyl-1-[5-(trifluoromethyl) 2-benzimidazolyl]pyridinium methanesulfonate;
2-[[(2-ethoxy-2-methylpropyl)thio]methyl]-4-methoxy-3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium chloride; and
Intramolecularly deprotonized 2-[[(2-ethoxy-2-methylpropyl)thio]methyl]-4-methoxy-3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium cation.
Likewise preferred compounds of formula I are, for example;
Intramolecularly deprotonized 2-[[(2-chloro-2-methylpropyl)thio]methyl]-4-methoxy-3-methyl-1-[5-(trifluoro-methyl)-2-benzimidazolyl]pyridinium cation;
2-[[(2-chloro-2-methylpropyl)thio]methyl]-4-methoxy-3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium chloride;
Intramolecularly deprotonized 2-[[(2-hydroxy 2-methylpropyl)thio]methyl]-4-methoxy-3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium cation;
Intramolecularly deprotonized 4-methoxy-2-[[(2-methoxy-2-methylpropyl)thio]methyl]-3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium cation;
Intramolecularly deprotonized 4-methoxy-3-methyl-2-[[(2-methylpropenyl)thio]methyl]-1-[5-(trifluoromethyl)2-benzimidazolyl]pyridinium cation;
Intramolecularly deprotonized 4-methoxy-3-methyl-2-[[(2-methyl-2-propoxypropyl)thio]methyl]-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium cation;
4-methoxy-3-methyl-2-[[(2-methylpropenyl)thio]methyl]1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium chloride; and
Intramolecularly deprotonized 2-[[(2-hydroxy-2-methylpropyl)thio]methyl]-4-methoxy-3,5-dimethyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium cation.
The compounds of formula I can be prepared by
(a) reacting a compound of the formula ##STR7## wherein R 1 , R 2 , R 3 , R 4 , R 6 , R 7 and R 8 are as defined above and R 5 ' is hydrogen, under acidic conditions with a compound of the formula
wherein R 9 ' and R 10 ' each are hydrogen or lower alkyl and R 11 ' and R 12 ' each are lower alkyl or two of the substituents R 9 ' and R 10 ' or R 9 ' and R 11 ' or R 11 ' and R 12' together with the carbon atom(s) to which they are attached are a 5-, 6- or 7-membered carbocyclic ring and two of the remaining substituents R 9 ' R 10 ', R 11 ' and R 12 ' each are hydrogen or lower alkyl,
and a compound of the formula
HX' IV
wherein X' is chlorine, bromine or a residue of the formula --OR 17 and R 17 is hydrogen or a residue of formula (k) above;
(b) reacting a compound of formula I in which X is chlorine or bromine with a compound of the formula
HOR.sup.17 ' V
wherein R 17 ' is hydrogen or a residue of formula (k) above; or
(c) dehydrating a compound of formula I in which X is a residue of the formula OR 17 and R 17 is hydrogen; or
(d) acylating a compound of formula I in which X is a residue of the formula --OR 17 , R 17 is hydrogen or a residue of formula (k) above and R 19 is lower hydroxyalkyl or hydroxy lower alkoxy-lower alkyl;
whereupon the product obtained is isolated as a salt or internal salt and, if desired, an internal salt is converted into a pharmaceutically acceptable salt.
Compounds of formula I in which either R 9 and R 10 each are hydrogen or lower alkyl and R 11 and R 12 each are lower alkyl or 1n which two of the substituents R 9 and R 10 or R 9 and R 11 or R 11 and R 12 together with the carbon atom(s) to which they are attached are a 5-, 6- or 7-membered carbocyclic ring and two of the remaining substituents R 9 , R 10 , R 11 and R 12 each are hydrogen or lower alkyl and in which X is chlorine, bromine or a residue of the formula --OR 17 and R 17 is hydrogen or a residue of formula (k) are obtained in accordance with process aspect (a). Compounds such as isobutylene, cyclohexene or the like are used as components of formula III and hydrogen chloride, hydrogen bromide, water or an alcohol of the formula
HO--CH(R.sup.18)R.sup.19 VI
wherein R 18 and R 19 have the significance mentioned earlier, are used as components of formula IV.
When hydrogen chloride or hydrogen bromide is used as the component of formula IV, then a corresponding compound of formula I in which X is chlorine or bromine is obtained. In this case, the starting material of formula II is reacted with hydrogen chloride or hydrogen bromide in the presence of the corresponding component of formula III, conveniently in t-butanol, in which case it can be advantageous to add a small amount of molecular sieve. The hydrogen chloride or hydrogen bromide used as the component of formula IV thereby simultaneously serves to bring about the required acidic conditions. Under certain circumstances the component of formula III need not be used as such. When, for example, in the end product of formula I R 9 and R 10 each are hydrogen, R 11 and R 12 each are methyl and X is chlorine or bromine, then a corresponding compound of formula II can be reacted in t-butanol with hydrogen chloride or hydrogen bromide. In such a case the corresponding component of formula III, i.e. isobutylene, is formed in situ from the t-butanol under the action of the hydrogen chloride or hydrogen bromide. The reaction is preferably effected at about room temperature and, depending on the remaining reaction parameters, takes about a half hour to about four days.
When water is used as the component of formula IV, then a corresponding compound of formula I in which X is hydroxy is obtained. In accordance with this embodiment, the components of formulas II and III are reacted with one another under acidic-aqueous conditions, for example, in aqueous hydrochloric acid, aqueous methanesulfonic acid or the like. It can be advantageous to add a water-miscible organic solvent which is inert under the reaction conditions such as, for example, tetrahydrofuran or the like.
When an alcohol of formula VI above is used as the component of formula IV, then a corresponding compound of formula I in which X is a residue of the formula --OR 17 and R 17 is a residue of formula (k) above is obtained. The alcohol of formula VI used as the component of formula IV can simultaneously also serve as the solvent. Methanesulfonic acid, hexafluorophosphoric acid, tetrafluoroboric acid or the like is conveniently used as the acid. The reaction is conveniently effected at room temperature and, depending on the remaining reaction parameters, takes about 20 minutes to about 20 hours.
Process aspect (b) yields compounds of formula I in which either R 9 and R 10 each are hydrogen or lower alkyl and R 11 and R 12 are lower alkyl or two of the substituents R 9 and or R 9 and R 11 or R 11 and R 12 together with the carbon atom(s) to which they are attached are a 5-, 6- or 7-membered carbocyclic ring and the remaining two of substituents R 9 , R 10 , R 11 and R 12 each are hydrogen or lower alkyl and in which X is a residue of the formula --OR 17 and R 17 is a residue of formula (k). Water or an alcohol of formula VI is used as the component of formula V. The reaction is conveniently effected under acidic conditions, i.e. the starting material of formula I in which X is chlorine or bromine is reacted with aqueous acid (e.g. dilute hydrochloric acid) or with a solution of an acid such as methanesulfonic acid or the like in the corresponding alcohol of formula VI. It can be advantageous to add an organic solvent which is inert under the reaction conditions and which is miscible with water or the alcohol of formula VI. The reaction is effected at about room temperature which is about 23° C. and, depending on the remaining reaction parameters, takes a few (e.g., about 5 to 15) hours.
Process aspect (c) yields compounds of formula I in which R 9 and X together are an additional carbon-carbon bond, R 10 is hydrogen or lower alkyl and R 11 and R 12 each are lower alkyl. The dehydration in accordance with this process aspect is effected according to suitable methods which are known to persons skilled in the art. Polyphosphoric acid ethyl ester, polyphosphoric acid or the like is used as the dehydrating agent. The dehydration is conveniently carried out in an organic medium which is inert under the reaction conditions, for example, in a halogenated hydrocarbon such as chloroform, 1,2-dichloroethane, an aromatic hydrocarbon such as toluene, benzene, or the like, or in a mixture of two or more of such solvents such as chloroform/toluene. The reaction is conveniently effected at the reflux temperature and, depending on the remaining reaction parameters, takes several (e.g. about 2 to 3) days.
Process aspect (d) yields compounds of formula I in which R 9 and R 10 each are hydrogen or lower alkyl, R 11 and R 12 each are lower alkyl and X is a residue of the formula --OR 17 in which R 17 is acyl or a residue of formula (k), wherein R 19 is acyloxy-lower-alkyl or acyloxy-lower-alkoxy-lower alkyl. The acylation is effected according to suitable methods which are generally known to those persons skilled in the art, advantageously by means of a reactive derivative of the acid corresponding to the acyl residue to be introduced, for example, by means of an acid anhydride, an acid halide, etc. The introduction of an acetyl group can be effected by reacting the starting material of formula I in acetic acid with acetic anhydride. It can be of advantage to add a small amount of perchloric acid, toluenesulfonic acid or the like. The acylation is conveniently effected at about room temperature and, depending on the remaining reaction parameters. takes a few (e.g., 4 to 6) hours.
Depending on the nature of the starting materials and on the reaction conditions which are used the products obtained can be isolated as salts or as internal salts. If desired, internal salts can be converted into pharmaceutically acceptable salts, for example with hydrogen chloride, hydrogen bromide, phosphoric acid, sulfuric acid, citric acid, methanesulfonic acid, p-toluene-sulfonic acid and the like.
The starting materials of formula II are known or can be prepared readily according to suitable methods known in the art. Moreover, some of the Examples further below contain detailed information concerning the preparation of certain compounds of formula II.
As mentioned earlier, the benzimidazol-2-yl pyridinium compounds of formula I have valuable pharmacodynamic properties.
Representative compounds of formula I were investigated with respect to their anti-ulcer activity, and gastric acid secretion-inhibiting activity. Toxicology studies were also conducted.
The experimental procedure described hereinafter was used to determine the anti-ulcer activity:
A number of groups of 8 male rats each with a body weight of 130-150 g are used for each dosage of a test substance. Prior to the beginning of the experiment the animals receive no food for 24 hours, but receive water ad libitum. Various dosages of the substances to be tested (suspended in 0.5% tragacanth) or the vehicle alone (controls) are administered twice perorally, namely. 1 hour before and 2 hours after the peroral administration 20 mg/kg of indomethacin. In the control animals, this dosage of indomethacin leads to lesions of the stomach within 5 hours. The animals are killed 6 hours after the first administration of the substance under investigation (or of the vehicle alone). The rats which remain protected from the occurrence of macroscopically visible lesions to the mucous membrane of the stomach are counted. The ED 50 is that dosage of a test substance at which 50% of the animals are protected from the occurence of such lesions.
The experimental procedure described hereinafter was used to determine the gastric acid secretion-inhibiting activity:
A part of the stomach fundus of female and male beagle hounds is separated from the remainder of the stomach in the form of a pouch of the Heidenhain type by a modification of the method described in Rudick et al., J. Surgical Research 7, 383-398 (1967). In the pouch there is fitted a steel cannula which is conducted externally through the abdominal wall. Before each experiment the animals receive no food for 18 hours, but receive water ad libitum. They are conscious and standing during the experiment and their gastric acid secretion is stimulated by the intravenous infusion of 4-methylhistamine, a selective against of the histamine H 2 -receptors. The gastric acid production is determined in 15 minute fractions of the stomach pouch juice. As soon as the gastric acid production has a constant value, the substances to be tested are administered orally as a dry powder filled into gelatin capsules. The ED 50 is that dosage of a test substance which brings about a 50% inhibition of the gastric acid production caused by 4-methylhistamine in the treated animals in comparison to the controls.
In the following Table there are given for a series of representative compounds of formula I the results of the testing with respect to their anti-ulcer activity and to their gastric secretion inhibiting activity. Moreover, this Table contains data concerning the acute toxicity (LD 50 in the case of single oral administration to mice).
______________________________________ Gastric acid secretion- Anti-ulcer, inhibition, Toxicity ED.sub.50 ED.sub.50 LD 50Compound mg/kg p.o. mg/kg p.o. mg/kg p.o.______________________________________A 4.4 4.9 2500-5000B 6.1 3.9 2500-5000C 6.0 5.5 1000-2000D 7.0 4.8 2500-5000E 3.2 3.0 2500-5000F 1.9 1.8 1250-2500G 2.8 1.5 2500-5000H 3.2 4.3 --I 4.1 3.8 2500-5000J 4.6 3.7 >5000______________________________________
A=2-[[[2-(2-Hydroxyethoxy)-2-methylpropyl]thio]-methyl]-4-methoxy-3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium methanesulfonate;
B=Intramolecularly deprotonized 2-[[[2-(2-hydroxyethoxy)-2-methylpropyl]thio]methyl]-4-methoxy-3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium cation;
C=4-Methoxy-2-[[[2-(2-methoxyethoxy)-2-methylpropyl}thio]methyl]-3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium methanesulfonate;
D=Intramolecularly deprotonized 4-methoxy-2-[[[2-(2-methoxyethoxy)-2-methylpropyl]thio]methyl]-3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium cation;
E=2-[[(2-Acetoxy-2-methylpropyl)thio]methyl]-4-methoxy-3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium methanesulfonate;
F=2-[[(2-Acetoxy-2-methylpropyl)thio]methyl]-4-methoxy-3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium chloride;
G=Intramolecularly deprotonized 2-[[(2-acetoxy-2-methylpropyl)thio]methyl]-4-methoxy-3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium cation;
H=2-[[(2-Ethoxy-2-methylpropyl)thio]methyl]-4-methoxy-3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium methanesulfonate;
I=2-[[(2-Ethoxy-2-methylpropyl)thio]methyl]-4-methoxy-3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium chloride; and
J=Intramolecularly deprotonized 2-[[(2-ethoxy-2-methylpropyl)thio]methyl]-4-methoxy-3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium cation.
The compounds defined above can be used as medicaments, e.g. in the form of pharmaceutical preparations. Oral administration in the form of solid pharmaceutical preparations such as tablets, coated tablets, dragees, hard gelatin capsules and soft gelatin capsules is preferred. Oral administration in the form of liquid pharmaceutical preparations such as solutions, emulsions and suspensions, rectal administration, e.g. in the form of suppositories, or parenteral administration, e.g., in the form of injection solutions, may also be used.
Pharmaceutical preparations or compositions containing one of the compounds defined above are another aspect of the present invention. The preparation of such medicaments can be effected by bringing one or more of the compounds defined above and, if desired, one or more other therapeutically active substances into a galenical administration form together with one or more therapeutically inert excipients.
For the preparation of tablets, coated tablets, dragees and hard gelatin capsules the compounds defined above can be processed with pharmaceutically inert inorganic or organic excipients. Such excipients may include lactose, maize starch or derivatives thereof, talc, stearic acid or its salts, etc, for tablets, dragees and hard gelatin capsules. For the preparation of pharmaceutical preparations which are resistant to gastric fluid it is necessary to apply a gastric fluid-resistant coating which can consist, e.g., of hydroxypropylmethyl-cellulose phthalate.
Soft gelatin capsules may include such suitable excipients as vegetable oils, waxes, fats, semi-solid and liquid polyols or any other suitable materials known in the art.
For the preparation of solutions and syrups, suitable excipients may include water, polyols, saccharose, invert sugar, glucose and the like.
For suppositories, suitable excipients include, e.g., natural or hardened oils, waxes, fats, semi liquid or liquid polyols and the like.
Injection solutions may include suitable excipients such as, e.g., water, alcohols, polyols, glycerine, vegetable oils or any other suitable materials known in the art.
The pharmaceutical preparations may further include preserving agents, solubilizers, stabilizing agents, wetting agents. emulsifying agents, sweetening agents, coloring agents, flavoring agents, salts for varying the osmotic pressure, buffers, coating agents or antioxidants. Other therapeutically valuable substances may also be included in the preparations.
In accordance with the invention the compounds defined above can be used in the control or prevention of illnesses, for example, in the control or prevention of gastric ulcers and duodenal ulcers. The dosage can vary within wide limits and is determined according to individual requirements in each particular case. In general, in the case of oral administration a daily dosage of about 30-400 mg should be appropriate and in the case of intravenous administration a daily dosage of about 30-400 mg should be appropriate.
The use of the compounds defined above for the preparation of pharmaceutical compositions for the treatment or prevention of gastric and duodenal ulcers is still another aspect of the invention.
The following Examples illustrate the present invention but are not intended to limit its extent in any manner. Ohile the examples describe what are at present considered to be the preferred embodiments of this invention, it will be obvious to those skilled in the art that various changes and modifications may be made therein without departing from the invention, and it is, therefore, aimed to cover all such changes and modifications as falling within the true spirit and scope of the invention.
Unless otherwise stated, percentages and ratios relating to solvent mixtures are expressed in volume, and the remaining percentages and ratios are expressed in weight. Temperatures are in degrees Celsius (°C.), normal pressure is about 1 atmosphere, and room temperature is about 23° C. Unless indicated otherwise, the Examples were carried out as written.
EXAMPLE 1
A suspension of 15 g of 2[[(4-methoxy-3-methyl-2-pyridyl)methyl]sulfinyl]-5-(trifluoromethyl)benzimidazole in a solution of 7.2 g of isobutylene in 130 ml of tert.-butanol was treated with 20 g of molecular sieve (Union Carbide, Type 3A) and with a solution of 19.5 g of gaseous hydrogen chloride in 150 ml of tert.-butanol. The reaction mixture was stirred at room temperature for 50 minutes and subsequently poured into a mixture of ice and 1.2 l of aqueous sodium bicarbonate solution, whereupon methylene chloride was added. The insoluble part of the mixture was filtered off over silica gel and the filtrate was extracted several times with methylene chloride. The organic phases were combined, dried with sodium sulfate, filtered and concentrated. The residue was dissolved in 800 ml of methylene chloride, whereupon 28 g of silica gel (particle size: 0.04-0.06 mm) were added and the mixture was stirred at room temperature for one hour. The silica gel was filtered off, the filtrate was concentrated and the residue was crystallized from ether. The intramolecularly deprotonized 2-[[(2-chloro-2-methylpropyl)thio]methyl]-4-methoxy-3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium cation obtained exhibited a melting point of 132°-134° (decomposition).
EXAMPLE 2
100 mg of intramolecularly deprotonized 2-[[(2-chloro-2-methylpropyl)thio]methyl]-4-methoxy-3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium cation were dissolved in 5 ml of ethyl acetate, whereupon 0.5 ml of 4.7N methanolic hydrochloric acid was added, the solution was concentrated and the residue was crystallized from tert.-butyl methyl ether/ether. The 2-[[(2-chloro-2-methylpropyl)thio]methyl]-4-methoxy-3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium chloride obtained exhibited a melting point of 140°-142° (decomposition).
EXAMPLE 3
A suspension of 5 g of intramolecularly deprotonized 2-[[(2-chloro-2-methylpropyl)thio]methyl]-4 -methoxy-3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium cation in 100 ml of 1N aqueous hydrochloric acid was stirred at room temperature for nine hours and then poured into a mixture of ice and aqueous sodium bicarbonate solution, whereupon the mixture was extracted several times with methylene chloride. The combined methylene chloride extracts were dried with sodium sulfate, filtered and concentrated. The residue was recrystallized twice from ether, whereby there was obtained intramolecularly deprotonized 2-[[(2-hydroxy-2-methylpropyl)thio]methyl]-4-methoxy-3methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium cation of melting point 144°-145°.
EXAMPLE 4
A solution of 200 mg of methanesulfonic acid and about 1 g of gaseous isobutylene in 20 ml of methanol was treated with 370 mg of 2-[[(4-methoxy-3-methyl-2-pyridyl)methyl]sulfinyl]-5-(trifluoromethyl)benzimidazole, whereupon the reaction mixture was stirred at room temperature for 18 hours and then evaporated. The residue was treated with methylene chloride and aqueous sodium bicarbonate solution, the methylene chloride phase was separated and the aqueous phase was extracted with methylene chloride. The combined organic phases were dried and concentrated. By recrystallization of the residue from ether/n-hexane there was obtained intramolecularly deprotonized 4-methoxy-2-[[(2-methoxy-2-methylpropyl)thio]methyl]-3-methyl-1-[5-(trifluoromethyl) 2 benzimidazolyl]pyridinium cation of melting point 155°-156°.
EXAMPLE 5
A solution of 200 mg of methanesulfonic acid and about 0.5 g of gaseous isobutylene in 20 ml of ethanol was treated with 350 mg of 2-[[(4-methoxy-3-methyl-2-pyridyl)methyl]sulfinyl]-5-(trifluoromethyl)benzimidazole, whereupon the reaction mixture was stirred at room temperature for 18 hours, concentrated and the residue was treated with methylene chloride and aqueous sodium bicarbonate solution. Thereupon, the methylene chloride phase was separated and the aqueous phase was extracted with methylene chloride. The combined organic phases were dried and concentrated. By recrystallization of the residue from ether there was obtained intramolecularly deprotonized 2-[[(2-ethoxy-2-methylpropyl)thio]methyl]-4-methoxy-3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium cation of melting point 132°-134°.
EXAMPLE 6
10 ml of ethylene glycol monomethyl ether saturated with isobutylene were treated with 192 mg of methanesulfonic acid and 370 mg of 2-[[(4-methoxy-3-methyl 2-pyridyl)methyl]sulfinyl]-5-(trifluoromethyl)benzimidazole. The solution was stirred at room temperature under an isobutylene atmosphere for four hours and then concentrated. The residue was treated with methylene chloride and aqueous sodium bicarbonate solution, whereupon the methylene chloride phase was separated and the aqueous phase was extracted with methylene chloride. The combined organic phases were dried and concentrated. The residue was crystallized from ether and there was obtained intramolecularly deprotonized 4-methoxy-2-[[[2-(2-methoxyethoxy)-2-methylpropyl]thio]methyl]-3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium cation of melting point 110°-112° (decomposition).
EXAMPLE 7
4 ml of ethylene glycol saturated with isobutylene were treated with 200 mg of methanesulfonic acid and 370 mg of 2-[[(4-methoxy-3-methyl-2-pyridyl)methyl]sulfinyl]-5-(trifluoromethyl)benzimidazole. The solution was stirred at room temperature under an isobutylene atmosphere for nine hours and then poured on to ice and sodium bicarbonate. The resulting aqueous solution was extracted several times with methylene chloride. The combined organic phases were dried and evaporated. The residue was chromatographed on silica gel with methylene chloride/methanol (10:1) as the elution agent, with the medium pressure flash chromatography method being used. By recrystallization from ether/n-hexane there was obtained intramolecularly deprotonized 2-[[[2-(2-hydroxyethoxy) -2-methylpropyl]thio]methyl]-4-methoxy-3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium cation of melting point 60°-70°.
EXAMPLE 8
(a) 10.6 g of 5-fluoro-2-benzimidazolethiol were suspended in 570 ml of alcohol and treated with 13.1 g of 2-chloromethyl-4-methoxy-3-methylpyridine hydrochloride. A solution of 5 g of sodium hydroxide in 130 ml of water was added dropwise thereto while cooling with ice, the mixture was left to boil at reflux overnight and then concentrated to about 1/3 of the volume in a vacuum. After the addition of 500 ml of water the resulting crystals were filtered off and washed thoroughly firstly with water and then with ether. There was obtained 5-fluoro-2-[[(4-methoxy-3-methyl-2-pyridyl)methyl]thio]benzimidazole of melting point 128°.
(b) 2.0 g of 5-fluoro-2-[[(4-methoxy-3-methyl-2-pyridyl)methyl]thio]benzimidazole dissolved in 100 ml of methylene chloride were treated with 1.2 g of potassium carbonate. 1.6 g of m-chloroperbenzoic acid were added thereto at -30°, the solution was stirred for a further 5 minutes and subsequently poured into a mixture of 30 ml of saturated sodium bicarbonate solution and 30 ml of water. The organic phase was separated, dried over sodium sulfate, treated with 5.0 ml of triethylamine and evaporated in a vacuum. Crystallization of the residue from methylene chloride/petroleum ether (low boiling)/ether gave 5-fluoro-2-[[(4-methoxy-3-methyl-2-pyridyl)methyl]sulfinyl]benzimidazole of melting point 175°.
(c) A solution of 3.2 g of 5-fluoro-2-[[(4-methoxy-3-methyl-2-pyridyl)methyl]sulfinyl]benzimidazole in 200 ml of tert.butanol was saturated with isobutylene gas for 30 minutes, then treated with a freshly prepared solution of 22.4 g of hydrogen chloride gas in 200 ml of tert. butanol, stirred at room temperature overnight and subsequently evaporated in a vacuum. The residue was taken up in methylene chloride, whereupon the solution was extracted with 100 ml of saturated sodium bicarbonate solution, washed neutral with water. dried and concentrated in a vacuum. Crystallization of the residue from methylene chloride/petroleum ether (low-boiling) yielded intramolecularly deprotonized 2-[[(2-chloro-2-methylpropyl)thio]methyl]-1-(5-fluoro-2-benzimidazolyl)-4-methoxy-3-methylpyridinium cation of melting point 136°-138°.
EXAMPLE 9
A solution of 2 g of methanesulfonic acid in 200 ml of methanol was saturated with isobutylene gas for 30 minutes, then treated with 3.2 g of 5-fluoro-2-[[(4-methoxy-3-methyl-2-pyridyl)methyl]sulfinyl]benzimidazole, stirred at room temperature overnight and subsequently evaporated in a vacuum. The residue was taken up in methylene chloride, whereupon the solution was extracted with 100 ml of saturated sodium bicarbonate solution, washed neutral with water, dried and concentrated in a vacuum. Crystallization of the residue from methylene chloride/petroleum ether (low-boiling) gave intramolecularly deprotonized 1-(5-fluoro-2-benzimidazolyl)-4-methoxy-2-[[(2-methoxy-2-methylpropyl)thio]methyl]-3-methylpyridinium cation of melting point 142°-143°.
EXAMPLE 10
450 mg of intramolecularly deprotonized 2-[[(2-ethoxy-2-methylpropyl)thio]methyl]-4-methoxy-3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium cation were dissolved in methylene chloride, whereupon 2 ml of 4.7N methanolic hydrochloric acid were added thereto, the solution was concentrated and the residue was crystallized from ether. The 2-[[(2-ethoxy-2-methylpropyl)thio]methyl]-4-methoxy-3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium chloride obtained exhibited a melting point of 119°-120°.
EXAMPLE 11
370 mg of intramolecularly deprotonized 2-[[[2-(2-hydroxyethoxy)-2-methylpropyl]thio]methyl]-4-methoxy-3-methyl-1-[5-(trifluoromethyl)-2-benzimdazolyl]pyridinium cation were dissolved in methanol, whereupon 100 mg of methanesulfonic acid were added thereto, the solution was concentrated and the residue was crystallized from ether/ethyl acetate. The 2-[[[2-(2-hydroxyethoxy)-2-methylpropyl]thio]methyl]-4-methoxy-3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium methanesulfonate obtained exhibited a melting point of 105°-107° (decomposition).
EXAMPLE 12
483.5 mg of intramolecularly deprotonized 4-methoxy-2-[[[2-(2-methoxyethoxy)-2-methylpropyl]thio]methyl]-3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium cation were dissolved in 5 ml of methanol, whereupon 96 mg of methanesulfonic acid were added thereto, the solution was concentrated and the residue was dissolved several times in ethyl acetate and the solution was concentrated each time. The resinous residue was dried in a high vacuum, whereby 4-methoxy-2-[[[2-(2-methoxyethoxy)-2-methylpropyl]thio]methyl]-3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]-pyridinium methanesulfonate was obtained as a foam. The microanalysis showed the following values:
Empirical formula; C 23 H 29 F 3 N 3 O 3 S 1:1CH 3 SO 3 ; MW 579.65
Calc.: C 49.73% H 5.56% N 7.25% S 11.06%
Found: C 49.59% H 5.76% N 7.19% S 10.97%
EXAMPLE 13
A solution of 160 mg of gaseous isobutylene and 350 mg of 2-[[(4-methoxy-3-methyl-2-pyridyl)methyl]sulfinyl]-5-(trifluoromethyl)benzimidazole in 5 ml of diethylene glycol monomethyl ether was treated with 200 mg of methanesulfonic acid, whereupon the reaction mixture was stirred at room temperature for 18 hours and then neutralized with 100 ml of saturated aqueous sodium bicarbonate solution. The sodium bicarbonate solution was extracted several times with ether; the combined organic phases were dried over sodium sulfate and concentrated. The residue was chromatographed on silica gel with methylene chloride/methanol (20:1) as the elution agent, with the medium pressure flash chromatography method being used. By recrystallization from n-hexane there was obtained intramolecularly deprotonized 4-methoxy-2-[[[2-[2-(2-methoxyethoxy)ethoxy]-2-methylpropyl]thio]methyl]-3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium cation of melting point 103°-106°.
EXAMPLE 14
A solution of 500 mg of intramolecularly deprotonized 2-[[(2-hydroxy-2-methylpropyl)thio]methyl]-4-methoxy-3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium cation in 1.5 ml of acetic anhydride and 3 ml of acetic anhydride was treated with 3 drops of perchloric acid and stirred at room temperature for 5 hours. The reaction mixture was neutralized with saturated aqueous sodium bicarbonate solution, extracted several times with methylene chloride, the extracts were dried over sodium sulfate, filtered and the methylene chloride was removed by evaporation. The residue was chromatographed on silica gel with methylene chloride/methanol (10:1) as the elution agent, using the medium pressure flash chromatography method. By crystallization from ether/n-hexane there was obtained intramolecularly deprotonized 2-[[(2-acetoxy-2-methylpropyl)thio]methyl]-4-methoxy-3-methyl-1-[5-(tri-fluoromethyl)-2-benzimidazolyl]pyridinium cation of melting point 71°-78°.
EXAMPLE 15
467.5 mg of intramolecularly deprotonized 2-[[(2-acetoxy-2-methylpropyl)thio]methyl]-4-methoxy-3 methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium cation were dissolved in 5 ml of methanol, whereupon 96 mg of methanesulfonic acid were added thereto, the solution was concentrated, the residue was dissolved several times in ethyl acetate and the solution was again concentrated each time. The resinous residue was dried in a high vacuum, whereby 2-[[(2-acetoxy-2-methylpropyl)thio]methyl]-4-methoxy-3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium methanesulfonate (1:1) was obtained as a foam. The microanalysis showed the following values:
Empirical formula; C 22 H 25 F 3 N 3 O 3 S 1:1 CH 3 SO 3 ; MW 563.61
Calc.: C 49.02% H 5.01% N 7.46% S 11.38%
Found; C 48.87% H 5.28% N 7.30% S 11.00%
EXAMPLE 16
A solution of 1 g of methanesulfonic acid and about 1 g of gaseous isobutylene in 15 ml of n-propanol was treated with 2 g of 2-[[(4-methoxy-3-methyl-2-pyridyl)methyl]sulfinyl]-5-(trifluoromethyl)benzimidazole, whereupon the mixture was stirred at room temperature for 18 hours in a flask equipped with a cooling trap (acetone/dry-ice) and then evaporated. The residue was treated with methylene chloride and aqueous sodium bicarbonate solution. The methylene chloride phase was separated and the aqueous phase was extracted with methylene chloride. The combined organic phases were dried and concentrated. The residue was chromatographed on silica gel with methylene chloride/methanol (20:1) as the elution agent, using the medium pressure flash chromatography method. By crystallization from ether/n-hexane there was obtained intamolecularly deprotonized 4-methoxy-3-methyl-2-[[(2-methyl-2-propoxypropyl)thio]methyl]-1-[(5-(trifluoromethyl)-2-benzimidazolyl]pyridinium cation of melting point 106°-108°.
EXAMPLE 17
A solution of 2 g of methanesulfonic acid and about 2 g of gaseous isobutylene in 5 ml of diethylene glycol was treated with 3 g of 2-[[(4-methoxy-3-methyl-2-pyrdidyl)methyl]sulfinyl]-5-(trifluoromethyl)benzimidazole, whereupon the mixture was stirred at room temperature for 18 hours in a flask equipped with a cooling trap (acetone/dry-ice) and then evaporated. The residue was treated with methylene chloride and aqueous sodium bicarbonate solution, the methylene chloride phase was separated and the aqueous phase was extracted with methylene chloride. The combined organic phases were dried and concentrated. The residue was chromatographed on silica gel (particle size: 0.04-0.06 mm) with methylene chloride/methanol (20:1) as the elution agent, using the medium pressure flash chromatography method.
The purified intramolecularly deprotonized 2-[[[2-[2-(2-hydroxyethoxy)ethoxy]-2-methylpropyl]thio]methyl]-4-methoxy-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium cation was dissolved several times in ethyl acetate and the solution obtained was concentrated each time. The resinous residue was dried in a high vacuum, yielding a foam. The microanalysis showed the following values:
Empirical formula; C 24 H 30 F 3 N 3 O 4 S; MW 513.57
Calc.: C 56.13% H 5.89% N 8.18% S 6.24%
Found: C 55.74% H 6.06% N 8.00% S 6.21%
EXAMPLE 18
A solution of 1 g of methanesulfonic acid and about 1 g of gaseous isobutylene in 15 ml of n-butanol were treated with 2 g of 2-[[(4-methoxy-3-methyl-2-pyridyl)methyl]sulfinyl]-5-(trifluoromethyl)benzimidazole, whereupon the mixture was stirred at room temperature for three hours in a flask equipped with a cooling trap (acetone/dry-ice) and then evaporated. The residue was treated with methylene chloride and aqueous sodium bicarbonate solution, the methylene chloride phase was separated and the aqueous phase was extracted with methylene chloride. The combined organic phases were dried and concentrated. The residue was chromatographed on silica gel with methylene chloride/methanol (20:1) as the elution agent, using the medium pressure flash chromatography method. By crystallization from ether/n-hexane intramolecularly deprotonized 2-[[(2-butoxy-2-methylpropyl)thio]methyl]-4-methoxy-3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium cation of melting point 78°-80° was obtained.
EXAMPLE 19
A solution of 19 g of polyphosphoric acid ethyl ester and 6.3 g of intramolecularly deprotonized 2-[[(2-hydroxy-2-methylpropyl)thio]methyl]-4-methoxy-3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium cation in 150 ml of chloroform and 45 ml of toluene was heated at reflux for about 60 hours. The reaction mixture was poured into saturated aqueous sodium carbonate solution, extracted several times with methylene chloride, the combined extracts were dried over sodium sulfate and the methylene chloride was removed by evaporation. The residue was chromatographed on silica gel with methylene chloride/methanol (20:1) as the elution agent, using the medium pressure flash chromatography method. By crystallization from ether/n-hexane there was obtained intramolecularly deprotonized 4-methoxy-3-methyl-2-[[(2-methylpropenyl)thio]methyl]-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium cation of melting point 126°-127°.
EXAMPLE 20
60 mg of intramolecularly deprotonized 4-methoxy 3-methyl-2-[[(2-methylpropenyl)thio]methyl]-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium cation were dissolved in methylene chloride, whereupon 0.5 ml of 4.7N methanolic hydrochloric acid was added thereto, the solution was concentrated and the residue was crystallized from ethyl acetate/ether. The 4-methoxy-3-methyl-2-[[(2-methylpropenyl)thio]methyl]-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium chloride obtained exhibited a melting point of 142°-144°.
EXAMPLE 21
A solution of 2 g of methanesulfonic acid in 200 ml of abs. ethanol was saturated with isobutylene gas for 45 minutes and then treated with 3.2 g of 5-fluoro-2-[[(4-methoxy-3-methyl-2-pyridyl)methyl]sulfinyl]benzimidazole, whereupon the mixture was stirred at room temperature overnight and subsequently evaporated in a vacuum. The residue was taken up in methylene chloride, whereupon the solution was extracted with 100 ml of saturated sodium bicarbonate solution washed neutral, dried and concentrated in a vacuum. Chromatography on silica gel with methanol-methylene chloride (5:95) and subsequent crystallization from methylene chloride/petroleum ether (low-boiling) gave intramolecularly deprotonized (-)-2-[[(2-ethoxy-2-methylpropyl)thio]methyl]-1-[(5-fluoro-2-benzimidazolyl)-4-methoxy-3-methylpyridinium cation of melting point 121°-122°.
EXAMPLE 22
A solution of 2 g of methanesulfonic acid in 200 ml of dioxan was saturated with isobutylene gas for 45 minutes and then treated with 3.2 g of 5-fluoro-2-[[(4-methoxy-3-methyl-2-pyridyl)methyl]sulfinyl]benzimidazole. After stirring for 10 minutes, 5 ml of ethylene glycol were added thereto, whereupon the mixture was stirred at room temperature for 48 hours and subsequently evaporated in a vacuum. The residue was taken up in methylene chloride, whereupon the solution was extracted with 100 ml of saturated sodium bicarbonate solution, washed neutral with water, dried and concentrated in a vacuum. Crystallization from methylene chloride/abs. ether/petroleum ether (low-boiling) yielded intramolecularly deprotonized 1-(5-fluoro-2-benzimidazolyl)-2-[[[2-(2-hydroxyethoxy)-2-methylpropyl]thio]methyl]-4-methoxy-3-methylpyridinium cation of melting point 75°-80°.
EXAMPLE 23
(a) 40.7 g of 4,5-difluoro-o-phenylenediamine dihydrochloride were suspended in 655 ml of isopropanol. A solution of 22.5 g of potassium hydroxide in 250 ml of water was added dropwise thereto while stirring and the mixture was treated with 39.7 g of potassium ethyl xanthogenate, whereupon the solution was boiled at reflux overnight, then diluted with 300 ml of water and made neutral with glacial acetic acid. The resulting suspension was stirred at 60°-70° for an additional hour. The isopropanol was largely removed from the mixture in a vacuum. After the addition of 1 liter of water, the solid was filtered off washed with water and then dissolved in ether. The solution was then extracted with 1.2 liters of water, treated with active charcoal, dried and evaporated in a vacuum. The residue was suspended in petroleum etber (low boiling) and filtered off. There was obtained 5,6-difluoro-2-benzimidazolethiol of melting point above 300°.
(b) A suspension of 23 g of 5,6-difluoro-2-benzimidazolethiol in 740 ml of alcohol was treated with 22.1 g of 2-chloromethyl-4-methoxy-3-methylpyridine hydrochloride. A solution of 10 g of sodium hydroxide in 350 ml of water was added dropwise thereto while cooling with ice, the mixture was left to boil at reflux overnight and then concentrated to about 1/3 of its volume in a vacuum. After the addition of 1200 ml of water the crystals were filtered off and thereupon washed thoroughly first with water and then with ether. There was obtained 5,6-difluoro-2-[[(4-methoxy-3-methyl-2-pyridyl)methyl]thio]benzimidazole of melting point 216°-218°.
(c) A solution of 13.7 g of 5,6-difluoro-2-[[(4-methoxy 3-methyl-2-pyridyl)methyl]thio]benzimidazole in 800 ml of methylene chloride and 130 ml of methanol was treated with 6.9 g of potassium carbonate. 9.6 g of m-chloroperbenzoic acid were added thereto at -30°, whereupon the solution was stirred for a further 5 minutes and subsequently poured into a mixture of 200 ml of saturated sodium bicarbonate solution and 200 ml of water. The separated organic phase was dried over sodium sulfate, treated with 5.0 ml of triethylamine and evaporated in a vacuum. Crystallization from methylene chloride-methanol-ether yielded 5,6-difluoro-2-[[(4-methoxy-3-methyl-2-pyridyl))methyl]sulfinyl]benzimidazole of melting point 188°-189°.
(d) A solution of 2 g of methanesulfonic acid in 200 ml of methanol was saturated with isobutylene gas for 45 minutes and then treated with 3.37 g of 5,6-difluoro-2-[[(4-methoxy-3-methyl-2 pyridyl)methyl]sulfinyl]benzimidazole, whereupon the mixture was stirred at room temperature overnight and subsequently evaporated in a vacuum. The residue was taken up in methylene chloride, whereupon the solution was extracted with 100 ml of saturated sodium bicarbonate solution, washed neutral with water, dried and concentrated in a vacuum. Crystallization of the residue from methylene chloride/petroleum ether (low boiling) gave intramolecularly deprotonized 1-(5,6-difluoro-2-benzimidazolyl)-4-methoxy-2-[[(2-methoxy-2-methylpropyl)thio]methyl]-3-methylpyridinium cation of melting point 153°-155°.
EXAMPLE 24
A solution of 2 g of methanesulfonic acid in 200 ml of ethanol was saturated with isobutylene gas for 45 minutes, then treated with 3.37 g of 5,6-difluoro-2-[[(4-methoxy-3-methyl-2-pyridyl))methyl]sulfinyl]benzimidazole, stirred at room temperature overnight and subsequently evaporated in a vacuum. The residue was taken up in methylene chloride, whereupon the solution was extracted with 100 ml of saturated sodium bicarbonate solution, washed neutral with water, dried and concentrated in a vacuum. Crystallization of the residue from methylene chloride/petroleum ether (low-boiling) gives intramolecularly deprotonized 1-(5,6-difluoro-2-benzimidazolyl)-4-methoxy-2-[[(2-ethoxy-2-methylpropyl)thio]methyl]-3-methylpyridinium cation of melting point 122°-124°.
EXAMPLE 25
A solution of 3.37 g of 5,6-difluoro-2-[[(4-methoxy-3-methyl-2-pyridyl))methyl]sulfinyl]benzimidazole in 200 ml of tert. butanol was saturated with isobutylene gas for 45 minutes, then treated with a freshly prepared solution of 23 g of hydrogen chloride gas in 200 ml of tert. butanol, stirred at room temperature for 48 hours and subsequently evaporated in a vacuum. The residue was taken up in methylene chloride, whereupon the solution was extracted with 100 ml of saturated sodium bicarbonate solution, washed neutral with water, dried and concentrated in a vacuum. Crystallization of the residue from methylene chloride/petroleum ether (low-boiling) gave intramolecularly deprotonized 2-[[(2-chloro-2-methylpropyl)thio]methyl]-1-(5,6-difluoro-2-benzimidazolyl]4-methoxy-3-methylpyridinium cation of melting point 138°-140°.
EXAMPLE 26
500 mg of 5,7-dihydro-2-[[(4-methoxy-3-methyl-2-pyridyl)methyl]sulfinyl]-5,5,7,7-tetramethylindeno[5,6-d]imidazol-6(1H)-one were dissolved in 50 ml of tert.-butanol saturated with gaseous hydrochloric acid and left to stand at room temperature for 3 days. The reaction mixture was concentrated and the residue was crystallized from ethyl acetate. The 2-[[(2-chloro-2-methylpropyl)thio]methyl]-4-methoxy-3-methyl-1-(1,5,6,7-tetrahydro-5,5,7, 7-tetramethyl- 6-oxoindeno[5,6-d]imidazol-2-yl)-pyridinium chloride obtained exhibited a melting point of 168°-172° (decomposition).
EXAMPLE 27
A suspension of 1.75 g of 2-[[(4-methoxy-3-methyl-2-pyridyl)methyl]sulfinyl]-5-(trifluoromethyl)benzimidazole in a solution of 800 mg of isobutylene in 25 ml of triethylene glycol monomethyl ether was treated with 1 g of methanesulfonic acid and stirred at room temperature for 18 hours. The reaction mixture was neutralized with saturated aqueous sodium bicarbonate solution; the aqueous phase was extracted several times with ether and the combined organic phases were dried over sodium sulfate and concentrated. The residue was chromatographed on silica gel with ether and methylene chloride/methanol (20:1) as the elution agent, using the medium pressure flash chromatography method. The resinous reaction product was dried in a high vacuum, whereby intramolecularly deprotonized 4-methoxy-2-[[[2-(2-methoxyethoxy)ethoxy]ethoxy]-2-methylpropyl]thio]methyl]-3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium cation was obtained as a foam. The microanalysis showed the following values:
Empirical formula; C 27 H 36 F 3 N 3 O 5 S; MW 571.66
Calc.: C 56.73% H 6.35% N 7.35% S 5.61%
Found: C 56.30% H 6.19% N 7.39% S 5.77%
EXAMPLE 28
A suspension of 1.75 g of 2-[[(4-methoxy-3-methyl-2-pyridyl)methyl]sulfinyl]-5-(trifluoromethyl)benzimidazole in 25 ml of triethylene glycol was treated under an isobutylene atmosphere with 1 g of methanesulfonic acid and stirred at room temperature for 25 minutes. The reaction mixture was neutralized with saturated aqueous sodium bicarbonate solution; the aqueous phase was extracted several times with ethyl acetate and the combined organic phases were dried over sodium sulfate and concentrated. The residue was chromatographed on silica gel with ether/methylene chloride (20:1) and methylene chloride/methanol (20:1) as the elution agent, using the medium pressure flash chromatography method. The resinous reaction product was dried in a high vacuum, whereby intramolecularly deprotonized 2-[[[2-[2-[2-(2-hydroxyethoxy)ethoxy]ethoxy]-2-methylpropyl]thio]methyl]-4-methoxy-3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium cation was obtained as a foam. The microanalysis showed the following values:
Empirical formula; C 26 H 34 F 3 N 3 O 5 S·8H 2 O·O0.25 AcOEt MW 594.07
Calc.: C 54.59% H 6.38% N 7.07% S 5.40%
Found: C 54.75% H 6.57% N 7.00% S 5.52%
EXAMPLE 29
A suspension of 1.75 g of 2-[[(4-methoxy-3-methyl-2-pyridyl)methyl]sulfinyl]-5-(trifluoromethyl)benzimidazole in 25 ml of tetraethylene glycol was treated under a constant isobutylene atmosphere with 1 g of methanesulfonic acid and stirred at room temperature for 25 minutes. The reaction mixture was neutralized with saturated aqueous sodium bicarbonate solution. The aqueous phase was extracted several times with ethyl acetate and the combined organic phases were dried over sodium sulfate and concentrated. The residue was chromatographed on silica gel with ether/methylene chloride (20:1) and methylene chloride/methanol (20:1) as the elution agent, using the medium pressure flash chromatography method. The resinous reaction product was dried in a high vacuum, whereby intramolecularly deprotonized 2-[[[2-[2-[2-[2-(2-hydroxyethoxy)ethoxy]ethoxy]ethoxy]-2-methylpropyl]thio]methyl]-4-methoxy-3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium cation was obtained as a foam. The microanalysis showed the following values:
Empirical formula; C 28 H 38 F 3 N 3 O 6 S; MW 601.68
Calc.: C 55.89% H 6.37% N 6.98% S 5.33%
Found: C 55.25% H 6.67% N 6.43% S 5.06%
EXAMPLE 30
A solution of 62 mg of gaseous isobutylene in 1.75 ml of methanol and 77 mg of methanesulfonic acid was treated with 93 mg of 2-[[(4-methoxy-3,5-dimethyl-2-pyridyl)methyl]sulfinyl]-5-(trifluoromethyl)benzimidazole, whereupon the reaction mixture was stirred at room temperature for 10 minutes and then neutralized with sodium bicarbonate solution. The sodium bicarbonate solution was extracted several times with methylene chloride. The combined organic phases were dried over sodium sulfate and concentrated. The residue was crystallized from ether/n-hexane in a refrigerator. The intramolecularly deprotonized 4-methoxy-2-[[(2-methoxy-2-methylpropyl)thio]methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium cation obtained exhibited a melting point of 90°-93° (decomposition).
EXAMPLE 31
A solution of 5 ml of cyclohexene and 1 g of methanesulfonic acid in 20 ml of methanol was treated with 2 g of 2-[[(4-methoxy-3-methyl-2-pyridyl)methyl]sulfinyl]-5 (trifluoromethyl)benzimidazole, whereupon the reaction mixture was stirred at room temperature for 24 hours and then neutralized with a sodium bicarbonate solution. The sodium bicarbonate solution was extracted several times with methylene chloride. The combined organic phases were dried over sodium sulfate and concentrated. The residue was crystallized from ether/n-hexane. The intramolecularly deprotonized 4-methoxy-2-[[(trans 2-methoxycyclohexyl)thio]methyl]-3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium cation obtained exhibited a melting point of 115°-120° (decomposition).
EXAMPLE 32
450 mg of intramolecularly deprotonized 2-[((2-ethoxy-2-methylpropyl)thio]methyl]-4-methoxy-3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium cation were dissolved in methanol and treated with 110 mg of methanesulfonic acid. The solution was concentrated several times while adding n-hexane each time. The residue was crystallized from tert. butyl methyl ether. The 2-[[(2-ethoxy-2-methylpropyl)thio]methyl]-4-methoxy-3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium methanesulfonate obtained exhibited a melting point of 49°-54°.
EXAMPLE 33
310 mg of intramolecularly deprotonized 2-[[(2-acetoxy-2-methylpropyl)thio}methyl}-4-methoxy 3 methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium cation were dissolved in methanol, whereupon the solution was acidified with 4.7N methanolic hydrochlorio acid and subsequently concentrated. Ethyl acetate was added to the residue, the mixture was concentrated, ethyl acetate was again added thereto and the mixture was again concentrated. Recrystallization was carried out from ether and there was obtained 2-[[(2-acetoxy-2-methylpropyl)thio]methyl]-4-methoxy-3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium chloride of melting point 116°-118°.
EXAMPLE 34
A suspension of 380 mg of 2-[[(4-methoxy-3,5-dimethyl-2-pyridyl)methyl]sulfinyl]-5-(trifluoromethyl)benzimidazole in a solution of 0.2 g of isobutylene in 3 ml of tert.-butanol was treated with 0.6 g of molecular sieve (Union Carbide, Type 3A) and with a solution of 0.5 g of gaseous hydrogen chloride in 3.7 ml of tert. butanol. The reaction mixture was stirred at room temperature for 50 minutes, subsequently poured into a mixture of ice and aqueous sodium bicarbonate solution and then methylene chloride was added thereto. The mixture was filtered and the filtrate was extracted with methylene chloride. The organic phase was dried and concentrated. The residue was dissolved in 10 ml of methylene chloride. whereupon 0.7 g of silica gel (particle size: 0.04-0.06 mm) was added thereto and the mixture was stirred at room temperature for one hour. The silica gel was filtered off and the filtrate was concentrated. The residue was chromatographed on silica gel with methylene chloride/methanol (20:1) as the elution agent, using the medium pressure flash chromatography method. By recrystallization from ether/n-hexane intramolecularly deprotonized 2-[[(2-chloro-2-methylpropyl)thio]methyl]-4-methoxy-3,5-dimethyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium cation of melting point 92°-93° was obtained.
EXAMPLE 35
A suspension of 100 mg of intramolecularly deprotonized 2-[[(2-chloro-2-methylpropyl)thio]methyl]-4-methoxy-3,5-dimethyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium cation in 2 ml of 1N aqueous hydrochloric acid was stirred at room temperature for 10 hours and then poured into a mixture of ice and aqueous sodium bicarbonate solution. The aqueous phase was washed several times with methylene chloride; the combined organic phases were dried and concentrated. The residue was chromatographed on silica gel with methylene chloride/methanol (10:1) as the elution agent, using the medium pressure flash chromatography method. The resinous reaction product was dried in a high vacuum. whereby intramolecularly deprotonized 2-[[(2-hydroxy-2-methylpropyl)thio]methyl]-4-methoxy-3,5-dimethyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium cation was obtained as a foam. The microanalysis showed the following values:
Empirical formula; C 21 H 24 F 3 N 3 O 2 S; MW 439.50
Calc.: C 57.39% H 5.50% N 9.56% S 7.29%
Found: C 57.15% H 5.96% N 9.11% S 7.00%
EXAMPLE 36
(a) A solution of 9.4 g of 2-(chloromethyl)-3-methyl-4-nitropyridine and 10 g of 5-(trifluoromethyl)-2-benzimidazolethiol in 260 ml of abs. acetone was treated with 3 g of finely ground potassium carbonate and stirred at room temperature under argon for 18 hours. 180 ml of acetone were distilled off in a vacuum, whereupon the remaining portion of the reaction mixture was poured on to ice. The crystallized-out product was filtered off and dried at 35° in a drying oven By recrystallization from ethyl acetate/n-hexane there was obtained 2-[[(3-methyl-4-nitro 2-pyridyl)methyl]thio]-5-(trifluoromethyl)benzimidazole of melting point 192°-193°.
(b) 600 mg of sodium hydride dispersion (55-60% in oil) were dissolved in 50 ml of abs. ethanol under argon. 3.68 g of 2-[[(3-methyl-4-nitro-2-pyridyl)methyl]thio]-5-(trifluoromethyl)benzimidazole were added thereto and the solution was left to stir at 70° for 1 hour. The solution was neutralized with glacial acetic acid and the mixture was then evaporated in a vacuum. The residue was treated with aqueous sodium bicarbonate solution and methylene chloride. The organic phase was separated and the aqueous phase was extracted several times with methylene chloride. The combined organic phases were dried and concentrated The residue was chromatographed on silica gel with methylene chloride/methanol (9:1), using the medium pressure flash chromatography method, pressure was produced with nitrogen gas. There was obtained 2-[[(4-ethoxy-3-methyl-2-pyridyl)methyl]thio]-5-(trifluoromethyl)benzimidazole. After recrystallization from ethyl acetate/ether the product melts at 173°-177°.
(c) 2-[[(4-Ethoxy-3 methyl-2-pyridyl)methyl]thio]-5-(trifluoromethyl)benzimidazole was also prepared as follows:
A solution of 5 g of 2-(chloromethyl) 4-ethoxy-3-methylpyridine and 5 g of 5-(trifluoromethyl) 2 benzimidazolethiol in 130 ml of abs. acetone was treated with 5 g of finely ground potassium carbonate and stirred at room temperature under argon for 2 hours. 100 ml of acetone were distilled off in a vacuum, whereupon the remaining portion of the reaction mixture was poured onto ice The crystallized-out product was filtered off and dissolved in methylene chloride. The solution obtained was washed with water, dried and concentrated. The residue was chromatographed on silica gel while eluting using methylene chloride and methylene chloride/ethyl acetate (1:1), with the medium pressure flash chromatography method. 2-[[(4 ethoxy-3-methyl-2-pyridyl) methyl]thio]-5-(trifluoromethyl)benzimidazole which melts at 173°-177° was obtained after recrystallization from ethyl acetate/ether.
(d) A solution of 2.5 g of 2-[[(4-ethoxy-3-methyl-2-pyridyl)methyl]thio]-5-(trifluoromethyl)benzimidazole in 20 ml of chloroform was treated rapidly under argon at -40° with a solution of 1.5 g of m chloroperbenzoic acid in chloroform The solution was subsequently stirred for 10 minutes and extracted with 10 percent sodium carbonate solution. The chloroform solution was treated with 3 drops of triethylamine, dried and concentrated. The 2-[[(4-ethoxy-3-methyl-2-pyridyl)methyl]sulfinyl]-5-(trifluoromethyl)-2-benzimidazole obtained was processed directly.
(e) 80 ml of ethanol saturated with isobutylene were treated with 2.7 g of 2 (4-ethoxy 3 methyl-2-pyridyl) methyl]sulfinyl]-5-(trifluoromethyl)-2-benzimidazole and a solution of 1 g of methanesulfonic acid in 5 ml of ethanol was added thereto under an isobutylene atmosphere The solution was stirred at room temperature for 18 hours and then concentrated. The residue was treated with methylene chloride and aqueous sodium bicarbonate solution The organic phase was separated and the aqueous phase was washed with methylene chloride The combined organic phases were dried and concentrated. The residue was chromatographed on silica gel while eluting using methylene chloride/methanol (10:1). with the medium pressure flash chromatography method. The intramolecularly deprotonized 4-ethoxy-2-[[(2-ethoxy-2-methylpropyl)thio]methyl]-1-[5-(trifluoromethyl)-2-benzimidazolyl]-pyridinium cation obtained was acidified in ether with gaseous hydrogen chloride, whereupon the solution was concentrated and the residue was crystallized from ether. There was obtained 4-ethoxy-2-[[(2-ethoxy-2-methylpropyl)-thio]methyl]-1-[5-(trifluoromethyl)-2-benzimidazolyl]-pyridinium chloride melting at 145°-147° with decomposition.
EXAMPLE 37
(a) A suspension of 13 g of 5,6-dichloro-2-benzimidazolethiol in 360 ml of alcohol was treated with 13 g of 2-chloromethyl-4-methoxy 3-methylpyridine hydrochloride. A solution of 4 g of sodium hydroxide in 170 ml of water was added dropwise thereto while cooling with ice. The mixture was left to boil at reflux overnight and then concentrated to about 1/3 of its volume in a vacuum. After the addition of 600 ml of water the crystals were filtered off and thereupon washed thoroughly with water and then with ether. There was obtained 5,6-dichloro-2-[[(4-methoxy-3-methyl-2-pyridyl)methyl]thio]benzimidazole of melting point 254°-256°.
(b) A solution of 1.0 g of 5,6-dichloro-2-[[(4-methoxy-3-methyl-2-pyridyl)methyl]thio]benzimidazole in 150 ml of methylene chloride and 30 ml of methanol was treated with 0.5 g of potassium carbonate. 0.6 g of m-chloroperbenzoic acid was added thereto at -30° while stirring, whereupon the solution was stirred for an additional 5 minutes and subsequently poured into a mixture of 20 ml of saturated sodium bicarbonate solution and 20 ml of water. The separated organic phase was dried over sodium sulfate, treated with 0.5 ml of triethylamine and evaporated in a vacuum. Crystallization from methylene chloride-methanol-ether yielded 5,6-dichloro-2-[[(4-methoxy-3-methyl-2-pyridyl)methyl]sulfinyl]benzimidazole of melting point 173°.
(c) A solution of 2 g of methanesulfonic acid in 200 ml of ethanol was saturated with isobutylene gas for 45 minutes then treated with 3.7 g of 5,6-dichloro-2-[[(4-methoxy-3-methyl-2-pyridyl)methyl]sulfinyl]benzimidazole, stirred room temperature overnight and subsequently evaporated in a vacuum. The residue was taken up in methylene chloride, whereupon the solution was extracted with 100 ml of saturated sodium bicarbonate solution, washed neutral with water, dried and concentrated in a vacuum. Crystallization of the residue from methylene chloride/ petroleum ether (low-boiling) yielded intramolecularly deprotonized 1-(5,6-dichloro-2-benzimidazolyl)-2-[[(2-ethoxy 2 methylpropyl)thio]methyl]-4-methoxy-3-methylpyridinium cation of melting point 141°-143°.
EXAMPLE 38
A solution of 3.7 g of 5,6-dichloro-2-[[(4-methoxy-3-methyl-2-pyridyl)methyl]sulfinyl]benzimidazole in 200 ml of tert.butanol was saturated with isobutylene gas for 45 minutes, then treated with a freshly prepared solution of 23 g of hydrogen chloride gas in 200 ml of tert.butanol, stirred at room temperature for 48 hours and subsequently evaporated in a vacuum. The residue was taken up in methylene chloride, whereupon the solution was extracted with 100 ml of saturated sodium bicarbonate solution washed neutral with water, dried and concentrated in a vacuum. Crystallization of the residue from methylene chloride/petroleum ether (low-boiling) gave intramolecularly deprotonized 2-[[(2-chloro-2-methylpropyl)thio]methyl]-1-(5,6-dichloro-2-benzimidazolyl) 4-methoxy-3-methylpyridinium cation of melting point 136°-138°.
EXAMPLE 39
A suspension of 2.7 g of 2-[[(4-ethoxy-3-methyl-2-pyridyl)methyl]sulfinyl]-5-(trifluoromethyl)benzimidazole in a solution of 1.4 g of isobutylene in 21 ml of tert.butanol was treated with 2 g of molecular sieve (Union Carbide type 3A) and with a solution of 3.5 g of gaseous hydrogen chloride in 26 ml of tert.butanol. The reaction mixture was stirred at room temperature for 50 minutes and subsequently poured on to a mixture of ice and 200 ml of aqueous sodium bicarbonate solution, whereupon methylene chloride was added. The insoluble part of the mixture was filtered off over silica gel and the filtrate was extracted several times with methylene chloride The organic phases were combined, dried with sodium sulfate, filtered and concentrated. The residue was dissolved in 80 ml of methylene chloride, whereupon 5 g of silica gel (particle size: 0.04-0.06 mm) were added and the mixture was stirred at room temperature for one hour. The silica gel was filtered off, the filtrate was concentrated and the residue was crystallized from ether. The intramolecularly deprotonized 2-[[(2-chloro-2-methylpropyl)thio]methyl]-4-ethoxy-3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]-pyridinium cation obtained exhibited a melting point of 152° (decomposition).
EXAMPLE 40
A suspension of 1.5 g of intramolecularly deprotonized 2-[[(2-chloro-2-methylpropyl)thio]methyl]-4-ethoxy 3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium cation in 3o ml of 1N aqueous hydrochloric acid was stirred at room temperature for 9 hours and then poured into a mixture of ice and aqueous sodium bicarbonate solution, whereupon the mixture was extracted several times with methylene chloride. The combined methylene chloride extracts were dried with sodium sulfate, filtered and concentrated. The residue was chromatographed on silica gel with methylene chloride/methanol (20:1) as the elution agent, using the medium pressure flash chromatography method. By crystallization from ether there was obtained intramolecularly deprotonized 2-[[(2-hydroxy-2-methylpropyl)thio]methyl]-4-ethoxy-3-methyl-1-[5-(trifluoromethyl) 2-benzimidazolyl]pyridinium cation of melting point 162° (decomposition).
EXAMPLE 41
A solution of 1.3 g of intramolecularly deprotonized 2-[[(2-hydroxy-2-methylpropyl)thio]methyl]-4-ethoxy-3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium cation in 4.1 ml of acetic acid and 8.3 ml of acetic anhydride was treated with 8 drops of perchloric acid and stirred at room temperature for 5 hours. The reaction mixture was neutralized with saturated aqueous sodium carbonate solution, extracted several times with ether. The extracts were dried over sodium sulfate, and the ether was evaporated off. The residue was crystallized from ether/n-hexane, whereby there was obtained intramolecularly deprotonized 2-[[(2-acetoxy-2-methylpropyl)-thio]methyl]-4-ethoxy-3-methyl-1-[5-(trifluoro methyl)-2-benzimidazolyl]-pyridinium cation of melting point 108°-109° (decomposition).
EXAMPLE 42
A solution of 2 g of intramolecularly deprotonized 2-[[[2-(2-hydroxyethoxy)-2-methylpropyl]thio]methyl]-4-methoxy-3-methyl-1-[5-(trifluoromethyl) 2 benzimidazoly)]pyridinium cation in 6.2 ml of acetic acid and 12.5 ml of acetic anhydride was treated with 8 drops of perchloric acid and stirred at room temperature for 5 hours. The reaction mixture was neutralized with saturated aqueous sodium carbonate solution, extracted several times with methylene chloride. The extracts were dried over sodium sulfate, filtered and the methylene chloride was evaporated off. The residue was chromatographed on silica gel with methylene chloride/methanol (10:1) as the elution agent, using the medium pressure flash chromatography method. By crystallization from ether/n hexane there was obtained intramolecularly deprotonized 2- [[[2-(2-acetoxyethoxy)-2-methylpropyl]thio]methyl]-4-methoxy-3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium cation of melting point 85°-89°.
EXAMPLE 43
A solution of 1.3 g of methanesulfonic acid and about 8 g of gaseous isobutylene in 100 ml of isopropanol was treated with 2.5 g of 2-[[(4-methoxy.3-methyl-2-pyridyl)methyl]sulfinyl]5-(trifluoromethyl)benzimidazole. whereupon the reaction mixture was stirred at room temperature under an isobutylene atmosphere for 66 hours and then evaporated. The residue was treated with methylene chloride and aqueous sodium bicarbonate solution, the methylene chloride phase was separated and the aqueous phase was extracted with methylene chloride The combined organic phases were dried and concentrated. The residue was chromatographed on silica gel with methylene chloride/methanol (20:1) as the elution agent, using the medium pressure flash chromatography method. The purified reaction product was dissolved in ethyl acetate and acidified with a solution of gaseous hydrochloric acid in ethanol, whereupon the solvent system was distilled off. The residue was crystallized from ethyl acetate/ether, whereby there was obtained 2-(2-isopropoxy-2-methylpropyl)-4-methoxy-3-methyl-1-[5-(trifluoromethyl)-2-benzimidazolyl]pyridinium chloride of melting point 123°-126°.
Example A
Crystalline compounds of formula I can be used as the active substance for the preparation of hard gelatin capsules, the content of which has the following composition per capsule:
______________________________________Active substance 50.0 mgLactose powd. 40.0 mgLactose cryst. 130.0 mgMaize starch white 20.0 mgTalc 8.0 mgMagnesium stearate 2.0 mgFill weight per capsule 250.0 mg______________________________________
The active substance and the adjuvants are mixed with one another and the mixture is filled into hard gelatin capsules of suitable size. If necessary, the capsules are subsequently provided with a gastric fluid-resistant coating of hydroxypropylmethylcellulose phthalate.
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A compound of the formula ##STR1## wherein R 1 -R 19 are as described in the specification. The present invention is concerned with benzimidazole derivatives, particularly benzimidazole-2-yl pyridinium compounds of formula I which are pharmaceutically useful in treating or preventing gastric and duodenal ulcers. The invention includes the compounds I, pharmaceutical compositions containing such compounds and the use of such compounds in therapeutic treatment or prevention of gastric and duodenal ulcers.
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TECHNICAL FIELD
The following description relates generally to computer-implemented methods for processing pharmaceutical claims for informational content, rather than for payment. More particularly, the description relates to a computer-implemented method for receiving input data relating to a person's claims for prescription drugs, establishing a pharmaceutical event record for the person, establishing pharmacy episode groupings of data records of related medication management patterns, correlating subsequent pharmaceutical claims events to a pharmacy episode category and manipulating pharmacy episode categories based upon time windows relating to physician's use instructions, multi-drug therapeutic strategy, concurrent drug use, and patient's patterns of compliance with physician-indicated use of the drug(s). In certain embodiments, a Pharmacy Episode Grouping System (PEGS) has logically consistent non-disease based rules for episode boundaries (start and end dates) and its methodology for episode creation is valid and consistent, regardless of medical condition, treatment setting, or drug type.
BACKGROUND OF THE INVENTION
The third-party payer healthcare industry is a well-established industry. In general, in such third-party payer health care industry, a “third party” (referred to herein generally as an “insurer”) pays for healthcare services received from a service provider (any person, such as a doctor, nurse, dentist, optometrist, pharmacist, etc., or institution, such as a hospital, clinic, or medical equipment provider, that provides medical care, services, drugs, healthcare supplies, medical equipment, home health, etc.) to a member (or “insured”) consumer. As used herein, a healthcare consumer is any person to whom healthcare services are rendered. In some situations, the healthcare consumer may be referred to herein as a “patient”, but the services rendered are not limited to those rendered by a physician and thus “healthcare consumer” is not limited to a patient. The healthcare consumer may also be referred to herein as a “member” because the consumer is a member of one or more healthcare plans under which a third-party payer (insurer) pays for at least a portion of certain healthcare services rendered to the consumer.
Examples of third-party payers (or “insurers”) include an insurance company (e.g., BlueCross® BlueShield®, Aetna® Inc., etc.), Health Maintenance Organization (“HMO”), Preferred Provider Organization (“PPO”), third-party administrator (TPA), Self Insured/Self Funded Employer, or local, state, or Federal Government (e.g., Medicare) and their approved intermediaries including private insurers providing Medicare or Medicaid health insurance in coordination with, or on behalf of, the Government (e.g., BlueCross® BlueShield® of South Carolina provides and administers Medicaid and Medicare insurance), as examples. The insurers generally negotiate with the service providers (e.g., hospitals, doctors, etc.) various terms, including the amounts (and corresponding conditions) that the insurers will pay the service providers for services rendered to the consuming members of the insurers. For instance, a negotiated contract may specify that an insurer will pay a service provider X amount for performance of a given healthcare service (e.g., caesarean-section procedure, open heart surgery, blood test, routine physical exam, LASIK eye surgery, dental root canal, prescribed pharmaceuticals, healthcare equipment (e.g., wheelchair), etc.) for one of its members. The contract may specify those healthcare services for which the insurer will reimburse the service provider, as well as the corresponding reimbursement rates for each service. That is, the contract may define how the reimbursement is to be computed for each service. For instance, the contract may list things that are not covered and/or may specify that certain items are limited in the number of services that are allowed.
Once the service is provided and the claim is submitted, then a claim processing and adjudication system may be used to evaluate the claim under the insurer's contract with the service provider, etc. and determine the insurer's liability as well as the consumer's liability for such service. In general claim adjudication refers to determination of liability of one or more parties (e.g., the patient/member, insurer, service provider, etc.) for a given healthcare service based on predefined relationships/responsibilities (e.g., the above-described contracts between the insurer and service provider and/or contracts between the member or member's employer, etc. and insurer). Such claim adjudication typically includes evaluation of the member's specific health benefit plan and status of their accumulators/financial accounts associated with their benefit plan to arrive at a determination of liability for the member/patient and/or insurer. Adjudication typically calculates patient liability based on such features as: 1) provider contracted rates/network benefit, 2) member's specific health benefit plan, 3) member's specific financial balances, accumulators, and accounts (deductibles, visits allowed/used, HRA, HSA, FSA, etc.), and 4) clinical edits for the member and their benefit plan. Traditional claim adjudication systems process received claims to adjudicate them (i.e., determine liability of the parties), and post/commit the adjudicated claim for payment by an insurer, in response to which funds are distributed from the insurer for the insurer's determined liability.
As described further herein, typically medical claims are adjudicated to determine the insurer's liability as well as the consumer's liability for medical services rendered by a medical service provider, such as a physician, hospital, etc. Similarly, in the event that pharmaceuticals (e.g., drugs, equipment, etc.) are prescribed, pharmaceutical claims are adjudicated to determine the insurer's liability as well as the consumer's liability for such pharmaceuticals rendered by a pharmaceutical service provider (or “pharmacy”).
Today, more than half of patient visits to physicians result in prescriptions, and most serious medical conditions are treated with one or more prescription medications. Experts at the Institute of Medicine estimate that 30-40% of hospitalizations are directly or indirectly associated with improper use of prescription drugs. Some 213,000 hospital emergency visits in 2005 were attributed to use or misuse of prescription painkillers alone. With expanded prescription drug coverage in the federal Medicare Program (Part D), the potential for inappropriate, as well as appropriate, drug use increases exponentially. Finally, drug costs during the past decade have experienced the most rapid rise of any component of medical service expense.
A consensus of recent research shows that proper and timely use of prescription drugs can prevent or ameliorate acute flare-ups in chronic conditions that are both dangerous and costly. However, major American corporations are eliminating or cutting co-pays for drugs for their employees, such as those for treating heart conditions, asthma, and diabetes (see e.g., Wall Street Journal, May 8, 2007, Personal Journal page D1). As a consequence, insurers seek information not only on the cost of drugs but on how, by whom, and whether they are used.
Yet, currently available computer-implemented methods dealing with pharmacy claims provide limited information. For instance, no currently available computer-implemented methods dealing with pharmacy claims provide information (a) in a clinically relevant time frame using (b) drug- and diagnosis-neutral measures and (c) transparent interactions between patients, prescribing physicians, and prescription drugs that (d) preserve evidence of the prescribing physician's clinical intent and (e) the patient's compliance, and that allows for (but does not require) (f) correlation with relevant medical claims.
Certain historical dimensions of the health care insurance industry are relevant to the context of the concepts presented herein. The first is that pharmacy benefits coverage has not been an integrated component of “standard package” medical insurance. As a consequence, both data and payment systems for pharmacy have historically been separate from those systems for other medical services, such as hospitalization and all aspects of physician and other professional care. One consequence is that even as the standard medical insurance benefit has been extended to pharmacy coverage, both data management and payment systems have remained separate domains. Whereas most health care insurers receive, manage, pay, and analyze their own medical claims, pharmacy claims activities are sub-contracted to Pharmacy Benefit Management (PBM) companies. As discussed below, PBM responsibilities for pharmacy claims analysis tends to be of limited scope.
Existing methods for dealing with pharmaceutical claims are of three general types. The most common type is cost-oriented methods employed by the PBMs. The second type uses methods that subsume pharmacy records within episodes defined by medical claims (hospital, other inpatient, outpatient, or professional claims containing medical diagnosis codes). The third type uses methods that aggregate pharmacy records over some extended time period, using the specific drugs prescribed as proxies for medical condition diagnoses, in order to calculate a patient's relative risk of incurring future medical expense. Each of these three pharmaceutical claim use types are discussed further below.
The presence of pharmacy benefit managers (PBMs) in third party (e.g., health care insurer) claims adjudication systems for payment of pharmacy claims is well established in the industry. A typical PBM receives a claim that is generated when a patient has a prescription from a doctor filled at a pharmacy, and the PBM determines if the drug prescribed is part of the patient's insurance coverage. If the drug is within the patient's coverage, the claim is paid. In some PBM systems, the claim is further examined in attempt to detect fraud, to determine provider utilization of certain drugs, and to encourage the use of generics. However, in the analysis of the pharmacy claims for these additional uses, the PBM does not allow for correlation of the pharmacy claim to another pharmacy claim except as a duplicate, as a substitute generic drug, or for cost review. It also does not allow for correlation to a medical claim. PBM-produced cost tracking reports are typically aggregated to plan or aggregate provider (IPA, clinic) level, but are available within 30 days of pharmacy events.
The second most common type of pharmacy grouper subsumes pharmacy claim data into medical episode grouping logic based on diagnosis codes in medical claims, such as those generated by hospitals, other inpatient facilities, outpatient clinics, and professional providers for billing insurers. Pharmacy claims are treated as incidental to medical claims which are grouped by diagnosis code(s) or relationships between diagnosis and procedure code(s) according to dates of service and prescribing providers. When pharmacy claims cannot be associated with the medical claims based on dates of service and prescribing provider, they are simply listed as pharmacy events based on drug, date, and prescribing provider so as to be associated with the patient/member or provider as a component of total cost. The pharmacy claims are not analyzed for utilization patterns within drugs or relationships between drugs; they are not classified by type, identified as Multi-Drug or Concurrent, and they do not establish intervals for monitoring patient compliance; and they provide no mechanism to analyze medication coordination among multiple prescribing physicians. Examples of this method is Episode Treatment Groups (ETGs) offered by Ingenix, Inc., and the methods described in U.S. Pat. No. 5,918,208 titled “System for providing medical information,” U.S. Pat. No. 5,557,514 titled “Method and system for generating statistically-based medical provider utilization profiles,” U.S. Pat. No. 6,223,164 titled “Method and system for generating statistically-based medical provider utilization profiles,” and U.S. Pat. No. 7,222,079 titled “Method and system for generating statistically-based medical provider utilization profiles.” Because such ETGs systems operate on medical data typically spanning 12 to 36 months, the information produced has limited clinical relevance and currency; rather, it is used largely in pricing services, financial planning, and cost management applications.
The third type of pharmacy grouping method in current use does not attempt to construct either medical or pharmacy episodes, but rather groups evidence of medical diagnoses and drugs from all providers over a period of time to predict a patient's “risk”—that is, a health plan member's probability of consuming future resources, measured in dollars, either for total medical consumption or for prescription drugs alone. Future risk is predicted based on the most recent 6 to 24 months of pharmacy claims (or pharmacy and medical claims). Specific drug codes and therapeutic classes are classified and grouped as proxies for implied disease states, with each diagnostic condition assigned a weighting factor for probable future cost (risk). A patient's drug use is considered in aggregate, with no attention to temporal sequence, prescribing physician, dosage or supply, whether used in a multi-drug therapeutic strategy or concurrent with other drugs, continuity, or any other aspect of a physician's clinical intent or a patient's pattern of use and compliance. Examples of this method include DxCG's Diagnosis Cost Groups (DxCGs), Johns Hopkins University's Adjusted Clinical Groups (ACGs), and Pharmacy Risk Groups (PRGs), the latter also owned and distributed by Ingenix, Inc. (like the above-mentioned ETGs).
BRIEF SUMMARY OF THE INVENTION
In view of the above, a desire exists for improved utilization of pharmaceutical claims data. For instance, a desire exists for systems and methods for grouping, categorizing, and profiling pharmaceutical claims data within a clinically relevant time frame. Similarly, a desire exists for logically consistent non-disease based rules for episode boundaries (start and end dates) that are applicable regardless of medical condition, treatment setting, or drug type. Finally, a desire exists for systems and methods for associating drug treatment strategies with specific physician prescribers, making it possible to recognize whether drug treatment complexity results from single or multiple sources.
Embodiments of the present invention provide a computer-implemented method for grouping, categorizing, and profiling pharmaceutical claims data to assist health care managers in determining (a) medication treatment experience, outcomes, and medication compliance behaviors of patients and (b) appropriate drug prescribing, medication coordination, and cost-efficiency of health care providers. An objective means is provided for categorizing and quantifying patterns of prescription drug utilization as a health care service within a clinically relevant time frame. A pharmacy episode group (PEG) is a pharmacologically homogenous grouping of drugs with the same therapeutic ingredients used by a patient once or over an extended period of time. The PEG is a patient-centered pharmacy classification unit, which uses script-level pharmacy claim data as input data and assigns each script to the appropriate episode. Pharmacy episodes are categorized based on algorithms linking the pattern of a physician's recommended use (drug supply) and the patient's pattern of compliance (intervals between fill dates). The system also identifies multi-drug and concurrent use drug episodes, flags patients' records where intervals between scripts suggest non-compliance with recommended therapy, selects the most recent claims, resets windows (episode start and end dates), and ultimately assigns all pharmacy claims to episodes.
Accordingly, it is a broad aspect of the present invention to provide a computer-implemented system and method for grouping, categorizing, and profiling pharmaceutical claims data.
Certain embodiments of the present invention provide a system and method that offer an objective means for categorizing and quantifying patterns of prescription drug utilization as a health care service within a clinically relevant time frame. A pharmacy episode group (PEG), as used herein, generally refers to a pharmacologically homogeneous grouping of drugs with substantially the same therapeutic ingredients used by a patient once or over an extended period of time. According to certain embodiments, a PEG grouper method is provided that uses line-item pharmacy claim data as input data and assigns each pharmacy record to a patient and to the appropriate pharmacy episode.
Certain embodiments of the present invention provide a methodology for identifying, organizing, and grouping individual prescription pharmacy claims to construct pharmacy episodes for analysis of provider treatment patterns and medical management for health plan patients in general and for specific drugs and medical diagnoses. In certain embodiments, the PEG determines, for each pharmacy episode, a corresponding episode category. For instance, in one embodiment, the PEG determines for each pharmacy episode whether the subject pharmaceutical (e.g., drug) is being used as a “maintenance” therapy (e.g., taken on a regular basis, such as for controlling high blood pressure), as an “acute intervention” (such as an antibiotic for a bacterial infection like pneumonia), or as an “extended intervention” (e.g., for the patient to use as needed, such as for common gastrointestinal discomfort). The mutually exclusive algorithms for assigning episode category (e.g., ME for Maintenance Episode, AI for Acute Intervention episode, and EI for Extended Intervention episode) are inclusive of all pharmacy claims. Pharmacy episode categories may be based on a combination of a prescribing physician's use recommendations, recorded on the pharmacy claim as “supply” and evidence of a patient's utilization in the form of fill dates and intervals between fill dates in relation to drug supply.
In certain embodiments, the PEG is also used to determine whether each drug is being used in conjunction with another drug or drugs as a Multi-Drug (MD) treatment strategy, and whether any specific drug is being taken concurrently (CC) with another or several other drugs. Each drug is considered independently, the episode type is identified, and then its status as Multi-Drug and/or Concurrent is established.
Thus, according to certain embodiments, a computer-implemented pharmaceutical claims profiling system is provided that is operable to perform grouping, categorizing, and profiling based on pharmaceutical claims data. Thus, in certain embodiments such profiling system provides for pharmaceutical claims grouping, categorizing, and profiling. For example, in certain embodiments, the pharmaceutical claims are processed to be assigned to corresponding pharmaceutical episodes, and each episode is then categorized as either ME, AI, or EI. In addition, profiling may be performed for determining whether a given drug is being used as a MD treatment strategy. For example, in addition to creating the episode and classifying it by type, the PEG identifies each prescriber contributing to an episode, making it possible to distinguish whether inappropriate treatment patterns result from single or multiple sources.
According to certain embodiments, the computer-implemented pharmaceutical claims profiling system advantageously offers an objective means for categorizing and quantifying patterns of prescription drug utilization as a health care service within a clinically relevant time frame.
According to certain embodiments, the computer-implemented pharmaceutical claims profiling system utilizes line item pharmacy claim data as input data. The system is operable to process such line item pharmacy claim data to determine the pharmaceutical episodes, and to categorize the pharmaceutical episodes, as discussed further herein.
According to certain embodiments, the computer-implemented pharmaceutical claims profiling system assigns every pharmacy claim contained in received pharmacy claim data to a patient. According to certain embodiments, the computer-implemented pharmaceutical claims profiling system further assigns each pharmacy claim to a pharmacy episode. Additionally, in certain embodiments, the computer-implemented pharmaceutical claims profiling system identifies new or repeat pharmacy episodes.
Further, in certain embodiments, the computer-implemented pharmaceutical claims profiling system assigns each pharmacy episode to an appropriate pharmacy episode category, such as the categories of “maintenance” therapy episode, “acute intervention” episode, and “extended intervention” episode. In certain embodiments, the computer-implemented pharmaceutical claims profiling system includes such categorization of pharmacy episodes based upon algorithms relating to physician's use instructions and/or patient's patterns of compliance with physician-indicated use of the drug(s).
According to certain embodiments, the computer-implemented pharmaceutical claims profiling system identifies the patient's compliance with physician-indicated use of the drug(s).
According to certain embodiments, the computer-implemented pharmaceutical claims profiling system addresses every pharmacy claim received and assigns each received pharmacy claim to one of a plurality of different episode categories (e.g., “maintenance” therapy, “acute intervention”, and “extended intervention”) with specific “start” and “end” dates based on rules for “intervals” between physician's instructions for days of treatment (supply) and patient's prescription fill dates.
Further, in certain embodiments, the computer-implemented pharmaceutical claims profiling system addresses every pharmacy episode and identifies those pharmacy episodes that are a component of a multi-drug episode. Further, in certain embodiments, the computer-implemented pharmaceutical claims profiling system addresses every pharmacy episode and identifies those pharmacy episodes that are concurrent with one or more other pharmacy episodes.
The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims. The novel features which are believed to be characteristic of the invention, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention, reference is now made to the following descriptions taken in conjunction with the accompanying drawing, in which:
FIG. 1 shows a block diagram of a system according to one embodiment of the present invention;
FIG. 2 shows an exemplary flow of logic in generating pharmacy episode groupings from the received pharmacy claims, member, span and provider files according to one embodiment of the present invention;
FIG. 3 shows a block diagram of an exemplary system in which an embodiment of the present invention may be implemented;
FIG. 4 shows an exemplary table illustrating groupings of episodes and claims according to one embodiment; and
FIG. 5 shows an exemplary system on which embodiments of the present invention may be implemented.
DETAILED DESCRIPTION OF THE INVENTION
As used herein, “pharmacy records” generally refer to claims that represent a prescription filled for a patient, typically at a retail pharmacy, the first instance of which is usually initiated by a service rendered by a physician or physician-authorized provider engaging in the direct evaluation, management, or treatment of a patient. Such pharmacy claims are typically submitted (e.g., electronically) to a claim adjudication system, such as that of a PBM, which adjudicates the claim data to determine financial responsibility of the consumer (patient) and a third-party payer (e.g., insurer). Refills of the same drug/script may be authorized within the initiating prescription or, more recently, they may be initiated by a patient's communication with a physician via telephone or e-mail.
According to one embodiment, grouping prescription drug records to episodes involves two interacting tables. The first table is a National Drug Code (NDC) table, which has in excess of 200,000 entries. Every pharmacy record contains one unique National Drug Code (NDC). The National Drug Code is a standard 11-digit identifier for each drug product, as recognized by the Centers for Medicare and Medicaid (CMS), other federal and state agencies, and most commercial enterprises. It is unique to each specific pharmaceutical product. The first 5 numbers identify the manufacturer of a product. The second 4 numbers identify the product (chemical composition/ingredients), and the last 2 numbers identify the package size of that product.
The second table is a smaller drug identification table. Certain embodiments of the present invention employ the smaller drug identification table to map NDC codes to a unique drug identification number (“drug_id”), a clinically unique identifier for the chemical(s) that constitutes a drug's pharmaceutical ingredient(s). According to certain embodiments, the computer-implemented pharmaceutical claims profiling system constructs pharmacy episodes based on the unique drug identifier (drug_id) so that differences between brand names or generic product names or packaging modes indicated by different NDC codes do not interrupt episode formation and continuity. At the same time, in certain embodiments, the computer-implemented pharmaceutical claims profiling system retains the NDC code submitted on the record both for verification and for users of the profiling system to perform secondary analysis, such as analysis regarding use of generics versus brand drugs.
FIG. 1 shows a block diagram of a system 100 according to one embodiment of the present invention. In this example, a Member file 101 contains a member's unique identifying number (Medicare or insurance plan ID). In addition, such member file 101 may further contain demographic information such as age, sex, and other data elements that might be used in secondary analysis. Such data may be stored digitally as computer-readable data stored to a computer-readable medium (e.g., hard disk, memory, magnetic storage device, optical storage device, etc.). The data may be stored in any readable format, such as a flat file, table, database, or other type of data structure.
A Member SPAN file 102 contains, for each unique member identification number, information on dates of plan and pharmacy benefit eligibility (e.g., arranged by month). The computer-implemented pharmaceutical claims profiling system uses Member SPAN file 102 to validate that the member was enrolled and eligible for the pharmacy benefit on the date that a pharmacy record indicating that a prescription has been filled is generated. Such data of Member SPAN file 102 may be stored digitally as computer-readable data stored to a computer-readable medium (e.g., hard disk, memory, magnetic storage device, optical storage device, etc.). The data may be stored in any readable format, such as a flat file, table, database, or other type of data structure.
A Pharmacy Record file 103 contains the member's unique identifying number, the NDC code identifying the drug prescribed, the provider identifying number for the prescriber, the date when the prescription is filled by a retail or other (such as clinic) pharmacy, and the number of days of treatment supplied. While such pharmacy records included in Pharmacy Record file 103 may contain other data elements that may be of interest for subsequent analysis, preferably at least the following five fields are included for each record: member ID, NDC, prescribing provider ID, date filled, and days (of treatment) supplied. The data of Pharmacy Record file 103 may be stored digitally as computer-readable data stored to a computer-readable medium (e.g., hard disk, memory, magnetic storage device, optical storage device, etc.). The data may be stored in any readable format, such as a flat file, table, database, or other type of data structure.
According to certain embodiments, the computer-implemented pharmaceutical claims profiling system is implemented to confer “production-scale” operation capable of handling hundreds of thousands of pharmacy claims simultaneously.
Pharmacy claim data is input electronically as data records into a computer storage device, such as a hard disk drive. The inventive pharmacy claims profiling system may reside in any of a number of computer system architectures. For instance, such computer-implemented pharmaceutical claims profiling system may be run from a stand-alone computer or exist in a client-server system, for example a local area network (LAN) or wide area network (WAN).
Once relevant pharmacy claim data is input, the pharmacy claims data is processed by the system by loading a computer-executable program into the computer system memory. During set-up of the program onto the computer system, the computer program will have previously-set pointers to the physical location of the data files and look-up tables written to the computer storage device.
According to one embodiment, the ETL (Extract Transfer Load) process of the pharmacy claims profiling system is controlled by a file containing XML code with a node per load module that is executed as in the following exemplary code:
-------------------------------------------XML CODE START----------------------------------
<Loader>
<LoadModule Name=“tbDimTime” Seq=“A” Type=“”>
<Success Status=“1” FileCreated=“0” Cleaned=“0” Detail=“0” LastCount=“0” /></LoadModule>
<LoadModule Name=“MemberType” Seq=“B” Type=“”><Success Status=“1” FileCreated=“0”
Cleaned=“0” Detail=“0” LastCount=“0” /></LoadModule>
<LoadModule Name=“SpanType” Seq=“C” Type=“”><Success Status=“1” FileCreated=“0”
Cleaned=“1” Detail=“0” LastCount=“0” /></LoadModule>
<LoadModule Name=“PharmacyType” Seq=“F” Type=“”><Success Status=“1” FileCreated=“1”
Cleaned=“1” Detail=“0” LastCount=“0” /></LoadModule>
<LoadModule Name=“PostLoadProcess” Seq=“H” Type=“”><Success Status=“1” FileCreated=“0”
Cleaned=“0” Detail=“0” LastCount=“0” /></LoadModule>
</Loader>
-----------------------XML CODE END-----------------------------------------------------------
Input files are copied to an input location which is configurable in the application configuration file. The application configuration is updated to indicate the number of input files for each load module. The input files are then renamed to be the same as the corresponding filename key, e.g. if there are two Pharmacy files, rename Pharmacy 1 , Pharmacy 2 and set number of files for Pharmacy to 2.
This process can be automated by enhancing the integration engine to support job sequencing and creating a job to listen to a folder. The interface to a user may then be a Web application (browser), for example.
Data on which the pharmaceutical claims profiling system operates, according to this embodiment is received and input in the form of flat files (or other appropriate form, such as tabular form, database, etc.) received from clients in conformity with a Data Specification document provided to the client. Client data undergoes a three step process, in this exemplary embodiment, to end up in a relational data warehouse 107 .
The application that reads and processes the flat file data is called the PDM “Loader”, and it performs the load database operation 104 shown in FIG. 1 . Preferably, the PDM Loader is part of the PDM Integration Engine family of classes and can be configured to run as an Integration Engine job. According to one embodiment, the PDM Loader design also allows for a distributed processing architecture by means of splitting large input data into much smaller files, so-called “atomic” input data.
The minimum input files employed for one exemplary implementation of the pharmaceutical claims profiling system are as follows, and are described in greater detail above:
1. Member file 101 (containing unique member identifying number and, in some cases, demographic data); 2. Member Span file 102 (containing dates of eligibility by month and other data); 3. Pharmacy Claims (or Record) file 103 (containing prescribing provider ID, NDC, fill date, days supply); and 4. NDC table to DrugID Table 105 , Crosswalk (updates periodically, e.g., twice a year)
The operations performed for loading pharmacy claim data to be processed by this exemplary embodiment of system 100 include the following:
Step 1 . The PDM Loader process 104 reads in the raw data files 101 - 103 , scrubs the data, and validates the input. It is then ready for pre-aggregation as input into the pharmaceutical claims profiling logic. In one embodiment, input data is split into smaller member-based files to allow more efficient processing and also allow for distributed processing, if so desired. Step 2 . The PDM Loader process 104 loads some tables 105 into the Load database and some tables directly into the data warehouse 107 . Step 3 . A Post-Load process checks for duplicates and identifies data updates (new inputs) that might close or extend an episode.
In one embodiment, the Load process 104 is largely file-based, rather than database-reliant to support scalability for larger amounts of input data. This exemplary design also lessens reliance on a single-threaded, single-resource (SQL Server database) and allows for a multi-resource, multi-threaded load system, if so desired.
According to one embodiment, the basic PDM Loader class can be initiated from the PDM Integration Engine (which is a Windows Service). Splitting large input files into smaller atomic files may leverage the fact that a member is the basic atomic unit within the load process. In fact, it is possible for the PDM Load application to run in entirety on a single member. This non-reliance on member interaction permits splitting input data based on groups of members. In one embodiment, the PDM Loader application assigns members to groups simply by dividing the total member count by a configurable value (e.g., 100 to then get 100 smaller member groups). Each member group is then sent through load processing modules. Each module represents unique load logic, so for example there may be a load module for Pharmacy Claims.
Irrespective of how the pharmacy claims data may be loaded, such data may then be processed to form corresponding pharmacy episode groupings, which may in turn be categorized (or classified) into corresponding categories. The process of grouping the received pharmacy records (pharmacy claim file) into pharmacy episodes, according to one exemplary embodiment, utilizes a minimum of six contiguous months of pharmacy claims, which can be added to continuously at monthly or quarterly intervals. Each update will address the previous as well as new incoming pharmacy records and either reclassify “open” episodes based on new information or “close” them.
In general, a pharmacy episode “start date” is set at the first instance of specific drug (drug_id) in each patient's pharmacy claims. A pharmacy episode “end date” is set at the latest prescription fill date for that drug_id in the pharmacy claims plus the physician's indicated “days supply” for treatment.
Episode creation, according to one embodiment, performs a series of passes through the claim load, which is sorted by Member_ID by prescription fill date (date of service), to apply the rules that distinguish the three types of episodes—Acute, Extended, and Maintenance—and to identify episodes that represent a Multi-Drug therapeutic strategy and also to identify drugs that are being used concurrently with other drugs.
The first pass through the pharmacy records creates a new field which is added to each pharmacy record to enable episode identification and classification. For each Member ID, at the first instance of a Drug_ID, label 001-01, which represents episode 001, script 1. If the same Drug_ID occurs for that Member ID, label the record 001-02, which represents episode 001, script 2.
At the first instance of a different Drug_ID, label the record 002-01, representing episode 2 and script 1. Increment each successive new DrugID for that member, labeling records as 003-01, 003-02, 003-03, through to the end of each member's records in the claim load.
The second pass is to establish episode boundary dates and classify episodes by type into either a Maintenance Episode, Acute Intervention, or Extended Intervention, as discussed below.
A) Maintenance Episode. If an identical Drug_ID recurs three or more times, and the intervals between successive fill dates are less than two times the days supply, label as “maintenance episode.” (Depending on the analytic period (claim load), the first instance of any Drug ID could be marked either as “new” or “refill,” so this information, if present, is ignored.)
Example: Drug ID 001-01 fill date is Mar. 10, 2006 and days supply=30. If 001-02 takes place before May 10, 2006, and 001-03 takes place in fewer than 60 days after 001-02, this is a “Maintenance Episode” (ME-01) but if 001-02 or 001-03 takes place more than 60 days later than the preceding fill date, this will be an EI (Extended Intervention) episode.
The Maintenance Episodes Boundary is established by first fill date and last fill date plus days supply converted to “begin” and “end” dates, respectively (mm/dd/yyyy). (The boundary may be equivalent to the analysis period if supply is continuous.) In the example above, episode begin date is Mar. 10, 2006 and the end date is the last fill date plus the days supply. If the analysis period were Jan. 01, 2006 to Dec. 30, 2006 and the last fill date was Dec. 10, 2006, the “end date” would be Jan. 09, 2007.
To designate Episode Type and Episode Type Number a new five-digit field is created and added to each pharmacy record. Possible field values are: ME-01 through ME-99 Maintenance Episode. To designate Episode Begin/End Dates, a new 17-digit field is created and added to each record, as follows: MMDDYYYY-MMDDYYYY
B) Acute Intervention. Identify member with a unique DRUG-ID script (or scripts) and no more than one refill at an interval less than two times the first script's days supply. If the date for the next script with the same Drug ID is greater than two times the first scripts days supply, begin EI (Extended Intervention) episode.
Example: New Drug ID episode 003-01 fill date Jul. 7, 2006 with days supply=15. If 003-02 occurs before Aug. 7, 2006 (double the days supply), then label as a Acute Intervention episode (AI-01). If fill-date occurs on Aug. 8, 2006 or after, label as Extended Intervention episode (EI-0?).
The Acute Intervention Boundary is established by first fill date and last fill date plus days supply, converted to start/end dates: mm/dd/yyyy-mm/dd/yyyy.
The designation of Episode Type and Episode Type Number is achieved by creating a new five-digit field. Possible field values are: AI-01 through AI-99 Acute Intervention Episode. Episode Begin/End Dates are recorded in a new 17-digit field appended to the pharmacy record.
C) Extended Intervention. Identify member with “new” Drug ID script where the interval between the original fill date and subsequent “refill” claims is three times or more than the days supply for the original script For example, new Drug ID script 004-01 fill date is Apr. 12, 2006 and days supply is 10. If refill date occurs before May 02, 2006, then it is AI. If the next fill date is May 03, 2006 or later, it is EI.
The EI Boundary is established by first “fill date” and last fill date plus days supply. If the next script same Drug ID date is more than six times the days supply of the last fill date, begin new episode.
The designation of Episode Type and Episode Type Number are achieved by creating a new five-digit field. Possible field values are: EI-01 through EI-99 Extended Intervention Episode. Episode Begin/End Dates are indicated by a new 17-digit field appended to each record, MMDDYYYY-MMDDYYYY.
The third pass identifies episodes as Multi-Drug episodes and identifies episodes of one drug that are concurrent or overlapping with use of other drugs. To identify Multi-Drug episodes and Concurrent episodes, distinct two-character fields are created: MD for Multi-Drug and CC for Concurrent. During processing in this third pass, the system identifies all episodes where two or more Drug IDs have SAME “fill date” and SAME “provider,” and those identified episodes are marked as “Multi-Drug”—MD. Also, during this third pass, the system labels any episode type as “CC” where the “fill date” plus “days supply” is overlapping any other date interval with the same Member ID and different Drug ID.
Operationally, one may designate a date when episode groupings will need to reset and be calculated from the start point again. In this case, episode sequence numbers will restart based on a date in the system or calculation of specified days.
FIG. 2 shows an exemplary flow of logic in generating pharmacy episode groupings from the received pharmacy claims, member, span and provider files according to one embodiment of the present invention. This process flow identifies when it is necessary to flag an episode as open (in block 216 ) or closed (in block 217 ) based on the operations described below.
Block 201 represents the entry point or receipt of these four data files in the system. The received claims are classified and sorted into three distinct groups in operational block 202 . According to one embodiment, each group is separated from the minimum date and maximum date of the current pharmacy record claims file in the data load. The first group is the single claim instance. The next is the two-claim instance and the last group is the three or more claim instances. Thus, in operational block 203 , the claims of the first group (single claim instance) are directed to block 204 for processing, the claims of the second group (two claim instances) are directed to block 205 for processing, and the claims of the third group (three or more claim instances) are directed to block 209 for processing. Each claim group thus represents a path for the PEG system logic to build episodes where each set of claims meets the criteria for Acute, Maintenance and Extended Intervention.
In this exemplary embodiment, the system defines an Acute Episode as a member with a “new” drug_ID script (or scripts) and no more than one refill at an interval less than two times the first script's day's supply. A Maintenance Episode is where an identical Drug_ID recurs three or more times, and the intervals between successive fill dates are less than two times the days supply. An Extended Intervention is defined as a “new” Drug_ID script (or Scripts) and subsequent “refill” claim or claims where the interval between the original and subsequent refill “fill date” is three times or more than the days supply for the original script.
In the first sort group, the single claim, a single pharmacy record is classified in block 204 as an Acute Episode if it meets the criterion: no more than one refill at an interval less than two times the first script's days supply. Operation then advances to block 215 where the process checks whether the episode can be considered Open (block 216 ) or Closed (block 217 ), as discussed further below.
In this embodiment, the system defines an episode as Open if the Load Date is equal to or less than six times the days supply added to the last fill date for that member/drug combination. An episode is Closed when the Load Date is greater than six times the days supply added to the last fill for that member/drug combination.
In the second sort group, where there are two pharmacy records in a given data load for a given member/drug combination, there are three possibilities for classification of the claim in block 205 . (1) If two claims meet the criteria for classification as an Acute Episode, and fall within six times the days supply added to the last fill for that member/drug combination, then the system classifies them into one acute episode in block 206 . (2) If the system determines that one claim falls within six times the days supply added to the last fill date for that member/drug combination and one is greater than six times the days supply added to the last fill for that member/drug combination, then it determines that there are two separate Acute episodes in block 207 . (3) If the interval between the original and subsequent refill “fill date” is three times or more than the days supply for the original script, the system classifies this episode as an Extended Intervention in block 208 . The operation then advances to block 215 where the process checks if the episode can be considered as Open (block 216 ) or Closed (block 217 ).
In the third sort group, which has three or more pharmacy records (3 . . . N) with the same member ID/Drug ID combination, the PEG system determines in block 209 whether the claims are all part of one episode or multiple episodes. If the intervals between successive fill dates are less than two times the days supply, all the records are classified as one Maintenance Episode in block 214 . If the remaining claims for a given member/drug_ID combination meet other criterion, the system classifies them accordingly either as Acute in block 212 , Individual Maintenance Episodes in block 211 , or Extended Interventions in block 213 . The operation then advances to block 215 where the process checks if the episode can be considered as Open (block 216 ) or Closed (block 217 ).
According to certain embodiments, new member, span, provider, and pharmacy records may be added monthly, quarterly, or at other frequencies to update existing episodes and to be processed for creation of new episodes. Episodes from the immediately preceding analysis periods may be revisited based on the latest data load (typically three months (one quarter)). As the system incorporates new data, the open/closed status, as well as classification (acute, maintenance, extended intervention, etc.) and concurrent status for all existing episodes, are re-evaluated.
FIG. 3 shows a block diagram of an exemplary system in which an embodiment of the present invention may be implemented. Typically, a patient 30 goes to a medical service provider 31 , such as a doctor, for treatment of a medical ailment. The doctor 31 examines the patient 30 and makes a diagnosis, and possibly gives the patient a prescription 32 for medication to treat the ailment. The patient 30 then leaves the doctor's office 31 and proceeds to fill the prescription 32 at a pharmacy 33 .
The medical service provider 31 may submit (e.g., electronically) a medical claim 34 to a medical claim adjudication system 35 for the services rendered to the patient 30 . The medical claim adjudication system 35 processes the medical claim to determine the financial responsibility of any third-party payer 36 (e.g., insurer) and that of the patient 30 .
Similarly, when the prescription 32 is filled by pharmacy 33 , a pharmacy claim 37 may be submitted (e.g., electronically) by pharmacy 33 to a pharmaceutical claim adjudication system 38 , which may be a PBM for instance. The pharmaceutical claim adjudication system 38 processes the pharmacy claim 37 to determine the financial responsibility of any third-party payer 36 (e.g., insurer) and that of the patient 30 .
Due to the complexities in submitting and processing many medical claims (e.g. accessing the correct form, correctly characterizing the visit, identifying the treatment accordingly, etc.), medical claims 34 for a given visit to a medical service provider may, in some instances, not be submitted for 90 days or more after the service is rendered. In contrast, pharmacy claims 37 are often submitted within a week of the prescription 32 being filled.
As shown in FIG. 3 , in certain embodiments, PEG system 39 may be implemented to process the pharmacy claim data received by pharmacy claim adjudication system 38 . Thus, for instance, in addition to adjudicating the received claims to determine financial responsibility of parties, the claim data may be further stored for processing by PEG system 39 , e.g., according to the exemplary operational flow described above with FIG. 2 .
An illustrative example of data fields that may be included in a pharmacy claim 37 is illustrated in Table 1 below:
TABLE 1
PlanID
HIC OR Member Number
Ordering Physician Provider ID OR
Ordering Physician DEA Number
Pharmacy ID
Prescription Number
New or Refill
NDC
Date Paid
Date Filled
Tier
Amount Paid
Ingredient Cost
Dispensing Fee
Copay Amount
Deduct Amt
Disallow Amt
AWP
Quantity
Days Supply
FIG. 4 illustrates an exemplary data table 400 that may be employed/generated by the PEG system according to certain embodiments of the present invention. Each patient 30 for which pharmacy claims are submitted may have a unique data table 400 populated by PEG system 39 based on the received pharmacy claim data. A unique ID 41 is assigned for each prescription/drug contained in the received pharmacy claim data. In one embodiment, unique ID 41 is a six digit number assigned for the prescription. The prescriptions are grouped into pharmacy episodes in the manner discussed above, thus forming pharmacy episodes 40 - 1 , 40 - 2 , 40 - 3 , . . . 40 -N in the example of FIG. 4 . Each of the pharmacy episodes is assigned a corresponding episode type (or category), which is stored in episode type column 42 . As discussed above, the PEG system 39 may evaluate the pharmacy claim data for each determined episode to determine a corresponding type, such as ME (Maintenance Episode), AI (Acute Intervention episode), and EI (Extended Intervention episode).
Additional information may be stored in the table 400 , which may be used for identifying pharmacy episodes, categorizing the episodes, and/or otherwise evaluating the episodes. Such information may include fill date 43 for each prescription/drug, the amount of supply 44 (e.g., 30 day, 90 day, etc.) for each prescription/drug, and/or a corresponding drug status 45 that may be determined by PEG system 39 , such as an identification of whether each prescription/drug is being used in conjunction with another drug or drugs as a Multi-Drug (MD) treatment strategy or whether any specific drug is being taken concurrently (CC) with another or several other drugs.
When implemented via computer-executable instructions, various elements of embodiments of the present invention are in essence the software code defining the operations of such various elements. The executable instructions or software code may be obtained from a computer-readable medium (e.g., a hard drive media, optical media, EPROM, EEPROM, tape media, cartridge media, flash memory, ROM, memory stick, and/or the like).
FIG. 5 illustrates an exemplary computer system 500 on which software code implementing PEG system 39 may be implemented according to one embodiment of the present invention. Central processing unit (CPU) 501 is coupled to system bus 502 . CPU 501 may be any general-purpose CPU. The present invention is not restricted by the architecture of CPU 501 (or other components of exemplary system 500 ) as long as CPU 501 (and other components of system 500 ) supports the inventive operations as described herein. CPU 501 may execute the various logical instructions according to embodiments of the present invention. For example, CPU 501 may execute machine-level instructions according to the exemplary operational flow described above in conjunction with FIG. 2 .
Computer system 500 also preferably includes random access memory (RAM) 503 , which may be SRAM, DRAM, SDRAM, or the like. Computer system 500 preferably includes read-only memory (ROM) 504 which may be PROM, EPROM, EEPROM, or the like. RAM 503 and ROM 504 hold user and system data and programs, as is well known in the art.
Computer system 500 also preferably includes input/output (I/O) adapter 505 , communications adapter 511 , user interface adapter 508 , and display adapter 509 . I/O adapter 505 , user interface adapter 508 , and/or communications adapter 511 may, in certain embodiments, enable a user to interact with computer system 500 in order to input information.
I/O adapter 505 preferably connects to storage device(s) 506 , such as one or more of hard drive, compact disc (CD) drive, floppy disk drive, tape drive, etc. to computer system 500 . The storage devices may be utilized when RAM 503 is insufficient for the memory requirements associated with storing data for operations of the PEG system 39 . Communications adapter 511 is preferably adapted to couple computer system 500 to network 512 , which may enable information to be input to and/or output from system 500 via such network 512 (e.g., the Internet or other wide-area network, a local-area network, a public or private switched telephony network, a wireless network, any combination of the foregoing). User interface adapter 508 couples user input devices, such as keyboard 513 , pointing device 507 , and microphone 514 and/or output devices, such as speaker(s) 515 to computer system 500 . Display adapter 509 is driven by CPU 501 to control the display on display device 510 to, for example, display information pertaining to pharmacy claim data and/or pharmacy episode data, according to certain embodiments of the present invention.
It shall be appreciated that the present invention is not limited to the architecture of system 500 . For example, any suitable processor-based device may be utilized for implementing PEG system 39 , including without limitation personal computers, laptop computers, computer workstations, and multi-processor servers. Moreover, embodiments of the present invention may be implemented on application specific integrated circuits (ASICs) or very large scale integrated (VLSI) circuits. In fact, persons of ordinary skill in the art may utilize any number of suitable structures capable of executing logical operations according to the embodiments of the present invention.
Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present invention. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.
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A computer-implemented method for grouping, categorizing, and profiling pharmaceutical claims data to assist health care managers in determining (a) medication treatment experience, outcomes, and medication compliance behaviors of patients and (b) appropriate drug prescribing, medication coordination, and cost-efficiency of health care providers. An objective means is provided for categorizing and quantifying patterns of prescription drug utilization as a health care service within a clinically relevant time frame. A pharmacy episode group (PEG) is a pharmacologically homogenous grouping of drugs with the same therapeutic ingredients used by a patient once or over an extended period of time. The PEG is a patient-centered pharmacy classification unit, which uses script-level pharmacy claim data as input data and assigns each script to the appropriate episode. Pharmacy episodes are categorized based on algorithms linking the pattern of a physician's recommended use (drug supply) and the patient's pattern of compliance (intervals between fill dates). The system also identifies multi-drug and concurrent use drug episodes, flags patients' records where intervals between scripts suggest non-compliance with recommended therapy, selects the most recent claims, resets windows (episode start and end dates), and ultimately assigns all pharmacy claims to episodes.
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FIELD OF THE INVENTION
[0001] This invention generally relates to the field of motor driven pool cleaning vehicle. More particularly, this invention relates to the structure for driving the pool cleaning vehicle located outside the interior volume of the housing of the pool cleaning vehicle.
BACKGROUND OF THE INVENTION
[0002] As shown in FIGS. 1 and 2 , there are two basic kinds of pool cleaning vehicles. With particular reference to FIG. 2 , there is shown the wheel embodiment of the pool cleaning vehicle 200 . The pool cleaning vehicle 200 has a housing 202 defining a body and the body having an interior space (not shown). Within the interior space is the drive motor (not shown). The drive motor is connected to the drive wheels by a belt (not shown). As the rotor of the drive motor rotates the belt (not shown) move in connection therewith. The drive wheels 204 are connected to the belt and rotates corresponding to the belt and motor.
[0003] As can be easily seen from FIGS. 1 and 2 , the belt is both inside and outside the interior. This means that the belt is exposed to the sun's uv rays and the pool's chemicals. Consequently, the belt cracks and loses its elasticity prematurely. Such premature wear is costly to the consumer and result is consumer dissatisfaction and great inconvenience.
[0004] Similarly with respect to FIG. 2 , the roller drive embodiment 200 a is belt driven and works in much the way as the wheel driven embodiment. In this embodiment, the drive roller 204 a is connected to output of the motor. Consequently the drive roller rotates corresponding the rotations of the motor. As in the earlier embodiment, the motor is located within the interior of the housing 202 a.
[0005] As described above, both embodiments include the drive motor within the interior space. In both embodiments the filter bag for collecting refuse from the filtered water. Quite clearly, the smaller the interior space, the less refuse can be collected. Thus, there is a need for increasing the space available for refuse collection and for doing so in a manner, which allows the pool cleaning vehicle to maintain all of its functions.
[0006] In order to increase the useable Interior space, it would be advantageous to reduce the number of elements in the housing of the pool cleaning vehicle.
[0007] Additionally, as the pool cleaning vehicle travels around the pool, it runs over various obstacles. Additionally, the elevation in the pool changes somewhat dramatically. It has been found helpful, just like in automobiles, to have a center of gravity that is lower rather than higher.
[0008] What is needed is a pool cleaning vehicle which maximizes interior space and also lowers the center of gravity, while allowing the pool cleaning vehicle to function in its normal manner.
SUMMARY OF THE INVENTION
[0009] The structure, in accordance with the present invention, is an internal drive assembly for a pool cleaning vehicle. The internal drive moves the motor assembly from the interior of the pool cleaning vehicle to a location in close proximity to the drive assembly for the pool cleaning vehicle.
[0010] Thus, It is an object of this invention is to provide an internal drive assembly for a pool cleaning vehicle which is location outside of the interior of the pool cleaning vehicle to provide greater space for the filtering assembly.
[0011] It is an additional object of this invention to provide such internal drive assembly for a pool cleaning vehicle having a roller drive assembly has the internal drive assembly located within the drive roller itself.
[0012] In accordance with the objects set forth above and as will be described and as will become herein, the internal drive assembly in accordance with this invention, comprises:
[0013] an internal drive propulsion assembly for a pool cleaning vehicle, the vehicle including a housing defining a body shell and the body shell having an interior for storage of a filter bag, and the pool cleaning vehicle including a drive mechanism including drive means for traveling around the underwater surface of the pool, the internal drive propulsion assembly comprising:
[0014] motor means for propelling the drive mechanism, the motor means mounted outside the interior of the body shell.
[0015] Additionally, in another exemplary embodiment, the vehicle includes a microprocessor. The microprocessor controls the movement of the vehicle, including left and right turns and its ability to escape from various obstacles.
[0016] In an exemplary embodiment of the internal drive assembly in accordance with the invention, the drive motor assembly is located within the drive roller embodiment of the pool cleaning vehicle. The drive assembly includes a gear assembly and the gear assembly is connected to the internal gear assembly of the drive roller, which, upon activation of the motor assembly correspondingly moves the drive roller.
[0017] In the wheel embodiment of the pool cleaning vehicle in accordance with the invention, the drive motor assembly is located outside the interior of the body shell and the internal drive assembly including a gear assembly is in close proximity to the drive wheel assembly and the drive wheel assembly including a gear assembly for mating connection with the internal drive gear assembly. Upon activation of the motor, the drive wheels correspondingly move.
[0018] It is an advantage of this invention to provide an internal drive assembly located outside of the interior body shell of the pool cleaning device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] For a further understanding of the objects and advantages of the present invention, reference should be had to the following detailed description, taken in conjunction with the accompanying drawing, in which like parts are given like reference numerals and wherein:
[0020] FIG. 1 is a belt driven prior art pool cleaning device exhibiting a roller drive embodiment.
[0021] FIG. 2 is a gear driven prior art pool cleaning device exhibiting a wheel drive embodiment.
[0022] FIG. 3 is a perspective plan view of a single gear embodiment of the internal drive assembly in accordance with this invention.
[0023] FIG. 4 is a perspective plan view of one multiple gear embodiment of the internal drive assembly in accordance with this invention.
[0024] FIG. 5 is a perspective plan view of another multiple gear embodiment of the internal drive assembly in accordance with this invention.
[0025] FIG. 6 is a perspective view of one exemplary embodiment of the roller drive pool cleaning vehicle having the internal drive assembly in accordance with this invention.
[0026] FIG. 7 is a perspective view of the drive gear assembly in the roller drive embodiment for the internal drive assembly in accordance with this invention.
[0027] FIG. 8 is a cross sectional view of the gear assembly of FIG. 7 .
DETAILED DESCRIPTION OF THE INVENTION
[0028] An exemplary embodiment of the internal drive assembly for a pool cleaning device 20 in accordance with the present invention generally denoted by the numeral 50 will now be described with reference to FIGS. 3-8 .
[0029] Illustrated in FIGS. 3-5 is the embodiment of the pool cleaning vehicle which includes drive wheels 30 . The internal drive assembly 50 includes a motor (not shown) with a housing 52 mounted on the exterior 22 of the pool cleaning vehicle 20 . The motor includes a pinion gear 54 , mounted on the rotor. When the motor rotates clearly so does the pinion gear.
[0030] The drive wheel 30 is securely and removeably mounted on an axle 32 , in a manner conventional with pool cleaning vehicles. The drive wheel 30 includes an internal gear 34 having an opening 36 concentric with the axle opening of the drive wheel 30 . Similar to the drive wheel 30 , the gear 34 slides over the axle 32 and fits securely on the axle 32 so that the pinion gear 54 meshes properly with the internal gear 34 . Thus, when the motor rotor turns, the drive wheel 30 turns.
[0031] The drive wheel 30 is locked in placed by a lock washer 38 . The lock washer 38 is mounted concentric with the internal gear opening 36 and drive wheel 30 .
[0032] The internal gear 34 in one embodiment is a separate element which is located as shown in FIG. 3 . In another embodiment, the gear 34 is formed as an integral part of the wheel 30 .
[0033] The housing 52 hermetically seals the drive motor. This protects the motor against damage that can be caused by the pool water and similar environmental issues. The drive wheel 30 rotates freely on the axle 32 . And, as mentioned above does so in response to rotation by the motor.
[0034] It will be appreciated that, although not shown, within the housing 52 , the motor, in another embodiment includes reduction gearing. This has the advantage of reducing drag and consequently wear. As is appreciated by those skilled in the art, the greater the rotation and speed of the motor the greater the wear rate on the seal. Therefore, by reducing the gearing and turning the motor slower as the rotor or shaft exits the housing, the sealed casing is maintained longer.
[0035] With particular reference to FIG. 4 , there is shown another embodiment of the internal drive assembly 50 . Here, the elements are the same as FIG. 3 with the exception that additional gear 56 is included. The additional gear 56 in one embodiment works as an idler gear. This allows the vehicle to move the motor mass to an appropriate location as a result of the buoyancy of the vehicle.
[0036] In another embodiment, the additional gear 56 serves as a further reduction gear for the drive assembly. In another embodiment, the additional gear is used to drive another device. Thus, the same motor is used to drive more than one device.
[0037] With particular reference to FIG. 5 , there is shown a multiple additional gear embodiment of the internal drive assembly 50 . As will be appreciated, as many as three additional gears may be included in the internal drive assembly in accordance with the invention herein. In other embodiments, 3 or more idler gears are used. With particular reference to FIG. 5 , there are three additional gears, 56 , 58 and 60 . In this embodiment at least 2 of the gears serve as idler gears.
[0038] In this embodiment, wear and tear is shared among the number of idler gears, which could be as many as three. In other embodiments, more than three gears can be used. Also, this embodiment allows the distance between the output shaft and the wheel axle to be reduced. Finally, as can be seen from FIG. 5 , the entire internal drive assembly 50 is enclosed by the drive wheel 30 . In an additional embodiment the entire internal drive assembly is sealed by the enclosure.
[0039] In the embodiment shown in FIG. 5 , the motor drive housing includes a bearing 62 for supporting and aligning the drive wheel 30 . The bearing 62 in another embodiment is in the form of a bushing.
[0040] With particular respect to FIG. 6-8 , there is shown is the embodiment of the pool cleaning vehicle which includes roller drive 40 instead of wheels 30 . The roller drive 40 has an interior 42 . Within the interior 42 is a motor assembly mounting bracket 44 . The mounting bracket 44 includes a journal 46 .
[0041] The motor assembly slides into position in the interior 42 of the roller drive 40 . A locking ring 70 includes a detent 72 extending therefrom. The detent 72 is sized and shaped to fit in the journal 46 . Upon complete insertion into the interior 42 , the motor assembly is journaled within the interior 42 .
[0042] As shown in FIGS. 7 and 8 , the drive roller 40 includes an internal gear 49 . In the embodiment shown in FIGS. 6-8 , there is shown the embodiment similar to FIG. 5 , except there are only two idler gears 58 and 60 and pinion gear 54 . And, similarly, the internal drive assembly works in the same fashion as described with respect to the earlier described embodiments in FIGS. 3-5 .
[0043] While the foregoing detailed description has described several embodiments of the internal drive assembly in accordance with this invention, it is to be understood that the above description is illustrative only and not limiting of the disclosed invention. Particularly, there are variety of propulsion assembly used by pool cleaning vehicle and each of them is within the spirit and scope of the invention providing the drive motor is located outside the interior of the body shell. It also will be appreciated that there are various modifications to the internal drive that are within the spirit and scope of the invention herein and that of particular interest is the ability of the motor assembly to remain outside the interior of the body shell and not the specific type of gearing or drive chosen for operation. Thus, the invention is to be limited only by the claims as set forth below.
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Disclosed herein is a pool cleaning device including an internal drive assembly mounted outside the interior cavity of the device housing. The device including a pool cleaning vehicle, the vehicle including a housing defining a body shell and the body shell including an interior cavity and the pool cleaning vehicle including a drive assembly; and an internal drive assembly, the internal drive assembly including a motor assembly for engaging the vehicle drive assembly for propelling the vehicle, the motor assembly mounted outside the interior of the body shell.
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FIELD OF THE INVENTION
This invention relates to processing of seismic data used in the search for oil, gas and other valuable minerals. More particularly, the invention relates to improved methods for automatic gain control of seismic data, by use of which the data can be more accurately interpreted.
BACKGROUND OF THE INVENTION
It is commonplace in the field of exploration for oil, gas and other minerals to use seismic techniques, in which a burst of acoustic energy is imparted to the earth or sea at a "shot point". The acoustic energy travels through the earth, including the ocean, and is reflected at the interfaces between rock layers of varying density to be returned back upwardly to the surface of the earth. Its arrival can be detected by an acoustic microphone, typically referred to as a geophone in earth-based processing and as a hydrophone in water-based prospecting.
Due to the spherical dispersion of the acoustic wave as it travels through the earth, the further the wave travels into the earth before it is reflected back upwardly, the more faintly it is detected upon its eventual arrival at a detector. Additionally, the presence of strongly reflecting rock layers interspersed with more weakly reflecting beds leads to substantial differences in the strength of the detected signals. For these reasons, the art has conventionally applied automatic gain control to the various portions of the seismic signal so that they can be more readily compared to one another, such that distinct events in the fainter portion of the data are not overlooked in comparison to the less attenuated portions. Typically what is done is that a "window" is established, this being a number of samples, e.g. 800 milliseconds long. The data is divided into overlapping windows of this length and the average values or root mean square values of the absolute values of the data in each window are calculated. These average absolute values are used to generate automatic gain control factors, for each window, which are then compared to one another, and can be applied to all of the samples within a given window.
The difficulty with this approach is that high amplitude events within a given window greatly exaggerate the amount of correction to be applied to the other samples in that window, such that a "shadow" effect is observed in the automatic gain control processed data. Relatively faint events within the shadow are thus obscured.
OBJECTS OF THE INVENTION
It is, therefore, an object of the invention to provide an improved automatic gain control apparatus and method for seismic data processing.
It is a further object of the invention to provide an automatic gain control method for seismic data processing according to which shadowing of low amplitude events by higher amplitude events within a given window is substantially avoided, whereby the low amplitude events can more readily be observed.
It is a further object of the invention to provide automatic gain control for processing of seismic data in which shadowing of the data is avoided and in which the overall trend of the data can also be preserved so as to retain the maximum amount of information provided by any given seismic record.
SUMMARY OF THE INVENTION
The present invention satisfies the needs of the art and the objects of the invention mentioned above by its provision of an automatic gain control method and apparatus, in which gain is calculated with respect to windows disposed both above and below a point of interest. The lesser of the two gain values is then used to modify the input signal. In this way, the shadow effect is reduced to a minimum.
This technique can be combined with other processing features shown in co-pending applications, such as the trend preservation discussed in commonly assigned Ser. No. 569,829, filed Jan. 11, 1984 for further improvements.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood if reference is made to the accompanying drawings, in which:
FIG. 1 shows seismic exploration operations generally;
FIG. 2 shows the prior art automatic gain control gain function;
FIG. 3 shows the improved automatic gain control function as proposed hereby;
FIG. 4 shows a flow chart of operations undergone in automatic gain control seismic data processing hereunder;
FIG. 5 shows an example of actual seismic data processed according to the prior art method of FIG. 2;
FIG. 6 shows the same data as in FIG. 5, but processed according to the present invention;
FIG. 7 shows operation of the prior art automatic gain control processing with respect to a single trace;
FIGS. 8 and 9 show the effect of displacement of the automatic gain control window before and after a given point of interest in the data;
FIG. 10 shows the selection and optimization thereof as performed according to the invention, again on a single trace;
FIG. 11 shows use of the method of the invention combined with trend retention, for further clarity;
FIG. 12 shows a folding process which can be used to supply samples to the early part of the data trace so as to obtain proper correction;
FIG. 13 comprising FIGS. 13a and 13b, shows the result of the techniques discussed in connection with FIG. 12.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows typical seismic exploration operations in schematic form. A source of seismic energy 16, typically a truck having a mechanically vibratable plate upon which the entire truck may be raised, transmits seismic energy indicated generally at 6 into the earth through various layers 10, 12, and 14. At the interfaces between rock layers of varying density and acoustic velocity, such as that between layers 12 and 14, the seismic energy is reflected back upwardly and can be detected by a number of detectors 22 connected by a cable to amplifying and recording devices 24 and 26 carried within a second truck 28 for subsequent analysis.
Those skilled in the art will recognize that as the seismic energy 6 travels through the earth, it is attenuated due to spherical divergence as well as due to reflection at the interfaces and the like. Accordingly, it is conventional in the art to perform gain equalization, generally referred to as automatic gain control (AGC), on the seismic data such that the amplitudes of the various portions of the recorded seismic signal are more directly comparable.
According to the prior art, a gain function g is defined by equation (1): ##EQU1## Thus, the gain function g i applied to any given input sample x i is equal to the average of the absolute values of a number L of samples in a window i of the data, where N is the total number of samples in a given trace. Each sample is thus brought more closely equal to the average of the L samples within that window according to this equation. The process is shown in block diagram form in FIG. 2, where a value x i corresponding to the amplitude of the ith sample is input. A gain value g i is calculated as above at 30, and the output amplitude y i corresponding to the ith sample is simply x i divided by g i as shown at 32.
Thus, the prior art method computes a running average of the absolute values of the trace samples x i over a window of length L centered around the sample x i . These gain values g i are then divided into the respective samples. Typically, at the start of the trace, the window length is typically reduced to half its selected length L and is increased by one sample per iteration until it is fully meshed with the data. This corresponds to adding zeros to the start of the trace in equation 1 and normalizing by the number of non-zero values. At the end of the trace, a similar problem occurs but in this case the computation stops when the window no longer fits the data, and the last computed gain value is then simply applied to the remainder of the trace values.
FIG. 7 illustrates this process on a single seismic trace. Here the output of a single geophone 22 (FIG. 1) is graphed versus time in seconds as the input trace, FIG. 7(a). The gain function g i is computed according to equation (1), as defined above, and is shown in FIG. 7(b). Here the window L is 800 milliseconds (ms) long. The output trace FIG. 7(c) shows the effect of applying automatic gain control as defined by equation 1. The high amplitude event 34 occurring at about 2 seconds causes the gain function to increase by a substantial factor about a window of length L centered on the high amplitude event. Accordingly, the data around the high amplitude event 34 is unrealistically distorted by division by the relatively high value of g calculated in accordance with equation 1 where the high amplitude event 34 is in the window. That is to say, the data 38 on either side of the high amplitude event 34 in the output trace of FIG. 7(c) is shown having been compressed unrealistically. What is shown, of course, is the intuitive result; the shadows shown at 38 of unrealistically low amplitude output data are simply caused by the inability of the gain function g to change as abruptly as the data. Low amplitude events therefore become lower due to the influence of the high amplitude event 34. On the other hand, perfect adaptability of the automatic gain control function would not be useful either, because this would call for a one-sample wide window which would adapt perfectly but would produce a trace carrying no more information than the sign of the data, destroying the desired shape detail.
The input trace of FIG. 7 is selected from an entire input trace which is shown as FIG. 5. This is a record derived from a large number of traces shot along a line. This particular exploration was performed on and beneath the sea bed but this is not critical to the method of the invention. The seismic event of chief interest lies below the high amplitude event which is centered roughly at about 2 seconds deep in the trace, that is, about one third of the way down the section. Accordingly, if it is necessary to have a shadow, as discussed above in connection with FIG. 7, it would be preferable to have the shadow only above the event 34. This would be possible if the gain value g i were calculated with respect to a sample x i located near the start of the window rather than at its center. The gain function would then be defined by equation (2) as seen below: ##EQU2## where B is the application sample number, that is, B is a measure of the offset from the lower edge of the window with respect to the sample of interest x i . (B of course is less than L/2.) The results of using this process are shown in FIG. 8. As can be seen, the shadow still exists above the high amplitude sample 34 as at 40. Hence, the next step is to remove the shadow above the window; that is, offset the widow towards its bottom. In this case, the application sample number is effectively L-B, as defined by equation (3). ##EQU3## FIG. 9 shows the result; the shadow 42 now appears below the high amplitude event 34.
According to the present invention, the solution to the shadow problem lies in the observation that one should use the gain function resulting in the display of in FIG. 8 below 2 seconds and that shown in FIG. 9 above 2 seconds, and in the further observation that the desired gain function in both cases is the minimum of the two functions, i.e., the lesser of the two functions. Accordingly, the best of both approaches can be realized by computing g i for the sample x i , offset first above and then below the center of the window, and selecting the minimum value for each g i such that the minimum correction is applied to low amplitude events around the high amplitude event 34.
FIG. 3 shows a block diagram corresponding to FIG. 2 of the process of the invention. Input values x i are input to two functions 44 and 46, in which g i is calculated with respect to windows of length L, with the sample x i offset by B and L-B respectively. The minimum value for g i computed in these two processes 44 and 46 is selected at 48 and output for calculation of y i at 32; as in FIG. 2, y i is simply x i divided by g i . g i is the minimum of g i (L,B) and g i (L,L-B). The results are shown with respect to a single trace in FIG. 10. The shadow in the gain function is reduced to a relatively small bump 50 corresponding to the relatively high amplitude event 34, and the effect of two shadows is greatly reduced on the output trace of FIG. 10(c).
The seismic data of the complete line processed according to the prior art described by Equation (1) and shown in FIG. 5 when reprocessed according to the invention as described in connection with FIG. 3 results in the seismogram of FIG. 6. It will be appreciated that the data both above and below the high amplitude event centered around 2 seconds is much more clear and easily readable than in the version processed according to the prior art of FIG. 5.
Those skilled in the art will recognize that the single trace shown in FIG. 10 does not appear to contain much if any useful information in the last few seconds of the input data shown in FIG. 10(a). This data when equalized according to the invention results in the output trace of FIG. 10(c) which appears to contain meaningful information. In order to avoid this possibly misleading portrayal, one can also incorporate what may be referred to as gain reduction or trend retention. An additional trend retention parameter p can be incorporated into the method described in connection with FIG. 3 by taking the pth root, p being selected by the operator, of the gain function, which tends to weaken the equalizing effect of the gain function by allowing strong trace amplitudes to remain stronger than weaker amplitudes, i.e. the amount of dynamic range reduction will be greatest for p=1. FIG. 11 shows the data of FIG. 10 with the trend retention parameter p set equal to 0.75. The use of the parameter p in trend preservation of automatic gain control process seismic data is more fully discussed and claimed in commonly assigned co-pending Ser. No. 569,829 filed Jan. 11, 1984.
As discussed above, in the prior art, automatic gain control is usually applied to the initial samples of a seismic trace by tapering the window, that is, using fewer samples to calculate the gain control factor towards the beginning of the trace. This tends to fail to equalize the initial samples, which because they are the first received have the highest amplitude. Instead the initial non-zero samples can be considered to be equivalent to a deep event. To simulate such a situation, a "folding" process can be used, selecting values from the trace after the initial high amplitude portions and supplying these to the "other side" of the initial window, including the high amplitude portions, for automatic gain correction of the initial samples. The process employed seeks the occurrence of the maximum absolute amplitude within the first 25 samples or within a selected window length, whichever is smaller. This maximum amplitude is assumed to lie on the strong event and its location is used to define the location of a "strong reflector". This sample is the "folding sample", and its location is set equal to J samples from the first non-zero sample. By folding this trace about the Jth sample, weak events which follow the strong event are used to extend the data earlier in time, i.e. to provide realistic amplitude data for use in the windows used for calculation of g to be applied to the first few samples. In one successfully tried implementation, the folded data is used prior to the first non-zero sample to preserve the non-zero data prior to the Jth sample. This amounts to extending the trace backwards from the first non-zero sample starting with the 2*Jth sample.
FIG. 12 shows this process schematically. In FIG. 12(a) a sample trace is shown. The highest amplitude sample is shown at 60; this is the Jth sample. The data occurring after sample 2J, shown at 62, is "folded" as in FIG. 12(b) prior to the mute time, i.e. prior to the first non-zero sample in the trace of FIG. 12(a). The two are then summed to generate a composite trace shown in FIG. 12(c) having the same data on either side of the mute time and the 2Jth sample, so that the automatic gain control correction applied to the samples up to 2J according to Equation (2) are such as to lead to realistic results.
FIG. 13 shows results of applying this folded window technique, used in connection with automatic gain control according to the invention, as compared with the tapered window technique used in the prior art and discussed above. FIG. 13(a) shows the folded window technique for equalizing the initial amplitudes and FIG. 13(b) shows the prior art tapered window technique. It can, of course, be argued as to which is more meaningful in terms of the actual geophysical structure of the earth being considered, but for display purposes, the folded window technique is considered to provide a more consistent gain value computation without sacrifice of the clean line of the water bottom reflection.
FIG. 4 shows generally the steps in seismic data processing according to the invention. A trace to be processed is selected at 70, and an initial window length L is selected at 72. An initial offset b is selected at 73. If the folding process discussed in connection with FIG. 12 is desired, this is implemented at 74. One then calculates the average of the absolute values in the window offset by B above the sample at 76, then the average of the absolute values in the window offset by B below the sample at 78. The minimum value for g calculated thereby is selected at 80, and the gain function g is applied at 81. Trend preservation is applied at 82, if desired, in accordance with the discussion referring to FIG. 11. The next sample is similarly processed at 84; finally, when all the data has been processed, the output is displayed as at 86.
It will be appreciated that there has been described a method for improved automatic gain control of seismic data which is readily implementable and which causes minimal additional complexity in processing operations.
It will also be appreciated that for constant B the lower window for one sample on a given trace will include the same data as the upper window for another, and that by appropriate programming the actual calculation of g need not be repeated.
While a preferred embodiment of the invention has been described above, it will be recognized that additional improvements can be made, particularly in the area of applying additional corrections and processing modifications to the method of the invention. Accordingly, the invention should not be construed to be limited by the above disclosure, which is merely exemplary, but only by the following claims.
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An improved apparatus and method for calculating automatic gain correction to be applied to seismic samples is disclosed which features apparatus and method for calculation of the average absolute value of a window of samples in the vicinity of the sample being processed, the calculation being performed a first time with the window shifted toward a first side of the sample and a second time with the window shifted toward a second side of the sample, and selecting for use in gain correction the minimum of the two calculated average absolute values, such that high amplitude samples in the vicinity of relatively low amplitude events is precluded from causing unrealistic shadowing around such events.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 10/992,870, filed Nov. 19, 2004, now U.S. Pat. No. 7,622,094, which is herein incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention pertains to the field of heat exchange and specifically to integrating a catalyst zone into an efficient heat exchanger.
2. Description of the Related Art
Plate fin and tube heat exchangers or externally finned tube exchangers have long been employed to recover process heat. These exchangers are most often employed to heat or cool a low density gas stream located on the finned side against a denser fluid with higher heat transfer coefficient within the tubes. The extended surface on the finned exterior pass allows greater heat transfer surface than a bare tube and provides greater heat transfer at a low-pressure drop.
The art has not heretofore recognized the unexpected advantage of applying a catalyst coating on the heat transfer fins, or support tubes and surrounding internal surface of the heat exchanger vessel/housing, to allow effective heat transfer while also allowing a catalytic reaction has not been recognized in the art.
SUMMARY OF THE INVENTION
The invention may be described in several ways as alternate embodiments of the novel discovery that positioning a mass transfer catalyst on the exterior surface of a plate and fin or finned tube heat exchanger achieves unexpected performance improvements over the conventional system of using separate catalyst beds and heat exchange elements.
The invention provides an improvement in a method of recovering energy using a heat exchanger that comprises:
a. providing a heat exchange unit selected from the group consisting of plate and fin heat exchangers and finned tubing heat exchangers in a heat transfer system having a finned exterior side and tubing that forms a separate circulation path for an interior second working fluid; b. providing a first working fluid contacting the finned exterior side of the heat exchange unit c. feeding the first working fluid to contact the exterior finned side of a heat transfer zone to transfer heat between the first working fluid and an interior second working fluid within the tubing of the heat exchanger d. feeding the second working fluid into a tube or group of tubes to be heated or cooled by the first working fluid.
By adding the improvement that comprises:
e. coating a portion of the exterior finned surface with a mass transfer catalyst to allow a mass transfer reaction between components of the first working fluid to be accelerated by the catalyst within the heat exchange zone.
The method may further comprise: feeding a third working fluid into a second separate circulation path to be heated or cooled by the first working fluid as disclosed in co-pending U.S. application Ser. No. 10/700,805 filed Nov. 3, 2003.
The method may further comprise: providing a plurality of interior working fluids, and providing each with a separate tubing circulation path in the interior tubing portion of the heat exchanger as disclosed in. U.S. application Ser. No. 10/700,805.
In a preferred embodiment the plurality of interior tubing circulation paths are interlaced and coating some or the entire finned surface with a catalyst to allow mass transfer within the heat exchange zone thereby accomplishing more effective heat transfer than would be possible with a plurality of tube side fluid streams arranged in series without interlacing the separate tubing circulation paths. In the method the second working fluid and the third working fluid may have the same composition or the second working fluid and the third working fluid have the a different composition In another optional embodiment the plurality of interior working fluids may have the same composition or at least one of the plurality of interior working fluids may have a different composition from the other interior working fluids. In a preferred embodiment the first working fluid is selected from the group consisting of flue gas, turbine exhaust gas, electrical generating plant stack gas, hydrocarbon gas, combustion exhaust gas, cat cracker gas, furnace exhaust, and mixtures thereof and the catalyst is selected from the group consisting of zeolites, NOX abatement catalysts, CO conversion catalysts, vanadium pentoxide, hydrocarbon cracking catalysts, SOX abatement catalysts, vanadium tungsten oxide catalysts, manganese oxide catalysts, and metal catalysts select from group VIII metals and their alloys. The preferred groups also include any sub grouping of the forgoing leaving out one or more members of each selection group. Especially preferred is the combination where the first working fluid is includes nitrogen oxides (NOX) and the catalyst is vanadium pentoxide or vanadium tungsten oxide on a titanium dioxide carrier.
The method may further comprise: in situ coating of the finned exterior surface of a heat exchange unit in an existing system with a catalytic coating. Alternatively the method may further comprise: rejuvenating the catalytic coating by injecting the catalyst upstream of the heat exchanger to renew in situ the coating of the finned exterior surface of a heat exchange unit in an existing system with a catalytic coating. In a preferred embodiment the catalyst is applied to the finned surface of the heat exchanger as a powder coating and deposited on the finned surface by giving the powder coating an electrical charge opposite to an electrical charge imposed on the finned exterior surface of the heat exchanger.
The invention may also be viewed as an energy recovery apparatus that comprises: a heat exchange unit selected from the group consisting of plate and fin heat exchangers and finned tube heat exchangers in a heat transfer system having a finned exterior side and tubing that forms a separate circulation path for an interior second working fluid and a catalytic coating surface covering at least a portion of the finned exterior side with a catalyst for a mass transfer reaction. In a preferred embodiment the apparatus further comprises a plurality of interior working fluids, and each confined within a separate interior tubing circulation path in the interior tubing portion of the heat exchanger, thereby providing additional heat recovery as disclosed in the above reference co-pending application Ser. No. 10/700,805. In a preferred embodiment the catalytic coating is selected from the group consisting of zeolites, NOX abatement catalysts, vanadium pentoxide, hydrocarbon cracking catalysts, SOX abatement catalysts, CO conversion catalyst, vanadium tungsten oxide catalysts, manganese oxide catalysts, and group VIII metal catalysts. The apparatus may further comprise means for injecting additional components upstream of the catalytic coating surface of the heat exchange surface to promote reactions with components of the first working fluid at the catalytic surface. For example ammonia or urea may be injected into a turbine exhaust stream up stream from a vanadium oxide catalyst to convert NOX to nitrogen and water at the catalyst coated surface. As the examples below show this system has a significantly lower pressure drop that the prior art system using separate heat exchange and catalytic zones. In a preferred apparatus the catalytic coating comprises vanadium pentoxide and the first working fluid is an exhaust stream from a gas turbine.
The apparatus may further comprise means for in situ formation of a catalytic coating on the finned exterior surface of the heat exchanger. A preferred means includes a means for injecting catalyst upstream from the heat exchanger for in situ deposition of catalyst on the heat exchanger exterior surface. In a preferred embodiment means for imposing opposite electrical charges on a catalytic material to be coated on the finned exterior surface of the heat exchanger and the finned exterior surface of the heat exchanger are included so that in situ electrostatic coating can be performed.
In summary, the invention provides a system for more efficient heat transfer in a plate fin and tube or finned tube exchanger while coating some or all of the finned surface with catalyst to simultaneously accomplish heat transfer and mass transfer. Additionally, the invention provides a system for the in situ maintenance and performance augmentation of a new or existing catalyst bed.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
FIG. 1 is a sketch of a typical coil having two working fluids that can have the finned surface coated with catalyst to simultaneously allow mass transfer and heat transfer.
FIG. 2 shows a conventional Waste Heat Recovery system with a NOX reduction catalytic conversion zone with an NH3 injection grid.
FIG. 3 shows a typical catalyst activity vs temperature chart for a Vanadium Tungsten Oxide catalyst and shows a preferred temperature window.
FIG. 4 shows the invention Waste Heat Recovery system with a NOX reduction catalyst coating applied to the finned surface.
FIG. 5 shows the invention catalyst coating being applied in situ by injecting the catalyst upstream of the finned surface of the heat exchanger.
DETAILED DESCRIPTION
The invention may be employed to increase the heat recovery efficiency of any gas turbine that produces a waste heat exhaust while simultaneously allowing catalytic conversion of one or more components in a heat exchange medium such as NOX or CO conversion. Therefore the invention integrated heat exchanger design can achieve the desired heat transfer while accomplishing mass transfer. By applying a catalyst such as vanadium pentoxide on a portion of the heat transfer fins that are maintained within a desired temperature range to promote a catalytic reaction and by adding ammonia or urea to a NOX containing first working fluid, exterior to the heat transfer apparatus, NOX content of the finned side working fluid can be reduced.
The invention also can use a method of interweaving streams with various working fluids in a common plate fin and tube or finned tube exchanger to accomplish more efficient heat transfer while simultaneously allowing a catalytic reaction on the finned side disclosed in a separate patent application filed on Nov. 3, 2003 U.S. Ser. No. 10/700,805.
The following examples are provided to illustrate the invention and not to limit the concepts embodied therein.
EXAMPLES
Example 1
Existing Technology is shown in FIG. 2 for a Waste Heat Recovery System with integrated NOX reduction V 2 O 5 catalyst zone on the exhaust of a gas turbine. A warm waste heat recovery zone cools the exhaust from the gas turbine while warming a desired working fluid, in this case a heat transfer medium. The exhaust gas is cooled to a preferred temperature for the selected NOX reduction catalyst, in this case Vanadium-Tungsten Oxide on a Porous Titanium Dioxide substrate (V 2 O 5 ) with a preferred temperature window of 550 F to 800 F. The temperature is selected based on the NOX selectivity of the catalyst vs operating temperature, by desired catalyst life which is reduced at higher temperature, and by formation of ammonium bisulfate at lower temperatures. FIG. 3 shows a typical temperature vs NOX conversion curve for a Vanadium Tungsten Oxide Catalyst commonly referred to as V 2 O 5 . This could also be a zeolite catalyst with different performance criteria. Dilute ammonia is introduced thru a distribution grid upstream of the catalyst zone to promote the chemical reaction NH3+NOX=>H2O+N2. An additional cool heat transfer zone is provided to further cool the exhaust stream while warming a desired working fluid, in this case a heat transfer medium.
The invention example is shown in FIG. 4 . The Vanadium Tungsten Oxide catalyst is applied to the exterior surface fins of a plate fin and tube or finned tube exchanger where the exhaust gas temperature is maintained in the preferred temperature range by sizing and choice of heat exchange properties to maintain optimum catalyst operation in the heat exchange zone. The NH3 is injected upstream of the zone and the NOX is converted to N2 and H2O.
Example 2
Using the example above, additional catalyst can be injected into the gas turbine exhaust upstream of the heat transfer surface and can be deposited on the finned surface of the heat exchanger. This may also be a powder coating and electroplated by electrostatic precipitation by electrically charging the heat transfer finned surface.
Example 3
A Solar Centaur gas turbine exhaust requires waste heat recovery for heating a thermal fluid and also requires NOx reduction based on the following design.
TABLE US 00001
Design Basis
Solar Centaur 40-T4700
Exhaust Flow
137,000 #/hr
Exhaust Temp
860° F.
NOx Content
42 ppm vd
mol %
Exhaust Gas Comp
O 2
13.47
H 2 O
10.32
N 2
71.46
CO 2
3.86
Ar
.86
Desired NOx Reduction
90%
NH 3 Slip
<10
ppm
Thermal Fluid
Fluid
Xceltherm 600
Hot Zone Duty
9,000,000
BTU/hr
Fluid Temp In
433
F.
Fluid Temp Out
550
F.
Cool Zone Duty
8,277,000
BTU/hr
Fluid Temp In
325
F.
Fluid Temp Out
433
F.
Heat Transfer Surface and Catalyst
Hot Zone Coils Cross Section
24
ft2
Hot Zone Surface
17300
ft2
Cool Zone Coils Cross Section
24
ft2
Cool Zone Surface
34,520
ft2
The NOx catalyst beds cross-section
24
ft2
Pressure Drop Thru the System
Hot Heat Exchange Zone Calc Pressure Drop
1.2″
WC
Catalyst Zone Pressure Drop
3″
WC
Cool Heat Exchange Zone Calc Pressure Drop
2″
WC
Conventional System Description
The heat recovery will occur in two coil sections with SCR catalyst bed between. A single two fluid spray nozzle is used for NH3 injection. The exhaust exits the gas turbine at 860 F and enters the Hot Heat Exchange Zone where it is cooled to 617 F. Upon exiting the Hot Heat Exchange Zone, the dilute NH3 is injected into the exhaust stream which then flows to the catalyst zone. The catalyst zone is a honeycomb matrix with V2O5-TiO2 based catalyst. The NOX reacts with the NH3 forming water and N2. The exhaust then flows to the Cool Heat Exchange Zone and is further cooled to 386 F while heating the thermal fluid.
Invention System Description
The V2O5-TiO2 based catalyst is applied to at least a portion of the heat-transfer surface and the Hot and Cold Heat Transfer Zones can be combined if desired. The gas turbine exhaust pressure drop can be reduced thru these zones from 6.2″ WC to 3.2″ WC. This could allow the cross section of the waste heat recovery unit to be reduced until an equivalent pressure drop (6.2″ WC) resulted reducing the size and cost of the unit. The dilute NH3 injection can be upstream of the Warm Heat Transfer Zone. By combining the two heat transfer zones and the catalyst zones, the exhaust flow path length can be reduced which will reduce the overall size and weight of the waste heat recovery housing. Preferably the plate fin and tube coils have a surface area ratio between the finned surface and the inside of tube surface between 8:1 and 40:1, therefore the slight reduction in heat transfer caused by the catalyst coating will have a small effect on heat transfer and can easily be compensated for by adding some small amount of coil surface.
While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.
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The invention provides a method and apparatus for integrating the heat transfer zones of plate fin and tube and finned tube exchangers and a catalytic mass transfer zone. The invention also provides a method for in situ regeneration of existing coated surface and augmentation of existing coated surface, or catalyst performance.
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BACKGROUND OF THE INVENTION
U.S. Pat. No. 3,936,465, issued Feb. 3, 1976, encompasses within its disclosure compounds having the formula ##STR2## wherein Y is alkanoyl, R is hydrogen or alkyl, R' is alkylamino or dialkylamino and A is alkylene. The compounds are disclosed as useful for the treatment of hypertension.
Aminoalkanol derivatives of a varied nature have been investigated in the field of medicinal chemistry. A review of some of these compounds, and of their various utilities is included in Burger, Medicinal Chemistry, second edition, Interscience Publishers, Inc., New York, 1960. Various aminoalkanol derivatives having the general formula ##STR3## are described as having cholinergic, pressor, central nervous system stimulant, vasoconstrictor and antimalarial activity.
The Burger test, supra., also discusses the hypotensive activity of veratrum alkaloids. The hypotensive activity of crude plant extracts containing veratrum alkaloids is largely attributable to ester alkaloids.
BRIEF DESCRIPTION OF THE INVENTION
Compounds having the formula ##STR4## and the pharmaceutically acceptable salts thereof, have cardiovascular activity. In formula I, and throughout the specification, the symbols are as defined below.
R 1 is alkanoyl having 1 to 7 carbon atoms; acetyl is the preferred alkanoyl group.
R 2 is alkyl; methyl is preferred;
R 3 is alkylamino, dialkylamino, 1-piperazinyl, 4-alkyl-1-piperazinyl, 4-aryl-1-piperazinyl, 4-aryl-1,2,3,6-tetrahydro-1-pyridinyl, N-alkyl-N-[(2-pyridinyl)alkyl]amino, N-alkyl-N-[(3-pyridinyl)alkyl]amino or N-alkyl-N-[(4-pyridinyl)alkyl]amino; and
N IS 1, 2 OR 3.
The term "aryl", as used throughout the specification, refers to phenyl or phenyl substituted with one or two halogen (fluorine, chlorine, bromine, or iodine), alkyl, trifluoromethyl, alkoxy or alkylthio groups.
The terms "alkyl", "alkoxy", and "alkylthio", as used throughout the specification, refer to groups having 1 to 6 carbon atoms.
DETAILED DESCRIPTION OF THE INVENTION
The compounds of this can be prepared by reacting an oxirane compound having the formula ##STR5## with a nitrogen containing compound having the formula
R.sub.3 --H. III
reaction conditions are not critical, but the reaction proceeds more rapidly when carried out with heating in an organic solvent, or mixture of organic solvents, e.g., benzene, glacial acetic acid, ethanol, etc.
The oxirane compounds of formula II are readily obtained from a corresponding cyclohexanetetrol derivative having the formula ##STR6## Compounds of formula IV are known; see, for example, U.S. Pat. No. 3,936,465 issued Feb. 3, 1976. Oxidation of a compound of formula IV yields the corresponding N-oxide having the formula ##STR7## Exemplary of the oxidizing agents which may be used are the peracids, e.g., m-chloroperbenzoic acid.
Vacuum pyrolysis of an N-oxide of formula V yields an olefin having the formula ##STR8## Oxidation of an olefin of formula VI yields the corresponding oxirane compound of formula II. Exemplary of the oxidizing agents which may be used are the peracids, e.g., m-chloroperbenzoic acid.
The oxirane compounds of formula II and the olefins of formula VI are novel intermediates which are useful in the preparation of the compounds of formula I, and as such, constitute an integral part of this invention.
The compounds of formula I can be converted to their pharmaceutically acceptable acid-addition salts with both organic and inorganic acids using methods well known in the art. Exemplary salts are hydrohalides (e.g., hydrochloride and hydrobromide), nitrate, phosphate, borate, acetate, tartrate, methanesulfonate, benzenesulfonate, toluenesulfonate and the like.
Formula I includes all stereoisomers and mixtures thereof. Particular stereoisomers are prepared by utilizing as the starting material the compound of formula IV with the corresponding stereoisomerism. The preferred stereoisomers are those in which the OR 1 groups are all axial.
The compounds of formula I, and the pharmaceutically acceptable salts thereof, are useful as hypotensive agents in mammals, e.g., domestic animals such as dogs and cats. Daily doses of from 5 to 50 milligrams per kilogram of animal body weight, preferably about 5 to 25 milligrams per kilogram of animal body weight, can be administered in single or divided doses. Both oral and parenteral administration are specifically contemplated.
EXAMPLE 1
1,2:1,4:4,5-trans-1-[4-(Dimethylamino)-3-hydroxybutyl]-2-methyl-1,2,4,5-cyclohexanetetrol, 1,2,4,5-tetraacetate ester
A. 1,2:1,4:4,5-trans-1-[4-(Dimethylamino)butyl]-2-methyl-1,2,4,5-cyclohexanetetrol, tetraacetate ester, N-oxide
A solution of 8.5 g of 1,2:1,4:4,5-trans-1-[4-(dimethylamino)butyl]-2-methyl-1,2,4,5-cyclohexanetetrol, tetraacetate ester in 200 ml of chloroform is cooled in an ice bath and 4.4 g of 85% m-chloroperbenzoic acid is added. The mixture is warmed to room temperature over 5 hours. The solution is partially evaporated in vacuo to one-third its volume and chromatographed on 400 g of neutral Alumina III (wet-packed in chloroform). The column is eluted with 600 ml of chloroform to remove any forerun and then the N-oxide product is eluted with 650 ml of 20% methanolic chloroform to give 10.4 g of oil Crystallization from ethyl acetate give 7.45 g of a hydroscopic white solid, melting point 128°-130° C.
B. 1,2:4:4,5-trans-1-Methyl-2-(3-butenyl)-1,2,4,5-cyclohexanetetrol, tetraacetate ester
An amount of 6.4 g of the above N-oxide is heated in a vacuum distillation set-up under 30 mm Hg vacuum with nitrogen bleed until all the solid is melted and vigorous evolution of volatile side products cease. The vacuum is then improved to 2-3 mm Hg and the product distilled as a pale yellow liquid which crystallizes on standing to give 4.55 g of the olefin as a white solid; boiling point of distillate 180°-200°0 C. (mainly 195° C.), at 2-3 mm Hg.
C. 1,2:1,4:4,5-trans-1-Methyl-2-(2-oxiranylethyl)-1,2,4,5-cyclohexanetetrol,tetraacetate ester
A solution of 2.0 g of the above tetraacetate-olefin and 1.05 g of 85% m-chloroperbenzoic acid in 50 ml of chloroform is prepared at 0° C. and stirred for about 16 hours at room temperature. The solution is then suction filtered through 30 g of neutral Alumina III. The alumina is washed with 100 ml of chloroform and the combined filtrate evaporated in vacuo to give a colorless oil, which solidifies on standing to give 1.85 g of the epoxide product as a white solid.
D. 1,2:1,4:4,5-trans-1-[4-(Dimethylamino)-3-hydroxybutyl]-2-methyl-1,2,4,5-cyclohexanetetrol, 1,2,4,5-tetraacetate ester
An amount of 20 ml of 3.87 M dimethylamine in benzene is added to a solution of 2.0 g of the tetraacetate-epoxide in 80 ml of benzene in a Parr bomb. The bomb is heated for about 16 hours at 100°±5° C. The bomb is cooled to room temperature and the solution evaporated in vacuo to give 2.3 g of oil. An acid-base extraction gives 1.65 g of basic material. Crystallization from 10 ml of 1:1 ethyl acetatehexane yields 564 mg of the title compound, melting point 94°-105° C.
Anal. Calc'd. for C 21 H 45 NO 9 (445.5 g/m): C, 56.61; H, 7.92; N, 3.14. Found: C, 56.50; H, 7.86; N, 3.21.
EXAMPLE 2
1,2:1,4:4,5-trans-1-[3-Hydroxy-4-[4-(2-methoxyphenyl)-1-piperazinyl]butyl]-2-methyl-1,2,4,5-cyclohexanetetrol, 1,2,4,5-tetraacetate ester, hydrochloride (1:1)
A solution of 1.4 g of 1-(2-methoxyphenyl)piperazine and 3.0 g of 1,2:1,4:4,5-trans-1-methyl-2-(oxiranylethyl)-1,2,4,5-cyclohexanetetrol, tetraacetate ester in 50 ml of absolute ethanol and 20 ml of benzene is stirred for about 16 hours at 55° C. The solvent is removed in vacuo, and the 4.5 g of residue is dissolved in ether and treated with an anhydrous solution of hydrogen chloride in isopropanol to yield a solid. The solid is collected, washed with ether and dried in vacuo. [The ether solution is washed (dilute hydrochloric acid, water and a saturated solution of sodium chloride), dried and evaporated in vacuo to give 0.55 g of recovered epoxide starting material.] The hydrochloride salt does not recrystallize. It is dissolved in water, made alkaline with cold concentrated ammonium hydroxide and extracted with chloroform to give 3.5 g of an oil-foam mixture. Crystallization from ether gives 2.6 g of the free base as a solid. Conversion of the free base to the monohydrochloride salt, and recrystallization for ethyl acetatemethanol gives 2.0 g of the title compound as a crystalline solid, melting point 213°-217° C.
Anal. Calc'd. for C 30 H 40 N 2 O 10 .HCl: C, 57.27; H, 7.21; N, 4.45; Cl, 5.64. Found: C, 57.26; H, 7.50; N, 4.32; Cl, 5.66
EXAMPLE 3
1,2:1,4:4,5-trans-1-[3-Hydroxy-4-[methyl[2-(2-pyridinyl)ethyl]-amino]butyl]-2-methyl-1,2,4,5-cyclohexanetetrol, tetraacetate ester, hydrochloride (1:2)
A solution of 1.7 g of 1,2:1,4:4,5-trans-1-methyl-2-(oxiranylethyl)-1,2,4,5-cyclohexanetetrol, tetraacetate ester (prepared as described in Example 1C) and 0.58 g of 2-(β-methylaminoethyl)pyridine in benzene and absolute ethanol (15:37.5) is stirred at 57° C. for about 16 hours. The solvent is removed in vacuo and the 2.25 g of residue is chromatographed on 100 g of neutral Alumina III. Elution with 800 ml of 25-45% ethyl acetate-hexane gives 0.4 g of forerun (mainly epoxide). Elution with 800 ml of 50-60% ethyl acetate-hexane and 600 ml of 5% methanol-ethyl acetate gives 1.1 g of the desired product as an oil. This material is dissolved in ether and converted to the dihydrochloride salt. Two recrystallizations from methanol-ethyl acetate give 0.82 g of the title compound, melting point 186°-187.5° C.
Anal. Calc'd. for C 27 H 40 N 2 O 9 .HCl (573.1/609.6 g/m): C, 53.20; H, 6.95; N, 4.60; Cl, 11.63. Found: C, 53.07; H, 7.05; N, 4.53; Cl, 11.55.
EXAMPLE 4
1,2:1,4:4,5-trans-1-[3-Hydroxy-4-(3,6-dihydro-4-phenyl-1(2H)-pyridinyl)butyl]-2-methyl-1,2,4,5-cyclohexanetetrol, tetraacetate ester
A solution of 1.65 g of 1,2:1,4:4,5-trans-1-methyl-2-(2-oxiranylethyl)-1,2,4,5-cyclohexanetetrol, tetraacetate esters (prepared as described in Example 1C) and 0.69 g of 4-phenyl-1,2,3,6-tetrahydropyridine in benzene-absolute ethanol (15:37.5) is stirred at 57° C. for about 16 hours. The solution is evaporated in vacuo and the residue crystallized from ether-hexane to give 1.1 g of solid. An additional 0.6 g is obtained from the next two crops. The 1.7 g of combined solid is recrystallized from ethyl acetate-hexane to give 0.80 g of the title compound, melting point 142°-147° C.
Anal. Calc'd. for C 30 H 41 NO 9 (559.67 g/m): C, 64.38; H, 7.38; N, 2.50. Found: C, 64.33; H, 7.47; N, 2.43.
EXAMPLES 5-18
Following the procedure of Example 1, but substituting the compound listed in column I for dimethylamine, yields the compound listed in column II.
__________________________________________________________________________Column I Column II__________________________________________________________________________5 methylamine 1,2:1,4:4,5-trans-1-[4-(methyl- amino)-3-hydroxybutyl]-2-methyl- 1,2,4,5-cyclohexanetetrol, 1,2,4,5- tetraacetate ester6 1-piperazine 1,2:1,4:4,5-trans-1-[3-hydroxy-4- (1-piperazinyl)butyl]-2-methyl- 1,2,4,5-cyclohexanetetrol, 1,2,4,5- tetraacetate ester7 1-methylpiperazine 1,2:1,4:4,5-trans-1-[3-hydroxy-4- (4-methyl-1-piperazinyl)butyl]-2-2 methyl-1,2,4,5-cyclohexanetetrol, 1,2,4,5-tetraacetate ester8 1-phenylpiperazine 1,2:1,4:4,5-trans-1-[3-hydroxy-4- (4-phenyl-1-piperazinyl)butyl]-2- methyl-1,2,4,5-cyclohexanetetrol, 1,2,4,5-tetraacetate ester9 1-(2-methylphenyl)- 1,2:1,4:4,5-trans-1-[3-hydroxy-4-piperazine [4-(2-methylphenyl)-1-piperazinyl]- butyl]-2-methyl-1,2,4,5-cyclohexane- tetrol, 1,2,4,5-tetraacetate ester10 1-[3-(trifluoromethyl)- 1,2:1,4:4,5-trans-1-[3-hydroxy-4-phenyl]piperazine [4-[3-(trifluoromethyl)phenyl]-1- piperazinyl]butyl]-2-methyl-1,2,4,5- cyclohexanetetrol, 1,2,4,5-tetra- acetate ester11 1-[2-(methylthio)phenyl]- 1,2:1,4:4,5-trans-1-[3-hydroxy-4-piperazine [4[2- (methylthio)phenyl]-1-piper- azinyl]butyl]-2-methyl-1,2,4,5- cyclohexanetetrol, 1,2,4,5-tetra- acetate ester12 1-(4-chlorophenyl)- 1,2:1,4:4,5-trans-1-[4-(4-chloro-piperazine phenyl)-1-piperazinyl]-3-hydroxy- butyl]-2-methyl-1,2,4,5-cyclo- hexanetetrol, 1,2,4,5-tetraacetate ester13 3-(β-methylaminoethyl)- 1,2:1,4:4,5-trans-1-[3-hydroxy-4-pyridine [methyl[2-(3-pyridinyl)ethyl]ethyl]amino] - butyl]-2-methyl-1,2,4,5-cyclo- hexanetetrol, tetraacetate ester14 4-(γ-methylaminopropyl)- 1,2:1,4:4,5-trans-1-[3-hydroxy-4-pyridine [methyl[3-(4-pyridinyl)propyl]- amino]butyl]-2-methyl-1,2,4,5- cyclohexanetetrol, tetraacetate ester15 4-(2-ethylphenyl)- 1,2:1,4:4,5-trans-1-[3-hydroxy-4-1,2,3,6-tetrahydro- [3,6-dihydro-4-[(2-ethylphenyl)-pyridine 1(2H)-pyridinyl]butyl]-2-methyl- 1,2,4,5-cyclohexanetetrol, tetra- acetate ester16 4-(2-ethylthiophenyl)- 1,2:1,4:4,5-trans-1-[3-hydroxy-4-1,2,3,6-tetrahydro- [3,6-dihydro-4-[(2-ethylthiophenyl)-pyridine 1(2H)-pyridinyl]butyl]-2-methyl- 1,2,4,5-cyclohexanetetrol, tetra- acetate ester17 4-(3-trifluoromethyl- 1,2:1,4:4,5-trans-1-[3-hydroxy-4-phenyl)-1,2,3,6-tetra- [3,6-dihydro-4-[(3-trifluoromethyl-hydropyridine phenyl)-1(2H)-pyridinyl]butyl]-2- methyl-1,2,4,5-cyclohexanetetrol, tetraacetate ester18 4-(4-bromophenyl)-1,2,- 1,2:1,4:4,5-trans-1-[3-hydroxy-4-3,6-tetrahydropyridine [(3,6-dihydro-4-[(4-bromophenyl)- 1(2H)-pyridinyl]butyl]-2-methyl- 1,2,4,5-cyclohexanetetrol, tetra- acetate ester__________________________________________________________________________
EXAMPLES 19-20
Following the procedure of Example 1, but substituting the compound listed in column I for 1,2:1,4:4,5-trans-1-[4-(dimethylamino)butyl]-2-methyl-1,2,4,5-cyclohexanetetrol, tetraacetate ester, yields the compound listed in column II.
__________________________________________________________________________Column I Column II__________________________________________________________________________19 1,2:1,4:4,5-trans-1-[3- 1,2:1,4:4,5-trans-1-[3-(dimethyl- (dimethylamino)propyl]- amino)-2-hydroxypropyl]-2-methyl- 2-methyl-1,2,4,5-cyclo- 1,2,4,5-cyclohexanetetrol, 1,2,4,5- hexanetetrol, tetra- tetraacetate ester acetate ester20 1,2:1,4:4,5-trans-1-[5- 1,2:1,4:4,5-trans-1-[5-(dimethyl- (dimethylamino)pentyl]- amino)-4-hydroxypentyl]-2-methyl- 2-methyl-1,2,4,5-cyclo- 1,2,4,5-cyclohexanetetrol, 1,2,4,5- hexanetetrol, tetra- tetraacetate ester acetate ester__________________________________________________________________________
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Compounds having the formula ##STR1## and the pharmaceutically acceptable salts thereof, wherein R 1 is alkanoyl; R 2 is alkyl; R 3 is alkylamino, dialkylamino, a 1-piperazinyl group, 4-aryl-1,2,3,6-tetrahydro-1-pyridinyl, or N-alkyl-N-(pyridinylalkyl)amino; and n is 1, 2 or 3; have useful hypotensive activity.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application is a divisional application of U.S. application Ser. No. 13/845,173, filed on Mar. 18, 2013, and claims priority under 35 U.S.C. 119(a) to Korean Application No. 10-2012-0139861, filed on Dec. 4, 2012, in the Korean Intellectual Property Office, which is incorporated herein by reference in its entirety as set forth in full.
BACKGROUND
[0002] Various Embodiments of the present disclosure generally relate to semiconductor memory devices and methods of testing open failures thereof.
[0003] Semiconductor integrated circuit devices may be fabricated using a plurality of unit processes and may be classified into good chips or failed chips through a function test. The function test may be performed to evaluate functions of peripheral circuits and memory cells constituting the semiconductor integrated circuit devices. Most of the semiconductor integrated circuit devices may tend to exhibit single bit fails more than dual bit fails. Accordingly, as the semiconductor integrated circuit devices increases a density of integration, test time of the highly integrated semiconductor integrated circuit devices have been more increased. Hence, a parallel test has been proposed to reduce the test time. The parallel test may be performed by simultaneously writing the same data into a plurality of memory cells of the semiconductor memory device and by simultaneously reading out the data stored in the plurality of memory cells. Thus, the parallel test may reduce the test time.
[0004] In general, test input/output (I/O) lines in addition to global I/O lines may be required to perform the parallel test. That is, when a read operation is executed in the parallel test mode, the data stored in the memory cells may be loaded on a plurality of test I/O lines and the data levels on the plurality of test I/O lines may be detected or sensed to discriminate whether at least one of the memory cells normally operate or not. That is, when the parallel test is performed, the data stored in the memory cells may be outputted through the test I/O lines instead of the global I/O lines through which the data stored in the memory cells are outputted in a normal read mode.
SUMMARY
[0005] According to an embodiment, a semiconductor memory device includes an input/output (I/O) drive controller, a data I/O unit and a data transmitter. The input/output (I/O) drive controller is configured to generate drive control signals and an input control signal for driving first and second global I/O lines in a first test mode or a second test mode. The data I/O unit is configured to drive the first global I/O line in response to an input data when a write operation is executed in the first test mode and to drive the first and second global I/O lines in response to the drive control signals when the write operation is executed in the second test mode. The data transmitter is configured to transfer data on the first global I/O line onto first and second local I/O lines to store the data on the first global I/O line in a memory cell array portion when the write operation is executed in the first test mode. The data transmitter is also configured to transfer data on the first and second global I/O lines onto the first and second local I/O lines to store the data on the first and second global I/O lines in the memory cell array portion when the write operation is executed in the second test mode.
[0006] According to an embodiment, a semiconductor memory device includes an input/output (I/O) drive controller, a data I/O unit and a data transmitter. The input/output (I/O) drive controller is configured to generate drive control signals and an input control signal for driving first and second global I/O lines in response to a write command signal and a read command signal in a test mode. The input/output (I/O) drive controller is also configured to generate a comparison signal by comparing data on a first test line with data on a second test line in the test mode. The data I/O unit is configured to drive the first and second global I/O lines in response to the drive control signals when a write operation is executed in the test mode. The data I/O unit is also configured to output the data on the first and second global I/O lines when a read operation is executed in the test mode. The data transmitter is configured to transfer data on the first and second global I/O lines to first and second local I/O lines to store the data on the first and second global I/O lines in a memory cell array portion when the write operation is executed in the test mode. The data transmitter is also configured to transfer the data outputted from the memory cell array portion through the first and second local I/O lines to the first and second global I/O lines and the first and second test lines when the read operation is executed in the test mode.
[0007] According to an embodiment, the I/O drive controller includes a selection signal generator, a drive control signal generator, a write controller and a comparison signal generator. The selection signal generator configured to generate a selection signal enabled in the test mode in response to a parallel test signal and a line test signal. The drive control signal generator configured to generate the drive control signals selectively enabled in response to the write command signal and the read command signal in the test mode. The write controller configured to generate an input control signal enabled in response to the write command signal and the read command signal when the write operation is executed in the test mode. The comparison signal generator configured to transfer the comparison signal to the first global I/O line when the read operation is executed in the test mode, wherein the drive control signals include first to fourth drive control signals.
[0008] According to an embodiment, the parallel test signal is enabled to activate the test mode that stores the data generated by driving the first and second global I/O lines in the memory cell array portion and outputs the data stored in the memory cell array portion through the first and second global I/O lines to evaluate failures of the first and second global I/O lines, wherein the line test signal is enabled to activate the test mode, and the data I/O unit operates without reception of input data when the write operation is executed in the test mode.
[0009] According to an embodiment, the data I/O unit drives the first and second global I/O lines to a first level in response to the drive control signals at a time that the write operation begins in the test mode.
[0010] According to an embodiment, the data I/O unit drives the first and second global I/O lines to a second level in response to the drive control signals after a predetermined period elapses from the time that the write operation begins in the test mode.
[0011] According to an embodiment, the data I/O unit includes a first input driver, a second input driver, a first output driver and a second output driver. The first input driver configured to transfer a first input data to the first global I/O line in response to the line test signal or to drive the first global I/O line according to the first to fourth drive control signals. The second input driver configured to transfer a second input data to the second global I/O line in response to the line test signal or to drive the second global I/O line according to the first to fourth drive control signals. The first output driver configured to generate a first output data in response to data loaded on the first global I/O line when the read operation is executed in the test mode. The second output driver configured to generate a second output data in response to data loaded on the second global I/O line when the read operation is executed in the test mode.
[0012] According to an embodiment, the first input driver includes a first input unit, a first driver, a first transfer unit and a second driver. The first input unit configured to transfer the first input data to a first node in response to the line test signal. The first driver configured to drive the first node in response to the first and second drive control signals. The first transfer unit configured to transfer a signal of the first node to a second node connected to the first global I/O line in response to the input control signal. The second driver configured to drive the second node in response to the third and fourth drive control signals.
[0013] According to an embodiment, the second input driver includes a second input unit, a third driver, a logic unit, a second transfer unit and a fourth driver. The second input unit configured to transfer the second input data to a third node in response to the line test signal. The third driver configured to drive the third node in response to the first and second drive control signals. The logic unit configured to generate a control signal enabled according to the input control signal and the selection signal when the write operation is executed in the test mode. The second transfer unit configured to transfer a signal of the third node to a fourth node connected to the second global I/O line in response to the control signal. The fourth driver configured to drive the fourth node in response to the third and fourth drive control signals.
[0014] According to an embodiment, the data transmitter includes a transmitter, a first write driver, a selection transmitter, a second write driver, a first sense amplifier and a second sense amplifier. The transmitter configured to transfer data loaded on the first global I/O line to a first transmission line when the write operation is executed in the test mode. The first write driver configured to drive the first local I/O line in response to data on the first transmission line to store the data on the first transmission line in a first memory cell block of the memory cell array portion. The selection transmitter configured to transfer data loaded on the first global I/O line to a second transmission line in response to the selection signal or to transfer data loaded on the second global I/O line to the second transmission line when the write operation is executed in the test mode. The second write driver configured to drive the second local I/O line in response to data on the second transmission line to store the data on the second transmission line in a second memory cell block of the memory cell array portion. The first sense amplifier configured to drive the first global I/O line and the first test line in response to data on the first local I/O line when the read operation is executed in the test mode. The second sense amplifier configured to drive the second global I/O line and the second test line in response to data on the second local I/O line when the read operation is executed in the test mode.
[0015] According to an embodiment, the selection transmitter includes a third driver and a fourth driver. The third driver configured to transfer data loaded on the first global I/O line to the second transmission line when the selection signal is disabled. The fourth driver configured to transfer data loaded on the second global I/O line to the second transmission line when the selection signal is enabled.
[0016] According to an embodiment, the comparison signal generator includes a comparator and a transfer unit. The comparator configured to compare data loaded on the first test line with data on the second test line to generate the comparison signal. The transfer unit configured to transfer the comparison signal to the first global I/O line in response to an enablement signal enabled when the read operation is executed in the test mode.
[0017] According to an embodiment, a method of testing a semiconductor memory device includes a step of writing data in a first memory cell block and a second memory cell block and a step of reading out data stored in the first and second memory cell blocks. Writing the data in the first and second memory cell blocks includes driving first and second global I/O lines in response to drive control signals generated in a test mode for evaluating failures of the first and second global I/O lines, storing the data on the first global I/O line in the first memory cell block, and storing the data on the second global I/O line in the second memory cell block. Reading out the data includes driving the first global I/O line and a first test line in response to data outputted from the first memory cell block and driving the second global I/O line and a second test line in response to data outputted from the second memory cell block.
[0018] According to an embodiment, the step of writing the data further comprises the step of blocking input data to be provided to the first and second global I/O lines.
[0019] According to an embodiment, wherein the step of writing the data further comprises the steps of driving the first and second global I/O lines to a first level in response to the drive control signals and driving the first and second global I/O lines to a second level in response to the drive control signals.
[0020] According to an embodiment, wherein the step of reading out the data further comprises a step of outputting a comparison signal generated by comparing the data on the first test line with the data on the second test line to the first global I/O line.
[0021] According to an embodiment, wherein the step of reading out the data further comprises the steps of generating a first output data in response to the data on the first global I/O line and generating a second output data in response to the data on the second global I/O line.
[0022] According to an embodiment, a semiconductor integrated circuit device, comprises a first test mode configured to test a plurality of memory cells by writing and reading data through a plurality of data lines; and a second test mode configured to test the plurality of data lines by driving the plurality of data lines.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] Embodiments of the inventive concept will become more apparent in view of the attached drawings and accompanying detailed description, in which:
[0024] FIG. 1 is a block diagram illustrating a configuration of a semiconductor memory device according to an embodiment;
[0025] FIG. 2 is a circuit diagram illustrating a selection signal generator of a I/O drive controller included in the semiconductor memory device shown in FIG. 1 ;
[0026] FIG. 3 is a block diagram illustrating a comparison signal generator of the I/O drive controller included in the semiconductor memory device shown in FIG. 1 ;
[0027] FIG. 4 is a circuit diagram illustrating a first input driver of a data I/O unit included in the semiconductor memory device shown in FIG. 1 ;
[0028] FIG. 5 is a circuit diagram illustrating a second input driver of a data I/O unit included in the semiconductor memory device shown in FIG. 1 ;
[0029] FIG. 6 is a circuit diagram illustrating a selection transmitter of a data transmitter included in the semiconductor memory device shown in FIG. 1 ;
[0030] FIG. 7 is a timing diagram illustrating a first test mode of the semiconductor memory device according to an embodiment; and
[0031] FIG. 8 is a timing diagram illustrating a second test mode of the semiconductor memory device according to an embodiment.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0032] Example embodiments of the inventive concept will be described hereinafter with reference to the accompanying drawings. However, the example embodiments described herein are for illustrative purposes only and are not intended to limit the scope of the inventive concept.
[0033] As illustrated in FIG. 1 , a semiconductor integrated circuit, for example, a semiconductor memory device 100 may be configured to include an input/output (I/O) drive controller 10 , a data I/O unit 20 , a data transmitter 30 and a memory cell array portion 40 .
[0034] The I/O drive controller 10 may be configured to include a selection signal generator 11 , a drive control signal generator 12 , a write controller 13 and a comparison signal generator 14 .
[0035] The selection signal generator 11 may be configured to generate a selection signal SELB in response to a parallel test signal TPARA and a line test signal TLINE. The selection signal SELB is enabled during a second test mode. The semiconductor memory device 100 enters the second test mode when the parallel test signal TPARA and the line test signal TLINE are enabled. The parallel test signal TPARA may be enabled to store data loaded on a first global I/O line GIO 1 in the memory cell array portion 40 . The semiconductor memory device 10 may enter a first test by the parallel test signal TPARA. The first test compares the data stored in the memory cell array portion 40 with each other to evaluate failures of a plurality of memory cells. Further, the parallel test signal TPARA may be enabled to store data generated by driving the data loaded on the first global I/O line GIO 1 and a second global I/O line GIO 2 in the memory cell array portion 40 and to activate the second test mode that outputs the data stored in the memory cell array portion 40 through the first and second global I/O lines GIO 1 and GIO 2 to evaluate open failures of the first and second global I/O lines GIO 1 and GIO 2 . The line test signal TLINE may be enabled to activate the second test mode. That is, the semiconductor memory device 100 may operate in the first test mode when the parallel test signal TPARA is enabled and the line test signal TLINE is disabled, and the semiconductor memory device 100 may operate in the second test mode when both the parallel test signal TPARA and the line test signal TLINE are enabled.
[0036] The drive control signal generator 12 may be configured to generate a plurality of drive control signals DRVCON<1:4> in response to the parallel test signal TPARA, the line test signal TLINE, a write command signal WT and a read command signal RD. First and second drive control signals DRVCON<1:2> of the plurality of drive control signals DRVCON<1:4> are selectively enabled when both the parallel test signal TPARA and the line test signal TLINE are enabled to activate the second test mode and when a write operation is executed in response to a write command signal WT and a read command signal RD. Third and fourth drive control signals DRVCON<3:4> of the plurality of drive control signals DRVCON<1:4> are enabled after predetermined periods from a beginning of the write operation.
[0037] The write controller 13 may be configured to receive the write command signal WT and the read command signal RD and generate an input control signal DINDRV when the write operation is executed in the first or second test mode.
[0038] The comparison signal generator 14 may be configured to receive an enablement signal EN to output a comparison signal COMP. The comparison signal is generated by comparing the data on a first test line TGIO 1 with the data on a second test line TGIO 2 and outputted through the first global I/O line GIO 1 when the read operation is executed in the first or second test mode. For example, if the enablement signal EN is enabled, the comparison signal COMP may be outputted onto the first global I/O line GIO 1 when the read operation is executed in the first or second test mode.
[0039] The data I/O unit 20 may be configured to include a first input driver 21 , a second input driver 22 , a first output driver 23 and a second output driver 24 .
[0040] The first input driver 21 may be configured to receive a first input data DIN<1> to drive the first global I/O line GIO 1 when the write operation is executed in a normal mode or the first test mode. Further, the first input driver 21 may configured to receive the line test signal TLINE and block an input the first input data DIN<1> when the write operation is executed in the second test mode. Further, the first input driver 21 may configured to receive the first and second drive control signals DRVCON<1:2> and drive the first global I/O line GIO 1 when the write operation is executed in the second test mode. In addition, the first input driver 21 may configured to receive the third and fourth drive control signals DRVCON<3:4> and drive the first global I/O line GIO 1 after a predetermined period from a beginning of the write operation.
[0041] The second input driver 22 may be configured to receive a second input data DIN<2> to drive the second global I/O line GIO 2 when the write operation is executed in the normal mode. The second input driver 22 may not drive the second global I/O line GIO 2 when the write operation is executed in the first test mode. Further, when the write operation is executed in the second test mode, the second input driver 22 may be configured to receive the line test signal TLINE and block an inputting of the second input data DIN<2>. Further, the second input driver 22 may be configured to drive the second global I/O line GIO 2 in response to the first and second drive control signals DRVCON<1:2>. In addition, the second input driver 22 may be configured to drive the data loaded on the second global I/O line GIO 2 in response to the third and fourth drive control signals DRVCON<3:4> after a predetermined period from a beginning of the write operation begins, thereby driving the second global I/O line GIO 2 .
[0042] The first output driver 23 may be configured to receive the data loaded on the first global I/O line GIO 1 to generate a first output data DOUT<1> when the read operation is executed in the normal mode, the first test mode or the second test mode.
[0043] The second output driver 24 may receive the data loaded on the second global I/O line GIO 2 to generate a second output data DOUT<2> when the read operation is executed in the normal mode or the second test mode. The second output driver 24 may not operate when the read operation is executed in the first test mode.
[0044] The data transmitter 30 may be configured to include a transmitter 31 , a first write driver 32 , a selection transmitter 33 , a second write driver 34 , a first sense amplifier 35 and a second sense amplifier 36 .
[0045] The transmitter 31 may be configured to transfer the data loaded on the first global I/O line GIO 1 to a first transmission line WGIO 1 when the write operation is executed in the normal mode, the first test mode or the second test mode.
[0046] The first write driver 32 may be configured to receive the data loaded on the first transmission line WGIO 1 and provide the data of the first transmission line WGIO 1 to the memory cell array portion 40 through a first local I/O line LIO 1 , to store the data on the first transmission line WGIO 1 into a first memory cell block 41 when the write operation is executed in the normal mode, the first test mode or the second test mode.
[0047] The selection transmitter 33 may be configured to transfer the data loaded on the second global I/O line GIO 2 to a second transmission line WGIO 2 in response to the selection signal SELB when the write operation is executed in the normal mode or the second test mode.
[0048] The second write driver 34 may be configured to receive the data loaded on the second transmission line WGIO 2 and provide the data of the second transmission line WGIO 2 to the memory cell array portion 40 through a second local I/O line LIO 2 to store the data on the second transmission line WGIO 2 into a second memory cell block 42 when the write operation is executed in the normal mode, the first test mode or the second test mode.
[0049] The first sense amplifier 35 may be configured to receive the data on the first local I/O line LIO 1 and drive the first global I/O line GIO 1 when the read operation is executed in the normal mode. Further the first sense amplifier 35 may be configured to receive the data loaded on the first local I/O line LIO 1 , drive the first global I/O line GIO 1 and the first test line TGIO 1 when the read operation is executed in the first or second test mode.
[0050] The second sense amplifier 36 may be configured to receive the data loaded on the second local I/O line LIO 2 , drive the second global I/O line GIO 2 when the read operation is executed in the normal mode. Further the second sense amplifier 36 may be configured to receive the data loaded on the second local I/O line LIO 2 , drive the second test line TGIO 2 when the read operation is executed in the first test mode. In addition, the second sense amplifier 36 may be configured to receive the data loaded on the second local I/O line LIO 2 , drive the second global I/O line GIO 2 and the second test line TGIO 2 when the read operation is executed in the second test mode.
[0051] The memory cell array portion 40 may be configured to include a first memory cell block 41 having a plurality of memory cells and a second memory cell block 42 having a plurality of memory cells. The first memory cell block 41 may be configured to receive the data through the first local I/O line LIO 1 and the second memory cell block 42 may be configured to receive the data through the second local I/O line LIO 2 .
[0052] A configuration of the selection signal generator 11 will be described more fully hereinafter with reference to FIG. 2 .
[0053] Referring to FIG. 2 , the selection signal generator 11 may be configured to include an inverter IV 10 inversely buffering the line test signal TLINE, a NAND gate ND 10 executing a NAND operation of an output signal of the inverter IV 10 and the parallel test signal TPARA, and an inverter IV 11 inversely buffering an output signal of the NAND gate ND 10 to generate the selection signal SELB. That is, the selection signal generator 11 may receive the parallel test signal TPARA and the line test signal TLINE to generate the selection signal SELB which is enabled in the normal mode or the second test mode.
[0054] A configuration of the comparison signal generator 14 will be described more fully hereinafter with reference to FIG. 3 .
[0055] Referring to FIG. 3 , the comparison signal generator 14 may be configured to include a comparator 140 comparing the data on the first test line TGIO 1 with the data on the second test line TGIO 2 to generate the comparison signal COMP and a transfer unit 141 transferring the comparison signal COMP onto the first global I/O line GIO 1 in response to the enablement signal EN. That is, the comparison signal generator 14 may transfer the comparison signal COMP, which is generated by comparing the data on the first test line TGIO 1 with the data on the second test line TGIO 2 , to the first global I/O line GIO 1 when the read operation is executed in the first or second test mode. For example, the comparator 140 may be an exclusive NOR gate.
[0056] A configuration of the first input driver 21 will be described more fully hereinafter with reference to FIG. 4 .
[0057] Referring to FIG. 4 , the first input driver 21 may be configured to include a first input unit 210 , a first driver 211 , a first transfer unit 212 and a second driver 213 .
[0058] The first input unit 210 may be configured to transfer the first input data DIN<1> to a first node ND 40 according to the line test signal TLINE. For example, the first input unit 210 may be a transfer gate.
[0059] The first driver 211 may be configured to pull up the first node ND 40 when the first drive control signal DRVCON<1> is enabled and pull down the first node ND 40 when the second drive control signal DRVCON<2> is enabled.
[0060] The first transfer unit 212 may be configured to output a signal on the first node ND 40 to a second node ND 41 electrically connected to the first global I/O line GIO 1 when the input control signal DINDRV is enabled.
[0061] The second driver 213 may be configured to pull up the second node ND 41 when the fourth drive control signal DRVCON<4> is enabled and pull down the second node ND 41 when the third drive control signal DRVCON<3> is enabled. That is, the first input driver 21 may transfer the first input data DIN<1> to the first global I/O line GIO 1 when the write operation is executed in the normal mode or the first test mode and may drive the first global I/O line GIO 1 without reception of the first input data DIN<1> when the write operation is executed in the second test mode.
[0062] A configuration of the second input driver 22 will be described more fully hereinafter with reference to FIG. 5 .
[0063] Referring to FIG. 5 , the second input driver 22 may be configured to include a second input unit 220 , a third driver 221 , a logic unit 222 , a second transfer unit 223 , and a fourth driver 224
[0064] The second input unit 2210 may be transferred the second input data DIN<2> to a third node ND 42 according to the line test signal TLINE.
[0065] The third driver 221 may be configured to pull up the third node ND 42 when the first drive control signal DRVCON<1> is enabled and pull down the third node ND 42 when the second drive control signal DRVCON<2> is enabled.
[0066] The logic unit 222 may be configured to generate a control signal CONB in response to the input control signal DINDRV and the selection signal SELB. For example, the logic unit 222 may include a inverter for inverting the selection signal SELB and a NAND gate for NAND operating the inversed selection signal SELB and the input control signal DINDRV.
[0067] The second transfer unit 223 may be configured to output a signal on the third node ND 42 to a fourth node ND 43 electrically connected to the second global I/O line GIO 2 when the control signal CONB is enabled.
[0068] The fourth driver 224 may be configured to pull up the fourth node ND 43 when the fourth drive control signal DRVCON<4> is enabled and pull down the fourth node ND 43 when the third drive control signal DRVCON<3> is enabled. That is, the second input driver 22 may transfer the second input data DIN<2> to the second global I/O line GIO 2 when the write operation is executed in the normal mode and may not transfer the second input data DIN<2> to the second global I/O line GIO 2 when the write operation is executed in the first test mode. Further, the second input driver 22 may drive the second global I/O line GIO 2 without reception of the second input data DIN<2> when the write operation is executed in the second test mode.
[0069] A configuration of the selection transmitter 33 will be described more fully hereinafter with reference to FIG. 6 .
[0070] Referring to FIG. 6 , the selection transmitter 33 may be configured to include a third driver 330 and the fourth driver 331 . The third driver 330 may be configured to operate when the selection signal SELB is disabled to transfer the data on the first global I/O line GIO 1 to the second transmission line WGIO 2 . The fourth driver 331 may be configured to operate when the selection signal SELB is enabled to transfer the data on the second global I/O line GIO 2 to the second transmission line WGIO 2 . That is, the selection transmitter 33 may transfer the data on the first global I/O line GIO 1 to the second transmission line WGIO 2 when the write operation is executed in the first test mode. In addition, the selection transmitter 33 may transfer the data on the second global I/O line GIO 2 to the second transmission line WGIO 2 when the write operation is executed in the normal mode or the second test mode.
[0071] An operation of the semiconductor memory device in the first test mode which is capable of sorting failed memory cells will be described in conjunction with an example that both the first and second input data DIN<1:2> have a logic “high” level with reference to FIG. 7 .
[0072] Referring to FIG. 7 , at a time T 1 , the selection signal generator 11 of the I/O drive controller 10 may receive the parallel test signal TPARA enabled to have a logic “high” level and the line test signal TLINE disabled to have a logic “low” level, to generate the selection signal SELB disabled to have a logic “high” level in order to enter the first test mode.
[0073] Subsequently, if the write operation is executed at a time T 2 , the drive control signal generator 12 of the I/O drive controller 10 may receive the write command signal WT in the first test mode, thus stop to generate the first to fourth drive control signals DRVCON<1:4>. The write controller 13 may receive the write command signal WT in the first test mode to generate the input control signal DINDRV which is enabled to have a logic “high” level.
[0074] The first input driver 21 of the data I/O unit 20 may provide the first input data DIN<1> to the first global I/O line GIO 1 in response to the line test signal TLINE having a logic “low” level. The second input driver 22 of the data I/O unit 20 may provide the second input data DIN<2> to the second global I/O line GIO 2 in response to the line test signal TLINE having a logic “low” level.
[0075] The transmitter 31 of the data transmitter 30 may receive the data of a logic “high” level on the first global I/O line GIO 1 and may transfer the data of a logic “high” level on the first global I/O line GIO 1 to the first transmission line WGIO 1 . The first write driver 32 may drive the first local I/O line LIO 1 in response to the data loaded on the first transmission line WGIO 1 to store the data on the first transmission line WGIO 1 into the first memory cell block 41 . The selection transmitter 33 may transfer the data loaded on the first global I/O line GIO 1 to the second transmission line WGIO 2 in response to the selection signal SELB having a logic “high” level. In such a case, the selection transmitter 33 may not receive the data on the second global I/O line GIO 2 because the selection signal SELB has a logic “high” level.
[0076] The second write driver 34 may drive the second local I/O line LIO 2 in response to the data loaded on the second transmission line WGIO 2 to store the data on the second transmission line WGIO 2 into the second memory cell block 42 .
[0077] Next, if the read operation is executed at a time T 3 , the first sense amplifier 35 of the data transmitter 30 may receive the data having a logic “high” level outputted from the first memory cell block 41 through the first local I/O line LIO 1 to drive the first test line TGIO 1 to a logic “high” level. The second sense amplifier 36 of the data transmitter 30 may receive the data having a logic “high” level outputted from the second memory cell block 42 through the second local I/O line LIO 2 to drive the second test line TGIO 2 to a logic “high” level. The comparator 140 of the comparison signal generator 14 may compare the data on the first test line TGIO 1 with the data on the second test line TGIO 2 to generate the comparison signal COMP having a logic “high” level.
[0078] Subsequently, if the enablement signal EN is enabled at a time T 4 , the transfer unit 141 may transmit the comparison signal COMP having a logic “high” level to the first global I/O line GIO 1 . The first output driver 23 of the data I/O unit 20 may receive the signal having a logic “high” level on the first global I/O line GIO 1 to generate the first output data DOUT<1> having a logic “high” level. Since the first output data DOUT<1> has a logic “high” level and the first and second input data DIN<1:2> have a logic “high” level, no failed memory cells may exist in the first and second memory cell blocks 41 and 42 .
[0079] As described above, the first test mode may be used to evaluate whether failed memory cells exist in the memory cell array portion 40 .
[0080] Now, an operation of the semiconductor memory device in the second test mode which is capable of evaluating open failures of the global I/O lines will be described in conjunction with an example that the first global I/O line GIO 1 has an open failure and has a logic “high” level with reference to FIG. 8 .
[0081] Referring to FIG. 8 , at a time T 10 , the selection signal generator 11 of the I/O drive controller 10 may generate the selection signal SELB enabled to have a logic “low” level in order to enter the second test mode in response to the parallel test signal TPARA and the line test signal TLINE which are enabled to have a logic “high” level.
[0082] Subsequently, if the write operation is executed at a time T 11 , the drive control signal generator 12 of the I/O drive controller 10 may receive the write command signal WT in the second test mode to generate the first drive control signal DRVCON<1> which is enabled to have a logic “high” level. The write controller 13 may receive the write command signal WT in the second test mode to generate the input control signal DINDRV which is enabled to have a logic “high” level.
[0083] The first input driver 21 of the data I/O unit 20 may pull up the first node ND 40 in response to the first drive control signal DRVCON<1> having a logic “high” level to drive the first global I/O line GIO 1 to a logic “high” level. The second input driver 22 of the data I/O unit 20 may pull up the third node ND 42 in response to the first drive control signal DRVCON<1> having a logic “high” level to drive the second global I/O line GIO 2 to a logic “high” level.
[0084] The transmitter 31 of the data transmitter 30 may transfer the data of a logic “high” level on the first global I/O line GIO 1 to the first transmission line WGIO 1 . The first write driver 32 may drive the first local I/O line LIO 1 in response to the data on the first transmission line WGIO 1 to store the data on the first transmission line WGIO 1 into the first memory cell block 41 . The selection transmitter 33 may transfer the data of a logic “high” level on the second global I/O line GIO 2 to the second transmission line WGIO 2 in response to the selection signal SELB having a logic “low” level. In such a case, the selection transmitter 33 may not receive the data on the first global I/O line GIO 1 because the selection signal SELB has a logic “low” level. The second write driver 34 may drive the second local I/O line LIO 2 in response to the data loaded on the second transmission line WGIO 2 to store the data on the second transmission line WGIO 2 into the second memory cell block 42 .
[0085] Next, the drive control signal generator 12 of the I/O drive controller 10 may generate the third drive control signal DRVCON<3> which is enabled to have a logic “high” level at a time T 12 that a predetermined period elapses from the time T 11 that the write operation begins. The first input driver 21 of the data I/O unit 20 may pull down the second node ND 41 in response to the third drive control signal DRVCON<3> having a logic “high” level to drive the first global I/O line GIO 1 to a logic “low” level. The second input driver 22 of the data I/O unit 20 may pull down the fourth node ND 43 in response to the third drive control signal DRVCON<3> having a logic “high” level to drive the second global I/O line GIO 2 to a logic “low” level. However, when the second global I/O line GIO 2 has an open failure, the second global I/O line GIO 2 may not be driven to a logic “low” level even though the second input driver 22 pulls down the fourth node ND 43 .
[0086] If the read operation is executed at a time T 13 , the first sense amplifier 35 of the data transmitter 30 may receive the data having a logic “high” level outputted from the first memory cell block 41 through the first local I/O line LIO 1 to drive the first test line TGIO 1 and the first global I/O line GIO 1 to a logic “high” level. The second sense amplifier 36 of the data transmitter 30 may receive the data having a logic “high” level outputted from the second memory cell block 42 through the second local I/O line LIO 2 to drive the second test line TGIO 2 and the second global I/O line GIO 2 to a logic “high” level. The comparator 140 of the comparison signal generator 14 may compare the data on the first test line TGIO 1 with the data loaded on the second test line TGIO 2 to generate the comparison signal COMP having a logic “high” level.
[0087] Subsequently, if the enablement signal EN is enabled at a time T 14 , the transfer unit 141 of the comparison signal generator 14 may transmit the comparison signal COMP having a logic “high” level to the first global I/O line GIO 1 . The first output driver 23 of the data I/O unit 20 may generate the first output data DOUT<1> having a logic “high” level in response to the signal having a logic “high” level on the first global I/O line GIO 1 . The second output driver 24 may receive to generate the second output data DOUT<2> having a logic “high” level, in response to the signal on the second global I/O line GIO 2 . The levels of the first and second output data DOUT<1:2> may be sensed or detected to evaluate whether an open failure exists in the global I/O lines GIO 1 and GIO 2 . However, since the second global I/O line GIO 2 has a logic “high” level due to an open failure, the second output data DOUT<2> may be generated to have a logic “high” level. Thus, the second global I/O line GIO 2 may be evaluated as being normal without any open failures. Accordingly, the first and second global I/O lines GIO 1 and GIO 2 may be driven to a logic “low” level to execute the write operation and the read operation again.
[0088] Hereinafter, an operation of driving the first and second global I/O lines GIO 1 and GIO 2 to a logic “low” level will be described.
[0089] First, if the write operation is executed at a time T 15 , the drive control signal generator 12 of the I/O drive controller 10 may receive the write command signal WT in the second test mode to generate the second drive control signal DRVCON<2> which is enabled to have a logic “high” level and the write controller 13 may receive the write command signal WT in the second test mode to generate the input control signal DINDRV which is enabled to have a logic “high” level.
[0090] The first input driver 21 of the data I/O unit 20 may pull down the first node ND 40 in response to the second drive control signal DRVCON<2> having a logic “high” level to drive the first global I/O line GIO 1 to a logic “low” level. The second input driver 22 of the data I/O unit 20 may pull down the third node ND 42 in response to the second drive control signal DRVCON<2> having a logic “high” level to drive the second global I/O line GIO 2 to a logic “low” level. However, since the second global I/O line GIO 2 has an open failure, the second global I/O line GIO 2 may not be driven to a logic “low” level even though the second input driver 22 pulls down the third node ND 42 .
[0091] The transmitter 31 of the data transmitter 30 may transfer the data of a logic “low” level on the first global I/O line GIO 1 to the first transmission line WGIO 1 . The first write driver 32 may drive the first local I/O line LIO 1 in response to the data loaded on the first transmission line WGIO 1 to store the data on the first transmission line WGIO 1 into the first memory cell block 41 . The selection transmitter 33 may transfer the data of a logic “high” level on the second global I/O line GIO 2 to the second transmission line WGIO 2 in response to the selection signal SELB having a logic “low” level. In such a case, the selection transmitter 33 may not receive the data on the first global I/O line GIO 1 because the selection signal SELB has a logic “low” level. The second write driver 34 may drive the second local I/O line LIO 2 in response to the data on the second transmission line WGIO 2 to store the data on the second transmission line WGIO 2 into the second memory cell block 42 .
[0092] Next, the drive control signal generator 12 of the I/O drive controller 10 may generate the fourth drive control signal DRVCON<4> which is enabled to have a logic “high” level at a time T 16 that a predetermined period elapses from the time T 15 that the write operation begins. The first input driver 21 of the data I/O unit 20 may pull up the second node ND 41 in response to the fourth drive control signal DRVCON<4> having a logic “high” level to drive the first global I/O line GIO 1 to a logic “high” level. The second input driver 22 of the data I/O unit 20 may pull up the fourth node ND 43 in response to the fourth drive control signal DRVCON<4> having a logic “high” level to drive the second global I/O line GIO 2 to a logic “high” level.
[0093] If the read operation is executed at a time T 17 , the first sense amplifier 35 of the data transmitter 30 may receive the data having a logic “low” level outputted from the first memory cell block 41 through the first local I/O line LIO 1 to drive the first test line TGIO 1 and the first global I/O line GIO 1 to a logic “low” level. The second sense amplifier 36 of the data transmitter 30 may receive the data having a logic “high” level outputted from the second memory cell block 42 through the second local I/O line LIO 2 to drive the second test line TGIO 2 and the second global I/O line GIO 2 to a logic “high” level. The comparator 140 of the comparison signal generator 14 may compare the data on the first test line TGIO 1 with the data on the second test line TGIO 2 to generate the comparison signal COMP having a logic “low” level.
[0094] Subsequently, if the enablement signal EN is enabled at a time T 18 , the transfer unit 141 of the comparison signal generator 14 may transmit the comparison signal COMP having a logic “low” level to the first global I/O line GIO 1 . The first output driver 23 of the data I/O unit 20 may generate the first output data DOUT<1> having a logic “low” level in response to the signal having a logic “low” level on the first global I/O line GIO 1 . The second output driver 24 may generate the second output data DOUT<2> having a logic “high” level in response to the signal on the second global I/O line GIO 2 to. The levels of the first and second output data DOUT<1:2> may be sensed or detected to evaluate whether an open failure exists in the global I/O lines GIO 1 and GIO 2 . Since the second global I/O line GIO 2 is not driven to a logic “low” level due to an open failure during the write operation, the second output data DOUT<2> may be generated to have a logic “high” level during the read operation. Thus, the second global I/O line GIO 2 may be evaluated as being abnormal with an open failure.
[0095] As described above, the semiconductor memory device according to the embodiments may be configured to find out open failures of the global I/O lines in the second test mode.
[0096] The example embodiments of the inventive concept have been disclosed above for illustrative purposes. Those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the inventive concept as disclosed in the accompanying claims.
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Semiconductor memory devices are provided. The semiconductor memory device includes an input/output (I/O) drive controller, a data I/O unit and a data transmitter. The input/output (I/O) drive controller generates drive control signals and an input control signal for driving first and second global I/O lines in a first test mode or a second test mode. The data I/O unit drives the first global I/O line in response to an input data when a write operation is executed in the first test mode and to drive the first and second global I/O lines in response to the drive control signals when the write operation is executed in the second test mode. The data transmitter transfers the data on the first global I/O line onto first and second local I/O lines to store the data on the first global I/O line in a memory cell array portion when the write operation is executed in the first test mode. The data transmitter also transfers the data on the first and second global I/O lines onto the first and second local I/O lines to store the data on the first and second global I/O lines in the memory cell array portion when the write operation is executed in the second test mode. Related methods are also provided.
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This invention relates to a luminous electric display unit of the inert gas-containing tube type and, more particularly, to such a display unit having an improved housing of simple and economical construction for supporting and protecting the lighting and electrical components of the sign.
BACKGROUND OF THE INVENTION
Luminous electric signs of the inert gas-filled tube type have long been employed in commercial and business establishments to provide decoration and/or impart information. Typically, such signs are referred to as "neon signs" and may be hung or placed in various locations, such as storefront windows, to advertise a product, decorate, or provide message information.
The tubular lighting elements of the sign may be conformed into an array of desired letters or decorative shapes, as in a glass tube-bending operation, and the array is supportably attached by suitable brackets or wires to a rigid open frame, to a support backing, or in some form of housing or box.
In luminous signs of the neon tube type, it is desirable to protect the glass tubular lighting array from breakage, and to protect the various elements the sign from collecting dust, foreign particles, and the like. In daylight conditions, it is often desirable that the lighted tubular array be backed by an opaque material for light containment and to provide solid background for better visibility of the sign.
It is also known to provide luminous electric display units, typically called electric blackboards, wherein a fluorescent or photoconductive plate, such as an acrylic plastic board, is edge lighted by a light-emitting element to concentrate light in the board whereby hand written information placed thereon by suitable means, such as water-soluble erasable high-pigment crayons, has a glow or brightness to display the information contained on the board.
Luminous electric display units of the types described are disclosed in the following U.S. Pat. Nos.:
______________________________________U.S. Pat. No. 1,654,255 U.S. Pat. No. 2,082,523U.S. Pat. No. 2,763,948 U.S. Pat. No. 3,085,224U.S. Pat. No. 4,903,172______________________________________
BRIEF OBJECTS OF THE PRESENT INVENTION
It is an object of the present invention to provide a luminous electric display unit of the inert gas-filled tube type having a support housing for the lighting array and electrical components of the unit which is of simplified and economical construction.
It is another object to provide a luminous electric display unit which protects the lighting array and electrical elements of the unit against glass breakage and contamination by dust and foreign matter.
It is a further object to provide a display unit having an improved support housing for the electrical and lighting elements of the unit to provide an improved high visibility to the lighting elements over conventional methods.
It is a further object, in one form the invention, to provide a display unit additionally having an edge-lighted message board which can be engraved with a message or written on with fluorescent markers and which can be combined with a lighted portion to display information apart from the edge-lighted message board.
It is another object to provide a display unit of two-piece housing construction having a face portion for display of lighted information and a back portion forming a compartment to contain and hide transformer and wiring components of the display unit.
BRIEF DESCRIPTION OF THE DRAWINGS
The above as well as other objects of the invention will become more apparent, and the invention will be better understood, from the following detailed description of preferred embodiments of the invention, when taken together with the accompanying drawings, in which:
FIG. 1 is a front elevation view of a first embodiment of an electric luminous display unit of the present invention;
FIG. 2 is a right side elevation view of the display unit of FIG. 1;
FIG. 3 is a front elevation view of the display unit of FIG. 1, with the glass tubing thereof removed to better show the grooves in and openings through the front face portion of the unit which receive and protect the tubing;
FIGS. 4 and 5 are front and rear elevation views, respectively, of the glass tubing, only, of the luminous display unit of FIG. 1;
FIG. 6 is a rear elevation view of the front face portion of the unit of FIG. 1, with the rear closure portion of the housing removed, showing electrical components and openings in the front face portion for receiving portions of the glass tubing therethrough;
FIG. 7a is an enlarged, broken-away, sectional view of a groove portion of the unit shown in FIG. 1 taken generally along line VII--VII looking in the direction of the arrows thereof, and showing the position and mounting of the glass tubing a groove of the display unit;
FIG. 7b is a broken-away, sectional view of a groove portion of the unit, as in FIG. 7a but showing alternate means for mounting the glass tubing in a groove of the display unit;
FIG. 8 in an enlarged, sectional view of the display unit of FIG. 1, taken generally along lines VIII--VIII looking in the direction of the arrows thereof, and showing internal components of the unit;
FIG. 9 is a front elevation view of another embodiment of the electrical luminous display unit of the present invention;
FIG. 10 is an enlarged, sectional view of the display unit of FIG. 9 taken generally along lines X--X and looking in the direction of the arrows;
FIG. 11 is a front elevation view of the display unit of FIG. 9, with the front panel covering a compartment of the unit removed to show the interior thereof; and
FIG. 12 is an enlarged, broken-away sectional view of a portion the unit of FIG. 11 taken along lines XII--XII and looking in the direction of the arrows thereof.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now more particularly to the drawings, FIGS. 1-8 show, in the various views, one embodiment of the present invention. As seen, the electrical luminous display unit 10 includes a support housing 12 having a substantially planar front face portion 14, and a rear closure portion 16, both formed of suitably rigid opaque plastic, such as a molded polystyrene resin, and of unitary construction. The front face portion 14 is substantanially planar except for; one or more elongated grooves 18, 20 for the receipt and protection of elongated glass tubing 22 for containing an inert gas, such as neon, which may be electrified to illuminate the tubing to convey visual information through transparent portions thereof. Substantially planar front face portion 14, in the area of closed off parts of characters, e.g., 90, does not have any cut-out portions, such as in Weigand, who, for example, removes the center from his "O" and the triangle from his "A". As shown, the visual information consists of block letters forming the word "OPEN" surrounded by a generally rectangular border of glass tubing. Finally, substantially planar front face portion 14 is recessed from a hollow lip 40 entirely surrounding the front of unit 10. Lip 40 protects glass tubing 22 from possibly hitting the window in which unit 10 may be placed as well as serves another function to be described below.
The glass tubing 22 for containing the inert gas is bent, as in a heat-shaping operation. In such shaping operation, a length of tubing, e.g., four feet, is suitably heated and bent in the shape of letters, e.g., OPEN. To separate and distinguish the letters, portions 22a of the length of tubing are bent to lie primarily in a plane separate from the plane of the letters of the message to be conveyed. These portions of tubing which are bent to lie in a separate plane, generally parallel to the plane of the letters, are called "transition" portions of the tubing. The transition portions 22a (FIGS. 4-6, and 8) are generally painted, or blacked out, to make them opaque and preclude passage of light therethrough.
Conventional electrical circuitry is present for operating the sign. End portions of the inert gas-containing tubing 22 are connected to electrodes 24 (FIGS. 6 and 8) which are in turn connected by electric wiring 26 to a transformer 28 which conventionally converts energy from a power source (not shown), such as a 110V electric power supply, to high voltage energy. The gas in the tubing is thus energized in conventional manner to illuminate the tubing and transmit light through the transparent portions thereof. Substantially planar front face 14, with its general lack of any open portions in areas 90, hides and protects the electrical circuitry and provide a much neater sign appearance since the background on which the sign is hung does not show through.
As best seen in FIGS. 1, 7a, 7b, and 8, the portion of glass tubing 22 forming the visual information "OPEN" surrounded by the border tubing is received within and protected by grooves 18, 20 of generally semicircular cross-section which contain and surround a major portion of the glass tubing. The face portion 14 and grooves 18, 20 thus provide an opaque background for the illuminated tubing and concentrate the light emitted therefrom in a forward direction toward a viewer. Location of the tubing in the grooves also provides protection for the tubing. The tubing 22 is suitably mounted and retained in the grooves 18, 20 by suitable fastening means, such as a silicone adhesive 23 (FIG. 7a), thin copper attachment wires, or clips 25 (FIG. 7b) attached to the face portion 14 in the grooves 18, 20.
To protect and hide the transition portions 22a of the glass tubing which lie in a plane behind the plane of the letters "OPEN" and inside the housing 12, portions of the grooves 18, 20 of the front face portion 14 of the unit 10 have elongated openings 18a, 20a therethrough (see FIGS. 3 and 6 ). These openings receive the transition portions 22a of the glass tubing therethrough for retention in the housing 12 of the unit, along with the electrical wiring 26, electrodes 24, and transformer 28 (see FIG. 8).
The rigid molded substantially planar front face of the unit portion 14 may be attached to the rear face by suitable means, such as fastening screws 29 spaced about the periphery of the unit. As shown in FIGS. 7A, 7B, and 8, edges 35 of rear portion 16 fit within the hollow portion of lip 40 to create a light- and element-tight seal. This seal results in a generally light-tight unit 10 which light and the elements cannot pass into except through openings 18a, 20a, which are substantially blocked by transitions 22a anyway. By having unit 10 generally black inside due to lack of light entry therein, the blending in of the transition elements with the black background will be substantially enhanced, thereby drastically improving the appearance of separation between characters or letters. If desired, in food service or outdoor use of the display unit, the face of the unit portion 14 may be further protected by a transparent cover 30 (FIG. 8).
FIGS. 7a, 7b, and 8 more particularly show the location and an arrangement for support of the glass tubing 18, 20 in the grooves by suitable adhesive 23 (FIG. 7a) or spring clip 25 (FIG. 7b). As seen, the groves are so dimensioned as to receive the full diameter of the tubing therein, thus protecting the tubes while emitted light from the tubes is concentrated and focused by the curved, non-rectangular walls of the groove in a forward-facing direction for view by the human eye.
Thus it can be seen that the display unit of FIGS. 1-8 provides a simplified, economical arrangement for supporting and protecting glass tubing and electrical components of a neon-type display sign, while providing improved visualization of the displayed information therefrom.
FIGS. 9-12 show a modified form of illuminated display unit of the present invention wherein the unit is in the form of an edge-lighted, information board for illuminating hand written information or other indicia thereon. In this embodiment, the display unit 40 comprises a support housing 42 consisting of an opaque sheet of suitably rigid plastic, such as a molded polystyrene resin, which is shaped as a front face portion to provide a flat central surface for receipt and support of a light-transmitting board 44 of rigid material, such as an acrylic plastic, on which information may be written by hand or by the placement of suitable indicia. The board 44 may have an opaque paint on its back face to facilitate light transmission through its front face.
As seen, surrounding the periphery of three sides of the rectangular board 44 and located in a continuous groove 46 in the peripheral portion of support housing 42 is an inert gas-containing glass tubing 48. As seen in FIGS. 10 and 12, the glass tubing 48 is received within peripheral groove 46 of the housing to lie approximately in the plane of the transparent display board 44 so as to provide edge lighting thereto, as well as to project border lighting of the board toward the viewer, while residing within the groove and below a peripheral rim 50 of housing 42 to be protected thereby. The tubing may be suitably supported in the groove, as by copper tie wires 52, and is spaced from the bottom of the grooves by spacer pads 54 of felt or the like. Alternatively, the tubing may be attached to the front face portion of the housing by adhesive or spring clip, as in the case of the tubing in the embodiment of FIGS. 1-8.
Located in the upper peripheral edge portion of the housing 42 is an elongated compartment 56 (FIG. 11), a front panel 58 (FIG. 9) which is slidingly received in grooves 60 to enclose end portions 62 of the glass tubing 48, electrodes 64, wiring 66, and a transformer 68 (FIG. 10) which supplies power to the unit. As seen in FIGS. 10 and 11, the housing compartment 56 is divided by a midwall 70 on which is supported the transformer 68 and a portion of the rear of the housing compartment is enclosed by a removable backplate 72.
As best seen in FIG. 12, the glass tubing 48 providing edge-lighting to the transparent display board 44 of the unit is recessed within the groove 46 with the rim 50 of the support housing providing additional protection for the tubing. Thus a continuous piece of glass tubing may be bent and shaped to not only provide edge-lighting and border lighting for the display board, but to backlight the front panel 58 of the compartment 56 on which more permanent visual information may be displayed, e.g., "SPECIALS", as seen.
Thus it can be seen from the foregoing detailed description of the disclosed embodiments, the present invention provides an electrical illuminated display unit of simplified and economic construction in which the illuminated tubing and electrical components of the unit may be supportably maintained within grooves of a molded plastic support housing and wherein the grooves and housing provide tubing protection and an opaque background to concentrate light emitted therefrom in a forward direction for viewing by an observer.
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An electric luminous display unit for conveying visual information including a housing comprising an opaque front face portion of substantially rigid molded plastic, an elongated groove in the front face portion of the housing, inert gas-containing glass tubing located in the groove and extending therealong, and electrical means located behind the front face portion of the housing and electrically connected to ends of the glass tubing for supplying electrical energy to illuminate the same.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of application Ser. No. 10/622,416, filed Jul. 18, 2003, entitled AUTOMATED ADAPTATION OF THE SUPPLY VOLTAGE OF A LIGHT-EMITTING DISPLAY ACCORDING TO THE DESIRED LUMINANCE, which prior application is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to light-emitting display array screens formed of an assembly of light-emitting diodes (LEDs). These are, for example, screens formed of organic diodes (“OLED”, for Organic Light-Emitting Display) or polymer diodes (“PLED”, for Polymer Light-Emitting Display). The present invention more specifically relates to the regulation of the supply voltage of the circuits controlling the LEDs of such screens.
2. Discussion of the Related Art
FIG. 1 shows an array screen comprised of n columns C 1 to C n and k lines L 1 to L k enabling addressing of n*k LEDs d, the anodes of which are connected to a column and the cathodes of which are connected to a line.
Line control circuits CL 1 , to CL k enable respectively biasing lines L 1 to L k . Only a single line is activated at a time, and is grounded. The non-activated lines are biased to a voltage V line .
Column control circuits CC 1 to CC n enable respective biasing of columns C 1 to C n . The columns addressing the LEDs which are desired to be activated are biased by a current to a voltage V col greater than the threshold voltage of the LEDs of the screen. The columns which are not desired to be activated are grounded.
An LED connected to the activated line and to a column biased to V col is then on and emits light. Voltage V line is provided to be sufficiently high so that the LEDs connected to the non-activated lines at voltage V col and to the columns are not conductive and do not emit light.
FIG. 2 shows a column control circuit CC and a line control circuit CL respectively addressing a column C and a line L connected to an LED d of the screen. Line control circuit CL comprises a power inverter 1 controlled by a line control signal φ L . Power inverter 1 comprises an NMOS transistor 2 enabling discharge of line L when φ L is high and a PMOS transistor 3 enabling charging line L to bias voltage V line when φ L is low.
Column control circuit CC comprises a current mirror formed in the present example with two transistors 4 , 5 of type PMOS. Transistor 4 forms the reference branch of the mirror and transistor 5 forms the duplication branch. The sources of transistors 4 and 5 are connected to a biasing voltage V pol on the order of 15 V for OLED screens. The gates of transistors 4 and 5 are connected to each other. The drain and the gate of transistor 4 are connected to each other. Transistor 4 is thus diode-assembled, the source-gate voltage (Vsg 4 ) being equal to the source-drain voltage (Vsd 4 ). The current conducted by transistor 4 is set by a current source 6 connected to the drain of transistor 4 . Current 6 provides a so-called “luminance” current I 1 . The drain of transistor 5 is connected to column C via a column selection circuit formed of a PMOS transistor 7 and of an NMOS transistor 8 . The source of PMOS transistor 7 is connected to the drain of transistor 5 and the drain of transistor 7 is connected to column C. The source of transistor 8 is grounded and its drain is connected to column C. A column control signal φ C is connected to the gate of PMOS transistor 7 and to the gate of NMOS transistor 8 . When column control signal φ C is high, transistor 8 discharges column C. When it is low, transistor 7 is on and column C charges to reach voltage V col . When line L and column C are activated, line control signal φ L and column control signal φ C are respectively high and low, LED d is on and the current flowing through the diode is equal to luminance current I 1 .
However, for column control circuit CC to operate as described previously, it is necessary for voltage V pol to be sufficiently high for the copy of current I 1 to be correct. Biasing voltage V pol is equal to the sum of source-drain voltage Vsd 2 of transistor 2 , of voltage V d across LED d, of source-drain voltage Vsd 7 of transistor 7 , and of source-drain voltage Vsd 5 of transistor 5 .
When the copy of current I 1 is correct, transistor 5 is in saturation state and voltage Vsd 5 is at least equal to source-drain voltage Vsd 4 of transistor 4 . A correct copy thus imposes requires for biasing V pol to be at least equal to the previously-mentioned sum when the current flowing therethrough is equal to luminance current I 1 . If biasing voltage V pol is too low, the current flowing through LED d is smaller than current I 1 and the luminance of the diodes is insufficient.
Luminance current I 1 provided by current source 6 may generally vary according to the luminance desired for the screen. When luminance current I 1 increases, source-drain voltage Vsd 4 of diode-assembled transistor 4 increases and voltage V d of light-emitting diode d also increases. As a result, biasing voltage V pol must be sufficiently high for transistor 5 to be in saturation whatever the luminance current.
However, in a concern for electric power saving, biasing voltage V pol is desired to be reduced, which then enables reducing voltage V line of the line control circuits.
There exist control circuits which have a fixed biasing voltage V pol determined according to the maximum desired luminance current I 1 . The disadvantage of such circuits is their large electric power consumption.
There exist other control circuits for which biasing voltage V pol varies according to the desired luminance current I 1 . If current I 1 is low, voltage Vpol is low, and conversely. However, it is necessary to provide a security margin to take the aging of the LEDs of the screen into account. Indeed, for an equal current in LED d, voltage V d across the diode increases along time. For a same luminance, the necessary minimum biasing voltage V pol thus progressively increases along time. The power savings obtained for these circuits are thus not optimal.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a column control circuit, biasing voltage V pol of which is as small as possible whatever the aging of the LEDs of the screen.
Another object of the present invention is to provide a control circuit of simple structure.
To achieve these objects, the present invention provides a device for regulating the biasing voltage of column control circuits of an screen array made of LEDs distributed in lines and columns, the column control circuits comprising a current mirror having a reference branch and several duplication branches connected to the biasing voltage, each duplication branch being coupled to a column of the screen, the reference branch being connected at a reference node to a reference current source providing a desired luminance current, said device comprising: first measuring means providing a first signal representative of the voltage of at least one of the columns; second measuring means providing a second signal representative of the voltage of the reference node; and an adjustment circuit receiving the first and second signals and being adapted to increase the biasing voltage when the first signal is higher than the second signal and conversely.
According to an embodiment of such a device, each branch of the current mirror includes a PMOS field effect transistor, having a source connected to the biasing voltage, the gates of each branch being connected together, the drain and the gate of the transistor of the reference branch being connected to the reference current source, the drains of the transistors of the duplication branches being connected to the columns.
According to an embodiment of such a device, first measuring means comprise for each column a diode having an anode connected to the column and having an cathode connected to a first observation current source and to a first input of the adjustment circuit, and wherein the second measuring means comprise a diode having an anode connected to the reference node and a cathode connected to a second observation current source and to a second input of the adjustment circuit.
According to an embodiment of such a device, the cathodes of all the diodes are connected to the first input of the adjustment circuit by a switch, a capacitor being connected between the first input of the adjustment circuit and a fixed voltage node.
According to an embodiment of such a device, the adjustment circuit comprises an error amplifier receiving the first signal on a positive input and receiving the second signal on a negative input, an output of error amplifier being connected to a D.C./D.C. voltage converter outputting the biasing voltage and being adapted to increase the biasing voltage when the first signal is higher than the second signal and conversely.
According to an embodiment of such a device, error amplifier comprises first and second PMOS transistors having their gates respectively connected to positive and negative inputs of the error amplifier, the source of each one of the first and second transistors being connected to the biasing voltage by a current source, the sources of first and second transistors being connected by a resistor, the drains of first and second transistors being connected to a converter providing the error signal, the source and drain of a third PMOS transistor being connected to the source and drain of the first transistor, the gate of the third transistor being connected to a fixed voltage.
The present invention also provides a method for regulating the biasing voltage of column control circuits of an screen array made of LEDs distributed in lines and columns, the column control circuits comprising a current mirror having a reference branch and several duplication branches connected to the biasing voltage, each duplication branch being coupled to a column of the screen, the reference branch being connected at a reference node to a reference current source providing a desired luminance current, comprising the following steps: providing a first signal representative of the voltage of at least one of the columns; providing a second signal representative of the voltage at the reference node; and increasing the biasing voltage when the first signal is higher than the second signal and conversely.
According to an embodiment of such a device, the first signal is an image of the maximum voltage of the activated LEDs.
The foregoing objects, features and advantages of the present invention, will be discussed in detail in the following non-limiting description of specific embodiments in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 , previously described, shows a light-emitting array display;
FIG. 2 , previously described, shows a column control circuit and a line control circuit addressing a an LED of a screen;
FIG. 3 illustrates an exemplary embodiment of the regulation device according to the present invention;
FIG. 4 illustrates a more detailed embodiment of the device of FIG. 3 ;
FIG. 5 illustrates another exemplary embodiment of the regulation device according to the present invention; and
FIG. 6 illustrates an embodiment of one element of the device of FIG. 4 .
DETAILED DESCRIPTION
FIG. 3 is a diagram of an embodiment of column control circuits and of the device for regulating biasing voltage V pol according to the present invention. The column control circuits comprise a current mirror 9 formed of a reference branch b ref and of n duplication branches b 1 to b n . Each branch is formed of a PMOS transistor, P ref for the reference branch and P 1 to P n for branches b 1 to b n . The sources of the transistors of each of the branches are connected to biasing voltage V pol and the gates are connected to one another. The drain and the gate of transistor P ref of the reference branch are connected to a reference current source 10 at a node C ref . Reference current source 10 provides a luminance current I 1 . The drain of each transistor P i , i ranging between 1 and n, is connected to a column C i of the screen via a column selection circuit such as described in relation with FIG. 2 . All the column selection circuits are represented by a selection device 11 controlled by a column signal φ C .
Each column C 1 , to C n is connected to the anode of a diode, respectively D 1 to D n . The cathodes of diodes D 1 to D n are connected to a current source 15 at a node C o . Current source 15 provides a so-called observation current I ob selected to be small as compared to the minimum luminance current. Further, connection node C ref is connected to the anode of a diode D ref identical to diodes D 1 to D n , the cathode of diode D ref is connected at a node C oref to a current source 16 providing a current equal to observation current I ob . Nodes C ref and C o are connected to two inputs of an adjustment circuit CR which provides biasing voltage V pol .
As indicated previously, the LEDs may, even when run through by a same current, exhibit across their terminals different voltage drops. Especially, this voltage drop tends to increase when the LEDs age. The present invention aims at adjusting voltage V pol to take these voltage variations into account and ensure that the chosen luminance current I 1 flows through all the selected columns, V pol remaining as small as possible.
Diodes D 1 to D n corresponding to the selected columns tend to be conductive. However, the diode connected to the column having the highest voltage imposes voltage V o on the cathodes of diodes D 1 to D n . The other diodes are thus not conductive since the voltage thereacross is smaller than their threshold voltage. Voltage V o is the image of the voltage on the column having the highest voltage shifted by diode threshold voltage. Similarly, voltage V oref at connection node C oref is the image of voltage V ref shifted by a diode threshold voltage.
When voltage V o is greater than voltage V oref , this means that the current in at least one of the screen columns is smaller than the chosen luminance current I 1 . Adjustment circuit CR then raises biasing voltage V pol until voltages V o and V oref are equal.
Conversely, when voltage V o is smaller than V oref , this implies that the chosen luminance current I 1 does flow through all the selected columns but that voltage V pol is too high, which results in a power overconsumption. To make electric power savings, the adjustment circuit decreases biasing voltage V pol down to the minimum voltage V pol ensuring a flow of luminance current I 1 in all the selected columns.
FIG. 4 is a diagram of the circuit for adjusting biasing voltage V pol according to the difference between voltages V o and V oref .
The adjustment circuit comprises an error amplifier 20 , an operational amplifier 21 , and an RS flip-flop 22 operating with a low supply voltage, for example, 3.3 V. Error amplifier 20 receives on a positive input voltage V o and on a negative input voltage V oref . In the case when the levels of voltages V o and V oref are very high for error amplifier 20 , a voltage converter providing voltages proportional to voltages V o and V oref over a lower voltage range may be provided.
Error amplifier 20 amplifies the difference between V o and V oref and provides an error signal er which varies for example between 1 and 2 V. When voltages V o and V oref are equal, the error signal is for example 1.5 V. The higher voltage V o with respect to V oref , the higher signal er, and conversely. Signal er is applied to the positive input of differential amplifier 21 . The output of differential amplifier 21 is connected to reset terminal R of RS flip-flop 22 . The output of an oscillator osc is connected to set terminal S of RS flip-flop 22 . Terminal Q is at a high logic level (for example, 3.3 volts) when set terminal S is high and is at a low logic level (for example, 0 V) when reset terminal R is high. When both set terminal S and reset terminal R are low, output Q keeps the last positioned level.
The output of RS flip-flop 22 is connected to the gate of an NMOS transistor Tf. A resistor R is connected between the source of transistor Tf and the ground. A coil L is connected between the drain of transistor Tf and the supply terminal at a voltage V bat , for example, at 3.3 V. The anode of a diode Df is connected to the drain of transistor Tf and its cathode is connected to a first electrode of a capacitor C. The second electrode of capacitor C is grounded. The first electrode of capacitor C provides voltage V pol . The source of transistor Tf is connected to the negative input of differential amplifier 21 .
On a rising edge of the signal of oscillator osc, output Q of RS flip-flop 22 switches high. Transistor Tf turns on and the voltage across coil L rapidly switches from 0 to V bat . Voltage VR across resistor R and the current through coil L are initially zero. The current in coil L progressively increases, and voltage VR thus also increases. When voltage VR reaches signal er of differential amplifier 20 , amplifier 21 switches high. Output Q of RS flip-flop 22 switches low and transistor Tf turns off. The voltage on the drain of transistor Tf abruptly increases. Diode Df turns on and capacitor C charges. The charge current is all the higher as the current flowing through coil L is high at the time when transistor Tf turns off.
At the next rising edge of oscillator osc, output Q of RS flip-flop 22 switches high again and a cycle identical to that previously described starts again.
When voltage V o is greater than voltage V oref , signal er is relatively high. Accordingly, transistor Tf remains on longer and the current flowing through coil L at the turn-off time of transistor Tf is significant. Capacitor C charges and voltage V pol increases. Conversely, when voltage V o is smaller than voltage V oref , voltage V pol decreases.
Biasing voltage V pol is thus adjusted according to the time variations of the voltage across the LEDs of the screen.
An advantage of the regulation device according to the present invention is that the biasing voltage is always minimum, which saves power.
Another advantage of such a device is that its design is very simple.
Of course, the present invention is likely to have various alterations, modifications, and improvements which will readily occur to those skilled in the art. In particular, other devices for evaluating the current flowing through the LEDs of the screen, as well as other devices for adjusting biasing voltage V pol according to the differences between the desired luminance current and the smallest current flowing through the LEDs of the screen, may be provided. Other D.C./D.C. voltage converters capable of providing a high biasing voltage V pol when error signal er is high and conversely may especially be used. Further, those skilled in the art will know how to make a current mirror different from that described, by using, for example, two transistors per branch.
FIG. 5 illustrates column control circuits similar to those of FIG. 3 , and a modified embodiment of the device for regulating biasing voltage V pol which solves the following problem. When a screen line is “black”, meaning that no LED of the selected line is conductive, the voltage V o at node C□C o of the regulation circuit of FIG. 3 decreases because none of the diodes D 1 to D n is on. When voltage V o decreases, the adjustment circuit CR decreases biasing voltage V pol . When a large number of consecutive screen lines are black, the biasing voltage V pol can strongly decrease. The conductive LEDs of bright lines may receive a current lower than the luminance current. The global luminance of the screen decreases.
In this modified embodiment, the device for regulating the biasing voltage V pol is similar to the one of FIG. 3 , except that the node C o is linked to the adjustment circuit CR by a switch 31 . Besides, a capacitor 32 is connected between the input of adjustment circuit CR and ground. Switch 31 is controlled so as to be non conductive when a screen line is black, i.e. when no LED of the selected line is conductive. Capacitor 32 holds the value of the voltage V o corresponding to the last non-black line. The switch control device, not shown, analyzes the column signal φ c to detect if at least one column is selected, meaning that at least one diode is conductive. Moreover, according to a more sophisticated embodiment, the switch control device analyzes the control signals of the line control circuits in such a way that switch 31 is turned on once the voltages of selected columns have changed from their precharge voltages to their operating voltages corresponding to the voltages induced by each one of the conductive LEDs.
An advantage of such a regulation device is that it is possible to adjust the biasing voltage V pol according to the features of the LEDs of the screen whatever the number of consecutive black screen lines is.
FIG. 6 is a diagram of an embodiment of the error amplifier 20 of the adjustment circuit CR of FIG. 4 which solves the following problem. When the screen or the column or line control circuits include manufacture defects, or an aging defect, corresponding to a cut between the LED and a column or a line, the voltage V o can be very close to the biasing voltage V pol . Such a defect leads not only to a drastic increase of the biasing voltage V pol , but also to overvoltages likely to damage the adjustment circuit CR. In case of an aging defect, it can be interesting to detect the defect in order to avoid damaging the rest of the circuit and to avoid increasing the power consumption to produce a high voltage V pol . The detection of a manufacture defect enables the detection of failing circuits before commercialization.
The error amplifier represented in FIG. 6 includes two PMOS transistors 40 and 41 the gates of which receive voltages V o and V oref respectively from the regulation device represented in FIG. 3 . Two identical current sources 42 and 43 are connected between the biasing voltage source V pol and the sources of transistors 40 and 41 . A resistor R 1 is connected between the sources of transistors 40 and 41 . The drains of transistors 40 and 41 are linked to a conversion device 44 , which provides the error signal er. A PMOS transistor 45 is connected in parallel with the transistor 40 . The source of transistor 45 is connected to the source of transistor 40 and the drain of transistor 45 is connected to the drain of transistor 40 . The gate of transistor 45 receives a “protection” voltage V protect which is produced by a device not shown. The protection voltage V protect corresponds to the maximum voltage V o corresponding to a correct operation of the screen and of the column and line control circuits.
During normal operation, with no defect in the circuit, the voltage V o is lower than protection voltage V protect . Transistors 40 , 41 and 45 conduct a current equal to the current provided by current sources 42 and 43 , their gate-source voltages being substantially equal to the threshold voltage of a PMOS transistor. Thus, when voltage V o is lower than voltage V protect , transistor 45 is non conductive. Similarly, when voltages V o and V oref are different, voltages on the sources of transistors 40 and 41 are different. The current flowing through resistor R 1 increases when the difference between voltages V o and V oref increases. Conversion device 44 analyzes the current differences in transistors 40 and 41 and provides an error signal er which is high when the current in transistor 40 is low compared to the current in transistor 41 and conversely.
When the circuit has a defect, voltage V o can be very close to biasing voltage V pol . When voltage V o is higher than the protection voltage V protect , transistor 45 is turned on and transistor 40 off. The biasing voltage V pol is then maximum. The maximum value of voltage V pol depends upon the choice of voltage V protect and voltage V oref which varies according to the desired luminance current. Thanks to transistor 45 , it is sure that biasing voltage V pol will not go over a maximum given value, and overvoltages which could damage adjustment circuit CR are suppressed.
Such alterations, modifications, and improvements are intended to be part of this disclosure, and are intended to be within the spirit and the scope of the present invention. Accordingly, the foregoing description is by way of example only and is not intended to be limiting. The present invention is limited only as defined in the following claims and the equivalents thereto.
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A method for regulating the biasing voltage of column control circuits of an array screen formed of LEDs distributed in lines and columns, the column control circuits being adapted to turning on at least one LED of a line. The method includes increasing the biasing voltage when the current flowing through at least one activated LED is smaller than a determined luminance current and of decreasing the biasing voltage when the current flowing through each activated LED is equal to the determined luminance current.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims benefit of U.S. provisional application serial No. 60/332,490, filed Nov. 16, 2001, which is herein incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to the field of hydrodynamic motors for disc drive data storage devices and, more particularly, to a spindle motor with one or more bearing surfaces having a wear resistant coating thereon.
[0004] 2. Description of the Related Art
[0005] Disc drive data storage devices, known as “Winchester” type disc drives, are well-known in the industry. In a Winchester disc drive, digital data is written to and read from a thin layer of magnetizable material on the surface of rotating discs. Write and read operations are performed through a transducer that is carried in a slider body. The slider and transducer are sometimes collectively referred to as a head, and typically a single head is associated with each disc surface. The heads are selectively moved under the control of electronic circuitry to any one of a plurality of circular, concentric data tracks on the disc surface by an actuator device. Each slider body includes a self-acting air bearing surface. As the disc rotates, the disc drags air beneath the air bearing surface, which develops a lifting force that causes the slider to lift and fly several microinches above the disc surface.
[0006] In the current generation of disc drive products, the most commonly used type of actuator is a rotary moving coil actuator. The discs themselves are typically mounted in a “stack” on the hub structure of a brushless DC spindle motor. The rotational speed of the spindle motor is precisely controlled by motor drive circuitry, which controls both the timing and the power of commutation signals directed to the stator windings of the motor. Typical spindle motor speeds have been in the range of 3600 RPM. Although, current technology has increased spindle motor speeds to 7200 RPM, 10,000 RPM, 15,000 RPM and above.
[0007] One of the principal sources of noise in disc drive data storage devices is the spindle motor. Disc drive manufacturers have recently begun looking at replacing conventional ball or roller bearings in spindle motors with “hydro” bearings, such as hydrodynamic or hydrostatic bearings. A hydrodynamic bearing relies on a fluid film which separates the bearing surfaces and is therefore much quieter and in general has lower vibrations than conventional ball bearings. A hydrodynamic bearing is a self-pumping bearing that generates a pressure internally to maintain the fluid film separation. A hydrostatic bearing requires an external pressurized fluid source to maintain the fluid separation. Relative motion between the bearing surfaces in a hydrodynamic bearing causes a shear element that occurs entirely within the fluid film such that no contact between the bearing surfaces occurs.
[0008] In a hydrodynamic bearing, a lubricating fluid or gas provides a bearing surface between, for example, a stationary member of the housing and a rotating member of the disc hub. Typical lubricants include oil or ferromagnetic fluids. Hydrodynamic bearings spread the bearing surface over a larger surface area in comparison with a ball bearing assembly, which comprises a series of point interfaces. This is desirable because the increased bearing surface decreases wobble or run-out between the rotating and fixed members.
[0009] Despite the presence of the lubricating fluid, in conventional hydrodynamic bearing spindle motors, the bearing surfaces are still subject to continuous wear. As a result, the gap between bearing surfaces gradually changes over the lifetime of the device, and often in a manner that is not uniform across the bearing surfaces. This results in reduced performance and eventual failure of the disk drive. Additionally, for a gas lubricated hydrodynamic bearing, low frictional properties for the bearing surfaces is also required.
[0010] Therefore, there exists a need in the art for a hydrodynamic fluid bearing surfaces having improved wear resistance as well as low frictional properties.
SUMMARY OF THE INVENTION
[0011] The disc drive data storage system of the present invention includes a housing having a central axis, a stationary member that is fixed with respect to the housing and coaxial with the central axis, and a rotatable member that is rotatable about the central axis with respect to the stationary member. A stator is fixed with respect to the housing. A rotor is supported by the rotatable member and is magnetically coupled to the stator. At least one data storage disc is attached to and is coaxial with the rotatable member. A hydrodynamic bearing couples the stationary member to the rotatable member. The hydrodynamic bearing includes at least one working surface with a wear resistant coating thereon.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] So that the manner in which the above recited features of the present invention are attained and can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to the embodiments thereof which are illustrated in the appended drawings.
[0013] It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
[0014] [0014]FIG. 1 is a top plan view of a disc drive data storage device in accordance with the present invention;
[0015] [0015]FIG. 2 is a sectional view of a hydrodynamic bearing spindle motor in accordance with the present invention;
[0016] [0016]FIG. 3 is a diagrammatic sectional view of the hydrodynamic bearing spindle motor taken along the line 3 - 3 of FIG. 2, with portions removed for clarity;
[0017] [0017]FIG. 4 is a close up view of FIG. 3, showing wear resistant coatings formed on one or more working surfaces of the hydrodynamic bearing; and
[0018] [0018]FIG. 5 is a sectional view of a hydrodynamic bearing with conical bearing surfaces.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0019] The present invention is a disc drive data storage device having a hydrodynamic bearing spindle motor in which one or more bearing surfaces have a wear resistant coating thereon. FIG. 1 is a top plan view of a disc drive 10 in which the present invention is useful. Disc drive 10 includes a housing base 12 that is combined with top cover 14 to form a sealed environment to protect the internal components from contamination by elements from outside the sealed environment.
[0020] Disc drive 10 further includes a disc pack 16 , which is mounted for rotation on a spindle motor (not shown) by a disc clamp 18 . Disc pack 16 includes a plurality of individual discs, which are mounted for co-rotation about a central axis. Each disc surface has an associated head 20 , which is mounted to disc drive 10 for communicating with the disc surface. In the example shown in FIG. 1, heads 20 are supported by flexures 22 , which are in turn attached to head mounting arms 24 of an actuator body 26 . The actuator shown in FIG. 1 is of the type known as a rotary moving coil actuator and includes a voice coil motor (VCM), shown generally at 28 . Voice coil motor 28 rotates actuator body 26 with its attached heads 20 about a pivot shaft 30 to position heads 20 over a desired data track along an arcuate path. While a rotary actuator is shown in FIG. 1, the present invention is also useful in disc drives having other types of actuators, such as linear actuators.
[0021] [0021]FIG. 2 is a sectional view of a hydrodynamic bearing spindle motor 32 in accordance with the present invention. Spindle motor 32 includes a stationary member 34 , a hub 36 and a stator 38 . In the embodiment shown in FIG. 2, the stationary member is a shaft that is fixed and attached to base 12 through a nut 40 and a washer 42 . Hub 36 is interconnected with shaft 34 through a hydrodynamic bearing 37 for rotation about shaft 34 . Bearing 37 includes radial working surfaces 44 and 46 and axial working surfaces 48 and 50 . Shaft 34 includes fluid ports 54 , 56 and 58 that supply lubricating fluid 60 and assist in circulating the fluid along the working surfaces of the bearing. Lubricating fluid 60 is supplied to shaft 34 by a fluid source (not shown) that is coupled to the interior of shaft 34 in a known manner.
[0022] Spindle motor 32 further includes a thrust bearing 45 , which forms the axial working surfaces 48 and 50 of hydrodynamic bearing 37 . A counterplate 62 bears against working surface 48 to provide axial stability for the hydrodynamic bearing and to position hub 36 within spindle motor 32 . An O-ring 64 is provided between counterplate 62 and hub 36 to seal the hydrodynamic bearing. The seal prevents hydrodynamic fluid 60 from escaping between counterplate 62 and hub 36 .
[0023] Hub 36 includes a central core 65 and a disc carrier member 66 , which supports disc pack 16 (shown in FIG. 1) for rotation about shaft 34 . Disc pack 16 is held on disc carrier member 66 by disc clamp 18 (also shown in FIG. 1). A permanent magnet 70 is attached to the outer diameter of hub 36 , which acts as a rotor for spindle motor 32 . Core 65 is formed of a magnetic material and acts as a back-iron for magnet 70 . Rotor magnet 70 can be formed as a unitary, annular ring or can be formed of a plurality of individual magnets that are spaced about the periphery of hub 36 . Rotor magnet 70 is magnetized to form one or more magnetic poles.
[0024] Stator 38 is attached to base 12 and includes stator laminations 72 and stator windings 74 . Stator windings 74 are attached to laminations 72 . Stator windings 74 are spaced radially from rotor magnet 70 to allow rotor magnet 70 and hub 36 to rotate about a central axis 80 . Stator 38 is attached to base 12 through a known method such as one or more C-clamps 76 which are secured to the base through bolts 78 .
[0025] Commutation pulses applied to stator windings 74 generate a rotating magnetic field that communicates with rotor magnet 70 and causes hub 36 to rotate about central axis 80 on bearing 37 . The commutation pulses are timed, polarization-selected DC current pulses that are directed to sequentially selected stator windings to drive the rotor magnet and control its speed.
[0026] In the embodiment shown in FIG. 2, spindle motor 32 is a “below-hub” type motor in which stator 38 has an axial position that is below hub 36 . Stator 38 also has a radial position that is external to hub 36 , such that stator windings 74 are secured to an inner diameter surface 82 (FIG. 3) of laminations 72 . In an alternative embodiment, the stator is positioned within the hub, as opposed to below the hub. The stator can have a radial position that is either internal to the hub or external to the hub. In addition, while FIG. 2 depicts a spindle motor with a fixed shaft, the spindle motor may have a rotating shaft. In this case, the bearing is located between the rotating shaft and an outer stationary sleeve that is coaxial with the rotating shaft.
[0027] [0027]FIG. 3 is a diagrammatic sectional view of hydrodynamic spindle motor 32 taken along line 3 - 3 of FIG. 2, with portions removed for clarity. Stator 38 includes laminations 72 and stator windings 74 , which are coaxial with rotor magnet 70 and central core 65 . Stator windings 74 include phase windings W 1 , V 1 , U 1 , W 2 , V 2 and U 2 that are wound around teeth in laminations 72 . The phase windings are formed of coils that have a coil axis that is normal to and intersects central axis 80 . For example, phase winding W 1 has a coil axis 83 that is normal to central axis 80 . Radial working surfaces 44 and 46 of hydrodynamic bearing 37 are formed by the outer diameter surface of shaft 34 and the inner diameter surface of central core 65 . The shaft 34 and central core 65 may be constructed of a metal such as, for example, steel or aluminum. Radial working surfaces 44 and 46 are separated by a lubrication fluid, which maintains a clearance c during normal operation.
[0028] [0028]FIG. 4 depicts a close-up sectional view of the hydrodynamic spindle motor 32 of FIG. 3. Either or both radial working surfaces 44 and 46 of hydrodynamic bearing 37 are treated with a wear resistant, low frictional coatings 44 c and 46 c . Wear resistant coatings 44 c and 46 c improve the wear resistance of radial working surfaces 44 and 46 by making working surfaces 44 and 46 more physically durable. Metal particle generation due to wear is reduced, resulting in much less mechanical failure of working surfaces 44 and 46 . The wear resistant and low frictional coatings 44 c and 46 c provide improved wear resistance and generally provide for a clearance c that remains constant throughout the lifetime of the spindle motor.
[0029] The wear resistant coatings 44 c and 46 c may comprise, for example, amorphous carbon, diamond-like carbon, or combinations thereof. The wear resistant coating may have a thickness in the range of about 100 nanometers to about 5 microns. The preferred thicknesses of wear resistant coatings 44 c and 46 c are dependent upon factors such as the composition of the outer diameter of shaft 34 and inner diameter of central core 65 , the magnitude of clearance c, surface roughness and loading, among others.
[0030] In one embodiment, wear resistant low frictional coatings 44 c and 46 c are deposited by physical vapor deposition (PVD), such as by a sputtering process. In another embodiment, wear resistant coatings 44 c and 46 c are deposited by chemical vapor deposition (CVD), such as plasma enhanced chemical vapor deposition (PECVD). In another embodiment, wear resistant coatings 44 c and 46 c are deposited by ion beam deposition. The wear resistant coating may also be sputtered in the presence of, for example, hydrogen (H 2 ) or nitrogen (N 2 ) to enhance the wear resistance and frictional properties thereof.
[0031] While FIG. 4 depicts wear resistant coatings 44 c and 46 c as consisting of only one layer, it is within the scope of the invention for wear resistant coatings 44 c and 46 c to consist of multiple coating layers. It is often desirable for wear resistant coatings 44 c and 46 c to consist of multiple layers in order to provide optimal adhesion, reduce crack propagation and to improve corrosion resistance of the shaft 34 and the central core 65 . In one embodiment, wear resistant coatings 44 c and 46 c comprise two or more layers of carbon. In one embodiment, wear resistant coatings 44 c and 46 c comprise a layer of silicon carbide.
[0032] In one embodiment, one or more adhesive layers 44 i and 46 i are deposited on the outer diameter of shaft 34 and inner diameter of central core 65 , respectively, prior to depositing wear resistant coatings 44 c and 46 c . Adhesive layers 44 i and 46 i provide improved adhesion and mechanical properties for the wear resistant coatings 44 c and 46 c to outer diameter of shaft 34 and inner diameter of central core 65 . Adhesive layers may comprise, for example, chromium, silicon, titanium, zirconium, silicon carbide, and combinations thereof.
[0033] In another embodiment, one or more adhesion layers 44 i and 46 i may be used in combination with one or more wear resistant coatings 44 c and 46 c . For example, an adhesion layer may be used in combination with a wear resistant layer and a wear resistant, low frictional layer.
[0034] The thickness of adhesive layers 44 i and 46 i may be in the range of about 1 nanometer to about 1 micron. The preferred thickness of adhesive layers 44 i and 46 l is dependent upon factors similar to those enumerated above for the wear resistant coatings 34 c and 36 c . In one embodiment, either or both outer diameter surface of shaft 34 and the inner diameter surface of central core 65 are treated with a nickel or nickel phosphide plating solution prior to depositing adhesive layers 44 i and 46 i or wear resistant layers 44 c and 46 c . Electroless nickel plating solutions may also be used.
[0035] In one embodiment, adhesive layers 44 i and 46 i are deposited by physical vapor deposition (PVD), such as by a sputtering process. In another embodiment, adhesive layers 44 i and 46 i are deposited by chemical vapor deposition (CVD), such as plasma enhanced chemical vapor deposition (PECVD). In another embodiment, adhesive layers 44 i and 46 i are deposited by ion beam deposition.
[0036] In one embodiment, the substrate is etched prior to depositing the adhesive layer and the wear resistant coating. In the case where no adhesive layer is deposited, the substrate may be etched prior to depositing the wear resistant coating. The substrate may be etched, for example, by a plasma etching process. The plasma etching process may comprise bombarding the substrate with ions of an inert gas such as, for example, argon.
[0037] Alternatively or in addition to wear resistant coatings 44 c and 46 c deposited on the outer diameter of shaft 34 and inner diameter of central core 65 , wear resistant coatings may be deposited upon other working surfaces of the spindle motor, such as, for example, axial working surface 48 on thrust bearing 45 or on lower surface 69 of counterplate 62 , shown in FIG. 2. Optionally, adhesive layers, such as those discussed above, may be deposited prior to the deposition of the wear resistant low frictional coatings.
EXAMPLE 1
[0038] An adhesive layer was deposited on a steel substrate. The adhesive layer comprised chromium. The adhesive layer was deposited by a sputtering process, in which an inert gas sputtered material from a chromium target. An adhesive layer having a thickness of about 0.3 microns to about 0.5 microns was deposited.
[0039] A wear resistant low frictional coating was deposited on the chromium adhesive layer. The wear resistant coating comprised carbon. The wear resistant coating was deposited by a sputtering process, in which an inert gas sputtered material from a carbon target. A wear resistant coating having a thickness of about 1.5 microns to about 2 microns was deposited. The wear resistant coating exhibited excellent adhesion to the substrate.
EXAMPLE 2
[0040] An adhesive layer was deposited on a steel substrate. The adhesive layer comprised silicon. The adhesive layer was deposited by a sputtering process in which an inert gas sputtered material from a silicon substrate. An adhesive layer having a thickness of about 0.3 microns to about 0.5 microns was deposited.
[0041] A wear resistant low friction coating was deposited on the silicon adhesive layer. The wear resistant coating comprised carbon. The wear resistant coating was deposited by a sputtering process in which an inert gas sputtered material from a carbon target. A wear resistant coating having a thickness of about 1.5 microns to about 2 microns was deposited. The wear resistant coating exhibited excellent adhesion to the substrate.
[0042] The use of wear resistant and adhesive layers for improved wear performance is not limited to thrust bearing designs described above. Wear resistant and adhesive coatings may be used, for example, with spindle motors having bearing surfaces of other geometries known to the art. Conical and spherical bearing surfaces may be coated with the wear resistant coating of the present invention to reduce wear on the bearing surfaces.
[0043] Referring to FIG. 5, a hydrodynamic bearing is shown with conical bearing surfaces, which is usable to drive the discs in the disc drive 10 of FIG. 1. The hydrodynamic bearing is shown incorporated in a spindle motor 150 . The design includes a drive rotor or hub 114 rotatably coupled to a shaft 152 . The shaft 152 includes an upper hemisphere or convex portion 154 and a lower hemisphere or convex portion 156 received in a sleeve 158 which rotates relative to the shaft. The shaft is fixedly attached to a base 160 , which may be incorporated in or supported from the housing base 12 described with respect to FIG. 1. The sleeve 158 receives the journal 162 of shaft 152 and has upper hemisphere shaped, concave receptacle 164 and lower hemisphere shaped concave receptacle 166 . A fill hole 168 is also provided to a reservoir 159 in (as drawn, the upper end) fixed member 152 , to provide bearing fluid to the hydrodynamic bearing. The rotor 114 includes a counterplate 170 , which is used to close off one end of the hydrodynamic bearing to the atmosphere. In operation, the bearings shown in this figure comprise hydrodynamic bearings in which fluid such as oil circulates through gaps between the fixed member, which is the shaft and the rotating member, which in this case is the sleeve. One or more of these bearing surfaces may also be coated with the wear resistant layers of the present invention.
[0044] While foregoing is directed to the preferred embodiment of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.
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A disc drive storage system including a housing having a central axis, a stationary member that is fixed with respect to the housing and coaxial with the central axis, and a rotatable member that is rotatable about the central axis with respect to the stationary member is described. A hydrodynamic bearing interconnects the stationary member and the rotatable member and includes at least one working surface comprising a wear resistant coating.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional application No. 62/066,240, filed on Oct. 20, 2014, which is entitled “SELF-ALIGNING CLAMPS FOR SECURING SOLAR ENERGY PANELS,” to U.S. Provisional application No. 62/066,243, filed on Oct. 20, 2014, which is entitled “METHOD OF INSTALLING A ROOF FLASHING,” and to U.S. Non-provisional application Ser. No. 14/887,231, filed Oct. 19, 2015, which is entitled “CLAMPS FOR SECURING SOLAR ENERGY PANELS,” each of which are expressly incorporated by reference herein in their entireties.
TECHNICAL FIELD
[0002] The present technology pertains to solar panel mounts, and more specifically pertains to self-aligning clamps for securing solar energy panels.
BACKGROUND
[0003] As solar energy becomes more economical to produce electricity for direct consumption, more solar energy systems are being installed on rooftops. Typically, components of the solar energy systems such as solar panels are installed using conventional mounting structures. However, conventional mounting structures typically require precise dimensions and can result in excessive material and extensive installation time.
SUMMARY
[0004] Additional features and advantages of the disclosure will be set forth in the description which follows, and in part will be obvious from the description, or can be learned by practice of the herein disclosed principles. The features and advantages of the disclosure can be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. These and other features of the disclosure will become more fully apparent from the following description and appended claims, or can be learned by the practice of the principles set forth herein.
[0005] Some embodiments of the present technology involve a clamp assembly for mounting solar panels and accessories. The clamp assemblies can include a top clamp with a substantially planar plate, raised flanges that extend away from the plate in opposite directions than the first raised flange; a geometric protrusion extending downward from the plate, and an aperture disposed through the plate and the geometric protrusion. The geometric protrusion of the top plate mates with a geometric cavity in a bottom clamp so that the top and bottom clamps self-align, thereby facilitating installation of a solar panel.
[0006] The bottom clamp can involve a base member having the geometric cavity disposed therein, flanges extending away from a lower surface of the base member in opposite directions and a bottom clamp aperture extending through the base member. The base member can also involve a geometric cavity in its top surface.
[0007] The top clamp and the bottom clamp are configured to freely rotate about a fastener inserted through the top clamp aperture and the bottom clamp aperture. However, when compressed enough, the geometric protrusion of the top plate mates with a geometric cavity in a bottom clamp so that the top and bottom clamps self-align. Also, in some embodiments, the top clamp aperture and the bottom clamp aperture are configured as a slot for allowing the top clamp and bottom clamp to adjust laterally without moving the fastener when the fastener is fixed to a particular location. The free rotation, the self-alignment, and the ability to laterally adjust the clamps are some of the features that facilitate installation of a solar panel.
[0008] The clamp assembly can include protrusions in the bottom clamp that act as a fulcrum for reducing toque on a fastener and for defining additional clamping surfaces for solar panel accessories, etc.
[0009] In some embodiments of the present technology, top and bottom flanges are substantially symmetrical on either side of the assembly, thereby enabling universal clamps. In some embodiments, the one base flange is angled upward toward the top clamp such that a solar panel can be inserted between the top clamp and the bottom clamp at an angle, thereby facilitating installation.
[0010] The clamp assembly can include various grooves for increasing the friction on a solar panel clamped between the top clamp and the bottom clamp, spikes for piercing an anodization layer of a solar panel clamped between the top clamp and bottom clamp for electrically bonding and grounding the clamp assembly and the solar panel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] In order to describe the manner in which the above-recited and other advantages and features of the disclosure can be obtained, a more particular description of the principles briefly described above will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. Understanding that these drawings depict only exemplary embodiments of the disclosure and are not therefore to be considered to be limiting of its scope, the principles herein are described and explained with additional specificity and detail through the use of the accompanying drawings in which:
[0012] FIG. 1 is an isometric view of a clamp assembly representing one example of the present technology;
[0013] FIGS. 2A and 2B are end views depicting the self-aligning action of the clamp assembly representing one example of the present technology;
[0014] FIGS. 3A and 3B are end views showing one and two solar energy panels engaging with the clamp assembly representing one example of the present technology;
[0015] FIG. 4 is an end view depicting an accessory being clamped in a secondary clamping location representing one example of the present technology;
[0016] FIG. 5A and 5B is a perspective view showing a sheet metal type lower clamping surface representing one example of the present technology;
[0017] FIG. 6 illustrates a side view of an asymmetrical clamp assembly according to some embodiments of the present technology;
[0018] FIGS. 7A and 7B illustrate views of an asymmetrical clamp assembly having solar panels installed therein according to some embodiments of the present technology;
[0019] FIG. 8A illustrates an example a bridge clamp assembly according to some embodiments of the present technology;
[0020] FIG. 8B illustrates a top view of a matrix of solar panels which are supported and secured together using clamp assemblies and bridge clamp assemblies according to some embodiments of the present technology; and
[0021] FIG. 9 illustrates a side view of another clamp assembly according to some embodiments of the present technology.
DESCRIPTION
[0022] Various embodiments of the disclosure are discussed in detail below. While specific implementations are discussed, it should be understood that this is done for illustration purposes only. A person skilled in the relevant art will recognize that other components and configurations may be used without parting from the spirit and scope of the disclosure.
[0023] As explained above, conventional solar panel mounting structures require precise dimensions and can result in excessive material and extensive installation time. Accordingly, the present technology involves mounting clamps and mounting bridges that facilitate solar panel mounting and installation.
[0024] Some embodiments of the present technology involve self-aligning clamp assemblies configured to secure solar energy panels to a fixed body. The clamp assemblies can consist of a bottom clamp, a top clamp, and a fastener, such as a bolt and nut, to compress the top clamp and bottom clamp together.
[0025] The self-aligning clamp assemblies can be specifically designed to support solar energy panels, solar energy panel frames, etc. A bottom clamp can support one or more solar energy panels from downward forces, such as gravity, positive wind pressure, snow loading, or other forces that push the solar energy panel towards Earth. The top clamp, being held in place with a fastener to the bottom clamp, can prevent one or more solar energy panels from upward forces, such as a difference in air pressure that would pull upwards on the solar energy panel. When the bottom clamp and top clamp are compressed together on one or more solar energy panels, the clamps additionally prevent the solar energy panels from moving laterally. The clamp assembly can be secured to a fixed connection point on an installation surface using its own fastener, or with a secondary fastener, as explained in greater detail below. In some embodiments of the present technology, the clamps each have two clamping surfaces on opposite sides of a fastener, such that one or more solar energy panels can engage on both sides of each clamp.
[0026] FIG. 1 is an isometric view of the clamp assembly 101 including of a top clamp 106 , a bottom clamp 108 , and a fastener 103 . The fastener 103 may consist of a fastener bolt 104 and a fastener nut 105 , and fastener bolt 104 extends through apertures 113 a, 113 b in the top clamp 106 and bottom clamp 108 , respectively. Apertures 113 a, 113 b may be circular in shape (i.e. a hole) or a slot shape, as shown in FIG. 1 . Turning the fastener nut 105 relative to the fastener bolt 104 will cause the fastener nut 105 and fastener bolt 104 to compress together, thereby compressing together the top clamp 106 to the bottom clamp 108 .
[0027] The top clamp 106 can have an offset flange 102 that protrudes horizontally away from the body of the clamp. The lower surface of offset flange 102 can be substantially parallel with the top surface of the top clamp 106 . Alternatively, the lower surface of offset flange 102 can be at an angle with the main top surface of the top clamp 106 such that, when the top clamp 106 is compressed to the solar energy panel (not shown), the top clamp 106 deflects under stress and the clamping surface is drawn down to be parallel with the top surface of the solar energy panel.
[0028] The bottom clamp 108 can have of a main body with one or more horizontal flanges 110 . As depicted in FIG. 1 , bottom clamp 108 is symmetrical in shape and has a horizontal flange 110 on both sides of fastener 103 in order to capture multiple solar energy panels. These horizontal flanges 110 act as the lower clamping surface on a solar energy panel (not shown). The horizontal flanges 110 can also be the same size and shape to make the bottom clamp 108 symmetrical in shape. This has the benefit of universality, whereby either horizontal flange 110 can be used first in the installation process, making the clamps easier to use.
[0029] Horizontal flange 110 may have lips 111 a, 111 b on its outward edge in order to help capture a solar energy panel and to prevent the solar energy panel from readily sliding off of the horizontal flange 110 (i.e. the clamping surface). Also, the horizontal flanges 110 can have bottom clamp grips 112 a, 112 b may be a textured surface, grooved surface, or similar gripping feature to help hold a solar energy panel from moving when compressed by the top clamp 106 and bottom clamp 108 .
[0030] Additionally, the horizontal flanges 110 can have a channel 115 a, 115 b traversing a lengthwise orientation with the module to fit a sheet metal part (not shown). This sheet metal part can have sharp spikes protruding upward and/or downward to cut a coating, such as anodization or paint, on the bottom clamp and/or the solar energy panel, thereby electrically bonding and grounding the two components together. The horizontal flange can have vertically protruding spikes (not shown) to penetrate the anodization layer of a solar energy panel with the purpose of creating an electrical grounding and bonding path. These spikes can be a separate component press or screw fit into a hole in the horizontal flange, and can be a molded or extruded as an integral feature of the horizontal flanges 110 .
[0031] As explained above, the top clamp 106 and bottom clamp 108 can have apertures 113 a, 113 b passing there through to allow a fastener 103 to pass through. The aperture can be a hole, slot, aperture or similar cut-out. A slot can be beneficial as it allows the top clamp 106 and bottom clamp 108 to adjust laterally (along the z-axis) without moving the fastener 103 , which can be fixed to a particular location.
[0032] Also, the top clamp 106 and the bottom clamp 108 can each consist of a single shape throughout their length (along the z-axis), allowing for manufacturing using an extrusion process which can be less expensive than other forms of manufacturing and allowing for universality during installation of a solar energy panel to the clamps 106 , 108 .
[0033] In some embodiments of the present technology, the top clamp 106 has a centrally positioned downward top clamp protrusion 107 . This protrusion can be substantially trapezoidal, triangular, or square in shape, and can extend the entire length of the top clamp. The top clamp protrusion 107 engages with a similarly positioned bottom clamp cavity 109 on the top surface of the bottom clamp 108 . As the top clamp 106 and bottom clamp 108 are drawn closer together, the top clamp protrusion 107 resides within the bottom clamp cavity 109 to prevent the two clamps from rotating relative to one another around the fastener. This ensures the two clamp pieces are substantially aligned with one another to provide even clamping surfaces on a solar energy panel. As shown in FIG. 1 , the top clamp protrusion 107 can nest into bottom clamp cavity 109 as the top clamp 106 and bottom clamp 108 are drawn towards one another.
[0034] FIG. 2A depicts the top clamp 106 rotated some arbitrary amount relative to bottom clamp 108 around fastener 103 such that the end edges of both clamps are not parallel. As top clamp 106 approaches bottom clamp 108 , an edge of top clamp protrusion 107 may contact an edge of bottom clamp cavity 109 at location 201 . In one example of the present invention as shown in FIG. 2A , the top clamp protrusion 107 and bottom clamp cavity 109 are substantially trapezoidal in shape. In FIG. 2B , top clamp 106 has approached closer to bottom clamp 108 , and the trapezoidal shape of top clamp protrusion 107 has slide along the surface of bottom clamp cavity 109 , thereby rotating top clamp 106 so that the end edge of top clamp 106 is now substantially parallel with the end edge of bottom clamp 108 , thereby reducing the need for positioning the clamps as they are compressed together during the installation on a solar energy panel.
[0035] FIG. 3A depicts an end view of clamp assembly 101 with solar energy panel frame section 301 clamped in one side between top clamp 106 and bottom clamp 108 .
[0036] In some embodiments of the present technology, the bottom clamp 108 can have two vertical protrusions 302 , 303 on its topmost surface symmetrically located to either side of the cavity. When a solar energy panel frame section 301 is clamped between the sides of a top clamp 106 and bottom clamp 108 , and the top clamp 106 is compressed towards the bottom clamp 108 using the fastener 103 , the vertical protrusion furthest from the solar energy panel ( 302 in FIG. 3A ) can be designed prevent the top clamp 106 from being tightened so much that the top clamp would exert too much torque on the fastener 103 when another solar energy panel is not installed on the opposite side.
[0037] The vertical protrusions 302 , 303 can be dimensioned above the top surface of the horizontal flanges 110 such that the angle of articulation of the top clamp 106 around the fulcrum is great enough to maintain a clearance space 316 between the top clamp 106 and bottom clamp 108 , yet small enough so not to impose permanent damage to the fastener 103 from bending. Also, the top clamp 106 will not be perfectly parallel with the bottom clamp 108 when the top clamp 106 is compressed to the solar panel frame section 301 using the fastener 103 , however the angle created will not be so great as to substantially damage the fastener 103 .
[0038] The overall height of bottom clamp 108 and vertical protrusions 302 and 303 may depend on the height of frame section 301 , meaning a frame section of a different height may require a bottom clamp and vertical protrusion of a also a different height. Vertical protrusions 302 and 303 may be the same height and position on bottom clamp 108 in order to maintain universal functionality should a solar energy panel be installed on the opposite side compared to the orientation in FIG. 3A . The clamping surface on offset flange 102 may be at an acute angle relative to the vertical plane of the clamp assembly 101 . This feature allows for the clamping surface to be relatively parallel with the top of the frame section 301 when the top clamp 106 articulates around frame section 301 as it is compressed down.
[0039] FIG. 3B depicts the assembly in FIG. 3A with the addition of a second frame section 305 . In some embodiments, as shown in FIG. 3B , the dimensions of the components are configured such that when solar panel frame sections 301 , 305 are located on both sides of clamp assembly 101 , and the top clamp 106 is compressed towards the bottom clamp 108 using the fastener 103 , the vertical protrusions 302 , 303 do not interfere with the top clamp 106 and a clearance space 317 can be maintained between the top clamp 106 and bottom clamp 108 such that pressure from tightening the fastener is transferred to the solar energy panels 301 , 305 and not to the vertical protrusions 302 , 303 . Also, in these configurations, the top clamp 106 and bottom clamp 108 can be substantially parallel to one another when compressed together using the fastener 103 .
[0040] Also, as shown in FIGS. 3A and 3B , the clamping surfaces of the top clamp 106 can have substantially triangularly shaped sets of grooves 304 a, 304 b or a textured surface that help induce additional friction on the solar energy panel to prevent it from moving when compressed by the top and bottom clamp.
[0041] FIG. 4 depicts a side view of a clamp assembly 101 with gaps 401 a, 401 b of a particular height and depth between the lower surface of the top clamp 106 and the upper surface of the bottom clamp 108 . The gaps 401 a, 401 b can be used as a second clamp for accessories, such as a formed piece to sheet metal that angles downward to restrict air movement under a solar energy panel, an electrical connections box, electrical conduit, or similar accessories. The accessories can have a horizontal tab that can be placed in the gaps 401 a, 401 b to secure the accessory to the clamp assembly. When the tab of an accessory is placed in the gaps 401 a, 401 b and the fastener 103 tightened to compress the top clamp 106 towards the bottom clamp 108 , the top clamp 106 may press down on the accessory's tab and not on the vertical protrusion furthest from the solar energy panel. The accessory tab causes the top clamp 106 to behave similar to as if two or more solar energy panels are on both sides of the clamp assembly 101 . The surfaces of the top clamp 106 and bottom clamp 108 creating the gap can be textured and can have grooves cut in place to increase friction on an accessory's tab. The vertical protrusion of the bottom clamp 108 may act as a wall to prevent the accessory's tab from sliding too far in between the top and bottom clamps.
[0042] In some embodiments of the present technology, a shaped plate is clamped in the gaps 401 a, 401 b between the top clamp 106 and bottom clamp 108 , and extends downward towards an installation surface over which the solar energy panels reside. One purpose of the plate is to deflect airflow over one or more solar energy panels, reducing pressures on the underside of the solar energy panels. Another purpose is to deflect flame over one or more solar energy panels and prevent a fire from spreading to under one or more solar energy panels. The plate can have one or more bends in it to conform to the top clamp 106 and bottom clamp 108 , and bend to rest on the outer edge of the bottom clamp's 108 horizontal flange 110 .
[0043] In FIG. 4 , a clamp assembly 101 has a solar energy panel frame section 301 engaged on one side, and wind deflector 402 engage on an opposing side. In this example embodiment, the gap 401 a is created between the top clamp 106 and bottom clamp 108 when the two pieces are compressed onto the frame section 305 and the top and bottom clamp remain substantially parallel with one another. The gap 401 a may have a textured or grooved surface 404 to aid in gripping any component that may be clamped, such as wind deflector 402 . Wind deflector 402 has a thickness such that the compressive forces from the top and bottom clamp will be placed on the wind deflector 402 , and not on vertical protrusions 302 and 303 . Vertical protrusion 302 also acts as a guide to prevent installing the wind deflector 402 too far into the gap 401 a. Other accessories, such as an electrical wiring box, wiring conduit clip, electronic inverter, or weather station, may have a tab that can be clamped in the gap 401 a in a similar method to that of the wind deflector 402 . In one example of the present invention, wind deflector 402 has one or more bends to reduce the horizontal distance occupied when achieving a desired height. In some embodiments of the wind deflector 402 , these bends may sum to an angle less than 90 degrees, thereby allowing multiple wind deflectors to snuggly nest upon one another for packaging and shipping. The wind deflector 402 may bend around the outer edge of horizontal flange 110 at point 403 . In this example, the wind deflector is supported at both gap 401 and point 403 .
[0044] Those with ordinary skill in the art having the benefit of this disclosure will appreciate that a wide variety of materials can be suited to carry out the present technology. In some embodiments of the present technology, the bottom clamp is formed of a sheet metal, a composite material, etc. FIG. 5A illustrates a self-aligning clamp according to some embodiments of the present technology. FIG. 5A illustrates a clamp assembly 500 with a sheet metal bottom clamp 501 having an upper plate 502 resting on lower plate 503 and assembled together to a top clamp 508 with a fastener through an aperture 504 .
[0045] When the bottom clamp 501 has a substantially rigid structure, meaning the horizontal flanges deflect significantly less in proportion to the deflection of a solar energy panel when under downward force, point stresses can build up on the solar energy panel at the edge of the bottom clamp. To prevent this stress build-up, the horizontal flanges of the bottom clamp 501 are used to bend downward a particular amount as the solar energy panel deflects, with the purpose being to reduce point stresses on the solar energy panel at the edge of the bottom clamp. A design pointing stresses between the horizontal flanges and the solar energy panel tapers the horizontal flanges as they extend along the length of the solar energy panel. This tapered feature reduces point stress induced on the solar energy panel or the solar energy panel frame by the bottom clamp as a downward force is applied to the solar energy panel.
[0046] As shown in FIG. 5A , the upper plate 502 and lower plate 503 can flex independently of one another when exposed to downward force and can have tapered ends 505 to reduce in cross sectional area as they extend away from the center of the sheet metal bottom clamp 501 , yielding a non-linear deflection at the points of the tapered ends 505 as compared to the main body of the sheet metal bottom clamp 501 . This tapered feature reduces the point stress imposed on a solar energy panel when exposed to a downward force. Upper plate flange 506 protrudes a vertical distance below the top clamp to have a similar functionality as the vertical protrusions 302 and 303 described in FIGS. 3A and 3B . Lower plate flange 507 extends vertically and exteriorly to upper plate 502 , and may be dimensioned to secure upper plate 502 to lower plate 503 via a press fit. Lower plate flange 507 has a width such that it will act as a guide similar to vertical protrusions 302 and 303 described in FIG. 4 . Lower plate flange 507 may extend a height to coincide with the edge of the top clamp at point 508 . The lower plate flange 507 may therefore prevent the top clamp from rotating relative to the sheet metal bottom clamp 501 . FIG. 5B depicts gap 509 created between upper plate flange 506 and the top clamp. Gap 509 has the similar functionality as gap 401 described in FIG. 4 .
[0047] FIG. 6 illustrates a side view of another clamp assembly 600 according to some embodiments of the present technology. The clamp assembly 600 includes a top clamp 606 and a bottom clamp 608 secured together with a fastener 603 through apertures (not shown) in the top clamp 606 and bottom clamp 608 and a nut 699 .
[0048] The top clamp 606 can have an offset flange 602 that protrudes horizontally away from the body of the clamp. Also, the bottom clamp 608 can have flanges 610 , 611 on both sides of fastener 603 in order to capture multiple solar energy panels. According to FIG. 6 , the flanges 610 , 611 are asymmetrical and can serve independent purposes. The flange 611 can include a surface for supporting downward forces from a solar panel. Also the flange 611 can have one or more vertically protruding spike 612 to penetrate the anodization layer of a solar panel and create an electrical grounding and bonding path.
[0049] The flange 610 can have an upward tilted configuration for allowing a solar panel to be slid between the top clamp 606 and bottom clamp 608 at an angle (as shown in FIGS. 7A and 7B below). In some embodiments, the flange 610 can be displaced (in the −y direction) when a solar panel is installed between the top clamp 606 and bottom clamp 608 .
[0050] The bottom clamp 608 can also have a vertical protrusion 613 to prevent the top clamp 606 from being tightened, when a solar energy panel is installed on the opposite side, so much that the top clamp 606 would exert excessive torque on the fastener 603 , as explained in greater detail above in discussing FIGS. 3A and 3B . Also, the vertical protrusion 613 can be dimensioned so as to create a gap 604 between the top clamp 606 and the bottom clamp 608 when they joined using the fastener 603 . The gap 604 can act as a secondary clamp (e.g. for accessories) as shown above in FIG. 4 . The top clamp 606 and the bottom clamp 608 can each have a set of grooves 607 , 609 facing each other in the gap 604 that help induce additional friction on the accessories.
[0051] FIGS. 7A and 7B illustrate views of a clamp assembly 700 with solar panels 750 , 751 installed therein according to some embodiments of the present technology. As shown in FIG. 7A , a solar panel 750 is clamped between top clamp 706 and the flange 711 of the bottom clamp 708 . The vertical protrusion 713 on its top surface of the bottom clamp 708 prevents the top clamp 706 from causing the fastener 703 to bend when a nut 799 is tightened down to secure the solar panel 750 in place. In other words, the vertical protrusion 713 maintains the top clamp 706 in a substantially parallel position relative to the bottom clamp 706 as the nut 799 is tightened down and only a solar panel 750 is in one side of the clamp assembly.
[0052] Also, the flange 710 is configured at an angle or radius to allow solar panel 751 to be slide into the clamp assembly 700 when the solar panel 750 is already clamped therein. The angled flange feature allows an installer to serially install adjacent solar panels without having to loosen a previously tightened fastener and without having to bend over to uncomfortable and/or dangerous angles.
[0053] As shown in FIG. 7B , after the solar panel 751 is placed between the angled flange 710 and the top clamp and is articulated to an installation level, e.g. planar to the installation surface, level with the solar panel 750 , etc. In some embodiments of the present technology, the solar panel 751 displaces the flange 710 . Additionally, when the solar panel 751 is clamped into the clamp assembly 700 , the solar panel 751 applies upward force on the top clamp, thereby removing pressure on the protrusion 713 and more evenly distributing pressure onto the nut 799 .
[0054] The clamps described in the present disclosure can be used to support solar energy panels on an installation surface. Additionally, the clamp assemblies can also be used to bridge adjacent solar energy panels. FIG. 8A illustrates an example of a bridge clamp assembly 800 according to some embodiments of the present technology. The bridge clamp assembly 800 includes a top bridge 806 and a bottom bridge 808 secured together with multiple fasteners 803 a, 803 b through apertures 813 a, 813 b and nuts 899 a, 899 b. The bottom clamp 808 of the bridge clamp assembly 800 has asymmetrical flanges 810 , 811 similar to the flanges 610 , 611 and 710 , 711 described above. In some embodiments, top bridge 806 and bottom bridge 808 have identical or substantially similar cross-sectional geometries as top clamp 710 and bottom clamp 711 . This allows for reduced manufacturing costs as the same profile shape can be used for multiple parts.
[0055] The bridge clamp assembly 800 may also include multiple spikes 812 a, 812 b to penetrate the anodization layer of a solar energy panel frame with the purpose of creating an electrical grounding and bonding path between adjacent solar panels.
[0056] FIG. 8B illustrates a top view of a matrix 850 of solar panels 852 , 854 , 856 , 858 which are supported and secured together using clamp assemblies 860 , 862 , 864 , 866 , 868 , 870 and which are further secured together using bridge clamp assemblies 872 , 874 , 876 . The clamp assemblies 860 , 862 , 864 , 866 , 868 , 870 can include sharp spikes protruding upward and/or downward to cut a coating, such as anodization or paint, on the bottom clamp, top clamp and/or the solar energy panel, thereby electrically bonding and grounding the components and the panels and creating a grounding/bonding path between vertically coupled (indicated by the arrows in the y-direction) solar panels and clamp assemblies. Similarly, the bridge clamp assemblies 872 , 874 , 876 can have multiple spikes that penetrate the anodization layer of a solar energy panels, thereby electrically bonding and grounding the components and the panels and creating a grounding/bonding path between horizontally coupled (indicated by the arrows in the x-direction) solar panels and clamp assemblies.
[0057] In some embodiments of the present technology, the top clamp and bottom clamp can be manufactured using an aluminum extrusion process having a good weight to strength ratio, while being less expensive than other processes. Additionally it allows for complex designs in one plane of each part. The top or bottom clamp can be manufactured using one or more stamped and formed pieces of sheet metal, (e.g. of aluminum or stainless steel). A stamped and formed process has the advantages of being cost effective while allowing different shapes and protrusions in three dimensions without a secondary machining operation. The top and bottom clamp can also be made of a composite material, a composite material molded over a reinforcing metal structure, etc. The composite material selection has the benefits of being electrically non-conductive, thereby reducing or eliminating the need to electrically ground and bond the top and bottom clamps to a solar energy panel or other metallic components.
[0058] FIG. 9 illustrates a side view of another clamp assembly 900 according to some embodiments of the present technology. The clamp assembly 900 includes a top clamp 906 and a bottom clamp 908 that can be secured together with a fastener 903 through apertures (not shown) in the top clamp 906 and bottom clamp 908 and with a nut 999 .
[0059] According to FIG. 9 , the bottom clamp 908 has flanges 910 , 911 on both sides of fastener 903 in order to capture multiple solar energy panels. The flange 911 can include a surface for supporting downward forces from a solar panel and a u-shaped groove 912 that can be configured to hold wires and that can be enclosed when a solar panel module 920 is clamped between the top clamp 906 and bottom clamp 908 . The flange 910 can also have a dipped groove 909 that acts as a recess to allow a solar panel to be installed between top clamp 906 and bottom 908 after fastener 903 has been tightened on a solar panel 920 has been installed. This process of installation is described in FIG. 7 . Flange 910 may have a curvature to on the top surface to more evenly distribute stresses induced when a solar panel (not shown) is installed.
[0060] Although a variety of examples and other information was used to explain aspects within the scope of the appended claims, no limitation of the claims should be implied based on particular features or arrangements in such examples, as one of ordinary skill would be able to use these examples to derive a wide variety of implementations. Further and although some subject matter may have been described in language specific to examples of structural features and/or method steps, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to these described features or acts. For example, such functionality can be distributed differently or performed in components other than those identified herein. Rather, the described features and steps are disclosed as examples of components of systems and methods within the scope of the appended claims.
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Clamp assemblies for mounting solar panels and accessories. Clamp assemblies can have geometric features, shaped apertures for fasteners, and measured protrusions for allowing clamp rotation, lateral adjustment, self-alignment, and angled surfaces for facilitating installation of a solar panel.
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FIELD OF THE INVENTION
[0001] The present invention relates to a method for a fixed-wing fighter to take off and land, and more particularly a method for a land-based and fixed-wing fighter to take off and land within an ultra-short distance.
BACKGROUND OF THE INVENTION
[0002] Reducing the running distance for takeoff and landing of a fighter and reliance of the runway that can be easily damaged, and minimizing the cost of runway construction and the negative impact of excessive resource allocation of fighter takeoff and landing are the long-term goals and global difficulties for military and fighter designers. Long runways can only be built in limited areas and for economic concerns, there are not many airports with long runways, which limits the activity range of fighters. Especially if these vulnerable long runways were attacked and damaged during wartime, the fighters would be stranded on the ground and destroyed. One striking example is that in the third Arab-Israeli War, on June 5 of 1967, Israeli air force raided and paralyzed the Arabic air bases and destroyed several hundreds of the then most advanced Soviet-made MiG-21 on the ground. Generally speaking, the power of the air force is a combined result of the four major subsystems including an information group (Intelligence), a command group, a fight group (fighters), and a support group (mostly for airbases and runways), and its operational capacity is determined by the integration of these subsystems. Inefficiency in any one of these subsystems can lead to the failure of the entire air force. Therefore, the power of the air force resembles a bucket assembled with four wood boards, and the capacity of the bucket is limited by the shortest board. Although significant progress has been made in other subsystems, the shortcomings in the support subsystem, more specifically the runway, will ultimately affect the operation of air force as the obvious “short board”. Although the world's military and the aviation industry have made unremitting efforts to solve this bottleneck problem, so far there has no any satisfactory result.
[0003] Existing approaches to solve this “short board” runway problem are unsatisfactory. The means of aerodynamic design, including the planar shape of the wing, airfoil profile, use of flaps (including jet flap) and the drag parachute, etc. have shown to be not remarkably useful, as the running distance remains very long, in particular the landing distance.
[0004] For fixed-wing vertical takeoff and landing fighters, such as the British Harrier Jump Jet, the former Soviet Yak-38 and Yak-141, and the United States V-22 Osprey, F-35B, etc., rely on the airborne system to generate an aerodynamic lift. Although these fighters do not depend on airport runways, their common feature of bulky, expensive lift-generating power system which functions only during the takeoff and landing phases significantly limits their performance and capacity. For example, the bulky and expensive lift-generating power system reduces the loading capacity of fuel and weapons, and weakens their performance in fight missions. Moreover, this system negatively affects these fighters' supersonic performance. For example, the Harrier Jump Jet and the Yak-38 do not support supersonic performance, and F-35B allows only a slightly higher speed above supersonic (M1.4). In addition, the V-22 Osprey, which simply relies on propeller and rotary wing to generate the lifting power, has a very low speed and cannot be categorized as a fighter. Also, these fighters are expensive and developed slowly, for instance, in order to meet the requirements of vertical takeoff and landing, progress of the F-35B development was significantly delayed with dramatically increased budget, resulting in the cost of more than 100 million US dollars for one F-35B.
[0005] Although the world's military and the aviation industry have made unremitting efforts to solve this bottleneck problem, so far there has no any satisfactory result. The fact that these means failed to generate a satisfactory result can be attributed to several key reasons. First, for a fighter to take off from the ground, it must accelerate to a threshold speed when the fighter is subjected to a lift greater than its own weight. Similarly, for a fighter to land, the speed of the fighter has to be reduced to a certain level, namely the landing speed, when the lift is equal to its own weight. So far, the long running distance for the fighter to take off and land cannot be shortened because these threshold speeds cannot effectively reduced. In other words, the fighter needs a long running distance for landing and takeoff.
[0006] Secondly, both military and fighter designers are inappropriately relying on the fighter design department to solve the problem of long runway. They attempt to reduce the running distance for takeoff and landing solely by changing the fighter design, and are not open for other solutions. Thus, there remains a new and improved method to overcome the problems presented above.
SUMMARY OF THE INVENTION
[0007] It is an object of the present invention to provide means for fighters to take off at less than normal takeoff speed, under the same condition of its own weight and external carriage loads.
[0008] It is another object of the present invention to provide means for fighters to land at less than the normal landing speed, under the same condition of its own weight and external carriage loads.
[0009] It is a further object of the present inventions to provide a tilted runway (at an angle of not less than 10 degrees) landing technique. This technique resolves the aforementioned key problems that lead to long running distances. By improving both the runway and the fighter, this technique reduces the takeoff and landing speed to allow the reduction in running distances. For the positive effect, this technique expands the potential of fighters without compromising the capacity for completing major missions and main performance features.
[0010] In one embodiment, the geometric relationship between the fighter and runway (e.g. height difference—using gravitational acceleration and deceleration) is used to reduce the takeoff and landing speed to achieve ultra short take off and landing (ultra-STOL). With the height difference, the fighter can accelerate and decelerate in the air to reach the normal takeoff and landing speed. In another embodiment, fighters can be landed on a tilted, specially-designed runway.
[0011] Using the method in the present invention, the landing distance of F-16A and MiG-21 can be reduced by 50% or more in comparison with the normal landing distance according to publicly available information. Similarly, the (takeoff) running distance is reduced by a similar degree. With the tilted runway in the present invention, F-16A may land within 150-200 meters. In particular, it can be more effective in reducing takeoff and landing distances for fighters equipped with vector thrust engines.
[0012] When the takeoff and landing distances are reduced, the length of an airport runway can be significantly shortened, allowing more airports and therefore more air force bases built under the same conditions and with same budget. The air force power can be extended to a much wider region, thereby significantly improving the capability of air missions.
[0013] Furthermore, the defense of the airport system, the air force and the overall viability of the protected targets during wartime are improved. During the wartime, more available airports indicate more targets for being attacked. In the case that a certain number of enemy assaulting weapons including fighters are dispatched, each airport provides the enemy a clear target to attack to further paralyze the air force on the other side. With the technique disclosed in the present invention, the costs to build the airport can be significantly reduced, and the number of airport can be increased. So, there become more targets to attack for the enemy's air force, which weakens the enemy's air attacking power.
[0014] The tilted runway has a dramatically increased viability. Even the runway was hit by bombs or missiles, it is unlikely to be totally destroyed the runway because of its geometric shape.
[0015] The present invention provides new opportunities and directions for optimizing national defense structure within a fixed budget. For example, with this technique, airports with short runways may be built on islands in the oceans or in high altitude areas. These airports require limited personnel for maintenance during peacetime, and can be used as stations for fighter fleets during wartime, and when necessary, a huge number of fighters can be gathered thereon. Comparing with aircraft carriers, the cost is obviously much lower than dispatching special mixed fleets. For optimizing the structure of force, the same missions can be accomplished, and the same fighting capability can be achieved with lowest cost. It is obvious that building multiple airports with ultra-short runways would be significantly more economic than having a number of task force fleets. Therefore, this ultra-STOL technology provides a new possible choice.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 illustrates one embodiment of fighters using ultra short running distance to take off in the present invention.
[0017] FIG. 2 illustrates another embodiment of fighters using ultra short distance for landing in the present invention.
[0018] FIG. 3 illustrates a further embodiment of fighters using the tilted runway for landing in the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0019] The detailed description set forth below is intended as a description of the presently exemplary device provided in accordance with aspects of the present invention and is not intended to represent the only forms in which the present invention may be prepared or utilized. It is to be understood, rather, that the same or equivalent functions and components may be accomplished by different embodiments that are also intended to be encompassed within the spirit and scope of the invention.
[0020] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this invention belongs. Although any methods, devices and materials similar or equivalent to those described can be used in the practice or testing of the invention, the exemplary methods, devices and materials are now described.
[0021] All publications mentioned are incorporated by reference for the purpose of describing and disclosing, for example, the designs and methodologies that are described in the publications that might be used in connection with the presently described invention. The publications listed or discussed above, below and throughout the text 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 inventors are not entitled to antedate such disclosure by virtue of prior invention.
[0022] The present invention provides an evolutionary change to the existing takeoff and landing technology of land-based fixed-wing fighters Implementation of this technique should start with one specific type of fighters and then extend to other major types. Performance characteristics of the target fighters must be fully studied.
[0023] Firstly, the fighter's status, capability and limitation should be studied, and the implementation of this technology should be proven technically feasible by ultra-STOL theoretical model analysis.
[0024] Secondly, the fighter types and their specific characteristics should be subjected to theoretical calculations to optimize their operation parameters for the desired ultra-STOL performance
[0025] Thirdly, through the use of a ground simulator, with the involvement of a few experienced pilots with experience in flying multiple types of fighters under various flight environments, a real-time simulating process of takeoff and landing using this ultra-STOL technique with multiple types of fighters has to be conducted. So, the sensitivity and accuracy of the pilots' responses during the simulation can be studied and the ultra-STOL technique can be improved. In addition, the simulation can also test the technical feasibility of the ultra-STOL technique. When necessary, the information of fighter performance characteristics (such as the autopilot system responsible for landing and corresponding fighter design parameters) may be required. Also, ground guidance, command and control equipment (with corresponding functional requirements and design parameters) and ground control personnel (number and division of functions) may be necessary to satisfy the need for the ultra-STOL. In addition, in the simulating process, conditions that may be encountered in actual STOL operations, such as various weather conditions, night condition, gust wind, crosswind, temperature, simultaneous takeoff or landing of multiple batches and different types of fighters, and possible terrain conditions, can be incorporated so it would be much closer to real situations. Since the simulating process is inexpensive and risk free, and acts as a partial alternative of the actual flight test, it can be a critical tool for testing the ultra-STOL technique as well as an essential step prior to actual flight test.
[0026] The method for verifying the effect of the tilted runway for fighter landing should start with a theoretical analysis, then test the results of the theoretical analysis with a ground simulator, and propose detailed instruction on how to implement the actual flight test of that specific type of fighters.
[0027] In order to implement this ultra-STOL technique, it is necessary to establish the associated ground guidance, command, control systems, as well as the corresponding computer and software systems. The systems should be tested by ground simulators to determine the design parameters. It should particularly be noted that, since the time for takeoff or landing using the ultra-STOL technique is extremely short, especially for landing, it might be difficult for the pilots to respond accurately and in a timely manner Therefore, the ground guidance, command and control system, as well as their computer and software system, and onboard equipment corresponding to ground systems, including an onboard autopilot system, would be the key for the implementation of this ultra-STOL technique. In the future, to test the effect of applying this ultra-STOL technique with a vector thrust engine equipped fighter, the test should also start with the appropriate theoretical analysis, and then the simulation stage with a ground simulator.
[0028] Based on the aforementioned, this technology should first be tested with certain types of the existing fighters and with suitable regular runways in certain existing airports, which are close and stretch to cliffs and can then be further extended to other types of fighters upon successful initial tests. On the basis of successful tests with regular runways in the existing airports, this technique will be further tested with newly constructed on tilted runways. Furthermore, the economic analysis of this ultra-STOL technology will be conducted, and compared with that of a conventional runway.
[0029] In addition to the analyses and tests, the existing and possible future airports that are suitable for this ultra-STOL technology, especially the construction on islands or on high altitude areas, need to determined. The corresponding effects, including the tactical and strategic effect as well as the economic impact should also be considered. The effect of using the ultra-short-runway airports on the distribution of air force power, as well as on the optimization of the force structure should also be assessed.
[0030] Referring to FIG. 1 , a fighter F 1 is disposed on a flat surface with a height H 1 , and distance of a runway for the fighter F 1 is D 1 , which is substantially shorted than a regular takeoff runway for the fighter F 1 . The fighter F 1 starts with an initial speed V 1 (preferably equals to zero) and a takeoff speed V 1 at the end of the runway, and when the fighter F 1 leaves the runway, the fighter F 1 may firstly go down along the direction of a e because of gravitational acceleration (g) and the fighter F 1 's accerleration a f , and the fighter F 1 can be accelerated by the acceleration a e until the fighter F 1 reaches its normal takeoff speed V e . Under such circumstances, the fighter uses a shorter runway D 1 with a smaller takeoff speed V t , and the normal takeoff speed V e can be obtained through the assistance of gravitational acceleration. In one embodiment, D 1 can be about fifty percent (50%) shorter than a normal runway. It is noted that when the fighter F 1 takes off, it may encounter a lifting force, a drag, gravity and thrust, and the acceleration a e results from the combination of the abovementioned force. Also, as can be seen in FIG. 1 , the direction of the speed V c when the fighter just takes off is different from the acceleration a e .
[0031] Referring to FIG. 2 , a fighter F 2 with an initial speed V 2 tries to land on a shorter landing distance D 2 on a flat surface with a height H 2 . The initially speed V 2 can be gradually reduced because the fighter F 2 is climbing to a higher landing surface against the gravitational force, and the fighter F 2 can be landed with the shorter landing distance D 2 It is noted that a landing speed V s can be calculated according to the height H 2 and the initial speed V 2 of the fighter F 2 , and the landing speed V s and fighter F 2 's flight path should be tangent to the landing surface when climbing thereto.
[0032] Referring to FIG. 3 , a fighter F 3 with an initial speed V 3 tries to land on a shorter landing distance D 3 on a tilted runway above a height H 3 . The fighter F 3 would start climbing to the height H 3 and then try to land on the tilted runway against the gravitational force. It is noted that D 3 can be much shorter than conventional landing distance, and can be even shorter than D 2 in FIG. 2 because the fighter is travelling against the gravitational force on the tilted runway. Also, on the titled runway, a plurality of stopping blocks are configured to pop out to prevent the fighters from falling down from the runway, and when the fighter F 3 is fully stopped, the unused stopping blocks can be restored to their original positions. In one embodiment, the angle θ is larger than 10 degrees. Furthermore, when this tilted runway is attacked, it is unlikely to be damaged due to its special geometrical shape. The fighter landed on the tilted runway would be transported to a facility so that the runway can be used for subsequent fighters for landing, and the landed fighters can be maintained and prepared for next flight.
[0033] Having described the invention by the description and illustrations above, it should be understood that these are exemplary of the invention and are not to be considered as limiting. Accordingly, the invention is not to be considered as limited by the foregoing description, but includes any equivalents.
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A method for a fix-wing fighter to take off and land on an ultra-short distance is disclosed. In one embodiment, a method for a fighter to take off with an ultra-short distance may include providing a runway on a predetermined height, wherein the runway is shorter than a normal runway; disposing the fighter at said runway; and providing the fighter with an initial speed and the fighter is able to accelerate on said runway; wherein the fighter reaches its takeoff speed (which is smaller than a normal takeoff speed of the fighter) at the end of the runway, and is then accelerated by a combination of the flighter's acceleration and gravitational acceleration until the fighter reaches its normal takeoff speed.
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FIELD OF THE INVENTION
The present invention relates to a heat-resistant film base-material-inserted B-stage resin composition sheet for producing a multilayer printed wiring board by lamination, its use and its production process. More specifically, a high-density multilayer printed wiring board excellent in copper adhesive strength, heat resistance and insulating reliability particularly in the Z direction can be produced by using the B-stage resin composition sheet of the present invention between circuit substrates or on an external layer at the time of multilayer formation. The obtained multilayer printed wiring board is suitable for use, as a high density small printed wiring board, in a semiconductor-chip-mounting, small-sized and lightweight novel semiconductor plastic package.
BACKGROUND OF THE INVENTION
In recent years, a high-density multilayer printed wiring board is used in electronic equipment that is increasingly becoming smaller, thinner and lighter. The multilayer printed wiring board is becoming thinner, and a multilayer printed wiring board having an insulating layer thickness of 20 to 30 μm between an internal copper foil and an external copper foil is produced. Conventionally, a glass fiber woven cloth or nonwoven cloth or an organic fiber woven cloth or nonwoven cloth is used as a base material for a B-stage resin composition sheet for buildup lamination. However, there is a limitation on the making of a thin base material, so that resin layers can not be sufficiently formed on front and reverse surfaces of the base material. After laminate-molding, the base material is in contact with an internal copper foil and an external copper foil so that the migration resistance in the Z direction and the soldering heat resistance after moisture absorption are poor. Accordingly, there is a problem in reliability as a high-density multilayer printed wiring board.
Further, an adhesive sheet obtained by attaching a B-stage resin composition to a release film or a copper foil is used. However, when the adhesive sheet is used to produce a high-density multilayer printed wiring board having a small insulating layer thickness, the obtained multilayer printed wiring board is poor in reliability such as migration resistance in the Z direction. Further, it is also poor in electric characteristics and heat resistance so that it has a limitation in use as a high-density printed wiring board.
Further, concerning the production of a high-density multilayer printed wiring board, there is a method of producing a multilayer printed wiring board by using an additive process as a method for forming a fine circuit. An additive process multilayer printed wiring board using a conventional adhesive sheet which is obtained by adding a large amount of rubber into an epoxy resin and is not reinforced with base material, is poor in reliability such as migration resistance in the Z direction, particularly when the insulating layer thickness is small. Further, the above additive process multilayer printed wiring board is also poor in electric characteristics and heat resistance so that it has a limitation in use as a high-density printed wiring board.
In addition, when an adhesive sheet for a subtractive process or an adhesive sheet for an additive process, each of which sheet is not reinforced with a base material, is used on each surface of a thin internal layer board, a buildup-multilayered printed wiring board is poor in mechanical strengths such as bending strength and tensile strength and elastic modulus (hardness) and warps and distortions are apt to occur. Further, a thickness variance after molding is large, which causes defectives in an assembly stage and the like.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a heat-resistant film base-material-inserted B-stage resin composition sheet for producing a high-density multilayer printed wiring board which is high in mechanical strengths, excellent in copper foil adhesive strength and heat resistance and also excellent in reliability by lamination like a conventional prepreg, use thereof and a process for the production thereof.
It is another object of the present invention to provide a heat-resistant film base-material-inserted B-stage resin composition sheet from which a multilayer printed wiring board excellent in insulating properties in the Z direction and excellent in reliability such as migration resistance can be produced particularly by using a heat-resistant film, use thereof and a process for the production thereof.
It is further another object of the present invention to provide a heat-resistant film base-material-inserted metal-foil-attached B-stage resin composition sheet for producing a high-density multilayer printed wiring board which is high in mechanical strengths, excellent in copper adhesive strength and heat resistance and also excellent in reliability by an additive process, use thereof and a process for the production thereof.
It is still further another object of the present invention to provide a thin-type high-density multilayer printed wiring board which is high in elastic modulus, excellent in copper adhesive strength and heat resistance and also excellent in reliability.
According to the present invention 1, there is provided a heat-resistant film base-material-inserted B-stage resin composition sheet for lamination, comprising a heat-resistant film base material and B-stage resin composition layers for lamination formed on both surfaces of the heat-resistant film base material.
According to the present invention 1, there is provided a heat-resistant film base-material-inserted B-stage resin composition sheet for lamination according to the above, wherein a metal foil is attached to one surface of the sheet.
According to the present invention 2, there is provided a heat-resistant film base-material-inserted B-stage resin composition sheet according to the above, wherein at least one layer of the B-stage resin composition layers formed on both surfaces of the heat-resistant film base material is a B-stage resin composition for an additive process.
According to the present invention 2, there is provided a heat-resistant film base-material-inserted B-stage resin composition sheet, wherein the metal foil attached to the one surface of the sheet has roughness on a metal foil surface on the resin composition side.
According to the present invention 2, there is provided a multilayer printed wiring board produced by stacking a conductor circuit and an interlayer resin insulating layer on a substrate sequentially, wherein a heat-resistant film layer is inserted in the insulating layer.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is an explanatory drawing showing steps of producing a printed wiring board in Example 2.
FIG. 2 is an explanatory drawing showing steps of producing a printed wiring board in Example 3.
FIG. 3 ( 1 ) is an explanatory drawing showing the structure of a heat-resistant film base-material-inserted B-stage resin composition sheet in Example 5.
FIG. 3 ( 2 ) is an explanatory drawing showing the structure of a heat-resistant film base-material-inserted B-stage resin composition sheet in Example 6.
FIG. 4 is an explanatory drawing showing steps of producing a printed wiring board in Example 6.
FIG. 5 is an explanatory drawing showing steps of producing a printed wiring board in Comparative Example 10.
FIG. 6 is an explanatory drawing showing steps of producing a printed wiring board in Comparative Example 11.
FIG. 7 is an explanatory drawing showing steps of producing a printed wiring board in Comparative Example 12.
FIG. 8 is an explanatory drawing showing steps of producing a printed wiring board in Example 7.
FIG. 9 is an explanatory drawing showing a roughened resin surface in Comparative Example 13.
FIG. 10 is an explanatory drawing showing steps of producing a printed wiring board in Comparative Example 15.
FIG. 11 is an explanatory drawing showing steps of producing a printed wiring board in Example 9.
FIG. 12 is an explanatory drawing showing steps of producing a printed wiring board in Comparative Example 19.
DETAILED DESCRIPTION OF THE INVENTION
In the present invention, symbols in drawings have the following meanings.
a: heat-resistant film, b: B-stage resin composition layer, c: release film, d: internal layer board insulating layer, e: internal layer copper foil circuit, f: copper foil, g: blind via hole, h: land, i: external layer copper foil circuit, j: copper foil convex portions, k: release film having roughness on one surface, l: concave and convex portions of release film, m: organic powder, n: inorganic powder, o: roughened concave and convex portions, p: release film having surface roughness or surface roughness after metal foil removal, q: glass fiber yarn, r: glass fiber cross section, s: protective film, t: prepreg, u: portion where a concave portion due to roughening reaches a glass cloth, v: aluminum foil, w: concave and convex portions of aluminum foil, x: B-stage resin composition layer for additive process, y: blind via hole filled with copper plating, z: second layer circuit formed by a semi-additive process, α: external layer circuit formed by a semi-additive process and β: resin filling through hole of internal layer substrate.
The present invention is characterized in that a B-stage resin composition sheet using a heat-resistant film as a base material is used as an adhesive sheet for producing a multilayer printed wiring board by stacking a conductor circuit and an interlayer resin insulating layer on an internal substrate concurrently or sequentially.
The heat-resistant film base-material-inserted B-stage resin composition sheet to be bonded to the internal substrate is a product in which thermosetting resin compositions are attached to both surfaces of the heat-resistant film. Heat-resistant film base-material-inserted B-stage resin composition sheets having release films or no materials attached to both surfaces are properly selected and used as required. Metal foils are used as outermost external layers. When the thickness of an insulating layer after molding is adjusted to 20 to 30 μm, the thickness of the heat-resistant film is preferably 4 to 20 μm, more preferably 4.5 to 12 μm. B-stage resin compositions which have the same constitution can be used on both surfaces of the heat-resistant film. Further, B-stage resin compositions which have different constitutions can be used.
Since the above heat-resistant film base-material-inserted B-stage resin composition sheet contains the heat-resistant film base material, a printed wiring board obtained by carrying out buildup using a particularly thin internal layer board is high in mechanical strength and small in warp and distortion and is excellent in molding thickness at the time of lamination as compared with a printed wiring board using a conventional B-stage resin composition sheet including no base material. The above printed wiring board is suitable for a thin-type high-density printed wiring board such as CSP. Further, the above printed wiring board is high in insulating reliability in the Z direction since the heat-resistant film interrupts the Z direction. Therefore, it is very excellent in migration resistance.
The resin compositions to be attached to the heat-resistant film, used in the present invention, are not specially limited. Concretely, the resin compositions include known resins such as an epoxy resin, a polyimide resin, a polyfunctional cyanate ester resin, a maleimide resin, a double-bond-addition polyphenylene ether resin and an epoxidized or cyanate-modified polyphenylene ether resin. The above resins may be used alone or in combination. Of these, the polyfunctional cyanate ester resin is preferred in view of migration resistance, heat resistance and heat resistance after moisture absorption.
Particularly, there is preferably used a thermosetting resin composition containing, as an essential component, a resin composition obtained by adding (b) an epoxy resin which is liquid at room temperature in an amount of 15 to 500 parts by weight to (a) a polyfunctional cyanate ester monomer and/or a polyfunctional cyanate ester prepolymer in an amount of 100 parts by weight and adding (c) a heat-curing catalyst in an amount ratio of 0.005 to 10 parts by weight per 100 parts of the (a+b) components. By using the above composition, there can be obtained a resin composition layer which is excellent in flexibility and is not easily cracked and peeled off when attached to the heat-resistant film. Therefore, it is preferred to use the above composition in view of increases in heat resistance and reliability.
The polyfunctional cyanate ester compound which is preferably used in the present invention refers to a compound whose molecule contains at least two cyanato groups. Specific examples of the above polyfunctional cyanate ester compound include 1,3- or 1,4-dicyanatobenzene, 1,3,5-tricyanatobenzene, 1,3-, 1,4-, 1,6-, 1,8-, 2,6- or 2,7-dicyanatonaphthalene, 1,3,6-tricyanatonaphthalene, 4,4-dicyanatobiphenyl, bis(4-dicyanatophenyl)methane, 2,2-bis(4-cyanatophenyl)propane, 2,2-bis(3,5-dibromo-4-cyanotophenyl)propane, bis(4-cyanatophenyl)ether, bis(4-cyanatophenyl) thioether, bis(4-cyanatophenyl)sulfone, tris(4-cyanatophenyl)phosphite, tris(4-cyanatophenyl) phosphate, and cyanates obtained by a reaction between novolak and cyan halide.
In addition to the above examples, there can be used polyfunctional cyanate ester compounds disclosed in Japanese Patent Publications Nos. 41-1928, 43-18468, 44-4791, 45-11712, 46-41112, 47-26853 and JP-A-51-63149. Further, prepolymers having a molecular weight of 400 to 6,000 and having a triazine ring formed by the trimerization of cyanato group of each of these polyfunctional cyanate ester compounds may be also used. The above prepolymer is obtained by polymerizing the above polyfunctional cyanate ester monomer in the presence of an acid such as a mineral acid or a Lewis acid; a base such as sodium alcoholate or a tertiary amine or a salt such as sodium carbonate as a catalyst. The prepolymer partially contains an unreacted monomer and is in the form of a mixture of monomer with prepolymer, and this material is preferably used in the present invention. When used, generally, it is dissolved in an organic solvent in which it is soluble. There can be used bromine-added compounds of these and liquid resins.
The epoxy resin which is liquid at room temperature can be generally selected from known epoxy resins. Specific examples thereof include a bisphenol A type epoxy resin, a bisphenol F type epoxy resin, a phenol novolak type epoxy resin, an alicyclic epoxy resin, diglycidyl compounds of polyether polyol and epoxidized compounds of acid anhydride. These epoxy resins may be used alone or in combination. The amount of the epoxy resin per 100 parts by weight of the polyfunctional cyanate ester compound and/or the polyfunctional cyanate ester prepolymer is 15 to 500 parts by weight, preferably 20 to 300 parts by weight. The term “liquid at room temperature” means “unbreakable at room temperature (25° C.)”.
Besides the above liquid epoxy compounds, there may be used known solid epoxy resins, which are breakable at room temperature, of the above epoxy resins, further, a cresol novolak type epoxy resin, a biphenyl type epoxy resin and a naphthalene type epoxy resin as a slightly soluble resin. These resins may be used alone or in combination. These resins may have bromine or phosphorus in molecules and such resins are suitable for producing a flame resistant B-stage resin composition.
The thermosetting resin composition used in the present invention may contain various additives other than the above compounds as required so long as the inherent properties of the composition are not impaired. Examples of the additives include various resins, known bromine compounds and phosphorus compounds of these resins, various known additives such as inorganic or organic filler, a dye, a pigment, a thickener, a lubricant, an anti-foamer, a dispersing agent, a leveling agent, a photo-sensitizer, a flame retardant, a brightener, a polymerization inhibitor and a thixotropic agent. These additives may be used alone or in combination as required. A known curing agent or a known catalyst is incorporated into a compound having a reactive group as required.
The thermosetting resin composition used in the present invention undergoes curing itself under heat. Since, however, its curing rate is low, it is poor in workability and economic performances, etc., and a known heat-curing catalyst is incorporated into the thermosetting resin. The amount of the catalyst per 100 parts by weight of the thermosetting resin is 0.005 to 10 parts by weight, preferably 0.01 to 5 parts by weight.
The method of kneading the components of the present invention homogeneously may be selected from generally known methods. For example, the components are mixed and then the mixture is kneaded with a three-roll mill at room temperature or under heat. Otherwise, a generally known machine such as a ball mill or a mortar machine is used. Further, a viscosity is adjusted by adding a solvent so as to meet a processing method.
Further, the heat-resistant film base material of the heat-resistant film base-material-inserted B-stage resin composition sheet is not specially limited in kind and thickness and can be selected from known heat-resistant film base materials. Specifically, it includes a polyimide (kapton) film, a polyparabanic acid film, a liquid crystal polyester film and a wholly aromatic polyamide film. The thickness of the heat-resistant film base material is properly selected depending upon a purpose. For adjusting the insulating layer thickness after laminate-molding to a small thickness of approximately 20 to 40 μm, there is used a heat-resistant film having a thickness of preferably 4 to 20 μm, more preferably 4.5 to 12 μm. When an adhesive resin layer is formed on a surface of the heat-resistant film, it is preferred to perform treatment such as corona treatment, plasma treatment, low ultraviolet radiation treatment, treatment with chemical or sandblast treatment to increase the adhesive property to the resin. In this case, it is acceptable to perform no treatment.
The method of producing the heat-resistant film base-material-inserted B-stage resin composition sheet is not specially limited. For example, it includes a method in which a resin composition varnish is applied to one surface of the heat-resistant film base material, the applied varnish is B-staged by drying, then the above resin composition varnish is again applied to the other surface opposite to the above surface and the applied varnish is dried to form B-stage resin composition layers on both the surfaces of the heat-resistant film, a method in which a resin composition varnish is applied to one surface of the heat-resistant film base material, the applied varnish is B-staged by drying and then a B-stage resin composition sheet with a release film is laminate-bonded to the other surface opposite to the above surface, and a method in which B-stage resin composition sheets with release films are disposed on both surfaces of the heat-resistant film, one sheet on one surface, and these materials are bonded to each other by lamination at once. The heat-resistant film base-material-inserted B-staged resin composition sheet having the B-stage resin composition layers formed on both surfaces is produced by the above methods or the like. The production method is not limited to the above methods.
When the B-stage resin composition layer is attached to the heat-resistant film, the method therefor can be selected from known methods. For example, the resin composition is directly applied to the heat-resistant film with a roll coater or the like, and then dried to B-stage the resin composition. Otherwise, it is applied to a release film and then dried to B-stage the applied resin composition, then the heat-resistant film is disposed on the resin composition side and the components are pressure-bonded with a heating and pressure roll to form an integrated release-film-attached B-stage resin composition sheet. In this case, a small amount of solvent may remain in the resin composition. The thickness of the resin composition is not specially limited, while it is generally 5 to 100 μm, preferably 6 to 50 μm, more preferably 7 to 20 μm. The above thickness is properly selected depending upon the thickness and copper survival rate of a copper foil of an internal layer board to be used for lamination and the roughness of a copper foil to be used as an external layer. For example, when the thickness of the copper foil of the internal layer board is 12 μm and the copper survival rate is 50%, the thickness of the resin layer on the heat-resistant film is 6 μm or more, for example 10 μm. Further, the resin layer is formed such that it has a thickness taller than tops of convex portions of the copper foil as an external layer.
The resin compositions to be bonded to the heat-resistant film can be selected from known resin compositions. In this case, it is preferred to treat the heat-resistant film by a known surface treatment in view of adhesiveness. Surface roughness due to the treatment is not specially limited, while it is preferably 0.1 to 5 μm. In this case, roughness is formed according to the thickness of a heat-resistant film to be used and the roughness is adjusted so as not to exceed the thickness of the heat-resistant film. By using the heat-resistant film, there can be produced a multilayer printed wiring board excellent in insulating properties in the Z direction and reliability such as migration resistance.
The resin layers on both the surface of the heat-resistant film may have the same thickness or different thickness. For example, when the resin layer on an external layer side has a thickness of 5 to 10 μm and the resin layer to be attached on an internal layer side has a thickness of 10 to 100 μm, the total thickness can become small. In this case, the thickness of the resin layer on the external layer side is adjusted such that roughness of metal foil do not reach to the heat-resistant film and the thickness of the resin layer on the internal layer side is adjusted such that an internal layer copper foil is not in contact with the heat-resistant film. When an internal layer board having IVH (interstitial via hole) is used, depending upon the diameter of IVH, the number of IVH and the thickness of the internal layer board and further depending upon the copper survival ratio of the internal layer board, a resin attached amount (thickness) on the internal layer board side is increased up to an amount sufficient for burying IVH and a circuit after laminate-molding such that the heat-resistant film is not in contact with the internal layer board circuit. The thickness of the resin layer on the internal layer side is preferably 10 to 100 μm and it is properly selected depending upon the diameter of IVH, the number of IVH and the survival ratio of circuit copper as required. In this case, the thickness of the resin layer on the metal foil side from tops of copper foil convex portions is preferably 3 to 15 μm, more preferably 5 to 10 μm, for decreasing the total thickness.
Multilayer formation is carried out by using the heat-resistant film base-material-inserted B-stage resin composition sheet for lamination, provided by the present invention, as follows. An internal layer board having conductor circuits formed is prepared by using a copper-clad laminate or a heat-resistant film base-material-reinforced copper-clad sheet and a known surface treatment is provided to the conductor. Otherwise, circuit boards having roughened foils on both surfaces for internal layer are prepared. The above heat-resistant film base-material-inserted B-stage resin composition sheets are disposed on front and reverse surfaces of the above internal layer board or between the circuit boards. Then, the resultant set is laminate-molded or laminated under heat and pressure, preferably in vacuum, according to a known method to cure the resin composition. In an additive process, curing treatment is carried out to attain such a cured degree that allows roughening with a roughening solution, then the metal foils or release films are removed, the resultant surfaces are roughened with a roughening solution to obtain intended concave and convex portions, and then electroless plating and/or electroplating are carried out. In a subtractive process, circuits are formed while retaining the metal foils to obtain a printed wiring board.
When release films are attached to both surfaces of the heat-resistant film base-material-inserted B-stage resin composition sheet of the present invention, the release films are removed and then the resultant B-stage resin composition sheet is disposed on the internal layer board. Otherwise, the release film on one surface is removed and then the resultant B-stage resin composition sheet is disposed on the internal layer board. Then, the resultant set is laminate-bonded with a heating roll under heat and pressure, the release film on the other surface is removed, an internal layer board or a metal foil is disposed thereon and the resultant set is laminate-molded.
The metal foil to be used is not specially limited. Specific examples thereof include aluminum foil, copper foil and nickel foil. Copper foil is preferably used. Generally a metal foil having roughness is preferably used in view of an increase in adhesive strength. The thickness of the metal foil is not specially limited. Generally, it is 3 to 35 μm.
The laminate-molding conditions for multilayer formation are not specially limited. Generally, the temperature therefor is 100 to 250° C., the pressure therefor is 5 to 50 kgf/cm 2 and the time therefor is 0.5 to 3 hours. Further, the laminate-molding is preferably carried out in vacuum. A device can be selected from known devices such as a vacuum laminater press and a general multistage vacuum press. In the case of the vacuum laminater press, when curing is insufficient, post-curing is carried out with an oven or the like.
The release film used in the present invention is not specially limited. Specifically, it can be selected from known films such as a polyethylene terephthalate (PET) film, a polypropylene film, a poly-4-methylpentene-1 film and a fluororesin film. These films are preferably treated by release agent treatment or antistatic treatment before use. Further, a release film having roughness formed on a surface to be applied can be used. The roughness of the surface to which the resin is to be attached is not specially limited. The surface preferably has an average roughness Rz of 1 to 12 μm, more preferably 2 to 10 μm. The thickness of the release film is not specially limited. It is generally 15 to 100 μm, preferably 20 to 50 μm.
According to the present invention 2, the B-stage resin composition sheet using a heat-resistant film as a base material, provided by the present invention, is used as an adhesive sheet for producing a multilayer printed wiring board by sequentially stacking a conductor circuit and an interlayer resin insulating layer on an internal layer substrate according to an additive process.
The above heat-resistant film base-material-inserted B-stage resin composition sheet which is to be bonded to the internal layer substrate is a product in which resin composition layers having no tackiness are formed on both surfaces of the heat-resistant film or a heat-resistant film base-material-inserted release-sheet-attached B-stage resin composition sheet having a structure in which a release film is attached to a resin composition layer surface having tackiness. Preferably, it has a structure in which a 5 to 20 μm thick resin composition layer for an additive process is bonded to at least one surface of the heat-resistant film. When the insulating layer thickness after molding is adjusted to 20 to 30 μm, a heat-resistant film having a thickness of 4 to 20 μm is preferably used.
Further, the insulating layer for an additive process formed on the at least one surface of the heat-resistant film base-material-inserted B-stage resin composition sheet contains a resin component which, when the sheet is roughened with a roughening solution after curing treatment, is slightly soluble in the roughening solution and a component which is soluble in the roughening solution. It is preferred to use a curable resin composition containing, as an essential component, a resin composition containing (a) a polyfunctional cyanate ester monomer and/or a polyfunctional cyanate ester prepolymer in an amount of 100 parts by weight, (b) an epoxy resin which is liquid at room temperature in an amount of 15 to 500 parts by weight, and (c) a heat-curing catalyst in an amount ratio of 0.005 to 10 parts by weight per 100 parts by weight of (a)+(b), as the slightly-soluble resin component for increasing heat resistance, reliability and the like. When the above curable resin composition contains, as essential components, at least two components selected from the group of three components consisting of a butadiene-containing resin and an organic powder as the component soluble in the roughening agent after curing treatment and an inorganic powder, there can be obtained excellent copper adhesive strength in plating.
The B-stage resin composition layer on at least one surface of the heat-resistant film base material of the present invention 2 is a resin composition on which a circuit can be formed by an additive process and it includes generally known resin compositions such as a thermosetting type and a phtocurable and thermosetting combination type. The resin composition layer of the heat-resistant film base-material-inserted B-stage resin composition sheet is not specially limited and it can be selected from generally known ones. The above resin composition layer contains a component soluble in a roughening solution, when subjected to curing treatment, and a resin component slightly soluble in a roughening solution. The soluble component is homogeneously dispersed in the slightly-soluble resin component. Here, the meanings of the term “soluble” and the term “slightly soluble” used in the present invention are as follows. In cases of immersions in the same roughening solution for the same period of time after curing treatment, a component which has a relatively fast rate of dissolution is expressed as “soluble” and a component which has a relatively slow rate of dissolution is expressed as “slightly soluble”.
The soluble resin in the present invention can be selected from generally known soluble resins. This resin is a resin which is soluble in a solvent or a liquid resin. It is incorporated in the slightly-soluble resin. It is not specially limited. Specifically, it includes known ones such as polybutadiene rubber, acrylonitrile-butadiene rubber, epoxidized compounds, maleinized compounds, imidized compounds, carboxyl group-containing compounds and (meth)acrylated compounds of these, and styrene-butadiene rubber. Particularly, resins having a butadiene skeleton in a molecule are preferably used in view of the solubility in a roughening solution or electric characteristics. Further, a resin containing a functional group is preferred as compared with a nonfunctional resin since it reacts with other unreacted resin functional groups in post-curing treatment to undergo crosslinking and improve characteristics.
The soluble organic powder in the present invention is not specially limited and it includes thermosetting resin powders and thermoplastic resin powders. It is not specially limited so long as the rate of dissolution thereof is faster than that of a curing-treated slightly-soluble resin when they are immersed in a roughening solution. The shape of the organic powder includes a spherical shape, a broken amorphous shape, a needle shape and the like. Organic powders having these shapes can be used in combination. An organic powder having a spherical shape and an organic powder having a broken shape are preferably used. The particle diameter thereof is not specially limited, while it has preferably an average particle diameter of 0.1 to 10 μm, more preferably 0.2 to 5 μm. It is preferred to use an organic powder having a large particle diameter and an organic powder having a small particle diameter in combination. In this case, when a release film having surface roughness is used, an organic powder having a maximum particle diameter smaller than a resin layer thickness is used. For example, when an applied resin layer has a thickness of 7 μm from tops of convex portions of the release film, the maximum particle diameter of the powder is 7 μm or less, preferably 6 μm or less such that particles are not exposed from the surface of the resin after application. The average particle diameter in this case is 6 μm or less.
Specific examples thereof include powders of an epoxy resin, a polyimide resin, a polyphenylene ether resin, a polyolefine resin, a silicon resin, a phenol resin, acrylic rubber, polystyrene, MBS rubber, ABS, and the like, and multiple structure (core-shell) rubber powders of these. These powders may be used alone or in combination as required.
The inorganic powder in the present invention 2 is not specially limited. Examples thereof include aluminum compounds such as alumina and aluminum hydroxide; calcium compounds such as calcium carbonate; magnesium compounds such as magnesia; and silica compounds such as silica and zeolite. These may be used alone or in combination.
As the slightly-soluble resin used in the present invention 2, known slightly-soluble resins such as thermosetting resins and photosensitive resins may be used alone or in combination. The slightly-soluble resin is not specially limited. Specific examples thereof include an epoxy resin, a polyimide resin, a polyfunctional cyanate ester resin, a maleimide resin, a double-bond-addition polyphenylene ether resin, a polyphenylene ether resin, a polyolefine resin, epoxy acrylate, an unsaturated-group-containing polycarboxylic acid resin and a polyfunctional (meth)acrylate. Further, known brominated compounds and phosphorus-containing compounds of these can be used. Of these, the polyfunctional cyanate ester resin is preferred in view of migration resistance, heat resistance, and heat resistance after moisture absorption. Particularly, it is preferred to use a thermosetting resin composition containing, as an essential component, a resin composition containing (a) a polyfunctional cyanate ester monomer and/or a polyfunctional cyanate ester prepolymer in an amount of 100 parts by weight, (b) an epoxy resin which is liquid at room temperature in an amount of 15 to 500 parts, and (c) a heat-curing catalyst in an amount ratio of 0.005 to 10 parts by weight per 100 parts by weight of (a)+(b).
The total amount of the soluble resin, the organic powder and the inorganic powder which are homogeneously dispersed in the resin composition of the present invention 2 is not specially limited, while it is preferably 3 to 50% by weight, more preferably 5 to 35% by weight, based on the whole. At least two components of the above three components are used. The diameters of these components are preferably different rather than the same. When the diameters are different, the shape of roughness becomes more complicate, which increase an anchor effect. Therefore, a resin composition layer excellent in copper plating adhesive strength can be obtained.
The method of producing the heat-resistant film base-material-inserted B-stage resin composition sheet of the present invention 2 is not specially limited. It is produced by a method in which a known adhesive for a heat-resistant film is applied to both surfaces of the heat-resistant film base material and then dried to B-stage the adhesive, and a B-stage resin composition sheet bonded to a release film is laminate-bonded to one surface of the resultant heat-resistant film, a method in which a known adhesive for a heat-resistant film is applied to one surface of the heat-resistant film base material and then dried to B-stage the adhesive and then a release-film-attached B-stage resin composition sheet is laminate-bonded to the other surface of the heat-resistant film base material, or other methods. The resin layers on both the surfaces of the heat-resistant film base material may have the same thickness. Further, generally, the resin composition layer for an additive process is made thin and the resin layer used for lamination to an internal layer board is made thick. The production method is not specially limited to the above methods.
In the present invention 2, when a varnish or the like is applied to a release film and then dried to B-stage it, the release film to be used is selected from known release films. A surface of the release film may be rough or smooth. The roughness of a surface to which the resin is to be attached is not specially limited. It preferably has an average roughness Rz of 1 to 10 μm, more preferably 2 to 7 μm. This is because, when the roughness before roughening is large, the roughening time is short and penetration of water content is small so that swelling of a plated copper layer due to heating can be decreased. The thickness of the release film is not specially limited, while a release film having a thickness of 15 to 50 μm is generally used.
When the B-stage resin composition layer is attached to the release film, the method therefor can be selected from known methods. For example, the resin composition is directly applied to the release film with a roll and then dried to B-stage the composition. In another method, the resin composition is directly applied to the release film and then dried to B-stage the composition, the thus-obtained release film with the B-stage resin composition is disposed on each surface of the heat-resistant film and the resultant set is pressure-bonded with a heating and pressure roll, to prepare an integrated release-film-attached B-stage resin composition sheet. In this case, a small amount of a solvent may remain in the resin composition. The thickness of the resin composition is not specially limited, while it is generally 3 to 100 μm, preferably 4 to 50 μm, more preferably 5 to 20 μm from tops of convex portions of a metal foil. The above thickness of the resin composition together with the thickness of the heat-resistant film is properly selected depending upon an intended insulating layer thickness. The above thickness is set such that it is sufficient for making roughness enough for securing adhesive strength to plated copper.
In the present invention 2, in the case of multilayer formation, an internal board obtained by forming a conductor circuit in a copper-clad laminate or a heat-resistant film base-material-reinforced copper-clad sheet is prepared and the conductor is treated by known surface treatment. Otherwise, a circuit board for internal layer which board uses roughened foils on both surfaces is prepared. The above heat-resistant film base-material-inserted release-film-attached B-stage resin composition sheets are disposed on front and reverse surfaces of the above internal layer board. Then, the resultant set was laminate-molded or laminated under heat and pressure preferably in vacuum according to a known method, to perform curing treatment and to obtain a curing degree which allows roughening with a roughening solution. After the laminate-molding or lamination, the release films are removed. Of course, there can be employed a method in which the heat-resistant film base-material-inserted release-film-attached B-stage resin composition sheet is laminate-bonded to an internal layer board, the release film of an external layer is separated and then a metal foil having surface roughness is disposed and the resultant set is laminate-molded. The metal foil used in the above case is selected from known metal foils such as an aluminum foil, a copper foil and a nickel foil. The surface roughness degree of the metal foil may be the same as the above degree of the release film.
Curing treatment laminate-molding conditions in multilayer formation are the same as those of the present invention 1.
After the metal foils or release films of the external layers of the metal-foil-clad or release-film-clad board obtained in the present invention 2 are removed, the resin layers are roughened with an acid or an oxidizer by a known method. The acid to be used includes sulfuric acid, hydrochloric acid, nitric acid, phosphoric acid and formic acid. The oxidizer includes sodium permanganate, potassium permanganate, chromic acid and chrome sulfuric acid. The acid and the oxidizer shall not be limited to these. Before the above treatment, a known swelling liquid is used as required. After the treatment, neutralization is carried out with a neutralization liquid. The average roughness of a roughened surface formed by above roughening treatment is 0.1 to 10 μm, preferably 0.2 to 5 μm, as an average roughness Rz, besides the roughness of the metal foil. The total roughness of the roughness of the metal foil or release film and the roughness formed by the roughening treatment is generally 3 to 15 μm, preferably 5 to 12 μm, as an average roughness RZ.
The curable resin composition in the present invention 2 contains at least two components selected from the group consisting of a butadiene-containing resin, an organic powder and an inorganic powder, small concave and convex shapes are present in roughened concave portions even when the average roughness is not very high. Therefore, when the resin composition is plated with copper, the adhesive strength becomes high. When only one component is contained, the roughness does not become a complication so that it is difficult to obtain high copper adhesive strength.
Thereafter, electroless plating, thickening electroless plating, deposition, sputtering, etc., are carried out by a semi-additive process or a full-additive process. Generally, electroplating is carried out to thicken a conductor. When a produced printed wiring board which still retains a curing degree that allows roughening with a roughening solution, it is poor in heat resistance and reliability and can not be used as a high-density printed wiring board, although it depends upon the constitution of the resin composition. Therefore, post-curing is generally carried out before forming a circuit. The post-curing is carried out at a temperature of 100 to 250° C. for 30 minutes to 5 hours, although these conditions differ depending upon the constitution of the resin composition. Then, a circuit is formed by a known method, thereby producing a printed wiring board. Buildup is carried out by repeating the same steps sequentially, to form a multilayer structure. Of course, in accordance with the constitution of the resin composition, it is possible to cure the resin composition in advance and then carry out roughening.
The above base-material-inserted B-stage resin composition sheet can be used also as a B-stage resin composition sheet for lamination used for a general copper-clad laminate or a multilayer board. It is also possible to carry out lamination by using copper foils after the release films are removed and then produce a printed wiring board by a subtractive process.
The present invention 2 further provides a heat-resistant film base-material-inserted B-stage resin composition sheet for an additive process in which a metal foil attached to one surface of a B-stage resin composition for lamination has roughness on a metal foil surface on the resin composition side.
The metal foil having roughness on a surface used in the present invention 2 is not specially limited. Specifically, it includes an aluminum foil, a copper foil, a nickel foil and the like. The roughness of the surface, to which the resin is to be attached, is not specially limited. It has preferably an average roughness Rz of 1 to 10 μm, more preferably 2 to 7 μm. This is because, when the roughness before roughening is large, the roughening time is short and penetration of water content is small so that swelling of a plated copper layer due to heating can be decreased.
The thickness of the metal foil is not specially limited, while a small thickness is better in view of subsequent removal of the metal foil by etching or the like. It is preferably 9 to 20 μm. Of course, even when a metal foil having no roughness is used, it is possible to obtain high copper plating adhesive strength by making a roughening time longer. However, a shorter roughening treatment time is preferred in view of water absorption or the like.
When B-stage resin composition layer is attached to the metal foil, the method therefor can be selected from known methods. For example, the resin composition is directly applied to the metal foil with a roll and then dried to B-stage the resin composition. Otherwise, the resin composition is applied to a release film and then dried to B-stage the resin composition, then the metal foil is disposed on the resin composition side and the resultant set is pressure-bonded with a heating and pressure roll, to prepare an integrated metal-foil-attached B-stage resin composition sheet. In this case, a small amount of a solvent may remain in the resin composition. The thickness of the resin composition is not specially limited, while it is generally 3 to 100 μm, preferably 4 to 50 μm, more preferably 5 to 20 μm from tops of convex portions of the metal foil. The above thickness of the resin composition together with the thickness of the heat-resistant film is properly selected depending upon an intended insulating layer thickness. The thickness is set such that it is sufficient for making roughness enough for securing adhesive strength to plated copper.
By using the heat-resistant film, there can be produced a multilayer printed wiring board which is excellent in insulating properties in the Z direction and is excellent in reliability such as migration resistance since the heat-resistant film stops plating adherence of subsequent electroless copper plating.
The present invention 2 further provides a multilayer printed wiring board which is produced by stacking a conductor circuit and an interlayer resin insulating layer on a substrate sequentially, wherein a heat-resistant film layer is inserted in the stacked insulating layer.
Further, the present invention 2 provides a multilayer printed wiring board according to the above, wherein the conductor circuit is formed by an additive process.
The above multilayer printed wiring board is a thin-type multilayer printed wiring board which is produced by stacking a conductor circuit and an interlayer resin insulating layer on a internal layer substrate sequentially and using a subtractive process or an additive process.
The method of producing the multilayer printed wiring board of the present invention 2 is not specially limited. Examples thereof are as follows.
a. a method in which a so-called metal-foil-attached or release-film-attached B-stage resin composition sheet, in which a heat-resistant film-inserted B-stage resin composition layer is attached to a metal foil or a release film, is used for buildup lamination. b. a method in which a varnish is applied to a surface of an internal layer substrate and dried to B-stage the varnish, a heat-resistant film is disposed on the above surface, a metal-foil-attached or release-film-attached B-stage resin composition sheet containing no substrate or a prepreg is disposed thereon, a metal foil is optionally disposed as required, and lamination is carried out. c. a method in which a heat-resistant film, to one surface or both surfaces of which a B-stage resin composition layer for lamination is attached, is placed on an internal layer substrate and a metal-foil-attached or release-film attached B-stage resin composition sheet containing no substrate or a prepreg is disposed thereon, a metal foil is disposed as required, and lamination is carried out.
Further, circuits can be made by a subtractive process or an additive process, and other known buildup methods can be also used.
When the B-stage resin composition for an additive process has a curing degree which allows roughening and is directly used to prepare a printed wiring board, the obtained printed wiring board is poor in heat resistance and reliability and can not be used as a high-density printed wiring board although it depends upon the constitution of the resin composition. Therefore, post-curing is generally carried out before forming a circuit. The post-curing is carried out at a temperature of 60 to 250° C. for 30 minutes to 5 hours, although these conditions differ depending upon the constitution of the resin composition. Then, a circuit is formed by a known method, thereby producing a printed wiring board. Buildup is carried out by repeating the same steps sequentially, to form a multilayer structure. Of course, in accordance with the constitution of the resin composition, it is possible to cure the resin composition in advance and then carry out roughening. When a multilayer board is produced by a subtractive process, the resin layer is completely cured or almost completely cured at the time of lamination such that respective properties can be retained.
When the resin layer on at least the metal foil or release film side of the heat-resistant film base-material-inserted metal-foil-attached or release-film-attached B-stage resin composition sheet is an insulating layer for an additive process, this insulating layer contains a resin component which, when the layer is roughened with a roughening solution after curing treatment, is slightly soluble in the roughening solution and a component which is soluble in the roughening solution. As the slightly-soluble resin component, it is preferred to use a curable resin composition containing, as an essential component, a resin composition composed of (a) a polyfunctional cyanate ester monomer and/or a polyfunctional cyanate ester prepolymer in an amount of 100 parts by weight, (b) an epoxy resin which is liquid at room temperature in an amount of 15 to 500 parts by weight, and (c) a heat-curing catalyst in an amount ratio of 0.0 05 to 10 parts by weight per 100 parts by weight of (a)+(b), in view of increases in heat resistance, reliability, etc. When the above curable resin composition contains, as essential components, at least two components selected from the group of three components consisting of a butadiene-containing resin and an organic powder as the component which is soluble in the roughening solution after curing treatment and an inorganic powder, there can be obtained a B-stage resin composition sheet which is also excellent in plating copper adhesive strength.
Further, since the above base-material-inserted metal-foil or release-film-attached B-stage resin composition sheet includes the heat-resistant film base material so that a printed wiring board obtained by carrying out buildup using a particularly thin internal layer board is high in mechanical strength and small in warp and distortion and is excellent in molding thickness at the time of lamination, as compared with a printed wiring board using a conventional B-stage resin composition sheet including no base material. The above printed wiring board is suitable for a thin-type high-density printed wiring board for a subtractive process or additive process. Further, the heat-resistant film interrupts the Z direction so that the above printed wiring board is high in insulating reliability particularly in the Z direction and very excellent in migration resistance.
The resin composition layer bonded to the metal foil or the release film of the heat-resistant film base-material-inserted metal-foil or release-film-attached B-stage resin composition sheet to be used for an external side, is made of a resin composition which allows a circuit to be formed by a subtractive process or an additive process. The above resin composition can be selected from generally known resin compositions such as a thermosetting type resin composition and a thermosetting-and-photocurable-combination type resin composition. The resin composition layer of the heat-resistant film base-material-inserted metal-foil or release-film-attached B-stage resin composition sheet is not specially limited and can be selected from generally known resin compositions.
Concerning the resin composition layers bonded to the heat-resistant film base material, the resin composition to be used for an internal layer board side can be selected from known resin compositions. Further, the resin composition for an additive process can be used as the resin composition to be used for an internal layer board side. However, the soluble component added for an additive process is poor in resistance to chemical in many cases. Therefore, it is generally preferred to use a resin composition containing mainly the above-mentioned slightly-soluble resin. Owing to the use of the heat-resistant film base material, there can be produced a multilayer printed wiring board excellent in reliability such as migration resistance in the Z direction.
In the case of multilayer formation, an internal layer board is prepared by forming a conductor circuit in a copper-clad laminate or a heat-resistant film base-material-reinforced copper-clad sheet and a known surface treatment is provided to the conductor. Otherwise, a circuit board having roughened foils on both surfaces for internal layer is prepared. The above heat-resistant film base-material-inserted metal-foil or release-film-attached B-stage resin composition sheets are disposed on front and reverse surfaces of the above internal layer board. Then, the resultant set is laminate-molded or laminated under heat and pressure preferably in vacuum according to a known method, to carry out curing treatment until the resin composition for an additive process reaches to a curing degree which allows roughening with a roughening solution. After the laminate-molding or the lamination, the metal foil is removed by etching or the like. The release film is removed by separating. In a subtractive process, the resin compositions are cured completely or almost completely at the time of laminate-molding.
For the additive process, after the removal of the metal foils or release films on external layers of an obtained metal-foil-clad board or a release-film-attached board, the resin compositions are roughened by a known method as described before. Before this treatment, a known swelling liquid is used as required. After the treatment, neutralization is carried out with a neutralization liquid. The average roughness of a roughened surface is as described before.
This heat-resistant film base-material-inserted B-stage resin composition sheet can be used also as a B-stage resin composition sheet for lamination used for a general copper-clad laminate or a multilayer board. When the release films are used, the release films are separated, then copper foils are disposed on the resultant surface or disposed between internal layer boards, lamination is carried out and a printed wiring board is produced by a subtractive process.
EFFECT OF THE INVENTION
According to the present invention 1, there is provided a heat-resistant film base-material-inserted B-stage resin composition sheet in which the B-stage resin composition layers are formed on both surfaces of the heat-resistant film. A printed wiring board obtained by laminate-molding using it is excellent in reliability such as migration resistance in the Z direction.
Further, when the resin composition containing (a) a polyfunctional cyanate ester monomer and/or a polyfunctional cyanate ester prepolymer in an amount of 100 parts by weight, (b) an epoxy resin which is liquid at room temperature in an amount of 15 to 500 parts by weight, and (c) a heat-curing catalyst in an amount ratio of 0.005 to 10 parts by weight per 100 parts by weight of (a)+(b) is essentially used as a resin component, there can be provided a multilayer printed wiring board which has high heat resistance and is excellent in reliability such as migration reliability and crack resistance and is also excellent in copper adhesive strength.
According to the present invention 2, there is provided a heat-resistant film base-material-inserted B-stage resin composition sheet for an additive process, which resin composition sheet has a structure in which the B-stage resin composition layers are bonded to both surfaces of the heat-resistant film, wherein the B-stage resin composition layer for an additive process is formed on at least a surface side to be used as an external layer. When the above sheet is used for buildup to obtain a multilayer printed wiring board, the obtained multilayer printed wiring board has high elastic modulus (hardness) and is excellent in warp resistance, distortion resistance and thickness accuracy and further excellent in migration resistance in the Z direction.
Further, when at least the resin composition for an additive process of the base-material-inserted metal-foil-attached B-stage resin composition uses a curable resin composition including, as an essential component, a resin composition containing (a) a polyfunctional cyanate ester monomer and/or a polyfunctional cyanate ester prepolymer in an amount of 100 parts by weight, (b) an epoxy resin which is liquid at room temperature in an amount of 15 to 500 parts by weight, and (c) a heat-curing catalyst in an amount ratio of 0.005 to 10 parts by weight per 100 parts by weight of (a)+(b), as a resin component which is slightly-soluble after curing treatment and further uses, as essential components, at least two members selected from the group of three components consisting of a butadiene-containing resin, an organic powder as a component which is soluble in a roughening solution after curing treatment and an inorganic powder, there is provided a multilayer printed wiring board having high copper plating adhesive strength and high heat resistance and having excellent reliability such as migration resistance and crack resistance.
According to the present invention 2, there is provided a heat-resistant film base-material-inserted metal-foil-attached B-stage resin composition sheet for an additive process in which the metal foil bonded to one surface of the B-stage resin composition for an additive process has roughness on a metal foil surface on the resin composition side. Accordingly, there is provided a multilayer printed wiring board which has high elastic modulus (hardness) and is excellent in warp resistance, distortion resistance and thickness accuracy and further excellent in migration resistance in the Z direction. Since the resin for an additive process is subjected to roughening treatment, an anchor effect increases, so that there is obtained a printed wiring board having high adhesive strength to copper plating.
According to the present invention 2, there is provided a multilayer printed wiring board produced by stacking a conductor circuit and an interlayer resin insulating layer on a substrate sequentially, wherein the heat-resistant film is inserted in the stacked insulating layer. Owing to the above structure, the multilayer printed wiring board is excellent in migration resistance in the Z direction.
EXAMPLES
The present invention will be concretely explained with reference to Examples and Comparative Examples hereinafter. In Examples and Comparative Examples, “part” stand for “part by weight” unless otherwise specified.
Example 1
400 Parts of 2,2-bis(4-cyanatophenyl)propane monomer was melted at 150° C. and allowed to react for 4 hours with stirring, to prepare a prepolymer having an average molecular weight of 1,900. The prepolymer was dissolved in methyl ethyl ketone, to prepare a varnish. To the varnish were added 100 parts of a bisphenol A type epoxy resin (trade name: Epikote 828, supplied by Japan epoxy resin), 150 parts of a bisphenol F type epoxy resin (trade name: EXA830LVP, supplied by Dainippon Ink And Chemicals, Incorporated) and 150 parts of a novolak type epoxy resin (trade name: DEN438, supplied by Dow Chemical) as epoxy resins liquid at room temperature, and 200 parts of a cresol novolak type epoxy resin (trade name: ESCN220F, supplied by Sumitomo Chemical Co., Ltd.) as an epoxy resin solid at room temperature. As a heat-curing catalyst, 0.3 part of iron acetylacetonate dissolved in methyl ethyl ketone was added thereto. 400 parts of talc (average particle diameter 1.8 μm, maximum particle diameter 4.2 μm) was added to the resultant mixture, and these materials were homogeneously stirred and mixed, to prepare a varnish.
The above varnish prepared from the epoxy resins liquid at room temperature, etc., was continuously applied to one surface of a 25 μm thick release PET film having a smooth surface, and the applied varnish was dried to obtain a B-stage resin layer having a gelatin time of 58 seconds and a thickness of 18 μm. At the time when the resultant film came out from a drying zone, a 20 μm thick polypropylene protective film was placed on the resin layer surface. These materials were laminated at 100° C. under a linear load of 4 kgf/cm, to prepare a release film-attached B-stage resin composition sheet. Further, the varnish prepared from the epoxy resins liquid at room temperature, etc., was continuously applied to one surface of a 25 μm thick release PET film having a smooth surface and the applied varnish was dried to form a B-stage resin layer having a gelatin time of 55 seconds and a thickness of 7 μm. At the time when the resultant film came out from a drying zone, a 20 μm thick polypropylene protective film was placed on the resin layer surface. These materials were laminated at 100° C. under a linear load of 4 kgf/cm, to prepare a release film-attached B-stage resin composition sheet. A 10 μm thick polyimide film was prepared and both surfaces thereof were treated by plasma treatment. Two kinds of the release film-attached B-stage resin composition sheets having different thickness from each other were disposed on both the plasma-treated surfaces of the polyimide film while separating each of the protective films, and these materials were continuously laminated at 90° C. under a linear load of 5 kgf/cm to integrate them, whereby heat-resistant film base-material-inserted release-film-attached B-stage resin composition sheets having a resin layer thickness of 35 μm were prepared.
Separately, circuits of a copper survival rate of 30% were formed on a BT resin copper-clad laminate having an insulating layer thickness of 0.2 mm and having 12 μm thick copper foils on both surfaces (trade name: CCL-HL830, supplied by Mitsubishi Gas Chemical Company, INC.) and then the copper foils were treated by black copper oxide treatment, to prepare an internal layer board. The above heat-resistant film base-material-inserted release-film-attached B-stage resin composition sheet was disposed on each surface of the internal layer board while separating the release film on one surface of the B-stage resin composition sheet such that the resin layer faced to the internal layer board. These materials were laminate-bonded with a heating roll at 90° C. under 5 kgf/cm, and then the release films on both the surfaces were peeled off. Electrolytic copper foils having a thickness of 12 μm and a nickel-treated shiny surface each were disposed on both the surfaces, one copper foil on one surface. The resultant set was placed in a press machine and it was laminate-molded under a vacuum of 30 mmHg or less for 2 hours at 110° C.·30 minutes+200° C.·90 minutes and 5 kgf/cm 2 ·20 minutes+20 kgf/cm 2 ·120 minutes, to obtain a multilayer board having four layers. The multilayer board had an insulation layer thickness of almost 20 μm. Each surface of the multilayer board was 1 shot irradiated directly with a carbon dioxide gas laser at an output of 12 mJ to make blind via holes having a diameter of 100 μm. The copper foils on the external surfaces were etched until the copper foils had a thickness of 4 μm each, and at the same time copper foil burrs in the blind via hole portions were removed. After desmear treatment, electroless copper plating was attached to a thickness of 0.7 μm and electrolytic copper plating was attached to a thickness of 15 μm. Then, circuits were formed by a general method. Black copper oxide treatment was carried out and then the above-prepared heat-resistant film base-material-inserted release-film-attached B-stage resin composition sheets were similarly disposed, and the resultant set was similarly processed to produce a six-layered printed wiring board. Table 1 shows results of evaluation of this printed wiring board.
Example 2
500 parts of a bisphenol A type epoxy resin (trade name: Epikote 1001, supplied by Japan epoxy resin), 450 parts of a phenol novolak type epoxy resin (trade name: DEN438, supplied by Dow Chemical), 30 parts of an imidazole type curing agent (trade name: 2E4MZ, supplied by Shikoku Corporation) and 400 parts of talc (average particle diameter 1.8 μm, maximum particle diameter 4.2 μm) were added. These materials were homogeneously dispersed with a three-roll mill, to prepare a varnish. The varnish was continuously applied to a 25 μm thick release PET film having a smooth surface and the applied varnish was dried to prepare a B-stage resin composition layer having a resin composition thickness of 23 μm and a gelation time of 65 seconds. The B-stage resin composition layer was disposed on each surface of a 4.5 μm thick wholly aromatic polyamide (aramid) film and continuously laminated with a heating roll at a temperature of 100° C. under a linear load of 5 kgf/cm, to produce heat-resistant film base-material-inserted release-film-attached B-stage resin composition sheets ( FIG. 1 ( 1 )). The insulating layer thickness thereof was approximately 50 μm.
Separately, circuits are formed on an epoxy type copper-clad laminate (trade name; CCL-EL170, supplied by Mitsubishi Gas Chemical Company, INC.) having a thickness of 0.2 mm and 12 μm thick copper foils on both surfaces and conductors were subjected to black copper oxide treatment to prepare an internal layer board. The above heat-resistant film base-material-inserted release-film-attached B-stage resin composition sheet was disposed on each surface of the internal layer board after separating the release PET film on one surface of the B-stage resin composition sheet. The resultant set was laminated with a heating roll at a temperature of 100° C. under a linear load of 5 kgf/cm, to prepare an internal layer board having the heat-resistant film base-material-inserted release-film-attached B-stage resin composition sheets attached to both the surfaces. Further, there was similarly prepared an internal layer board in which the heat-resistant film base-material-inserted release-film-attached B-stage resin composition sheet was attached to one surface of an internal layer board having conductors treated by black copper oxide treatment. The surface, to which the resin composition sheet was not attached, of the internal layer board having the resin composition sheet attached to the one surface was brought into contact with one surface of the above internal layer board having the resin composition sheets attached to both the surfaces, after the attached release films were separated. Electrolytic copper foils having a thickness of 12 μm and a nickel-treated shiny surface each were disposed on outermost external layers of the above internal layer boards, one copper foil on each external layer. The resultant set was placed in a press machine and it was laminate-molded under a vacuum of 30 mmHg or less for 2 hours at 110° C.·30 minutes+180° C.·90 minutes and 5 kgf/cm 2 ·15 minutes+20 kgf/cm 2 ·125 minutes, to obtain a multilayer board having six layers ( FIG. 1 ( 2 )). The insulating layer thickness between the internal layer boards was almost 30 μm. Each surface of the multilayer board was 1 shot irradiated with a carbon dioxide gas laser at an output of 12 mJ to make blind via holes having a diameter of 100 μm. The copper foils on the external surfaces were etched and dissolved until the copper foils had a thickness of 3 μm each, and at the same time copper foil burrs occurring in the hole portions were dissolved and removed. After a remaining resin layer in the bottom of each blind via hole was removed by desmear treatment, electroless copper plating was attached to a thickness of 0.7 μm and electrolytic copper plating was attached to a thickness of 15 μm. Then, circuits were formed by a general method, to produce a printed wiring board ( FIG. 1 ( 3 )). Table 1 shows results of evaluation of this printed wiring board.
Comparative Examples 1-2
The same varnishes as those obtained from the epoxy resins, etc., in Example 1 and Example 2 were used. Release-film-attached B-stage resin composition sheets were similarly obtained except that the thickness of the B-stage resin layer attached to the release film in Example 1 was changed to 21 μm and the thickness of the B-stage resin layer attached to the release film in Example 2 was changed to 50 μm, respectively. In Example 1 and 2, only these release film-attached B-stage resin composition sheets were used without the heat-resistant films used in Example 1 and 2, and the sheets were similarly laminate-molded to prepare multilayer printed wiring boards having six layers, as Comparative Examples 1 and 2. Table 1 shows results of evaluation of these printed wiring boards.
Comparative Example 3
In Example 1, a glass woven cloth having a thickness of 20 μm was impregnated with the same varnish obtained from the epoxy resins, etc., as that obtained in Example 1 and the impregnated varnish was dried to obtain a prepreg having a total thickness (glass woven cloth+resin composition layer) of 45 μm and a gelation time (170°) of 85 seconds. The prepreg was disposed on each surface of an internal layer board (BT resin copper-clad laminate). Electrolytic copper foils having a thickness of 12 μm and a nickel-treated shiny surface were disposed on both outer surfaces of the resultant board, one copper foil on one surface. The resultant set was placed in a press machine and then it was laminate-molded under the same conditions as those in Example 1 to prepare a multilayer board having four layers. Then, a multilayer printed wiring board having six layers was similarly produced. Table 1 shows results of evaluation of this printed wiring board.
Comparative Example 4
A glass woven cloth having a thickness of 27 μm was impregnated with the same varnish obtained from the epoxy resins, etc., as that obtained in Example 2 and the impregnated varnish was dried to obtain a prepreg having a total thickness (glass woven cloth+resin composition layer) of 50 μm and a gelation time (170°) of 88 seconds. The prepreg was disposed on each surface of an internal layer board (BT resin copper-clad laminate). Electrolytic copper foils having a thickness of 12 μm and a nickel-treated shiny surface were disposed on both outer surfaces of the resultant board, one copper foil on one surface. The resultant set was placed in a press machine and then it was laminate-molded under the same conditions as those in Example 2 to prepare a multilayer board having four layers. Then, a multilayer printed wiring board having six layers was similarly produced. Table 1 shows results of evaluation of this printed wiring board.
TABLE 1
Examples
Comparative Examples
Item
1
2
1
2
3
4
Copper adhesive strength (kgf/cm)
1.40
1.48
1.40
1.49
1.43
1.48
Soldering heat resistance
No
No
No
Partial
Partial
Partial
failure
failure
failure
swelling
swelling
swelling
Glass transition temperature DMA (° C.)
208
165
210
158
209
167
Elastic modulus 25° C. (kgf/mm 2 )
1,579
1,378
995
791
1,990
1,899
Warp · distortion (mm)
1.5
1.8
4.6
5.7
1.5
1.6
Thickness variance (μm)
4.8
5.0
9.8
12.9
—
—
Migration resistance (Ω)
Ordinary
5 × 10 13
5 × 10 13
6 × 10 13
6 × 10 13
7 × 10 13
6 × 10 13
state
100
5 × 10 11
8 × 10 10
6 × 10 10
8 × 10 8
6 × 10 9
1 × 10 8
hours
500
3 × 10 11
4 × 10 10
<10 8
<10 8
<10 8
<10 8
hours
<Measurement Methods>
1) Copper adhesive strength: Measured according to JIS C6481.
2) Soldering heat resistance: After pressure cooker test treatment (PCT: 121° C.·203 kPa·4 hours), a printed wiring board having six layers was immersed in solder at 260° C. for 30 seconds and then checked for failures.
3) Grass transition temperature: A plurality of sheets of each base-material-inserted B-stage resin composition sheet were stacked so as to have a thickness of about 0.8 mm and the stacked sheets were similarly laminate-molded under each lamination condition, then copper foils on external layers were etched and then the resultant laminate was measured by DMA method. In Comparative Examples 1 and 2, laminates obtained by applying a resin several times so as to have a thickness of about 0.8 mm and carrying out laminate-formation similarly were used.
4) Elastic modulus: Table 1 shows elastic modulus at 25° in the chart of DMA measured in 3).
5) Warp·distortion: A six-layered printed wiring board having a size of 250×250 mm was placed on a surface plate and a maximum value of warp or distortion was measured.
6) Thickness variance: The same six-layered printed wiring board having a size of 250×250 mm as that in 5) was measured for thickness variance at nine points, per adhesive sheet of the board, with a thickness measurement apparatus. It was represented by (maximum value−minimum value). In Example 2, the thickness variance of the adhesive sheet used between the internal layer boards was obtained by measuring its cross section.
7) Migration resistance: Copper foil portions having a size of 10×10 mm were left in the first layer and the second layer of the six-layered board of each of Examples and Comparative Examples at the same positions. 100 such copper foil portions were connected. The board was measured for insulating resistance in the insulating layer in the Z direction at 85° C.·85% RH under application of 100 VDC.
Example 3
A release-film-attached B-stage resin composition sheet was prepared in the same manner as in Example 1. Further, a varnish was prepared from epoxy resins, etc., in the same manner as in Example 1. The varnish was continuously applied to a mat surface of an electrolytic copper foil having a thickness of 12 μm and a shiny surface having a 0.5 μm thick nickel treatment, and the applied varnish was dried to form a B-stage resin layer having a gelation time of 51 seconds and a thickness, from tops of convex portions of the electrolytic copper foil, of 5 μm. At the time when the resultant copper foil came out from a drying zone, a 20 μm thick polypropylene protective film was placed on the resin layer surface. These materials were laminated at 100° C. under a linear load of 4 kgf/cm, to prepare a copper-foil-attached B-stage resin composition sheet. A polyimide film having a thickness of 12 μm was prepared and both surfaces of the polyimide film were treated by plasma treatment. The above two kinds of the B-stage resin composition sheets were disposed on both the surfaces of the polyimide film while separating each protective film. These materials were continuously laminated at 100° C. under a linear load of 5 kgf/cm to integrate them, whereby heat-resistant film base-material-inserted metal-foil-attached B-stage resin composition sheets having an insulating layer thickness of 35 μm were produced ( FIG. 2 ( 1 )).
Separately, circuits of a copper survival rate of 30% were formed on a BT resin copper-clad laminate having an insulating layer thickness of 0.2 mm and having 12 μm thick copper foils on both surfaces (trade name: CCL-HL830, supplied by Mitsubishi Gas Chemical Company, INC.) and then the copper foils were treated by black copper oxide treatment, to prepare an internal layer board. The above heat-resistant film base-material-inserted metal-foil-attached B-stage resin composition sheets were disposed on both the surfaces of the internal layer board while separating the release films such that the resin layers each faced to the internal layer board ( FIG. 2 ( 2 )). These materials were laminate-molded under a vacuum of 30 mmHg or less for 2 hours at 110° C.·30 minutes+200° C.·90 minutes and 5 kgf/cm 2 ·20 minutes+20 kgf/cm 2 ·120 minutes, to obtain a multilayer board having four layers ( FIG. 2 ( 3 )). The multilayer board had an insulation layer thickness of almost 25 μm. Each surface of the multilayer board was 1 shot irradiated directly with a carbon dioxide gas laser at an output of 12 mJ to make blind via holes having a diameter of 100 μm. The copper foils on the external surfaces were etched until the copper foils had a thickness of 4 μm each, and at the same time copper foil burrs in the blind via hole portions were removed. After desmear treatment, electroless copper plating was attached to a thickness of 0.5 μm and electrolytic copper plating was attached to a thickness of 15 μm. Then, circuits were formed by a general method. After black copper oxide treatment was carried out, the above-prepared heat-resistant film base-material-inserted copper-foil-attached B-stage resin composition sheets were similarly disposed, and the resultant set was similarly processed to produce a six-layered printed wiring board. Table 2 shows results of evaluation of this printed wiring board.
Example 4
A varnish was prepared from epoxy resins, etc., in the same manner as in Example 2. The varnish was applied to a release PET film and the applied varnish was dried to prepare the same B-stage resin composition layer as that prepared in Example 2. At the time when it came out from a drying zone, a 20 μm thick polypropylene protective film was placed on its resin layer surface. These materials were laminated at 100° C. under a linear load of 4 kgf/cm, to prepare a release-film-attached B-stage resin composition sheet. Further, the above varnish was continuously applied to a mat surface of the same electrolytic copper foil having a thickness of 12 μm and having a nickel-treated shiny surface as that used in Example 3, and the applied varnish was dried to form a B-stage resin layer having a gelation time of 65 seconds and a thickness, from tops of convex portions of the copper foil, of 8 μm. At the time when the resultant copper foil came out from a drying zone, a 20 μm thick polypropylene protective film was placed on the resin layer surface. These materials were laminated at 100° C. under a linear load of 4 kgf/cm, to prepare a copper-foil-attached B-stage resin composition sheet. The above B-stage resin composition sheets were disposed on both surfaces of a 4.5 μm thick wholly aromatic polyamide (aramid) film while separating each protective film. These materials were continuously laminated with a heating roll at 100° C. under a linear load of 5 kgf/cm, whereby heat-resistant film base-material-inserted copper-foil-attached B-stage resin composition sheets were produced. The insulating layer thickness thereof was almost 35 μm.
Separately, an internal layer board was prepared in the same manner as in Example 3. The above heat-resistant film base-material-inserted copper-foil-attached B-stage resin composition sheet was disposed on each surface of the internal layer board. The resultant set was placed in a press machine and then it was laminate-molded under a vacuum of 30 mmHg or less for 2 hours at 110° C.·30 minutes+180° C.·90 minutes and 5 kgf/cm 2 ·15 minutes+20 kgf/cm 2 ·125 minutes, to obtain a multilayer board having four layers. The multilayer board had an insulation layer thickness of almost 25 μm. Each copper foil surface of the multilayer board was 1 shot irradiated with a carbon dioxide gas laser at an output of 12 mJ to make blind via holes having a diameter of 100 μm. The copper foils on the external surfaces were etched until the copper foils had a thickness of 3 μm each, and at the same time copper foil burrs occurring in the blind via hole portions were dissolved and removed. A remaining resin layer in the bottom of each blind via hole was removed by desmear treatment. Then, electroless copper plating was attached to a thickness of 0.5 μm and further electrolytic copper plating was attached to a thickness of 15 μm. Circuits were formed by a general method. The above procedures of black copper oxide treatment, lamination, the formation of holes, etc., were repeated to carry out buildup, whereby a six-layered printed wiring board was obtained. Table 2 shows results of evaluation of this printed wiring board.
Comparative Examples 5-6
The same varnishes as those obtained from epoxy resins, etc., in Example 3 and Example 4 were respectively used. These varnishes were respectively applied to copper foils to form B-stage resin layers having a thickness of 35 μm each, and copper-foil-attached B-stage resin composition sheets were similarly obtained, respectively. Laminate-molding was carried out in the same manner as in Example 3 or Example 4 except that only the above copper-foil-attached B-stage resin composition sheets were used without the heat-resistant film base materials used in Example 3 and 4, whereby multilayer printed wiring boards having six layers were respectively obtained as Comparative Examples 3 and 4. Table 2 shows results of evaluation of these printed wiring boards.
Comparative Example 7
In Example 3, a glass woven cloth having a thickness of 20 μm was impregnated with the same varnish obtained from epoxy resins, etc., as that obtained in Example 3 and the impregnated varnish was dried to obtain a prepreg having a total thickness (glass woven cloth+resin composition layer) of 35 μm and a gelation time (170°) of 86 seconds. The prepreg was disposed on each surface of an internal layer board. Electrolytic copper foils having a thickness of 12 μm and a nickel-treated shiny surface were disposed on both outer surfaces or the resultant board, one copper foil on one surface. The resultant set was placed in a press machine and then it was laminate-molded under the same conditions as those in Example 3 to prepare a multilayer board having four layers. Then, a multilayer printed wiring board having six layers was similarly produced. Table 2 shows results of evaluation of this printed wiring board.
Comparative Example 8
In Example 4, a glass woven cloth having a thickness of 20 μm was impregnated with the same varnish obtained from epoxy resins, etc., as that obtained in Example 4 and the impregnated varnish was dried to obtain a prepreg having a total thickness (glass woven cloth+resin composition layer) of 35 μm and a gelation time (170°) of 92 seconds. The prepreg was disposed on each surface of an internal layer board. Electrolytic copper foils having a thickness of 12 μm and a nickel-treated shiny surface were disposed on both outer surfaces of the resultant board, one copper foil on one surface. The resultant set was placed in a press machine and then it was similarly laminate-molded to prepare a multilayer board having four layers. Then, a multilayer printed wiring board having six layers was similarly produced. Table 2 shows results of evaluation of this printed wiring board.
TABLE 2
Examples
Comparative Examples
Item
3
4
5
6
7
8
Copper adhesive strength (kgf/cm)
1.39
1.48
1.40
1.48
1.40
1.47
Soldering heat resistance
No
No
No
Partial
Partial
Partial
failure
failure
failure
swelling
swelling
swelling
Glass transition temperature DMA (° C.)
209
166
210
168
209
167
Elastic modulus 25° C. (kgf/mm 2 )
1,663
1,520
1,022
938
1,915
1,870
Warp · distortion (mm)
1.1
1.4
3.6
4.0
1.4
1.5
Thickness variance (μm)
3.5
4.3
7.5
8.3
—
—
Migration resistance (Ω)
Ordinary
6 × 10 13
6 × 10 13
6 × 10 13
5 × 10 13
5 × 10 13
6 × 10 13
state
100
4 × 10 11
5 × 10 10
3 × 10 10
5 × 10 8
5 × 10 9
1 × 10 8
hours
700
1 × 10 11
2 × 10 10
<10 8
<10 8
<10 8
<10 8
hours
Example 5
400 Parts of 2,2-bis(4-cyanatophenyl)propane monomer was melted at 150° C. and allowed to react for 4 hours with stirring, to prepare a prepolymer having an average molecular weight of 1,900. The prepolymer was dissolved in methyl ethyl ketone, to prepare a varnish. To the varnish were added 100 parts of a bisphenol A type epoxy resin (trade name: Epikote 828, supplied by Japan epoxy resin), 50 parts of a bisphenol F type epoxy resin (trade name: EXA830LVP, supplied by Dainippon Ink And Chemicals, Incorporated) and 50 parts of a novolak type epoxy resin (trade name: DEN438, supplied by Dow Chemical) as epoxy resins liquid at room temperature, and 300 parts of a bisphenol A type epoxy resin (trade name: Epikote 1001, supplied by Japan epoxy resin) and 100 parts of a cresol novolak type epoxy resin (trade name: ESCN220F, supplied by Sumitomo Chemical Co., Ltd.) as epoxy resins solid at room temperature. As a heat-curing catalyst, 0.3 part of iron acetylacetonate dissolved in methyl ethyl ketone was added to the mixture. 100 parts of a liquid epoxidized polybutadiene resin (trade name: E-1000-8.0, supplied by NIPPON PETROCHEMICALS CO., LTD) and 50 parts of an epoxy-group-modified acrylic multilayer structure organic powder (trade name: Staphyloid IM-203, average particle diameter 0.2 μm, maximum particle diameter 0.5 μm) were added to the resultant mixture, and these materials were homogeneously stirred and mixed, to prepare a varnish.
The above varnish prepared from the epoxy resins, etc., was continuously applied to a 25 μm thick PET film having a roughened surface treated with a release agent (roughness 3.7˜6.0 μm, average roughness Rz: 4.5 μm), and the applied varnish was dried to obtain a B-stage resin composition layer having a thickness, from top of a maximum convex portion of the release film, of 5.9 μm and a gelatin time of 46 seconds at 170° C. At the time when the resultant film came out from a drying zone, a 20 μm thick protective polypropylene film was placed on the resin layer surface. These materials were laminated at 100° C. under a linear load of 4 kgf/cm, to prepare a release film-attached B-stage resin composition sheet A.
Further, 700 parts of a bisphenol A type epoxy resin (trade name: Epikote 1001, supplied by Japan epoxy resin), 140 parts of a bisphenol F type epoxy resin (trade name: EXA830LVP, supplied by Dainippon Ink And Chemicals, Incorporated) and 160 parts of a cresol novolak type epoxy resin (trade name: ESCN220F, supplied by Sumitomo Chemical Co., Ltd.) were added to 1,000 parts, solid content, of the above varnish obtained from the prepolymer of the propane monomer. As a heat-curing catalyst, 0.5 part of iron acetylacetonate dissolved in methyl ethyl ketone was added to the mixture. 150 parts of a liquid epoxidized polybutadiene resin (trade name: E-1800-8.0, supplied by NIPPON PETROCHEMICALS CO., LTD), 80 parts of an epoxy-group-modified acrylic multilayer structure powder (trade name: Staphyloid IM-203, average particle diameter 0.2 μm, maximum particle diameter 0.5 μm) and 300 parts of talc (average particle diameter 1.8 μm, maximum particle diameter 4.2 μm) were added to the resultant mixture, and these materials were homogeneously stirred and mixed, to prepare a varnish C.
This varnish C was continuously applied to one surface of a 25 μthick release PET film having smooth surfaces, and the applied varnish was dried to obtain a B-stage resin layer having a gelatin time of 55 seconds and a thickness of 23 μm. At the time when the resultant film came out from a drying zone, a 20 μm thick polypropylene protective film was placed on the resin layer surface. These materials were laminated at 100° C. under a linear load of 4 kgf/cm, to prepare a release film-attached B-stage resin composition sheet B. A 12 μm thick polyimide film was prepared and both surfaces thereof were treated by plasma treatment. The release film-attached B-stage resin composition sheet B was disposed on one surface of the polyimide film while separating the protective film, and the above release film-attached B-stage resin composition sheet A was disposed on the other surface of the polyimide film while separating the protective film. These materials were continuously laminated at 100° C. under a linear load of 5 kgf/cm to integrate them, whereby heat-resistant film base-material-inserted release-film-attached B-stage resin composition sheets were prepared ( FIG. 3 ( 1 )). The insulating layer thickness from tops of convex portions of the copper foil was about 41 μm.
Separately, circuits were formed on a BT resin copper-clad laminate having an insulating layer thickness of 0.2 mm and having 12 μm thick copper foils on both surfaces (trade name: CCL-HL830, supplied by Mitsubishi Gas Chemical Company, INC.) and then the copper foils were treated by black copper oxide treatment, to prepare an internal layer board. The above heat-resistant film base-material-inserted release-film-attached B-stage resin composition sheets were placed on both surfaces of the internal layer board such that the resin layer of each B-stage resin composition sheet faced to the internal layer board. The resultant set was placed in a press machine. The temperature was increased from room temperature to 170° C. over 25 minutes and the pressure was set at 15 kgf/cm 2 from the beginning. The above set was maintained at a vacuum degree of 0.5 Torr at 170° C. for 30 minutes. Then it was allowed to cool and then taken out to obtain a multilayer board having four layers. The release films having the roughness on the external surfaces were removed. Then, each surface was 1 shot irradiated with a carbon dioxide gas laser at an output of 12 mJ to form blind via holes having a diameter of 100 μm each. The multilayer board was swollen with a potassium permanganate type desmear solution (supplied by Nippon MacDermid Co., Inc.), desmear (dissolution) was carried out and neutralization was carried out, to attain concave portions of 3.4˜5.0 μm from the resin surface (average roughness Rz: 4.2 μm) and a total roughness, from the external layer, of 6.7˜10.9 μm (average roughness Rz: 8.4 μm). At the same time, a remaining resin layer in the bottom of each blind via hole was dissolved and removed. Then, an electroless copper plating layer having a thickness of 0.7 μm was attached to each of the above roughened surfaces and an electrolytic copper plating layer having a thickness of 25 μm was further attached thereto. The board was placed in a heating furnace, and temperature was gradually increased from 100° C. to 150° C. over 30 minutes. Further, the temperature was gradually increased up and the board was cured under heat at 200° C. for 60 minutes. The thickness of the insulating layer was measured in a cross section and it was almost 30 μm. The resultant board was used to form a copper conductor circuit by a semi-additive process and the surface of the conductor circuit was treated by black copper oxide treatment. The above procedures were repeated to produce a multilayer printed wiring board having six layers. Table 3 shows results of evaluation of this printed wiring board.
Example 6
500 parts of a bisphenol A type epoxy resin (trade name: Epikote 1001, supplied by Japan epoxy resin), 500 parts of a phenol novolak type epoxy resin (trade name: DEN438, supplied by Dow Chemical), 30 parts of an imidazole type curing agent (trade name: 2PHZ, supplied by Shikoku Corporation), 50 parts of a carboxyl-group-modified acrylic multilayer structure powder (trade name: Staphyloid IM-301, average particle diameter 0.2 μm, maximum particle diameter 0.5 μm), 40 parts of a finely-pulverized silica (average particle diameter 2.4 μm, maximum particle diameter 5.0 μm) and 30 parts of acrylonitrile-butadiene rubber (trade name: Nipol 1031, supplied by ZEON Corporation) were dissolved in methyl ethyl ketone, to obtain a solution. The solution was homogeneously dispersed with a three-roll mill to prepare a varnish D. The varnish D was continuously applied to one surface of a 25 μm thick release PET film having smooth surfaces, and the applied varnish was dried to prepare a release-film-attached B-stage resin composition sheet A having a 15 μm thick resin composition layer (gelation time at 170° C., 67 seconds). At the time when it came out from a drying zone, a 15 μm thick protective polypropylene film was placed on its resin layer surface. These materials were continuously laminated at 100° C. under a linear load of 5 kgf/cm and then rolled up.
Further, 500 parts of a bisphenol A type epoxy resin (trade name: Epikote 1001, supplied by Japan epoxy resin), 450 parts of a phenol novolak type epoxy resin (trade name: DEN438, supplied by Dow Chemical), 30 parts of an imidazole type curing agent (trade name: 2E4MZ, supplied by Shikoku Corporation), 150 parts of a carboxyl-group-modified acrylic multilayer structure organic powder (trade name: Staphyloid IM-301, average particle diameter 0.2 μm) were added and these materials were homogeneously dispersed with a three-roll mill, to prepare a varnish. The varnish was continuously applied to a 25 μm thick release PET film having smooth surfaces, and the applied varnish was dried to obtain a B-stage resin composition layer B having a resin composition thickness of 30 μm and a gelatin time of 65 seconds. This B-stage resin composition layer B was disposed on one surface of a wholly aromatic polyamide (aramid) film having a thickness of 4.5 μm, the above release-film-attached B-stage resin composition sheet A was disposed on the other surface of the polyamide film while peeling off the protective film of the B-stage resin composition sheet, and these materials were continuously laminated with a heating roll at a temperature of 100° C. under a linear load of 5 kgf/cm and then rolled up, whereby heat-resistant film base-material-inserted double-side-release-film-attached B-stage resin composition sheets were produced ( FIG. 3 ( 2 )). The insulating layer thickness thereof was approximately 49 μm.
Separately, circuits were formed on an epoxy type copper-clad laminate having a thickness of 0.2 mm and having 12 μm thick copper foils on both surfaces (tradename: CCL-EL170, supplied by Mitsubishi Gas Chemical Company, INC.) and then the conductor circuits were treated by black copper oxide treatment. The above heat-resistant film base-material-inserted release-film-attached B-stage resin composition sheets were disposed on both surfaces of the copper-clad laminate after peeling off the release PET films. The resultant set was placed in a press machine. Temperature was increased from room temperature to 170° C. over 25 minutes and the pressure was set at 15 kgf/cm 2 from the beginning. The above set was maintained at a vacuum degree of 0.5 Torr at 170° C. for 30 minutes, to carry out curing treatment. Then, it was allowed to cool and then taken out to obtain a multilayer board having four layers. The release films on the external surfaces were removed ( FIG. 4 ( 1 )). Then, each surface was 1 shot irradiated with a carbon dioxide gas laser at an output of 12 mJ to form blind via holes having a diameter of 100 μm each.
Roughening treatment was carried out with a chromic acid aqueous solution, to attain a total roughness, from the resin surface, of 4.7˜10.1 μm (average roughness Rz: 8.3 μm) ( FIG. 4 ( 2 )). In this case, a top of a concave portion did not reach the heat-resistant film. At the same time, a remaining resin layer in the bottom of each blind via hole was dissolved and removed. The insulating layer thickness after the molding was almost 30 μm.
Then, an electroless copper plating layer having a thickness of 0.5 μm was attached to each of the above roughened surfaces and an electrolytic copper plating layer having a thickness of 25 μm was further attached thereto. The board was placed in a heating furnace and temperature was gradually increased from 100° C. to 150° C. over 30 minutes. The temperature was further increased and the board was post-cured under heat at 170° C. for 60 minutes. The resultant board was used to form a copper conductor circuit by a semi-additive process and the surface of the conductor circuit was treated by black copper oxide treatment. Similar procedures were carried out to produce a multilayer printed wiring board having six layers. Table 3 shows results of evaluation of this printed wiring board.
Comparative Examples 9-10
In Examples 5 and 6, the same varnish C as that obtained in Example 5 and the varnish D as that obtained in Example 6 were respectively used to form a B-stage resin layer having a thickness, from tops of convex portions, of 40 μm on a release film, Example 5, and a B-stage resin layer having a thickness of 50 μm on a release film, Example 6, and release film-attached B-stage resin composition sheets were respectively obtained. Only these release film-attached B-stage resin composition sheets were used without the heat-resistant film base materials used in Example 5 and 6. Similar laminate-molding curing-treatment was carried out androughening treatment was similarly carried out, to attain a total roughness, from the external layer, of 5˜11 μm (average roughness Rz: 8˜9 μm) similarly to Examples 5 and 6 ( FIG. 5 ( 1 ) ( 2 )), Comparative Example 10), and multilayer printed wiring boards having six layers were respectively similarly produced. Table 3 shows results of evaluation of these printed wiring boards.
Comparative Example 11
In Example 5, a glass woven cloth having a thickness of 20 μm was impregnated with the same varnish C as that obtained in Example 5, and the impregnated varnish was dried to obtain a prepreg having a total thickness (glass woven cloth+resin composition layer) of 40 μm and a gelation time (170°) of 84 seconds. The prepreg was disposed on each surface of an internal layer board. A release film having roughness was disposed thereon. Lamination-molding curing-treatment was similarly carried out to prepare a multilayer board having four layers. After separating the release films on the external layers, blind via holes were made. Roughening treatment was similarly carried out to attain a total roughness, from the external layer, of 5˜11 μm ( FIG. 6 ( 1 )). After electroless copper plating and electrolytic copper plating, the formation of circuits and conductor black copper oxide treatment were similarly carried out. Then, prepregs were disposed, release films having roughness were disposed and lamination was similarly carried out. Then, the release films on the external surfaces were removed and blind via holes were formed. Desmear treatment, electroless copper plating and electrolytic copper plating were carried out. Then, circuits were formed to produce a multilayer printed wiring board having six layers. In observation of a copper plating cross section, there were found many portions where concave portions due to the roughening reached the glass cloth ( FIG. 6 ( 2 )) and the copper plating was attached. Table 3 shows results of evaluation of this printed wiring board.
Comparative Example 12
A varnish was prepared in the same manner as in the preparation of the varnish D in Example 6 except that the carboxyl-group-modified acrylic multilayer structure powder, the finely-pulverized silica and the acrylonitrile-butadiene rubber were not used. The varnish was applied to a release film having flat surfaces and then the applied varnish was dried to prepare release-film-attached B-stage resin composition sheets having a resin layer having a thickness of 50 μm and a gelation time (170° C.) of 75 seconds. The release-film-attached B-stage resin composition sheet was disposed on each surface of an internal layer board and the resultant set was laminated at 100° C. under a linear load of 5 kgf/cm. Then, the release films were separated. Electrolytic copper foils having a thickness of 18 μm each (surface roughness 3.7˜5.5 μm, average roughness Rz 4.5 μm) were disposed on the resultant resin surfaces, one copper foil on one surface. Laminate-molding-curing treatment was similarly carried out to prepare a multilayer board having four layers. After the release films on the external layers were removed, blind via holes were similarly made with a CO 2 laser. Roughening treatment was carried out under the same conditions as those in Example 6 ( FIG. 7 ( 1 ) ( 2 )). Electroless copper plating and electrolytic copper plating were carried out. Then, conductor circuits were formed and the conductor was subjected to black copper oxide treatment. The release-film-attached B-stage resin composition sheets were disposed and laminate-molding was carried out. Then, similar procedures were carried out to produce a six-layered printed wiring board. Table 3 shows results of evaluation of this printed wiring board.
TABLE 3
Examples
Comparative Examples
Item
5
6
9
10
11
12
Copper adhesive strength (kgf/cm)
1.22
1.31
1.21
1.39
1.08
0.47
Soldering heat resistance
No
No
No
Partial
Partial
Many
failure
failure
failure
swelling
swelling
swellings
Glass transition temperature DMA (° C.)
197
153
198
154
192
168
Elastic modulus 25° C. (kgf/mm 2 )
1,502
1,321
1,078
987
1,826
887
Warp · distortion (mm)
1.2
1.6
4.3
5.4
1.6
5.3
Thickness variance (μm)
4.6
5.7
9.9
12.8
7.8
12.9
Blind via hole · Heat cycle test
Rate of change of resistance (%)
1.5
2.1
2.2
2.7
1.7
>10
Crack occurrence
100
0/1,000
0/1,000
—
—
0/1,000
150/1,000
cycles
300
0/1,000
5/1,000
—
—
0/1,000
768/1,000
cycles
500
0/1,000
201/1,000
—
—
87/1,000
993/1,000
cycles
Migration resistance (Ω)
Ordinary
6 × 10 13
4 × 10 13
5 × 10 13
5 × 10 13
4 × 10 13
5 × 10 13
state
200
6 × 10 11
6 × 10 10
2 × 10 10
5 × 10 8
3 × 10 9
3 × 10 8
hours
500
1 × 10 11
2 × 10 10
8 × 10 9
<10 8
<10 8
<10 8
hours
<Measurement Methods>
1) Glass transition temperature: Each varnish was applied to a copper foil and the applied varnish was dried. These procedures were repeated to attain a thickness of 0.8 mm. Then, a copper foil was disposed on the resin composition surface and the resin composition layer was cured under each lamination curing condition. Then, the copper foils on the external surfaces were etched and measurement was carried out by DMA method. In Comparative Example 3, twenty prepregs were used and laminate-molded to attain a thickness of almost 0.8 mm.
2) Rate of change of resistance and cracks in blind via hole·heat cycle test: 1,000 blind via holes (diameter 100 μm, land 180 μm) formed between the second layer and the third layer of each six-layered printed wiring board were connected to one another alternately on the second layer and the third layer. One cycle consisted of −65° C./30 minutes⇄+150° C./30 minutes and 200 cycles were repeated. The maximum value of changes of resistance values was measured. Further, hole cross sections were observed at 100 cycles, 300 cycles and 500 cycles to check the occurrence of resin cracks. Numerator shows the number of occurrence and denominator shows the number of tested pieces.
Example 7
400 Parts of 2,2-bis(4-cyanatophenyl)propane monomer was melted at 150° C. and allowed to react for 4 hours with stirring, to prepare a prepolymer having an average molecular weight of 1,900. The prepolymer was dissolved in methyl ethyl ketone, to prepare a varnish. To the varnish were added 100 parts of a bisphenol A type epoxy resin (trade name: Epikote 828, supplied by Japan epoxy resin), 150 parts of a bisphenol F type epoxy resin (trade name: EXA830LVP, supplied by Dainippon Ink And Chemicals, Incorporated) and 100 parts of a novolak type epoxy resin (trade name: DEN438, supplied by Dow Chemical) as epoxy resins liquid at room temperature, and 150 parts of a bisphenol A type epoxy resin (trade name: Epikote 1001, supplied by Japan epoxy resin) and 100 parts of a cresol novolak type epoxy resin (trade name: ESCN220F, supplied by Sumitomo Chemical Co., Ltd.) as epoxy resins solid at room temperature. As a heat-curing catalyst, 0.3 part of iron acetylacetonate dissolved in methyl ethyl ketone was added to the mixture. 100 parts of a liquid epoxidized polybutadiene resin (trade name: E-1000-8.0, supplied by NIPPON PETROCHEMICALS CO., LTD) and 30 parts of an epoxy-group-modified acrylic multilayer structure powder (trade name: Staphyloid IM-203, average particle diameter 0.2 μm, maximum particle diameter 0.5 μm) were added to the resultant mixture, and these materials were homogeneously stirred and mixed, to prepare a varnish.
The above varnish was continuously applied to a mat surface of a 18 μm thick copper foil (roughness 3.5˜6.2 μm, average roughness Rz: 4.6 μm), and the applied varnish was dried to obtain a B-stage resin composition layer having a thickness, from top of the maximum convex portion of the copper foil, of 5.7 μm and a gelatin time of 48 seconds at 170° C. At the time when the resultant copper foil came out from a drying zone, a 20 μm thick protective polypropylene film was placed on the resin layer surface. These materials were laminated at 100° C. under a linear load of 4 kgf/cm, to prepare a copper-foil-attached B-stage resin composition sheet.
Further, 700 parts of a bisphenol A type epoxy resin (trade name: Epikote 1001, supplied by Japan epoxy resin), 140 parts of a bisphenol F type epoxy resin (trade name: EXA830LVP, supplied by Dainippon Ink And Chemicals, Incorporated) and 160 parts of a cresol novolak type epoxy resin (trade name: ESCN220F, supplied by Sumitomo Chemical Co., Ltd.) were added to 1,000 parts, solid content, of the above varnish obtained from the prepolymer of the propane monomer. As a heat-curing catalyst, 0.5 part of iron acetylacetonate dissolved in methyl ethyl ketone was added to the mixture. 150 parts of a liquid epoxidized polybutadiene resin (trade name: E-1800-8.0, supplied by NIPPON PETROCHEMICALS CO., LTD), 80 parts of an epoxy-group-modified acrylic multilayer structure powder (trade name: Staphyloid IM-203, average particle diameter 0.2 μm, maximum particle diameter 0.5 μm) and 400 parts of talc (average particle diameter 1.8 μm, maximum particle diameter 4.2 μm) were added to the resultant mixture, and these materials were homogeneously stirred and mixed, to prepare a varnish A.
This varnish A was continuously applied to one surface of a 25 μm thick release PET film having smooth surfaces and the applied varnish was dried to obtain a B-stage resin layer having a gelatin time of 55 seconds and a thickness of 25 μm. At the time when the resultant film came out from a drying zone, a 20 μm thick polypropylene protective film was placed on the resin layer surface. These materials were laminated at 100° C. under a linear load of 4 kgf/cm, to prepare a release film-attached B-stage resin composition sheet. A 10 μm thick polyimide film was prepared and both surfaces thereof were treated by plasma treatment. The release film-attached B-stage resin composition sheet was disposed on one surface of the polyimide film while separating the protective film, and the above copper-foil-attached B-stage resin composition sheet was disposed on the other surface of the polyimide film while separating the protective film. These materials were continuously laminated at 100° C. under a linear load of 5 kgf/cm to integrate them, whereby heat-resistant film base-material-inserted copper-foil-attached B-stage resin composition sheets were prepared ( FIG. 8 ( 1 )). The insulating layer thickness thereof from tops of convex portions of the copper foil was about 41 μm.
Separately, circuits were formed on a BT resin copper-clad laminate having an insulating layer thickness of 0.2 mm and having 12 μm thick copper foils on both surfaces (trade name: CCL-HL830, supplied by Mitsubishi Gas Chemical Company, INC.) and then the copper foils were treated by black copper oxide treatment, to prepare an internal layer board. The above heat-resistant film base-material-inserted copper-foil-attached B-stage resin composition sheets were placed on both surfaces of the internal layer board, one sheet on one surface, such that the resin layer of each B-stage resin composition sheet faced to the internal layer board. The resultant set was placed in a press machine. Temperature was increased from room temperature to 170° C. over 25 minutes and the pressure was set at 15 kgf/cm 2 from the beginning. The above set was maintained at a vacuum degree of 0.5 Torr at 170° C. for 30 minutes. Then it was allowed to cool and then taken out to obtain a multilayer board having four layers. The copper foils on the external surfaces were etched and removed. Then, each surface was 1 shot irradiated directly with a carbon dioxide gas laser at an output of 15 mJ to make blind via holes having a diameter of 100 μm each. The multilayer board was swollen with a potassium permanganate type desmear solution (supplied by Nippon MacDermid Co., Inc.), desmear (dissolution) was carried out and neutralization was carried out, to attain concave portions of 3.4˜5.1 μm from the resin surface (average roughness Rz: 4.2 μm) and a total roughness, from the external layer, of 6.9˜11.0 μm (average roughness Rz: 8.6 μm) ( FIG. 8 ( 2 ) ( 3 )). At the same time, a remaining resin layer in the bottom of each blind via hole was dissolved and removed. Then, an electroless copper plating layer having a thickness of 0.7 μm was attached to each of the above roughened surfaces and an electrolytic copper plating layer having a thickness of 25 μm was further attached thereto. The board was placed in a heating furnace and temperature was gradually increased from 100° C. to 150° C. over 30 minutes. Further, it was gradually increased up and the board was cured under heat at 200° C. for 60 minutes. The thickness of the insulating layer was measured in a cross section and it was almost 30 μm. The resultant board was used to form a copper conductor circuit by a semi-additive process and the surface of the conductor circuit was treated by black copper oxide treatment. The above procedures were repeated to produce a multilayer printed wiring board having six layers. Table 4 shows measurement results of properties of this printed wiring board.
Example 8
500 parts of a bisphenol A type epoxy resin (trade name: Epikote 1001, supplied by Japan epoxy resin), 500 parts of a phenol novolak type epoxy resin (trade name: DEN438, supplied by Dow Chemical), 30 parts of an imidazole type curing agent (trade name: 2E4MZ, supplied by Shikoku Corporation), 50 parts of a carboxyl-group-modified acrylic multilayer structure powder (trade name: Staphyloid IM-301, average particle diameter 0.2 μm, maximum particle diameter 0.9 μm), 40 parts of a finely-pulverized silica (average particle diameter 2.4 μm, maximum particle diameter 5.0 μm) and 30 parts of acrylonitrile-butadiene rubber (trade name: Nipol 1031, supplied by ZEON Corporation) were dissolved in methyl ethyl ketone, to obtain a solution. The solution was homogeneously dispersed with a three-roll mill to prepare a varnish. The varnish was continuously applied to one surface of a 20 μm thick aluminum foil (trade name: 20CF1, supplied by JAPAN CAPACITOR INDUSTRIAL CO., LTD.) having a surface roughness of 1.3˜5.5 μm (average roughness Rz: 4.0 μm), and the applied varnish was dried to prepare an aluminum-foil-attached B-stage resin composition sheet having a resin composition layer having a thickness, from top of the maximum convex portion, of 6.0 μm (gelation time at 170° C., 51 seconds). At the time when it came out from a drying zone, a 25 μm thick protective polypropylene film was placed on the resin layer surface. These materials were continuously laminated with a roll at 100° C. under a linear load of 5 kgf/cm and then rolled up.
Further, 500 parts of a bisphenol A type epoxy resin (trade name: Epikote 1001, supplied by Japan epoxy resin), 450 parts of a phenol novolak type epoxy resin (trade name: DEN438, supplied by Dow Chemical), 30 parts of an imidazole type curing agent (trade name: 2E4MZ, supplied by Shikoku Corporation), 50 parts of a carboxyl-group-modified acrylic multilayer structure epoxy resin powder (trade name: Staphyloid IM-301, average particle diameter 0.2 μm) were added, further 300 parts of a talc (average particle diameter 4.2 μm) was added, and these materials were homogeneously dispersed with a three-roll mill, to prepare a varnish B. The varnish was continuously applied to a 25 μm thick release PET film and the applied varnish was dried to obtain a B-stage resin composition layer having a resin composition thickness of 19 μm and a gelatin time of 60 seconds. The B-stage resin composition layer was continuously disposed on one surface of a liquid crystal polyester film having a thickness of 25 μm, the above aluminum-foil-attached B-stage resin composition sheet was disposed on the other surface of the liquid crystal polyester film while separating the protective film of the B-stage resin composition sheet, and these materials were continuously laminated with a heating roll at a temperature of 100° C. under a linear load of 5 kgf/cm and then rolled up, whereby heat-resistant film base-material-inserted aluminum-foil-attached B-stage resin composition sheets were produced. The insulating layer thickness thereof from tops of convex portions of the metal foil was approximately 50 μm.
Separately, circuits were formed on an epoxy type copper-clad laminate having a thickness of 0.2 mm and having 12 μm thick copper foils on both surfaces (tradename: CCL-EL170, supplied by Mitsubishi Gas Chemical Company, INC.) and then the conductor circuits were treated by black copper oxide treatment. The above heat-resistant film base-material-inserted aluminum-foil-attached B-stage resin composition sheets were placed on both surfaces of the copper-clad laminate, one sheet on one surface, after separating the release PET films. The resultant set was placed in a press machine. The temperature was increased up to 170° C. over 25 minutes and the pressure was set at 15 kgf/cm 2 from the beginning. The above set was maintained at a vacuum degree of 0.5 Torr at 170° C. for 30 minutes, to carry out curing treatment. Then, it was allowed to cool and then taken out to obtain a multilayer board having four layers. The aluminum foils on the external surfaces were dissolved and removed with 10% hydrochloric acid solution. Then, each surface was 1 shot irradiated with a carbon dioxide gas laser at an output of 12 mJ to make blind via holes having a diameter of 100 μm each.
Roughening treatment was carried out with a chromic acid aqueous solution, to form concave portions of 3.6˜5.0 μm from the resin surface (average roughness Rz: 4.1 μm) and attain a total roughness, from the external layer, of 4.7˜10.0 μm (average roughness Rz: 8.0 μm). In this case, a top of a concave portion did not reach the heat-resistant film. At the same time, a remaining resin layer in the bottom of each blind via hole was dissolved and removed. The insulating layer thickness after the molding was almost 40 μm.
Then, an electroless copper plating layer having a thickness of 0.5 μm was attached to each of the above roughened surfaces and an electrolytic copper plating layer having a thickness of 25 μm was further attached thereto. The board was placed in a heating furnace and temperature was gradually increased from 100° C. to 150° C. over 30 minutes. Further, it was gradually increased and the board was cured under heat at 170° C. for 60 minutes. The resultant board was used to form a conductor circuit by a semi-additive process and the conductor circuit was treated by black copper oxide treatment. Similar procedures were carried out to produce a multilayer printed wiring board having six layers. Table 4 shows measurement results of properties of this printed wiring board.
Comparative Example 13-14
In Examples 7 and 8, the same varnish A as that obtained in Example 7 and the varnish B as that obtained in Example 6 were respectively used to form a B-stage resin layer having a thickness, from tops of convex portions, of 40 μm on rough portions of a copper foil and a B-stage resin layer having a thickness, from tops of convex portions, of 50 μm on rough portions of a metal foil and to prepare metal-foil-attached B-stage resin composition sheets respectively. Only these metal-foil-attached B-stage resin composition sheets were used without the heat-resistant films used in Example 7 and 8. Similar laminate-molding curing treatment was carried out, roughening treatment was similarly carried out, to attain a total roughness, from the external layer, of 5˜11 μm (average roughness Rz: 8˜9 μm) similarly to Examples 7 and 8 ( FIG. 9 ( 1 ), Comparative Example 13), and multilayer printed wiring boards having six layers were respectively similarly produced. Table 4 shows results of evaluation of these printed wiring boards.
Comparative Example 15
In Example 7, a glass woven cloth having a thickness of 20 μm was impregnated with the same varnish A as that obtained Example 7 and the impregnated varnish was dried to obtain a prepreg having a total thickness (glass woven cloth+resin composition layer) of 40 μm and a gelation time (170°) of 54 seconds. The prepreg was disposed on each surface of an internal layer board. A copper foil having a thickness of 18 μm was disposed thereon. Lamination-molding-curing-treatment was similarly carried out to prepare a multilayer board having four layers ( FIG. 10 ( 1 )). After removing the copper foils on the external layers by etching, blind via holes were made. Roughening treatment was similarly carried out to attain a total roughness, from the external layer, of 5˜11 μm ( FIG. 10 ( 2 )). After electroless copper plating and electrolytic copper plating, the formation of circuits and conductor black copper oxide treatment were similarly carried out. Then, prepregs were disposed, electrolytic copper foils having a thickness of 18 μm each were disposed, and lamination was similarly carried out. Then, the copper foils on the external surfaces were removed, blind via holes were formed. Desmear treatment, electroless copper plating and electrolytic copper plating were carried out. Then, circuits were formed to produce a multilayer printed wiring board having six layers. In observation of a copper plating cross section, there were found many portions where concave portions due to the roughening reached the glass cloth ( FIG. 10 ( 3 )) and the copper plating was attached. Table 4 shows results of evaluation of this printed wiring board.
Comparative Example 16
A varnish was prepared in the same manner as in Example 8 except that the epoxy resin powder, the carboxyl-group-modified acrylic multilayer structure powder, the finely-pulverized silica and the acrylonitrile-butadiene rubber were not used. The varnish was similarly applied to an aluminum foil surface having roughness and then the applied varnish was dried, to prepare aluminum-foil-attached B-stage resin composition sheets having a resin layer having a thickness, from tops of convex portions, of 50 μm and a gelation time (170° C.) of 77 seconds. The aluminum-foil-attached B-stage resin composition sheet was disposed on each surface of an internal layer board and the resultant set was similarly subjected to laminate-molding-curing-treatment, to prepare a multilayer board having four layers. Then, the aluminum foils on the external layers were dissolved and removed with 10% hydrochloric acid. Then, blind via holes were similarly made with a CO 2 laser. Roughening treatment was carried out under the same conditions as those in Example 8. Electroless copper plating and electrolytic copper plating were carried out. Then, conductor circuits were formed and the conductor was subjected to black copper oxide treatment. The aluminum-foil-attached B-stage resin composition sheets were disposed and laminate-molding was carried out. Then, similar procedures were carried out to produce a six-layered printed wiring board. Table 4 shows results of evaluation of this printed wiring board.
TABLE 4
Examples
Comparative Examples
Item
7
8
13
14
15
16
Copper adhesive strength (kgf/cm)
1.25
1.37
1.24
1.37
1.16
0.46
Soldering heat resistance
No
No
No
Partial
Partial
Partial
failure
failure
failure
swelling
swelling
swelling
Glass transition temperature DMA (° C.)
201
153
201
153
202
168
Elastic modulus 25° C. (kgf/mm 2 )
1,505
1,389
1,087
995
1,829
776
Warp · distortion (mm)
1.2
1.5
4.0
5.1
1.6
5.3
Thickness variance (μm)
4.5
6.1
9.8
12.6
7.8
12.9
Blind via hole · Heat cycle test
Rate of change of resistance (%)
1.6
2.0
2.0
2.8
1.8
>10
Crack occurrence
200
0/1,000
0/1,000
0/1,000
0/1,000
0/1,000
210/1,000
cycles
400
0/1,000
51/1,000
0/1,000
70/1,000
66/1,000
970/1,000
cycles
Migration resistance (Ω)
Ordinary
6 × 10 13
4 × 10 13
5 × 10 13
6 × 10 13
4 × 10 13
5 × 10 13
state
200
6 × 10 11
6 × 10 10
4 × 10 10
5 × 10 8
5 × 10 9
2 × 10 8
hours
500
3 × 10 11
5 × 10 10
2 × 10 9
<10 8
<10 8
<10 8
hours
<Measurement Method>
1) Grass transition temperature: In Comparative Example 15, fourteen prepregs were used and laminate-molded to attain a thickness of almost 0.8 mm. Except for the above, measurement was carried out similarly to the other Examples.
Example 9
400 Parts of 2,2-bis(4-cyanatophenyl)propane monomer was melted at 150° C. and allowed to react for 4 hours with stirring, to prepare a mixture of monomer and prepolymer having an average molecular weight of 1,900. The mixture was dissolved in methyl ethyl ketone, to prepare a varnish. To the varnish were added 50 parts of a bisphenol A type epoxy resin (trade name: Epikote 828, supplied by Japan epoxy resin), 50 parts of a bisphenol F type epoxy resin (trade name: EXA830LVP, supplied by Dainippon Ink And Chemicals, Incorporated) and 50 parts of a novolak type epoxy resin (trade name: DEN438, supplied by Dow Chemical) as epoxy resins liquid at room temperature, and 300 parts of a bisphenol A type epoxy resin (trade name: Epikote 1001, supplied by Japan epoxy resin) and 100 parts of a cresol novolak type epoxy resin (trade name: ESCN220F, supplied by Sumitomo Chemical Co., Ltd.) as epoxy resins solid at room temperature. As a heat-curing catalyst, 0.3 part of iron acetylacetonate dissolved in methyl ethyl ketone was added to the mixture. 100 parts of a liquid epoxidized polybutadiene resin (trade name: E-1000-8.0, supplied by NIPPON PETROCHEMICALS CO., LTD) and 100 parts of an epoxy-group-modified acrylic multilayer structure organic powder (trade name: Staphyloid IM-203, average particle diameter 0.2 μm, maximum particle diameter 0.5 μm) were added to the resultant mixture, and these materials were homogeneously stirred and mixed, to prepare a varnish A.
The above varnish A was continuously applied to a 18 μm thick aluminum foil (roughness 6.0˜10.9 μm, average roughness Rz: 8.9 μm) and the applied varnish was dried to obtain a B-stage resin composition layer having a height, from top of the maximum convex portion, of 5.9 μm and a gelatin time of 53 seconds at 170° C. At the time when the resultant aluminum foil came out from a drying zone, a 15 μm thick protective polypropylene film was placed on the resin layer surface. These materials were laminated at 100° C. under a linear load of 4 kgf/cm, to prepare an aluminum-foil-attached B-stage resin composition sheet.
Further, 700 parts of a bisphenol A type epoxy resin (trade name: Epikote 1001, supplied by Japan epoxy resin), 140 parts of a bisphenol F type epoxy resin (trade name: EXA830LVP, supplied by Dainippon Ink And Chemicals, Incorporated) and 160 parts of a cresol novolak type epoxy resin (trade name: ESCN220F, supplied by Sumitomo Chemical Co., Ltd.) were added to 1,000 parts, solid content, of the above varnish obtained from the prepolymer of the propane monomer. As a heat-curing catalyst, 0.5 part of iron acetylacetonate dissolved in methyl ethyl ketone was added to the mixture. 300 parts of calcined talc (average particle diameter 2.5 μm) was added to the resultant mixture, and these materials were homogeneously stirred and mixed, to prepare a varnish.
This varnish was continuously applied to one surface of a 25 μm thick release PET film having smooth surfaces and the applied varnish was dried to obtain a B-stage resin layer having a gelatin time of 59 seconds and a thickness of 22 μm. At the time when the resultant film came out from a drying zone, the resin surface of this film was bought into contact with one surface of a 12.5 μm thick polyimide film having both surfaces treated by plasma treatment and the above aluminum-foil-attached B-stage resin composition sheet was disposed on the other surface of the polyimide film. These materials were continuously laminated at 100° C. under a linear load of 5 kgf/cm to integrate them, whereby heat-resistant film base-material-reinforcing aluminum-foil-attached B-stage resin composition sheets were prepared.
Separately, circuits were formed on a BT resin copper-clad laminate having an insulating layer thickness of 0.2 mm and having 12 μm thick copper foils on both surfaces (trade name: CCL-HL830, supplied by Mitsubishi Gas Chemical Company, INC.) and then the copper foils were treated by black copper oxide treatment, to prepare an internal layer board. The above heat-resistant film base-material-reinforcing aluminum-foil-attached B-stage resin composition sheets were placed on both surfaces of the internal layer board, one sheet on one surface, after separating the releasing films such that the resin layer of each B-stage resin composition sheet faced to the internal layer board. The resultant set was placed in a press machine. It was temperature-increased from room temperature to 165° C. over 25 minutes and the pressure was set at 20 kgf/cm 2 from the beginning. The above set was maintained at a vacuum degree of 0.5 Torr at 165° C. for 30 minutes. Then it was allowed to cool and then it was taken out to obtain a multilayer board having four layers ( FIG. 11 ( 1 )). The aluminum foils on the external surfaces were dissolved and removed. Then, each surface was 1 shot irradiated with a carbon dioxide gas laser at an output of 12 mJ to form blind via holes having a diameter of 100 μm each. The multilayer board was swollen with a potassium permanganate type desmear solution (supplied by Nippon MacDermid Co., Inc.), desmear (dissolution) was carried out and neutralization was carried out, to attain a total roughness, from the external layer, of 7.8˜12.5 μm (average roughness Rz: 9.9 μm) ( FIG. 11 ( 2 ) ( 3 )). At the same time, a remaining resin layer in the bottom of each blind via hole was dissolved and removed. Then, an electroless copper plating layer having a thickness of 0.5 μm was attached to each of the above roughened surfaces and an electrolytic copper plating layer having a thickness of 25 μm was further attached thereto. The board was placed in a heating furnace and temperature was gradually increased from 100° C. to 150° C. over 30 minutes. Further it was gradually increased up and the board was cured under heat at 200° C. for 60 minutes. The thickness of the insulating layer was measured in a cross section and it was almost 30 μm. The resultant board was used to form a copper conductor circuit by a semi-additive process and the surface of the conductor circuit was treated by black copper oxide treatment. The above procedures were repeated to produce a multilayer printed wiring board having six layers ( FIG. 11 ( 4 )). Table 5 shows results of evaluation of this printed wiring board.
Example 10
500 parts of a bisphenol A type epoxy resin (trade name: Epikote 1001, supplied by Japan epoxy resin), 450 parts of a phenol novolak type epoxy resin (trade name: DEN438, supplied by Dow Chemical), 30 parts of an imidazole type curing agent (trade name: 2E4MZ, supplied by Shikoku Corporation), 60 parts of a carboxyl-group-modified acrylic multilayer structure organic powder (trade name: Staphyloid IM-301, average particle diameter 0.2 μm), 40 parts of a finely-pulverized silica (average particle diameter 2.4 μm) and 30 parts of acrylonitrile-butadiene rubber (trade name: Nipol 1031, supplied by ZEON Corporation) were dissolved in methyl ethyl ketone, to obtain a solution. The solution was homogeneously dispersed with a three-roll mill to prepare a varnish B. The varnish was continuously applied to a surface of a 25 μm thick PET film and the applied varnish was dried to prepare release-film-attached B-stage resin composition sheets X having a resin layer having a thickness of 15.0 μm (gelation time at 170° C., 63 seconds).
Further, 500 parts of a bisphenol A type epoxy resin (trade name: Epikote 1001, supplied by Japan epoxy resin), 500 parts of a phenol novolak type epoxy resin (trade name: DEN438, supplied by Dow Chemical) and 30 parts of an imidazole type curing agent (trade name: 2E4MZ, supplied by Shikoku Corporation) were added and these materials were homogeneously dispersed with a three-roll mill, to prepare a varnish C. The varnish was continuously applied to a 25 μm thick release PET film having smooth surface and the applied varnish was dried to obtain a B-stage resin composition sheet Y having a resin composition thickness of 20 μm and a gelatin time of 65 seconds. The B-stage resin composition sheet Y was continuously disposed on one surface of a wholly polyamide (aramid) film having a thickness of 4.5 μm. These materials were continuously laminated with a heating roll at a temperature of 100° C. under a linear load of 5 kgf/cm and then rolled up, whereby heat-resistant film base-material-reinforcing release-film-attached B-stage resin composition sheets were produced.
Separately, circuits were formed on an epoxy type copper-clad laminate having a thickness of 0.2 mm and having 12 μm thick copper foils on both surfaces (trade name: CCL-EL170, supplied by Mitsubishi Gas Chemical Company, INC.) and then the conductor circuits were treated by black copper oxide treatment. After separating the release PET films of the B-stage resin composition sheets Y, the above heat-resistant film base-material-reinforcing release-film-attached B-stage resin composition sheets were placed on both surfaces of the copper-clad laminate, one on each surface. The release-film-attached B-stage resin composition sheets X were disposed thereon, one on each surface. The resultant set was placed in a press machine. It was temperature-increased from room temperature to 170° C. over 25 minutes and the pressure was set at 25 kgf/cm 2 from the beginning. The above set was maintained at a vacuum degree of 0.5 Torr at 170° C. for 30 minutes, to carry out curing treatment. Then, it was allowed to cool and then taken out to obtain a substrate. The release films on the external surfaces were removed. Then, each surface was 1 shot irradiated with a carbon dioxide gas laser at an output of 12 mJ to form blind via holes having a diameter of 100 μm each.
Roughening treatment was carried out with a chromic acid aqueous solution, to attain a total roughness, from the resin layer, of 4.8˜10.3 μm (average roughness Rz: 8.4 μm). In this case, a top of a concave portion did not reach the heat-resistant film. At the same time, a remaining resin layer in the bottom of each blind via hole was dissolved and removed. The insulating layer thickness after the molding was almost 20 μm.
Then, an electroless copper plating layer having a thickness of 0.5 μm was attached to each of the above roughened surfaces and an electrolytic copper plating layer having a thickness of 25 μm was further attached thereto. The board was placed in a heating furnace and temperature was gradually increased from 100° C. to 150° C. over 30 minutes. Further, it was gradually increased and the board was post-cured under heat at 170° C. for 60 minutes. The resultant board was used to form a conductor circuit by a semi-additive process and the conductor circuit was treated by black copper oxide treatment. Similar procedures were carried out to produce a multilayer printed wiring board having six layers. Table 5 shows results of evaluation of this printed wiring board.
Comparative Example 17-18
In Examples 9 and 10, the same varnish A as that obtained in Example 9 and the varnish B as that obtained in Example 10 were used. The varnishes were applied to the same metal foil as that used in Example 9 and the same release film as that used in Example 10, respectively, to form a resin layer having a thickness, from tops of convex portions, of 40 μm, Example 9, and a resin layer having a thickness of 40 μm on the release film, Example 10, whereby a metal-foil-attached B-stage resin composition sheet and a release-film-attached B-stage resin composition sheet were prepared respectively. Only the metal-foil-attached B-stage resin composition sheet and the release-film-attached B-stage resin composition sheet were used without the heat-resistant film base-material-reinforcing B-stage resin composition sheets used in Example 9 and 10. Similar laminate-molding-curing-treatment was carried out and roughening treatment was similarly carried out, to attain a total roughness, from the external layer, of 7˜13 μm (average roughness Rz: 8˜11 μm) similarly to Examples 9 and 10, and multilayer printed wiring boards having six layers were similarly produced respectively. Table 5 shows results of evaluation of these printed wiring boards.
Comparative Example 19
In Example 9, a glass woven cloth having a thickness of 20 μm was impregnated with the same varnish A as that obtained in Example 9 and the impregnated varnish was dried to obtain a prepreg having a total thickness (glass woven, cloth+resin composition layer) of 40 μm and a gelation time (170°) of 84 seconds. The prepreg was disposed on each surface of an internal layer board. Aluminum foils having the same roughness were disposed on both surface of the resultant board ( FIG. 12 ( 1 )). Lamination-molding-curing-treatment was similarly carried out to prepare a multilayer board having four layers. After dissolving and removing the aluminum foils on the external layers, blind via holes were made. Roughening treatment was similarly carried out to attain a total roughness, from the external layer, of 5˜11 μm ( FIG. 12 ( 2 )). After electroless copper plating and electrolytic copper plating, the formation of circuits and conductor black copper oxide treatment were similarly carried out. Then, prepregs were disposed, aluminum foils having roughness were disposed, and lamination was similarly carried out. Then, the aluminum foils on the external surfaces were removed, blind via holes were formed. Desmear treatment, electroless copper plating and electrolytic copper plating were carried out. Then, circuits were formed to produce a multilayer printed wiring board having six layers. In observation of a copper plating cross section, there were found many portions where concave portions due to the roughening reached the glass cloth ( FIG. 12 ( 3 )) and the copper plating was attached. Table 5 shows results of evaluation of this printed wiring board.
Comparative Example 20
The same varnish C as that prepared in Example 10 was used. 100 parts of a finely-pulverized silica was added to the above varnish, to prepare a varnish. This varnish was applied to the aluminum foil as that used in Example 9 and then the applied varnish was dried to prepare an aluminum-foil-attached B-stage resin composition sheet having a resin layer having a thickness, from tops of convex portions of the aluminum foil, of 40 μm and a gelation time of 67 seconds. The aluminum-foil-attached B-stage resin composition sheet was disposed on each surface of the same internal layer board as that used in Example 10 and the resultant set was subjected to curing-treatment lamination similarly to Example 10. Then, the aluminum foils were dissolved and removed. Then, roughening treatment was similarly carried out. Copper plating and circuit formation and black copper oxide treatment were repeated, to produce a six-layered printed wiring board. Table 5 shows results of evaluation of this printed wiring board.
Example 11
500 parts of a bisphenol A type epoxy resin (trade name: Epikote 1001, supplied by Japan epoxy resin), 450 parts of a phenol novolak type epoxy resin (trade name: DEN438, supplied by Dow Chemical), 30 parts of an imidazole type curing agent (trade name: 2E4MZ, supplied by Shikoku Corporation) and 400 parts of talc (average particle diameter 1.8 μm, maximum particle diameter 4.2 μm) were added. These materials were homogeneously dispersed with a three-roll mill, to prepare a varnish A. The varnish was continuously applied to a 25 μm thick release PET film having smooth surfaces, and the applied varnish was dried to prepare a B-stage resin composition layer having a resin composition thickness of 20 μm and a gelation time of 65 seconds. The B-stage resin composition layer was disposed on one surface of a wholly aromatic polyamide (aramid) film having a thickness of 4.5 μm and continuously laminated with a heating roll at a temperature of 100° C. under a linear load of 5 kgf/cm, whereby heat-resistant film base-material-reinforcing release-film-attached B-stage resin composition sheets were produced. Further, the varnish A was continuously applied to a mat surface of an electrolytic copper foil having a thickness of 12 μm and a shiny surface having a 1 μm thick nickel·cobalt alloy treatment, and the applied varnish was dried, whereby copper-foil-attached B-stage resin composition sheets having a B-stage resin composition layer having a thickness, from tops of convex portions, of 6.0 μm and a gelation time of 67 seconds were produced. At the time when the resultant copper foil came out from a drying zone, a 15 μm thick protective polypropylene film was disposed. These materials were bonded with a heating roll at 90° C. under a linear load of 5 kgf/cm, to integrate them.
Separately, circuits are formed in an epoxy type copper-clad laminate (trade name; CCL-EL170, supplied by Mitsubishi Gas Chemical Company, INC.) having a thickness of 0.2 mm and having 12 μm thick copper foils on both surfaces and conductors were subjected to black copper oxide treatment to prepare an internal layer board. The above heat-resistant film base-material-reinforcing release-film-attached B-stage resin composition sheet was disposed on each surface of the internal layer board after separating the release film on one surface of the B-stage resin composition sheet. These materials were bonded to each other with a heating roll at a temperature of 100° C. under a linear load of 5 kgf/cm. The copper-foil-attached B-stage resin composition sheets were disposed on both surfaces of the resultant board, one sheet on each surface, after separating the protective films. The resultant set was laminate-molded under a vacuum of 30 mmHg or less for 2 hours at 110° C.·30 minutes+180° C.·90 minutes and 5 kgf/cm 2 ·15 minutes+20 kgf/cm 2 ·125 minutes. The insulating layer thickness of external layer was almost 20 μm. Each surface of the multilayer board was 1 shot irradiated with a carbon dioxide gas laser at an output of 13 mJ to form blind via holes having a diameter of 100 μm. Copper foil burrs occurring in the blind via hole portions were dissolved with an etching solution and at the same time the copper foils were dissolved until the copper foils had a thickness of 4 μm each. After desmear treatment, electroless copper plating was attached to a thickness of 0.5 μm and electrolytic copper plating was attached to a thickness of 15 μm. At the same time, the inside of each blind via hole was filled with the plating. Then, circuits were formed by a general method and black copper oxide treatment was carried out. Then, similar procedures were repeated to produce a six-layered printed wiring board. Table 6 shows results of evaluation of this printed wiring board.
Comparative Example 21
The same varnish A obtained in Example 11 was used. A glass woven cloth having a thickness of 20 μm was impregnated with the varnish and the impregnated varnish was dried to prepare a prepreg having a gelation time of 67 seconds and a thickness of 40 μm. The prepreg was placed on each surface of an internal layer board. An electrolytic copper foil having a shiny surface having a 1 μm thick nickel·cobalt alloy treatment was disposed thereon and the resultant set was similarly laminate-molded to prepare a four-layered board. Holes were similarly made with a carbon dioxide gas laser and the resultant board was similarly processed to prepare a four-layered printed wiring board. Further, a six-layered printed wiring board was produced therefrom. Table 6 shows results of evaluation of this printed wiring board.
TABLE 5
Examples
Comparative Examples
Item
9
10
17
18
19
20
Copper adhesive strength (kgf/cm)
1.24
1.34
1.23
1.34
1.15
0.53
Soldering heat resistance
No
No
No
Partial
Partial
Many
failure
failure
failure
swelling
swelling
swellings
Glass transition temperature DMA (° C.)
197
153
198
154
197
167
Elastic modulus 25° C. (kgf/mm 2 )
1,502
1,321
1,078
987
1,826
990
Warp · distortion (mm)
1.1
1.7
4.4
5.4
1.6
5.0
Thickness variance (μm)
4.5
5.8
10.0
12.8
7.8
12.5
Migration resistance (Z direction) (Ω)
Ordinary
5 × 10 13
5 × 10 13
5 × 10 13
5 × 10 13
4 × 10 13
5 × 10 13
state
200
6 × 10 11
6 × 10 10
2 × 10 10
5 × 10 8
3 × 10 9
9 × 10 8
hours
600
1 × 10 11
2 × 10 10
2 × 10 8
<10 8
<10 8
<10 8
hours
Migration resistance (X direction) (Ω)
Ordinary
6 × 10 13
5 × 10 13
—
—
—
—
state
200
4 × 10 11
3 × 10 9
—
—
—
—
hours
500
5 × 10 10
<10 8
—
—
—
—
hours
TABLE 6
Comparative
Item
Example 11
Example 21
Glass transition temperature DMA (° C.)
167
168
Migration resistance (Z direction) (Ω)
Ordinary state
5 × 10 13
5 × 10 13
100 Hours
1 × 10 11
7 × 10 8
500 Hours
8 × 10 10
<10 8
<Measurement Methods>
1) Elastic modulus: In each Example and Comparative Example, all internal and external metal foils were removed, laminations on front and reverse surfaces were carried out two times, to prepare a six-layer structure and elastic modulus was measured by DMA method. Table 5 shows elastic modulus at 25° C. in a DMA chart.
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The present invention relates to a heat-resistant film base-material-inserted B-stage resin composition sheet for producing a multilayer printed wiring board which is excellent in copper adhesive strength, heat resistance and insulating reliability particularly in the Z direction and is suitable for use, as a high density small printed wiring board, in a semiconductor-chip-mounting, small-sized and lightweight novel semiconductor plastic package, and to a use thereof.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims benefit of U.S. Provisional Application No. 61/456,800 entitled “Snow Removal System for Artificial Turf and Other Fragile Surfaces” and filed on Nov. 12, 2010, which is specifically incorporated by reference herein for all that it teaches and discloses.
TECHNICAL FIELD
[0002] The invention relates generally to the snow removal industry and more particularly to a snow removal system for artificial turf and other fragile surfaces.
BACKGROUND
[0003] There are many different types of snow removal equipment, from shovels and brooms to very large, vehicle-mounted blades, plows, and blowers. The particular type of equipment chosen to remove snow depends not only on an operator's personal preferences, but also on the effects said equipment will have on the surface from which the snow is to be removed. One surface that has very specialized properties is artificial turf. Artificial turf is a manufactured surface comprising synthetic fibers that are made to resemble natural grass. It has been traditionally used as a replacement field surface for sports that were originally or are normally played on grass. Additionally, artificial turf is now being used on residential lawns and in commercial applications as well.
[0004] As the use of artificial turf fields expands into more and more areas that receive substantial amounts of snowfall every year, a significant problem has developed: traditional snow removal devices either damage the artificial turf field or are too time-intensive; or more likely, cause both problems simultaneously. Three means currently employed to remove snow from artificial turf are: (1) a standard, light-truck-mounted snowplow, which can rip or otherwise damage the artificial turf or cause problems with the in-fill (the in-fill comprises small, round, rubber particles that are placed underneath the artificial turf mat); (2) a snow-blower, which can take 8-10 hours to clear a field and have a large potential of damaging the field if they break-down or if they pick up an object in their brushes; and (3) a rubber-bladed snowplow, which “chatters” (i.e., hops up and down) and digs into the field, ripping out small portions of turf fibers and causing significant problems with the in-fill.
[0005] Thus, there is a need for a snow removal system for artificial turf that can effectively remove snow in a timely fashion, without damaging the artificial turf surface or the in-fill.
SUMMARY
[0006] One embodiment of the present invention comprises a tubular metallic pipe or sleeve (any appropriate material may be used) of a length sufficient to cover the entire blade on a snowplow, having flared or curved-up end components, a channel in which the snowplow blade can be placed, and relatively large-surface-area “footies” to disperse the weight of the snowplow blade and system. The footies can have flared or curved-up edges so that they can glide over the artificial turf surface instead of digging in or otherwise damaging the surface. In other embodiments, the system is used without footies. A means of attaching the device to various snowplows is also described as is a recommended method of using the system to quickly and effectively remove snow from an artificial turf surface. It is to be understood that the system can be used on other, relatively fragile surfaces in addition to artificial turf.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The aforementioned and other features and objects of the present invention and the manner of attaining them will become more apparent and the invention itself will be best understood by reference to the following descriptions of a preferred embodiment and other embodiments taken in conjunction with the accompanying drawings, wherein:
[0008] FIG. 1 shows a perspective view of an exemplary embodiment of a snow removal system for artificial turf and other fragile surfaces;
[0009] FIG. 2 illustrates a left side elevation view of an exemplary embodiment of a snow removal system for artificial turf and other fragile surfaces;
[0010] FIG. 3 illustrates a front elevation view of an exemplary embodiment of a snow removal system for artificial turf and other fragile surfaces;
[0011] FIG. 4 illustrates a top plan view of an exemplary embodiment of a snow removal system for artificial turf and other fragile surfaces; and
[0012] FIG. 5 illustrates an exemplary embodiment of a method for removing snow from artificial turf and other fragile surfaces.
DETAILED DESCRIPTION
[0013] Referring now to the accompanying figures, FIG. 1 shows a representative snowplow blade 160 with an embodiment of the system 100 . The components shown in FIG. 1 include a sleeve 110 , first and second flare ends 120 and 122 , first and second sleeve attachment means 130 and 132 , and first and second footies 140 and 142 . Also shown in FIG. 1 are additional exemplary snowplow blade components including a cutting edge 164 and mounting bolts 162 .
[0014] The sleeve 110 extends the entire length of the snowplow blade 160 and has first and second flare ends 120 and 122 . The sleeve 110 can comprise a pipe or other tubular structure and can be made from metal or other resilient material(s) that do not become overly brittle and break under the conditions encountered when plowing snow. Further, the sleeve 110 needs to have a relatively low coefficient of friction as it needs to glide over an artificial turf field without damaging the turf. The first and second footies 140 and 142 help to prevent contact between the sleeve 110 and the turf surface but as field use requirements may necessitate nearly complete snow removal, the footies 140 may need to be removed and the sleeve 110 lowered to be in contact with the artificial turf in some cases.
[0015] Although not shown in detail in FIG. 1 , the sleeve 110 includes a channel for receiving the main cutting edge 164 of the snowplow blade 160 therein. This ensures that the blade 160 can not contact the turf or do damage thereto. Further, the channel helps to ensure that the sleeve 110 stays properly installed on the snowplow blade 160 . Exemplary embodiments of first and second sleeve attachment means 130 and 132 are shown in FIG. 1 as well. The illustrated sleeve attachment means 130 and 132 each comprise a bracket that is attached to the sleeve 110 and provides attachment points to affix the sleeve 110 to a snowplow blade 160 . In other embodiments, other shaped brackets are appropriate. It is contemplated that a number of various attachment means 130 and 132 will be utilized as there are a plethora of different blade designs and shapes that can employ the system 100 .
[0016] The first and second footies 140 and 142 as illustrated in FIG. 1 each comprise a relatively large, flat surface having one or more flared edges. The footies 140 and 142 in the embodiment shown in FIG. 1 resemble a portion of a snowboard having a long flat body and an upturned nose so that they can glide over a surface without damaging it. As discussed above, the footies 140 are designed to prevent contact between the sleeve 110 and the artificial turf or other fragile surface. Instead, the weight of the snowplow blade 160 and system 100 is distributed onto the relatively large surface area of the plurality of footies 140 and 142 (usually two, but any number of footies are contemplated). The footies 140 and 142 are designed to glide over the surface of the turf without damaging either the turf or the in-fill. As discussed above, the footies can be removed when it is necessary to reduce the snow depth as far as possible on an artificial turf field. At other times, it may be prudent to leave one, two, three or more inches of snow on the turf field. This can be accomplished by adjusting the distance between the bottom of the sleeve 110 and the footies 140 using the locking adjustment screws (see later Figures for details). For example, when plowing the turf field using a winter maintenance strategy, it is desirable to leave approximately two inches of snow on the field. Allowing more than six inches of snow to build up causes the weight to be too great to safely plow the field when it later becomes necessary to do so (e.g., to make the field ready for use in the spring). When adjusting the footies 140 and 142 , care should be taken so that they run true and straight in the direction of travel rather than at a particular angle relative to the snowplow blade 160 .
[0017] FIG. 2 illustrates a left side elevation view of an exemplary embodiment of a snow removal system for artificial turf and other fragile surfaces 200 in an unattached configuration. The channel 212 in the sleeve 210 can be clearly seen. As discussed above, the channel 212 is configured for receipt of the cutting edge of the snowplow blade therein. This ensures that the blade can not touch the artificial turf and damage it in any way. Also shown in FIG. 2 is the second flare end 222 which provides a relatively safe end to the sleeve 210 such that no sharp surfaces are exposed and in a position to damage the turf.
[0018] A second exemplary sleeve attachment means 232 is displayed in FIG. 2 . Other sleeve attachment means 232 are contemplated, especially as the shape and configurations of individual snowplow blades vary considerably. In many configurations, a plurality of sleeve attachment means 232 is contemplated. In some cases, a single attachment means is sufficient, in others two or more attachment means are preferred.
[0019] An exemplary embodiment of a second footie 242 is illustrated in FIG. 2 . Each footie 242 is preferably shaped similar to a snowboard and has a footie attachment means 250 . Each footie attachment means 250 includes a shaft 251 , a first set of locking nuts 252 , a second set of locking nuts 253 , a safety bolt 254 , and a mounting plate 255 . The shaft 251 is mounted to the backside of the snowplow blade and/or the snowplow blade supports. The shaft 251 engages the nuts 252 and 253 above and below mounting points (or alternatively, below and above mounting points on the snowplow blade. The first and second set of locking nuts 252 and 253 are then locked in place, also thereby locking the footie in place relative to the snowplow blade. Furthermore, since the shaft 251 can be formed with threads that engage the locking nuts 252 and 253 , the action of turning the nuts causes the footie 242 to raise or lower relative to the blade of the snowplow. The locking nuts 252 and 253 can be tightened in order to lock the footie in position. The safety bolt 254 ensures that the footie 242 does not become unattached from the plow blade. Finally, the mounting plate 255 attaches the shaft 251 to the footie 242 . The plate 255 can be shaped with flared ends in order to minimize any damage to the turf that might result if the footie 242 is somehow ripped off of the footie attachment means 250 . In other embodiments, other footie attachment means 250 can be used.
[0020] FIG. 3 illustrates a front elevation view of an exemplary embodiment of a snow removal system for artificial turf and other fragile surfaces 300 in an alternate embodiment without the use of footies and unmounted. Exemplary embodiments of first and second sleeve attachment means 330 and 332 are shown in FIG. 3 . The illustrated sleeve attachment means 330 and 332 each comprise a bracket that is attached to the sleeve 310 and provides attachment points to affix the sleeve 310 to a snowplow blade. In the embodiment shown in FIG. 3 , the brackets are simply bolted to the front of the snowplow blade by a plurality of bolts. In other embodiments, other shaped brackets are appropriate. It is contemplated that a number of various sleeve attachment means 330 and 332 will be utilized as there are a plethora of different blade designs and shapes that can employ the system 300 . One embodiment of first and second flare ends 320 and 322 can be seen in FIG. 3 as well. The flare ends 320 and 322 are angled up at the ends of the sleeve 310 in order to ensure that ends of the sleeve 310 do not cut into or otherwise damage an artificial turf or other fragile surface during the act of removing snow from such a surface. Note that the flare ends 320 and 322 can be curved upwards instead of angled upwards.
[0021] FIG. 4 illustrates a top plan view of an exemplary embodiment of a snow removal system for artificial turf and other fragile surfaces 400 . The components shown in FIG. 4 are discussed in detail above, and include: a sleeve 410 , first and second flare ends 420 and 422 , first and second sleeve attachment means 430 and 432 , a plurality of footies 440 and 442 , and a plurality of footie attachment means 450 and 480 .
[0022] FIG. 5 illustrates an exemplary embodiment of a method for removing snow from artificial turf and other fragile surfaces 570 . The method comprises the following steps: Installing the Snow Removal System on a Snowplow 571 , Positioning the Snowplow at One End of the Field in Approximately the Center 572 , Lowering the Plow and System Until the Weight Is on the Footies 573 , Plowing in Straight Lines Until Windrows Get Too Deep 574 , Moving System to Edges of Field and Working Back Inwards 575 , and Avoiding Spinning Plow Vehicle's Tires or Braking 576 .
[0023] The step of Installing the Snow Removal System on a Snowplow 571 involves the following: (1) Raise the plow blade; (2) Remove the skids; (3) Align the channel on the sleeve to the cutting edge of the plow blade; (4) Make sure the sleeve is centered on the plow blade; (5) Start at one side of the sleeve and use a floor jack to lift the sleeve, lightly tapping onto plow blade edge; (6) Work down the length of the sleeve until it is firmly seated against the cutting edge of the plow blade; (7) Drill holes through the turf plow bracket and plow mouldboard; (8) Install ½ bolts and locking nuts; (9) Install footies to original skid mounting bolt holes on plow; (10) Adjust footies to desired height using lower nut; (11) Align footies to direction of travel; (12) Tighten nuts to plow and lock the jam nuts; (13) Install safety bolt through top nut and screw of footies; and (14) Tighten lock nuts.
[0024] The step of Positioning the Snowplow at One End of the Field in Approximately the Center 572 involves maneuvering the vehicle, plow, and system to one end of the field and positioning it in approximately the center of the field. On subsequent snow removal jobs, be sure to vary the exact starting position so that ruts are not formed in the field surface.
[0025] The step of Lowering the Plow and System Until the Weight Is on the Footies 573 involves operating the plow's controls so that the weight of the plow and system is distributed onto the footies (or onto the sleeve if not using the footies). The plow should be set to float and no down pressure should be placed on the plow.
[0026] The step of Plowing in Straight Lines Until Windrows Get Too Deep 574 involves plowing the turf field in straight lines and not turning, especially while the plow vehicle is at rest on the field. The vehicle works slowly outwards until the windrows of snow get too deep.
[0027] The step of Moving System to Edges of Field and Working Back Inwards 575 involves repositioning the plow and system at the edges of the field (again avoid starting in the same exact position repeatedly in subsequent snow removal episodes as this may create ruts) and then plowing back inwards towards the previously plowed area.
[0028] The step of Avoiding Spinning Plow Vehicle's Tires or Braking 576 involves the use of the back pressure caused by the snow impacting the plow to slow the vehicle and plow rather than application of the brakes while on the field. Also, it involves accelerating gradually and not spinning the vehicles tires and thus reducing all extra stresses on the artificial turf field when removing snow therefrom.
[0029] Additional use recommendations are as follows:
[0030] 1. Maximum allowable weight on the field is a ¾ ton pickup truck.
[0031] 2. Turning must be avoided on the field. A very gradual arc might be allowable under certain circumstances.
[0032] 3. Avoid braking on the field (let the snow slow down the vehicle).
[0033] 4. Do not spin the tires.
[0034] 5. Avoid being parked on the field. If sitting still on the field the vehicle's front wheels must not be turned.
[0035] 6. Avoid sudden starts or stops.
[0036] 7. No fluids may leak on the field. Frequently check hydraulics on plow for leaks. Use blue hydraulic fluid as it stands out on snow.
[0037] 8. Operate plow at speeds under 8 mph.
[0038] 9. Operate the plow in float mode.
[0039] 10. Use a long blade (eight feet or more) to minimize the number of passes it takes to clear the field.
[0040] 11. Change your starting place to avoid creating ruts in the field over the winter season.
[0041] 12. Use diagonal passes to cut down heavy wind rows.
[0042] 13. Plow to opposite ends of the field to avoid heavy build up of wind rows at one end of the field.
[0043] 14. Reverse direction of travel to keep build up of wind rows balanced on both ends of the field.
[0044] 15. Make several passes across the field to clear the goal posts.
[0045] 16. Avoid shifting gears on the field and accelerate gently.
[0046] 17. Use tires having adequate tread depth and slightly decreased tire pressure to avoid spinning out and to increase traction.
[0047] 18. If running an automatic transmission, stay in LOW instead of DRIVE; for a standard transmission, use high range, low gear.
[0048] 19. A new cutting edge on the plow to be fitted with the system is recommended to provide adequate support.
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A snow removal system for artificial turf and other fragile surfaces is disclosed. The present invention comprises a tubular metallic pipe or sleeve of a length sufficient to cover the entire blade on a snowplow, having flared or curved-up end components, a channel in which the snowplow blade can be placed, and relatively large-surface-area “footies” to disperse the weight of the snowplow blade and system. The footies can have flared or curved-up edges so that they can glide over the artificial turf surface instead of digging in or otherwise damaging the surface. In other embodiments, the system is used without footies. A means of attaching the device to various snowplows is described as is a recommended method of using the system to remove snow from a surface. It is to be understood that the system can be used on other, relatively fragile surfaces in addition to artificial turf.
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FIELD OF INVENTION
[0001] The invention is related to nickel-chromium-molybdenum alloys and to producing two-phase nickel-chromium-molybdenum.
BACKGROUND
[0002] Nickel alloys containing significant quantities of chromium and molybdenum have been used by the chemical process and allied industries for over eighty years. Not only can they withstand a wide range of chemical solutions, they also resist chloride-induced pitting, crevice corrosion, and stress corrosion cracking (insidious and unpredictable forms of attack, to which the stainless steels are prone).
[0003] The first nickel-chromium-molybdenum (Ni—Cr—Mo) alloys were discovered by Franks (U.S. Pat. No. 1,836,317) in the early 1930's. His alloys, which contained some iron, tungsten, and impurities such as carbon and silicon, were found to resist a wide range of corrosive chemicals. We now know that this is because molybdenum greatly enhances the resistance of nickel under active corrosion conditions (for example, in pure hydrochloric acid), while chromium helps establish protective, passive films under oxidizing conditions. The first commercial material (HASTELLOY C alloy, containing about 16 wt. % Cr and 16 wt. % Mo) was initially used in the cast (plus annealed) condition; annealed wrought products followed in the 1940's.
[0004] By the mid-1960's, melting and wrought processing technologies had improved to the point where wrought products with low carbon and low silicon contents were possible. These partially solved the problem of supersaturation of the alloys with silicon and carbon, and the resulting strong driving force for nucleation and growth of grain boundary carbides and/or intermetallics (i.e. sensitization) during welding, followed by preferential attack of the grain boundaries in certain environments. The first commercial material for which there were significantly reduced welding concerns was HASTELLOY C-276 alloy (again with about 16 wt. % Cr and 16 wt. % Mo), covered by U.S. Pat. No. 3,203,792 (Scheil).
[0005] To reduce the tendency for grain boundary precipitation of carbides and/or intermetallics still further, HASTELLOY C-4 alloy (U.S. Pat. No. 4,080,201, Hodge et al.) was introduced in the late 1970's. Unlike C and C-276 alloys, both of which had deliberate, substantial iron (Fe) and tungsten (W) contents, C-4 alloy was essentially a very stable (16 wt. % Cr/16 wt. % Mo) Ni—Cr—Mo ternary system, with some minor additions (notably aluminum and manganese) for control of sulfur and oxygen during melting, and a small titanium addition to tie up any carbon or nitrogen in the form of primary (intragranular) MC, MN, or M(C,N) precipitates.
[0006] By the early 1980's, it became evident that many applications of C-276 alloy (notably linings of flue gas desulfurization systems in fossil fuel power plants) involve corrosive solutions of an oxidizing nature, and that a wrought, Ni—Cr—Mo alloy with a higher chromium content might be advantageous. Thus, HASTELLOY C-22 alloy (U.S. Pat. No. 4,533,414, Asphahani), containing about 22 wt. % Cr and 13 wt. % Mo (plus 3 wt. % W) was introduced.
[0007] This was followed in the late 1980's and 1990's by other high-chromium, Ni—Cr—Mo materials, notably Alloy 59 (U.S. Pat. No. 4,906,437, Heubner et al.), INCONEL 686 alloy (U.S. Pat. No. 5,019,184, Crum et al.), and HASTELLOY C-2000 alloy (U.S. Pat. No. 6,280,540, Crook). Both Alloy 59 and C-2000 alloy contain 23 wt. % Cr and 16 wt. % Mo (but no tungsten); C-2000 alloy differs from other Ni—Cr—Mo alloys in that it has a small copper addition.
[0008] The design philosophy behind the Ni—Cr—Mo system has been to strike a balance between maximizing the contents of beneficial elements (in particular chromium and molybdenum), while maintaining a single, face-centered cubic atomic structure (gamma phase), which has been thought to be optimum for corrosion performance. In other words, designers of the Ni—Cr—Mo alloys have been mindful of the solubility limits of possible beneficial elements and have tried to stay close to these limits. To enable contents just slightly above the solubility limits, advantage has been taken of the fact that these alloys are generally solution annealed and rapidly quenched, prior to use. The logic has been that any second phases (that might occur during solidification and/or wrought processing) will be dissolved in the gamma solid solution during annealing, and that the resultant single atomic structure will be frozen in place by the rapid quenching. Indeed, U.S. Pat. No. 5,019,184 (for INCONEL 686 alloy) goes so far as to describe a double homogenization treatment during wrought processing, to ensure a single (gamma) phase structure after annealing and quenching.
[0009] The problem with this approach is that any subsequent thermal cycles, such as those experienced during welding, can cause second phase precipitation in grain boundaries (i.e. sensitization). The driving force for this sensitization is proportional to the amount of over-alloying, or super-saturation.
[0010] Pertinent to the present invention is work published in 1984 by M. Raghavan et al (Metallurgical Transactions, Volume 15A [1984], pages 783-792). In this work, several nickel-based alloys of widely varying chromium and molybdenum contents were made in the form of cast buttons (i.e. not subjected to wrought processing), for study of the phases possible under equilibrium conditions, at different temperatures in this system, one being a pure 60 wt. % Ni-20wt. % Cr-20 wt. % Mo alloy.
[0011] Also pertinent to the present invention is European Patent EP 0991788 (Heubner and Köhler), which describes a nitrogen-bearing, nickel-chromium-molybdenum alloy, in which the chromium ranges from 20.0 to 23.0 wt. %, and the molybdenum ranges from 18.5 to 21.0 wt. %. The nitrogen content of the alloys claimed in EP 0991788 is 0.05 to 0.15 wt. %. The characteristics of a commercial material conforming to the claims of EP 0991788 were described in a 2013 paper (published in the proceedings of CORROSION 2013, NACE International, Paper 2325). Interestingly, the annealed microstructure of this material was typical of a single phase Ni—Cr—Mo alloy.
SUMMARY OF THE INVENTION
[0012] We have discovered a process that can be used to produce homogeneous, two-phase microstructures in wrought nickel alloys containing sufficient quantities of chromium and molybdenum (and, in some cases, tungsten), resulting in a reduced tendency for side-bursting during forging. A likely additional advantage of materials processed in this fashion is improved resistance to grain boundary precipitation, since, for a given composition, the degree of super-saturation will be less. Moreover, we have discovered a range of compositions that, when processed this way, are much more resistant to corrosion than existing, wrought Ni—Cr—Mo alloys.
[0013] The process involves an ingot homogenization treatment between 2025° F. and 2100° F., and a hot forging and/or hot rolling start temperature between 2025° F. and 2100° F.
[0014] The range of compositions that, when processed this way, exhibit superior corrosion resistance is 18.47 to 20.78 wt. % chromium, 19.24 to 20.87 wt. % molybdenum, 0.08 to 0.62 wt. % aluminum, less than 0.76 wt. % manganese, less than 2.10 wt. % iron, less than 0.56 wt. % copper, less than 0.14 wt. % silicon, up to 0.17 wt. % titanium, and less than 0.013 wt. % carbon, with nickel as the balance. The combined contents of chromium and molybdenum should exceed 37.87 wt. %. Traces of magnesium and/or rare earths are possible in such alloys, for control of oxygen and sulfur during melting.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is an optical micrograph of Alloy A2 Plate after having been homogenized at 2200° F., hot worked at 2150° F., and annealed at 2125° F.
[0016] FIG. 2 is an optical micrograph of Alloy A2 Plate after having been homogenized at 2050° F., hot worked at 2050° F., and annealed at 2125° F.
[0017] FIG. 3 is a graph of the corrosion resistance of Alloy A1 in several corrosive environments.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] We provide a means by which homogeneous, wrought, two-phase microstructures can be reliably generated in highly alloyed Ni—Cr—Mo alloys. Such a structure requires: 1. an ingot homogenization at 2025° F. to 2100° F. (preferably 2050° F.), and 2. hot forging and/or hot rolling at a start temperature of 2025° F. to 2100° F. (preferably 2050° F.). Moreover, we have discovered a range of compositions that, when processed under these conditions, exhibit superior corrosion resistance, relative to existing, wrought Ni—Cr—Mo alloys.
[0019] These discoveries stemmed from laboratory experiments with a material of nominal composition: balance nickel, 20 wt. % chromium, 20 wt. % molybdenum, 0.3 wt. % aluminum, and 0.2 wt. % manganese. Two batches (Alloy A1 and Alloy A2) of this material were vacuum induction melted (VIM), and electro-slag re-melted (ESR), under identical conditions, to yield ingots of diameter 4 in and length 7 in, weighing approximately 25 lb. One ingot was produced from Alloy A1; two ingots were produced from Alloy A2. Traces of magnesium and rare earths (in the form of Misch Metal) were added to the vacuum furnace, during melting, to help with the removal of sulfur and oxygen, respectively.
[0020] The ingot of Alloy A1 was processed to wrought sheets and plates in accordance with the laboratory's standard procedures for nickel-chromium-molybdenum alloys (i.e. a homogenization treatment of 24 h at 2200° F., followed by hot forging and hot rolling at a start temperature of 2150° F.). Metallography revealed a two-phase microstructure (in which the second phase was homogeneously dispersed and occupied considerably less than 10% of the volume of the structure) after annealing for 30 min at 2125° F., followed by water quenching. Unexpectedly, given the previous desire for a single phase in the realm of Ni—Cr—Mo alloys, Alloy A1 exhibited superior resistance to general corrosion than existing materials, such as C-4, C-22, C-276, and C-2000 alloys.
[0021] Conventional processing of Alloy A1 resulted in a two-phase microstructure. But conventional processing of the compositionally similar Alloy A2 did not produce a two-phase microstructure. Alloy A1 and Alloy A2 were made from the same starting materials and we see no significant differences between the composition of Alloy A1 and the composition of Alloy A2. Therefore, we must conclude that for some nickel-chromium-molybdenum alloys conventional processing may or may not produce a two-phase microstructure. However, if a two-phase microstructure is desired one cannot reliably obtain that microstructure using conventional processing.
[0022] Alloy A2 was key to this discovery in more ways than one. In fact, the two ingots of Alloy A2 were used to compare the effects of conventional homogenization and hot working procedures (upon microstructure and susceptibility to forging defects) with those of alternate procedures, derived from heat treatment experiments with Alloy A1.
[0023] Those experiments involved exposure of Alloy A1 sheet samples to the following temperatures for 10 h: 1800° F., 1850° F., 1900° F., 1950° F., 2000° F., 2050° F., 2100° F., 2150° F., 2200° F., and 2250° F. The main purpose was to ascertain the dissolution temperature (or range of temperatures) for the second phase, believed to be the rhombohedral intermetallic, mu phase.
[0024] Interestingly, temperatures in the range 1800° F. to 2000° F. caused a third phase to occur, in the alloy grain boundaries. Possibly, this was M 6 C carbide, since its dissolution temperature (solvus) appeared to be within the range 2000° F. to 2050° F., whereas the solvus of the homogeneously dispersed second phase appeared to be within the range 2100° F. to 2150° F.
[0025] The alternate procedure derived from those experiments involved homogenization for 24 h at 2050° F., followed by hot forging at a start temperature of 2050° F., then hot rolling at a start temperature of 2050° F. The intention of this approach was to avoid dissolution of the useful, homogeneously dispersed, second phase, while avoiding precipitation of the third phase in the alloy grain boundaries. To accommodate the fact that industrial furnaces are only accurate to about plus or minus 25° F., and to stay under the solvus of the useful second phase, a range 2025° F. to 2100° F. (for ingot homogenization, and at the start of hot forging and hot rolling) is indicated as appropriate.
[0026] Regarding the comparison of microstructures induced by the two approaches to the processing of Alloy A2 (to plate material), the conventionally processed plate of Alloy A2 exhibited a single phase after annealing at 2125° F., apart from some fine oxide inclusions peppered sparsely throughout the microstructure, a feature of all the experimental alloys associated with this invention. FIG. 1 shows the microstructure of Alloy 2 after this conventional processing. The use of the alternate procedures yielded a similar microstructure to that of Alloy A1 sheet which is shown in FIG. 2 .
[0027] Furthermore, the use these alternate procedures reduced substantially the tendency of the forgings to crack on the sides (a phenomenon known as side-bursting).
[0028] The range of compositions over which superior corrosion resistance is exhibited by alloys with the two-phase microstructure was established by melting and testing experimental alloys B through J, the compositions of which are given in Table 1.
[0000]
TABLE 1
Experimental Alloy Compositions (wt. %)
Alloy
Ni
Cr
Mo
Cu
Ti
Al
Mn
Si
C
Others
A1*
Bal.
19.95
20.31
—
—
0.21
0.18
0.06
0.003
Fe: 0.06, N: 0.005, O: 0.003
A2
Bal.
19.82
19.69
—
—
0.20
0.20
0.12
0.004
Fe: 0.09, O: 0.003
B
Bal.
18.72
19.15
0.03
<0.01
0.19
0.18
0.05
0.004
Fe: 0.05, N: 0.012, O: 0.003
C*
Bal.
20.22
20.71
0.03
<0.01
0.23
0.20
0.06
0.016
Fe: 0.06, N: 0.016, O: 0.003
D*
Bal.
18.47
20.87
0.01
<0.01
0.24
0.18
0.06
0.004
Fe: 0.05, N: 0.009, O: <0.002
E*
Bal.
20.78
19.24
0.02
<0.01
0.25
0.20
0.07
0.005
Fe: 0.07, N: 0.010, O: <0.002
F*
Bal.
19.47
20.26
0.05
<0.01
0.22
0.20
0.09
0.009
Fe: 0.79, N: 0.006, O: 0.003
G
Bal.
19.52
20.32
0.56
<0.01
0.62
0.76
0.14
0.013
Fe: 2.10, N: 0.006, O: <0.002
H*
Bal.
19.82
20.58
0.02
0.17
0.28
0.19
0.07
0.004
Fe: 0.05, N: 0.009, O: <0.002
I
Bal.
16.13
16.35
—
—
0.23
0.51
0.09
0.006
Fe: 4.98, W: 3.94, V: 0.26, O: 0.005
J
Bal.
19.55
20.38
—
—
0.08
<0.01
0.13
0.002
Fe: 0.07
K
Bal.
17.75
18.06
0.02
<0.01
0.23
0.20
0.06
0.003
Fe: 0.05, N: 0.003, O: 0.012, S: <0.002
Bal. = Balance
*Alloys which exhibit superior corrosion resistance (A2 was not corrosion tested) and the desired two-phase microstructure
The values for Alloys A1, A2, and B to K represent chemical analyses of ingot samples
[0029] All of these alloys were processed using the parameters defined in this invention. However, Alloys G and J cracked so severely during forging that they could not be subsequently hot rolled into sheets or plates for testing. The cracking is attributed high aluminum, manganese, and impurity (iron, copper, silicon, and carbon) contents in the case of Alloy G, and low aluminum and manganese contents in the case of Alloy J, which was an attempt to make a wrought version of the alloy made in cast form by M. Raghavan et al. (and reported in the literature in 1984).
[0030] Alloy I was an experimental version of an existing alloy (C-276), processed using the procedures of this invention. It did exhibit a two-phase microstructure after annealing at 2100° F., indicating that (if present) tungsten might play a role in achieving such a microstructure; however, it did not exhibit the superior corrosion resistance of the compositional range encompassing Alloys A1, C, D, E, F, and H.
[0031] Alloy K was made prior to the discovery of this invention, and was therefore processed conventionally. However, it is included to show that, if the chromium and molybdenum levels are too low, then the crevice corrosion resistance is impaired.
[0032] The possibility of superior corrosion resistance was first established during the testing of Alloy A1, which only exhibited the two-phase microstructure by chance. A comparison between the corrosion rates of Alloy A1 and existing, single-phase, commercial Ni—Cr—Mo alloys (the nominal compositions of which are shown in Table 2) in several aggressive chemical solutions is shown in FIG. 3 .
[0000]
TABLE 2
Commercial Alloy Compositions (wt. %)
Alloy
Ni
Cr
Mo
Cu
Ti
Al
Mn
Si
C
Others
C-4
Bal.
16
16
0.5*
0.7*
—
1*
0.08*
0.01*
Fe: 3*
C-22
Bal.
22
13
0.5*
—
—
0.5*
0.08*
0.01*
Fe: 3, W: 3, V: 0.35*
C-276
Bal.
16
16
0.5*
—
—
1*
0.08*
0.01*
Fe: 5, W: 4, V: 0.35*
C-2000
Bal.
23
16
1.6
—
0.5*
0.5*
0.08*
0.01*
Fe: 3*
*Maximum
The values represent the nominal compositions
[0033] The chosen test environments, namely solutions of hydrochloric acid, sulfuric acid, hydrofluoric acid, and an acidified chloride, are among the most corrosive chemicals encountered in the chemical process industries, and are therefore very relevant to the potential, industrial applications of these materials.
[0034] The acidified 6% ferric chloride tests were performed in accordance with the procedures described in ASTM Standard G 48, Method D, which involves a 72 h test period, and the attachment of crevice assemblies to the samples. The hydrochloric acid and sulfuric acid tests involved a 96 h test period, with interruptions every 24 h for weighing and cleaning of samples. The hydrofluoric acid tests involved the use of Teflon apparatus and a 96 h, uninterrupted test period.
[0035] Two tests were performed on each alloy in each environment. The results given in Tables 3 and 4 are average values.
[0000]
TABLE 3
Uniform Corrosion Rates (mm/y)
Solution
Alloy
1
2
3
4
5
6
7
8
9
10
A1
0.01
0.35
0.41
0.41
0.01
0.01
0.01
0.01
0.22
0.07
B
0.01
0.43
0.48
0.50
0.02
0.03
0.08
0.04
0.27
0.08
C
0.01
0.44
0.53
0.55
0.01
0.02
0.02
0.03
0.18
0.05
D
0.01
0.37
0.43
0.40
0.02
0.02
0.02
0.13
0.21
0.06
E
0.01
0.53
0.59
0.57
0.02
0.02
0.07
0.06
0.21
0.05
F
0.01
0.53
0.57
0.56
0.02
0.02
0.03
0.20
0.21
0.11
H
0.01
0.48
0.56
0.54
0.02
0.02
0.10
0.26
0.21
0.06
I
0.33
N/T
0.72
N/T
N/T
N/T
0.24
0.07
0.37
0.22
K
0.05
0.43
0.46
0.44
0.01
0.01
0.06
0.02
0.33
0.10
C-4
0.42
0.57
0.57
0.55
0.07
0.63
0.46
0.71
0.31
0.25
C-22
0.44
0.98
0.98
0.90
0.09
0.40
0.56
0.89
0.31
0.13
C-276
0.31
0.46
0.54
0.55
0.06
0.26
0.16
0.05
0.33
0.55
C-2000
<0.01
0.65
0.70
0.69
0.01
0.02
0.07
0.07
0.22
0.12
1 = 5% HCl at 66° C.,
2 = 10% HCl at 66° C.,
3 = 15% HCl at 66° C.,
4 = 20% HCl at 66° C.,
5 = 30% H 2 SO 4 at 79° C.,
6 = 50% H 2 SO 4 at 79° C.,
7 = 70% H 2 SO 4 at 79° C.,
8 = 90% H 2 SO 4 at 79° C.,
9 = 1% HF (Liquid) at 79° C.,
10 = 1% HF (Vapor) at 79° C.,
N/T = Not tested
[0000]
TABLE 4
Crevice Corrosion Test Results in Acidified 6% Ferric Chloride
Corrosion Rate (mpy)
Corrosion Rate (mpy)
Alloy
(80° C.)
(100° C.)
A1
0.01
0.04
B
0.01
0.02
C
0.03
0.04
D
0.02
0.04
E
0.01
0.03
F
0.02
0.04
H
0.02
0.05
K
0.02
0.07
(Creviced)
(Creviced)
C-22
<0.01
0.61
(Creviced)
(Creviced)
C-2000
<0.01
0.26
(Creviced)
(Creviced)
(Creviced) indicates the occurrence of crevice attack on at least one of the two test samples
[0036] Two of the most important test environments used in the experimental work were 5% hydrochloric acid at 66° C. and acidified 6% ferric chloride, the first because dilute hydrochloric acid is a commonly encountered industrial chemical, and the second because acidified ferric chloride provides a good measure of resistance to chloride-induced localized attack, one of the chief reasons that the Ni—C—Mo materials are chosen for industrial service.
[0037] It should be noted that the experimental alloys within the claimed compositional range are significantly more resistant to 5% hydrochloric acid at 66° C. than C-4, C-22, C-276, Alloy I (the material similar in composition to C-276, but processed in accordance with the claims of this invention), and Alloy K (the composition and processing parameters of which were outside the claims) Indeed, only C-2000 alloy was equal to alloys within the claimed compositional range in this regard. However, C-2000 alloy exhibited crevice attack in acidified ferric chloride, whereas alloys within the claimed range did not.
[0038] Although we have described certain present preferred embodiments of our nickel-chromium-molybdenum alloy and method for producing two-phase nickel-chromium-molybdenum alloys our invention is not limited thereto, but may be variously embodied within the scope of the following claims.
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In a method for making a wrought nickel-chromium-molybdenum alloy having homogeneous, two-phase microstructures the alloy in ingot form is subjected to a homogenization treatment at a temperature between 2025° F. and 2100° F. , and then hot worked at start temperature between 2025° F. and 2100° F. The alloy preferably contains 18.47 to 20.78 wt. % chromium, 19.24 to 20.87 wt. % molybdenum, 0.08 to 0.62 wt. % aluminum, less than 0.76 wt. % manganese, less than 2.10 wt. % iron, less than 0.56 wt. % copper, less than 0.14 wt. % silicon, up to 0.17 wt. % titanium, less than 0.013 wt. % carbon, and the balance nickel.
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TECHNICAL FIELD
[0001] The present disclosure is related generally to household toilet devices, and, more particularly, to a system and method for improving the convenience and use of a household toilet device.
BACKGROUND
[0002] The technology underlying the modern toilet was invented in the 1700's, but there has been little substantial improvement since that time. In particular, while complaints of inadequacy abound, solutions to noted problems have been few and far between. For example, men and women employ the traditional toilet in different ways, and this is a known source of conflict and disagreement, and yet little has been done to address the issue.
[0003] The current state of technology as to that particular issue is for men to lift the seat prior to urinating and then lower the seat again after urinating. While this is a simple system, it is not reliable nor is it convenient. In addition, even if properly executed, it does not solve other conflicts that arise in low light settings such as during night time use.
[0004] While the present disclosure is directed to a system that can eliminate certain shortcomings noted in or apparent from this Background section, it should be appreciated that such a benefit is neither a limitation on the scope of the disclosed principles nor of the attached claims, except to the extent expressly noted in the claims. Additionally, the discussion of technology in this Background section is reflective of the inventors' own observations, considerations, and thoughts, and is in no way intended to accurately catalog or comprehensively summarize the art currently in the public domain. As such, the inventors expressly disclaim this section as admitted or assumed prior art. Moreover, the identification or implication above of a desirable course of action reflects the inventors' own observations and ideas, and should not be assumed to indicate an art-recognized desirability.
SUMMARY
[0005] In keeping with an embodiment of the disclosed principles, a toilet modernizer device includes a housing configured for attachment beneath a lid of a toilet and a latching member having a first position wherein the latching member latches under a seat of the toilet so as to lift the toilet seat when the housing is lifted, and a second position wherein the latching member clears the toilet seat such that only the toilet lid is lifted when the housing is lifted. An actuator member is included, having a grip portion for the user to grip the actuator member. The actuator member is linked to the latching member for moving the latching member between the first position and the second position.
[0006] In keeping with another embodiment of the disclosed principles, a toilet includes a housing attached to the lid, a latching member having a first position wherein the latching member latches under the seat and a second position wherein the latching member clears the seat. An actuator member having a grip is linked to the latching member and enables a user to move the latching member between the first position and the second position.
[0007] Other features and aspects of embodiments of the disclosed principles will be appreciated from the detailed disclosure taken in conjunction with the included figures.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0008] While the appended claims set forth the features of the present techniques with particularity, these techniques, together with their objects and advantages, may be best understood from the following detailed description taken in conjunction with the accompanying drawings of which:
[0009] FIG. 1 is a partial cross-sectional side view of a toilet assembly in relation to which embodiments of the disclosed principles may be implemented;
[0010] FIG. 2 is a partial cross-sectional side view of a toilet and toilet moderniser in accordance with an embodiment of the disclosed principles;
[0011] FIG. 3 is a top plan view of an alternative lever system in accordance with an embodiment of the disclosed principles;
[0012] FIG. 4 is a partial cross-sectional side view of a toilet and toilet moderniser in accordance with an alternative embodiment of the disclosed principles;
[0013] FIG. 5 is a partial cross-sectional side view of a toilet moderniser in accordance with an alternative embodiment of the disclosed principles; and
[0014] FIG. 6 is a partial cross-sectional side view of a toilet moderniser in accordance with a further alternative embodiment of the disclosed principles.
DETAILED DESCRIPTION
[0015] Before presenting a fuller discussion of the disclosed principles, an overview is given to aid the reader in understanding the later material. As noted above, despite the almost ancient nature of the modern toilet, there have been no substantial steps taken to eliminate the known problem of leaving the seat up or down as the case may be, nor has the toilet become any easier to use in low light conditions such as during night time use.
[0016] However, in accordance with an embodiment of the disclosed principles, a toilet moderniser device is provided which allows movement of the toilet seat up and down without requiring the user to contact the seat. In a further embodiment, the device provides illumination for low light conditions and may also provide a triggered, timed or manual scent function to allow a fragrance or deodorizing spray to be emitted.
[0017] With this overview in mind, and turning now to a more detailed discussion in conjunction with the attached figures, FIG. 1 shows a schematic cross-sectional view of a toilet, toilet seat and toilet lid within which embodiments of the disclosed principles may be implemented. The illustrated toilet 100 includes a bowl 101 as well as a seat 103 and a lid or cover 105 . Each of the seat 103 and lid 105 is liftable such that the toilet 100 may be used with the lid 105 up and the seat 103 down, or with the lid 105 up and the seat 103 up as well. Typically, female users will use the toilet 101 in the first mode while male users will use the toilet 100 in the second mode, especially while urinating.
[0018] As noted above, male users may neglect to return the seat 103 to the lowered position after urinating, thus causing a subsequent female user to accidentally sit directly on the rim of the bowl 101 . This not only causes consternation in the female user, but may also pose a hygienic issue.
[0019] Turning to FIG. 2 , this figure shows a toilet 200 such as that shown in FIG. 1 , including a moderniser 207 in keeping with an embodiment of the disclosed principles. The moderniser 207 in the illustrated embodiment comprises a body portion 203 which may be made of one or more parts and which generally houses the remainder of the elements of the moderniser 207 . In the illustrated embodiment, the moderniser 207 is affixed to an underside of the lid 205 . The manner of affixing the toilet moderniser 207 to the lid 205 is not critical, and any permanent or impermanent means may be used, including screws, nails, Velcro™, suction cups, adhesives and so on.
[0020] A prominent feature of the moderniser 207 in the illustrated embodiment is a lever or arm 209 that, when moved, allows the user to connect the seat 203 to the lid 205 or to detach the seat 203 from the lid 205 . The lever 209 may also serve as a holding point to allow the user to lift the moderniser 207 , thus lifting the lid 205 and also lifting the seat 203 if the two are attached.
[0021] The mechanism by which the lever 209 attaches and detaches the seat 203 from the lid 205 is not critical, but in an embodiment the lever 209 attaches to a latch member 211 , such that pivoting of the lever 209 serves to pivot the latch member 211 into engagement under the seat 205 . In other embodiments, the lever 209 may be pulled in and out to attach/detach and detach/attach the seat 203 and lid 205 . Any number of variations are possible, although it is not preferred to have the lever 209 operate vertically since the lever 209 may also be used as a control point by the user to lift and lower the seat 203 and lid 205 together, or the lid 205 alone.
[0022] FIG. 3 is an overhead plan view of the latch and lever portion of the moderniser 207 . As can be seen, in the illustrated embodiment, the latch member 211 is not only displaced downward from the lever 209 but is also disposed at a right angle to the lever 209 .
[0023] In the configuration shown, the lever 209 includes a finger hole 301 to allow the user to easily slide the lever 209 and lift and lower the moderniser and the seat 203 or the seat 203 /lid 205 unit. Other shapes may be used to allow easy grip by the user's hand, including dimples, serrations and so on. It is preferred that the length of the lever and location of the finger hole 301 are such that the user's finger is spaced away from the lid 205 and seat 203 to avoid accidental touching of the user's finger to any component of the toilet.
[0024] FIG. 4 shows an alternative configuration of the moderniser 207 in which a slide latch is used instead of a rotating latch. In this embodiment, the lever 400 slides in and out of the moderniser 207 housing, and an attached latch 401 slides with it. The attached latch 401 is located so as to engage the seat 203 when the lever 400 is pulled outward to the extended position, and to disengage the seat 203 when the lever 400 is pushed inward to the compressed position.
[0025] Although pivoting and outwardly sliding latches have been shown by way of example, it will be appreciated that other types of latch mechanisms are possible. These include for example, twisting latches, laterally sliding latches, pinch latches and so on. Also, although the latching element is shown to be inward of the seat in the examples, other configurations are possible. For example, the latching element may be outside the seat instead, although this would make the latch element visible to the user.
[0026] As noted above, the toilet moderniser described herein may also include a lighting option and/or a fragrance option. With respect to the lighting option, the toilet moderniser in this embodiment includes a light such as an LED that directs illumination to aid the user in low light conditions. An example of this embodiment is shown in FIG. 5 .
[0027] In particular, FIG. 5 shows a simplified cross-sectional side view of the toilet moderniser 500 wherein a lighting fixture 501 is included in the housing 503 of the moderniser 500 . As noted above, the lighting fixture 501 may comprise an LED or other light source and is powered by one or more batteries 505 within the housing 503 . A hatch 507 in the housing 503 allows the batteries to be changed. In the event that rechargeable batteries 505 are used, a charging port (not shown) may be provided.
[0028] In a further related embodiment, a light sensor 509 is provided to trigger the lighting fixture 501 . For example, the lighting fixture 501 may be turned on when low light conditions are detected by the light sensor 509 and may be turned off when normal lighting is detected. Although the placement of the light sensor 509 and the lighting fixture 501 are not critical, placing the light sensor 509 at the opposite side of the device as the lighting fixture 501 as shown may provide an efficient way to prevent the turning on of the lighting fixture 501 from triggering the light sensor 509 to depower the lighting fixture 501 .
[0029] It was also noted above that a fragrance option is provided in an embodiment of the disclosed principles. In this embodiment, the fragrance option includes a canister or other container, preferably under pressure, that may be selectively triggered to release a controlled amount of a scent or deodorant. An example of this embodiment is shown FIG. 6 .
[0030] The embodiment of the toilet moderniser 600 illustrated in FIG. 6 shows a fragrance canister 601 within the housing 603 and having an outlet through the housing 603 . The canister 601 is linked to a trigger 605 , which may be electrical or mechanical. In an optional embodiment, the trigger 605 is electronic and is based on presence detection, e.g., via IR or optical sensing. In an alternative optional embodiment, the trigger 605 is manual and is depressed by the user when desired.
[0031] Although the various embodiments are shown separately for clarity, it will be appreciated that the options need not be used one at a time and may of course be combined in a single implementation of the moderniser. Thus, for example, in an embodiment the moderniser includes both a lighting option and a scent or fragrance option. Alternatively either option alone may be provided in an implementation.
[0032] It will be appreciated that the described toilet moderniser is not permanently affixed to the toilet lid but instead can be added to or removed from the toilet lid with little effort and without modification (other than possibly screw holes) to the lid. As noted above, the attachment mechanism may be one or more of screws (wood screws or machine screws and matching threaded inserts), bolts and nuts, Velcro, adhesives, suction cups and so on.
[0033] It will be appreciated that system and techniques for improved toilet operation have been disclosed herein. However, in view of the many possible embodiments to which the principles of the present disclosure may be applied, it should be recognized that the embodiments described herein with respect to the drawing figures are meant to be illustrative only and should not be taken as limiting the scope of the claims. Therefore, the techniques as described herein contemplate all such embodiments as may come within the scope of the following claims and equivalents thereof
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A toilet modernizer is provided for allowing touchless manipulation of a toilet seat and lid by a user. An outer housing that is attachable under the toilet lid contains the other components of the device in one simple module. As part of the module, a latching member actuated by a user-manipulated actuator element selectively latches and unlatches the seat and lid, so that the user can select to lift the two elements as a unit or to lift only the lid, all the while without having to touch any part of the toilet. In an embodiment a lighting element is included, and in a further embodiment, a scent spray module is also included in the module.
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BACKGROUND OF THE INVENTION
The present invention relates to a wet press for a paper making machine and particularly to a press with several press nips and wherein the web is supported on its path between the nips, sometimes without a supporting felt belt.
A press of this type is known from U.S. Pat. No. 4,556,451. This press is comprised of four press rolls which form a continuous chain so that the web of paper is always wrapped around a press roll over a part of the circumference of the roll during passage through the press. A total of three press nips are formed by the four press rolls. Upstream of the four roll press, there is a two roll press which receives the paper web coming from the wire section of the paper making machine.
A large number of paper making machine press sections of quite different configurations are known. U.S. Pat. No. 2,694,348 discloses a press section in which the web of paper is first removed by a first felt belt or first felt from the wire section of the paper machine and is then conducted by that first felt through a first two roll press. A second felt belt, which also passes through the first two roll press, receives the web of paper and conducts it through a second two roll press. Thereupon the web of paper is taken up by a third felt belt which passes through the second two roll press. The third felt belt conducts the web of paper through a third two roll press and then further through a fourth two roll press. This press section thus has a total of four press nips. Felt belts are passed through all of the press nips simultaneously along with the web of paper. The web of paper is transported by the felt belts between the individual press nips, over a path on which a felt belt bridges over each free path together with the web of paper present on the felt belt or hanging from it.
In general, wet presses or entire wet press sections should be adapted to the high demands of high speed paper machines. Wet presses should have a high pressing efficiency, should take up as little space as possible, particularly in the direction of travel of the paper web and in the horizontal direction, and furthermore should be of inexpensive construction.
However, with the increasing speeds of modern paper making machines, technical problems become greater, and new problems must constantly be solved. Such problems occur, for instance, upon restarting the paper making machine after it has been stopped, when a narrow strip of paper or tail must be passed through the press section. Furthermore, the danger of the paper web tearing increases with increasing speed of the paper machine. Furthermore, with this increasing speed, the water removal capacity of the press section must be increased. That cannot be done without increasing the number of press nips. However, this requires more space in the direction of travel of the paper machine. Another problem is marking of the paper web by the press felt belts while the web is still moist. Finally, wearing of the press felt belts increases with increasing speed of the machine and increasing linear pressures in the press nips, so that the felt belts must be more frequently replaced by new ones, which naturally increases the cost.
SUMMARY OF THE INVENTION
The foregoing problems have not been optimally solved by known devices. The object of the present invention therefore is so to develop a wet press having a series of press nips in succession and without the web being unsupported by one of the press rolls in such a manner that, while the press has a high degree of pressing efficiency and operates at high speeds, dependable transfer of the narrow lead strip or tail or of the entire wide paper web is assured, the marking of the moist paper web by felts or wires or with hole patterns of suction rolls is reduced or avoided entirely, and the wear of the felt is reduced.
This object is achieved by the invention. A wet press for a paper making machine presses out water from a moist paper web. The wet press has a plurality of press rolls, at least four and preferably five. The press rolls are paired, such that each pair defines a respective press nip. There are at least three and preferably at least four press nips defined by the paired press rolls. The press rolls are so placed, the press nips are so defined and the web is so trained on the path through the wet press that the paper web is always supported by an outer surface of a press roll on the web path from the first press nip to the last press nip. In the successive press nips, e.g. at the second press nip in the path of the web, each of the press rolls there forms a felt free second press nip, and where there is no felt supporting the web at the second nip, each of the press rolls at the second nip has a closed outer surface.
Other objects and features of the invention are explained with reference to the drawings.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 schematically shows a press section having a five roll press which contains two shoe press or extended nip press rolls;
FIG. 2 shows a press section having a four roll press, including one shoe press;
FIG. 3 shows a press section which contains, inter alia, a five roll press, wherein one of the rolls is a shoe press roll;
FIG. 4 shows a press section having a five roll press, including two shoe press rolls.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1, a forming section wire screen 1 in an endless belt form travels in the direction indicated by the arrow and wraps around a suction roll 2 and then around a deflection roll 3 which rolls define an oblique path between rolls 2 and 3. The wire screen 1 carries a paper web 4 on its outer surface, and the web is indicated in dashed line.
There is a first felt 5, which is also developed as an endless loop felt belt. The felt 5 is wrapped around a number of guide rolls, including the guide roll 6, the suction guide roll 7, and the guide roll 8, and further passes around a first press roll 9, which is part of the press.
The first press roll 9 forms a first press nip I with a second press roll 10. The first press roll 9 is a shoe press roll having a press shoe 9.1, which is shown only diagrammatically here. It produces a press nip which is relatively long or extended in the direction of travel of the felt. The press shoe 9.1 is displaceable radially in known manner relative to a stationary support member (not shown), so that the pressing force which acts in the press nip I is variable. The first roll 9 includes a tubular, flexible, press jacket which also travels through the press nip I. The jacket slides over the press shoe 9.1. Its outer surface may have fine recesses (for instance, blind holes) for temporary storage of water. Those recesses are indicated symbolically by a dashed line around the roll 9.
The second press roll 10 is followed in sequence in the web path by a third press roll 11. The two press rolls 10 and 11 are directly contacted by the paper web 4 without a felt on either side of the web. The rolls 10 and 11 form a felt free second press nip II. Press roll 11 is mounted for being displaceable in the directions indicated by the double headed arrow 11', which enables adjustment of the pressing force in the press nip II.
The third press roll 11 is followed in the web path by a fourth press roll 12, which is also a shoe press roll and includes a press shoe 12.1. The third and fourth rolls 11 and 12 form a third press nip III with each other.
A fifth press roll 13, which is developed as a suction press roll, forms a fourth press nip IV with the third press roll 11. Press roll 13 is mounted for being displaced towards or away from the third press roll 11, as indicated by the double headed arrow 13.1, so that the press nip IV may be dispensed with, depending upon the operating conditions.
Fourth press roll 12 is located within the endless loop of a second press felt 14. Felt 14, in its turn, is wrapped around guide rolls 15, 16, 17, etc.
Press roll 12 comprises a flexible press jacket which can also have fine recesses on its outer side as shown in dashed line. This design is used particularly in the event that a relatively thin, finely woven press felt 14 is used which has only a relatively slight water absorbing ability.
The fifth press roll 13 is located within the endless loop of a third press felt 18. The felt 18 is moved around guide rolls, including rolls 19, 20.
The wet press is followed in the customary manner by a drying section. A single tier drying section is illustrated. It comprises a plurality of drying cylinders 21, 22, a plurality of deflection suction rolls 23, etc., arranged in each case between two drying cylinders, a drying wire 24 guided by guide rolls 25, 26, etc. The upstream, starting end of the drying section has a deflection suction roll 27, which removes the paper web 4 from the third press felt 18.
Other less important parts include, for instance, a scraper 10.1 associated with the press roll 10 after the second nip, a scraper 11.1 associated with the press roll 11 after the fourth nip, and a broke discharge chute 10.2 located below the press roll 10.
The path of the paper web 4 is as follows. The paper web 4 is first removed from the forming wire 1 by the first press felt 5 and the pick-up roll 7. The web then hangs on the bottom of the first press felt 5. The felt and the web together pass through the first press nip I. Then the web leaves the press felt 5 and remains on the circumference of the press roll 10 until the web passes through the second press nip II. The second nip is felt free. Then the web remains on the circumference of the third press roll 11 until at least the third press nip III is reached, and possibly until the fourth press nip IV. After the fourth press nip, the web is then transferred by means of the deflection suction roll 13 onto the third press felt 18. The web is removed from the felt 18 by the deflection suction roll 27 and is thereafter conducted by the drying section wire 24 through the drying section.
Upon its passage through the wet press from nip I to nip IV, the paper web is constantly adhered to the outer surface of one of the press rolls, so that tearing of the web is practically impossible on this critical section of the travel of the paper web.
It is also important that the first press roll 10 have a relatively soft outer surface in contact with the web, while the second press roll 11 has a relatively hard outer surface in contact with the web. The change from the felted press nip I, formed by a shoe press, to the felt free press nip II, which is formed of completely smooth or closed roll surfaces, and then to the felted press nip III, which is formed again by a shoe press, has also proven particularly favorable. Press felt 18 is preferably formed of a relatively fine fabric, so that the paper web 4 is marked relatively little by the press felt 18 at the last press nip IV, if such a nip is present. In other words, the bottom side of the paper web 4 remains relatively smooth upon contact with the press felt 18.
The embodiment shown in FIG. 2 is similar to that shown in FIG. 1. Again, there is a wire section with the moving wire 1, the wire suction roll 2, the deflection roll 3 and the paper web 4, shown in dashed line, which is carried on the wire 1. A first press felt 5 conducts the paper web 4 through a first press nip I between the first and second press rolls 9 and 10. Roll 9 is a press roll with a smooth, i.e. closed, outer surface, and not a shoe press as in FIG. 1. Alternatively, the outer surface of the first press roll 9 can also be provided with fine recesses, for instance circumferential grooves, for the temporary storage of water. The remaining structure of the press is also very similar to that shown in FIG. 1. However, roll 13 directly contacts the web and therefore has a closed outer surface. In other words, there is no felt like belt 18 around the roll 13, and the web is not supported by a felt as it moves to the roll 27. The paper web 4 is transferred from the roll 13 onto the drying section wire 24, at a suction zone of roll 27.
The embodiment shown in FIG. 3 is similar to the first two, except for what follows the pick-up roll 7. This roll is followed by an initial press having a press roll nip Ia which is formed of two press rolls 30 and 31. Press roll 30 has a suction zone 30.1 to conduct the paper web 4 dependably to the press nip Ia. Press roll 31 has a suction zone 31.1 in order to transfer the paper web 4 reliably to a second press felt 11'.
The following press again has five press rolls 9, 10, 11, 12, and 13. The first roll 9 has a smooth or a grooved surface and is also located within the loop of the second felt 11'. Together with the second roll 10, the first roll 9 forms a first press nip I. The second and third rolls 10 and 11 form a second press nip II. The third and fourth rolls 11 and 12 form a third press nip III. The third and fifth rolls 11 and 13 form a fourth press nip IV.
The fourth roll 12 is located within the loop of a third press felt 17. The fifth roll 13 is at the same time a suction deflection roll which transfers the paper web onto a drying wire 18 of the following drying section. The drying section basically has the same construction as the drying sections of the other two embodiments.
In the press of the invention, comprising the press rolls 9-13, on its course from the first press nip I to the last press nip IV, the paper web always follows the circumferences of the press rolls concerned. The web thus never travels freely. In FIG. 3 also, the second press nip II of the press is formed of a roll with a relatively soft jacket, the roll 10, and of a roll with a hard jacket, the roll 11. The roll 10 having the soft jacket is arranged upstream of the roll 11 having the hard jacket, as seen in the direction of travel of the paper web 4. Roll 12 with a press jacket which is smooth on the outside or which is provided with recesses, is again a shoe press roll having a shoe 12.1.
The embodiment shown in FIG. 4 is similar to the first two embodiments shown in FIGS. 1 and 2 because the five press rolls shown provide the only press and there is no two roll press in front of it. However, it is obvious that this arrangement could also be altered. A further press could be arranged either upstream or downstream of the illustrated press.
The five press rolls 9, 10, 11, 12, 13 in FIG. 4 form a total of four press nips I, II, III, IV with each other. Differing from FIGS. 1 and 2, the first press roll 10 which is contacted by the paper web without a felt interposed is now a shoe press roll, and the tubular, flexible rotating press jacket of that shoe press roll is smooth. The roll 10 has a radially movable press shoe 10a, with a concave pressing surface, which forms the press nip I with the preferably grooved press roll 9. Furthermore, the shoe press roll 10 has a radially movable ledge 10b, preferably with a convex pressing surface, located at the press nip II. The ledge 10b is movable for opening or closing the press nip II and for varying the pressing force in the press nip II. Due to the movable ledge 10b, the press roll 11 need not be adjustable in its position, which differs from the embodiments of FIGS. 1 to 3. In other words, the four press rolls 9 to 12 can all be supported substantially rigidly on a foundation or on a machine frame. This provides an extremely simple, space saving arrangement of the entire wet press.
The paper web 4 is removed by the press felt 5 and the pick-up roll 7 from the wire 1 and the web is then passed, together with the felt 5, though the first press nip I. On the other hand, the paper web 4 passes by itself through the second press nip II, i.e. without a felt. At the press nip III, the condition is the same as at the press nip I, as the paper web 4 and a felt 14 pass together through the press nip III. Press nip IV passes the web alone without a felt, as in the case of the press nip II. The paper web 4 travels by itself through this press nip. This alternate guidance of the web, first with, then without, then again with and finally without a felt, is advantageous. The pressing with a felt permits relatively strong removal of water but the felt has the disadvantage of the marking the moist paper web with the felt fabric pattern, while the following press nip without a felt smoothes out the preceding felt marking.
A spray tube 13.1 is associated with the press roll 13. It applies a water spray mist onto the outer surface of the roll 13 over the entire width of the roll, shortly upstream of the press nip IV. This assures that, if necessary, the paper web continues to travel with the roll 13 after leaving the press nip IV. A scraper 13.2 cleans the outer surface of the roll 13.
Although the present invention has been described in relation to particular embodiments thereof, many other variations and modifications and other uses will become apparent to those skilled in the art. It is preferred, therefore, that the present invention be limited not by the specific disclosure herein, but only by the appended claims.
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A wet press for a paper making machine presses out water from a moist paper web. The wet press has a plurality of press rolls, preferably five. The press rolls are paired so that each pair defines a respective press nip. There are preferably at least four press nips defined by the paired press rolls. The press rolls are so placed and the press nips are so defined and the web is so trained on the path through the wet press that the paper web is always supported by the outer surface of one of the press rolls on the web path from the first press nip to the last press nip. At the second press nip in the path of the web, each of the press rolls there forms a felt free second press nip and each of the press rolls at the second nip has a closed outer surface. The same may be true for the fourth press nip. Some of the press rolls may be shoe press rolls.
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BACKGROUND OF THE INVENTION
One of the most troubling occurrences to shoes and their function is the frequency of the slippage of the shoelace knot once it has been tied. This is dangerous when participating in any type of athletic activity or something as fundamental as walking. Moreover, most young children are unaware of the danger of an untied shoe and the severity of the injury it can cause when they inadvertently step on the loose lace with their other foot and cause themselves to trip. Needless to say it is quite painful especially when the front teeth are lost in the process. In Stanfield U.S. Pat. No. 5,372,510 where a device was designed to aid handicapped children in tying a bow in a shoelace that is mounted to a shoe. In short, prior art does not provide a remedy for slippage of the knot on both sides of the knot once the shoelace has been tied, nor address the semi or permanent need for placement of the device on the shoe itself to eliminate loss or destruction.
SUMMARY OF THE INVENTION
The primary function of the present invention is to keep shoelaces that have been tied in the traditional knot with bows on each side securely fastened in the tied state. The device has two clamping members, with a locking system to add strength and reliability, which are joined together by a flexible arm. Once in place, the device will secure the excess laces and bow on both sides of the knot. This will keep the knot tightly affixed. Also the device has an adjoining flexible arm in the shape of an oval with a stiff end or tip to aid in the device being placed through the top shoelace hole. Once through the shoelace hole the device will be inserted through the oval flexible arm forming a noose around the surrounding shoe material, semi affixing the device to the shoe. The following drawings accompanied by the preferred embodiments will fully describe the unique, practical usefulness of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top view of a shoe with the device incorporated and engaged.
FIG. 2 is a side view of a shoe and the device hanging unengaged.
FIG. 3 is a top view of the device.
FIG. 4 is an open view of the device.
FIG. 5 is a side view of one of the clamps unengaged showing the teeth and the locking mechanism.
FIG. 6 is a side view of the bottom half of a clamp displaying its teeth and twist lock.
FIG. 7 is an open view of a clamp displaying the teeth, hole, locking apparatus and flexible arm that connects one clamp to the other.
FIG. 8 is a side view of a clamp with a tie shoelace in-between the clamp.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a shoe 2 and the position of the apparatus with the clamps 10 and 20 engaged and fastened about the shoelace 16 , the bows 12 , and 14 . Clamps 10 and 20 are placed one on either side of the knot 8 to keep the knot 8 , the bows 14 and 12 and the shoelace 16 tightly bound to preclude slippage of the knot 8 and bows 12 and 14 . FIG. 2 illustrates a side view of a shoe 2 and the apparatus hanging unengaged through a hole 4 displaying the apparatuses semi permanent position when it is not in use. FIG. 3 illustrates the entire apparatus removed from the shoe 2 and how clamps 10 and 20 are connected by an arm 6 which viers off to form a loop 5 with a tip 3 on its end to aid the device in being inserted through the upper hole 4 of a shoe 2 . Once the tip 3 and the loop 5 have been inserted through the hole 4 , clamps 10 and 20 , and the arm 6 will be inserted through the loop 5 to form a noose through and around the upper hole 4 and the upper material of the shoe 2 . The apparatus, by being semi attached, allows it to be readily available when needed and to avoid loss or misplacement. FIG. 4 Illustrates the apparatus with clamps 10 and 20 open to display the teeth 9 whose purpose is to bite into the shoelace 16 to keep it from slipping through clamps 10 and 20 . FIG. 4 also illustrates the prongs 11 and 13 whose main function is to engage a latch 17 to keep the clamping parts of 10 and 20 securely fastened. Both clamps have a hole 3 in-between latches 11 and 13 . Stem 7 serves as a back up or safety locking mechanism that inserts through the hole 3 of both clamp members 10 , and 20 . Once the stem 7 is inserted through the hole 3 the head of stem 7 will swivel to a locking position in a groove 25 . FIG. 5 illustrates a side view of the clamp 10 and the apparatuses members responsible for the effectiveness of holding the shoelace in a tied state. FIG. 5 further illustrates the Stem 7 and how it will be inserted through the hole 3 and locked in place in the groove 25 , with a prong 11 engaging the latch 17 . Once the clamp 10 is closed the teeth 9 will hold the knot 8 , the bows 12 and 14 , and the shoelace 16 tightly fastened. FIG. 6 illustrates the bottom half of the clamp 10 and the location of the teeth 9 , the latch 13 and the stem 7 . FIG. 7 illustrates an open view of the inventions members to further demonstrate the positions of the clamp 10 , the teeth 9 , the prongs 11 , the hole 3 , the stem 7 , the latch 13 and the arm extension 6 . The clamps 10 and 20 will snap together the same as a traditional hair barrette except for the added feature of a stem 7 and a hole 3 in the top of the clamps 10 and 20 . The stem 7 once inserted through the hole 3 will pivot or turn until it comes to rest in the groove 25 . This locking system will securely fasten the shoelace 16 and bows 12 and 14 and the knot 8 in place. This invention allows the shoelace 16 to fulfill its ultimate purpose of securely tightening the shoe 2 about the foot. FIG. 8 illustrates a clamp 20 with a tied shoelace bow 14 and excess lace 16 resting in-between and on the teeth 9 . Once the stem 7 is inserted in the hole 3 and twisted and locked in place in the groove 25 , the force of the closure of the clamp 20 will fixate the bow 14 and the lace 16 in place and preserve the integrity of the knot 8 .
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The devices sole function is to aid the shoelace once tied in obtaining its ultimate purpose of securing the shoe about the foot. This is done by the device being placed on both sides of the knot and fastening the excess lace in a manner to alleviate slippage of the knot, the bow and the excess lace.
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BACKGROUND OF THE INVENTION
To satisfy the high demand for food products in patty form, particularly hamburgers, machines have been designed for this purpose which are capable of producing such patties on a high volume basis.
Particularly when dealing in high volumes of patties, it is essential that the portions be controlled precisely, since a small variation in patty size will result in an appreciable difference in the amount of product utilized.
Additionally, it is important that the product, which is usually fairly homogeneous when it is deposited in the patty machine, remain this way during the patty forming operation without undue segregation of specific components of the product. For example, in forming meat patties, there is often a problem with an accumulation or build up of fatty components of the ground meat along surfaces of the patty machine.
Build ups of this type will eventually break away as clots of fat and be charged into the patty mold, resulting in a patty of unacceptable quality. Aside from this, the accumulation of fat or the like along components of the patty machine can interfere with the efficient operation of the machine.
In many patty machines the apparatus used for delivering the product to some type of charging device operates on a continuous basis. This has the effect of providing a constant working or kneading of the product which can affect deleteriously the texture and appearance of the finished patties.
It will also be apparent that since the machines are intended to deliver a food product for human consumption, sanitation is a prime consideratiion. Therefore, an efficient patty machine must be susceptible of thorough cleaning without complicated cleaning procedures.
SUMMARY OF THE INVENTION
The present invention provides a method and apparatus for forming successive, controlled portions of a product in patty form from a quantity of the product in bulk form.
The apparatus includes a charging chamber having an entrance and an exit with the latter communicable with a reciprocating patty mold. Mounted within the charging chamber are intermeshing, self-wiping compressor screws which feed the product by positive displacement under pressure into the patty mold when it is in communication with the chamber exit.
The compressor screws are undercut along the leading faces of their threads to capture the product as it is picked up by the compressor screws and carry it forward without significant radially outward movement of the product as it is forced under pressure out of the charging chamber exit into the patty mold.
Preferably the charging chamber is formed as a one-piece casing, thus simultaneously avoiding the problem of leaks of the pressurized product from the chamber and also facilitating removal of the chamber for clean-up purposes.
By virtue of the self-wiping character of the compressor screws significant accumulations of components of the product, such as fat in ground meat, are avoided and consequently, the problem of large clots of fat being accidentally charged into the patty mold.
It has been found that for best results the upstream ends of the compressor screws should extend out of the charging chamber and into the hopper into which the product is deposited in bulk form. With this configuration it is believed that the upstream ends of the compressor screws, in effect, "capture" a quantity of the product and carry it into the compressor chamber. To assist in this "capturing" of the product by the compressor screws, a baffle is preferably installed in the hopper projecting over the upstream ends of the compressor screws at the entrance of the charging chamber.
Conveyor screws carry the product to the compressor screws and the conveyor screws are also self-wiping to prevent fat accumulation along the faces of the threads thereof. The conveyor screws operate only as needed to supply the compressor screws charging the patty mold, or in other words, on a demand basis, to avoid unnecessary working or kneading of the product.
The compressor screws are single flight screws keyed to and driven directly by shafts extending the length of the machine. Since the compressor screws are of the single flight type and intermeshed they must by necessity be mounted for counter rotation. The conveyor screws on the other hand are preferably multiple flight screws, such as double flight screws, with no appreciable external thread and since they are also intermeshed they must rotate in the same direction.
By keying both compressor screws to the shafts while keying only one of the conveyor screws to a shaft and allowing the opposing conveyor screw or screws to be driven through intermeshing contact, both the conveyor and compressor screws can be mounted on common shafts which can be driven from one end of the patty machine.
Of course, while a pair of compressor screws and a pair of conveyor screws are referred to above, it will be apparent that more than two of each such screws may be used in accordance with the present invention.
From the above and the following detailed description it will be seen that the present invention provides an improved method and apparatus for producing successive controlled portions of a product in patty form of uniform quality, texture and quantity on a high volume basis.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view, with parts in phantom, showing the general arrangement of certain components of the machine of the present invention;
FIG. 2 is an exploded perspective view of a pair of intermeshing compressor screws illustrating diagrammatically the self-wiping character of the screws;
FIG. 3 is a top plan view of the patty machine of the present invention;
FIG. 4 is a view taken generally along line 4--4 of FIG. 3;
FIG. 5 is a view taken generally along line 5--5 of FIG. 4 and showing the coaxial mounting of the compressor and conveyor screws;
FIG. 6 is an exploded perspective view of the product handling portion of the machine;
FIG. 7 is a cross-sectional view taken substantially along line 7--7 of FIG. 4, but showing both conveyor screws;
FIG. 8 is an end view of the compressor screws taken along line 8--8 of FIG. 4;
FIG. 9 is a cross-sectional view generally along line 9--9 of FIG. 4 through a conveyor screw and a portion of a second conveyor screw meshing therewith and illustrating a modification thereof;
FIG. 10 is an exploded perspective view of the compressor and conveyor screws and the drive mechanism therefor; and
FIG. 11 is an end view with parts in section showing a portion of the drive mechanism.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIGS. 1 and 3 through 5 of the drawings, it will be seen that a patty machine 10 in accordance with the present invention includes a feed hopper 12 and a charging chamber 14 (see particularly FIGS. 4 and 5) communicating with the hopper 12 at an entrance 16 to the charging chamber. The charging chamber 14 is also communicable with a cavity 18 in a reciprocating mold plate 20 through an exit 22 in the downstream end of the charging chamber.
With this general arrangement it will be seen that a food product, such as ground meat, may be deposited in the feed hopper 12 where a paddle assembly 24 prevents the accumulation of the product along the side walls of the feed hopper and conveyor screws 26 and 27, rotating in the same direction, carry the product forward in the direction indicated by the arrows in FIG. 4 of the drawings to the entrance 16 of the charging chamber 14.
A quantity of the product is picked up adjacent the entrance of the charging chamber by compressor screws 28 and 29 and pumped to the exit 22 from the charging chamber so that when the cavity 18 of the reciprocating mold plate 20 is in communication with the exit 22 the cavity is charged under pressure with a quantity of the product sufficient to fill the cavity 18. 8
It will be noted that both the compressor and conveyor screws are carried on common shafts 30 and 31 which are keyed, as at 32, to drive shafts 34 and 35 projecting from the housing 36. Shafts 30 and 31 are rotatably mounted at their opposite ends 38 in openings 40 formed in the downstream end of the charging chamber 14.
With reference to FIGS. 1, 10, and 11 of the drawings it will be seen that a motor 40 is mounted within the framework of the patty machine and has projecting therefrom a drive shaft (not shown) to which is rigidly fixed a crank arm 42. Journalled, as at 44, on an outer end of the arm 42 is an adjustable drive rod 46 which is also journalled at its opposite end 48 to a plate member 50.
Plate member 50 is provided with bushings 52 slidably receiving fixed guide rods 54 carried by brackets 56 and 58. An inner spring plate 60 is provided with a bushing 62 slidable on the lower guide rod 54 and has connected thereto a plurality of springs 64, four being shown for purposes of illustration, with the springs being connected at their opposite ends to the plate 50.
An outer spring plate 66 is provided with a bushing 68 slidably receiving the upper guide rod 54 and carrying a plurality of springs 70, six being shown for purposes of illustration, which are attached at their opposite ends to the plate 50.
With the above construction it will be seen that rotation of the crank arm 42 in the direction indicated by the arrow in FIG. 10 of the drawings will cause reciprocating movement of the drive rod 46 in the direction indicated by the double headed arrow. Reciprocating motion of the drive rod 46 is transferred to the drive plate 50 causing it to reciprocate back and forth on the upper and lower guide rods 54.
As long as there is no restraining force resisting movement of the spring plates 60 and 68 toward the motor 40, the tension of the springs 64 and 70 will be sufficient to cause the plates 60 and 66 to reciprocate back and forth in unison with the plate 50. However, if a force tends to restrain movement of the plate 68 in a direction toward the motor 40 the springs 70 will elongate. Similarly if a restraining force is exerted against movement of spring plate 60 toward the motor 40, the springs 64 will elongate.
Referring now to the left hand side of FIG. 10 and FIGS. 1 and 11, it will be seen that a chain 72 is trained about an idler sprocket 74 and a second sprocket 76 mounted for rotation on the shaft 78. One end of the chain 72 is fixed to the spring plate 60, as at 78, and the opposite end of the chain is attached to a spring 80, anchored to any convenient portion of the machine, such as on the motor 40, as seen in FIG. 1 of the drawings.
An internally splined member 82 is slidably received on the splined hub 84 attached to a toothed sprocket 86. A face of the member 82 adjacent the sprocket 76 is provided with keys, one of which is shown at 88, engageable with complementary sockets 90 formed in the face of the sprocket 76. The periphery of the member 82 is grooved at 83 to receive a fork-like switching device 92 mounted, as seen in FIG. 11, for movement in the directions indicated by the double headed arrows in FIGS. 10 and 11.
With this construction it will be seen that with the member 82 shifted toward the sprocket 86, the keys 88 will be out of engagement with the sockets 90, so that movement of the sprocket 76 around the shaft 78 due to reciprocating motion of the spring plate 60 will result in no rotational movement of the sprocket 86. However, if the member 82 is shifted by means of the member 92 so that the keys 88 are received in the sockets 90, rotation of the sprocket 76 will result in rotation of the sprocket 86.
Wrapping a portion of the sprocket 86 is a chain 94 which is anchored, as at 96, to the sprocket 86 and at its opposite end to a spring 98, the latter being anchored to any suitable portion of the machine as shown diagrammatically in FIG. 10 of the drawings. It will also be noted from FIGS. 10 and 11 that the chain 94 is rotated 90° at the point 102 to permit it to wrap a sprocket 104 whose axis of rotation is at 90° to the axis of rotation of the sprocket 86.
Sprocket 104 is connected through a one-way clutch 106 to a toothed gear 108 which meshes with a toothed gear 110 fixed to the drive shafts 35, and the toothed gear 110 in turn meshes with a second toothed gear 112 fixed to the other of the drive shafts 34.
With this construction and with the member 82 interconnecting sprockets 76 and 86, it will be seen that movement of the spring plate 60 toward the motor 40 will result in rotation of the sprocket 104 in a clockwise direction as seen in FIG. 10 of the drawings.
This rotational movement is transferred through the one-way clutch 106 to the gear 108, which in turn results in counter-clockwise rotation of gear 110 and clockwise movement of gear 112. Since the shafts 30 and 31 are keyed to the drive shafts 34 and 35, shafts 30 and 31 will be rotated in opposite directions, as indicated by the arrows in FIG. 10 of the drawings.
As best seen in FIG. 6 of the drawings, the compressor screws 28 and 29 are keyed to the shafts 30 and 31 by keys 114 received in complementary keyways in the compressor screws (see also FIG. 8 of the drawings). Thus, the single flight, intermeshing compressor screws 28 and 29 are driven positively in opposite directions to carry the product into the compression chamber 14 and out the exit 22 therefrom.
The conveyor screws 26 and 27 are also carried by the shafts 30 and 31. However, conveyor screw 26 is mounted for rotation about the shaft 30 while conveyor screw 27 is keyed to the shaft 31 by means of the key 116. Therefore, the rotational movement of drive shaft 35 is transmitted directly to conveyor screw 27 through the shaft 31 but drive shaft 34 merely rotates within the conveyor screw 26. However, since the conveyor screws 26 and 27 are intermeshing, double flight screws, rotation of the screw 27 causes rotation in the same direction of the screw 26.
With this configuration it will be seen that reciprocating movement of the plate 50 will be transmitted through the springs 64, spring plate 60, the sprockets 76, 86 and 104, one-way clutch 106, and gears 108, 110 and 112 to rotate conveyor screws 26 and 27 in a counter-clockwise diretion as seen in FIG. 10, and compressor screws 28 and 29 in clockwise and counter-clockwise directions, respectively.
As the product being portioned into patties tends to restrain rotational movement of the screws, as, for example, when cavity 18 is out of communication with the charging chamber, the springs 64 will tend to elongate. Additionally, if voids occur in the product while it is in the charging chamber, the springs can compensate for such voids to insure that the mold cavity 18 is filled each time it is in communication with the charging chamber.
In this regard, and with reference to FIGS. 4 and 6 of the drawings, it will be seen that the mold plate 20 in which the cavity 18 is formed slides between lower and upper shear plates 118 and 120 with an opening 122 in the lower shear plate in registration with the exit 22 from the charging chamber. The upper shear plate 20 is provided with a scrap return channel 124 having a perforated section 126 disposed above the opening 122 and a plate 128 fits over the scrap return channel and is attached to the plate 120 by means of pins 130 received in corresponding openings in the plate 128.
In this way, air in the empty mold cavity is exhausted through the openings 126 and channel 124 as the product is packed under pressure into the cavity 18. The channel 124, as best seen in FIG. 4 of the drawings, extends back into the hopper so that any of the product which is forced through the openings 126 is returned to the hopper 12.
The entire assembly of mold plate and shear plates is secured to a forward portion of the machine by means of pressure screws 132 threaded into a cross plate 134 fixed to the side members 136. Forward and rearward movement of the plate 118 is prevented by means of the pin 138 received in an opening 140 in the plate. The plate 20 is attached to a bracket 141 by means of pins 142 received in openings 144 in the mold plate and the bracket 141 is carried by slide rods 146. The bracket 141 is attached to one end of a drive rod 148, with the latter mounted in a housing 150 for reciprocating movement in any convenient manner.
Of course as the mold plate 20 reaches the position shown in dotted lines in FIG. 3 of the drawings, the knockout device 152, which may be cam operated and driven off the motor 40, knocks out a formed patty onto a conveyor or other receiver positioned to move the formed patties.
Should the product being formed into patties be of somewhat stiffer mixture than that contemplated in the description above, it may be necessary to transmit greater rotational force to the screws 26, 27, 28 and 29. This can be accomplished by disengaging the keys of member 82 from the sockets 90 of the sprocket 76 and engaging keys 154 of a member 156 with complementary sockets, not shown, in a sprocket 158. Member 156 is internally splined to receive the external splines 160 on sprocket 86 and shifting movement of the member 156 can be accomplished by the shifting member 162 received in a groove 163 in the member 156 and mounted for movement in the direction of the double headed arrows by a cam device or the like as seen in FIG. 11.
With this construction and with the machine in this configuration, it will be seen that reciprocating movement of the plate 50 is transmitted through the six springs 70 to the outer spring plate 66. A chain 164 is trained about a sprocket 166 mounted for rotation on the bracket 158, as indicated at 168, and about the sprocket 158. The chain is anchored at one end 170 to the rear face of the plate 66 and at its opposite end 172 to the forward face of the plate 66.
Therefore, reciprocating movement of the plate 66 is transmitted through the chain 164, the sprocket 158, member 156, sprockets 86 and 104, one-way clutch 106 and the gears 108, 110 and 112 to the conveyor and compressor screws 26, 27, 28 and 29. Assuming that the springs 70 are of the same strength as the springs 64 it will be apparent that a greater force must be imposed to restrain rotation of the screws and cause elongation of the six springs 70 than with the four springs 64.
To provide a balanced construction it will be noted from FIG. 10 of the drawings that the sprocket 158 is fixed to the shaft 78 and that the opposite end has a sprocket 174 also fixed thereto. A chain 176 wraps the sprocket 174 and is anchored thereto as at 178 and the opposite end of the chain 176 is attached, as at 180, to the forward face of the outer spring plate 66.
Of course, if an especially stiff material is being worked, it is possible to engage both sprockets 76 and 158 with the sprocket 86, thereby requiring a force necessary to overcome the tension of all ten springs 64 and 70 before rotation of the screws is terminated.
As best seen in FIGS. 3, 5 and 7 of the drawings, the double flight conveyor screws 26 and 27 are formed with crest portions 182 defined by the faces 184 of the screw threads. The faces 184 slope away sharply from the crest 182 and thereby facilitate entrance of the product to the screws and prevent an accumulation of the product on the crests, as might be the case if screws of the type used for compressor screws 28 and 29 were utilized.
Additionally, it will be seen that the crest portions 182 of the conveyor screws are in wiping contact with the face portions 184, providing a continuous, self-wiping of one screw by the other as they are rotated in the same direction.
Where the self-wiping feature is not required to the extent that it might be in certain operations, and/or where a more positive conveying of the product forward is desired, the conveyor screws 26 and 27 may be provided with undercut portions 186 along their forward faces, as best seen in FIG. 9 of the drawings.
Of course if desired, one or both of the conveyor screws can be formed with undercut portions and the conveyor screws reversed on their shafts 30 and 31, allowing the undercut portion or portions of the screws to face forwardly or rearwardly if desired. If facing rearwardly the undercut portions would have little or no effect, but they would be available by simply reversing the screws.
The compressor screws are intended to receive the product conveyed to them by the conveyor screws and pressure feed the product through the exit 22 in the charging chamber into the mold cavity 18. The compressor screws are formed as single flight screws intermeshing and therefore rotating in opposite directions. As can be best seen in FIG. 4 of the drawings, the compressor screws are undercut at 188 to substantially eliminate radially outward movement of the product as they carry it forward under pressure to the mold cavity 18.
Preferably the rearward ends of the compressor screws project from the charging chamber 14 back into the hopper 12 to allow them to bite into and capture a portion of the product and convey it into the charging chamber.
The compressor screws, similarly to the conveyor screws, are designed for self-wiping. The self-wiping action is attained, as best seen in FIG. 2 of the drawings, by the edge portions 190 along the outer circumferences 192 of the screws being in wiping contact with the face portions 194 thereof along lines 196 extending outwardly from adjacent the inner diameters 197 of the screws to the outer circumferences 192 thereof, and by the inner diameters 197 and outer circumferences 192 being in wiping contact.
With this construction it will be apparent that at all times edge portions along the circumferences of each of the screws are moving across the thread faces and preventing appreciable build ups of fatty deposits or the like while the outer circumferences and inner diameters of the screws cooperate to prevent build-up along these surfaces.
To facilitate cleaning and prevent leakage from the charging chamber 14, the chamber is preferably constructed as a one-piece, molded section, contoured to receive the compressor screws 28 and 29 and held in place by a plate 198 which may be bolted to a portion of the machine structure beneath the shear and mold plates.
As noted above, the compressor screws preferably project back into the hopper 12 to enhance movement of the product into the charging chamber. As seen in FIGS. 3 and 4, the lower shear plate 118 projects back into the hopper 12 and forms a baffle which prevents flow of the product away from the upstream ends of the compressor screws and thereby assists in insuring that the charging chamber is filled with the product being formed.
In operation, one of the three spring settings is selected, that is, either the four springs 64, the six springs 70 or all ten springs, depending upon the product being formed, the temperature of the product and the size patties to be formed. A quantity of the product is then deposited in the hopper 12 where the conveying screws move the product forward to the compressor screws 28 and 29, with the latter moving the product forward under pressure and forcing it into the mold cavity 18 when the cavity is in communication with the exit 22 of the charging chamber.
The mold plate then moves forward out of communication with exit 22 to the knock-out position, where the knock-out removes the freshly formed patty from the cavity 18. While the cavity 18 is out of communication with the exit 22, the product cannot be forced out of the charging chamber 14 and, assuming there are no voids in the product, the compressor screws will be stopped even though the motor 40 continues to run. During this condition the springs 64 or 70 or both compensate for lack of movement of the compressor screws. Of course if there is a void in the product this void will generally be collapsed by the increased pressure generated when the exit from chamber 14 is closed.
Since the conveyor screws 27 is driven in unison with compressor screw 29 and conveyor screw 26 is driven by conveyor screw 27 there will be no movement of the conveyor screws unless the compressor screws are also moving. Therefore, rather than the conveyor screws moving continuously and kneading and working the product unnecessarily while the compressor screws are stopped, screws 26 and 27 operate only to provide product to the compressor screws as needed, thereby operating on a demand basis and providing improved texture to the patties.
It will also be noted that with this construction, the entire drive for both sets of screws is positioned at one end of the machine, rather than requiring separate drives for the two sets of screws and even though one set rotates in the same direction while the other set rotates in opposite directions.
From the above it will be apparent that the present invention provides a method and apparatus for forming portions of a bulk product into patties of a uniform size and quality and without fat build-up or unnecessary working of the product.
While the method herein described, and the forms of apparatus for carrying this method into effect, constitute preferred embodiments of the invention, it is to be understood that the invention is not limited to this precise method and forms of apparatus, and that changes may be made in either without departing from the scope of the invention.
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A patty machine for forming successive patties of a predetermined size from a quantity of a bulk product, such as ground meat. The machine includes a charging chamber in which the product is pressure-fed into a patty mold cavity by means of intermeshing, positive displacement, self-wiping compressor screws. The product is delivered from a feed hopper to the entrance of the charging chamber by means of intermeshing, self-wiping conveyor screws which operate on a demand basis to convey the product to the compressor screws only as needed to thereby avoid unnecessary working or kneading of the product. Shafts for driving and supporting the conveyor and compressor screws extend throughout the length of the machine and each carries one conveyor and one compressor screw. The compressor screws are keyed positively to their respective shafts while only one conveyor screw need be so keyed, the unkeyed conveyor screw or screws being driven through intermeshing relationship with the keyed conveyor screw. By virtue of the self-wiping characteristics of both the conveyor and compressor screws, fat accumulations along the screws, which are often a problem in working with ground meat and similar products, are prevented, thereby avoiding the problem of fatty accumulations breaking off as large clots and being charged into the patty mold.
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RELATED APPLICATION
This application claims priority of Switzerland Application No. 1997 1432/97, filed Jun. 12, 1997 FEDERALLY SPONSORED RESEARCH: Not Applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention.
The present invention relates to a sorting device in a conveyor of plate-like workpieces, and more particularly to a sorting device within a belt conveyor situated between the output of a machine for processing successive sheets of paper or cardboard panel, and a piling station. The sorting device ejects defective sheets or panels toward a delivery area.
2. Brief Description of the Background Art.
The processing machines considered here may be machines for die-cutting blanks and /or printing of on, or more colors or metalized patterns onto the blanks and/or folding blanks into flat boxes. The potential faults requiring rejection of blanks may be, for example, color registration errors, glue stains, or inaccurate folding. These faults are detected by automatic quality control devices, based upon the scanning of photocells arranged in the travelling plane of the workpieces. The workpieces detected as being faulty are taken out of the stream of workpieces by sorting devices, also called ejectors, before the workpieces are piled into delivery batches.
A known rotating ejector rotates about a vertical axis, pivoting the sheet to be ejected between the belts of the conveyor. However, the conveyor speed and the maximum size of the sheets that can be ejected, are limited. Moreover, the rotational motion imparted to the ejected sheet may interfere with the flow of the accurate sheets, or even cause a jam.
A Linear ejector moving the ejected sheets at an angle of 45° or 60° to the normal stream is also known. This ejector has the advantage of not interfering with the flow of accurate sheets. However, the minimum and maximum sizes of the sheets that can be handled by this device are also limited. Also, these ejectors require accurate adjustment of the sheet thickness and are comparatively difficult to use.
Moreover, these two ejector types each require one of the conveyor belts to be raised in order to ensure an appropriate ejection. This makes the transport of the other sheets more uncertain. In addition, the ejection at high speed may be hazardous to people near the machine.
The document EP 045 713 describes a sorting device for flat folded cardboard boxes, based on mounting a lower intermediate part of the belt conveyor in a frame that is tiltable by means of a pneumatic cylinder. The frame rotates around the axis of the conveyor's rear end roller in such a way that its lowered front end roller opens an ejecting path in the downward direction for (defective boxes detected by a photocell.
U.S. Pat. No. 4,324,522 discloses a device of the same type provided for sorting metallic plates into different stacks, in which the selecting part of a tilting conveyor is the front end of a long feed conveyor. The rear end of the following conveyor may include a deflection plate which simultaneously raises with the lowering of the adjacent selecting part in order to complete the descent of the plates to be ejected.
However, this type of sorting equipment, first, uses large and heavy elements involving significant inertias, requiring powerful and hence costly drive means. Moreover, this type of sorting equipment occupies a significant volume within the machine. In addition, in the second, embodiment, a mechanism for keeping the tension in the belts of the first feed conveyor as the front end tilts should be provided.
Most important, in each of the aforementioned devices, the ejected plate-like workpieces, such cardboard boxes, are not always adequately controlled i.e. they are not held or driven along, their deflection and ejection paths. This fact may lead to situations of selective accumulation, o(r even jam, requiring machine stoppage.
The document F# 2 688 493 discloses a device for cutting out and deflecting a faulty part of a continuously processed web. This device comprises a slanted deflection plate oriented in the forward and downward direction between the vertical pairs of drive shafts of the web in normal horizontal travel. The upper edge of the plate which is located just underneath the normal path forms an anvil. A lower flap with a separation blade that is normally in raised position guides the web above the plate. When a defective web part is detected, the lower flap lowers and an upper separation flap with a blade edge rotates down against the anvil in order to cut the web and to direct it along the plate toward the ejection path, where the defective web is pulled by traction roller. At the arrival of a new adequate web part, the upper separating flap raises and the lower flap strikes the anvil so as to again cut the web and to direct the new front edge of the web in the direction of the normal travel path.
However, this processing device for a continuous web is ill-suited and too complex, hence too costly for processing successive plate-like workpieces that do not have to be cut and that preferably, must be almost continually driven by a belt conveyor or a conveyor with closely spaced parallel rollers.
SUMMARY OF THE INVENTION
The aim of the present invention is a particularly reliable sorting device within a conveyor of plate-like workpieces, i.e. one that is able to unambiguously change the direction of a selected workpiece so as to make impossible for the latter to collide with a mechanical element of the conveyor. If required, the device must be able to bend a workpiece, even if it is heavy, when directing it toward the new direction.
This device must at a minimum reduce the risks of jam, particularly by compensating for reduced separation of the workpieces in such a way that the workpieces remain as much as possible under the control of the forwarding drive elements, whether directed towards the normal path or toward the ejection path.
In addition, this device has to be particularly dynamic, i.e. having a very rapid tilting time, in order to operate at high production rates. Preferably, the number of movable sorting elements should be as few as possible and should each have a low mass and/or inertia. Preferably, the operation of this device should also consume relatively little mechanical power.
Finally, it is desirable that this sorting device occupy as little space as possible, in order to leave enough space for a salvage container, for drive means in the ejection path, and for accessing the elements for maintenance or repair.
These aims are achieved by a sorting device within a conveyor of plate-like workpieces comprising, in combination:
a first lower rear conveyor ending in a front wheel or roller driven in rotation;
a second lower front conveyor behind the first and beginning with a rear wheel or roller driven in rotation;
a pressure means for pressing the plate-like workpieces against the lower conveyors;
a sorting means, interposed between the front wheel or roller of the first conveyor and the rear wheel or roller of the second conveyor, this means having in cross section, a rear facing corner with a first side aligned with the normal path but located slightly below that path, and a second slanted side aligned with an ejection path between the first and second lower conveyors; and
a deflection means disposed slightly above the front half of the front wheel or roller of the first conveyor, which, in raised position, does not interfere with the normal path of the workpieces along the first side of the sorting means, and which in lowered position, forces the workpieces to follow a path that is bent against the front surface of the front wheel or roller such that the ejection path continues under the slanted side of the sorting means.
The terms "front" and "rear" define a direction with respect to the travelling direction of the workpieces, i.e. respectively in the downstream direction and in the upstream workpiece feeding direction: the term "length" of an element is also taken in the travelling direction, a "width" being perpendicular to the traveling direction and in the horizontal plane.
There are two possible implementations of the lower conveyors. In one implementation, a conveyor width one or a plurality of belts extends in the workpiece travelling direction and passes along an upper path around end rollers, returning to the end around pulleys along a lower. return path, ore of the pulleys, for example, being motorized. In the other implementation a conveyor consists of a series of parallel rollers transverse to the traveling direction of the workpieces and disposed one after another, these rollers each being driven at one of their common ends by a single drive belt.
There are two possible implementations of the pressure means. In one implementation, a belt conveyor passes under pressure rollers. In the other implementation a series of pressure rollers are arranged one after another in the travelling direction of the workpieces.
In addition, the invention takes advantage of the convex shape of the half-cylindrical front periphery of the last front wheel or roller of the first lower rear conveyor, and by means of a deflection means, imparts a bend to a plate-like workpiece, whose inherent rigidly normally keeps it on its normal path, passing by the first side of the sorting means then onto the second lower front conveyor. This bend makes the workpiece on the other hand, take a second path called the ejection path. The second path is immediately confirmed by the second slanted side of the sorting means.
More particularly, this sorting method is made more effective, since at least one of its components, i.e. the front wheel or roller of the first conveyor, is driven in rotation and consequently serves to force the forward motion of the plate-like workpiece both in the normal path or the ejection path.
Advantageously, the deflection means can include one or a plurality of deflection shoes, their total width substantially corresponding to the width of the front edge of the plate-like workpiece. Th(e lower deflection surface of each deflection shoe is slanted or concave corresponding to the front periphery of the lower front wheel or roller, for example arc shaped with an angle varying from 5 to 90 degrees.
This deflection means of particularly simple construction, proves to be particularly effective in imparting a bend to the workpieces, in combination with the front wheel or roller of the rear conveyor, and can easily be rapidly operated.
Advantageously, the deflection means can be the lower rear surface of a deflection wheel or roller, prefer-ably a wheel or roller driven in rotation. More particularly, implementation of the deflection means is a band or a belt passing under the lower rear periphery of the front end wheel or roller of the front end of the upper rear belt conveyor, opposite the lower rear conveyor, or belonging to the front end of a rear part of the upper belt conveyor.
This deflection means is also particularly effective because it also applies, besides the deflection, a complementary forward driving force to the plate-like workpiece. Preferably, the deflection means is a combination of a band or belt passing under the roller by which the belt is driven, and two deflection shoes on either side of the roller, ensuring the bending of the whole width of the front edge of the plate-like workpiece.
Preferibly, an ejection conveyor beginning with a pair of motorized rollers mounted facing one another is situated below the slanted side of the sorting means, if desired, the roller or the two rollers being the input of a belt conveyor to handle the ejected workpiece.
This ejection conveyor, situated immediately after the sorting means, avoids the risk of jamming the deflected plate-like workpieces, by intentionally driving these workpieces at a higher speed thin the speed of the workpieces in the normal path.
Preferatly, the distance between the pair of wheels or rollers defining the end of the first lower rear conveyor and either the pair of wheels or rollers defining the beginning of the second lower front conveyor or the pair of wheels or rollers defining the beginning of the ejection conveyor is less than the smallest length of workpiece to be handled.
The plate-like workpieces are then always controlled by drive means, thus forcing these workpieces to move forward in one direction or in the other.
Preferably, the deflection means are mounted on the substantially horizontal short arm of a lever, the other end of the long arm of which is upwardly oriented. The long arm is moved by an actuator such that deflection means are moved between their raised and lowered position in a direction perpendicular to the normal path of the plate-like workpieces.
This lever constitutes a mechanical amplifier permitting imparting a short movement to the deflection means between the normal raised position and the lowered deflection position but with strong actuating force, and this by means of an actuator exerting only a weak force, the stroke of the control rod of which can be greater. Through this arrangement, it is possible to use a less expensive but very rapidly acting cylinder.
Preferably, the second lower front conveyor is mounted on frame that is forwardly tiltable in order to facilitate access to the sorting means, to the deflection means, and to the ejection conveyor, for the purpose of maintenance and repair.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood by the study of an embodiment taken by way of nonlimiting example and illustrated by the following drawings:
FIG. 1 is a schematic side view of a conveyor including a sorting device of the invention;
FIG. 2 is a schematic side view of the sorting section of the conveyor to FIG. 1;
FIG. 3 is schematic view in enlarge scale of the sorting device FIGS. 1 and 2; and
FIG. 4 is a schematic top view of the sorting device of the preceding drawings.
In all these drawings, the identical elements or parts have a same reference numeral.
DETAILED DESCRIPTION OF THE INVENTION
An entire belt conveyor of sorting station is illustrated in FIG. 1. Such a station is provided to separate a plurality of printed blanks that are die-cut in a sheet of cardboard side by side broadwise, and according to a plurality of successive lines in the longitudinal direction by different rotary or platen die-cutting and printing stations that are located in the upstream direction, i.e. to the right of FIG. 1. This sorting device comprises a plurality of belt conveyors arranged fan-shaped side by side so as to separate the blanks laterally, each of these conveyors having a forward speed that is higher than the speed of the previous station, in order to also separate the blanks in the longitudinal direction.
Each of these belt conveyors leads the blanks according to a substantially horizontal path Tn toward a corresponding blank piling station located to the left of FIG. 1. Each conveyor includes a sorting device 26, 32, 42, 60 better shown in FIG. 2, illustrating in enlarged manner the front part of this conveyor. The sorting device allows removal of blanks of inadequate quality along an ejection path Te toward a salvage container 79. To accomplish this, each blank individually travels under a scanning area comprising, for example, a camera and/or scanning cells detecting printing errors, for example, color registration, glue tracks, stains, or even inaccurate folding. This scanning area is connected to electronic and/or data processing means that control the actuation of the sorting device as soon as the passage of the rear edge of the last accurate blank has been detected by another photocell located near the rear of the sorting device.
As better seen in FIG. 1, this belt conveyor comprises, first, a first lower belt conveyor 40 following an upper horizontal path passing over a plurality of supporting rollers 44 up to a last front roller 42. This belt 40 returns to a lower path where it passes through a tightening mechanism and a lower drive shaft before being twisted then returned to its upper horizontal path. The guiding and supporting rollers 42, 44 of this conveyor 40 are mounted on a lower vertical supporting plate 41 pivotally mounted at its rear edge on a hinge 39 which is fixed to the frame of the sorting station.
In addition to the sorting device, the conveyor comprises a second lower front conveyor 50, the belt of which starts its upper horizontal path by passing around a first rear roller 52, continues it by passing over supporting rollers 54, said belt being returned to its lower return path around its front end roller 59. In addition, these supporting and guiding rollers 52, 54, 59 of the belt 50 are mounted on a vertical supporting plate 58 adapted to be tilted forward for the purpose of providing access to the sorting device, if necessary.
As better seen in FIG. 2, for this purpose the plate 58 is mounted through pivot 48 to a stirrup 51, the position of which is adjustable along a cross beam 53 of the sorting station. The beam 53 is carried on both sides of the frame of the station by two lateral T-shaped tilting plates 55, one right, and one left, pivoting respectively around their pivot 57. On both sides of the station, the T-shaped plate 55 is tiltable by a hydraulic or pneumatic cylinder 49 acting between a fixed point of the frame and the plate's rear arm. Thus, the position and orientation of each of the vertical supporting plates 58 of the lower front conveyor 50 can be adjusted in order to be aligned with the lower vertical supporting plate 41 of the first lower conveyor 40.
More particularly, according to the invention and as illustrated in FIGS. 1 and 2, this conveyor includes a single upper conveyor 30 following a lower substantially horizontal path passing under support rollers 35, and this path corresponding to the upper path of the lower conveyor. This upper conveyor is returned along an upper return path guided by rollers 38 where it passes around different tightening devices and an upper rear drive shaft before returning to the lower drive path.
More particularly, and as better shown in FIG. 2, the lower path of this belt 30 describes an upwardly oriented loop at the level of the sorting device 60 by being successively guided by the front end roller 32 of the rear part of the upper conveyor, by two upper rollers 34, 34', then returned by area end roller 36 of the second front part of the upper conveyor. This deflection loop is approximately T-shaped, i.e. the belt 30, on the one hand, rolls up at least on the front half of the surface of the roller 32, the roller 34 being situated to the rear with respect to this roller 32; and on the other side, rolls up at least on the rear half of the surface of the roller 36, the roller 34' being situated in front of roller 36.
All the support rollers 35 of the lower path, the guiding rollers 38 of the upper return path as well as the two loop rollers 34, 34' are mounted on a vertical supporting plate in two parts 31 and 31' fixed to one another and mounted by a hinge 37 to the frame of the sorting station so as to align with, the supporting plate 41. On the other hand, the front parts are both mounted on a lever 20 of the sorting device.
As better visualized in FIGS. 2 and 3, the sorting device according to the invention comprises, first, a sorting corner 60 situated under the normal path Tn, between the front end roller 42 of the lower rear conveyor 40 and the rear end roller 52 of the lower front conveyor 50. This sorting corner is a machined piece having an angled cross section facing the rear (upstream direction) of the device. The upper surface 62 of this machined piece makes up the first side of the corner provided to support the normal path Tn, and is formed of a rear horizontal plane, followed by a slanted raising intermediate plane and ending in third front plane, also horizontal. The lower rear surface 64 makes up the second side of the corner provided to guide the ejection path Te, and consists of a plane slated upwardly at an angle of about 60 degrees with respect to the horizontal plane.
The machined piece is bolted to two lateral plates, the slanted rear edges of which extend the second slanted deflection side 64. A first roller 73 of an ejection belt 74 is situated underneath the machined piece, between the lateral plates, passing around a lower pulley 76 movable under the action of an elastic device (not shown) for tightening this belt. A powerful motorized roller 72 is provided at the level of this upper roller 73 of the belt 74, running at peripheral speed that is higher than the speed of the conveyors so as to very rapidly eject the defective workpieces.
The nip 70 of the ejection drive between the rollers 72 and 73 is located at a short distance from the upper surface of the front end roller 42 of the lower conveyor 40, this distance being less than 80 mm more than the minimum length of the blanks to be processed by the sorting station. It should be noted, that the distance between the nip 56 of the front conveyor on the normal path Tn, made up by the two upper 36 and lower rollers 52 is also located at a short distance, for example about 80 mm from the upper surface of the roller 42, where the blank is released by the rear conveyors.
As better seen in FIGS. 1 and 2, the ejection belt 74 guides the ejected blanks in a chute formed by the guiding rails 77 and 78 leading the ejected blanks into the salvage container 79.
In addition, the sorting device includes a lever 20, better visualized in FIGS. 3 and 4. This lever comprises, on the one hand, a short arm 24, which is substantially horizontal and arranged slightly above the sorting corner 60 and the roller 42, and, on the other hand, a vertical long arm 22, which is substantially slanted forward. This lever 20 pivots around an axle supported by a bearing 36' of the upper supporting plate 31', this axle also carrying the rear end roller 36 of the front part of the upper conveyor 30.
As better seen in FIGS. 3 and 4, the short arm 24 carries, approximately at its middle, the front end roller 32 of the rear part of the conveyor 30 and at its rear end, a vertical connecting strap 25, supporting two deflection shoes 26 on both sides of the roller 32. These shoes have the shape of plates, slightly slanted with respect to the horizontal plane, and extend substantially across the expected width of the blanks. It should be observed that the roller 32 is supported on the short arm 24 in such a manner that its rear half is at the same level as the front half of the end roller 42. In similar manner, the front half of the shoes 26 are also located level with the front half roller 42, said front half having a lower surface which is arc-shaped in downward direction, for example, half-cylindrical with an angle varying from 10° to 30°.
As illustrated in FIG. 3, the lever 20 can take two positions. In the first position, the short arm 24 is raised, such that the belt 30, guided by the roller 32 and the shoe 26 does not interfere with the normal path in of the blanks. In the second position, marked with reference 26', the short arm 24 is lowered, such that the rear parts of the shoes 26 and the belt 30, guided by the roller 32, surround a part of the upper front surface of the end roller 42 so as to force the blanks to bend downward. This bend is such that the front edge of the blank is forced to pass under the slanted deflection side 64 of the sorting corner 60. In other words, the front end of the roller 42 of the rear conveyor 40 becomes a deflection roller by which a blank is bent forward and downward under the deflecting action jointly imposed by the shoes 26 and the belt 30 passing under the lowered deflection roller 42 on the one hand, and the combination of the shoes 26 and the upper front end and deflection roller 32 on the other hand, is reinforced as the lower 40 and upper belts 30 force the forward motion of the blank. The deflection roller 42 or the shoes 26 could separately act to deflect the workpieces toward the ejection path.
More particularly, the movement of the deflection shoes/rollers between the non-interfering position 26 and the lower deflection position 26' is more easily imposed as the other arm of the lever 22 is lengthened. This long arm of lever 22 is controlled by the end of the actuating rod of the pneumatic cylinder 28, the rear of the body of which is supported by a vertical extension 31" located at the end of the upper vertical supporting plate 31'. The tilting of the sorting device in one direction then in the other can thus be particularly rapid, allowing it to operate at high conveyor speeds, for example of about 500 meters per minute.
In particular, it will be noted that the only elements that must move are the cylinder rod 38, the lever 20, the deflection roller 32 with its belt part 30, and the shoes 26. This assembly has a mass that possesses distinctly less inertia than the whole part of the lower conveyor as used in prior art devices.
Furthermore, it should be observed that the length of the path formed by the belt 30 passing around the deflection roller 32 is almost unchanged between the raised position and the lowered position of the roller in the configuration of this sorting device, such that it is not necessary to provide supplementary means for following variations of the length of the path of this belt 30. Moreover, due to the upward arrangement of said deflection loop by means of rollers 34 and 34', a common belt can be used for the rear and front part of the upper conveyor surrounding the sorting device. This upper conveyor thus remains easy to adjust and to operate.
As may Save been gathered from the reading of this description, the sorting device of the invention can be integrated into a narrow conveyor, but could be adapted without difficulty to a sorting device for a wider conveyor by replacing the initial shoes with wider shoes or a series of shoes extending across the width of the workpieces to be sorted. Alternatively, a plurality of conveyors side by side with their associated deflection devices can be provided, which would then be simultaneously actuated. The words "wheel" and "roller" are generally synonymous, with "wheel" indicating a relatively narrower article and "roller" indicating a relatively wider article.
Numerous improvements can be added to this sorting device within the scope of the claims.
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The disclosed sorting device, within a conveyor of plate-like workpieces, comprises a first lower rear conveyor (40) ending in a front wheel or roller (42) driven in rotation. It also comprises a second lower front conveyor (50) located behind the first and beginning with a rear wheel or roller (52) driven in rotation. It is also provided with compression device (30, 35) for pressing the plate-like workpieces against the lower conveyors, and a sorter (60) interposed between the front roller (42) of the first conveyor (40) and the rear roller (52) of the second conveyor (50), the sorter (60) having, in cross section, a corner facing the upstream or feed end of the conveyor, with a first side parallel to the normal path of the conveyors, and a second slanted side along an ejection path passing between the first and second lower conveyors. The device also comprises deflection means (26, 32) situated slightly above the front half of the front wheel or roller (42) of the first conveyor (40).
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 12/049,746, filed Mar. 17, 2008, which in turn, is a continuation of U.S. patent application Ser. No. 10/362,359 which is the U.S. National Stage of International Application No. PCT/JP01/07191, filed Aug. 22, 2001, the disclosures of which are incorporated herein by reference in their entireties. This application claims priority to Japanese Patent Application No. JP 2000-265414, filed Sep. 1, 2000, the disclosure of which is incorporated herein by reference in its entirety.
BACKGROUND
[0002] The present invention relates to a method of producing FR901228 which is useful as an antibacterial agent and an antitumor agent. More particularly, it relates to a method of producing FR901228 which comprises culturing a FR901228 producing strain in a medium added with at least one amino acid selected from the group consisting of L-arginine, L-histidine, L-cystine and L-cysteine or salt thereof.
[0003] FR901228 is a compound produced by culturing a strain belonging to Chromobacterium, e.g., Chromobacterium violaceum WB968 strain (FERM BP-1968) in a nutrient medium, and represented by the following formula (Japanese Patent Publication No. Hei 7 (1995)-64872):
[0000]
[0004] In addition to the fermentation method described above, it is known that FR901228 can also be prepared by semisynthesis or whole synthesis utilizing techniques known in the art (J. Am. Chem. Soc., 118, 7237-7238 (1996)).
[0005] FR901228 is known to have a histone deacetylase inhibiting activity (Nakajima, H et al., Experimental Cell Research, 241, 126-133 (1998)), and it has been proposed to expand its utility as an antibacterial agent and an anticancer agent.
[0006] However, the fermentation method shows an unsatisfactory production titer of FR901228. Accordingly, it has been demanded a discovery of a strain excellent in FR901228 producing ability or development of a production method capable of increasing the yield of FR901228.
SUMMARY
[0007] The inventors of the present invention have noticed the culture conditions for the fermentation method. Upon investigation of the addition of amino acids to a medium, they have found that the addition of specific amino acids represented by L-cysteine unexpectedly increases the yield, though valine or threonine considered to be possible components of FR901228, as well as methionine regarded as effective for production of S-containing compounds do not show increase in yield of FR901228. Thus, the present invention has been achieved.
[0008] According to the present invention, provided is a novel fermentation method of producing FR901228, more particularly, a method of producing FR901228 which comprises culturing a FR901228 producing strain in a medium added with at least one amino acid selected from the group consisting of L-arginine, L-histidine, L-cystine and L-cysteine or salt thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
[0010] FIG. 1 is a graph for illustrating a comparison of yields of FR901228 in accordance with the addition of various cysteine-related compounds;
[0011] FIG. 2 is a graph for illustrating a result of comparative examination on an optimum concentration of L-cysteine added in a medium;
[0012] FIG. 3 is a graph for illustrating a result of powder X-ray diffraction analysis of type A crystals (crystals obtained from ethanol/water);
[0013] FIG. 4 is a graph for illustrating a result of powder X-ray diffraction analysis of type A crystals (crystals obtained from acetone/water); and
[0014] FIG. 5 is a graph for illustrating a result of powder X-ray diffraction analysis of type B crystals.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0015] As the FR901228 producing strain, used are strains belonging to the above-described Chromobacterium, more specifically, Chromobacterium violaceum WB968 strain (FERM BP-1968: deposited with NIBH on Jul. 20, 1988 under Budapest Treaty). Any other producing strains than the above may be utilized as long as they can produce FR901228. They may be spontaneous mutation strains, or artificial mutation strains obtained by X-ray irradiation, UV irradiation, or treatment with various chemical substances such as N-methyl-N′-nitro-N-nitrosoguanidine, 2-aminopurine and the like.
[0016] The amino acid used in the method of the present invention is selected from the group consisting of L-arginine, L-histidine, L-cystine and L-cysteine, which may be singly or in combination of two or more kinds thereof. Further, the amino acid may be in the form of its acid addition salt with an acid such as hydrochloric acid, phosphoric acid, acetic acid, citric acid, succinic acid, lactic acid, tartaric acid, fumaric acid and maleic acid.
[0017] An amount of the amino acid added to the medium may vary a little depending on the kind of the amino acid. The amino acid however may be generally added to be its concentration of 2 mM or more, preferably 2 to 30 mM in total with respect to the medium in a volume of 1 liter. With such addition amount, FR901228 is produced in an increased yield.
[0018] In case two or more amino acids are mixed, those amino acids may be optionally mixed without any particular limitation to the combination and ratio thereof. However, according to the inventors' experiments, it is confirmed that the addition of L-cysteine shows remarkable increase in the yield of FR901228 as compared with other amino acids that are added individually. Accordingly, where the amino acid mixture is used, it is considered that the yield will be more increased by mixing L-cysteine as one of components of the mixture in a greater mixing ratio.
[0019] FR901228 is efficiently produced by culturing the FR901228 producing strain in a nutrient medium containing at least the above-described amino acid and a carbon source and a nitrogen source that can be utilized by the FR901228 producing strain under an aerobic condition.
[0020] Examples of the carbon source include glucose, galactose, starch, fructose, dextrin, glycerin, maltose, arabinose, mannose and the like. Examples of the nitrogen source include inorganic or organic nitrogen compounds such as bouillon, yeast extract, peptone, gluten meal, cottonseed flour, soy flour, corn steep liquor, dried yeast, ammonium salts (e.g., ammonium nitrate, ammonium sulfate and ammonium phosphate), or urea and the like.
[0021] It is preferred to combine a single carbon source and a single nitrogen source both of high purity, but those of low purity each containing a small amount of a growth factor and a considerable amount of an inorganic nutrient may be used. These sources may properly be used depending on needs.
[0022] The above-described medium may contain an inorganic salt such as an alkali metal carbonate (e.g., sodium carbonate, potassium carbonate and the like), an alkali metal phosphate; a magnesium salt (e.g., magnesium sulfate and the like); a copper salt (e.g., cupric nitrate) and a cobalt salt (e.g., cobalt acetate); and liquid paraffin, fatty oil, vegetable oil, mineral oil as well as an antifoaming agent such as silicon and the like, if required.
[0023] Preferably, the culture is conducted under deep aerobic condition in a large scale and under shaking or surface culture condition in a small scale. Where the strain is cultured in a large tank, it is preferred to use a preculture of the strain as a seed culture. For example, the preculture may be prepared by inoculating spores or hyphae of the strain in a relatively small amount of a medium and culturing the inoculated medium. In such a case, the medium used for preparing the preculture may substantially be the same as or different from a medium used for production of FR901228 performed later.
[0024] During the culture, stirring and aeration may be carried out by various methods known in the art. For example, the stirring may be performed by using various stirrers such as a propeller or a pump equipped with a culture apparatus, or by shaking or rotating the apparatus itself. Alternatively, the stirring and aeration may be performed simultaneously by passing sterilized air in the culture.
[0025] The culture may be generally carried out at a temperature in the range of about 10 to 40° C., preferably about 25 to 35° C., for a period of about 15 to 50 hours. The condition may appropriately be varied depending on various factors such as culture scale and the like.
[0026] FR901228 obtained by the above-described culture may be isolated and purified by conventional methods, e.g., solvent extraction, concentration under reduced pressure, filtration, pH adjustment, adsorption treatment using an inorganic adsorbent, an adsorption resin or the like, crystallization and the like, or by a combination thereof.
[0027] For example, FR901228 is a substance produced in the inside of the strain cells and should be isolated from the strain cells. Accordingly, for easy isolation of FR 901228, pH is adjusted to 1 to 4, preferably 1.5 to 2 by suitably adding an inorganic acid such as sulfuric acid, hydrochloric acid, phosphoric acid, nitric acid or the like; or an organic acid such as citric acid, acetic acid, malic acid, lactic acid or the like to the culture solution.
[0028] Examples of the inorganic adsorbent used for the adsorption treatment include silica gel, porous ceramic and the like. As the adsorption resin, DIAION HP10, DIAION HP20, DIAION HP21, DIAION HP40, DIAION HP50 and the like (trademark, manufactured by Mitsubishi Chemical Corporation) may be used.
EXAMPLES
[0029] Hereinafter, the production method of the present invention will be explained in detail by way of examples, but the invention is not limited thereto.
[0030] Culture:
[0031] A medium (20 ml) containing glucose (1%) and bouillon (2%) was put in a 100 ml Erlenmeyer flask, and sterilized at 121° C. for 20 minutes.
[0032] A loopful of slant culture of Chromobacterium violaceum WB 968 was inoculated on the medium and cultured at 30° C. for 24 hours on a rotary shaker.
[0033] Another medium (20 ml) containing glucose (1% w/v), bouillon (2% w/v), monopotassium phosphate (1.1% w/v), disodium phosphate dodecahydrate (0.72% w/v), ammonium sulfate (0.1% w/v) and magnesium sulfate heptahydrate (0.006% w/v) was put in a 100 ml Erlenmeyer flask and sterilized at 120° C. for 20 minutes. To this medium, a part of the culture obtained above (400 μl) was inoculated. Further, glucose sterilized at 120° C. for 20 minutes (40%, 1 ml) and filter-sterilized (with a membrane filter having pores of 0.45 μm or less) various amino acid solutions (200 mmol/l) or sterilized water containing no amino acid (500 μl) were added to the medium. Then the culture was conducted at 26.5° C. for 48 hours in a rotary shaking culture apparatus.
Example 1
[0034] As the amino acid added to the medium in the above-described culture method, L-amino acids of 5 mM/L each described in Table 1 below were used and the influence of the amino acids upon the FR901228 production was examined.
[0035] An amount of FR901228 in the culture solution was measured by high performance liquid chromatography (column: Mightysil RP-18 GP (particle size: 3 μm), manufactured by KANTO KAGAKU, 3.0 mm I.D.×150 mm; column temperature: kept constant around 35° C.; detection wavelength: 210 nm; flow rate: 0.3 ml/min; injection amount: 2 μl; mobile phase: THF/acetonitrile/water/phosphoric acid (570:380:50:1)). The culture solution was centrifuged and the resulting strain was dried and the weight was measured. Thus an amount of dried strain was obtained and its amount with the respect to the culture solution was calculated.
[0000]
TABLE 1
Amount of
Amount of
Amount of FR901228
FR901228
dried strain
(×10 3 )/
(μg/ml)
(mg/ml)
amount of dried starin
Control
151
17.8
8.5
(without
amino acid)
Arg
208
20.9
10.0
His
204
21.4
9.5
Cys
224
18.3
12.2
Val
128
17.0
7.5
Tbr
150
17.0
8.9
Gly
131
15.8
8.2
Met
152
17.8
8.5
[0036] As shown in Table 1, a yield of FR901228 was increased through the addition of arginine (Arg), histidine (His) or cysteine (Cys). Arginine and histidine also increased the amount of dried strain together with the addition, but cysteine did not show change in the amount of dried strain as compared with the control. Accordingly, the yield per dried strain amount was remarkably high when the cysteine was added.
[0037] Unexpectedly, valine (Val), threonine (Thr) and glycine (Gly) that were possible components of FR901228, as well as methionine (Met) which was an amino acid containing a sulfur atom did not show increase in yield of FR901228.
Example 2
[0038] In the same manner as in Example 1, various cysteine-related compounds were used to examine the influence of them on the production of FR901228. L-cystine (L-Cys-Cys) was used in a ½ amount.
[0039] As a result, L-cysteine (L-Cys), its hydrochloride (Cys.HCl) and L-cystine showed increase in yield of FR901228 as shown in FIG. 1 .
[0040] Although the cysteine moiety in FR901228 was in the D form, the yield of FR901228 was not increased by addition of D-cysteine (D-Cys). Further, the yield was not increased though dithiothreitol (DTT), reduced glutathione (GSH) or acetylated cysteine compound, i.e., N-acetyl-L-cysteine (Ac-L-Cys), each of which was a compound containing a SH group, was added respectively.
Example 3
[0041] In the same manner as in Example 1, an optimum concentration of L-cysteine added in the medium was examined and the results shown in FIG. 2 were obtained. Amino acid solution of 500 mmol/L was used.
[0042] From the results, it was found that the concentration of L-cysteine in the medium was not directly related to the yield of FR901228.
Example 4
[0043] From the control sample without amino acid prepared in Example 1, FR901228 was isolated and purified by the following method.
[0044] A culture solution (2190 ml) was prepared in a scale of 100 times greater than that described in the section of Culture. After the culture, pH was adjusted to 2.0 with 1N sulfuric acid and the culture solution was filtrated. The strain was washed with water and the washing water was combined with the filtrate obtained in the previous step. The combined solution (5000 ml) was introduced in a column containing an adsorption resin DIAION HP20 (trademark, manufactured by Mitsubishi Chemical Corporation, 54 ml). The column was washed with water (100 ml) and 25% aqueous acetone (100 ml) and then eluted with 65% aqueous acetone.
[0045] The eluate was diluted with water to obtain water content of 70% or higher. The diluted solution (720 ml) was introduced in a column containing DIAION HP20SS (trademark, manufactured by Mitsubishi Chemical Corporation, 40 ml), washed with 40% aqueous acetone (160 ml) and then eluted with 47% aqueous acetone.
[0046] The eluate (120 ml) was diluted with water to obtain water content of 70% or higher. Thus obtained solution (200 ml) was introduced in a column of DIAION HP20 (9 ml), washed with 20% aqueous acetone (18 ml) and then eluted with acetone (50 ml). The eluate was concentrated to dryness under reduced pressure and the resulting residue was dissolved in ethyl acetate (3 ml). The solution was introduced in a column of silica gel (silica gel 60, 70-230 mesh, 60 ml), which is previously filled with n-hexane:ethyl acetate (1:1 v/v). The column was developed with n-hexane:ethyl acetate (1:1 v/v, 180 ml) and n-hexane:ethyl acetate (1:2 v/v). Fractions containing FR901228 were combined and concentrated under reduced pressure. The residue was dissolved in acetone (20 ml), which was then added with methanol and concentrated under reduced pressure to obtain FR901228 (250 mg).
[0047] Purification-1:
[0048] FR901228 (150 mg) was dissolved in 85% ethanol in a concentration of 94 mg/ml. To this solution, water in an amount of 0.8 times greater than that of the solution was added over about 10 minutes (concentration of 52 mg/ml), and then water in an amount of 4.2 times greater was added over about 3 hours (final concentration of about 15 mg/ml). After the total amount of water was added, the precipitate was collected by filtration to give type A crystals of FR901228 (100 mg).
[0049] The crystals obtained from ethanol/water were measured by using a powder X-ray diffraction apparatus, Philips MPD 1880 under the following conditions: voltage 40 kv; current 30 mA; Gonio meter PW1775; scanning mode continuous; rate of 0.10 deg/s; distance 0.02 deg; sampling time 0.20 s; DS 10; RS 0.2 mm; and SS 1°. FIG. 3 shows the results.
[0050] Purification-2:
[0051] FR901228 (150 mg) was dissolved in 85% aqueous acetone in a concentration of 94 mg/ml. To the solution, water in an amount of 0.8 times greater than that of the solution was added over about 10 minutes (concentration of 52 mg/ml), and then water in an amount of 4.2 times greater was added over about 3 hours (final concentration of about 15 mg/ml). After the total amount of water was added, the precipitate was collected by filtration to give type A crystals of FR901228 (120 mg).
[0052] The crystals obtained from acetone/water were subjected to the powder X-ray diffraction in the same manner as in Purification-1. FIG. 4 shows the results.
[0053] Purification-3:
[0054] FR901228 (510 mg) was dissolved in acetone in a concentration of about 11 mg/ml. The solution containing FR901228 was cooled to 5° C. After cooling, n-hexane in an amount equivalent to that of the solution was added over about 20 minutes (concentration of about 5.6 mg/ml) and then n-hexane was added in an amount of 8 times greater than that of the solution over about 70 minutes (final concentration of about 1.2 mg/ml) while maintaining the temperature at 10° C. or lower. After the total amount of n-hexane was added, the precipitate was collected by filtration to give type B crystals of FR901228 (465 mg).
[0055] FIG. 5 shows the results of the powder X-ray diffraction of the type B crystals (diffraction conditions were the same as those in Purification-1).
[0056] According to the present invention, provided is a method of producing FR901228 which comprises culturing a FR901228 producing strain in a medium added with at least one amino acid selected from the group consisting of L-arginine, L-histidine, L-cystine and L-cysteine or salt thereof.
[0057] According to this method, FR901228 can be produced more efficiently than conventional methods using no amino acid. Therefore, the utilization of FR901228 having high industrial utility value can be further promoted.
[0058] In the above detailed description, reference was made by way of non-limiting examples to preferred embodiments of the invention. Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.
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Depsipeptides and congeners thereof are disclosed having structure (I), wherein m, n, p, q, X, R1, R2 and R3 are as defined herein. These compounds, including FR901228, have activity as, for example, immunosuppressants, as well as for the prevention or treatment of patients suffering or at risk of suffering from inflammatory, autoimmune or immune system-related diseases including graft-versus-host disease and enhancement of graft/tissue survival following transplant. Also provided are methods for inhibiting lymphocyte activation, proliferation, and/or suppression of IL-2 secretion.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/910,947, filed on Apr. 10, 2007, the disclosure thereof incorporated by reference herein in its entirety.
BACKGROUND
The present invention relates generally to data communications. More particularly, the present invention relates to a wireless application service system.
SUMMARY
In general, in one aspect, the invention features an apparatus comprising: a first network interface comprising a transmitter to wirelessly transmit a beacon comprising an indication of the capability of the apparatus to provide wireless application services; a receiver to wirelessly receive a wireless application service request from a wireless client, the wireless application service request comprising a request for one of the wireless application services, and an identifier of a service access point for the requested wireless application service; a second network interface to obtain an application for the requested wireless application service from the service access point in response to the wireless application service request; and a processor to execute the application, wherein the application provides the requested wireless application service to the wireless client.
Some embodiments comprise a wireless access point comprising the apparatus. In some embodiments, the wireless access point is compliant with all or part of IEEE standard 802.11, including draft and approved amendments 802.11a, 802.11b, 802.11e, 802.11g, 802.11i, 802.11k, 802.11n, 802.11v, and 802.11w. Some embodiments comprise a memory to store data for the application. In some embodiments, the wireless application service request further comprises one or more of: a class-of-device identifier for the wireless client; a vendor identifier for the wireless client; and a capabilities identifier for the wireless client. In some embodiments, the processor determines whether the wireless application service request is to be granted; and wherein the transmitter wirelessly transmits a wireless application service request response to the wireless client indicating whether the wireless application service request is granted. In some embodiments, the receiver wirelessly receives an authentication request from the wireless client; wherein the processor generates an authentication result based on the authentication request; and wherein the transmitter wirelessly transmits an authentication response to the wireless client, the authentication response representing the authentication result. Some embodiments comprise a user interface comprising an authentication device to authenticate a user of the user interface. In some embodiments, the authentication device comprises: a fingerprint reader.
In general, in one aspect, the invention features a method comprising: wirelessly transmitting, from an apparatus, a beacon comprising an indication of the capability of the apparatus to provide wireless application services; wirelessly receiving a wireless application service request from a wireless client, the wireless application service request comprising a request for one of the wireless application services, and an identifier of a service access point for the requested wireless application service; obtaining an application for the requested wireless application service from the service access point in response to the wireless application service request; and executing the application, wherein the application provides the requested wireless application service to the wireless client.
In some embodiments, a wireless access point comprises the apparatus. In some embodiments, the wireless access point is compliant with all or part of IEEE standard 802.11, including draft and approved amendments 802.11a, 802.11b, 802.11e, 802.11g, 802.11i, 802.11k, 802.11n, 802.11v, and 802.11w. Some embodiments comprise storing data in the apparatus for the application. In some embodiments, the wireless application service request further comprises one or more of: a class-of-device identifier for the wireless client; a vendor identifier for the wireless client; and a capabilities identifier for the wireless client. Some embodiments comprise determining whether the wireless application service request is to be granted; and wirelessly transmitting a wireless application service request response to the wireless client indicating whether the wireless application service request is granted. Some embodiments comprise wirelessly receiving an authentication request from the wireless client; generating an authentication result based on the authentication request; and wirelessly transmitting an authentication response to the wireless client, the authentication response representing the authentication result.
In general, in one aspect, the invention features a computer-readable media embodying instructions executable by a computer to perform a method comprising: causing wireless transmission, from an apparatus, of a beacon comprising an indication of the capability of the apparatus to provide wireless application services, wherein the apparatus wirelessly receives a wireless application service request from a wireless client, the wireless application service request comprising a request for one of the wireless application services, and an identifier of a service access point for the requested wireless application service; obtaining an application for the requested wireless application service from the service access point in response to the wireless application service request; and executing the application, wherein the application provides the requested wireless application service to the wireless client.
In some embodiments, a wireless access point comprises the apparatus. In some embodiments, the wireless access point is compliant with all or part of IEEE standard 802.11, including draft and approved amendments 802.11a, 802.11b, 802.11e, 802.11g, 802.11i, 802.11k, 802.11n, 802.11v, and 802.11w. In some embodiments, the method further comprises: storing data in the apparatus for the application. In some embodiments, the wireless application service request further comprises one or more of: a class-of-device identifier for the wireless client; a vendor identifier for the wireless client; and a capabilities identifier for the wireless client. In some embodiments, the method further comprises: determining whether the wireless application service request is to be granted; and causing wireless transmission of a wireless application service request response to the wireless client indicating whether the wireless application service request is granted. In some embodiments, the method further comprises: generating an authentication result based on an authentication request wirelessly received from the wireless client; and causing wireless transmission of an authentication response to the wireless client, the authentication response representing the authentication result.
In general, in one aspect, the invention features an apparatus comprising: means for wirelessly transmitting a beacon comprising an indication of the capability of the apparatus to provide wireless application services; means for wirelessly receiving a wireless application service request from a wireless client, the wireless application service request comprising a request for one of the wireless application services, and an identifier of a service access point for the requested wireless application service; means for obtaining an application for the requested wireless application service from the service access point in response to the wireless application service request; and means for executing the application, wherein the application provides the requested wireless application service to the wireless client.
Some embodiments comprise a wireless access point comprising the apparatus. In some embodiments, the wireless access point is compliant with all or part of IEEE standard 802.11, including draft and approved amendments 802.11a, 802.11b, 802.11e, 802.11g, 802.11i, 802.11k, 802.11n, 802.11v, and 802.11w. Some embodiments comprise means for storing data for the application. In some embodiments, the wireless application service request further comprises one or more of: a class-of-device identifier for the wireless client; a vendor identifier for the wireless client; and a capabilities identifier for the wireless client. In some embodiments, the means for executing determines whether the wireless application service request is to be granted; and wherein the means for wirelessly transmitting transmits a wireless application service request response to the wireless client indicating whether the wireless application service request is granted. In some embodiments, the means for receiving wirelessly receives an authentication request from the wireless client; wherein the means for executing generates an authentication result based on the authentication request; and wherein means for wirelessly transmitting wirelessly transmits an authentication response to the wireless client, the authentication response representing the authentication result. Some embodiments comprise means for authenticating a user of the apparatus.
The details of one or more implementations are set forth in the accompanying drawings and the description below. Other features will be apparent from the description and drawings, and from the claims.
DESCRIPTION OF DRAWINGS
FIG. 1 shows a wireless application service system according to embodiments of the present invention.
FIG. 2 shows a process for the wireless application service system of FIG. 1 according to some embodiments of the present invention.
FIG. 3 shows the format of an information element (IE) according to some embodiments of the present invention.
FIG. 4 shows the format of a wireless application service request according to some embodiments of the present invention.
FIG. 5 shows the format of a TLV field according to some embodiments of the present invention.
FIG. 6 shows the format of a wireless application service request response according to some embodiments of the present invention.
FIG. 7 shows the format of an authentication request according to some embodiments of the present invention.
FIG. 8 shows the format of an authentication response according to some embodiments of the present invention.
FIGS. 9A-9E show various exemplary implementations of the present invention.
The leading digit(s) of each reference numeral used in this specification indicates the number of the drawing in which the reference numeral first appears.
DETAILED DESCRIPTION
As used herein, the terms “client” and “server” generally refer to an electronic device or mechanism, and the term “message” generally refers to an electronic signal representing a digital message. As used herein, the term “mechanism” refers to hardware, software, or any combination thereof. These terms are used to simplify the description that follows. The clients, servers, and mechanisms described herein can be implemented on any standard general-purpose computer, or can be implemented as specialized devices. Furthermore, while some embodiments of the present invention are described with reference to a client-server paradigm, other embodiments employ other paradigms, such as peer-to-peer paradigms and the like.
Embodiments of the present invention provide a wireless application service system. The wireless application service system can include a wireless client to request wireless application services and a wireless access point to advertise and provide wireless application services. For example, a television remote control can include the wireless client. When the remote control detects an advertisement for a television guide service, the remote control can request the television guide service. The wireless access point obtains a television guide application from a service access point specified by the request, and executes the application, which provides the television guide service wirelessly to the remote control.
In some embodiments, a wireless client wirelessly receives advertisements for one or more wireless application services. For example, a beacon transmitted by a wireless access point can include an indication of the capability of the wireless access point to provide wireless application services. The wireless client can wirelessly transmit a request to the wireless access point for one of the wireless application services. The request can include an identifier of a service access point for the requested wireless application service.
In response, the wireless access point obtains an application for the wireless application service from the service access point and executes the application. The application provides the wireless application service to the wireless client. In some embodiments, the wireless client must be authenticated by the wireless access point before the wireless application service is provided.
FIG. 1 shows a wireless application service system 100 according to embodiments of the present invention. Although in the described embodiments, the elements of wireless application service system 100 are presented in one arrangement, other embodiments may feature other arrangements, as will be apparent to one skilled in the relevant arts based on the disclosure and teachings provided herein. For example, the elements of wireless application service system 100 can be implemented in hardware, software, or combinations thereof.
Referring to FIG. 1 , wireless application service system 100 includes a wireless device 128 comprising a wireless client 102 in communication a with a wireless access point 104 over a wireless local-area network (WLAN) 106 . In some embodiments, WLAN 106 is compliant with all or part of IEEE standard 802.11, including draft and approved amendments such as 802.11a, 802.11b, 802.11e, 802.11g, 802.11i, 802.11k, 802.11n, 802.11v, and 802.11w. However, while embodiments of the present invention are described in terms of wireless access points 104 and wireless clients 102 , other sorts of wireless network devices can be used instead. Furthermore, while embodiments of the present invention are described in terms of a WLAN 106 , other sorts of wireless networks can be used instead.
Wireless application service system 100 also includes an application server 108 in communication with wireless access point 104 over a wide-area network (WAN) 110 . However, while embodiments of the present invention are described in terms of a WAN 110 , other sorts of networks can be used instead.
Referring again to FIG. 1 , wireless access point 104 includes a WLAN interface 112 , a WAN interface 114 , a processor 116 , and a memory 118 . WLAN interface 112 includes a transmitter 120 and a receiver 122 . Wireless access point 104 can also include a user interface 136 including a fingerprint reader 138 or other authentication device, for example to enter fingerprints of users. The fingerprints can then be used to authenticate users when they employ wireless device 128 to respond to authentication challenges issued by wireless access point 104 , as described below. In some embodiments, WAN interface 114 is compliant with all or part of IEEE standard 802.11, including draft and approved amendments such as 802.11a, 802.11b, 802.11e, 802.11g, 802.11i, 802.11k, 802.11n, 802.11v, and 802.11w.
Wireless device 128 includes a user interface 130 , a controller 132 , and wireless client 102 . Wireless client 102 includes a receiver 124 and a transmitter 126 . In some embodiments, receiver 124 and transmitter 126 are compliant with all or part of IEEE standard 802.11, including draft and approved amendments such as 802.11a, 802.11b, 802.11e, 802.11g, 802.11i, 802.11k, 802.11n, 802.11v, and 802.11w.
FIG. 2 shows a process 200 for wireless application service system 100 of FIG. 1 according to some embodiments of the present invention. Although in the described embodiments, the elements of process 200 are presented in one arrangement, other embodiments may feature other arrangements, as will be apparent to one skilled in the relevant arts based on the disclosure and teachings provided herein.
Referring to FIG. 2 , transmitter 120 of WLAN interface 112 of wireless access point 104 transmits wireless beacon signals (step 202 ). Each beacon signal can include one or more information elements (IE). In some embodiments, the beacon signals and information elements are compliant with all or part of IEEE standard 802.11, including draft and approved amendments such as 802.11a, 802.11b, 802.11e, 802.11g, 802.11i, 802.11k, 802.11n, 802.11v, and 802.11w.
FIG. 3 shows the format of an information element (IE) 300 according to some embodiments of the present invention. IE 300 begins with a one-byte Element ID 302 that can be used to identify a manufacturer of wireless access point 104 . Element ID 302 is followed by a one-byte length field 304 that identifies the length of IE 302 , a three-byte WAP Organizationally Unique Identifier (OUI) 306 representing a manufacturer of wireless access point 104 , a one-byte proprietary IE Type 308 , and a two-byte version field 310 .
In some embodiments, Element ID 302 is used to advertise wireless application services. That is, the value of Element ID 302 provides an indication of the capability of wireless access point 104 to provide wireless application services. Referring again to FIG. 2 , receiver 124 of wireless client 102 receives the beacon signal, and determines whether wireless access point 104 is capable of providing wireless application services (step 204 ), for example by examining the value of Element ID 302 in the beacon signal.
If wireless client 102 determines that wireless access point 104 is capable of providing wireless application services (step 204 ), transmitter 126 of wireless client 102 can transmit a wireless application service request to wireless access point 104 (step 206 ). Controller 132 generates a packet representing the wireless application service request, and transmitter 126 transmits a wireless signal representing the packet.
FIG. 4 shows the format of a wireless application service request 400 according to some embodiments of the present invention. Wireless application service request 400 begins with a six-byte destination address (DA) 402 that includes the address of wireless access point 104 , followed by a six-byte source address (SA) 404 that includes the address of wireless client 102 . Wireless application service request 400 also includes a two-byte length field (Len.) 406 , a 3-byte IEEE 802.2 Logical Link Control (LLC) portion including a one-byte field 408 comprising the value 0xAA, another one-byte field 410 comprising the value 0xAA, and a one-byte field 412 comprising the value 0x03, a three-byte WAP OUI 414 representing a manufacturer of wireless access point 104 , a two-byte field 416 comprising a frame type (which can have a value of 0x0001 for a wireless application service request 400 ), an identifier of a service access point for the wireless application service including a three-byte Vendor OUI 418 of a vendor of the application(s) that provides the requested wireless application service(s) and a two-byte vendor port number 420 of a port where the application is available, a variable-length list 422 of one or more Tag Length Value (TLV) fields each representing one of the requested wireless application services, and a two-byte frame check sequence (FCS) 424 . Other embodiments can include the same and/or different fields of the same or different lengths in the same or different order.
FIG. 5 shows the format of a TLV field 500 according to some embodiments of the present invention. TLV field 500 includes a 2-byte tag 502 , a two-byte length 504 representing a length of TLV field 500 , and a variable value 506 representing a requested wireless application service. Variable value 506 can also represent one or more of the following: a class-of-device identifier for wireless client 102 , a vendor identifier for wireless client 102 , and a capabilities identifier for wireless client 102 . Other embodiments can include the same and/or different fields of the same or different lengths in the same or different order.
Referring again to FIG. 2 , receiver 122 of wireless access point 104 receives the wireless application service request. In response to the wireless application service request, wireless access point 104 determines whether the application(s) that provide the requested wireless application service(s) are already installed in wireless access point 104 (step 208 ). If not, WAN interface 114 of wireless access point 104 obtains the required application(s) from application server 108 , which is specified by the vendor service access point in the wireless application service request (step 210 ). Processor 116 of wireless access point 104 then installs and executes the obtained application(s) in wireless access point 104 (step 212 ). Transmitter 120 of wireless access point 104 can then transmit a wireless application service request response to wireless client 102 (step 214 ). Processor 116 generates a packet representing the wireless application service request response, and transmitter 120 transmits a wireless signal representing the packet.
FIG. 6 shows the format of a wireless application service request response 600 according to some embodiments of the present invention. Wireless application service request response 600 begins with a six-byte destination address (DA) 602 that includes the address of wireless client 102 , followed by a six-byte source address (SA) 604 that includes the address of wireless access point 104 . Wireless application service request response 600 also includes a two-byte length field (Len.) 606 , a 3-byte IEEE 802.2 Logical Link Control (LLC) portion including a one-byte field 608 comprising the value 0xAA, another one-byte field 610 comprising the value 0xAA, and a one-byte field 612 comprising the value 0x03, a three-byte WAP OUI 614 representing a manufacturer of wireless access point 104 , a two-byte field 616 comprising a frame type (which can have a value of 0x8001 for a wireless application service request response 600 ), an identifier of a service access point for the wireless application service including a three-byte Vendor OUI 618 of a vendor of the application(s) that provides the requested wireless application service(s) and a two-byte vendor port number 620 of a port where the application is available, a variable-length list 622 of one or more Tag Length Value (TLV) fields each representing one of the requested wireless application services, and a two-byte frame check sequence (FCS) 624 . Other embodiments can include the same and/or different fields of the same or different lengths in the same or different order.
The TLV fields in TLV list 622 can have the same format as TLV field 500 of FIG. 5 . Each TLV field in TLV list 622 can include information for one of the wireless application services specified in the TLV field(s) in the TLV list 422 of the corresponding wireless application service request 400 .
In some embodiments, wireless client 102 must be authenticated before receiving a wireless application service. In some cases, the application can perform the authentication. In other cases, wireless access point 104 can perform the authentication for the application. In such cases, wireless access point 104 determines whether authentication is required (step 216 ). If so, wireless access point 104 challenges wireless client 102 (step 218 ). In response to the challenge, wireless client 102 transmits an authentication request to wireless access point 104 (step 220 ). In some embodiments, user interface 130 of wireless device 128 includes a fingerprint reader 134 or other authentication device to authenticate the user, for example before responding to the challenge.
FIG. 7 shows the format of an authentication request 700 according to some embodiments of the present invention. Authentication request 700 begins with a six-byte destination address (DA) 702 that includes the address of wireless access point 104 , followed by a six-byte source address (SA) 704 that includes the address of wireless client 102 . Authentication request 700 also includes a two-byte length field 706 , a 3-byte IEEE 802.2 Logical Link Control (LLC) portion including a one-byte field 708 comprising the value 0xAA, another one-byte field 710 comprising the value 0xAA, and a one-byte field 712 comprising the value 0x03, a three-byte WAP OUI 714 representing a manufacturer of wireless access point 104 , a two-byte field 716 comprising a frame type (which can have a value of 0x0002 for an authentication request 700 ), a three-byte Vendor OUI 718 representing a provider of the desired wireless application service, a two-byte vendor port number 720 , a variable-length security certificate 722 , and a two-byte FCS 724 . Other embodiments can include the same and/or different fields of the same or different lengths in the same or different order.
Referring again to FIG. 2 , wireless access point 104 attempts to authenticate wireless client 102 (step 222 ), for example using security certificate 722 of FIG. 7 . Referring again to FIG. 2 , wireless access point 104 then sends an authentication response to wireless client 102 (step 224 ).
FIG. 8 shows the format of an authentication response 800 according to some embodiments of the present invention. Authentication response 800 begins with a six-byte destination address (DA) 802 that includes the address of wireless client 102 , followed by a six-byte source address (SA) 804 that includes the address of wireless access point 104 . Authentication response 800 also includes a two-byte length field 806 , a 3-byte IEEE 802.2 Logical Link Control (LLC) portion including a one-byte field 808 comprising the value 0xAA, another one-byte field 810 comprising the value 0xAA, and a one-byte field 812 comprising the value 0x03, a three-byte WAP OUI 814 representing a manufacturer of wireless access point 104 , a two-byte field 816 comprising a frame type (which can have a value of 0x8002 for an authentication response 800 ), a three-byte Vendor OUI 818 , a two-byte vendor port number 820 , a variable-length authentication result 822 representing the success or failure of the authentication attempt, and a two-byte FCS 824 . Other embodiments can include the same and/or different fields of the same or different lengths in the same or different order.
Referring again to FIG. 2 , if the authentication was successful (step 224 ), the application(s), now executing on processor 116 of wireless access point 104 , provides the requested wireless application service(s) to wireless client 102 (step 226 ).
As an example of the operation of embodiments of the present invention, consider the case where a consumer has purchased a wireless device 128 comprising a wireless client 102 . User interface 130 includes an “easy configuration” button that, when pressed, initiates a configuration process such as process 200 of FIG. 2 . When contacting application server 108 , wireless access point 104 can register wireless device 128 with its vendor and obtain an application from the vendor to provide wireless application services to wireless device 128 . For example, the wireless services can install firmware, upgrades and the like in wireless device 128 .
Referring again to FIG. 1 , applications providing wireless application services can use memory 118 of wireless access point 104 so that little storage is required in wireless device 128 . In the example where wireless device 128 is a television remote control having a display screen, the application can obtain preview clips of television shows, store the clips in memory 118 , and stream the clips to the remote control when needed.
FIGS. 9A-9E show various exemplary implementations of the present invention. Referring now to FIG. 9A , the present invention can be implemented in a high definition television (HDTV) 912 . The present invention may implement either or both signal processing and/or control circuits, which are generally identified in FIG. 9A at 913 , a WLAN interface and/or mass data storage of the HDTV 912 . The HDTV 912 receives HDTV input signals in either a wired or wireless format and generates HDTV output signals for a display 914 . In some implementations, signal processing circuit and/or control circuit 913 and/or other circuits (not shown) of the HDTV 912 may process data, perform coding and/or encryption, perform calculations, format data and/or perform any other type of HDTV processing that may be required.
The HDTV 912 may communicate with mass data storage 915 that stores data in a nonvolatile manner such as optical and/or magnetic storage devices. The HDD may be a mini HDD that includes one or more platters having a diameter that is smaller than approximately 1.8″. The HDTV 912 may be connected to memory 916 such as RAM, ROM, low latency nonvolatile memory such as flash memory and/or other suitable electronic data storage. The HDTV 912 also may support connections with a WLAN via a WLAN network interface 917 .
Referring now to FIG. 9B , the present invention implements a control system of a vehicle 918 , a WLAN interface and/or mass data storage of the vehicle control system. In some implementations, the present invention implements a powertrain control system 919 that receives inputs from one or more sensors such as temperature sensors, pressure sensors, rotational sensors, airflow sensors and/or any other suitable sensors and/or that generates one or more output control signals such as engine operating parameters, transmission operating parameters, and/or other control signals.
The present invention may also be implemented in other control systems 922 of the vehicle 918 . The control system 922 may likewise receive signals from input sensors 923 and/or output control signals to one or more output devices 924 . In some implementations, the control system 922 may be part of an anti-lock braking system (ABS), a navigation system, a telematics system, a vehicle telematics system, a lane departure system, an adaptive cruise control system, a vehicle entertainment system such as a stereo, DVD drive, compact disc system and the like. Still other implementations are contemplated.
The powertrain control system 919 may communicate with mass data storage 925 that stores data in a nonvolatile manner. The mass data storage 925 may include optical and/or magnetic storage devices including HDDs and/or DVD drives. The HDD may be a mini HDD that includes one or more platters having a diameter that is smaller than approximately 1.8″. The powertrain control system 919 may be connected to memory 926 such as RAM, ROM, low latency nonvolatile memory such as flash memory and/or other suitable electronic data storage. The powertrain control system 919 also may support connections with a WLAN via a WLAN network interface 927 . The control system 922 may also include mass data storage, memory and/or a WLAN interface (all not shown).
Referring now to FIG. 9C , the present invention can be implemented in a cellular phone 928 that may include a cellular antenna 929 . The present invention may implement either or both signal processing and/or control circuits, which are generally identified in FIG. 9C at 930 , a WLAN interface and/or mass data storage of the cellular phone 928 . In some implementations, the cellular phone 928 includes a microphone 931 , an audio output 932 such as a speaker and/or audio output jack, a display 933 and/or an input device 934 such as a keypad, pointing device, voice actuation and/or other input device. The signal processing and/or control circuits 930 and/or other circuits (not shown) in the cellular phone 928 may process data, perform coding and/or encryption, perform calculations, format data and/or perform other cellular phone functions.
The cellular phone 928 may communicate with mass data storage 935 that stores data in a nonvolatile manner such as optical and/or magnetic storage devices including HDDs and/or DVD drives. The HDD may be a mini HDD that includes one or more platters having a diameter that is smaller than approximately 1.8″. The cellular phone 928 may be connected to memory 936 such as RAM, ROM, low latency nonvolatile memory such as flash memory and/or other suitable electronic data storage. The cellular phone 928 also may support connections with a WLAN via a WLAN network interface 937 .
Referring now to FIG. 9D , the present invention can be implemented in a set top box 938 . The present invention may implement either or both signal processing and/or control circuits, which are generally identified in FIG. 9D at 939 , a WLAN interface and/or mass data storage of the set top box 938 . The set top box 938 receives signals from a source such as a broadband source and outputs standard and/or high definition audio/video signals suitable for a display 940 such as a television, a monitor and/or other video and/or audio output devices. The signal processing and/or control circuits 939 and/or other circuits (not shown) of the set top box 938 may process data, perform coding and/or encryption, perform calculations, format data and/or perform any other set top box functions.
The set top box 938 may communicate with mass data storage 943 that stores data in a nonvolatile manner. The mass data storage 943 may include optical and/or magnetic storage devices including HDDs and/or DVD drives. The HDD may be a mini HDD that includes one or more platters having a diameter that is smaller than approximately 1.8″. The set top box 938 may be connected to memory 942 such as RAM, ROM, low latency nonvolatile memory such as flash memory and/or other suitable electronic data storage. The set top box 938 also may support connections with a WLAN via a WLAN network interface 943 .
Referring now to FIG. 9E , the present invention can be implemented in a media player 944 . The present invention may implement either or both signal processing and/or control circuits, which are generally identified in FIG. 9E at 945 , a WLAN interface and/or mass data storage of the media player 944 . In some implementations, the media player 944 includes a display 946 and/or a user input 947 such as a keypad, touchpad and the like. In some implementations, the media player 944 may employ a graphical user interface (GUI) that typically employs menus, drop down menus, icons and/or a point-and-click interface via the display 946 and/or user input 947 . The media player 944 further includes an audio output 948 such as a speaker and/or audio output jack. The signal processing and/or control circuits 945 and/or other circuits (not shown) of the media player 944 may process data, perform coding and/or encryption, perform calculations, format data and/or perform any other media player functions.
The media player 944 may communicate with mass data storage 949 that stores data such as compressed audio and/or video content in a nonvolatile manner. In some implementations, the compressed audio files include files that are compliant with MP3 format or other suitable compressed audio and/or video formats. The mass data storage 949 may include optical and/or magnetic storage devices including HDDs and/or DVD drives. The HDD may be a mini HDD that includes one or more platters having a diameter that is smaller than approximately 1.8″. The media player 944 may be connected to memory 950 such as RAM, ROM, low latency nonvolatile memory such as flash memory and/or other suitable electronic data storage. The media player 944 also may support connections with a WLAN via a WLAN network interface 951 . Still other implementations in addition to those described above are contemplated.
A number of implementations of the invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. Accordingly, other implementations are within the scope of the following claims.
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Apparatus having corresponding methods and computer-readable media comprises a first network interface comprising a transmitter to wirelessly transmit a beacon comprising an indication of the capability of the apparatus to provide wireless application services; a receiver to wirelessly receive a wireless application service request from a wireless client, the wireless application service request comprising a request for one of the wireless application services, and an identifier of a service access point for the requested wireless application service; a second network interface to obtain an application for the requested wireless application service from the service access point in response to the wireless application service request; and a processor to execute the application, wherein the application provides the requested wireless application service to the wireless client.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a technology for judging that a shut-off valve used in a vehicle fuel gas supply system is in a failure state.
2. Description of the Related Art
In recent years, natural gas (NG) has been used as one of alternative fuels to gasoline and gas oil, and in a case where natural gas is used as fuel for vehicles, in particular, passenger vehicles, a compressed-gas cylinder (bomb) is mounted on a passenger vehicle. A natural gas compressed to in the order of 200 kg/cm 2 is then filled in the compressed-gas cylinder, and the natural gas so filled is then reduced in pressure by means of a pressure reducing valve to become a low pressure gas for supply to a combustion chamber. A natural gas as compressed to a high pressure like this is called a compressed natural gas (CNG).
Research on vehicles using compressed natural gas as a fuel has been progressing, and Japanese Patent Unexamined Publication No. Hei.7-189731 entitled “Residual Fuel Volume Display Device for Gas-Fueled Vehicles” proposes a technology for displaying the volume of residual fuel more accurately by correcting pressure and temperature fluctuations attributed to a compressible fluid. This publication discloses a CNG tank, a high pressure piping for supplying a compressed natural gas taken from the CNG tank, a first solenoid shut-off valve provided upstream of the high pressure piping, and a second solenoid shut-off valve provided downstream of the high pressure piping. The first and second solenoid shut-off valves are able to be closed by means of an ECU.
In general, used as the solenoid shut-off valves is a shut-off valve in which the valve is opened when a plunger (rod) is axially moved by virtue of the electromagnetic force of the solenoid, while the valve is closed when the plunger is returned by virtue of the compression force of a spring used. In order to allow the plunger to reciprocate in the axial directions, there must be provided a gap. However, if this gap is too large, the plunger may be moved in radial directions, causing “chattering.” To cope with this, the gap between the plunger and a component for supporting the plunger thereon needs to be as small as possible.
Natural gas consists mainly of methane gas, and since it is collected from the underground, the natural gas tends to contain water. Even if much labor is spent in producing a dried compressed natural gas, there exists a risk of water contained in air entering into a fuel tank mounted on a vehicle when the dried compressed natural gas is transferred into the fuel tank. In addition, it is well considered that water cannot be removed in a complete fashion even in producing a fuel line system.
There is a risk of the water so present generating rust at metallic portions of the solenoid valves. To cope with this, plungers are made of stainless steel or plated, but those countermeasures are not perfect.
There are considered the following two cases of failure in operation of the first solenoid shut-off valve.
The first case is where rust disturbs to open the shut-off valve cannot be opened because of rust. With the shut-off valve being left closed, a sufficient amount of fuel cannot be supplied to the engine, and therefore, although the engine can be started with fuel remaining within the fuel line, the engine stops soon thereafter.
The second case is where the shut-off valve from cannot be closed because of rust. With the shut-off valve being left opened, even if the engine is stopped, the compressed natural gas is kept supplied from the compressed gas cylinder to the high pressure piping, and therefore, there is a high risk of gas leakage while the engine is being stopped. In addition, in view of safety servicing of a vehicle, such a gas leakage is undesirable.
SUMMARY OF THE INVENTION
Then, an object of the present invention is to provide a technology for efficiently judging of a failure state of a solenoid shut-off valve used in a vehicle fuel gas supply system having a high probability of a risk of water entering into the fuel supply system.
With a view to attaining the aforesaid object, according to the present invention, there is provided a vehicle fuel gas supply system in which a shut-off valve and a pressure sensor are disposed in that order along a fuel line for supplying a fuel gas to a gas engine, comprising a control section for closing the shut-off valve based on a diagnostic signal, calculating a pressure drop rate based on pressure information taken in from the pressure sensor after the closure of the shut-off valve and an elapsed time, and judging that the shut-off value is in a failure state when the pressure drop rate so calculated is smaller than a predetermined pressure drop rate threshold value.
With this fuel gas supply system constructed as described above, it is possible to judge of a failure state of the shut-off valve while the vehicle is being stopped or running.
The diagnosis of failure consists of the following two types; the shut-off valve is kept opened and cannot be closed, and the shut-off valve is locked to the opened side and a sufficient degree of closure cannot be attained.
According to the present invention, it is possible not only to diagnose that the shut-off valve properly operates at suitable times but also to prevent a trouble that would be entailed by the failure of the shut-off valve.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram showing a vehicle to which the present invention is applied;
FIG. 2 is a drawing showing the principle of a fuel gas supply system according to the present invention;
FIG. 3 is an enlarged view of a part indicated by a reference numeral III in FIG. 2;
FIGS. 4A and 4B are drawings showing operations of a check valve and a first shut-off valve according to the present invention;
FIG. 5 is an enlarged view of a part indicated by a reference numeral V in FIG. 2;
FIG. 6 is a bottom view of a pressure control unit shown in FIG. 5;
FIG. 7 is a drawing showing the operational principle of the pressure control unit adopted in the present invention.
FIG. 8 is a fuel gas supply system drawing for use in explaining a failure judgement technology according to the present invention;
FIG. 9 is a flowchart for detecting a failure of the first shut-off valve according to the present invention (part 1 );
FIG. 10 is a flowchart for detecting a failure of the first shut-off valve according to the present invention (part 2 );
FIG. 11 is a flowchart for detecting a failure of the first shut-off valve according to the present invention (part 3 );
FIG. 12 is a time chart showing a failure diagnosis of the shut-off valve according to the present invention; and
FIG. 13 is a time chart showing a failure diagnosis of the shut-off valve according to another embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the accompanying drawings, a mode of carrying out the present invention will be described below. In the following description, a first, a second, . . . or a primary, a secondary, . . . are a nominal identification prefix that is given in the order fuel gas flows in a fuel gas supply system.
FIG. 1 is a diagram showing a vehicle to which the present invention is applied. The vehicle 10 is shown as being provided with a fuel gas supply system in which a CNG tank 12 filled with a compressed natural gas as a fuel gas is mounted at a rear part of a vehicle body 11 of this vehicle 10 , the compressed natural gas within the CNG tank is supplied to a combustion chamber of a gas engine 16 mounted at a front portion of the vehicle body 11 via high pressure piping 13 , a pressure control unit 60 , low pressure piping 14 , and an injector 15 . The other reference numerals will be described later on.
FIG. 2 is a diagram explaining the principle of the fuel gas supply system according to the present invention. In this fuel gas supply system 20 , a compressed natural gas can be filled in the CNG tank 12 from the outside via a filler port 21 , a filler pipe 22 and a check valve 40 , while the compressed natural gas so filled and stored in the CNG tank 12 can be sent to an intake port 26 via a first shut-off valve 50 , the high pressure piping 13 , a joint box 23 , a manual On/Off valve 24 , a filter 25 , the pressure control unit 60 , the low pressure piping 14 and the injector 15 , which are disposed along the high pressure piping 13 .
In addition, this system comprises a first pressure sensor 31 and a first temperature sensor 23 which are provided in the joint box 23 , a second pressure sensor 33 provided at an outlet of the pressure control unit 60 , a second temperature sensor 34 provided at the injector 15 , an injector driver 35 for controlling the injector 15 and a control section 36 for controlling the first shut-off valve 50 and a second shut-off valve (which will be described in detail later on) installed in the pressure control unit 60 so as to be opened or closed.
Namely, the pressure P 0 and temperature T 0 of the compressed natural gas in the high pressure piping 13 are measured by means of the first pressure sensor 31 and the first temperature sensor 32 , and information resulting from such measurements is inputted into the control section 36 . The pressure P 2 and temperature, T 2 of the compressed natural gas in the low pressure piping 14 ! are measured by means of the second pressure sensor 33 and the second temperature sensor 34 , and information resulting from such measurements is inputted into the control section 36 . Then, the control section 36 controls the first shut-off valve 50 and the second shut-off valve installed in the pressure control unit 60 based on the inputted information to thereby judge whether or not those shut-off valves are in a failure state.
The compressed natural gas is a gas and a compressible fluid, and therefore, it follows the Boyle-Charles Law (PV/T=constant, where P is an absolute pressure, V is a volume or a capacity, and T is an absolute temperature). Here, the capacity of the flow path is constant, and therefore, V remains the same. With fluctuations in temperature, the pressure fluctuates in proportion thereto, and thus, there is a possibility that the pressure changes at all times, this causing a problem in control. To cope with this, the pressure P 0 is temperature corrected at the temperature T 0 . Similarly, the pressure P 2 is temperature corrected at the temperature T 2 . With such temperature corrections, any pressures can be regarded as a pressure referencing zero (0) degree, thereby making it possible for them to relatively be compared with each other.
FIG. 3 is an enlarged sectional view of a portion indicated by a circle denoted by reference numeral III in FIG. 2 . The check valve 40 and the first shut-off valve 50 are incorporated in a common valve cage 41 , and this valve cage 41 is screwed into an opening in the CNG tank 12 . In particular, the first shut-off valve 50 is called an in-tank shut-off valve because a main part thereof resides inside the CNG tank 12 . The construction of the check valve 40 and the first shut-off valve 50 will be described sequentially.
The check valve 40 is constructed such that a sleeve 42 is screwed into the valve cage 41 , that a valve element 43 is brought into abutment with a lower opening of the sleeve 42 , that the valve element 43 is pushed to a valve closing side by means of a spring 44 , that this spring 44 is supported by another sleeve 45 and a rod 46 , and that a flow path 47 and a throttle portion 48 are formed in the rod 46 . An operation of the check valve 40 will be described referring to FIG. 4 A. Reference numeral 49 denotes a stop plug, which is shown as being put in an open state. The plug 49 can be turned with a hexagon wrench so as to close an upper opening 41 a . This is used in periodically inspecting the filler pipe 22 for maintenance.
The first shut-off valve 50 is a solenoid controlled shut-off valve which is constructed such that a cylindrical solenoid holder 52 for supporting a solenoid 51 is screwed into the valve cage 41 , that a rod 53 is put through the solenoid holder 52 , that a valve element 55 is fixed to a tip of the rod 53 via a pin 54 , and that the valve element 55 is caused to confront a valve seat of the valve cage 41 . When the solenoid 51 is excited, the rod 53 is withdrawn so as to open the shut-off valve by virtue of the attracting action of the solenoid 51 resulting, while, when the excitation of the solenoid 51 is stopped, the shut-off valve is closed by virtue of the pushing action of a spring 56 activated when the attracting action of the solenoid 51 disappears. Reference numeral 57 denotes a port opened in the solenoid holder 52 .
An operation of the first shut-off valve 50 will be described referring to FIG. 4 B. Reference numeral 58 also denotes a stop plug, which is shown as being in an open state. This plug can also be turned with the hexagon wrench to close an upper opening 41 b.
FIGS. 4A and 4B show operations of the check valve and the first shut-off valve according to the present invention.
In FIG. 4A, when compressed natural gas under high pressure is supplied as shown by a while arrow, the valve element 43 is moved to a valve opening side by virtue of the pressure of the gas. As a result of this, the compressed natural gas reaches the CNG tank 12 as indicated by an arrow {circle around ( 1 )} via the throttle portion 48 . When the supply of the compressed natural gas is stopped, the valve element 43 is returned by virtue of the action of the spring 45 , whereby a reverse flow is prevented.
In FIG. 4B, when the solenoid 51 is excited, the valve element 55 is withdrawn to thereby produce a valve opened state, whereby the compressed natural gas stored in the CNG tank 12 flows as indicated by an arrow {circle around ( 2 )} through the port 57 . When the excitation of the solenoid 51 is stopped, the shut-off valve is closed by virtue of the action of the spring 56 .
Returning to FIG. 3, a gap 59 is provided between the solenoid holder 52 and the rod 53 so that the rod 53 can move relative to the solenoid holder 52 . If this gap 59 is too large, the rod 53 is allowed to swing in radial directions, and therefore, the gap 59 must be kept as small as possible. If natural gas is dried imperfectly, it eventually contains water, or, as shown in FIG. 4A, when compressed natural gas is filled in the CNG tank 12 , there is a risk of water contained in nearby air entering into the CNG tank 12 .
With the water present:, the water may penetrate into the gap 59 and produce foreign matters thereat, slowing the movement of the rod 53 .
To cope with this, the present invention provides a technology that can cope with the slowed movement of the shut-off valve 50 resulting from a reason as described above. The technology will be described later.
FIG. 5 is an enlarged sectional view of a portion indicated by a circle denoted by reference numeral V in FIG. 2 . An operation thereof will be described later referring to FIG. 7, and therefore, the construction thereof will briefly be described here.
The pressure control unit 60 is an integrated body comprising the second shut-off valve 65 , a primary pressure reducing valve 70 , a safety valve 77 and a secondary pressure reducing valve 80 . Although a detailed description of the construction thereof will be omitted, the second shut-off valve 65 is a solenoid controlled shut-off valve using a solenoid 66 as a driving source, and the primary pressure reducing valve 70 is a pressure regulator comprising a diaphragm 71 , pressure regulating spring 72 , a back pressure chamber 73 , a back pressure inlet port 74 and a pressure regulating screw 75 . The safety valve 77 is a valve comprising a valve element 78 and a spring 79 , and the secondary pressure reducing valve 80 is a pressure regulator comprising a diaphragm 81 , a pressure regulating spring 82 , a back pressure chamber 83 , a back pressure inlet port 84 and a pressure regulating screw 85 .
FIG. 6 is a bottom view of the pressure control unit shown in FIG. 5 . The compressed natural gas entering into the pressure control unit 60 as indicated by an arrow {circle around ( 3 )} flows as indicated by an arrow {circle around ( 4 )} via an inner filter 86 and the second shut-off valve 65 . Returning to FIG. 5, the flow indicated by the arrow {circle around ( 4 )} passes through the primary pressure reducing valve 70 , flows upwardly as indicated by an arrow {circle around ( 5 )} and reaches the secondary pressure reducing valve 80 .
FIG. 7 is a diagram showing the operational principle of the pressure control unit adopted in the present invention. The primary pressure reducing valve 70 is intended to reduce the pressure P 0 to the pressure P 1 . To be specific, the pressure P 0 acts on an upper surface of the diaphragm 71 as viewed in the drawing, and the pressure P 1 and a pushing force of the spring 72 act on a lower surface of the diaphragm 71 as viewed in the drawing. When the opening degree of the valve is determined by a balance of three forces acting on the diaphragm, the natural gas is allowed to flow. If the pressure P 1 is increased higher than a set pressure therefor, the pressure inside the back pressure chamber 73 is increased to thereby push up the diaphragm 71 , whereby the valve is throttled. As a result of this, the pressure P 1 is reduced. In the event that the pressure P 1 is lower than the set pressure, on the contrary, the opening degree of the valve is increased, and the pressure P 1 is increased. Thus, the primary pressure reducing valve 70 can maintain the pressure P 1 at the predetermined set pressure.
In this embodiment, the pressure P 0 ranges 10 to 260 kg/cm 2 , and the pressure P 1 is 6 kg/cm 2 . Even if the pressure P 0 is remarkably changed, the pressure P 1 can be maintained so as to provide a constant pressure.
The secondary pressure reducing valve 80 is intended to reduce the pressure P 1 to the pressure P 2 , and a basic operation thereof is the same as that of the primary pressure reducing valve 70 , and therefore, a description thereof will be omitted. The pressure P 1 is 6 kg/cm 2 and the pressure P 2 is 2.6 kg/cm 2 . It is needless to say that the pressure P 2 can be maintained at the predetermined set pressure even if the pressure P 1 fluctuates. The pressure P 2 is detected by the second pressure sensor 33 .
The pressure values described above are illustrated as examples only, and the present invention is not limited to those numerical values.
When the solenoid 66 is excited, the second shut-off valve 65 is opened so as to allow the natural gas to flow as indicated by an arrow {circle around ( 6 )}, and when the excitation of the solenoid 66 is stopped, the shut-off valve is closed by virtue of the action of the spring 67 .
The safety valve 77 is provided so as to cope with a remarkable increase in the pressure P 1 that would be caused by a trouble taking place in the primary pressure reducing valve 70 and is constructed so as to be opened when such a remarkable increase actually occurs to: thereby protect the low pressure piping 14 including the secondary pressure reducing valve 80 .
Next, described below will be a technology for judging of a failure of the shut-off valves used in the aforesaid fuel gas supply system according to the present invention.
FIG. 8 is a fuel gas supply system drawing for use in explaining a failure judgement technology according to the present invention and is a combination of the main part extracted from FIG. 2 and a starter switch 90 additionally shown therein in order to suffice a control flow that will be described below. The starter switch 90 comprises ACC-OFF contact 91 , ACC-ON contact 92 , IG-ON contact 93 and ST-ON contact 94 . With ACC-OFF contact 91 being selected, an accessory OFF state is produced, with ACC-ON contact 92 selected, an accessory ON state is produced, with IG-ON contact 93 selected, an ignition ON state is produced, and with ST-ON contact 94 selected, the rotation of a starter is initiated.
The other reference numerals have been described and therefore they will not be described here in order to avoid a repeated description thereof. However, as described referring to FIG. 3, there is a possibility that there is caused a trouble with the first shut-off valve 50 in which the shut-off valve is left “opened” and cannot be closed due to rust generated by water contained in methane gas or entering thereinto during the production process. A means for judging of the trouble will be described below.
FIG. 9 is a flowchart (part 1 ) for detecting a failure of the first shut-off valve, and in the flowchart, STXX denotes a step number.
ST 01 : first, it is judged whether or not the engine is in a cranking state, that is, whether or not the crank shaft of the engine is in a rotating state occurring before a complete explosion is caused to take place in the cylinders by an engine starter. To be specific, the number of rotations of the crank shaft is measured by a crank shaft rotation sensor (not shown), and in the event that the number of rotations so measured falls within a range which is greater than zero (0) and is smaller than 500 rpm (rotations/minute), then the answer is YES, and the flowchart jumps to ST 07 .
ST 02 : If NO in ST 01 , a complete explosion signal or a signal indicating whether or not a complete cylinder combustion is occurring is investigated. Specifically, the complete explosion signal is judged as YES if the number of rotations of the crank shaft exceeds a predetermined number of rotations (for instance, 500 rpm).
ST 03 : If the complete explosion signal indicates NO in ST 02 , this means that the engine has not yet been started, and therefore, whether or not the engine starter switch is positioned in the accessory ON state is checked. If No, in other words, if the starter switch is not in the accessory ON state, this means that the engine is not in a started state, and therefore the flowchart ends, and no further failure diagnosis is carried out.
ST 04 : In the event that the starter switch is confirmed to be in the accessory ON state in ST 03 , the control system is put in a stand-by state. To be specific, in FIG. 8, power is supplied to the control section 36 and the injector driver 35 from the power supply so as to activate the first and second pressure sensors 31 , 33 and the first and second temperature sensors 32 , 34 , and a diagnostic timer, not shown, is started.
ST 05 : A fuel meter is put in a display state,
ST 06 : The solenoids of the first shut-off valve 50 and the second shut-off valve 65 shown in FIG. 8 are excited so as to open the valves. This produces a state in which a fuel gas can be supplied from the compressed gas cylinder to the engine.
ST 07 : Check whether or not a complete explosion signal has been detected. If NO, wait until the signal can be detected. If YES, advance to (A).
ST 08 : If the complete explosion signal is detected in ST 02 and the vehicle is cruising, the answer is YES, and then jump directly to (A) bypassing ST 02 to ST 07 .
FIG. 10 is a flowchart (part 2 ) for detecting a failure of the first shut-off valve according to the present invention, which follows (A) in the previous flowchart. As a matter of convenience, the step number starts from ST 11 .
ST 11 : Here, the fuel meter is updated before a failure diagnosis is carried out. This is because the display of the meter is not updated when the valve is judged as being in a failure state while the meter display is updated when the valve is judged as not being in a failure state.
ST 12 : Pressure information is taken in from the first pressure sensor and stored. This pressure information is an initial value of the pressure P 0 and is called a pressure P 0 (1).
ST 13 : The excitation of the solenoid of the first shut-off valve is stopped so as to close the same. The second shut-off valve is left opened (refer to ST 06 ).
ST 14 : The diagnostic timer is reset so as to make tf=0.
ST 15 : The pressure P 0 then is sampled by taking in pressure information from the first pressure sensor.
ST 16 : The sampling of the pressure P 0 is continued until the integrated time tf of the diagnostic timer equals to or exceeds a predetermined judging time t 0 (an elapsed time required for judgement). Every time the sampling is repeated, the pressure P 0 becomes a new value. If tf≧t 0 is satisfied, then advance forward. How to determine the judging time t 0 will be described later on.
ST 17 : The pressure P 0 is taken in, and the pressure so taken in is regarded as a new value, this being called a pressure P 0 (2).
ST 18 : If P 0 (1)−P 0 (2) equals to or greater than a predetermined pressure difference ΔP, then advance directly to (B), and on the contrary, if it is smaller than ΔP, then advance to ST 19 .
ST 19 : Impart 1 to flag FL as a failure detection identification.
ST 11 to ST 19 described above is a failure diagnosis mode, and a diagnosis operation will be described in detail referring to FIG. 12 .
FIG. 11 is a flowchart (part 3 ) for detecting a failure of the first shut-off valve according to the present invention. The flowchart should follow (B) in the previous flowchart, but as a matter of convenience, the step number starts from ST 21 .
ST 21 : Check whether or not the flag indicates “1” which designates a failure, and if it does not so indicate, then advance directly to END, and on the contrary, if it does, move to the following step.
ST 22 : Since the valve is judged as in a failure state, the fuel meter is not updated. This is because the meter display is updated when the valve is judged as not being in a failure state, while the display of the meter is not updated when the valve is judged as being in a failure state.
ST 23 : A failure of the first shut-off valve is displayed in a warning display section (announcement panel or instrument panel) by means of a lamp or the like.
When the warning is displayed, the driver drives the vehicle to a garage for repair to eliminate the failure so warned of without any delay.
In the above embodiment, the pressure sensor information is directly read in for failure diagnosis, but a pressure value may be used for failure diagnosis that is corrected based on a reference value by respective pressure sensor information and temperature sensor information.
FIG. 12 is a time chart showing a failure diagnosis of the shut-off valves according to the present invention.
In (a) of FIG. 12, assume that a failure diagnostic signal is inputted. It is desirable that this signal is generated in the control section in step (A) in FIG. 10 .
This input of the signal initiates the failure diagnosis mode, and as shown in (b) of FIG. 12, after the diagnostic timer is reset, the counting is started (refer to the aforesaid ST 14 ), and simultaneously with this, as shown in (d) of FIG. 12, the first shut-off valve is switched from “open” to “close” (refer to the aforesaid ST 13 ). As shown in (c) of FIG. 12, the second shut-off valve is left opened.
In FIG. 8, when the first shut-off valve 50 is closed with the second shut-off valve being left opened while the engine is running, since the supply of the compressed natural gas from the CNG tank 12 to the high pressure piping 13 is stopped, only the compressed natural gas remaining in the high pressure piping 13 and the low pressure piping 14 is allowed to flow to the intake port 26 , and as a result of this, it is supposed that the pressure inside the high pressure piping 13 is greatly reduced.
However, when the first shut-off valve 50 fails so as not to be closed, being left opened, the CNG tank 12 continues to supply the compressed natural gas to the high pressure piping 13 , and therefore, the pressure inside the high pressure piping 13 is not reduced or reduced slowly. This will be explained by referring to a graph shown.
As shown in (e) of FIG. 12, assuming that time is expressed by the axis of abscissas and pressure by the axis of ordinates, in a normal state, as shown in a thick solid line, the pressure P 0 (2) is greatly reduced after an elapse of time t 0 . On the other hand, with the first shut-off valve being not completely closed, as shown in a broken line, there is caused only a slight pressure drop.
Then, experiments are repeatedly carried out on the degree of pressure drop using an actual engine and a fuel gas supply system, so that ΔP as a threshold value and time t 0 required for a diagnosis are determined, and those so determined are then stored. This procedure is substantially identical to a procedure in which a “pressure drop rate threshold value” is determined from the ΔP and time t 0 for storage in the control section.
A diagnosis is carried out using this pressure drop rate threshold value as a reference. To be concrete, it is determined that if the pressure drop amount after the elapse of time to is equal to or greater than ΔP, it is to be regarded as normal, while it is smaller than ΔP, then it is to be regarded as a failure.
FIG. 13 is a time chart showing a diagnosis of the shut-off valves according to another embodiment of the present invention.
(a), (c) and (d) of FIG. 13 are identical to those described in FIG. 12, and therefore a description thereof will be omitted here.
In (b) of FIG. 13, time t 0 , is obtained that is required until the initial pressure P 0 (1) is reduced by ΔP.
In (e) of FIG. 13, pressure is expressed by the axis of abscissas and time by the axis of ordinates, and a thick solid line indicates that the time is short that is required until the pressure is reduced by ΔP. Since the short time indicates a drastic pressure drop, it is regarded as normal. On the contrary, as shown in a broken line, if a long time is required until the pressure is reduced by ΔP, this means that the pressure drop is slow, and therefore it is regarded as a failure. Consequently, time t 1 and a certain ΔP are predetermined as a threshold value and stored in the control section. This procedure is substantially identical to a procedure in which a “pressure drop rate threshold value” is determined from the ΔP and time t 1 for storage in the control section.
A diagnosis is carried out using this pressure drop rate threshold value as a reference.
A control flowchart corresponding to (a) to (e) of FIG. 13 will be omitted.
In FIG. 12, the pressure drop is investigated with the time being predetermined, while in FIG. 13, the time is investigated with the pressure being predetermined. In either way, the “pressure drop rate” can be obtained which corresponds to what is obtained by dividing the pressure drop amount by the time.
The first shut-off valve 50 shown in FIG. 8 is opened and/or closed based on a command from the control section 36 . Therefore, if the present invention is applied to that construction, the first shut-off valve 50 is closed by a command from the control section 36 so as to exhibit a shut-off function, whereby it is possible to judge whether or not the shut-off valve is in a failure state while the vehicle is being stopped or driven.
In addition, in the embodiments of the present invention, since no diagnosis is designed to be carried out when the vehicle is not cruising, it is possible to avoid a diagnosis in an unstable condition, whereby the reduction in reliability in judgement can be prevented.
The shut-off valve and the pressure sensor may be the second shut-off valve and the second pressure sensor. In other words, since the present invention is constructed so as to function through a combination of a shut-off valve and a pressure sensor disposed downstream (or on the secondary side) thereof, it is possible to diagnose the first shut-off valve and the second shut-off valve in an alternate fashion. However, it is necessary that pressure drop threshold values are set separately for the respective valves.
In addition, as described in the embodiments, the present invention becomes more advantageous when it is applied to the first shut-off valve closer to the CNG tank. This is because since the first shut-off valve is disposed closer to the CNG tank than the second shut-off valve, the first shut-off valve is considered to be more badly affected by water penetrating into the CNG tank than the second shut-off valve.
Furthermore, the fuel gas may be of any kind of fuel gas including compressed natural gas, hydrogen gas and coal gas, and therefore there is no limitation to the kind thereof.
Constructed as described above, the present invention exhibits the following advantages.
According to the invention, the shut-off valve used in the fuel gas supply system can be diagnosed with respect to a failure in which the shut-off valve is left open and cannot be closed while the vehicle is being stopped or driven. From this diagnosis, it is possible to further diagnose that the shut-off valve operates properly at suitable timings, whereby a trouble can be prevented that is entailed by a failure of the shut-off valve.
While only certain embodiments of the invention have been specifically described herein, it will apparent that numerous modification may be made thereto without departing from the spirit and scope of the invention.
The present disclosure relates to the subject matter contained in Japanese patent application No. Hei. 11-76257 field on Mar. 19, 1999 which is expressly incorporated herein by reference in its entirety.
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A vehicle fuel gas supply system includes, a fuel line supplying a fuel gas to a gas engine, a shut-off valve and a pressure sensor disposed on said fuel line, and a control section. The pressure sensor is disposed closer to the gas engine in comparison with the shut-off valve. The control section closes the shut-off valve based on a failure diagnostic signal, calculates a pressure drop rate based on pressure information taken in from the pressure sensor after the closure of the shut-off valve and an elapsed time, and judges that the shut-off valve is in a failure state when the pressure drop rate so calculated is smaller than a predetermined pressure drop rate threshold value.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application Ser. No. 60/613,925 filed on Sep. 28, 2004, which has the same title as the present application. It is also closely related to the U.S. application entitled “Advanced Friction Stir Welding Tools”, application Ser. No. 11/100,878 Filed on Apr. 7, 2005 and the application entitled “Fracture Resistant Friction Stir Welding Tools”, application Ser. No. 11/133,083 filed on May 19, 2005. The teachings of these applications are incorporated herein by reference thereto. These applications have the same inventors and the same assignee as the present application.
FIELD OF THE INVENTION
The present invention relates to friction stir welding and, more particularly, the present invention relates to simultaneous friction stir welding of a plurality of parallel joints between components having parallel portions.
BACKGROUND OF THE INVENTION
The Friction Stir Welding (FSW) process is a solid-state based joining process, which makes it possible to weld a wide variety of materials alloys (Aluminum, Copper, Stainless Steel, etc.) to themselves and combinations (e.g. 6xxx/5xxx, 2xxx/7xxx, etc.). The joining is affected by a rotating FSW tool, which is forced into the joining area to heat it by friction and thus “plasticizes” the parts about it. Plasticized material flows around the axis of the rotating FSW tool, and the plasticized regions coalesce into sound metallurgical bonds. The process can be implemented with conventional FSW tools each consisting of a single pin and shoulder that requires backup with an anvil during welding. FIG. 1 illustrates a prior art friction stir welding tool 10 having a shank 18 that may be held in a chuck or collet of an FSW machine. Shank 18 may have a flat 19 to facilitate the application of torque to FSW tool 10 .
FSW tool 10 also includes a pin 12 and shoulder 14 having a workpiece engaging surface 16 . Pin 12 may include a thread 13 and flats 15 . FSW tool 10 is rotated in the direction which causes thread 13 on pin 12 to push plasticized material toward the tip of pin 12 . Workpiece engaging surface 16 of shoulder 14 may include a spiral thread 17 . The pitch of spiral thread 17 is such that it tends to move plasticized material inwardly, toward the base of pin 12 , when FSW tool 10 is rotated in the direction which tends to push plasticized material toward the tip of pin 12 .
FIG. 2 illustrates two plates 111 being butt welded to each other by FSW tool 10 . A backup anvil 11 on the back side of plates 111 is necessary to counteract the forging force exerted by the FSW tool onto the plasticized joint and prevent escape of plasticized material, and produce a smooth surface on the back side. Hence, FSW tools similar to FSW tool 10 have the limitation that they cannot be employed for welds for which it is not possible to access the back side of the components being welded.
In order to weld components wherein it is not possible to access the back side of the weld to place a backup anvil, bobbin-type tools may be employed. Such tools include two shoulders and a pin between them. The concept for such tools was patented by Kevin Colligan on 2003 Dec. 30, U.S. Pat. No. 6,660,075 ( FIG. 3 ). The bobbin-type FSW tool 20 illustrated in FIG. 3 includes a FSW pin 21 and a pair of shoulders 22 , shoulders 22 including workpiece engaging surfaces 23 . Since the shoulders 22 have the taper angle 24 , they can be integral with pin 21 . In order to impart the forging force to weld workpieces 111 having some tolerance in thickness, the workpiece engaging surfaces 23 are tapered away from workpieces 111 at the taper angle 24 shown in FIG. 3 .
Not only does the taper angle 24 enable workpieces having somewhat variable thicknesses to be welded, it also ensures that the necessary forging force is applied to the plasticized region whereby plasticized material is confined to the weld region, and smooth surfaces are produced on the upper and lower surfaces of the weld. The teachings of U.S. Pat. No. 6,660,075 are included herein by reference thereto.
A more complete drawing of a bobbin-type FSW tool is given in FIG. 4 . Bobbin-type FSW tool 30 includes a shank 36 and an FSW pin 39 . Pin 39 includes a proximal pin portion 31 on the proximal side of the center 38 of pin 39 , and a distal pin portion 37 on the distal side of the center 38 of pin 39 . Proximal pin portion 31 and distal pin portion 37 have opposite pitch, and FSW tool 30 is rotated in the direction which tends to cause plasticized material to flow towards the center 38 of pin 39 .
FSW tool 30 also includes a proximal shoulder 32 having workpiece engaging surface 33 and distal shoulder 34 having workpiece engaging surface 35 . Again, the workpiece engaging surfaces 33 and 35 are tapered to tolerate variations in workpiece thickness and to apply the required forging force to the plasticized material. The bobbin-type FSW tool 30 is described in the copending patent application entitled “Advanced Friction Stir Welding Tools”, application Ser. No. 11/100,878 Filed on Apr. 7, 2005.
FSW tool 30 includes a tension member 27 , which is placed in tension by nut 28 acting through spring washer 29 . The purpose of tension member 27 is to place pin 39 in compression to prevent fracture of pin 39 due to the combination of severe cyclic torsion and bending moments it experiences during friction stir welding.
FIG. 5 illustrates the bobbin type FSW tool 30 in position for welding joint 113 , which is one of a pair of joints 113 and 114 needed to produce a rectangular tube from a pair of elongate members, each elongate member having a cross-section shaped like a square bracket, each elongate member corresponding to one half of the cross-section of the rectangular tube. It is noted that bobbin tools of the type taught by Mr. Colligan are capable of welding only one joint at a time.
FIG. 6 illustrates a prior art FSW tool 50 having superior mechanical properties. It includes an integral shank-pin ensemble with a shoulder 54 threaded onto the shank-pin ensemble. FSW tool 50 , preferably, has a close fit 57 between the shank 53 and the inside of the shoulder 54 . It also has a close fit 58 between the pin 52 and the inside of shoulder 54 near the base of pin 52 , and it has a firm stop 59 between the inside of shoulder 54 and the shank 53 . FSW tool 50 is presented in the copending patent application: “Advanced Friction Stir Welding Tools”, application Ser. No. 11/100,878 Filed on Apr. 7, 2005.
That application also advances the concept of including an internal tension member to provide compression loading of the pin of a bobbin type FSW tool. FIG. 7 provides preferred internal detail regarding the prior art bobbin-type FSW tool. Preferably, FSW tool 30 includes a snug fit 42 at the proximal end of proximal shoulder 32 , snug fit 41 at the distal end of proximal shoulder 32 , and firm stop 42 . Likewise, FSW tool 30 includes snug fit 44 at the proximal end of distal shoulder 34 , and the firm stop 45 . Both shoulder 32 and shoulder 34 may be assembled by threading them on from the distal end of FSW tool 30 .
While the FSW tools described above have a number of desirable features, each is capable of welding only one joint at a time. A need remains for a FSW tool which can make a plurality of welds such as joint 113 and 114 shown in FIG. 5 .
SUMMARY OF THE INVENTION
In one aspect, the present invention is a friction stir welding tool for simultaneously making a plurality of parallel welds. The friction stir welding tool includes a plurality of friction stir welding modules, each of the friction stir welding modules including at least one friction stir welding pin, and a pair of workpiece engaging surfaces facing the at least one friction stir welding pin. Each of the workpiece engaging surfaces is disposed on a shoulder attached to or integral with the at least one friction stir welding pin, whereby the shoulders and pin(s) rotate in unison. The friction stir welding modules are connected to each other or integrally formed whereby the modules rotate in unison. At least one shank is attached to or integral with at least one of the friction stir welding modules, whereby the shank and the modules rotate in unison. The at least one shank is for engagement with a chuck or collet of a friction stir welding machine to be rotated thereby.
In another aspect, the present invention is a method of making a plurality of parallel friction stir welds simultaneously to join a pair of workpieces. The method comprises placing the workpieces in juxtaposition, moving the workpieces through a FSW machine, the FSW machine having a FSW tool having a plurality of welding modules, whereby the plurality of FSW welds are produced by the FSW tool.
In another aspect, the present invention is a weldment comprising two or more parallel friction stir welds made in a single pass.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sketch of a prior art friction stir welding tool;
FIG. 2 is a schematic illustration of a prior art friction stir welding tool with a backup anvil;
FIG. 3 is a drawing from an issued United States patent for a bobbin type friction stir welding tool;
FIG. 4 is an illustration of a prior art bobbin type friction stir welding tool including a tension member for placing the pin in compression;
FIG. 5 is an illustraton of a prior art bobbin type friction stir welding tool readied for welding one of a pair of parallel joints;
FIG. 6 is an illustration of a prior art bobbin type friction stir welding tool readied for welding one of a pair of parallel joints;
FIG. 7 is a sectional drawing of a bobbin type friction stir welding tool having an integral pin-shank and a pair of shoulders that self lock to the pin-shank and also having an internal tension member which places the pin in compression;
FIG. 8 is a sketch of a multi-shouldered fixed bobbin type friction stir welding tool for welding two parallel joints simultaneously;
FIG. 9 is a sketch of a multi-shouldered bobbin type friction stir welding tool, according to the present invention, for simultaneously welding three parallel joints;
FIG. 10 is a detail of the multi-shouldered bobbin type friction stir welding tool illustrated in FIG. 9 ;
FIG. 11 is an illustration, partly in section, of the multi-shouldered bobbin type friction stir welding tool illustrated in FIG. 9 , the shoulders being sectioned to show the self-locking feature;
FIG. 12 is a sketch of a FSW tool according to the present invention readied for simultaneous welding of two parallel joints;
FIG. 13 is a sketch of a FSW tool according to the present invention readied for simultaneous welding of three parallel joints;
FIG. 14 is an illustration of a system for simultaneous welding of extrusions with multiple parallel walls using a multi-shouldered fixed bobbin tool according to the present invention;
FIG. 15 is a detail showing the extrusions shown in FIG. 14 being welded;
FIG. 16 is a sketch of a mechanical arm having two parallel welds made by the FSW tool of the present invention;
FIG. 17 is a sketch of an angled mechanical link having two parallel welds made by the FSW tool of the present invention;
FIG. 18 is an illustration of a coaxial structure having multiple pairs of parallel welds made by the FSW tool of the present invention;
FIG. 19 is an illustration of a double walled structure made by the FSW tool of the present invention;
FIG. 20 is an illustration of a multi-width double walled panel made by the FSW tool of the present invention;
FIG. 21 illustrates optional torque communication features on adjacent pins;
FIG. 22 illustrates a threaded tension member which is an optional aspect of the present invention; and
FIG. 23 illustrates a portion of an alternative multi-shouldered fixed bobbin tool having an integral shank-pin ensemble wherein the shoulders are threaded onto the shank-pin ensemble from the shank sides.
FIG. 24 is a median section of a multi-shouldered fixed bobbin tool that is integrally formed.
NOMENCLATURE
10 Prior art FSW tool
11 Backup anvil
12 Pin
13 Threads on pin 12
14 Shoulder
15 Flat on Pin
16 Workpiece engaging surface of shoulder
17 Spiral thread on shoulder
18 shank
19 Flat on shank
20 Prior art Fixed bobbin tool
21 Pin of tool 20
22 Shoulder of tool 20
23 Workpiece engaging surface of shoulder 22
24 Taper angle of workpiece engaging surface 23
27 Tension member
28 Nut
29 Spring washer
30 Prior art bobbin tool
31 Proximal pin portion
32 Proximal shoulder
33 Workpiece engaging surface of shoulder 32
34 Distal shoulder
35 Workpiece engaging surface of shoulder 34
36 Shank of FSW tool 30
37 Distal pin portion
38 Center of pin 39
39 Pin
41 Snug fit of proximal shoulder near working face thereof
42 Snug fit of proximal shoulder
43 Firm stop of proximal shoulder
44 Snug fit of distal shoulder
45 Firm stop on distal shoulder
50 Prior art FSW tool having integral pin and shank
52 Pin
53 Shank
54 Shoulder
55 Workpiece engaging surface of shoulder
56 Threaded interface between shank and shoulder
57 Proximal close fit
58 Distal close fit
59 Firm stop
60 FSW tool for simultaneously welding two joints
61 Tension member
62 Nut
63 Spring washer
66 Long shank
67 Right handed shoulder
68 Left handed shoulder
69 Spacer washer
70 Multi-shouldered fixed bobbin tool for FSW 3 points
71 L.H. Pin portion
72 Abutting ends of pins
73 R.H. Pin portion
75 Long shank
76 Tension member
77 Nut
78 Compression washer
82 L.H. Shank
83 Spacer washer
84 R.H. shank
85 Snug fit at proximal end of L.H. shoulder
86 Snug fit at distal end of L.H. shoulder
87 Firm stop on L.H. shoulder
88 Snug fit at distal end of R.H. shoulder
89 Snug fit at proximal end of R.H. shoulder
90 Firm stop on R.H. shoulder
111 Plate being welded
112 C-shaped extrusion
113 Lower joint to be welded
114 Upper joint to be welded
122 E-shaped extrusion
123 Upper joint to be welded
124 Center joint to be welded
125 Lower joint to be welded
130 Machine for welding extrusions
132 Loading conveyor
134 Unloading conveyor
136 FSW motor
138 Upper FSW chuck or collet
140 Lower FSW chuck or collet
142 Grippers
144 Belt
150 Mechanical link arm made by present invention
152 Upper weld
154 Lower weld
156 Angle link arm
157 Upper weld
158 Lower weld
160 Cylindrical structure
162 Weld in cylindrical structure
170 U-shaped member
172 Weld in U-shaped member
180 Deck plate
182 Weld in deck plate
192 Tension member
194 Upper pin
195 Non axisymmetric end of pin 194
196 Lower pin
197 Mating non axisymmetric end of pin 196
202 Threaded tension member
204 Upper pin having internal threads
205 Planar end of pin 204
206 Lower pin having internal threads
207 Planar end of pin 206
210 Bobbin type FSW tool with shoulders which thread on from shank
212 Shank
214 First shoulder
215 Firm stop on first shoulder
216 First pin
217 Proximal portion of pin 216
218 Distal portion of pin 216
219 Second shoulder
222 Third shoulder
224 Firm stop on third shoulder
226 Spacer washer
228 Second pin
230 Integral multi shouldered fixed bobbin type FSW tool
232 Shank
234 Upper shoulder
236 Working face of shoulder
238 Upper pin portion
240 Lower pin portion
242 Working face of shoulder
244 Center shoulder
246 Lower shoulder
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The present invention teaches the concept of multi-shouldered fixed bobbin tools that afford simultaneous friction stir welding of multiple parallel walls between parts. The term “wall” here can mean a sheet, a plate, a flange or web, a planar portion of an extrusion or rolled product, or a planar portion of a casting, etc.
In the discussion which follows, directional terms such as “top”, “bottom”, “upper”, “lower”, etc are for reference only. The tools described are for use in any orientation.
FIG. 8 illustrates a multi-shouldered fixed bobbin tool 60 , according to the present invention. Bobbin tool 60 is for making two parallel welds simultaneously.
The inventors have realized that in order to FS weld with a multi-shouldered fixed Bobbin tool:
a) Multiple parallel walls (e.g. 2–4), b) Relatively thick walls (2.5 cm), and c) Tough/strong alloys (e.g. 7085), the tool must be extra strong to resist the severe bending and twisting at its pins during welding. Fortuitously this realization coincided with a recent invention for Advanced Friction Welding Tools”, which was cited above in the Cross Reference to Related Applications.
In order to impart to the proposed multi-shouldered Bobbin tool the required strength to resist the intense cyclic bending and twisting during welding of multiple parallel walls, the present invention advances the concept of combining the use of compression loading of the pins, between the shoulders, with the aid of an internal tension member and also the concept of an integral pin/shank ensemble with a self-locking shoulder threaded onto the pin/shank ensemble.
In regard to the Presently preferred embodiments:
a) Each tool will include a threaded tension member ( FIG. 8 ), which runs along the entire length of the tool (i.e. through all pins and shoulders).
b) The proposed tools will be assembled by threading opposing pairs of pin/shanks, with their respective self-locking shoulders already threaded on, and firmly “lightening” them against each other at their abutting noses, to the required level (torque and/or required elongation of the tension member). This will put the opposing pins into compression and the internal threaded rod into tension. During FSW the internal tension member will be “protected” (or “shielded”) from excessive flexing by the compressing pins, the near-perfect forced abutment between the noses of the pins and/or use of torque-sharing locks between the abutting noses of the pins ( FIG. 21 ). Torque can also be shared through roughening of the pins' noses and/or other transitional locking parts placed between the noses of the pins. The compression applied to the pins by the tension member makes it possible to employ ceramics or hard, brittle alloys.
c) Once the required number of pin/shanks, with their respective self-locking shoulders have been threaded onto the tension member and tightened against each other, compression will be applied to the pins by tightening one or two tension nuts at the end(s) of the internal tension member ( FIG. 8 ). d) Because each pair of opposing pins represents a discrete welding area of two abutting or overlapping walls, the total number (e.g. 2–4) of parallel walls to be welded between parts would be accommodated by varying the number of pin-pairs and their corresponding number of shoulders. e) By varying the length of the pins of each pair, a bobbin tool according to the present invention can be adjusted for welding parallel walls with different thickness. f) If the distances between different parallel walls (three or more) are not the same, with the proposed multi-shouldered FSW tool these distances are accommodated by adding or removing spacer-washers.
The FSW tool 60 illustrated in FIG. 8 is for producing a pair of parallel welds, for example, one weld between the upper pair of plates 112 and one weld between the lower pair of plates 112 . FSW tool 60 includes a long shank 66 which may be held in a chuck or collet of a friction stir welding machine. FSW tool 60 includes two each of shoulders 67 and 68 and two each of pin portions 71 and 73 .
In the following discussion, it is presumed that FSW tool 60 is to be rotated clockwise, as seen from the lower end of long shank 66 . In that case, both shoulders 67 are right handed shoulders, that is to say, have clockwise internal threads so that friction with workpieces 112 forces the right handed shoulders 67 into firm engagement with the shank-pin ensembles to which they are attached. For example, the lower right hand shoulder 67 is attached to a shank-pin assembly including long shank 66 and the lowest pin 71 . The upper right hand shoulder 67 is attached to a shank pin assembly which includes pin portion 71 .
Similarly, both of the shoulders 68 are left handed shoulders, that is to say, they have counterclockwise internal threads so that friction with workpieces 112 forces the left handed shoulders 68 into firm engagement with the shank-pin ensembles to which they are attached. These shank-pin ensembles include the pin portions 73 .
The threads on pin portions 71 are left handed threads, so that plasticized material is urged toward the juncture of pin portion 71 and pin portion 73 when FSW tool 60 is rotated in a clockwise direction as seen from long shank 66 . Likewise, the threads on pin portions 73 are right handed threads so that plasticized material is urged toward the juncture of pin portion 71 and pin portion 73 when FSW tool 60 is so rotated.
An optional spacer washer 69 may be employed to accommodate variable separation between the workpieces 112 . The shoulders 67 and 68 , the pin portions 73 and 73 , and spacer washer 69 are held in compression by tension member 61 , which, preferably has threaded ends and is placed in tension by nut 62 acting through a spring washer 63 . Spring washer 63 may, for example only, be a Belleville© washer.
FIGS. 9 , 10 and 11 show a FSW tool 70 which is for making three welds simultaneously. FSW tool 70 includes a long shank 66 which, preferably, is integral with the lowest pin 71 . FSW tool 70 is made to be rotated clockwise, as seen from long shank 66 . Preferably, each of the three welding units includes a right handed shoulder 67 , a left handed shoulder 68 , a left handed pin portion 71 and a right handed pin portion 73 .
FIGS. 10 and 11 show detail of the abutting pin portions 71 and 73 , which meet at abutting junction 72 . The purpose of having the abutting junction 72 rather than making the pin portions 71 and 73 integrally is so that the shoulders 67 and 68 can be assembled by passing them over the pin portions 71 and 73 , respectively. Preferably, the right handed shoulder 67 shown in FIGS. 10 and 11 is assembled to the shank-pin ensemble comprising pin 71 and right handed shank 84 , prior to the final assembly of FSW tool 70 . Likewise, the left handed shoulder 68 is assembled to the shank-pin ensemble comprising the long shank 75 and pin 73 shown in FIGS. 10 and 11 , prior to the final assembly of FSW tool 70 . The thread on pin 71 is left handed and the thread on pin 73 is right handed to cause plasticized material to move toward abutting junction 72 when FSW tool 70 is rotated in a clockwise direction, as seen from the long shank 66 seen in FIG. 9 .
Each of the shoulders 67 and 68 are assembled to their respective shank-pin ensembles, before the final assembly of FSW tool 70 . FIG. 10 shows a pair of spacer washers 83 which may be placed between the left handed shank 82 and right handed shank 84 . Final assembly of FSW tool 70 is accomplished by placing all the components, including the shoulders, each assembled to its corresponding shank-pin ensemble, and any spacer washers required onto the tension member 76 , attaching nuts 77 and spring washers 78 , and then tightening nuts 77 to provide the appropriate tension on tension member 76 , and thus the corresponding compression on pin portions 71 and 73 . To ensure torque transmission between shanks 82 and 84 the 83 washers may be designed to lock into each other and to the two shanks.
Preferably, FSW tool 70 is rotated synchronously at both ends, by rotating long shanks 66 and 75 . Two electric motors, which are connected electrically, may be employed for this purpose, or one electric motor attached to a chuck or collet for one of the long shanks, and gearing to drive a chuck or collet for the other long shank may be employed.
FIG. 12 illustrates FSW tool 60 , which was shown in FIG. 8 , positioned to weld joints 113 and 114 between two extrusions 112 . Likewise, FIG. 13 illustrates FSW tool 70 , which was illustrated in FIGS. 9 , 10 and 11 , being employed to simultaneously weld joints 123 , 124 and 125 between two extrusions 122 .
FIG. 14 illustrates a production FSW machine 130 for making a plurality of welds simultaneously, in this case, three welds. FIG. 15 shows a section cut along the axis of FSW tool 70 , which is included in FSW machine 130 . FIG. 14 illustrates a loading conveyor 132 and an unloading conveyor 134 . FIG. 14 also shows a motor 136 which is for rotating the chuck or collet 138 shown in FIG. 15 . Preferably the chuck or collet 140 at the lower end of FSW tool 70 is also turned by a second motor which has electrical connection to motor 136 , or by shafts and gears driven by motor 136 .
Preferably, the workpieces, as for example, the extrusions 122 , are held and moved by grippers 142 attached to moving belt 144 . A person skilled in the art will recognize that the motive power for belt 144 must be carefully controlled to obtain a preferred velocity for the welding process, and to prevent breaking of FSW tool 70 .
FIG. 16 is an illustration of a link arm having joints 152 and 154 , which can be produced in a single pass by a FSW tool such as FSW tool 60 , shown in FIG. 8 .
FIG. 17 illustrates an angle link arm having joints 157 and 158 which can likewise be produced in a single pass by a FSW tool such as FSW tool 60 .
FIG. 18 illustrates a cylindrical double-walled vessel having joints 162 , which can be made by repeated passes of a FSW tool such as FSW tool 60 .
FIG. 19 illustrates a double walled structure such as a boat hull, vat, tank, etc, having joints 172 , which can be made by repeated passes of a FSW tool such as FSW tool 60 .
FIG. 20 illustrates a multi-width panel having joints 182 which can be made by FSW tool 60 .
FIGS. 21 and 22 illustrate two approaches to enhancing the ability of adjacent pin portions to communicate the torsion required for friction stir welding. In FIG. 21 , a tension member 192 is employed, which, preferably is not threaded, except at the ends to receive tightening means such as nuts 62 .
In order for pin portions 194 and 196 to communicate torque between them, pin portion 194 has a non-axisymmetric surface 195 , and pin portion 196 has a complimentary non-axisymmetric surface 197 . When tension in tension member 192 forces pin portion 194 tightly against pin portion 196 , torsion may be communicated between non-axisymmetric surface 195 and non-axisymmetric surface 197 . In the configuration shown in FIG. 22 , the tension member 202 is threaded, and inside threads are formed in pin portion 204 and 206 . The threads on tension member 202 and the inside threads on pin portion 204 and 206 are employed to force the end 205 of pin portion 204 against the end 207 of pin portion 206 , so that torsion can be communicated between pin portion 204 and pin portion 206 .
FIG. 23 illustrates an alternative embodiment of the present invention. FSW tool 210 includes a pin 216 having pin portions 217 and 218 . Pin portions 217 and 218 are integrally formed. There is no abutting junction such as abutting junction 72 between pin portions 71 and 73 shown in FIG. 10 . Accordingly, shoulders 214 and 219 are threaded on from the shank sides, not from the side of the pin portions.
Shoulder 214 is threaded on over shank 212 and threaded on until firm stop 215 is encountered. Likewise, shoulder 219 is threaded on from below until firm stop 220 is encountered. Likewise, shoulder 222 , lying below spacer washer 226 is threaded on until firm stop 224 is encountered. Pin 228 , like pin 216 , is integrally formed and lacks an abutting junction such as abutting junction 72 .
FIG. 24 illustrates an embodiment of the present invention which is integrally formed. FSW tool 230 is for making two FSW welds simultaneously. FSW tool 230 includes upper and lower shanks 232 to be held in chucks or collets of a FSW machine. Upper shoulder has working face 236 which is adjacent upper pin portion 238 . Lower pin portion 240 is adjacent working face 242 of shoulder 244 . Shoulder 244 also has a lower working face 236 . Below the lower working face 236 of shoulder 244 is an upper pin portion 238 , which lies above a lower pin portion 240 . Lower shoulder 246 has a working face 242 adjacent lower pin portion 240 .
Pin portions 238 and 240 , preferably, have opposed threads so that when FSW tool 230 is rotated in an appropriate direction, pin portions 238 and 240 urge material toward the centers of the plates being welded. Likewise when tool 230 is rotated in that direction, threads on working faces 236 and 242 urge material inwardly toward the pin portions 238 and 240 , respectively.
Although presently preferred and various alternative embodiments of the present invention have been described in considerable detail above with particular reference to the figures, it should be understood that various additional modifications and/or adaptations of the present invention can be made or envisioned by those persons skilled in the relevant art without departing from either the spirit of the instant invention or the scope of the appended claims.
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A tool for making simultaneously a plurality of parallel friction stir welds includes at least one shank for holding in a chuck or collet of a friction stir welding machine, a plurality of friction stir welding pins, and friction stir welding shoulders including at least four working surfaces adjacent said pins, the shoulders and pins mounted in axial relationship; dimensions of said friction stir welding pins and shanks corresponding to dimensions and spacings of said friction stir welds.
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FIELD OF THE INVENTION
This invention relates to drilling devices and processes. More specifically, the invention is concerned with the control of fluid pressure within a wellbore while drilling.
BACKGROUND OF THE INVENTION
When rotary drilling an underground wellbore from the surface, a drilling fluid in the wellbore is typically used to prevent wellbore wall caving and prevent the intrusion of formation fluid, such as unwanted oil, gas, and water. Another important function of the drilling fluid (typically a "drilling mud" mixture) is to entrain drilled cuttings and circulate them to the surface and out of the borehole. The drilling fluid typically also cools and lubricates the moving drill string components and strikes the drilling face of the underground formation with an impact force that may further assist in drilling.
Although density, viscosity, and surface pressures on the drilling fluid are controlled, the density of the drilling fluid is the most important to control in order to provide a hydrostatic pressure in excess of formation pore pressure along the wellbore. This "overbalanced" pressure strengthens the wellbore (helping to avert wall cavings) and prevents a formation fluid influx or "kick" into the wellbore. However, the overbalanced pressure also strengthens the formation face being drilled similar to the strengthening of the walls of the drilled well. This now "harder" drilling face drills at a lower rate of penetration, increasing drilling time and cost.
Reducing the normally overbalanced pressure to minimize rotary drilling cost increases the risk of wellbore caving damage and well control problems. Thus, a drilling operator has to consider the conflicting fluid pressure needs of maintaining the integrity of the bore and economically drilling the formation face.
SUMMARY OF THE INVENTION
Such conflicting pressure needs are avoided in the present invention by controlling and isolating the pressure at the drill face from the pressure in the rest of the wellbore. This is accomplished by adding a jet pump to the drilling tool and a flow restricting housing to form an underbalanced pressure cavity at the drilling face. A first portion of the pressurized drilling fluid is introduced into the cavity and circulates to entrain cuttings at underbalanced pressure. The drilling fluid also serves as the power fluid of the jet pump which pressurizes the underbalance-pressure fluid and entrained cuttings back to the surface at overbalanced pressures. At the surface, the cuttings are separated (by conventional equipment such as shale shakers) and the drilling fluid is pressurized (typically by mud pumps) to be recycled back as the power fluid. The recycled drilling fluid can be introduced into the underbalanced pressure cavity formed by the housing as a plurality of streams for improved circulation, cooling, and lubrication.
One embodiment includes a cutting separator located in the jet pump housing near the jet pump diffuser outlet. A portion of the overbalanced-pressure fluid mixture continues to entrain the cuttings while a remaining portion (substantially free of cuttings) is diverted to the drilling face (and/or drill bit) within the cavity.
The invention uses the inherent fluid restriction of the drilling tool (including drill bit and shoe) combined with a housing which contains a jet pump. The housing and drilling tool restriction combined with the jet pump produce different (overbalanced and underbalanced) pressures above and below the drilling tool. The jet pump must not only handle the injected streams, but also fluid leakage past the around the drilling tool and any formation fluids produced across the drilling face. In addition to restricting or channeling flow, the shoe or outside lip of the drilling tool tends to support the wellbore at the overbalanced/underbalanced pressure transition zone.
The preferred process for drilling an underground borehole from a surface places the housed drilling tool and jet pump at or near the formation face to be drilled. Power fluid actuates the jet pump to maintain an underbalanced drilling fluid pressure while the drill bit is rotating and cutting into the formation face. The power fluid driven jet pump draws in the underbalanced-pressure drilling fluid and entrained cuttings mixture and discharges a majority of the mixture upwards towards the surface. A portion of the pump actuating fluid is diverted to supply drilling fluids to the rotary drill as jets to assist drilling and entrain cuttings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a schematic cross-section of a rotary drilling tool and a jet pump housing;
FIG. 2 shows sectional with 1--1, as shown in FIG. 1;
FIG. 3 shows sectional view 2--2 as shown in FIG. 1;
FIG. 4 shows alternative drill bit as viewed as a sectional from line 2--2, as shown in FIG. 1;
FIG. 5 shows an alternative jet pump embodiment; and
FIG. 6 shows a process flow schematic.
In these Figures, it is to be understood that like reference numerals refer to like elements or features.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a schematic cross-section of a bottom hole assembly or rotary drilling tool 2 embodiment of the invention in an underground wellbore 8. A housing 3 partially covers a rotary drill bit 4 and a cavity 12 which nearly encloses a jet pump jacket 5. The housing 3 extends from a drill pipe connection 6 to a shoe or outer lip 7. The drill pipe connector 6 is typically threadably connected to a drill pipe or other fluid conductor extending up to-the surface (not shown). The outer diameter of the shoe 7 is typically proximate to or substantially in contact with wellbore 8 when drilling. The housing 3 (and reinforcing ring 18) supports the drill bit 4 and jet pump jacket 5 within the drilling tool 2, and forms an inverted cup-like enclosure of the drilling face 9.
The formation at the drilling face 9 is typically cut into by forcing (typically by a weight on bit) the drill bit against the drilling face 9 and rotating the attached drill pipe from the surface. The drill pipe rotation rotates the drilling tool 2 through attached connector 6 and housing 3. Alternatively, the rotation of the drilling tool 2 can be accomplished by means of a downhole mud motor. The rotation of the drill bit 4 (supported by substrate 18a) within the housing 3 (and reinforced by ring 18) cuts into or abrades the underground formation at drilling face 9. Cuttings, as illustrated by one particle 10 shown in FIG. 1 near the drilling face, are generated by the rotating drill bit 4 and must be carried out of the wellbore to the surface if the drilling is to continue.
Drilling fluid is supplied from nozzles 11 in the jet pump jacket 5 (fluid flow is shown in FIG. 1 by arrows) to the drill bit 4 and drilling face 9. The drilling jets of fluid emanating from the nozzles 11 can be directed to lubricate and cool the drill bit 4 as well as provide sufficient flow to the drilling face 9 to entrain cuttings 10. Although the number of nozzles 11 is theoretically infinitely variable, for a nominal "shoe" and housing outside diameter of 81/2 inches (21.59 cm), the number of nozzles 11 is expected to range from no less than about 1 to no more than about 27, more typically ranging from about 3 to 5. Typical nozzle 11 shape is essentially a constant diameter hole or orifice, but contracting and/or expanding nozzle shapes (from a minimum throat dimension) are also possible. Typical orifice or minimum nozzle diameters for a nominal housing outside diameter of 81/2 inches (21.59 cm) having 3 nozzles 11 in jet pump jacket 5 may range from as small as about 1/32 inch (0.0794 cm) to as large as about 1/2 inch (1.27 cm), but diameters are more typically expected to range from about 1/16 to 3/16 inch (0.159 to 0.476 cm).
Each nozzle 11 is sized to produce a drilling jet in the fluid-filled cavity 12 which will impact a target. The target may be a portion of the drill bit 4 (e.g., for cooling and/or lubrication) or a portion of the drilling face 9, e.g., directed between drill bit elements (as shown in FIGS. 2 and 3) to entrain cuttings. If the target is a portion of the drill bit, the nozzle stream may also be required to carry past the drill bit 4 and onto the drilling face 9 to serve multiple purposes.
The number and size of nozzles 11, when combined with the pressure performance of the jet pump within jacket 5 and other sources of fluid into the cavity 12, produce a sufficient number of jet streams to create a flow of drilling fluid to entrain drilling cuttings 10. This flowrate is expected to be comparable to the circulation rate for comparable drilling tool diameters less an amount similar to the leakage flow (around the outside diameter) and formation fluid influx (at the drilling face).
The total fluid flow through nozzles 11, plus any influx of formation fluids at drilling face 9, cuttings, and leakage of fluid between the housing 3 and wellbore 8, forms a post-drilling fluid stream (at underbalanced pressure) which is drawn to suction ports 13 of the jet pump. The underbalanced-pressure stream flow is shown by generally upward pointing arrows in cavity 12 until suction ports 13 are reached. The nozzles 11 must also be sized to produce drilling jets which will overcome the underbalanced-pressure stream flow and reach the targets of the drilling jets.
The underbalanced-pressure stream must have a sufficient flowrate and velocity to entrain cuttings 10 and lift them to a suction port 13. For a nominal 81/2 inch (21.59 cm) outside diameter drill tool, upward fluid velocity in the cavity 12 is expected to range from about 80 to 300 feet/sec (24.38 to 91.44 meters/sec), preferably no less than about 120 feet/sec (36.58 meters/sec).
The desired (underbalanced) pressure in cavity 12 and at the drilling face 9 is a function of the formation pore pressure at the drilling face. The underbalanced pressure in cavity 12 depends upon several other factors, including jet pump performance, power fluid pressure in drill pipe connector 6, and the cutting speed (i.e., the volume of cuttings 10 generated). Cutting speed and source fluid pressure are typically controlled by a drilling operator to attain the desired underbalanced pressure.
The underbalanced pressure in cavity 12 allows drilling to proceed economically. Pressure near the drilling face 9 is generally expected to be at least about 30 psi (2.0 atmospheres) less than the formation pore pressure at drilling face 9, more typically ranging from 100 to 1000 psi (6.8 to 68 atmospheres) less than the formation pore pressure at drilling face 9. At times, the average pressure in cavity 12 may be more than formation pore pressure (e.g., during transients or drilling into highly fractured formations), but an underbalanced pressure is expected to assist in economic rotary drilling most formations and therefore be underbalanced most of the time during drilling.
Once the upward flowing underbalanced-pressure stream (with entrained cuttings) in cavity 12 reaches the suction throats of ports 13 within housing 3, the stream is induced into the jet pump jacket 5. The energy to increase the pressure of the underbalance pressure stream is supplied by a power fluid flowing from the surface through the drill pipe and drill pipe connector 6 to jet pump nozzle 14. The jet pump nozzle 14 size and power fluid flowrate and pressure are selected to produce a high speed, venturi-like low pressure zone extending across the suction ports 13. This low pressure zone induces and accelerates the flow of underbalanced fluid and cuttings along with the high speed power fluid from jet pump nozzle 14 prior to entry into the diffuser section 15 housed in jacket 5.
Although a single jet pump nozzle 14 is shown directed into the diffuser cavity 15, a plurality of jet pump nozzles 14 may be also used. Some of the nozzles may be used to help divert or otherwise protect the diffuser throat from the erosive effects of the accelerated cuttings. The diffuser throat may also be composed of hard or hardened materials, such as tungsten carbide, to further resist erosion.
The high speed mixed power fluid and induced flows (including cuttings) enter a diffuser cavity 15 to convert the kinetic energy into increase pressure. The downwardly enlarging cross-sectional area of the diffuser cavity 15 slows the mixed power fluid speed and induced (fluid and cuttings) flows and increases the pressure (to an overbalanced pressure). This increased or overbalance pressure in diffuser cavity 15 is again controlled by the drilling operator primarily by the selection of power fluid pressure and flows at the surface. Although the overbalanced pressure can theoretically vary over a much wider range, the overbalanced pressure in diffuser cavity 15 is typically at least 100 psi (6.8 atmospheres) above formation pore pressure at drilling face 9, more typically ranging from about 200 to 500 psi (13.6 to 34.0 atmospheres) above formation pore pressure at drilling face 9.
After slowing in the diffuser cavity 15, the overbalanced pressure fluid then encounters a partial cuttings separator 16. In this embodiment, the separator 16 is a fixed, helically-shaped baffle swirling the mixed fluid and cuttings stream around the centerline of the drilling tool 2. The density differences between the swirling cuttings 10 and the swirling mixed fluids in separator 16 force the normally heavier cuttings outward towards discharge ports 17 along with a portion of the fluid flow. However, a portion of the (lighter-than-drill-cuttings) fluid stream separates from the entrained cuttings (nearer the centerline of the diffuser) to become the source for the drilling jet streams from nozzles 11.
The overbalanced-pressure, entrained mixture discharged from discharge ports 17 then flows up the wellbore 8 in the annulus between the walls of the wellbore 8 and the drill pipe towards the surface (not shown), as shown by generally upward pointing arrows proximate to the walls of wellbore 8. The overbalanced pressure in the wellbore 8 substantially prevents the influx of formation fluids into the wellbore (except proximate to the drilling face) as the fluid rises to the surface. For a typical discharge stream in the wellbore 8, a minimum fluid velocity of 80 ft/sec (24.38 meters/sec) is expected, preferably at least 120 ft/sec (36.58 meters/sec).
At the surface, the mixed discharge stream is recycled. The entrained cuttings in the mixed stream are substantially fully separated by conventional means, such as cyclones, shakers, screens, and/or a setting basin (not shown). The cuttings-removed stream is then recycled by treating as necessary, pressurizing the stream in a conventional mud pump at the surface (not shown), and returning the pressurized stream downhole through the drill pipe as the power fluid supplied to the drill pipe connector 6. Treating can include further fluid monitoring and processing at the surface, such as monitoring density and adding muds to compensate for any influx of unwanted formation fluids.
The power fluid is expected to be a drilling mud entrained in water or other fluids, similar to other drilling fluids since the power fluid must also function as a drilling fluid as well as the means for operating the jet pump. This added jet pump requirement can require slightly different properties than that required for a drilling fluid only application. For example, the power fluid viscosity is expected to be slightly less than a similar drilling-fluid-only application.
Other possible uses for the power fluid/drilling fluid mixture emanating as a drilling jet stream from nozzles 11 include cooling and lubricating the drill bit 4. Drill bit 4 is shown schematically in FIGS. 1 and 3 as a segmented face type, e.g, diamonds or other hard inserts embedded in a segmented substrate. These types of drill bits are expected to require minimal lubrication and cooling other than that supplied by leakage around the shoe and formation fluids influx at the drilling face 9. But other types of drill bits can also be used which may require greater attention to separate jet streams for cooling and/or lubrication. This includes conventional cone-type rolling cutter bits which may require greater lubrication, but less cooling. (See FIG. 4.)
In addition to any cooling and lubrication provided by the drilling jet streams from nozzles 11 shown in FIG. 1, entrainment, lubrication and cooling flows to the drill bit 4 (and formation face 9) may also be provided by a conduit or passageway from the drill pipe connector 6 through housing 3 to near the drill bit 4 (shown dotted as an option for clarity). A separate fluid source instead of the power fluid may also be provided, such as lubricating fluid string. The conduits or passageways would transmit the power (or other) fluid to the drill bit, such as a roller axis, or impinge the drilling face 9. The separate conduit could further supplement or replace the cooling and lubrication provided by the drilling jet streams from nozzles 11. If the conduit replaces the nozzles 11, the separator 16 could be eliminated.
Instead of leakage, channels in the outside diameter of the shoe of housing 3 (not shown) are another alternative that can provide additional or bypass flows of entrainment, lubrication, and/or cooling fluids to near the drill bit 4. Increased amounts of fluid would flow through the channels from the overbalanced pressure wellbore 8 to the underbalanced pressure cavity. Although cuttings and sediment may tend to accumulate at this lowest point of the overbalanced-pressure wellbore cavity, the rotation of the housing 3 and the continuous jet pump suction is expected to keep these channels free flowing.
FIG. 2 is the sectioned view 1--1, as shown on FIG. 1. Eight drill stream nozzles 11 around a central nozzle 11 are shown in diffuser jacket 5, but other nozzle numbers and geometries are possible.
The preferred drilling jet stream nozzles 11 not only direct the jet streams downward and outward (as shown in FIG. 1), but circumferentially as shown by the arrows in FIG. 2 emanating from the nozzles 11. This circumferential component of the jet stream directs the drilling jet streams onto the side of a segment of drill bit 4 and (from there) onto the drill face 9 (also see FIGS. 1 and 3). Other configurations can have some of the drilling jet streams from nozzles 11 directed between the drill bit segments (see FIG. 3) to directly impinge the drill face (see FIG. 1).
In addition to providing discharge conduits through the cavity 12 to the outer annulus 8a between the upper portion of the housing 3 and the wellbore 8 (see FIG. 1), the discharge ports 17 shown on FIG. 2 further serve to laterally support and stabilize the jet pump jacket 5 with respect to the drill tool housing 3. If additional lateral and/or axial support of the jacket 5 is needed, jacket-to-housing struts (not shown) or added discharge ports 17 approximately 90 degrees from those shown may be provided.
FIG. 3 is the sectioned view 2--2, as shown on FIG. 1. Eight radial or spoke-like drill bit segments 19 (only one identified for clarity) of drill bit 4 are spaced around the cutting face enclosed by housing 3. In addition to the structural rigidity provided by housing 3 and the radially oriented substrates 18a (see FIG. 1) which form the drill bit segments 19 shown in FIG. 3, the inner ring 18 reinforces the drill bit segments 19 and provides additional strength. Depending upon contact and pressures between the lip 7 of housing 3 (see FIG. 1), the reinforced housing also stress relieves the formation just above the drilling face.
The inner ring 18 may also tend to segregate drilling fluid circulation patterns as shown by the arcuate arrow near the drilling face 9 as shown on FIG. 1. The segregated circulation patterns can prevent hot spots and/or areas where cuttings are not fully entrained.
Within the spoke-like drill bit segments 19 in FIG. 3 are channel spaces 20 for fluid flow. The channels 20 (in the substrate 18a as shown in FIG. 1) shown in FIG. 3 are provided between hardened cutting faces 21 to allow cuttings and fluid flow across a drill bit segment 19 as well as around it. Cutting faces 21 are shown embedded in the substrate 18a or otherwise fixed in position relative to the housing 3, but cutting faces 21 may also be rotatable around an axis parallel or nearly parallel to the length of the drill bit segment 19 they are mounted on.
FIG. 4 shows an alternative roller drill bit 22 as it would be viewed at Section 2--2, as shown in FIG. 1, similar to the view of drill bit 4 shown in FIG. 3. Each of the three roller cones 23 shown in FIG. 4 has alternative hardened cutting protrusions 24 (identified only on one roller cone for clarity) embedded in a roller cone substrate.
The roller cones 23 rotate around individual centerline axis (only one shown for clarity) which is typically doubly offset. It is offset slightly from the (housing) radial direction and slightly out a plane parallel to section 2--2, (as shown in FIG. 1). The slight centerline offsets produce a scraping action as the roller cones 23 rotate as the entire roller drill bit 22 rotates, facilitating the cutting action. The roller cones 23 can be freely rotating as shown, geared to rotate together, driven to rotate (for example by a mud motor), or assisted in rotating by an offset impingement of a drilling jet stream.
Drilling jet streams from nozzles 11 (see FIGS. 1 and 2) could directly or offset impinge on the roller cones 23 shown in FIG. 4, but could also be directed towards the drilling face 9 (see FIG. 1) between the roller cones in spaces 25. The drilling fluid mixture and entrained cuttings would return through the spaces 25 to a cavity similar to cavity 12 shown in FIG. 1 and be drawn into a jet pump as previously discussed.
FIG. 5 is a cross-sectional schematic of an alternative and preferred embodiment which deletes the need for the partial downhole separator 16 (shown in FIG. 1). A power fluid (typically pressurized using a surface mounted pump in conjunction with the hydraulic head developed at the underground location), similar to that previously discussed, is conducted down an alternative drill pipe or other conduit connector 6a. Portions of the power fluid (shown as arrows) exit as alternative drilling jet streams through alternative drilling jet nozzles 11a and the remainder serves as to actuate the alternative jet pumps 5a. The drilling fluid and entrained cuttings in alternative cavity 12a (with flow shown as arrows) are drawn into alternative suction ports (similar to ports 13 shown in FIG. 1) to be increased to overbalanced pressure and directed back towards the surface through the annulus proximate to the wellbore 8. It will be understood by those skilled in the art that still other alternative suction ports locations and drilling jet nozzle configurations and orientations can be made, e.g., when improved erosion resistance or proximity of the suction ports to the drilling face is required.
The alternative discharge parts 17a are shown arched to discharge in a slightly upward direction toward the surface proximate to where they are attached to the alternative housing 3a, but many other directions are also possible. The arced embodiment tends to throw cutting to the outside surface of the arc, allowing takeoff (not shown) of relatively cuttings-free fluids from the inside surface of the arc, if required. Alternative discharge ports 17a may be nearly straight and oriented in a nearly vertical direction (discharging fluid near the top of the alternative housing 3a) or further curved to form a nearly 90 degree turn from a nearly horizontal orientation near the alternative suction ports (similar to ports 13 shown in FIG. 1) to discharge into annulus 8a near the alternative housing 3a. Still further, the structure forming the alternative discharge ports 17a can also be part of the drill bit substrate 18a, supporting the combined functions of the jet pumping and rotary drilling.
FIG. 6 shows a process flow schematic. A recycled source of fluid at the surface (from pump V) supplies power fluid source I, along with additives, makeup fluids, data, and controls as required. Controls may be operated manually by a drilling rig operator or may be computer controlled by a programmable controller to which data signals, such as rotational speed, are transmitted. The power fluid source I is typically mounted at the surface near the wellbore being drilled.
The pressurized (and controlled flowrate of) power fluid is transmitted downhole, typically via rotating drill pipe, to a jet pump II, such as that shown in FIG. 1. The jet pump II creates a suction which draws in drilling fluids and entrained cuttings from the drilling face.
The mixture of power fluid, drilling fluid, and entrained cuttings is discharged to a partial separator III in the preferred embodiment. The partial separator III concentrates the cuttings in a first portion of the power fluid and drilling fluid mixture, which is directed back up towards the surface to a surface separator IV. The remaining second portion can form a primary source of the drilling fluid, which is throttled to a lower pressure, sprayed towards the formation face being drilled, and drawn back into the jet pump II (possibly along with formation fluids and leakage and/or channeled bypass flows as previously discussed).
The surface separator IV removes most of the cuttings, along with some (excess) fluids, producing a fluid relatively free of large cut particles. The fluid is then directed to a pump V where it is recycled back to the power fluid source I for treatment and/or controls. Alternatively, the locations of pump V and power fluid source I can be interchanged.
The process of using the alternative embodiment shown in FIG. 5 is the same as shown in FIG. 6 except the first and second portions are produced at the jet pump II intake, shown as a dotted line. This allows the elimination or bypassing of the partial separator III.
Still other alternative embodiments are possible. These include: a variable throat jet pump nozzle 14, e.g., a moveable conical plug place at the throat of the jet pump nozzle; a variable diffuser throat, e.g. a moveable throat to allow for erosion; a plurality of jet pumps, at least one of which does not supply drilling jet nozzles and at least one which does; and inverting the orientation of the jet pump within the jacket 5, placing the suction ports 13 closer to the drilling face 9.
While the preferred embodiment of the invention has been shown and described, and some alternative embodiments also shown and/or described, changes and modifications may be made thereto without departing from the invention. Accordingly, it is intended to embrace within the invention all such changes, modifications and alternative embodiments as fall within the spirit and scope of the appended claims.
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A method for rotary drilling and removing cuttings provides a underbalanced drilling fluid pressure at the drilling face but overbalanced pressure in the wellbore. The preferred method uses a rotary drill within a housing which also encloses a jet pump which draws and pressurizes the cuttings and drilling fluid, a separator of the cuttings and a portion of the pressurized drilling fluid, and a nozzles to supply separated and reduced pressure drilling fluid back to drilling face while the cuttings and remaining pressurized drilling fluid flows up towards the surface. The method avoids overpressure strengthening of the drill face and underpressure damage to the wellbore.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention refers to a method for determining the three-dimensional surface of an object and a relevant computer program.
2. Description of Related Art
For describing and analysing the geometry of objects that have to be produced, modelling methods that use computers are known. In particular, when a three-dimensional surface enclosed by a set of points acquired from a real object has to be obtained, a technique called level-set that describes an enclosed surface as a level surface of a volumetric function (or implicit function) is normally used.
The level-set technique provides for the time evolution of the volumetric function, according to a suitable equation of the partial derivatives, typically belonging to the Hamilton—Jacobi family of equations.
The volumetric function describes the distance of each point from the enclosed surface and this distance will have positive or negative sign according to the point considered whether it is inside or outside the surface. Thus the set of points that possess a null distance from the surface S represent the surface itself. The technique provides for the evolution of the enclosed surface, defined by the Hamilton—Jacobi equation so that it surrounds and adheres to the cloud of 3D points that describes the object.
This technique is used as it is capable of adapting to the various types of objects and to the most diverse point acquisition techniques. This technique in fact, does not require any additional information about the topology of the points acquired and is insensitive to the technique used: the density of the points can vary in the different zones of the object considered; no information is required about the point acquisition sequence or about their relative spatial positions; and the number of objects enclosed separated from each other is not relevant for the algorithm.
As this technique requires the updating of a volumetric function at each step of evolution of the front, the calculation cost is usually very high, so much so that it makes the method of very little practical utility. Methods are known that permit the reduction of the calculation cost of this technique, for example limiting the updating of the volumetric function in an enclosed zone surrounding the front in evolution. Despite this the calculation cost remains prohibitive.
Alternative techniques to the level-set technique are also known. For example, methods such as those of the Delaunay triangulation are known, as well as the NURBS (Non Uniform Rational B-Splines) and the HRBF (Hierarchical Radial Basis Function). Each of these methods has limitations and imposes a series of restrictions on the set of the points acquired, such as for example the calculation complexity depends heavily on the number of points, or they need to have a spatial distribution of the points acquired as uniform as possible.
BRIEF SUMMARY OF THE INVENTION
In view of the state of the technique described, an object of the present invention is to provide for a rapid method for determining the three-dimensional surface of an object that does not have the inconveniences of the known art.
In a first aspect, the present invention relates to a method for determining the three-dimensional surface of an object comprising the phases of: defining the coordinates of a plurality of points of said object; defining a three-dimensional matrix of cells that contains said object to which a value can be associated; determining the distance between each centre of said cells of said three-dimensional matrix of cells and the closest point of said plurality of points of said object; setting the value of several cells of said three-dimensional matrix of cells at a first preset value; determining the value that each cell of said three-dimensional matrix of cells assumes, with the exception of said several cells, by means of the following formula
F
(
x
_
i
,
t
+
1
)
=
F
(
x
_
i
,
t
)
·
v
i
+
w
·
∑
j
F
(
x
_
j
,
t
)
·
v
j
v
i
+
w
·
∑
j
v
j
where
x i represents the coordinates of the centre of the i_th cell,
F( x i ,t) represents the value of the i_th cell at time t,
v i represents said distance,
w represents a second preset value, and
j indicates a neighbourhood of cells of the i_th cell;
determining the module sum of the variations of the value of each cell between the time t and the time t+1; and repeating said phase of determining the value that each cell of said three-dimensional matrix of cells assumes if said sum is higher than a third preset value.
In its second aspect, the present invention relates to a computer program comprising a program code that carries out all the phases of the method for determining the three-dimensional surface of an object when said program is carried out on said computer.
In its third aspect, the present invention relates to a computer program stored in a memory that can be used by a computer to control the execution of all the phases of the method for determining the three-dimensional surface of an object.
In the present invention, by replacing the differential equation of the partial derivatives normally used in literature (Hamilton-Jacobi) with one that is very well suited to describing discontinuous functions such as those that describe the interface between two immiscible fluids, that is one of the Navier-Stokes equations, derived from the fluid dynamics, the calculation cost is considerably reduced, and a much quicker convergence can be obtained. The surface can be interpreted as the front between two viscous fluids that moves until it completely encloses the object. In particular, acting on the viscosity value of the fluids used it is also possible to control the level of roughness permitting smooth surfaces to be obtained even if the points presented deviations from their correct spatial position. In addition, the method proposed permits the introduction of elements and strategies that enable an end control of the evolution of the front, based on simple principles which are interpretable physically. For example, an artificial turbulence can be introduced in the fluids that facilitates penetration inside particularly narrow cavities. Thus it is possible to provide a correct determination even of configurations of points that traditionally had been negated. Thanks to its flexibility, the Navier-Stokes equation can be used for determining more volumetric functions that describe different parts of the object considered. Objects that are particularly complex or that have high resolutions can thus be represented by calculating separately the evolution of the volumetric function on the different parts that make them up. The individual results obtained are then recomposed to obtain the overall volumetric function using a simple mathematic operator.
BRIEF DESCRIPTION OF THE DRAWINGS
The characteristics and advantages of the present invention will appear evident from the following detailed description of an embodiment thereof, illustrated as non-limiting example in the enclosed drawing, in which FIG. 1 shows a flow diagram of the method for determining the three-dimensional surface of an object.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is based on the Navier—Stokes differential equation for the conservation of mass in which a redefinition of the velocity vector is used according to a criterion described hereunder. It describes the motion of two immiscible fluids that converge, one from inside and the other from outside, towards the cloud of points that describes the object considered. At the end of the evolution, when both the fluids adhere to the points of the object, the surface of separation between the two coincides with the surface of the object itself.
The volumetric function describes the contents of the two fluids in each elementary cell or voxel, where voxel means the elementary element of the volumetric grid, such as how the pixel is used for a two-dimensional grid. To distinguish the two fluids we have assigned opposite sign mass to them. Therefore a cell in which the volumetric function is worth −1 contains exclusively the internal fluid, while a value of +1 indicates that only external fluid is present.
If between two adjacent cells the volumetric function changes sign it implies that the surface of separation passes between them and thus also the surface of the object. The exact point of passage is determined by means of interpolation operations.
The exact position of the contact surface between the two fluids is thus identified by the position of the level-set zero (that is the set of points with null distance from the surface).
The law for the conservation of mass is one of the fundamental principles of classical physics and it is independent from the nature of the fluids and from the forces that act on it; it expresses the principle according to which in a fluid dynamic system mass cannot disappear or be created unless sinks or sources are present.
The value F of the volumetric function in each cell indicates the quantity of fluid inside it and this value is modified by the forces acting on the fluid, by its velocity, by the diffusion coming from the adjacent cells and from the sources or sinks.
The evolution of a fluid inside a system can be described by means the flow vector G that expresses the quantity of fluid that crosses a surface in a given interval of time.
In its classic formulation the law of conservation for mass affirms that the time variation of the quantity of matter F inside a volume Ω,
∂
∂
t
∫
Ω
F
ⅆ
Ω
is equal to the net contribution of the flow that crosses the external surface S of Ω, to the contribution Q V of sources (or sinks) inside the volume, and to the contribution of sources Q S oriented along its surface S. The contributions due to the different sources can thus be written as:
∫
Ω
Q
v
ⅆ
Ω
+
∫
S
Q
_
s
·
ⅆ
S
_
The general formulation for the conservation of mass equation can thus
∂ ∂ t ∫ Ω F ⅆ Ω = - ∫ S G _ · ⅆ S _ + ∫ Ω Q v ⅆ Ω + ∫ S Q _ S ⅆ S _
be written as:
The negative sign in front of the flow integral is due to the fact that the area d S is orientated outwards from Q.
Using the Gauss theorem the previous equation can be rewritten using exclusively volume terms:
∂
F
∂
t
+
∇
_
·
G
_
=
Q
v
+
∇
_
·
Q
_
S
The flow density vector G can be decomposed in a diffusive component G D and in a convective component G C , the convective part of the flow vector describes the transport phenomenon due to the external forces and is defined as the product between the velocity v of the flow and the quantity of matter transported F: therefore it results G C = v F.
The diffusive component instead derives from the remixing, present also in resting fluids, due to thermal agitation, and is usually proportional, according to the law of Fick, to the gradient of F
G D =γ∇F where γ is the diffusivity constant. The time evolution of the volumetric function F due to the diffusivity is regulated (as can be verified forcing the conservation of mass) by the differential heat equation and thus its results are mainly connected to regularizing and a flattening of the function F. The effect of the diffusive contribution is thus taken into consideration applying a Gaussian filtering to the entire volumetric function.
The intensity and the orientation of the velocity v of the fluid is determined in each cell of the matrix. This velocity has been defined orientating the flow towards the point of the 3D cloud (that describes the object) closest to the cell, and the modulus of this vector has been selected directly proportional to the distance: in this manner both the fluids progressively slow down coming closer to the cloud of points and converge at the final surface of contact. The equation that has thus been used to describe the evolution of the two fluids is the following:
∂
F
(
x
_
i
,
t
)
∂
t
=
∫
Ω`
F
(
x
_
,
t
)
v
_
(
x
_
)
·
ⅇ
x
_
-
x
_
l
2
2
σ
2
ⅆ
x
∫
Ω`
v
_
(
x
_
)
·
ⅇ
x
_
-
x
_
l
2
2
σ
2
ⅆ
x
The local variation of the quantity of fluid contained in the i_th cell F( x i ,t) between two successive instants therefore results determined by the convective contribution deriving from each cell F( x i ,t) | v ( x )| weighed with a Gaussian function whose standard deviation σ describes the degree of diffusion of the fluid between the different cells.
The velocity v ( x ) has been defined for each cell according to the distance between the centre of the cell and the closest point belonging to the 3D cloud. In particular the modulus of this velocity equals | x i − p | α where x i is the centre of the i_th cell, while p is the closest point of the cloud of points (the point at least distance from the centre of the i_th cell), α is instead a parameter that regulates the course of the velocity function. Experimentally it has been determined that acceptable values for α are between 1.5 and 2.5. The greater this value is, the slower the velocity will be in proximity to the points while it will be rapid at a great distance. Even though this characteristic is very important for a rapid evolution of the values of the matrix it can however lead to a slow final convergence. A preferred value of the value of α equals 2.0.
Another property of the fluids used in the model is the viscosity, whose value determines the standard deviation σ inside the equation. This property describes the viscous friction that acts inside the fluid limiting its mobility. Considering this property we prevent the fluids from crossing the reconstructed surface and flowing between the interstices of the various points. This property is particularly important as through it special arrangement of points can be correctly met such as fine blades or particularly pointy objects. Thanks to the viscosity, the fluids do not cross the surface which remains adherent to the blade or to the point. It is also possible to reduce the curving of the entire surface obtaining particularly smooth surfaces and reducing the surface roughness that can also have originated from the error in measurement. It must be remembered however that high values can limit the capacity of the algorithm to represent objects with particularly jagged surfaces and to enable the flow of the liquid inside concave zones. Because of the above-mentioned, the viscosity is a parameter whose choice is determined according to the typology of the object considered, by the imprecision of the acquisition system used, and by the degree of definition required for the adhesion of the final surface to the cloud of points.
Another aspect that has been used in the physical modelling of the fluids is turbulence, which treats the presence of whirlpools that describe local variations of the velocity function.
The presence of turbulence can locally develop high pressures and can generate instability in the flow but at the same time can favour the penetration of the fluid inside very small openings and prevent stagnation in zones with modest velocities.
The presence of vortexes is introduced by modulating the field of velocity with small oscillations in the different directions around the initial configuration. Because of the close correlation between the velocity vector in each cell and the vector that points towards the closest point of the 3D cloud, the local oscillations of the velocity field can also be interpreted as an elastic deformation of the cloud of points in the various directions which can facilitate the entrance of the fluid inside the restricted zones.
The modulation of the velocity function is applied cyclically along the three spatial axes by multiplying by a factor the terms v of the velocities of the cells that lie orientated in parallel to these axes in relation to the i_th cell under examination and its intensity can be controlled externally, in particular at each iteration the velocity is amplified in a given direction and/or the velocity in the other two directions is reduced by an equal quantity.
Obviously the greater the expansion coefficients used the greater will be the turbulence. Values that are too high can however determine an excessive remixing between the two fluids on the contact surface causing the leakage of the internal fluid or an excessive penetration of the external fluid in the object considered.
The previous equation that was used to describe the evolution of the two fluids has been discretized to be able to carry out the operations more easily by means of a computer and is described by the following equation.
F
(
x
_
i
,
t
+
1
)
-
F
(
x
_
i
,
t
)
=
F
(
x
_
i
,
t
)
·
v
i
+
w
·
∑
j
F
(
x
_
j
,
t
)
·
v
j
v
i
+
w
·
∑
j
v
j
-
F
(
x
_
i
,
t
)
where
x i represents the spatial coordinates (three-dimensional array) of the
i_th cell,
F( x i ,t) represents the value of the i_th cell at time t, v i represents the velocity (or the distance as previously defined), w represents a preset value of viscosity, and j is a preset value that indicates a neighbourhood of cells of the i_th cell.
In particular, the index summation j considers the contribution of the closest cells to the point under examination. Preferably, this interaction was chosen to be limited exclusively to the first 6 cells near each cell under examination, that is that share with it an entire face of the cubical cell (the cells at distance 1 from the cell under examination).
We now refer to FIG. 1 that shows the flow diagram of the method for determining the three-dimensional surface of an object. This flow diagram describes how a computer program carries out the calculation for determining the three-dimensional surface of an object.
Phase 1—Data Definition.
In this phase the coordinates of a plurality of points of the object that is needed to be represented are defined. The set of the points is described as a set of vectors with 3 components, containing the spatial coordinates of each point. No additional information is requested in relation to the points.
Phase 2—Definition of Cell Matrix.
In this phase the cell matrix (or three-dimensional grid) that defines the evolution domain of the value of F is described. The number of cells is chosen on the basis of the dimensions of the object that is needed to be represented. The number of cells that will be used is determined on the basis of the extensions along the three axes of the object. Thus keeping a cubical form for each elementary cell of the matrix, a grid that contains the object is defined. It is also possible to define a form of the cells that is not cubical, that is a different resolution of the matrix along the different axes can be set. This can be very important for objects in which a high resolution is necessary only in a dimension such as low relief, building faces, etc.
It is also possible to define a rotated matrix in relation to the axes according to which the object has been acquired and, in particular, align it with the main directions of the object itself. Thus it is possible to minimize the number of cells used at the same time keeping the same resolution. A centre with the appropriate coordinates belongs to each cell, and a value can be associated to each cell.
Phase 3—Determining the Velocity.
In this phase the field of the velocities that belong to each cell of the grid is defined. As we saw previously the velocity field depends closely on the distance of each centre of the cells from the closest point of the cloud of points. Thus, the field of the distances is a three-dimensional matrix with the same dimensions as the grid. For each cell the point of the 3D cloud that is the closest (at least distance) is determined and the distance is calculated as | x i − p | α between this point and the centre of the cell. This value is stored in memory in an equivalent cell of the matrix of the distances.
Take note that it is not necessary to know the direction of the velocities but only the modulus.
It is important to note that, the dependence of the calculational complexity of this method on the number of points of the 3D cloud is limited exclusively to the determination of the velocity field, only once at the beginning of the procedure, and all the evolutive phase it is completely independent from the number of sample points used.
Phase 4—Arrangement of the Sources.
Different arrangements of the sources are possible. A first arrangement provides for the external sources to be placed exclusively on the edges of the matrix (a first portion of the cells, which will thus always be kept at the value +1 during the entire evolution) and all the remaining cells instead to be filled with external fluid (value equal to −1). A second arrangement instead provides also for one or more internal sources to be provided, in this case the cells of the edge will always be kept at +1, the value of the internal cells will be equal to 0, while the internal sources will always be kept at −1. This method permits an even more rapid evolution but requires initial information relative to the arrangement of the additional internal sources that is not easily available.
Phase 5—Fixing Viscosity and Turbulence Parameters.
The viscosity (in the discretized formula represented by w) regulates the diffusion of the fluid and thus the weight of the interaction between each single cell and its neighbours. The preferred value of w is between 0.1 and 0.9.
The parameters relating to the turbulence indicate how the velocities of the fluid, in each cell, are altered at each iteration with the purpose of simulating the turbulent effect. In particular it is possible to set for each of the 3 axes the coefficient by which the velocity in this direction will be multiplied cyclically. The multiplicative factors for the velocity vary preferably by a minimum of 0.5 up to a maximum of 1.5. The use of the turbulent regime is optional.
Phase 6—Starting Up the Procedure.
To accelerate the operations, and optionally, provision is made in this field for another three-dimensional matrix with the dimensions of the matrix of the cells in which the information regarding the updating or not of the different cells is contained. If a cell can be updated its contents will be processed by the evolutive algorithm and thus the contents of liquid inside it can vary between two iterations. Cells that cannot be updated are the sources (that are always kept at the same value, +1 or −1). During the evolution also those cells for which the variation of liquid between two iterations has not been relevant (below a certain set threshold) can become non-updateable and thus these cells are frozen until the evolutive front approaches them.
Phase 7—Updating Cells.
It is the main phase of the method in which the value of the quantity of fluid present in each cell of the three-dimensional matrix of cells is determined.
The use of the Gaussian function inside the integral would provide for the analysis at each iteration of the interaction of each cell with all the matrix of the cells, which would result in being particularly cumbersome in computational terms.
In the case with the discretized formula, it is possible and preferable to limit the extension of this interaction exclusively to a neighbourhood of cells closer to the i_th cell, that can be for example 6 or 18 or 26 (the cell considered is at the centre of a matrix 3×3×3), that is those that are respectively in face, edge or vertex contact (that is at distance 1 , √ 2 and √ 3 from the cell under examination, in the case of cubic cells) from the i_th cell. Preferably the 6 closest cells have been chosen, that is the 6 cells that contact the 6 faces of the i_th cell.
Once the cell has been updated, the variation in relation to the previous value is assessed and if this value is lower than a threshold set by the user the contents of the cell are frozen and the cell is declared not updateable.
Phase 8—Visualization
It is possible, if it interests, to visualize the level-set zero, that is the surface of separation between the two fluids. The algorithm used is that commonly known with the name of Marching Cubes (see for example the article “Marching cubes: a high resolution 3D surface construction algorithm”, by William E. Lorensen and Harvey E. Cline, from Computer Graphics, Volume 21, Number 4, July 1987) by means of which it is possible to obtain an effective triangulation of the level-set zero and a sub-pixel resolution thanks to the linear interpolation carried out on adjacent cells. The triangulation thus obtained is represented on video, for example, by means of an interface program called OpenGL that permits visualization in real time and a direct interaction with the user who can interactively change at will the view point analysing the evolution of the level-set in real time.
Phase 9—Determining the flow variations.
At the end of each evolution the overall quantity of fluid that has been moved is assessed.
Phase 10—Evolution cycle.
If the overall quantity of fluid that has been moved is slower than a preset threshold the evolution is interrupted at phase 11 , otherwise it carries out further iteration.
At phase 11 , when the calculation is completed, a three-dimensional matrix of points is obtained that defines the values that each point assumes the volumetric function.
It is possible to apply a low-pass filter to this matrix so as to obtain a smoother reconstructed surface removing possible errors of sampling without acting on the viscosity parameters (that could prejudice the correct determination of concave zones). The implementation of this filter is the same as that to carry out a one- and two-dimensional filtering: the entire volumetric function is conveyed with a three-dimensional matrix containing values of the filter. For example it can be made in low-pass filter using a matrix 3×3×3 in which the central element has the maximum value and the other elements possess a value given by the value of a Gaussian function depending on their distance from the centre of the matrix.
With the present method, in which case it is possible and convenient to decompose a surface of large dimensions in distinct parts, it is possible to calculate the evolution singularly on each part and recompose then the various volumetric functions. In this manner it is also possible to use different resolutions for the different parts, then recomposing them on a single common matrix. It is preferable, in order to improve the link between the different parts, between the different defined zones, that there is overlapping, that is that part of the end points belonging to a zone are also incorporated in the adjacent zone. Once the matrices of the various zones are obtained, they are arranged on a common matrix with resolution equal to the maximum resolution used. In the case the contents of a cell of the final grid are contemporarily described by two volumetric functions (because they overlap) the minimum between all the volumetric functions that describe it is chosen as value for this cell.
The method for determining the three-dimensional surface of an object, herein described, can be transcribed in a program code, in a manner well known to a technician of the sector, that can be stored on any type of memory or support (floppy, CD) and/or can be carried out by a computer.
|
A method for determining the three-dimensional surface of an object comprises the phases of: defining (1) the coordinates of a plurality of points of said object; defining (2) a three-dimensional matrix of cells that contains said object to which a value can be associated; determining (3) the distance between each centre of said cells of said three-dimensional matrix of cells and the closest point of said plurality of points of said object; setting (4) the value of several cells of said three-dimensional matrix of cells at a first preset value; determining (7) the value that each cell of said three-dimensional matrix of cells assumes, with the exception of said several cells, by means of the following formula
F
(
x
_
i
,
t
+
1
)
=
F
(
x
_
i
,
t
)
·
v
i
+
w
·
∑
j
F
(
x
_
j
,
t
)
·
v
j
v
i
+
w
·
∑
j
v
j
where x i represents the coordinates of the centre of the i_th cell,
F( x i , t) represents the value of the i_th cell at time t,
v i represents said distance,
w represents a second preset value, and
j indicates a neighborhood of cells of the i_th cell;
determining (9) the sum in module of the variations of the value of each cell between the time t and the time t+1; repeating (10) said phase of determining the value that each cell of said three-dimensional matrix of cells assumes if said sum is greater than a third preset value.
| 6
|
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to a mask for optical projection systems and to a process for its production.
Optical projection systems are used, for example, in semiconductor fabrication for transferring image structures.
During the projection of image structures standing individually or standing partially individually on the mask, distortion of the image occurs, as compared with compact image structures that are distinguished by the fact that further structures are disposed beside an image structure. The distortion leads to a line width deviation in the separated structure, which can lead to the individually standing image structure not being capable of being projected at the same time as the compact image structure. Furthermore, the depth of focus of the individually standing image structure is very low.
One known solution to the problem consists in changing the mask, in which the line width on the mask is changed in such a way that the optical distortion of the projection is counteracted. This method is also referred to as optical proximity correction. The optical proximity correction has the disadvantage, however, that the layout correction of the mask is very complicated and in each case necessitates preliminary trials, which are included iteratively in the distortion correction of the mask. Furthermore, the method of proximity correction suffers from the drawback that the distortion correction of the masks can be carried out only with finite, incremental steps. However, the decisive drawback consists in the small process window that can be achieved for the individually standing or partially individually standing image structures. The process window is understood here to be a limited field in the two-dimensional space that is covered by the focal axis, that is to say a spatial position of the focal plane and the dose axis. The process window is limited in the direction of the focal axis by the depth of focus and in the direction of the dose axis by the exposure freedom.
One known photomask technique consists in the use of “embedded phase shifters”. These are masks that are specifically used to shift the phase of the light. One example of such a mask is given in U.S. Pat. No. 5,700,606. There, a phase shifting layer is applied to a semitransparent carrier material. An opaque layer is then disposed on the phase shifting layer. The “embedded phase shifter” technique leads to the imaging of undesired structures, which are produced by side bands (side lobes) being avoided.
A further known solution consists in the generation of what are known as sub-resolution structures, which are disposed in the vicinity of the individually standing or partially individually standing image structure. Sub-resolution structures are understood to be structures which, on account of their low geometric extent in at least one spatial dimension, are not transferred into a photosensitive layer. They are also referred to as lithographic dummy structures.
One drawback of the sub-resolution structure consists in the low structure size, which cannot be produced on the mask with the necessary accuracy and reproducibility. Furthermore, at present there are also unsolved problems for these structures in defect inspection and therefore also in defect repair.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide a mask for optical projection systems, and a process for its production which overcome the above-mentioned disadvantages of the prior art devices and methods of this general type, with which a compact image structure can be transferred into a photolithographic recording medium at the same time as an isolated image structure, with the same exposure dose.
With the foregoing and other objects in view there is provided, in accordance with the invention, a mask for an optical projection system. The mask contains a transparent carrier material, an image structure disposed on the carrier material, and a dummy structure disposed on the carrier material. The dummy structure is spaced apart from the image structure and differs from the image structure in terms of transparency and phase rotation.
With respect to the process, the object set is achieved by a process for producing the mask for an optical projection system, with the steps of forming the image structure on the transparent carrier material, and forming the dummy structure on the carrier material. The dummy structure is spaced apart from all the image structures and differing from the image structure in terms of transparency and phase rotation.
The present invention provides for the dummy structure to be spaced apart from all the image structures and to differ from the image structure in terms of transparency and phase rotation. As a result, an enlarged process window for the projection of the image structures is achieved, which has an advantageous effect on the reproducibility and accuracy of the structures to be projected.
One advantageous embodiment of the invention provides for the dummy structure to be semitransparent. The use of a semitransparent and, if necessary, also phase shifting material, which in the most favorable case produces a phase rotation of 360°, makes it possible to apply the dummy structures which, in terms of their geometric dimensions, do not have to be smaller than the image structures to be projected. The semitransparency results in that the dummy structures are not transferred into the photolithographic recording medium. The advantage resides in the fact that only the same conditions are placed on the dummy structures, relating to minimum structure width, reproducibility and lithographic resolution during the production of the mask, as those placed on the actual image structures to be transferred. The semitransparent dummy structures achieve the situation where the process window for the relevant image structures is enlarged, so that the depth of focus of individual image structures is enlarged and the dose fluctuation sensitivity is reduced. The semitransparent dummy structures are therefore not geometrically below the resolution limit but in the sense of the photolithographic sensitivity of the recording medium. The dose that is transmitted through the semitransparent layer, the dose being lower as compared with the transparent carrier material, exposes the recording medium below its tolerance threshold.
A further advantageous embodiment of the invention provides for the smallest lateral extent of the dummy structure to be at least half as large as the smallest lateral extent of the image structure. In this case, the advantage resides in the relatively large dummy structures, which can be formed at the same order of magnitude as the image structures. As a result, the same conditions relating to minimum structure width, reproducibility and lithographic resolution during the production of the mask are placed on the dummy structures as those placed on the image structures actually to be transferred.
It is advantageous if the smallest lateral extent of the dummy structure is greater than 0.25 · λ NA ,
where λ is a wavelength of a projecting light and NA is a numerical aperture of the projecting system.
A further advantageous embodiment of the invention provides for the smallest lateral extent of the dummy structure to be at least as large as the smallest lateral extent of the image structure. The fact that the dummy structure is semitransparent results in that it does not have to be significantly smaller, in terms of its geometric dimensions, but preferably can be at most exactly as small as the image structure to be transferred. As a result, the requirements on the mask production are significantly more relaxed, more reproducible and it is possible to inspect these structures more simply for defects and to carry out repair measures.
In a further advantageous embodiment of the mask according to the invention, the dummy structure is composed, in terms of its geometric dimensions and its transparency, in such a way that it is not transferred into a photographic recording medium as an independent image structure. This configuration ensures that the dummy structure is used in increasing the depth of focus and therefore enlarging the process window, but does not cause any undesired structures in the recording medium.
A further advantageous embodiment of the mask according to the invention provides for the semitransparent dummy structure to be optically homogeneous. The optical homogeneity improves the reproducibility and uniform action of the semitransparent auxiliary layer.
In a further advantageous embodiment of the mask according to the invention, the semitransparent auxiliary layer is, at least to some extent, disposed approximately parallel to the corresponding image structure.
A further advantageous embodiment of the mask according to the invention provides for the semitransparent dummy structure to be formed as a group of island-like individual structures, the island-like individual structures having a uniform geometric shape. The island-like embodiment and group-like configuration of the semitransparent dummy structure makes it possible to use an elementary optical correction module which, in terms of its optical effect, can be predicted by fast, simple and compact simulation methods, in particular in the case of a non-rectilinear configuration of the image structure to be supported. As a result, fast and efficient correction is possible for such structure geometries.
In a further advantageous embodiment of the configuration according to the invention, the light which is used for exposure in the optical projection system exhibits a phase rotation of a multiple of 360° as it passes through the semitransparent dummy structure, with a deviation of at most ±30° with respect to the passage through the carrier material. Since the light experiences a phase shift of a multiple of 360°, the interferences which are produced on the projection plane can advantageously be used to expose the photographic recording medium, and the process window is advantageously enlarged. In practice, a tolerance range of ±30° has been shown to be a practicable solution. In addition, it has also proven to be advantageous to use a tolerance range of at most ±10°.
In an advantageous embodiment of the mask according to the invention, the image structure to be projected contains an opaque layer.
In a further advantageous embodiment of the mask according to the invention, the image structure to be projected contains a semitransparent layer. Within the context of the solution according to the invention, provision is also made to form the image structure to be projected as a layer stack containing an opaque layer and a semitransparent layer.
In a further advantageous embodiment of the mask according to the invention, the semitransparent dummy structure contains a semitransparent layer. This makes it possible to etch the semitransparent dummy structure out of a semitransparent layer applied to the entire surface, following a lithographic structuring process.
In a further advantageous embodiment of the mask according to the invention, the semitransparent layer is formed of the same material as the opaque layer, but has a lower thickness. This makes it possible to form the semitransparent layer from the opaque layer, by the opaque layer being thinned at points provided for that purpose.
In a further advantageous embodiment of the mask according to the invention, the carrier material is thinned in an interspace. As a result of this procedure, the phase shift between the passage of light through the carrier material and the passage of light through the semitransparent layer can be matched to each other, so that, advantageously, it exhibits a relative phase difference of only n·360°±30° or, in an advantageous embodiment of ±10° or, in a particularly advantageous embodiment, of ±0° (n is an element from the whole numbers).
In an advantageous embodiment of the process according to the invention, a largely opaque layer is formed and structured on the carrier material. In addition, it is advantageous to form a semitransparent layer on the carrier material and likewise to structure the layer. This procedure likewise makes it possible to form the semitransparent layer underneath the opaque layer, so that a layer stack containing a semitransparent layer and an opaque layer is produced. Then, in a lithographic step and in an etching step, the opaque layer and the semitransparent layer are structured at the same time.
Furthermore, a layer is deposited on the mask, the layer is suitable to set the transparency and the phase of the semitransparent dummy structures.
In a further mode of the invention, the carrier material is thinned in a region to form an interspace.
In a concomitant mode of the invention, the opaque layer is thinned in regions.
Other features which are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in a mask for optical projection systems, and a process for its production, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an illustration of an image structure that is to be transferred into a photographic recording medium;
FIG. 2 is an illustration of a mask which has been modified by optical proximity correction, in order to transfer the image structure illustrated in FIG. 1 into the photographic recording medium;
FIG. 3 is an illustration of the mask with sub-resolution structures, which is used to correct optical distortion in projections;
FIG. 4 is an illustration of the mask with a tonal-value inverse structure of FIG. 3;
FIG. 5 is an illustration of an embodiment of the mask according to the invention;
FIG. 6 is an illustration of a further embodiment of the mask which, as compared with FIG. 5, has a tonal value-inverse configuration of the structures;
FIG. 7 is an illustration of a further mask which has island-like individual structures;
FIG. 8 is an illustration of a further exemplary embodiment of the mask, which is configured as a tonal-value inverse to the mask illustrated in FIG. 7;
FIG. 9 is a diagrammatic, cross-sectional view through a mask according to the invention;
FIG. 10 is a cross-sectional view through a second embodiment of the mask;
FIG. 11 is a cross-sectional view through a third exemplary embodiment of the mask;
FIG. 12 is a cross-sectional view of a fourth exemplary embodiment of the mask.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In all the figures of the drawing, sub-features and integral parts that correspond to one another bear the same reference symbol in each case. Referring now to the figures of the drawing in detail and first, particularly, to FIG. 1 thereof, there is shown a structure of the type which is to be produced in a photographic recording medium by optical projection. The structure contains an image structure 2 and further image structures 2 ′ and 2 ″. In general, the designations marked with ′ designate further embodiments of the feature provided with the designation.
FIG. 2 illustrates a mask according to the prior art corrected by line widening, which can be used for the purpose of generating the structure illustrated in FIG. 1 with equal-sized lines in a photographic recording medium by projection. The mask from FIG. 2 is formed on a transparent carrier material, on which the image structure 2 is disposed. The image structure 2 is broader than the image structure 2 illustrated in FIG. 1, in which the proximity correction exists. Likewise, the image structures 2 ′ and 2 ″ have been modified as compared with FIG. 1 .
FIG. 3 shows a further mask according to the prior art, which has the image structures 2 , 2 ′ and 2 ″ to be projected on a carrier material 1 . Furthermore, what are known as sub-resolution structures 9 and 9 ′ are disposed on the mask and lie considerably below the structure size that can be transferred to the carrier material by an optical projection process. The sub-resolution structures 9 and 9 ′ are suitable for enlarging the process window and therefore the depth of focus for the projection of the image structures 2 , 2 ′ and 2 ″. However, the sub-resolution structures 9 , 9 ′ have the disadvantage that the necessary small structure size, which lies far below the projection wavelength, can be produced only with great difficulty with the required accuracy and reproducibility. Furthermore, the sub-resolution structures 9 , 9 ′ evade a simple inspection method, since, because of their small dimensions, they cannot be checked for defects with the conventional inspection instruments used in mask technology. The repair of possible defects that have occurred in the sub-resolution structures 9 , 9 ′ is therefore virtually impossible.
FIG. 4 illustrates a tonal-value inverse structure to FIG. 3 . The illustration shows the carrier material 1 and an image structure 2 . The “sub-resolution structures” are used in FIG. 4, as already in FIG. 3, and are accompanied by the known disadvantages.
By use of the masks illustrated in FIG. 3 and FIG. 4, both isolated webs and isolated gaps in the projection fidelity can be improved.
FIG. 5 illustrates a first mask according to the invention. The image structures 2 , 2 ′ and 2 ″ to be projected are disposed on the carrier material 1 . In this exemplary embodiment, the carrier material 1 is transparent and, for example, is formed of glass or quartz. The image structure 2 to be projected is opaque. It is formed, for example, of a chromium layer that is disposed on the carrier material 1 . Also disposed on the carrier material 1 are semitransparent dummy structures 3 , 3 ′ and 3 ″. The semitransparent dummy structures 3 , 3 ′ and 3 ″ are configured in this exemplary embodiment in such a way that they enlarge the lithographic process window of the image structures 2 , 2 ′ and 2 ″. The semitransparent dummy structures 3 are, for example, a thinned chromium layer that, as a result of its low thickness, has an optical transparency which is greater than the transparency of the image structure 2 to be projected. In addition, it is also possible, instead of using chromium, to use any other suitable, semitransparent material and to structure it appropriately.
FIG. 6 illustrates a second exemplary embodiment of the mask according to the invention. The mask illustrated in FIG. 6 is substantially a tonal-value inverse structure to the mask illustrated in FIG. 5 . The mask in FIG. 6 contains the carrier material 1 that is transparent. Disposed on the carrier material 1 is an opaque layer, in which the image structure 2 is disposed. Also disposed on the carrier material 1 is a semitransparent dummy structure 3 . The semitransparent dummy structure 3 has a transparency that lies between the transparency of the carrier material 1 and the transparency of the opaque layer. Here, too, the depth of focus of the image structures 2 , 2 ′ and 2 ″ to be projected is increased by the configuration of the semitransparent dummy structure 3 , 3 ′, 3 ″.
FIG. 7 illustrates a third exemplary embodiment according to the invention. The mask from FIG. 7 contains the carrier material 1 on which the image structure 2 is disposed. Disposed beside the image structure 2 is the semitransparent dummy structure 3 , which consists of island-like individual structures 4 .
FIG. 8 illustrates the tonal-value inverse photomask to the photomask illustrated in FIG. 7 . The mask contains the carrier material 1 , which is covered by the opaque layer in which the image structure 2 is disposed. Also disposed on the carrier material 1 are the semitransparent dummy structures 3 and 3 ′ which, in this exemplary embodiment, consist of island-like individual structures 4 .
FIG. 9 illustrates a section through the mask according to the invention for use in an optical projection system. The mask contains the carrier material 1 to which a semitransparent layer 7 is applied. The semitransparent layer 7 is structured in such a way that the semitransparent dummy structure 3 is produced on the carrier material 1 . Also on the semitransparent layer 7 is an opaque layer 6 . The opaque layer 6 is likewise structured, so that the image structure 2 is disposed on the carrier material 1 . In this exemplary embodiment, the image structure 2 contains the semitransparent layer 7 and the opaque layer 6 that is disposed on the semitransparent layer 7 . With reference to FIG. 9, a manufacturing process for the mask according to the invention will now be described. First, the carrier material 1 is provided, to which the semitransparent layer 7 is applied. The opaque layer 6 is applied to the semitransparent layer 7 . The opaque layer 6 and the semitransparent layer 7 are subsequently structured in such a way that the image structure 2 is produced. In a second process step, the opaque layer resting on the dummy structures 3 is removed, so that the semitransparent dummy structure 3 is produced.
FIG. 10 illustrates a further embodiment of the mask according to the invention. The mask contains the carrier material 1 on which the image structure 2 is disposed that is formed, for example, of chromium. In addition, the mask contains the semitransparent dummy structure 3 , which is likewise disposed on the carrier material 1 . In this exemplary embodiment, the semitransparent dummy structure 3 likewise is formed of a chromium layer, but it has a substantially lower thickness, so that it is semitransparent. In addition, the carrier material 1 is thinned in an interspace 10 which is not covered by an image structure 2 or a semitransparent dummy structure 3 .
A further production process for the mask according to the invention will be explained with reference to FIG. 10 . First, the carrier material 1 is provided. The opaque layer 6 which, in this exemplary embodiment, is formed of chromium, is disposed on the carrier material 1 . The opaque layer 6 is then covered at the positions at which the image structure 2 and the semitransparent dummy structure 3 are produced. Using an etching process, the opaque layer 6 is removed in the regions that are not covered. With a further etching process, the semitransparent dummy structure 3 is thinned in such a way that it has a higher transparency than the image structure 2 . In a further etching process, the carrier material 1 is thinned in the interspace 10 , so that the phase difference when light passes through the thinned carrier material experiences a phase rotation of a multiple of 360° as compared with the semitransparent dummy structure 3 .
FIG. 11 illustrates a further exemplary embodiment of the mask according to the invention. The mask contains the carrier material 1 , on which the image structure 2 and the dummy structure 3 are disposed. The image structure 2 is formed of the opaque layer 6 , the semitransparent dummy structure 3 is formed of a semitransparent layer 7 .
A corresponding production process provides the carrier material 1 . The opaque layer 6 is formed and structured on the carrier material 1 , so that the opaque image structure 2 is produced. The semitransparent layer 7 is then produced and structured on the carrier material 1 and on the image structure 2 , so that the semitransparent dummy structure 3 is produced. The order in which the opaque layer 6 and the semitransparent layer 7 are formed and structured can be interchanged in this exemplary embodiment.
FIG. 12 illustrates another exemplary embodiment of the mask according to the invention. The mask contains the carrier material 1 on which the image structure 2 is disposed. The image structure is formed from the opaque layer 6 . Also disposed on the carrier material 1 is the semitransparent dummy structure 3 , which is formed from the semitransparent layer 7 . FIG. 12 differs from FIG. 11 in that the carrier material 1 is thinned at positions that are not covered by the image structure 2 and not covered by the semitransparent dummy structure 3 . In order to produce the mask illustrated in FIG. 12, the process explained in FIG. 11 is used. However, the carrier material 1 is subsequently thinned at envisaged positions.
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A mask contains a transparent carrier material on which an opaque region is disposed as an image structure. Also disposed on the carrier material is a semitransparent dummy structure, which is spaced apart from all the image structures and differs from the image structure in terms of transparency and phase rotation. The smallest lateral extent of the dummy structure is then selected to be at least half as large as the smallest lateral extent of the image structure. The semitransparent dummy structure is formed in such a way that it is suitable for increasing the depth of focus of structures that stand individually or at least partially individually, in order thereby to improve the process window of the optical projection.
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This is a continuation of application Ser. No. 07/956,830, filed on Oct. 5, 1992 now abandoned, which is a continuation of application Ser. No. 07/448,195, filed on Dec. 14, 1989, now abandoned.
The present invention is directed to chemically-modified group B polysaccharides of Neisseria meningitidis. The invention also provides vaccines in which the respective modified polysaccharides are conjugated to a protein carrier.
BACKGROUND OF THE INVENTION
Meningitis caused by group B N. meningitidis and E. coli K1 remain major world health problems. Group B meningitis occurs in both endemic and epidemic situations and accounts for approximately half of all recorded cases of meningococcal meningitis, while K1-positive E. coli are the leading cause of meningitis in neonates. Currently there is no vaccine commercially available against disease caused by group B meningococci and E. coli K1. This is in large part due to the fact that the group B meningococcal polysaccharide (GBMP) is only poorly immunogenic in humans. There are some recently reported candidate vaccines based on complexes of the GBMP with outer membrane proteins, but, as yet, there is no clear evidence of their efficacy in humans.
Recently, a new concept of a vaccine based on a synthetic chemically modified (N-propionylated) group B polysaccharide-protein (N-Pr-GBMP-protein) conjugate has been developed. The vaccine induces in mice high titers of IgG antibodies which are not only protective, but also cross-react with unmodified GBMP (i.e. N-acetyl-GBMP). This concept is described and claimed in U.S. Pat. No. 4,727,136, issued Feb. 23, 1988 to Harold J. Jennings et al.
It has been inferred that a vaccine which raises cross-reactive antibodies such as that described in U.S. Pat. No. 4,727,136 could only be successful at the expense of breaking immune tolerance. This hypothesis is legitimized by the identification of a common epitope consisting of a chain of α-(2-8)-linked sialic acid residues (with a minimum requirement of ten residues) in both the native N-Ac-GBMP and in human and animal tissue (Jennings, Contrib. Microbiol. Immunol. Basel, Karger, 1989, Vol. 10, 151-165). These polysialosyl chains function as developmental antigens and have for the most part been associated with the fetal state in embryonic neural cell adhesion (Finne et al, Biochem. Biophys. Res. Commun., 1983, 112, 482). During post-natal maturation, this antigen is down-regulated (Friedlander et al, J. Cell Biol. 1985, 101, 412) but is expressed in mature humans during the regeneration of diseased muscles (Cashman et al, Ann. Neuron., 1987, 21, 481) in tumor cells (Roth et al, Proc. Natl. Acad. Sci., 1988, 85, 299) and in natural killer (NK) and CD3 + T cells (Husmann et al, Eur. J. Immunol., 1989, 19, 1761. Although the consequences of breaking tolerance to these fetal antigens have not yet been established, it is generally conceded that, because of this cross-reaction, the N-Pr-GBMP-protein conjugate would be severely scrutinized by licensing agencies, resulting in considerable expense and delays because of the complex experimentation necessary to prove the safety of the vaccine before its approval for commercial marketing.
It is an object of the present invention to develop a vaccine having immunogenic properties which are enhanced as compared to those of the N-Pr-GBMP-protein. It is also an object of the invention to provide a vaccine which exhibits substantially reduced cross-reactivity with GBMP.
SUMMARY OF THE INVENTION
In one aspect of the present invention, there is provided a modified B polysaccharide of Neisseria meningitidis having sialic acid residue N-acetyl (C 2 ) groups replaced by a C 4 -C 8 acyl group.
In another aspect, there is provided an
antigenic conjugate comprising the N-C 4 -C 8 acyl polysaccharide conjugated to an immunologically suitable protein, having enhanced immunogenicity with substantially reduced inducement of cross-reactive antibodies.
In a further aspect, there is provided a vaccine comprising the N-C 4 -C 8 acyl polysaccharide-protein conjugate in association with a suitable carrier or diluent. The vaccines of the invention may also comprise a therapeutically effective amount of an adjuvant suitable for human use, for example aluminum phosphate or aluminum hydroxide.
In a yet further aspect, there is provided a method of immunizing mammals against N. meningitidis and E. coli K1 infections, which method comprises administering parenterally to mammals subject to such infections, including humans, an immunologically effective amount of the vaccine of the invention. The vaccine is typically administered in an amount of about 1 to 50 micrograms per kilogram body weight, for example 5 to 25, micrograms per kilogram body weight.
In yet another aspect, the invention provides a gamma globulin fraction capable of protection against meningitis caused by group B N meningitidis and E. coli K1. The fraction is produced by immunizing a mammal with a vaccine of the invention. The fraction is then administered to an individual to provide protection against or to treat on-going infection caused by the above organisms. From this, it will be appreciated that the immunogenic vaccine conjugates of the invention will provide for a source of therapeutic antiserum in light of their favorable immunogenicity with minimal inducement of GBMP cross-reactive antibodies. The conjugates of the invention will also be useful for raising monoclonal antibodies and, possibly, antidiotype antibodies.
It has been found in our recent experiments that most of the bactericidal and protective antibodies induced by the N-Pr-GBMP-protein conjugate described in the above-referred to Jennings et al U.S. Pat. No. 4,727,136 are not associated with the GBMP cross-reactive antibodies. In fact, most of the protective activity is contained in an N-Pr-GBMP-specific antibody population which does not cross-react with GBMP. In light of this, it is believed that the N-Pr-GBMP mimics a unique bactericidal epitope on the surface of group B meningococci.
The present invention is based on the discovery that it is possible to synthesize chemically modified GBMP's which mimic the bactericidal epitope and which, in their conjugated form, not only exhibit enhanced immunogenicity but also avoid substantially the inducement of antibodies that cross-react with GBMP.
In arriving at the present invention, a number of different chemically modified GBMP's have been synthesized and conjugated individually to protein, followed by injection of the conjugates into mice and the effects compared to those produced by the N-Pr-GBMP protein conjugate. Surprisingly, it has been found that the N-C 4 -C 8 acyl GBMP-protein conjugates, for example the n-butanoyl, iso-butanoyl, n-pentanoyl, iso-pentanoyl, neo-pentanoyl, hexanoyl, heptanoyl, and octanoyl, and especially the N-butanoyl (N-Bu) GBMP-protein conjugate, substantially mimic the bactericial epitope with substantially reduced inducement of cross-reactive antibodies.
DETAILED DESCRIPTION OF THE INVENTION
The group B meningococcal polysaccharide is isolated from N. meningitidis by methods which are known in the art. In one such method, group B meningococci (strain 981B) were grown at 37° C. in a fermenter using 30 g. of dehydrated Todd Hewitt Broth (Difco Laboratories, Detroit, Mich.) per liter of distilled water. Prior to fermenter growth, the lyophilized strain was grown initially in a candle jar at 37° C. on 5% (v/v) Sheeps' Blood Agar (Difco Laboratories, Detroit, Mich.) plates. The bacteria were then transferred to 1.0 liter of Todd Hewitt Broth (as above) in an Erlenmeyer flask which was shaken at 37° C. for 7 hours at 190 r.p.m. This inoculum was then transferred to the fermenter. After fermenter growth (16 hours) the bacteria were killed by the addition of formalin to a final concentration of 0.75%. The bacteria were removed by continuous centrifugation and the group B meningococcal polysaccharide was isolated from the supernatant and purified essentially as described by Bundle et al, J. Biol. Chem., 249, 4797-4801 (1974) except that the protein was extracted by stirring a solution of the crude polysaccharide with cold (4° C.) 90% phenol instead of hot (50°-60° C.). This latter process ensures that a high molecular weight form of the GBMP is produced.
E. coli (018:K1:H7) (NRCC 4283) were grown at 37° C. in a fermenter in distilled water containing dehydrated Brain Heart Infusion (BHI; 37 g/liter) (Difco Laboratories, Detroit, Mich.). Prior to fermenter growth, the lyophilized strain was grown on 50 ml of BHI solution (same as above) in an Erlenmeyer flask which was shaken at 37° C. for 7 hours at 200 r.p.m. This growth was then transferred to 1.5 liters of BHI (as above) and grown under the same conditions as described above for 7 hours. The inoculum was then transferred to the fermenter.
The procedures employed in the isolation and purification of the capsular polysaccharide of E. coli K1 were identical to those described above for the isolation of the group B meningococcal polysaccharide.
It will be appreciated that the isolation and purification procedures described above are not the only ones which may be utilized, and that other published procedures are available, for example those described by Watson et al, J. Immunol., 81, 331 (1958) and in the above-mentioned U.S. Pat. No. 4,727,136.
The native polysaccharide is N-deacetylated to provide a reactive amine group in the sialic acid residue parts of the molecule. The N-deacetylation can be carried out by any known method, for example in a basic aqueous medium at elevated temperatures, for example about 90° to 110° C., and at a pH of about 13 to 14. The basic aqueous medium is suitably an aqueous alkali metal hydroxide solution, for example sodium hydroxide of about 2M concentration. Alternatively, hydrazine in aqueous solution may be used. The degree of N-deacetylation may vary from about 30% to 100%, depending on the conditions. It is preferred to achieve about 90 to 100% N-deacetylation. N-deacetylated product can be recovered for example by cooling, neutralizing, purification if desired, and lyophilization.
Prior to the N-deacetylation procedure, the native polysaccharide has an average molecular weight in the region of about 500,000 to 800,000 Daltons. As a result of N-deacetylation, fragments of the polysaccharide are produced having an average molecular weight ranging from about 10,000 to 50,000 Daltons.
The N-deacetylated polysaccharide fragments are then N-acylated to produce the corresponding N-acylated product. The N-acylation may be carried out by dissolving the N-deacetylated polysaccharide in an aqueous medium having a pH of about 7.5 to 9.0, followed by adding the appropriate acyl anhydride, optionally with an alcohol to increase solubility, and cooling to below 10° C. until the reaction is complete. The reaction medium can be purified, if desired, for example by dialysis, and the N-acylated product then recovered, typically by lyophilization. The reaction is substantially complete within about 10 to 20 hours. The degree of N-acylation, as measured by analytical techniques, typically 1 H nmr, is at least 90%, and likely close to 100%. The N-acylation reaction does not result in any significant molecular weight reduction of the fragments.
It is preferred, according to the present invention, to select, for conjugation purposes, the N-acylated material having an average molecular weight corresponding to about 30 to 200 sialic acid residues. This is generally achieved by way of gel filtration of the N-acylated GBMP using an Ultragel (trademark) AcA 44 (Bead diameter 60-140 um) column, using PBS as eluant. Alternatively, a suitable sizing membrane may be employed.
N-acylated material of average molecular weight of 10,000 to 40,000 Daltons, for example 10,000 to 15,000 Daltons, is employed for the invention. This is obtained by collecting the fractions of the eluate of the column containing N-acylated GBMP material having that average molecular weight range. N-acylated material of higher average molecular weight, for example in the region of 30,000 to 40,000 Daltons, has also proved to be useful according to the invention.
The vaccines of the invention are produced by conjugating the N-acylated polysaccharide with an immunologically suitable carrier protein. Preferably, the carrier protein itself is an immunogen. Examples of suitable carrier proteins are tetanus toxoid, diphtheria toxoid, cross-reacting materials (CRMs), preferably CRM 197 , obtained from Sclavo Ltd., Siena, Italy, and bacterial protein carriers, for example meningococcal outer membrane proteins.
Any mode of conjugation may be employed to conjugate the modified polysaccharide fragments with the carrier protein. A preferred method is that described in U.S. Pat. No. 4,356,170, i.e. by introducing terminal aldehyde groups (via oxidation of cis-vicinal hydroxyl groups) into the N-acylated polysaccharide and coupling the aldehyde groups to the protein amino groups by reductive amination. The polysaccharide and the protein are thereby linked through a --CH 2 --NH-protein linkage.
It is to be understood, however, that the conjugate vaccines of the invention are not limited to those produced via reductive amination. Thus, the vaccines may also be produced by conjugating the N-acylated polysaccharide with the carrier protein using an adipic dihydrazide spacer, as described by Schneerson, R., et al, Preparation, Characterization and Immunogenicity of Haemophilus influenzae type b Polysaccharide-Protein Conjugates, J. Exp. Med., 1952, 361-476 (1980), and in U.S. Pat. No. 4,644,059 to Lance K. Gordon. Alternatively, there may be used the binary spacer technology developed by Merck, as described by Marburg, S., et al, "Biomolecular Chemistry of Macromolecules: Synthesis of Bacterial Polysaccharide Conjugates with Neisseria meningitidis Membrane Protein", J. Am. Chem. Soc., 108, 5282-5287 (1986) or, possibly, the reducing ends methodology, as referred to by Anderson in U.S. Pat. No. 4,673,574.
The resulting N-acylated polysaccharide-protein conjugates do not possess significant cross-linking and are soluble in aqueous solutions. This makes the conjugates of the invention good candidates for vaccine use.
The resulting N-acylated-polysaccharide-protein conjugates of the invention have been tested in in vitro tests in mice, and have generally been shown to possess improved immunogenic properties as compared with the N-propionylated-polysaccharide. In addition, substantially reduced formation of cross-reactive antibodies is observed. In light of this, it is believed that the vaccines of the invention will be useful against meningitis caused by group B N. meningitidis or by E. coli K1 organisms. Of particular interest are vaccines for protecting human infants who are most susceptible to bacterial meningitis.
The vaccines of the invention are typically formed by dispersing the conjugate in any suitable pharmaceutically acceptable carrier, such as physiological saline or other injectable liquids. The vaccine is administered parenterally, for example subcutaneously, intraperitoneally or intramuscularly. Additives customary in vaccines may also be present, for example stabilizers such as lactose or sorbitol and adjuvants such as aluminum phosphate, hydroxide, or sulphate.
A suitable dosage for the vaccine for human infants is generally within the range of about 5 to 25 micrograms, or about 1 to 10 micrograms per kilogram of body weight.
EXAMPLES
The invention is illustrated by the following non-limiting examples. The N-acetyl, N-propionyl, N-butanoyl, N-isobutanoyl, N-pentanoyl and N-hexanoyl-GBMP-protein conjugates have been prepared for evaluation purposes, and the results are discussed in the examples.
Materials and Methods for Preparing Conjugates
(a) Materials
Propionic, butanoic, isobutanoic, pentanoic, and hexanoic anhydrides together with colominic acid were obtained from Sigma Chemicals Co., St. Louis, Mo. Because colominic acid is structurally identical to the group B meningococcal polysaccharide (GBMP), it is referred to henceforth as GBMP. Tetanus toxoid (TT) was obtained from the Institut Armand Frappier, Laval, Quebec, and its monomeric form, used in all the conjugations, was obtained by passage of the above preparation through a Bio-Gel (trademark) A 0.5 (200-400 mesh) column (1.6×90 cm) (Bio-Rad, Richmond, Calif.), equilibrated and eluted with 0.01M phosphate buffered physiologic saline (PBS) (pH 7.4)
(b) N-Deacetylation of the GBMP
The GBMP (Na + salt) (1.0 g) was dissolved in 5 ml of 2M NaOH and, following the addition of NaBH 4 (150 mg), the solution was heated at 110° C. for 6 hours in a screw cap Teflon (trademark) container (60 mL). This procedure is essentially as described in J. Immunol., 134, 2651 (1985) and U.S. Pat. No. 4,727,136, both in the name of Harold J. Jennings, et al. The cooled diluted solution was then exhaustively dialyzed against distilled water at 4° C., and lyophilized. The fact that N-deacetylated GBMP was obtained was determined by the absence of the methylacetamido signal (singlet at delta 2.07) in the 1 H-nmr spectrum of the N-deacetylated GBMP.
(c) N-Acylations of the GBMP
N-Deacetylated GBMP (1.0g) was dissolved in 50 mL of 5% aqueous NaHCO 3 . To five individual aliquots (10 mL of the above solution) were added either propionic, butanoic, isobutanoic, pentanoic or hexanoic anhydrides. These reagents were added in 3×0.5 mL aliquots over a 3 hour period of time at room temperature while the solution was maintained at pH 8.0 with 0.5N NaOH. Methanol (0.5 mL) was added simultaneously with each addition of anhydride in order to increase their solubility. Finally the solutions were stirred for 16 hours at 4° C., exhaustively dialysed against distilled water at 4° C., and lyophilized. The individual N-propionylated, N-butanoylated, N-isobutanoylated, N-pentanoylated and N-hexanoylated GBMP were all obtained in yields in excess of 90% In each case essentially complete N-acylation was confirmed by the disappearance in the respective 1 H-nmr spectrum of N-deacetylated GBMP.
(d) Sizing of the fragments of the different N-acylated GBMP
Gel filtration, using an Ultragel (trademark) AcA 44 (bead diameter 60-140 μm) column (IBF Biotechnics, Savage, Md.) with PBS as eluant, was employed to obtain the desired average molecular weight N-acylated GBMP material. Fractions eluting from the column at K D 0.5 to K D 0.7 as measured by FLPC (see below) were collected, dialyzed, and lyophilized. This range of K D values corresponds to N-acylated GBMP of approximately 30-50 sialic acid residues (10,000 to 15,000 Daltons, typically 12,000 Daltons average molecular weight). Fractions in the range of K D 0.2 to 0.4 corresponding to fragments having an average molecular weight in the range of 30,000 to 40,000 Daltons have also been collected and conjugated. Thus, N-acylated material eluting in the K D range of 0.2 to 0.7 is of particular interest.
(e) Polysaccharide Conjugates
Terminal aldehyde groups were introduced into the N-acylated GBMP by periodate oxidation (see U.S. Pat. No. 4,356,170). The N-acylated GBMP fragments above were oxidized in 0.1M aqueous NaIO 4 (sodium metaperiodate) (10 mL) for 2 hours at room temperature in the dark. Excess periodate was then destroyed by the addition of 1 mL of ethylene glycol and the solution was then exhaustively dialyzed at 4° C., and lyophilized. The use of NaBH 4 in the N-deacetylation procedure (except for the GBMP) results in the transformation of the terminal reducing sialic acid residues of each of the N-acylated GBMP, to open chain polyol residues. This type of residue is periodate sensitive (see J. Immunol., 127, 1011 (1981) and U.S. Pat. No. 4,356,170 Harold J. Jennings et al), thereby resulting in the introduction of aldehyde groups into the N-acylated GBMP fragments at both termini.
The oxidized fragments (100 mg) were dissolved in 0.1M NaHCO 3 (pH 8.1) buffer (2 mL) and TT (20 mg) was added to the solution. Finally, following the addition of sodium cyanoborohydride (NaCNBH 3 ) (40 mg), the solution was gently stirred at room temperature. The course of the conjugation was followed by FPLC using a gel filtration column containing Superose (trademark) 12 HR10/30 (Pharmacia), run isocractically at 1 mL/min in PBS buffer at pH 7.2, both the protein and N-acylated GBMP fragments being monitored at 214 nm. The fragments had K D 0.6, TT had K D 0.39 and the conjugates had K D 0.23. The conjugation was complete when all the TT was expended as determined by the loss of the peak in the FPLC chromatogram corresponding to the component at K D 0.39. In most cases, the conjugations were complete in 2 days but were left for a total reaction time of 4 days. The potential unreacted aldehyde groups were finally reduced with sodium borohydride (20 mg) prior to gel filtration.
The polysaccharide-TT conjugates were separated from the polysaccharide fragments by gel filtration using a Bio Gel A column with PBS as eluant. The eluant containing the conjugate was dialyzed against distilled water and lyophilized. The N-acylated GBMP-TT conjugates contained from 12-30%, typically 12-20%, sialic acid as determined by the resorcinol method described by Svennerholm, L., Quantitative Estimation of Sialic Acids, II A Colorimetric Resorcinol-Hydrochloric Acid Method, Biochim. Biophys. Acta. 24, 604 (1957). This indicates that the conjugates had a molar ratio of polysaccharide to TT of 2-3:1 respectively.
Immunization and Immunoassays
(a) Immunization Procedures
Twenty female white CFI mice (8-10 weeks old) were immunized intraperitoneally (3 times at 3 week intervals) with each individual N-acylated GBMP-TT conjugate in Freunds' complete adjuvant (FCA) (Difco, Detroit, Mich.). Each immunization contained sufficient conjugate (10-12 μg) to contain 2 μg of sialic acid. Eleven days after the third injection, the mice were exsanguinated. The following tests were done on the sera.
(b) Radioactive antigen binding assay
This assay was carried out by a modification of the Farr technique using extrinsically [ 3 H]-labeled GBMP (Jennings H. J., et al, Determinant Specificities of the Groups B and C polysaccharides of Neisseria meningitidis, J. Immunol., 134, 2651 (1985), or [ 3 H]-labeled N-Pr-GBMP (Jennings H. J., et al, Unique Intermolecular Bactericidal Epitope involving the Homo-Sialo Polysaccharide Capsule on the Cell Surface of Group B Neisseria meningitidis and Escherichia coli K1, J. Immunol., 142, 3585-3591 (1989). The reaction mixture for the radioactive antigen-binding assay was obtained by mixing in Eppendorf polypropylene micro test tubes 20 uL of pooled antisera, from groups of 20 mice immunized with each individual N-acylated GBMP-TT conjugate, diluted to 100 μL with PBS, with [ 3 H]-labeled GBMP and [ 3 H]-labeled N-Pr-GBMP in 50 μL of PBS. After incubation at 4° C. for 16 hours, 150 μL of saturated (at 4° C.) ammonium sulfate (pH 7.0) was added to the tubes and the tubes agitated and left to stand at 4° C. for 30 min. The tubes were centrifuged at 15,000 rpm for 10 min. and two aliquots of 130 μL were drawn from the tubes. The aliquots were mixed with 2 mL of water and a scintillant-containing xylene (ACS aqueous scintillant) and the mixtures were counted in a liquid scintillation counter. Results are given in Table 1.
TABLE 1______________________________________Binding of [.sup.3 H]-labeled-N-Ac-GBMP to differentmouse anti- N-acyl-GBMP-TT conjugate sera. % Binding.sup.aAntiserum 1 2 3 4______________________________________ N-Pr-GBMP-TT 41 40 39 12 N-Bu-GBMP-TT 4 4 7 4 N-IsoBu-GBMP-TT 9 -- -- -- N-Pen-GBMP-TT 36 -- -- -- N-Hex-GBMP-TT 16 -- -- --______________________________________ .sup.a The four binding experiments were carried out on pooled antisera from 20 immunized mice.
Abbreviations used in Table 1 and other tables: N-Ac-, N-Pr, N-Bu, N-IsoBu, N-Pen, N-Hex- stand for N-Acetyl, N-Propionyl-, N-Butanoyl-, N-Isobutanoyl-, N-Pentanoyl- and N-Hexanoyl-.
The numerals 1, 2, 3 and 4 are results of four repeat experiments. Table 1 demonstrates conclusively that the N-Ac-GBMP (which carries the same epitope as fetal N-CAM) binds less to the antiserum induced by the N-Bu-GBMP, N-IsoBu-GBMP, N-Pen-GBMP and N-Hex-GBMP than that induced by the N-Pr-GBMP. From this, it can be deduced from Table 1 that the N-Bu-, N-IsoBu, N-Pen- and N-Hex-polysaccharide-conjugates raise less cross-reactive antibodies than the N-Pr-conjugate.
(c) Quantitative precipitin analyses
These experiments were carried out by the method of Kabat and Mayer, Experimental Immunochemistry Charles C. Thomas, Springfield, p. 22 (1961). Aliquots (100 μL) of anti-N-acyl GBMP-TT sera (diluted 5 fold in PBS) were reacted in tubes with increasing concentrations of the N-acetyl (colominic acid), N-propionyl, N-butanoyl, N-isobutanoyl, N-pentanoyl and N-hexanoyl GBMP in a total volume of 200 μL (adjusted with PBS). The higher molecular weight fractions of these derivatives were used in these experiments and they were obtained from the eluate of the Ultragel AcA 44 column (K D 0.4 as measured by FPLC) previously used to size the fragments of the N-acylated GBMP. The tubes were incubated at 4° C. for 4 days with daily mixing, centrifuged, and the quantity of antibody protein was determined by the method of Lowry et al, Protein Measurement with the Folin phenol reagent, J. Biol. Chem., 1933, 265 (1951). The results are given in Table 2.
TABLE 2______________________________________Precipitation.sup.a of mouse anti-N-acyl-GBMP-TT serausing different N-acyl GBMP as precipitating antigens. N-acyl-GBMP antigen N- N- N- N- N-Antiserum acetyl propyl butyl pentyl hexyl______________________________________ N-Pr-GBMP-TT 0.16 0.40 0.20 0.15 0.15 N-Bu-GBMP-TT 0.04 1.15 2.60 3.20 1.90 N-Pen-GBMP-TT 0.13 0.38 0.44 6.35 3.55 N-Hex-GBMP-TT 0.02 0.08 0.80 4.15 4.40______________________________________ .sup.a Maximum amount of antibody precipitated expressed in mg/mL of antiserum
As regards cross-reactivity, the first column of Table 2 indicates that very little cross-reactive antibodies are produced by the N-Bu and N-Hex conjugates as compared to the N-Pr conjugate. It can also be seen that the N-Pen conjugate produces less cross-reactive antibodies than the N-Pr conjugate.
With reference to immunogenicity, in terms of homologous response, it can be seen from Table 2 that the N-Bu- (2.60), N-Pen- (6.35) and N-Hex- (4.40) GBMP-TT conjugates are more immunogenic than the N-Pr-GBMP analog (0.40).
(d) ELISA
The wells of EIA microtitration plates (Flow Labs, Mississauga, Ontario, Canada) were coated with a 10 μg/mL solution of either GBMP-, NPrGBMP- or NBu-GBMP-BSA conjugates in PBS (100 μL/well). The plates were left for 18 hours at 4° C. and after coating they were washed with 1% bovine serum albumin in PBS for 10 min. at room temperature (blocking step). The wells were then filled with 100 μL of serial 10-fold dilutions in PBS of anti-mouse-N-acyl GBMP-TT conjugate sera and the plates were incubated for 1 hour at room temperature. After washing with SBT the plates were incubated for 1 hour at room temperature with 50 μL of the appropriate dilution of goat antimouse immunoglobulin peroxidase labeled conjugates (Kirkegard and Perry Laboratories), then the contents of the wells were aspirated and the plates washed five times with SBT. Finally 50 μL of Tetramethylene blue-peroxidase substrate (TMB) (Kirkegard and Perry Laboratories) were added to each well after 10 min the absorbance at 450 nm was measured with a Multiscan spectrophotometer (Flow Laboratories, Mississauga, Ont.). Results are given in Table 3.
TABLE 3__________________________________________________________________________ELISA titrations of pooled mouse anti- N-acyl-GBMP-TTconjugate serum against N-acyl-GBMP-BSA conjugates. Titers.sup.a of AntiseraCoating Antigen a. N-Pr-GBMP.sup.b a. N-Bu-GBMP.sup.b a. N-Isobu-GBMP.sup.b__________________________________________________________________________ N-Ac-GBMP-BSA 7800 1000 7000 N-Pr-GBMP-BSA 40000 39000 9800 N-Bu-GBMP-BSA 26000 52000 9700 N-IsoBu-GBMP-BSA -- -- 25000__________________________________________________________________________ .sup.a titer (GM) = reciprocal of dilution at 50% of the maximum absorbance at 450 nm. .sup.b Nacyl specific antisera induced in mice by homologous Nacyl-GBMP-T conjugates.
With reference to cross-reactivity, it can be seen from Table 3 that the N-Bu-GBMP-TT conjugate raises less cross-reactive antibodies with respect to N-Ac-GBMP (1000) than does the N-Pr-GBMP-TT conjugate (7800). The reason for this is that the GBMP binds less to antibody induced by the N-Bu-GBMP-TT conjugate than that induced by the N-Pr-GBMP-TT conjugate. Similar comments apply with respect to the N-IsoBut-GBMP-TT conjugate.
As regards immunogenicity, the N-Bu conjugate is more immunogenic than the N-Pr analogue, as shown by the homologous binding titers of 52,000 (N-Bu) and 40,000 (N-Pr).
(e) Radioactive binding inhibition assay
Increasing concentration of the larger molecular sized N-acyl GBMP inhibitor in PBS (80 μL) were added to 20 μL of mouse anti-N-Pr-GBMP-TT conjugate antiserum, an amount sufficient to bind 50% of the ( 3 H)-labeled N-Pr-GBMP in the absence of inhibitor. The tubes were incubated for 1 hour at 37° C. and 50 μL of ( 3 H)-labeled N-Pr-GBMP in PBS was added. After gentle mixing the tubes were incubated at 4° C. for 16 hours and the assays were performed exactly as described previously for the radioactive antigen binding assay. The % inhibition was calculated using the following formula:
______________________________________ percent inhibition = 100 × [(cpm with inhibitor minus cpmwithout inhibitor)/(cpm without antibody minus cpm withoutinhibitor)].______________________________________
Results are given in Table 4.
TABLE 4______________________________________Inhibition of binding of [.sup.3 H]-labeled N-Pr-GBMPto mouse anti- N-Pr-GBMP-TT conjugate induced IgG.sub.2a,IgG.sub.2b (A).sup.a and IgG.sub.1 (B).sup.a antibodies.Inhibitor.sup.b A B______________________________________ N-Ac-GBMP >50.0 >50.0 N-Pr-GBMP 0.6 0.3 N-Bu-GBMP 0.3 0.2 N-IsoBu-GBMP >50.0 -- N-Pen-GBMP 2.3 2.5 N-Hex-GBMP 10.2 10.0______________________________________ .sup.a These were fractions of mouse polyclonal antiN-Pr-GBMP-TT, serum, described in Jennings et al, J. Immunol., 142, 3585-3591 (1989). .sup.b Micrograms of inhibitor to give 50% inhibition.
Bactericidal assays These assays were carried out by the method described by Jennings et al, J. Exp. Med., 165, 1207-1211 (1987).
Neisseria meningitidis strain B (M 986) was used in these assays. Results are given in Table 5.
TABLE 5______________________________________Binding of [.sup.3 H]-labeled-N-Pr-GBMP to different mouseanti-N-acyl-GBMP-TT conjugate sera and the bactericidaltiters of the respective antisera. μL of BactericidalAntiserum antiserum.sup.a Titer.sup.b______________________________________ N-Pr-GBMP-TT 13 128 N-Bu-GBMP-TT 10 64 N-IsoBu-GBMP-TT ND 64 N-Pen-GBMP-TT 24 64 N-Hex-GBMP-TT >100 8 N-Ac-GBMP-TT >100 8______________________________________ .sup.a μL of antiserum (diluted 5 fold with PBS) required for 50% binding. .sup.b Dilution experiment: one dilution difference, e.g. 128 as compared to 64, is within experimental error.
Table 4 illustrates that N-Bu-GBMP is as good an inhibitor as the N-Pr-GBMP for the binding of the latter to its own homologous antibodies. Therefore, the use of N-Bu-GBMP in place of N-Pr-GBMP does not result in any significant loss of properties exhibited by N-Pr-GBMP. Table 5 demonstrates that the N-Bu-GBMP binds as well as the N-Pr-GBMP to antibodies induced by the N-Pr-GBMP-TT conjugate. Antisera induced by both the N-Bu-GBMP-TT and N-Pr-GBMP-TT conjugates gave similar bactericidal titers. This evidence indicates the equivalence of the N-Bu-, N-IsoBu- and N-Pen-GBMP to the N-Pr-GBMP in their ability to mimic the bactericidal epitope on the surface of the group B meningococci.
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Neisseria meningitidis group B polysaccharide (GBMP) modified by having sialic acid residue N-acetyl groups replaced by N-acyl groups exhibits enhanced immuno response thereto. In addition, induction of antibodies which cross-react with unmodified group B meningococcal and E. coli K1 capsular polysaccharide and other tissue cells having a common epitope is minimized. Conjugation of the modified polysaccharides with a physiologically acceptable protein such as tetanus toxoid induces the production of specific protective antibodies with negligible levels of GBMP-cross reactive antibodies, to thereby afford protection against infections caused by group B meningococci and E. coli K1.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority under 35 U.S.C. 119(e) and 37 C.F.R. 1.78(a)(4) based upon copending U.S. Provisional Application Ser. No. 61/596,697 for CONTAINER HANDLING SYSTEM filed Feb. 8, 2012, the entirety of which is incorporated herein by reference.
FIELD
[0002] The present disclosure is broadly concerned with product container carriers. More particularly, it is concerned with a carrier for receiving a container from an assembly line and supporting it in an upright position and secured against rotation for filling and capping.
BACKGROUND
[0003] Automated bottling and packaging systems make it possible to handle, fill and cap a wide variety of containers at high speed. These systems may also provide product identification, verification and package labeling. These latter functions enable automated handling systems to be used by regulated industries such as pharmaceutical distribution and dispensing, for example, by mail order pharmacies. In general, these automated systems include structures for loading containers onto a transporting conveyor which delivers them to a series of stations at which they are filled, sealed with a cap or the like, and eventually deposited into a receiving container such as a tote or bin.
[0004] The conveyor may be equipped with a series of larger container carriers, or pucks that receive the containers to be filled and support them in an upright position as they are transported along the conveyor. The pucks may be equipped with data elements such as radio frequency identification (RFID) devices or tags having read-write memory. The containers may be labeled with optically readable data such as bar codes. Association of the RFID tag on the puck with the bar code on the container enables computer verification of the contents of the container. In some industries, such as pharmaceutical distribution, the RFID tag may contain both information associated with the bar code on the container as well as information from a stored database regarding the patient and the order number. Where collection totes used in an automated system, they may also include an RFID tag that is associated with the RFID tag on the puck and the bar code on the container. The RFID tag and/or bar code are read along the assembly line and verified by the stored database. If verification of a container fails, it is diverted to a verification station for further processing. Alternatively, it may be shunted to a rejection tote or bin.
[0005] The Poison Prevention Packaging Act currently requires prescription pharmaceuticals and medications as well as certain non-prescription drugs, medications, and dietary supplements, household chemical and cosmetic products to be packaged in child-resistant containers unless an exception is claimed. Virtually all such containers employ some form of screw type cap in which threading or one or more radially expanded flanges at the opening or on the neck of the container engage complementary threading, a groove or slot in the cap. The screw capping operation in automated systems involves engaging the complementary threading or the slot in the cap with the flanges and rotating the cap until it is snugged against the container at a preselected torque. Automated capping systems such as the KAPS-ALL® packaging systems, generally use a pair of side belts to capture the puck during the capping operation. These systems may experience some slippage problems in capturing and holding currently available cylindrical pucks. In addition, these systems are not well-suited to receiving or handling irregularly shaped containers such as the triangular bottles used for some popular liquid medications. In particular, the triangular, oval and other non-cylindrical containers tend to be difficult to align and introduce into a container carrier. They also tend to rotate within the carrier during the capping operation. Missed container insertion (no container), slippage and internal rotation can each trigger shut down of the assembly line and result in product waste.
[0006] Movement of the container carriers through such automated systems can generate substantial noise. The carriers are generally constructed of a hard synthetic resin material so that they will be durable and can be easily cleaned and sterilized if product spillage occurs. The container carriers are accumulated for use in an accumulating or staging area, where collisions between their hard surfaces produce noise. Some systems employ a vibratory mechanism to align and move the carriers along, which causes them to slap against each other. Some systems employ one or more pneumatic cylinders to push the carriers to various stations along the production line. Such cylinders strike the external surface of the carrier, causing noise. The carriers also generate noise when they transition from one conveyor to another, as well as along the production line when they collide as they are stopped for filling or other operations. High volume automated bottling and packaging systems employ extremely large number of container carriers, which may generate unacceptable levels of occupational noise exposure for their workers.
[0007] Container carriers are frequently designed to accommodate more than one size or type of container. This reduces the need for additional carriers and minimizes changeover time for dispensing different products on the same line. However, taller product containers have a higher center of gravity, which subjects them to tipping when filled with liquids or other heavier products.
[0008] Accordingly, there is a need for an improved product container carrier that enables a container to be easily loaded into a carrier, that centers the container on the vertical axis of the carrier, that prevents rotation of the container within the carrier, that enables a capper to capture the carrier and prevent slippage or rotation of the carrier, as well as the product container, during cap placement and torque down, that includes effective noise damping features, and that can be configured with a selected weight distribution to accommodate product containers having any of various shapes and weights so as to maintain the product container in an upright position during an automated filling and capping operation.
SUMMARY
[0009] An improved product container carrier includes a radially expanded base and an upstanding container holder with a recess for receiving a container. The external surface of the carrier includes a series of abutment surfaces to facilitate gripping the container and holding it in place. The internal surface of the container holder includes a plurality of abutment surfaces to facilitate loading and gripping of the container. A plurality of beveled surfaces assist in guiding the container into position at the center of the carrier and into contact with the abutment surfaces.
[0010] The carrier may also include a data element such as an RFID tag and/or bar coding. The base and the container holder may be constructed separately and secured together, or they may be of unitary construction. The base may include one or more recesses for receiving the container holder and/or data element.
[0011] In one embodiment, the carrier includes a housing module, a bumper and a base. The housing module may include a platform member that supports a product holder. A plurality of lugs depend from the platform member for reception within apertures in the bumper and bottom cap to receive fasteners that join the components together. In one aspect, the bottom cap is recessed to include a data element and a weight, and the bumper is recessed to include a weight. In another aspect, a data element and a weight are formed into the bottom cap and a weight is formed into the bumper.
[0012] The housing module may include a holder having a plurality of container abutment surfaces and angled surfaces at the opening to guide a container into engagement with the abutments.
[0013] The housing module may include a holder having a plurality of spaced container abutment surfaces. The abutment surfaces are separated by relief vents to enable air to escape when the carrier receives a container within the holder.
[0014] The housing module may include a holder having a pair of upright support members, which may be supported by a connecting base. Lateral openings between the upright supports permit engagement of the exposed side areas of the container by belts or other means.
[0015] A housing module may be selected in accordance with the type of container to be carried. The housing module is connected with the bumper and base by structure that extends between the housing and the base and passes through apertures in the bumper. This structure secures the parts of the carrier together. The bumper and the base may each include a weight positioned at a location selected to raise or lower the center of gravity to uphold the filled container within the carrier.
[0016] Various objects and advantages of this product container carrier 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 container carrier.
[0017] The drawings constitute a part of this specification, include exemplary embodiments of the carrier, and illustrate various objects and features thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a perspective view of a product container carrier with a triangular-type container in place;
[0019] FIG. 2 is a top plan view of the sleeve of FIG. 1 with a product container carrier in place of FIG. 1 ;
[0020] FIG. 3 is a perspective view of the product container carrier of FIG. 1 with the container removed;
[0021] FIG. 4 is a perspective view of the base shown in FIG. 1 ;
[0022] FIG. 5 is a perspective view of the sleeve shown in FIG. 1 ;
[0023] FIG. 6 is a top plan view of the sleeve of FIG. 3 with the container removed;
[0024] FIG. 7 is a perspective view of product container carriers including a bumper shown in line formation on a production line conveyor;
[0025] FIG. 8 is an exploded perspective view of an embodiment of a product container carrier with triangular container;
[0026] FIG. 9 is a perspective view of the product container carrier of FIG. 8 with the container removed;
[0027] FIG. 10 is a sectional view taken along line 10 - 10 of FIG. 9 ;
[0028] FIG. 11 is a perspective view of an exemplary product container carrier with upright support members, showing a container in position for reception within the carrier; and
[0029] FIG. 12 is a perspective view of an exemplary product container carrier with spaced interior abutment surfaces forming relief vents, showing a container in position for reception within the carrier.
DETAILED DESCRIPTION
[0030] As required, detailed embodiments of the product container carrier are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the device, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the apparatus in virtually any appropriately detailed structure.
[0031] Referring now to the drawing figures, an exemplary product container carrier 10 is illustrated in FIG. 1 in association with an exemplary container 12 . The carrier 10 includes a housing 14 having a base 16 supporting a container holder or sleeve 18 .
[0032] As best shown in FIGS. 4 and 5 , the base 16 has an approximately cylindrical external overall shape presenting an external sidewall 20 . A shorter internal sidewall 22 is positioned in axial spaced relation to the external sidewall. The internal sidewall 22 circumscribes an aperture, cavity or recess 24 in the base for receiving the sleeve 18 . The sleeve 18 has an approximately cylindrical external overall shape that is generally more elongate than the base and includes an external sidewall 26 and a coaxial internal sidewall 28 . The sleeve internal sidewall 28 circumscribes a bore, cavity or recess 30 for receiving a container 12 through an upper opening 31 ( FIG. 6 ). While the base and sleeve are each illustrated to have an approximately cylindrical external overall shape, any suitable external shape may be employed, including generally multilateral, oval, or multi-curved or combinations thereof. It is also foreseen that the base 16 and sleeve 18 may have the same outer diameter and/or surface configuration as, for example, a cylinder or oval, so that delineation of the base is not apparent from the external geometry of the carrier 14 . It is further foreseen that the carrier 14 may be constructed as if bored through, so that the sleeve 18 is contiguous with the base 16 . The sleeve 18 and base 20 may be constructed as separate pieces, or they may be of unitary construction.
[0033] The surfaces of the external and internal sidewalls 20 and 22 of the base 16 each include a series of respective abutment or gripping surfaces 32 and 34 . The surface of the external sidewall 26 of the sleeve 18 also includes a series of abutment surfaces 36 . The abutment surfaces 32 , 34 and 36 are depicted in the drawing figures as generally vertically oriented flattened surfaces. It is foreseen that these surfaces may also be knurled, swaged, crenate, scalloped or configured in any other suitable manner or combination of manners to provide the sidewalls 20 , 22 and 26 with a series of gripping surfaces. Where the sleeve 18 and base 16 are constructed as separate components, the internal abutment surfaces 32 and 34 of the sleeve and base aid in mutual engagement and gripping of the surfaces. This provides a friction fit for seating and holding the sleeve 18 in the recess 24 of the base during use, and also allows for quick and easy manual disengagement of the parts. Such construction enables substitution of different sleeve and base components or modules. It is also foreseen that the base internal sidewall 22 may be configured to include a smooth surface to facilitate application of an adhesive substance for permanently securing the sleeve 18 in the recess 24 .
[0034] The surface of the sleeve internal sidewall 28 includes a series of container abutment or gripping surfaces 38 . Preferably, the surface 38 is broached, molded, swaged or otherwise configured to provide a series of internal grooves that serve to position the container 12 at the center of the sleeve 18 and prevent slippage and/or rotation. The grooves are generally axially oriented and distributed so as to provide a plurality of container-contacting surfaces. In one example, the grooves are generally evenly distributed along the sleeve inner sidewall 28 . As best shown in FIG. 3 , the upper portion of the surfaces 38 may also include a series of bevels or chamfers 40 that are angled inwardly and serve to facilitate or ease the entry of the container 12 through the opening 31 and into the center of the sleeve 18 . It is also foreseen that the surface 38 may have a configuration similar to surfaces 32 , 34 and 36 . The container abutment surfaces 38 may be of integral construction with the sleeve 18 , or they may be independently formed as a bushing or insert, which may be removable or secured in place. Independently formed abutment surfaces may be constructed from a resilient material such as a silicone polymer or other suitable composition. The abutment surfaces 38 may also take the form of a smooth-walled tubular insert or bushing constructed of a resilient material. In such construction, the resiliency of the material would enable the insert to engage the container surface(s). The insert or bushing may be removable, or it may be secured in place by an adhesive composition or fasteners.
[0035] As shown in FIGS. 1 and 2 , the exemplary container has a body 42 , including an upstanding neck 44 , which may be tapered. The body 42 includes three walls 46 that meet at acute angles to form corners 48 , imparting a generally triangular shape when viewed from above. The upper portion of the neck 44 includes a plurality of outstanding flanges 50 for reception within corresponding tracks or grooves in a cap. The abutment surfaces 38 on the internal sidewall 38 of the sleeve receive the container corners 48 and grip them in place when a cap is inserted over the container neck and rotated to engage the flanges 50 . This construction prevents the container from rotating within the sleeve 18 along with the cap as it is tightened to a predetermined torque. While the exemplary container described and shown in FIGS. 1 and 2 presents a generally triangular cross section, it is foreseen that the product container carrier 10 can be used to prevent rotation within the carrier of a container having virtually any construction capable of engagement by the abutment surfaces 38 . It is also foreseen that the angular orientation of the abutment surfaces 38 may be specially configured to maximize gripping contact with the sidewalls of virtually any container.
[0036] Any of the previously described components of the container carrier 10 may be constructed of any known or hereafter developed synthetic resin, rubber, metal or other suitable material or combination thereof. The carrier components may be of solid construction, or they may be generally or partially hollow with internal support ribs. A nonslip coating composition may be applied to any or all of the abutment surfaces 32 , 34 , 36 , 38 to facilitate gripping.
[0037] In a method of manufacture of the container carrier 14 , the base 16 and sleeve 18 are constructed separately. The base 16 is constructed so that the internal sidewall 22 and recess 24 are axially oriented in the base. A data element such as an RFID unit 39 may be molded in or otherwise installed in the base 16 , either in the recess 24 or any other suitable location, or in the sleeve 18 . An adhesive substance such as, for example, a glue, epoxy, fusion weld are applied to one or more of the bottom surface of the sleeve 18 the lower portion of the sleeve exterior sidewall 26 , the internal sidewall 22 of the base and the portion of the base recess 24 adjacent the internal sidewall 22 . The base and sleeve are connected by sliding the sleeve 18 into the recess 24 in a press fit. The puck 14 may be constructed of a synthetic resin material or any other suitable material, including but not limited to a metal or organic material.
[0038] Alternatively, the base 16 and sleeve 18 may be of unitary construction with the sleeve 18 positioned coaxial on the base 16 . A data unit 39 may be installed on or in the base portion 16 or on or in the sleeve 18 .
[0039] In another embodiment shown in FIGS. 8-12 , a modular container carrier includes a noise-damping base with a variety of selectable container housing modules designed to accommodate various types of containers. An exemplary product container carrier 100 is illustrated in FIG. 8 in association with an exemplary container 112 . The container carrier 100 includes a base or bottom cap 116 supporting a bumper element 118 , and a housing module 120 .
[0040] The base 116 is approximately disc-shaped, with an upper or top surface 122 , a lower or bottom surface 124 and a circumscribing sidewall 126 . The lower surface 124 may be substantially planar, or it may include a recess 128 to receive a data element 130 , which may also be molded in place during formation of the base 116 . Optically readable data may also be inscribed on or applied to the base sidewall 126 or to the sleeve sidewall 166 . A weight unit or element 132 is molded into a recess 123 in the upper surface 122 of the base. The weight 132 may also rest or be attached to the upper surface 122 so that it is captured between the base upper surface 122 and the bumper 118 . The weight may be constructed of a metal, such as lead, steel or other ferrous metal, aluminum, or any other suitable material. It may be in the shape of a disc, as shown in FIG. 8 , or it may have any other suitable configuration, such as an apertured washer or multilateral body. Multiple weight elements may also be arranged in axial spaced relation or in axial and vertical spaced relation. The upper surface 122 includes an axial expansion groove 134 to facilitate snugging the upper surface of the base 122 against the lower surface of the bumper. The base 116 includes a plurality of spaced apertures to receive fastener structure for connecting the base, bumper and housing module, as will be described.
[0041] The bumper 118 includes upper and lower surfaces 138 , 140 and a sidewall 142 . A central recess 144 is provided adjacent either the upper or lower surface or at the center to receive a weight unit 144 , which may be molded into the bumper. The bumper 118 also includes a plurality of spaced apertures 148 for receiving connecting structure therethrough. The apertures 148 are positioned for alignment with the corresponding apertures 136 in the base. The bumper is sized to have a diameter greater than that of the base 116 as well as the housing module 120 , so that it is outstanding from the carrier 100 . The bumper is constructed of a resilient material such as rubber or a synthetic resin, so that it will cushion the impact of a collision with another object such as the bumper of another container carrier, the guide rails 194 or other portion of the conveyor system 188 , or any other equipment or materials encountered along the production line. By cushioning such impacts, the noise usually associated with impact is damped, resulting in a quieter production line.
[0042] The housing module 120 may be variously configured, but generally includes a platform 152 supporting a container holder, which may be in the form of a support sleeve 154 . The platform 152 includes an upper surface 156 , lower surface 158 and sidewall 160 . A plurality of support structures, legs or lugs 162 depend from the platform lower surface 158 . The lugs 162 are sized and positioned for alignment with the bumper apertures 148 . Each lug terminates in a stud or pin 164 . The pins 164 are undersized to enable a slip fit in the base apertures 136 . The arrangement of the supports 162 may be reversed, so that the apertures 136 are positioned in the platform 152 , rather than the base 116 and the legs 162 extend upwardly from the base 116 for registry with apertures 136 in the platform 152 .
[0043] In one aspect, the container support sleeve 154 of the upper housing module 120 is substantially as previously described, including an external sidewall 166 and a coaxial internal sidewall 168 circumscribing a recess or bore having an opening 172 at its upper end for receiving the container 112 . The internal sidewall 168 includes a series of abutment surfaces 172 and a series of bevels or chamfers 174 adjacent the opening 172 . A similarly configured bushing may be used. The lower end of the recess 170 terminates at a generally planar container support surface 176 positioned between the platform upper and lower surfaces 156 and 158 . The surface 176 may also be positioned on a level with either of the platform upper or lower surfaces 156 and 158 . The sleeve internal sidewall includes a plurality of container abutment surfaces 178 as previously described.
[0044] An exemplary container 112 is shown in FIG. 8 with a cap 180 installed. The container is substantially as previously described, and includes a body 182 having a flanged or threaded neck (not shown) and three walls 184 that meet at angles to form corners 186 .
[0045] When the container 112 is filled with a heavy product, the carrier unit 100 with filled container 112 may become top-heavy and likelihood of tipping the container and spilling the product may be increased. Such likelihood is substantially increased in the case of taller narrow containers such as shampoo bottles. Advantageously, the weight distribution of the container carrier 100 may be adjusted to raise or lower the center of gravity of the carrier to accommodate a particular type of product. This may be accomplished by raising or lowering the positions of one or more of the weights 132 and 146 and/or the weighted bumper 118 in the carrier until the center of gravity is positioned for maximum efficiency. The bumper 118 and base 116 may also be constructed to have taller sidewalls 118 and 126 , allowing greater flexibility in vertically positioning the respective weights 146 and 132 . In another aspect, a weight unit may be constructed to include a central aperture sized for installation over the sleeve 154 , to rest on the upper surface 156 of the platform 152 . Such a weight unit may be an additional weight (not shown), or one or both of weight units 132 and 146 may be constructed to include a central aperture and repositioned in this manner.
[0046] In a method of manufacture of the container carrier 100 , the base 116 , bumper 118 and housing 120 are constructed separately. In the exemplary embodiment shown, the platform 152 and sleeve 154 are depicted as being of unitary construction. However, it is foreseen that they may also be constructed separately. A data element 130 and weight 132 are molded in or otherwise installed in respective recesses 128 , 123 in the base 116 . A weight 146 is molded in or otherwise installed in puck recess 144 . The parts of the container carrier 100 are assembled and fastened together using thermoplastic or heat staking. The base 116 , bumper 118 and housing module 120 are aligned and assembled so that the lugs 162 project through the bumper apertures 148 and the pins 164 project through the base apertures 136 . In the reversed configuration previously described, the lugs 162 project from the base 116 , through the bumper apertures 148 and the pins 164 project through the platform 152 . Heat and pressure are then applied to deform the pins 164 to form a rivet-type head on the lower surface 124 of the base, or alternately, on the upper surface 156 of the platform. Heat staking is particularly well-suited to fasten the parts together in close relation; however conventional fasteners may also be employed.
[0047] Removable fasteners such as screws (not shown) or any other suitable fastener element may be used to enable substitution of alternate housing modules 120 and bases 116 to accommodate a variety container types. Where conventional fasteners are used, the pins 164 may be omitted and the fasteners project upwardly through the base apertures 136 for reception into the lugs 162 from below. Alternately, the fasteners project downwardly through the platform apertures for reception into the lugs 162 from above. In another aspect, the pins and the lugs may both be omitted and the fasteners project upwardly through the base apertures 136 and into the platform 156 or downwardly through the platform apertures into the base 116 . While three fasteners are shown in the drawing figures, any suitable number may be employed, including a single fastener. It is also foreseen that an adhesive substance, either alone or in combination with other fasteners, may be employed to fasten the parts together.
[0048] FIG. 12 illustrates an exemplary container carrier 200 having a housing module 202 designed to receive and transport a generally cylindrical container 204 having a circumscribing sidewall 206 . While the housing module 202 is designed to support any generally cylindrical or other container having a generally circular cross section, the illustrated exemplary container also includes a concentric upstanding neck 208 including threads 210 . The housing module 202 includes a platform 212 as previously described supporting a container support sleeve 214 . The sleeve includes an external sidewall 216 and a coaxial internal sidewall 218 circumscribing a recess or bore 220 having an opening 222 at its upper end for receiving the container 204 . The external sidewall 216 may include a plurality of abutment surfaces as previously described or a similarly configured bushing may be employed. The recess 220 may also include a smaller opening or drainage hole at its lower end. As shown in FIG. 12 , the sleeve 214 may be designed so that the sidewalls 216 and 218 are shortened to allow a greater portion of the container 204 to project above the sidewalls for engagement with container handling structure such as a side belt.
[0049] The internal sidewall 218 includes a plurality of spaced abutment members 224 , in the form of ribs, ridges, or other vertically oriented structures for engaging the container sidewall 206 . The ribs 224 , the sleeve internal sidewall 218 , and the container sidewall 206 cooperate to form a series of circumferential spaces or vents 226 between the sidewall of the container 204 and the sleeve. The relief vents 226 enable air to escape as the container 204 is introduced into the recess 220 , reducing back pressure on the container 204 as it is loaded and thus speeding the carrier loading process. The method of manufacture of the container carrier 200 is as previously described.
[0050] FIG. 11 illustrates an exemplary container carrier 300 having a housing module 302 configured to receive and transport a container 304 having a sidewall 306 . While the housing module 302 is designed to support a container having virtually any shape, the illustrated exemplary container is a cylindrical vial having a plurality of spaced apart lugs 308 adjacent an upper opening 310 . The housing module 302 includes a platform 312 , having an upper surface 314 . The platform 312 supports a container holder 316 . The holder includes a base 318 supporting a pair of upright support members or posts 320 . The posts are positioned in spaced relation equidistant from the central vertical axis of the carrier, with the distance between them selected to accommodate the diameter or width of the container 304 . The posts 320 each include an exterior sidewall 322 and an interior sidewall 324 . The interior sidewalls 124 of the posts cooperatively form a container receiving area 326 having a pair of opposed side openings 328 extending from a lower container support surface 330 to the tops of the posts 320 . It is foreseen that the base 318 may be omitted, and the posts 320 connected directly to the platform 312 , which in this aspect also serves as the container support surface 330 . One or more of the posts 320 may also include structure providing lateral adjustability so that the posts may be adjusted to receive larger or smaller containers. In one aspect, the interior sidewalls 324 or a portion thereof may include a resilient compressible collar adjacent the opening or bushings on the interior sidewalls 324 . The bushings are compressed by the container sidewalls 306 when the container is introduced into the carrier 300 . The compressed bushings push against the container sidewalls 306 , providing lateral support to containers 304 that are too small to engage the interior sidewalls 324 .
[0051] As shown in FIG. 11 , the container holder 316 is designed so that opposed portions of the generally cylindrical container sidewall 306 will extend radially outwardly beyond the uprights 320 for engagement with container handling structure such as a side belt or star wheel. In addition, the full length of the opposed portions that extend radially outwardly will be exposed, for example, for optical reading of a label, bar code, or the like.
[0052] A modular container carrier system includes a base 116 , bumper 118 , weights 132 and 146 , data element 130 and housing modules 14 , 120 , 202 and 302 . Bases 116 and bumpers 118 are provided having the weight 147 positioned in the middle or adjacent the upper or lower surface, 138 or 148 . A carrier is assembled by selecting a base and bumper 118 having a weight distribution selected to provide sufficient ballast for the filled container. A housing module is selected based on the type of container to be filled. The base, weight 132 , bumper with weight 147 and lugs 162 of the housing module 14 , 120 , 202 or 302 are aligned and assembled as previously described. The parts may be fastened together using heat staking or a removable fastener. An additional weight may be installed by aligning a central aperture over the holder element 154 , 214 , or 316 and sliding the weight downwardly until it contacts the upper surface of the platform or base 318 . The resultant carrier may be subsequently disassembled and reassembled using a different base, housing module or vertical positioning of the weights to enable use of the carrier with a different type of container as well as distribution of the weight of the carrier in accordance with the shape of the container and weight of the filled product.
[0053] FIG. 7 illustrates a plurality of exemplary container carriers 100 loaded onto a portion of a packaging system conveyor 188 . The conveyor includes a frame 190 having an endless conveyor or bottom belt 192 , which serves as a load-supporting surface. The belt 192 transports the carriers along a predetermined path through an assembly or production line to be filled, capped and labeled. The frame 190 includes a pair of opposed guide rails 194 , which are adjusted to a selected spaced distance to accommodate the width of the carriers 100 and maintain them in centered relation on the belt 192 as it travels over the frame 190 . Such conveyor systems also generally include one or more pairs of bottle gripper or side belts (not shown) for use with tall or unstable containers or tall container carriers 100 .
[0054] In use, a quantity of container carriers 100 is loaded onto a conveyor belt 192 with their container holders in an upward-facing orientation for transport along the production line. The carriers may be accumulated on an accumulating table, so-called “puck pond” or similar area awaiting production line demand, and shunted onto another conveyor for transport to the next station. The carriers may be pushed by mechanical means to urge them into position and jostle each other during transport. Advantageously, the outstanding bumpers 118 prevent the platform sidewalls 160 and bases 116 of the carriers 100 from making noise-generating contact with the hard sidewalls and bases of adjacent carriers. Instead, when the carriers 100 collide, the resilient bumpers 118 contact each other, absorbing the force of the collision and damping any noise.
[0055] A container 112 is typically dropped by a loading component of the packaging system into the sleeve portion 154 of the housing module 120 of each carrier 100 . The bevels 174 serve to introduce the container 112 into the container carrier 100 and guide it into contact with the container abutment surfaces 178 , which cooperate to center the container 112 in the carrier with the mouth or opening centered along the central vertical axis of the carrier 100 . While the container 112 is illustrated in FIGS. 1 and 8 as a generally triangular shaped bottle, it may have any suitable three dimensional shape and need not be symmetrical along any axis.
[0056] For example, the container may present multiple planar surfaces such as a solid rectangular, square, star-shaped or irregular container. It may also present single or multiple curved surfaces, such as a cylinder, oval, heart shape or irregularly curved container. It may also present a combination of planar and curved surfaces.
[0057] The carrier 100 and container 112 proceed along the conveyor to at least a station where the container is filled with one or more preselected products. Preferably, the package handling system also includes a series of scanning and verifying stations where the data unit in the carrier is read and compared with a bar code on the container 112 . The filled container 112 is then transported in its carrier 100 to a capping station where a cap 180 is positioned on the container to engage a fastening member such as a flange 50 ( FIG. 1 ). While the fastening member is illustrated in FIG. 1 to include a plurality of radially expanded flanges 50 , it may include threading, a continuous circumferential rib or any other suitable fastening means.
[0058] Typically, the capping station employs side belts or a rotary assembly such as a star wheel, or other structure to engage the housing module 120 or the container. Side belts capture the carrier 100 against rotation and position it so that the container opening is centered under the cap. Where the sleeve 18 is configured to include abutment surfaces 36 as shown in FIG. 1 , they provide additional areas of belt-to-carrier or wheel-to-carrier contact that assist in securing the carrier against rotation. Where the housing module 202 is configured to allow the container 204 to project above the sleeve 214 as shown in FIG. 12 , the side belts or star wheel engage the free surface of the container sidewall 206 rather than the carrier. Where the housing module 302 is configured to allow the container 304 to project outwardly from the container holder 316 , the belts or wheels engage the free sides of the container 304 rather than the carrier 300 .
[0059] The internal abutment surfaces 178 of the sleeve 154 ( FIG. 9 ) provide a series of seating surfaces for the container 112 that grasp or grip the container corners 186 ( FIG. 8 ) and hold the container in place. Where the container is shaped other than as depicted, the abutment surfaces 178 grip the edges, protrusions, or any other suitable grippable portions of the container. Thus securely seated within the carrier 100 , rotation or spinning of the container 112 is prevented during the capping operation. The container 112 remains stationary and coaxial with a central vertical axis of the carrier 100 while capping structure positions the cap 180 over the flanges 50 , rotates the cap into mating engagement with flanges and snugs the cap in place on the container 112 to a preselected torque. Once filled and capped the conveyor belt 192 transports the container 112 past any additional scanning and verifying stations onto an order accumulation lane, which brings together multiple orders. In the case of a single component order, the container is then transported to a packing station for final packaging and/or delivery. In the case of a multi-component order, the container is deposited into a tote for further processing.
[0060] It is to be understood that while certain forms of the product container carrier have been illustrated and described herein, it is not to be limited to the specific forms or arrangement of parts described and shown.
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A carrier for receiving and restraining a container against rotation during an automated filling and capping operation includes an array of modular container housings. A bumper is disposed below the housing and projects outwardly to cushion the carrier against impact. The bumper is supported by a base. Structure extends from the housing through the bumper and into the base to secure the carrier. One housing module includes a recess having container abutment surfaces and angled surfaces at the opening to guide a container into engagement with the abutments. One housing module includes a recess having ribs separated by relief vents to relieve air pressure as a container is loaded into the carrier. One housing module includes a container holder having a pair of upright supports separated by side openings. The bumper and the base each including a weight positioned at a selected location to uphold the filled container.
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BACKGROUND
1. Technical Field
The present disclosure relates to electronic devices, and particularly to an electronic device with a table stand which is adjustable to select a desirable viewing angle.
2. Description of Related Art
Some electronic devices are equipped with a support such as a table stand that swivels out from the device to support the device on a tabletop. However, most current table stands are not adjustable or not easily adjustable. That is, the table stand folds out at a predetermined angle with the electronic device. As a result, the viewing angle for different users cannot be adjusted.
Therefore, it is desirable to provide an electronic device having an adjustable table stand which can overcome the above-mentioned problems.
BRIEF DESCRIPTION OF THE FIGURE
The components of the drawings are not necessarily drawn to scale, the emphasis instead being placed upon clearly illustrating the principles of the embodiment of an electronic device having an adjustable table stand. Moreover, in the drawings, like reference numerals designate corresponding parts throughout several views.
FIG. 1 is an assembled, isometric, schematic view of an electronic device having an adjustable table stand in a first state, according to an exemplary embodiment.
FIG. 2 is a partially exploded view of the electronic device of FIG. 1 .
FIG. 3 is another partially exploded view of the electronic device of FIG. 1 .
FIG. 4 is a partial cut away view of the electronic device of FIG. 1 .
FIG. 5 is a partial cross-sectional view of the electronic device, taken along V-V line of FIG. 4 .
FIG. 6 is an assembled, isometric, schematic view of the electronic device of FIG. 1 in a second state.
DETAILED DESCRIPTION
Embodiments of the present disclosure will now be described in detail with reference to the drawings.
Referring to FIG. 1 , a device 100 includes a main body 10 and a table stand 20 rotatably connected to the main body 10 . The main body 10 includes a front body 12 and a rear cover 11 covering the back of the front body 12 . In this embodiment, the device 100 is a digital photo frame.
Referring to FIGS. 2-4 , the rear cover 11 includes an outer surface 120 and an inner surface 121 . The inner surface 121 faces the front body 12 , while the outer surface 120 faces away from the front body 12 . The rear cover 11 defines a rectangular space 122 and a groove 126 communicating with the space 122 . The rear cover 11 further defines an opening 123 through the outer surface 120 and the inner surface 121 and a pair of pivot holes 124 communicating with the groove 126 . The pivot holes 124 are coaxially positioned at two opposite sides of the opening 123 . The opening 123 is positioned between the pair of the pivot holes 124 . The rear cover 11 further includes two fixing columns 125 protruding from the inner surface 121 and adjacent to the opening 123 . Each of the fixing columns 125 defines a screw hole (not labeled).
The main body 10 further includes a fixing mechanism 13 positioned on the inner surface 121 of the rear cover 11 . The fixing mechanism 13 includes a bottom cover 132 , a top cover 131 , an elastic member 133 , a positioning member 134 , and two screws 135 . Each of the top cover 131 and the bottom cover 132 defines two through holes 138 . The top cover 131 and the bottom cover 132 are sleeved on the fixing columns 125 via the through holes 138 . The screws 135 are screwed into the fixing columns 125 to fix the top cover 131 and the bottom cover 132 on the inner surface 121 .
The top cover 131 and the bottom cover 132 further jointly define a first hole 136 and a second hole 137 . The second hole 137 communicates with the first hole 136 and faces the opening 123 . The elastic member 133 is received in the first hole 136 . The positioning member 134 includes a first portion 134 a and a second portion 134 b formed on the first portion 134 a . The first portion 134 a is received in the first hole 136 adjacent to the second hole 137 and resists the elastic member 133 . Accordingly, the elastic member 133 applies an elastic repelling force to the positioning member 134 . The second portion 134 b is inserted through the second hole 136 and protrudes outward from the top cover 131 and the bottom cover 132 .
The table stand 20 includes a supporting plate 21 , two shafts 22 , and a positioning plate 23 . The supporting plate 21 is a substantially rectangular plate having a bent end 210 . The two shafts 22 extend coaxially from two opposite sides of the bent end 210 respectively. The positioning plate 23 protrudes upward from the bent end 210 and defines a plurality of positioning holes 24 . The plurality of positioning holes 24 are substantially aligned in an arc. The table stand 20 further defines two slots 25 in the bent end 210 at opposite sides of the positioning plate 23 , such that two bendable portions 212 are formed adjacent to the two slots 25 correspondingly. The two bendable portions 212 can be flexibly pressed toward the positioning plate 23 .
Further referring to FIG. 5 , the two bendable portions 212 are pressed toward the positioning plate 23 , such that the two shafts 22 move toward the positioning plate 23 . Then, the positioning plate 23 is inserted through the opening 123 , and the bent end 210 is received in the groove 126 . Finally, the two bendable portions 212 are released, such that the two shafts 22 are pivotably inserted into the two pivot holes 124 . As such, the table stand 20 is assembled to the main body 10 .
To provide support for the main body 10 , the table stand 20 is rotated relative to the main body 10 to a support position. If the second portion 134 b is aligned with one of the positioning holes 24 , the second portion 134 b is inserted into the aligned positioning hole 24 due to the repelling force of the elastic member 133 . As such, the table stand 20 is fixed and forms a predetermined angle with respect to the main body 10 . Otherwise, the second portion 134 b is resisted by the positioning plate 23 and received in the second hole 137 . The angle between the table stand 20 and the main body 10 can be adjusted via fixing the table stand 20 at different positions corresponding to the plurality of positioning holes 24 . Thereby, the main body 10 can be placed at an appropriate viewing angle for a user. Referring to FIG. 6 , the table stand 20 can be rotated to be received in the space 122 if the main body 10 does not need to be supported.
While various exemplary and preferred embodiments have been described, it is to be understood that the disclosure is not limited thereto. To the contrary, various modifications and similar arrangements (as would be apparent to those skilled in the art) are intended to also be covered. 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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An electronic device includes a main body and a table stand connected to the main body for supporting the main body. The main body comprises a positioning member. The table stand defines at least two positioning holes. The table stand is operable to rotate relative to the main body. The positioning member is operable to be selectively inserted into either one of the at least two positioning holes, such that the table stand is operable to form a corresponding predetermined angle with the main body.
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PRIORITY
[0001] This is a continuation application of U.S. patent application Ser. No. 10/122,927, filed Apr. 16, 2002. No new matter has been added to the specifications or drawings.
BACKGROUND OF THE INVENTION
[0002] This invention relates to an adaptation of bi-component fiber spinning to a melt-blowing process as described in U.S. Pat. No. 5,476,616, which is herewith incorporated as reference. More particularly, it relates to the improvement whereby the number of rows of spinning orifices can be extended beyond the number possible before and still maintain fiberforming spinning quality, using polymer pairs of greatly differing melt viscosities and other properties.
OBJECTS OF THE INVENTION.
[0003] It is an object of the present invention to provide a bi-component spinning system whereby a spinning nozzle fed by one type of polymer from one chamber is located inside another slightly larger spinning nozzle fed by a second chamber, said nozzle pairs being arranged in multiple rows of spinning orifices, and directing streams of gas to each row of spinning orifices.
[0004] Another object of the invention is to provide a uniform stream of attenuating gas around each spinning nozzle by centering the nozzle pairs in round holes of gas cover plates to achieve an even gas flow around the circumference of each nozzle pair.
SUMMARY OF THE INVENTION
[0005] These and other objects of the invention are achieved by directing a gas flow to the base of the spinning nozzle pair by means of baffle plates, and extending the length of the spinning nozzle pairs. The spinning nozzle pairs are guided through a family of gas cover plates providing for the centering of the round spinning nozzle pairs through round gas supply holes and supplying a uniform stream of gas to each nozzle pair and row of nozzle pairs.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] A better understanding of the present invention as well as other objects and advantages thereof will become apparent upon consideration of the detailed disclosure Thereof, especially when taken with the accompanying drawings, wherein like numerals designate like parts throughout; and wherein FIG. 1A is a partially schematic side view of a spinnerette assembly of the present invention, showing the path of gas and the two polymer flows.
[0007] [0007]FIG. 1B is the same spinnerette where the inner nozzles 4 have been shortened by the distance 22 .
[0008] [0008]FIG. 2A is a partial bottom view of the concentric spinning nozzles and gas cover plates, taken along the lines 23 - 23 .
[0009] [0009]FIG. 2B is a partial bottom view of the concentric spinning nozzles and gas cover plates, taken along the lines 24 - 24 .
[0010] [0010]FIG. 3 is a partial bottom view of a spinnerette assembly, wherein the inner nozzle is off-center and shaped in a half-circle to form side-by-side bi-component fibers.
DETAILED DESCRIPTION OF THE INVENTION
[0011] In previous bi-component spinning assemblies, side-by-side or sheath-core structures are being formed by having two polymers flow through capillaries in a laminar flow pattern without mixing before exiting the capillary and then solidifying. This limits the polymer pairs to such groups that are capable of laminar flow, i.e. have similar melt-viscosities and other properties at similar extrusion temperatures. Bi-component designs have been disclosed in U.S. Pat. Nos: 2,931,091 and 3,039,174. Most of these designs were used in traditional textile yarn spinning and are not easily adaptable to the melt-blowing process.
[0012] In U.S. Pat. No. 6,057,256 to Krueger et al. a bi-component met-blowing process is shown where the polymers are contacted with each other inside the die-body as previously described, and, by laminar flow exit the spinning orifice and are drawn down by high velocity air. This design, however, is limited to a single row of spinning orifices and consequently relatively low capacity.
[0013] In the present invention, a bi-component melt-blowing system is shown where bi-component fibers are being spun out of multiple rows of spinning orifices, and whereby the contact time of two or more polymers inside the die-body can be controlled from zero to any finite time chosen, by having one capillary in which a first polymer flows, being fed from one polymer manifold, is surrounded by a second, larger than the first capillary, through which a second polymer fed from a second polymer manifold flows; at the exit point, each tubular nozzle is surrounded by a concentric flow of high velocity air as described in previously cited U.S. Pat. No. No. 5,476,616.
[0014] Referring now to FIG. 1, the spinnerette assembly is mounted on the die body 1 which supplies polymer melt 2 to first supply cavity 3 feeding the spinning nozzles 4 which are mounted in the spinnerette body plate 5 wherein nozzles 4 are mounted. A second set of nozzles 6 , larger than nozzles 4 , having an identical mounting pattern as nozzles 4 , is mounted on the die body plate 7 and is being fed with a second polymer 8 from the die body 1 and through plate 5 to cavity 9 which feeds nozzles 6 . Nozzles 4 are inserted into nozzles 6 , and have the same or shorter length than nozzles 4 . The nozzles 4 and 6 lead through the gas cavity 10 , which is fed with gas, air or other suitable fluids from gas inlet slot 11 . The primary gas supply enters the spinnerette assembly through pipe 12 into the supply cavity 13 . The baffle plate 14 diverts the gas stream and forces the gas through the slot 11 toward the base of nozzles 6 . The nozzles 4 and 6 protrude through gas cover plate 15 through tight fitting holes 16 arranged in the same pattern as the nozzle mounts in spinnerette body plates 5 and 7 . The gas cover plate family further consists of spacer plate 18 , which forms a second gas cavity 19 between plate 15 and 20 . The complete path of the gas is now from inlet pipe 12 into the gas supply cavity 13 through inlet slot 11 into gas cavity 19 . The gas then flows through gas holes 17 of plate 15 into the gas cavity 19 and then around the nozzles 6 through holes 21 , in which nozzles 6 are centered. The high velocity gas out of holes 21 accelerates and attenuate the exiting polymer melts to form fine fibers. FIG. 2A and B show the bottom view of plates 15 and 20 , respectively. FIG. 3 shows a bottom view of plate 20 , wherein the inner nozzles 4 are shaped in a half circle to produce a side-by-side bi-component fiber.
[0015] The following examples are included for the purpose of illustrating the invention and it is understood that the scope of the invention is not to be limited thereby.
EXAMPLE 1
[0016] A 5″ long spinnerette was used of the type shown in FIG. 1. The spinnerette had 12 rows of nozzles, spaced 0.060″ apart, within each rows, the nozzles were also spaced 0.060″ apart, resulting in a total number of nozzles of 1000. The inner nozzles 4 mounted in plate 5 had an outside diameter of 0.020″ and an inside diameter of 0.010″. The outside nozzles 6 mounted in plate 7 had an outside diameter of 0.035″ and an inside diameter of 0.023″. Air cavity 10 had a height of 0.500″, air cover plate 15 a thickness of 0.063″. Air holes 17 shown in FIG. 1 and 2 A had a diameter of 0.020″. Air cavity 19 had a height of 0.100″ and air cover plate 20 a thickness of 0.063″. The air holes 21 in plate 20 had a diameter of 0.048″. The resin inlets 2 and 8 were each connected to a 1″ (24/1 length/diameter ratio) extruder, subsequently referred to as extruder A and B, respectively, each capable of extruding approximately 10 lb/hr of polymer resin.
[0017] Extruder B (sheath polymer) was charged with high-density polyethylene of Melt Index 105 (Dow Chemical Company's “ASPUN” 6808A) and the resin was extruded into the spinnerette at a rate of 30 gram per minute; Extruder A (core polymer) was charged with polypropylene of MFR 70 (Melt Flow Rate, as determined by ASTM-Method D-1238-65T)(HIMONT “HH442”) and extruded at a rate of 45 gram per minute, 3% of blue polypropylene color concentrate was added to the polypropylene resin to give the core fiber a blue appearance. The spinnerette temperature and the air temperature were 480 degree Fahrenheit, and the air pressure was 20 psi. 12″ below the spinnerette there was a moving screen that collected a web of highly entangled blue fibers of 3 to 6 micrometer diameter. The web had a typical slick, silk like polyethylene feel, indicating that the polyethylene from extruder B was on the outside. Parallel strands of fibers were imbedded and cured into an epoxy resin, and cross sections were cut therefrom. Microscopic examination showed a concentric sheath/core fiber structure, with the blue color visible in the core section. When the fibrous web was heated to a temperature of 250 degree F., most of the point of intersection bonded by coalescence and the web formed a stiff, shape-retaining structure.
EXAMPLE II
[0018] Additional experiments were conducted using polymer pairs as shown in Table 1:
TABLE 1 Experiment No.: 1 2 3 4 Polymer from PET 1 6,6 Nylon 2 PBT 3 Polypropylene Extruder A 0.59 IV 4 35 RV 5 0.59 IV 70 MFR Extrusion rate 30 g/min 35 g/min 45 g/min 40 g/min Polymer from 6,6 Nylon PET Nylon 6 6 Nylon 6 Extruder B 35 RV 0.59 IV 40 RV 40 RV Extrusion rate 45 g/min 50 g/min 30 g/min 25 g/min Spinnerette 520 520 480 470 Temp. (F.) Air Temp. (F.) 510 520 480 470 Air pressure (psi) 25 25 23 24
[0019] Microscopic examination of the fiber cross-sections, which ranged from 3 to 7 micrometer in diameter, revealed that the sheath/core structure was concentric or near concentric.
EXAMPLE III
[0020] Example I was repeated using identical polymers and process conditions, but with a spinnerette described in FIG. 1B where the inner nozzles 4 where recessed by the length 22 of 0.150″. Under a microscope, the fiber cross-sections showed the same concentric sheath/core structure as in Example I, with the blue polypropylene inside.
EXAMPLE IV
[0021] Example I was repeated using a nozzle arrangement as shown in FIG. 3. Upon microscopic examination, the fiber cross-section showed that the two polymers had each formed a semi-circle in a side-by-side configuration.
[0022] While the invention has been described in connection with several exemplary embodiments thereof, it will be under stood that many modifications will be apparent to those of ordinary skill in the art, and that this application is intended to cover any adaptations and variations thereof. Therefore, it is manifestly intended that this invention be only limited by the claims and the equivalents thereof.
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Disclosed is a novel melt blown spinnerette and process for making bicomponent fine fibers whereby a spinning nozzle fed by one type of polymer from one chamber is located inside another larger spinning nozzle fed by a second chamber, said nozzle pairs being arranged in multiple rows of spinning orifices, and directing high speed streams of gas to each row of spinning orifices. The design of having a nozzle inside a nozzle does not require laminar flow of layered molten masses of different polymers. The fibers made hereby have a broad fiber size distribution.
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This application is a continuation of application Ser. No. 09/714,322, filed Nov. 16, 2000 now U.S. Pat. No. 6,837,020.
FIELD OF THE INVENTION
The present invention relates to the field of building construction materials, and more particularly to building architectural trim products.
BACKGROUND OF THE INVENTION
The architectural distinctiveness of a house or other building is often attributable to the trim that provides a finishing touch to an otherwise common shape. Trim distinctiveness has, through the years, evolved from Greek, Roman, Gothic, and Victorian to contemporary and modernistic. Each style has various characteristic details and shapes that sets it apart from the others.
Parallel changes have come about through the development of building materials, especially those materials that form the visible surface of a house or building. Common exterior surface materials in use today are wood, brick, vinyl, and aluminum. Vinyl and aluminum have the advantage of being supplied from the factory with its final color applied, and need no more than minimum maintenance. With each of these exterior surface materials, the trim portions of the building, e.g., the crosshead piece over a door or window, the fascia below the roofline, the transition frieze, or molding, between a wall and ceiling, are almost always made of wood. The reason for wood being used for this purpose is that wood can be efficiently formed into attractive shapes that are distinctive to a particular style. Forming similar shapes of plastic requires complex molds, and shapes of metal or concrete have traditionally been heavy. Even where the exterior siding of a building is made of vinyl or aluminum, modern siding materials that are mass produced with their surface colors applied at the factory, the trim has generally been made of wood. However, wood has the drawback of requiring periodic maintenance in the form of scraping and painting to prevent degradation.
One known exception is a line of architectural trim products made of plastic resin from Style-Mark, Inc. of Archbold, Ohio. These known plastic trim products require substantial molding investment and capacity to produce, and involve either a substantial inventory or a significant delivery delay to obtain. In addition, in order to keep inventory within reason, these trim products are available in white only; if another color is desired, the parts must be painted at the construction site.
A process and apparatus exists for forming factory painted aluminum sheet into rain gutters. The aluminum is supplied in roll form and is drawn as a sheet through a mechanism having complementary convex and concave rollers to form the profile gutter shape. Forming aluminum rolled sheet into gutters at the site of installation has the advantage of permitting a seamless, continuous length of gutter to be installed across the entire edge of a house's roof, without the need to transport long gutter sections, e.g. 10 meter (39 feet), over the roads to the building site.
While forming aluminum sheet into gutters is known, the objective has been to achieve long, continuous sections, as described above. Furthermore, gutters are typically of a simple and functional cross sectional contour with an upwardly open channel. In the design of architectural trim products, a degree of flexibility is necessary since the style of the building will dictate the style and the width of the trim.
Therefore, it is an object of the present invention to provide an architectural trim product that can be economically produced in a variety of shapes and styles.
It is another object of the present invention to provide an architectural trim product that can be produced in a variety of colors without the need for painting at the construction site.
It is a further object of the present invention to provide an architectural trim product that does not require periodic maintenance.
These and other objects of the present invention will become apparent through the disclosure of the invention to follow.
SUMMARY OF THE INVENTION
The present invention provides an architectural trim product fabricated of sections formed out of aluminum sheet material. The sections have a cross sectional profile shape that includes curved portions and right angle bends. The sections are optionally used as a fascia, a frieze in lengths matching the length of a wall-to-soffit joint, crosshead trim over a window or door or other trim uses. In the crosshead application, the horizontal section piece is mitered at each end and the ends are each closed with a short piece of similar miter-cut section, giving the appearance of a three-dimensional solid. An attaching bolster, or stiffening block, is formed in a shape to fit behind the contour of the trim section to support it to a wall while minimizing the tendency of the aluminum to bend. In all forms, the method of mounting the trim product of the invention to the building structure provides secure attachment with no visible nails, screws, or adhesive.
The sections of architectural trim are made from aluminum sheet pieces that have been cut to length and then bent. The curves are formed first by pressing the sheet between two shaped components, for example pipe segments. After forming the curves, the right-angle bends are made on a conventional brake, or the like. An alternate forming process uses a set of matching rollers to form the aluminum sheet into a contour-shaped trim piece.
BRIEF DESCRIPTION OF THE DRAWINGS
In order for the invention to become more clearly understood it will be disclosed in greater detail with reference to the accompanying drawings, in which:
FIG. 1 is a front elevation view of a building wall having a window over which a crosshead architectural trim product according to the invention is mounted.
FIG. 2 is a perspective view of a section of formed sheet material for making an architectural trim product of the invention.
FIG. 3 is a perspective view of the crosshead trim product according to FIG. 1 .
FIG. 4 is a side elevation view of the architectural trim product according to FIG. 3 , further showing a bolster support piece therewithin.
FIG. 4A is a perspective view of the bolster support piece of FIG. 4 .
FIG. 4B is a side elevation view of the architectural trim product according to FIG. 3 , further showing a J-hook and a block as mounting pieces therewithin.
FIG. 5 is a side elevation view of a second embodiment of the invention as mounted to a building wall with a mounting clip.
FIG. 5A is a side elevation view of the embodiment of FIG. 5 showing the steps involved in mounting the trim product to the mounting clip.
FIG. 5B is a side elevation view of an alternate shape trim product of the embodiment of FIG. 5 .
FIG. 6 is a side elevation view of a portion of a building to which a frieze with a concave curve portion according to the invention has been mounted.
FIG. 6A is a side elevation view of a portion of a building to which a frieze with a convex curve according to the invention has been mounted.
FIG. 6B is a side elevation view of a portion of a building to which a frieze with concave and convex curve portions according to the invention has been mounted.
FIG. 6C is a side elevation view of a portion of a building to which a frieze with a convex curve according to the invention has been mounted by means of a J-hook.
FIG. 7 is a front elevation view of a portion of a building roofline to which a fascia trim product according to the invention is mounted.
FIG. 7A is an enlarged cross sectional view taken in the direction of line 7 A— 7 A of FIG. 7 and depicting a fascia of a first contour.
FIG. 7B is an enlarged cross sectional view taken in the direction of line 7 A— 7 A and depicting a fascia of a second contour.
FIG. 8 is an end elevation view of a press die set having curved and angular portions for creating curved and angular contour portions in a sheet of bendable materials.
FIG. 9 is a perspective view of a pair of engageable die rollers having surfaces formed with curved and angular portions for creating curved and angular contour portions in a sheet of bendable material.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The architectural trim product of the present invention is an economical and versatile component for enhancing the appearance of the interior or exterior of a building. The trim product can be formed to emulate the appearance of most of the building trim products that are currently available in wood or molded plastic resin, in an efficient and attractive way. Examples of types of trim products to which the present invention pertains include, but are not limited to, crosshead trim over windows and doors, friezes between an exterior wall and an adjacent soffit, cove molding between an interior wall and a ceiling, and fireplace mantles. In all embodiments of the invention, the component that will remain in view covers the wall-mounting component and any fasteners.
Referring now to FIG. 1 , a wall of building 10 is illustrated with typical window 12 located therein. Window 12 may be of the type having a plurality of individual frames (as shown) or of the type with a single frame for each of its upper and lower sections. A first side trim 16 a is mounted in vertical orientation on the left side of window 12 and a second side trim 16 b is mounted similarly on the right side thereof. Side trims 16 a and 16 b preferably are formed of a bendable sheet material. A crosshead 18 is mounted above window 12 and extends laterally to slightly overlap each of side trims 16 a and 16 b for architectural interest. The particular shape of crosshead 18 as illustrated is stepped from its bottom surface (as shown), of length L 1 , to its top surface of length L so that its top surface overhangs side trims 16 a and 16 b by a greater amount than does its bottom surface. Each end of crosshead 18 is closed by a short piece of the same profile shape of which the central portion of crosshead 18 is made with the central portion and the end portions cut at a complementary shape with their mutual joint sealed with a pliant material, for example caulking compound.
FIG. 2 illustrates, in perspective view, a length of formed sheet material 20 that has been bent to create a desired profile for being assembled to make crosshead 18 as described above. Formed sheet 20 is formed by making a number of curved and square bends in an elongate sheet of material of the type that is able to retain a shape to which it is bent. A sheet material that has been found to be satisfactory is aluminum sheet of 0.56 mm (0.022 inch) thickness. Such aluminum sheet material is available with one surface painted during the manufacturing process, and is available from a variety of suppliers, for example, Aluminum Corporation of America. Alternate materials that provides the requisite characteristics of retaining a bent shape are, for example, copper sheet and galvanized steel sheet. Formed sheet material 20 comprises a series of linear bends oriented parallel to the elongate linear edges of sheet 20 , including vertically oriented rear lip 22 , horizontally oriented top panel 24 , vertically oriented top face 26 , horizontal return 28 , curved portion 30 , vertically oriented middle face 34 , horizontally oriented middle return 36 , vertically oriented skirt 40 , horizontally oriented bottom return 42 , and angularly oriented grip 44 . As will be apparent to those skilled in the trade, formed sheet material 20 may incorporate various arrangements of right angle, curved, and angled bends. Any curved portions formed may be either concave or convex and either circular or another form of curve, e.g. parabolic. Additionally, more than one curved portion may be formed to achieve a different appearance.
Referring now to FIG. 3 , crosshead 18 is shown in perspective view including front panel 58 and end cap 60 . Length L of crosshead 18 is substantially greater than width 1 thereof. Front panel 58 and end cap 60 are each cut from a length of formed sheet material 20 (see FIG. 2 ). Front panel 58 and end cap 60 are cut along their mating edges at complementary miter angles to be assembled to each other and form a three-dimensional component. For mounting crosshead 18 over window 12 , as illustrated in FIG. 1 , the opposite end of front panel 58 and a second end cap (not shown) are similarly prepared and assembled. Upper tab 60 a and lower tab 60 b are configured to securely engage the mating end of front panel 58 . When end cap 60 is assembled to front panel 58 , a weather resistant sealant, e.g. silicone caulk, is applied to the rear of the mating edge, preferably in a color to match the exposed surfaces of crosshead 18 .
FIGS. 4 and 4B show side elevation views of alternate means of mounting a length of formed sheet 20 to a building wall 62 . FIG. 4 shows bolster 50 fastened to wall 62 by multiple fasteners N, such as nails, screws, or adhesive. Bolster 50 is preferably formed in a profile shape that is established to substantially follow the interior profile of formed sheet material 20 . Bolster 50 , in the preferred embodiment, is made by cutting a sheet of bendable material, e.g. aluminum, to an appropriate profile shape. Preferably, the profile shape of bolster 50 is cut in two mirror image flaps 56 and 57 that are separated by a flat area extending from extended top tab 52 to extended bottom tab 54 , as shown in perspective in FIG. 4A . Bolster 50 serves to mount formed sheet 20 to wall 62 and also to minimize bending of formed sheet 20 if it is hit by an object. Bolster 50 is secured to wall 62 with a fastener N through top tab 52 and a second fastener N through bottom tab 54 . Top fastener N is hidden by rear lip 22 . Second fastener N through bottom tab 54 will be subsequently hidden by exterior siding panels (not shown) when they are assembled to wall 62 . Thus, the finished trim product will have no visible means of attachment to wall 62 . The parallel profile provision of two flaps 56 and 57 enhances the resistance of bolster 50 to bending. Grip 44 (see FIG. 4 ) maximizes the security of mounting formed sheet 20 to bolster 50 through pressure and sharp edge engagement, with a sharp edge existing at the bottom of rear lip 22 to engage the top portion of bolster 50 and a sharp edge at the end of grip 44 to engage the bottom portion of bolster 50 .
Referring now to FIG. 4B , formed sheet 20 is shown mounted to wall 62 by means of block 64 and J-hook 66 . Block 64 is a substantially elongate member having a substantially rectangular cross section, for example wood or plastic foam. J-hook 66 is formed of a strip of bendable material, e.g., aluminum, that has been bent in the general shape of a “J” so that when the upper straight portion thereof is fastened to wall 62 by fastening means N, for example nails or screws, the lower portion of the “J” is facing upwards. Block 64 is fastened to wall 62 by fastening means N at a height so that when rear lip 22 of formed sheet 20 is placed in the lower portion of J-hook 66 , and the bottom of formed sheet 20 is brought toward wall 62 , grip 44 grippingly engages the bottom surface of block 64 to secure formed sheet 20 in place.
Referring now to FIG. 5 , a third embodiment of the invention is illustrated in side elevation view. A mounting clip 70 is formed with a substantially planar central portion, a bottom lip 72 , and a top lip 74 . The central planar portion of mounting clip 70 is affixed to wall 62 by any convenient means, e.g. fasteners N, and bottom lip 72 and top lip 74 are not anchored. Bottom lip 72 is formed with its lowermost part spaced from wall 62 . Top lip 74 is formed with its uppermost part slightly spaced from wall 62 with an angularly oriented planar portion leading toward its uppermost part.
Continuing with FIG. 5 , face trim 76 is formed to mount onto mounting clip 70 . Face trim 76 has bottom hook 78 , formed to engage bottom lip 72 of mounting clip 70 . Face trim 76 also has top hook 80 , formed to engage top lip 74 of mounting clip 70 .
The assembly of face trim 76 to mounting clip 70 is illustrated in sequential steps in FIG. 5A . After bottom hook 78 of face trim 76 has been placed in engagement with bottom lip 72 of mounting clip 70 (see FIG. 5 ), top hook 80 is placed against the angled portion of top lip 74 as seen as dashed line A. Pressure is exerted against top hook 80 in the general direction indicated by arrow X, causing top hook 80 to bend upwardly relative to the body of face trim 76 (see FIG. 5A ), moving from position A (dashed lines) to position B (dashed lines). As top hook 80 approaches the uppermost end of top lip 74 , its extreme end snaps over and into place between top lip 74 and wall 62 as indicated at position C (solid lines). Once in this mounted position, depending on the length of top hook 80 that enters behind top lip 74 , removal of face trim 76 is difficult, if not impossible, without substantial distortion.
Referring now to FIG. 5B , a further profile shape of this second embodiment of the invention is shown. In this profile shape, mounting clip 70 is formed similarly to that discussed and shown above, but face trim 76 ′ has a more exaggerated profile. Top hook 80 ′ and bottom hook 78 ′ securely hold face trim 76 ′ to mounting clip 70 . In this manner, differing architectural styles can be accommodated using the mounting principles described above.
The face trim products shown in FIGS. 5 , 5 A, and 5 B and described above are adaptable for a variety of interior and exterior construction components. In addition to the exterior components of crosshead, fascia, and frieze described in relation to the first embodiments of the present invention, this second embodiment is useful as crown molding, window or door casings, baseboards, and mantle pieces.
As briefly described above, a frieze, being a building component that is installed as a transitional trim between a vertical wall and a ceiling or soffit, is typical of a further embodiment of the present invention. A side elevation view of a frieze 88 , mounted between an exterior wall of building 10 and a soffit 84 , is illustrated in FIG. 6 . Frieze 88 has single concave curve section 90 and a number of alternating inwardly and outwardly oriented right angle bends. Anchor 92 is formed at an upper end of frieze 88 and configured to engage an adjacent edge of soffit 84 . The lower edge of frieze 88 is typically secured to building wall 10 by fastening means N prior to the application of exterior siding. Stiffening block 95 is made to substantially conform to the contour of and provide reinforcement for frieze 88 . Stiffening block 95 is preferably formed of foamed plastic resin. As shown in FIG. 6 , the stiffening block 95 includes an upper ledge 97 that engages the rearwardly extending anchor 92 .
FIG. 6A illustrates a side elevation view of a frieze 94 which is a variation of the frieze contour shown in FIG. 6 and described above. Frieze 94 comprises a convex curve section 96 , as differing from concave curve section 90 described above. Stiffening block 95 a is similar to stiffening block 95 described above.
FIG. 6B illustrates a side elevation view of a frieze 98 that incorporates concave curve section 100 and convex curve section 102 . Additional variations, for example, curved sections positioned at the center or the lower end of the frieze, multiple concave or multiple convex sections, and parabolic or elliptical curves are also obtainable. Stiffening block 95 b is similar to stiffening block 95 described above.
FIG. 6C depicts frieze 104 which is similar in contour to frieze 94 of FIG. 6A . Frieze 104 is formed with an anchor portion for engagement with an inside edge of soffit 84 as described above. The visible face area of frieze 104 may be formed with a variety of convex or concave curves and one or more square bends. Stiffening block 95 c is positioned between frieze 104 and the structure of house 10 to reduce the chance of frieze 104 being dented or bent after installation. Frieze 104 terminates with an upwardly facing edge 108 that engages J-hook 106 , assembled to house 10 in inverted orientation by fastener N. Fastener N may be screws, nails, or adhesive, e.g. silicone caulk material.
Referring now to FIG. 7 , a portion of a roofline of a building 10 is shown in front elevation view. Fascia 112 is positioned at the forward surface of the eave with roofing material 110 above.
FIG. 7A is a cross sectional view of fascia taken in the direction of line 7 A— 7 A of FIG. 7 configured with a first contour. Block 128 a is mounted to the side of rafter 116 by adhesive or other fastener means. J-hook 118 is mounted in inverted orientation beneath block 128 a . Fascia 112 a is then placed with its lower end 122 a engaging J-hook 118 and its upper edge 124 a engaging roof sheathing 114 . Upper edge 124 a may optionally be affixed to sheathing 114 by means of an adhesive such as, for example, silicone caulk material. Exterior roofing material, e.g. shingles, 110 is applied last. Fascia 112 a is configured to mount with edges P, Q, and R in contact with block 128 a , thus affording sufficient stiffening to avoid bending or minor denting.
FIG. 7B provides a cross sectional view of a fascia 112 b that differs in contour and means of support from fascia 112 a of FIG. 7A . Fascia 112 b is configured to extend further outwardly from rafter 116 at its top portion than at its bottom portion. To accommodate this greater extension of fascia 112 b , roof sheathing 114 is mounted to protrude a greater distance beyond rafter 116 than occurs in the illustration of FIG. 7A . Stiffening block 128 b substantially conforms to the interior dimensions of fascia 112 b and is adhesively or otherwise mounted to rafter 116 . Fascia 112 b is mounted with its lower edge engaging inverted J-hook 118 and its upper edge 124 b engaging and adhered to roof sheathing 114 , thus supporting corners P′, Q′, and R′ and the surfaces between. As with prior described trim products, any nails, screws, or adhesive used for mounting the trim product or a supporting J-hook or other component are positioned to be totally hidden when the siding panels or other exterior parts are installed. In this way, a finished installation without visible fasteners is achieved.
Referring now to FIG. 8 , a side elevation view is shown of a first embodiment set of forming dies 132 , 136 according to the present invention. The solid line drawing shows forming dies 132 and 136 prior to closure with sheet 130 of bendable material in position with surface A painted and surface B unpainted. The dashed line drawing shows formed sheet 130 ′ after closure of forming dies 132 , 136 . The lower part of the die set consists of lower die 132 , having a selected contour, for example including one or more curved sections and one or more angular sections, and is substantially elongate in a direction perpendicular to the plane of the drawing. Columns 134 support base 132 . Upper die 136 is made in a matching contour to the contour of base 132 . Form 136 is supported above base 132 by ram 138 . Rear lip 22 , bottom return 42 , and grip 44 (see FIG. 2 ) are formed in a subsequent bending operation.
In operation, bendable sheet 130 is placed substantially flat on lower die 132 and a downwardly directed force F is applied to upper die 136 through ram 128 to bend sheet 130 to become, after forming, sheet 130 ′, shown in dashed lines. According to the desired configuration of sheet 130 ′, different combinations and relationships of curved and angular portions create differing architectural effects.
Referring now to FIG. 9 , an alternate device employing base die roller 140 and form die roller 144 is disclosed for the continuous formation of contours in a sheet 130 of bendable material. A cross sectional view through base die roller 140 and form die roller 144 is substantially equal to the elevation view of forming dies 132 , 136 shown in FIG. 8 . By forming a set of dies as rollers, longer continuous lengths of formed sheet are possible than with a fixed length set of opposed dies. Base die roller 140 mounts on shaft 142 and is driven in the rotational direction indicated by arrow Y. Form die roller 144 mounts on shaft 146 and is driven in the rotational direction indicated by arrow Y′. Both base die roller 140 and form die roller 144 have matching areas of curvature and a number of alternating inwardly and outwardly oriented right angle bends to form a sheet of bendable material 130 similarly when die rollers 140 and 144 are brought together in the direction of arrows K and rotated and sheet 106 moves in the direction of arrow Z. As will be readily understood, the result will be similar whether base die roller 140 moves up or form die roller 144 moves down, or both move toward each other. Depending on the length of sheet material supply and the length of formed sheet required, transverse cuts are made at selected intervals along the formed sheet. As noted above in respect to forming dies 132 and 136 of FIG. 8 , rear lip 22 , bottom return 42 , and grip 44 (see FIG. 2 ) are formed in a separate bending operation.
In each of the disclosed embodiments of the present invention, a sheet of material is bent to obtain a selected cross sectional profile between linear edges thereof. The architectural trim products thus formed are mounted to a building with both of the linear edges in contact with a building surface and with all fasteners, e.g. nails or screws, positioned to be subsequently masked by other trim components or siding. Thus, no fasteners of the trim products of the invention are visible in the finished building.
The above detailed description of a preferred embodiment of the invention sets forth the best mode contemplated by the inventor for carrying out the invention at the time of filing this application and is provided by way of example and not as a limitation. Accordingly, various modifications and variations obvious to a person of ordinary skill in the art to which it pertains are deemed to lie within the scope and spirit of the invention as set forth in the following claims.
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An elongated horizontal transitional trim product includes an elongated, molded, horizontally-positionable stiffening block. The block has a flat, vertical back surface; a flat, horizontal top surface; a flat, horizontal bottom surface; and a front surface. The front surface extends between an outer edge proximate to the top surface and an outer edge proximate to the bottom surface, and has a cross-sectional profile that includes a plurality of interconnected curved and vertical and horizontal flat surfaces. The stiffening block is capable of being secured directly to a flat, vertical surface of a building. The trim product further includes an elongated deformable metallic sheet terminating in respective upper and lower end sections located above and below a central section. The central section of the metallic sheet includes a plurality of interconnected, continuous surfaces in its cross-sectional profile which mate and snugly fit with the cross-sectional profile of the stiffening block. The metallic sheet is capable of being mounted onto the stiffening block by utilizing the shape of the central, upper, and lower end sections of the sheet to support and maintain the sheet on the stiffening block prior to installing other support means.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention is directed to a device for the multi-axis adjustment of a plurality of elements relative to one another, wherein the elements are rotatable relative to one another via two or more bearings having differently oriented axes of rotation, and wherein each bearing has two parts that can be rotated relative to each other about their respective axes of rotation, particularly to a hub of a wind turbine having rotor blades that are mounted to the hub by means of blade bearings and can be adjusted about their respective longitudinal axes.
[0003] 2. Description of the Prior Art
[0004] Modern large rolling bearings have diameters above the 2-meter range in many applications, and use cases involving diameters of 5 or even 8 meters are not uncommon nowadays. One example of such an application is modern wind turbines, whose wind wheels are constantly being built larger to increase performance. The larger the diameter of such a bearing, the more important its rigidity, since even slight deformation of the bearing rings will alter the pressure on the rolling elements, not only causing greater losses, but also reducing the achievable service life of the rings. On the other hand, increased rigidity means an increased thickness for the rings, and thus, of course, a larger mass, i.e., a greater weight. Since this is unacceptable in many applications, the mating structure itself is usually enlisted to increase rigidity; this does not substantially change much either, however, since the weight of the mating structure then increases as well, leading to the same disadvantages in most cases. This is especially true of wind turbines, where a number of large rolling bearings are installed, here as gondola or nacelle bearings, there as main or rotor bearings for the rotating wind wheel, and finally as blade bearings for adjusting the rotor blades as a function of wind speed.
SUMMARY OF THE INVENTION
[0005] From the disadvantages of the described prior art comes the problem initiating the invention: to improve an arrangement of the above species, particularly an adjusting device or hub of a wind turbine, so as to ensure rigidity for the bearings even under extremely high stresses while at the same time keeping the mass required for this purpose to a minimum.
[0006] The solution to this problem is achieved, in an adjusting device of this species, in that one rotatable part in each of at least two bearings is formed by processing or shaping a common, multiple-connected base body, particularly by processing or shaping the hub body of a wind turbine, thus uniting these rotating parts with one another, wherein the extent of a bearing parallel to the axis of rotation, measured across all the raceways between the base body and the particular element, is shorter than the radius of the particular bearing, whereas the respective other rotatable part of the bearing is configured as a double-connected ring having a planar abutment surface and is separate from the particular element and is screwed together with the abutting contact surface of the respective element via coronally arranged fastening bores extending parallel to the axis of rotation of the particular bearing.
[0007] The invention achieves the effect that the adjustable elements, particularly rotor blades of a wind turbine, can be rotated relative to one another via open-center large rolling bearings having differently oriented axes of rotation, the elements, particularly rotor blades of a wind turbine, can be rotated relative to one another via open-center large rolling bearings having differently oriented axes of rotation [repetition sic], wherein at least two open-center large rolling bearings have only one ring each, whereas their double-connected parts that are able to rotate relative to the ring are formed by processing or shaping a common base body and are unified with each other, particularly by processing or shaping the hub body of a wind turbine. In the hub of a wind turbine, the outer rings of at least two blade bearings are embodied in one piece with the hub body, so that at least one raceway of each of a plurality of blade bearings having differently oriented axes of rotation is formed on a common hub body.
[0008] The invention thereby deviates from conventional large rolling bearings with two mutually concentric rings which are then screwed to the particular mating structure. Even such screw connections do not make for a completely rigid connection, of the kind obtained by welding, for example, and further require thick rings or plates on the mating structure to produce the necessary rigidity. Instead, the invention makes use of the fact that in certain cases a number of adjacent bearings are present that nevertheless have differently oriented axes of rotation; “fusing” a circumferential portion of each of these bearings to a common body results in a three-dimensionally curved component, and curvatures of this kind constitute a very rigid design even for thin, i.e., wall-like components, especially if they possess a double convex curvature, for example like the surface of a sphere, or—depending on the perspective—a double concave curvature, for example like the inner surface of a hollow sphere. This is because (hollow) spheres constitute a form that is exactly defined topographically and therefore undergo little deformation, i.e., are extremely stable. This means that the shaping of such a component common to both or all of the large rolling bearings stabilizes them with respect to one another, that is, no additional masses are necessary for stabilization, but instead, the already-present masses of the participating large rolling bearings themselves contribute in large part to the rigidification, and moreover do so directly, i.e., without the interposition of additional, possibly elastically acting elements, such as screws, for example.
[0009] In the context of a hub of a wind turbine having rotor blades that are mounted to the hub by means of blade bearings and can be adjusted about their respective longitudinal axes, the inventive idea is actualized by the fact that the outer rings of at least two blade bearings are embodied in one piece with the hub body, such that at least one raceway of each of a plurality of blade bearings having differently oriented axes of rotation is formed on a common hub body, wherein the extent of the entire blade bearing parallel to the blade bearing axis of rotation, measured across all the raceways of that blade bearing, is shorter than the radius of the blade bearing, whereas, as counterpart thereto, outer rings integrated with the hub body are each provided with one respective inner ring, which is separate from the rotor blade and is screwed to the rear end face of the particular rotor blade via coronally arranged fastening bores extending parallel to the longitudinal axis of the particular rotor blade.
[0010] This design takes advantage in particular of the fact that due to their higher torsional rigidity, the rolling-element raceways integrated with the hub body always remain optimally precisely aligned, thus ensuring smooth and wear-free rotation.
[0011] It has proven advantageous if one raceway in each of a plurality of large rolling bearings having differently oriented axes of rotation is formed by processing or shaping a common base body, particularly by processing or shaping the hub body of a wind turbine. In such a case, not only is the base body according to the invention combined with a respective ring for each large rolling bearing, but the respective raceways are also incorporated directly into this base body, and consequently there are neither any gaps nor any flexible elements between the rows of circulating rolling elements, so the rigidity of the structure as a whole is maximal.
[0012] Configuring the common base body or hub body as hollow or sleeve-shaped, particularly corresponding to the jacket surface—provided with through-holes—of a point-symmetric or rotationally symmetric body—makes it possible to minimize its mass without compromising dimensional stability.
[0013] It is within the scope of the invention that a raceway of the base body or hub body is incorporated into a concave surface region thereof. The outer raceway of a large rolling bearing can be integrated into such a surface region, particularly by having a raceway-containing region of the base body or hub body be formed by a concavely curved region in the region of the inner face of an opening preferably passing all the way through the jacket of a hollow or sleeve-shaped base body or hub body.
[0014] The invention recommends providing a preferably continuous row of teeth on the common base body or hub body next to a raceway for the rolling elements of each rolling bearing, particularly blade bearing. This creates the possibility of relative adjustment of the various bearings, particularly by means of pinions, toothed wheels, or the like, engaging in this row of teeth.
[0015] Further advantages are obtained if at least one row of teeth is offset from the particular raceway in parallel with the particular axis of rotation, preferably toward the interior space or center of the base body or the hub. In such a case, the row of rolling elements absorbing the load-bearing forces is shifted as far as possible toward the rotating part to be adjusted.
[0016] Further, at least one row of teeth should be offset from the particular raceway radially to the particular axis of rotation, preferably toward the particular axis of rotation. Such a design makes it possible, for example, to arrange the ring rotating opposite the base body next to the teeth, which can be advantageous from a design standpoint.
[0017] If the row of teeth is straight-toothed, then straight-toothed pinions or toothed wheels can mesh with it. Straight toothing can usually be produced with the least possible expenditure.
[0018] In addition, for each blade bearing, a respective anchoring arrangement or thrust surface for at least one seal is preferably provided on the common base body or hub body concentrically with each raceway, particularly offset outwardly in relation to the base body or hub body, i.e., away from the center thereof. By means of seals inserted therein, the interior space of a hollow base body can be sealed against the outside in the region of the transition to the mated-on rotating parts in order to shield it from external influences, especially the weather.
[0019] The invention can be developed further in that for each blade bearing, one or more fastening means for at least one cover plate or for a bearing shield is additionally provided on the common base body or hub body concentrically with each raceway, particularly offset inwardly in relation to the base body or hub body, i.e., toward the center thereof. Such cover plates or bearing shields can create a seal inside the annular large rolling bearings, particularly inside their inner rings. They can thus, under some circumstances, help to further rigidify the structure as a whole and/or serve as a mounting platform, for example for one or more drive motors.
[0020] Fastening means provided for mounting such cover plates or bearing shields can be embodied as fastening bores that are arranged distributed coronally around the particular axis of rotation, and which then afford multiple screw connections between the parts involved.
[0021] The invention allows of further development in that a raceway disposed opposite the raceway incorporated into the base body or hub body is incorporated into a ring, particularly into a convex surface region thereof. Another option would be to instead incorporate this second raceway into the periphery of a disk. This arrangement does usually entail greater weight and can therefore be advantageous in special use cases, particularly if the base body is to be hermetically sealed even inside such a rotating connection; in many use cases, however, where this consideration does not come into play, weight can instead be saved by giving the rotating part of the large rolling bearing an annular structure.
[0022] Further advantages are obtained by additionally providing, on a ring containing a raceway, a preferably fully circumferential row of teeth arranged concentrically with the raceway for the rolling elements of the rolling bearing concerned. This row of teeth is also used for rotational adjustment of the machine part connected to said ring.
[0023] If a set of teeth is also provided on the base body adjacent to the above-mentioned set of teeth, then the invention recommends selecting the number of teeth z 1 in the toothing on the base body so that it is slightly different from the number of teeth z 2 on the particular ring, i.e., z 1 ≠z 2 , but z 1 ≈z 2 . This creates the option of making a rotational adjustment by means of one or more toothed wheels, each having a uniform number of teeth z 3 and engaging in both sets of teeth together.
[0024] Such a row of teeth on a ring or a disk-shaped rotating part can be offset from the particular raceway radially to the particular axis of rotation, preferably toward the particular axis of rotation. One such arrangement that has proven advantageous has the respective raceway of a ring disposed on its outer side while its teeth are located on its inner side, i.e., radially speaking, offset toward the particular axis of rotation.
[0025] As noted earlier hereinabove, there can be use cases in which a disk-shaped geometry for the part that is rotatable relative to the base body is to be preferred over an annular geometry, and for a use case of this kind, the invention provides that the ring be provided with, connected to or integrated with a cover plate or a bearing shield. Such a cover plate or bearing shield can, in turn, have a through-hole at its center, but it also can be configured as continuous, without an opening.
[0026] A preferred design rule provides that a drive device is provided, particularly that a drive motor is fastened and/or a drive pinion mounted or guided, on at least one cover plate or at least one bearing shield. Such a cover plate or bearing shield can be used to draw conclusions as to force, in order to achieve a defined adjustment.
[0027] An additional feature of the invention is that the drive device, particularly the drive motor and/or the drive pinion, is arranged concentrically with the axis of rotation of the particular rolling bearing. This produces an arrangement that is ideally concentric or coaxial with the particular axis of rotation, which accordingly causes the least possible imbalance and thus makes for particularly smooth operation of all the rotating parts involved. Moreover, a concentric drive can be coupled to a sun gear that transmits the rotational movement to a gear train.
[0028] In the latter case, a further development is to arrange a plurality of planet gears in the annular space between the outer toothing of the drive pinion or sun gear, the cover plates or bearing shields, and the inner toothing of the rotatable ring. The arrangement thus takes on the characteristics of a planetary gear train.
[0029] These planet gears can be mounted in cantilever fashion, i.e., without a spider or planet carrier. On the one hand, the absence of a spider or planet carrier further simplifies the arrangement as a whole; on the other hand, weight can be saved in this way.
[0030] To save still more weight, the planet gears themselves can be configured as hollow. It should be kept in mind, here, that in a planetary gear train the tooth differential between the sun gear and the gear ring has an effect on gear ratio. Thus, if a particularly large tooth differential is desired, the diameter of the sun gear must be chosen to be substantially smaller than the diameter of the gear ring, with the result that the planet gears, which mesh with the sun gear on the one side and the gear ring on the other, receive a very large diameter, which is preferably larger than the diameter of the sun gear. In such a case, a substantial reduction in weight can be achieved if the planet gears are configured as hollow, particularly annular. The hollow space can, for example, be used as a reservoir for a lubricant, particularly grease.
[0031] If the planet gears mesh with the inner teeth both on the inner side of the ring and on the inner side of the opening in the base body or hub body, a still higher gear ratio can be obtained, particularly in the manner of a Wolfrom gear train; to this end—as explained previously hereinabove—the number z 2 of teeth in the toothing on the inner side of the ring and the number z 1 of teeth in the toothing on the inner side of the respective opening in the base body or hub body differ slightly from each other: z 1 ≠z 2 , with z 1 ≈z 2 .
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] Further features, details, advantages and effects based on the invention will emerge from the following description of a preferred embodiment of the invention, read with reference to the drawing. Therein:
[0033] FIG. 1 is a partially broken-away sectional view through a wind turbine hub according to the invention; and
[0034] FIG. 2 is a view corresponding to FIG. 1 of a modified embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0035] FIG. 1 depicts a hub 1 of a wind turbine, as an example of a device according to the invention for adjusting a plurality of elements relative to one another. This broken-away sectional representation reveals the hub body 2 , which has approximately the shape of a ring with multiple openings therethrough. This ring has, for example, a jacket 3 with an approximately cylindrical structure, preferably tapering to both end faces 4 , 5 .
[0036] On the end face 4 proximate the nacelle, the end-face opening 6 there is narrowed further by a circumferential, inwardly projecting flange 7 . Provided therein is a plurality of fastening bores 8 to effect attachment to an output-side rotation device, for example a main bearing of the wind turbine, a gearbox input or a generator.
[0037] The end face 5 remote from the nacelle, on the other hand, can be closed off directly or by means of a cowl (not shown), to keep the oncoming wind out of the interior space 9 of the hub 1 .
[0038] The jacket 3 of this one-piece hub body 2 has a plurality of through-holes 10 , each for the rotatable connection of a respective rotor blade (not shown)—in the present case, by way of example, three thereof.
[0039] In the region of the rim 11 of such a through-hole 10 , the shape of the hub body 2 deviates from the ideal cylindrical shape, specifically in such a way that the circumferential rim 11 of a through-hole 10 lies entirely in one plane.
[0040] In the concave inner side 12 of a through-hole 10 there is an annular raceway 13 formed or incorporated into the hub body 2 and provided for rolling elements 14 rolling thereon. In the case of spherical rolling elements 14 , this raceway has, for example, a concave cross section.
[0041] The counterpart to this raceway 13 is formed by another, annular raceway 15 on the outer side of a ring 16 , which is disposed in the through-hole 10 and, for its part, has for example a rectangular or even square cross section, and which, by virtue of the rolling elements 14 , is able to rotate relative to the hub body 2 about the center axis of the particular jacket-side through-hole 10 .
[0042] Disposed in the preferably planar end face 17 of this rotatable ring 16 that faces away from the interior space 9 of the hub body 2 is a plurality of coronally distributed bores 18 for connecting a rotor blade. The bores 18 are preferably configured as blind bores provided with internal threading.
[0043] In this case, a planar, preferably annular sealing plate 19 is preferably inserted between the outward-facing end face 17 of the rotatable ring 16 and a rotor blade fastened thereto, and is clamped in place by tightening the particular screws, thereby tightly sealing the interior space 9 inside the rotatable ring 16 in this region. A central opening 20 in the center of the closing plate 19 can be sealed by a closing cap 21 engaging therein.
[0044] A similar sealing plate 22 is fixed to the inner surface 23 , facing interior space 9 , of the rim 11 of through-hole 10 , particularly by means of screws that engage through openings in the sealing plate 22 and are screwed into coronally distributed, internally threaded blind bores 24 in the inner surface 23 of the rim 11 of through-hole 10 . The sealing plate 22 can also have an annular base area, with an opening or through-hole 39 in the center.
[0045] A ring 25 can be inserted in this through-hole 39 , and in turn receives against its inner periphery the outer ring of a rolling bearing 26 . A similar rolling bearing 27 is disposed on the inner side of the closing cap 21 . The inner rings of these two rolling bearings 26 , 27 support a toothed sun gear 28 rotatably about a central axis. The sun gear 28 has in its end face 29 turned toward the interior space 9 of the hub body 2 a central opening, for example having a polygonal cross section, particularly for coupling to it a drive motor 30 in a rotationally fixed manner, for example for the insertion of a motor output shaft or a square or hexagonal piece or the like at the end of a rotating body that can be driven by a motor (not shown).
[0046] The sun gear 28 has a circumferential set of teeth 31 on its outer periphery. A set of teeth 32 with the same modulus is located on the radially inwardly disposed side of the rotatable ring 16 , facing the teeth 31 of the sun gear 28 .
[0047] Since the two sealing plates 19 , 22 are at a distance from each other, there remains between these sealing plates 19 , 22 and the teeth 31 , 32 on the sun gear 28 , on the one hand, and on the radially inwardly disposed side of the rotatable ring 16 an approximately annular hollow space 33 in which a plurality of toothed planet gears 34 are received—specifically, depending on the embodiment, are cantilever-mounted or spiderlessly guided or mounted on a spider or a sealing plate 19 , 22 .
[0048] For this purpose, the pitch circle diameter d P of a toothed planet gear 34 corresponds to the difference between the pitch circle diameter d S , d H of the sets of teeth 31 , 32 on the sun gear 28 , on the one hand, and on the radially inwardly disposed side of the rotatable ring 16 , on the other hand: d P =d H −d S .
[0049] Due to the cantilevered mounting, the planet gears 34 can be configured as hollow.
[0050] As a result of the sun gear 28 being driven in rotation by the drive motor 30 , the planet gears 34 are constrained to move around the sun gear 28 , thus imparting a slow rotational movement to the ring 16 meshing therewith via its teeth 32 .
[0051] Hence, the structure obtained is that of a planetary gear train 35 with sun gear S, 28 , planet gears P, 34 and the rotatable ring 16 as gear ring H. The standard gear ratio of this planetary gear train i 12 is defined by the quotient of the numbers of teeth H/S of the sun gear S and the gear ring H, or the quotient of their pitch circle diameters d H /d S : i 12 =H/S=d H /d S . If the planet gears 34 are mounted, for example, to the sealing plate 22 , the rotation speed ratio is n H /n S =1/i 12 =S/H=d S /d H /, thus a rotation speed n H that is lower than the input rotation speed n S by a factor of 1/i 12 .
[0052] In the case of hub 1 ′ according to FIG. 2 , this rotation speed n H can be reduced further by using a Wolfrom gear train 36 instead of the planetary gear train 35 from FIG. 1 . The Wolfrom gear train 36 differs from the planetary gear train 35 primarily in the region of the gear wheel H:
[0053] Whereas the set of teeth 32 of the gear wheel H in the planetary gear train 35 is disposed entirely on the rotatable ring 16 and thus is not divided in the axial direction, the Wolfrom gear train 36 has in the region of the gear wheel H two toothed regions 37 , 38 that are separated from each other in the axial direction. The toothed region 37 that is the lower of the two in FIG. 2 is again located on the radially inwardly disposed side of the rotatable ring 16 , but the upper toothed region 38 is not. Instead, the latter is located on the radially inwardly disposed side of the rim 11 of a through-hole 10 in the hub body 2 .
[0054] Further, in a preferred embodiment, the pitch circle diameters d 1 , d 2 of these two toothed regions 37 , 38 are identical.
[0055] The teeth H 1 , H 2 in the two toothed regions 37 , 38 do differ slightly from each other: H 1 ≠H 2 , H 1 ≈H 2 , with ΔZ=H 1 −H 2 .
[0056] This yields, for instance, a gear ratio n H /n S :
[0000]
n
H
/
n
S
=
S
·
(
H
1
-
H
2
)
H
1
·
(
H
1
+
S
)
[0000] which is much larger than in the case of the planetary gear train 35 according to FIG. 1 . Due to the high speed ratio and the resultant high torque reduction, a much smaller and lower-performance drive motor 30 will suffice with the Wolfrom gear train 36 than in the case of the exclusively planetary gear train 35 according to FIG. 1 .
[0057] If the tooth differential ΔZ=H 1 −H 2 is equal to the number p of planet gears 34 : ΔZ=H 1 −H 2 =p, it is feasible to use one-piece planet gears 34 arranged at approximately equidistant intervals around the central sun gear 28 . If ΔZ=H 1 −H 2 ≠p, at least one planet gear 34 must have two mutually offset toothed regions. However, this can easily be achieved by taking two gear bushings, each with a uniform toothed region, and sliding them in the offset state onto a central body or central bushing in such a way that they are fixed in rotation. Such a rotationally fixed connection can be created, for example, by means of intermeshing teeth between the central body or central bushing, on the one hand, and the gear bushings, on the other.
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A wind turbine hub having both blades mounted thereon by means of blade bearings adjustable about the longitudinal axes thereof. The turbine includes means for effecting multi-axes adjustments of a plurality of elements relative to one another. The elements are rotatable about bearings having selectively oriented axes of rotation, each bearing comprising two parts rotatable relative to each other.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. patent application Ser. No. 10/713,460 filed on Nov. 14, 2003.
FIELD OF THE INVENTION
The present invention relates to a sprayer with a water purifier, and to a valve system and a selector switch for the same.
BACKGROUND OF THE INVENTION
Sprayers of various types are known. In some cases, sprayers have a filter or other type of purifier associated therewith. The search for improved sprayers with water purifiers, and valve systems and selector switches for the same has continued.
SUMMARY OF THE INVENTION
This invention relates to a sprayer with a water purifier, and to a valve system and a selector switch for the same. There are numerous non-limiting embodiments of the present invention. It should be understood that the water purifier need not comprise part of the sprayer, particularly when the sprayer is not in use. The water purifier may be a separate component that is used with the sprayer when the sprayer is in use.
In one non-limiting embodiment, the sprayer is for spraying water and when in use comprises a purifier cartridge for purifying water. The sprayer may be compact and ergonomic. The sprayer may comprise a valve system that provides a selection of water flow paths and/or nozzles or other output mechanisms for the sprayer, and a selector switch for controlling the valve system. In certain embodiments, the sprayer is provided with a multiple position selector switch that can be controlled by one of the operator's fingers, or by the operator's thumb, so that the operator can use the sprayer and select the sprayer setting with one hand.
Numerous other embodiments are also possible, including, but not limited to those described in the following detailed description.
The present invention will become more readily apparent when considered in reference to the following description and when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter which is regarded as forming the present invention, it is believed that the invention will be better understood from the following description taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a front perspective view of one non-limiting embodiment of a sprayer with a water purifier.
FIG. 2 is a rear perspective view of the sprayer shown in FIG. 1 .
FIG. 3 is a side view of the sprayer shown in FIG. 1 shown with a portion of the housing cut away to show the internal components of the sprayer.
FIG. 4 is an exploded perspective view of the components of one non-limiting embodiment of the valve system.
FIG. 5 is a perspective view showing the top of the inner valve component and the selector switch.
FIG. 6 is a perspective view showing the top of the inner valve component and the selector switch from another angle with the same positioned in an “off” setting.
FIG. 7 is a perspective view showing the top of the inner valve component and the selector switch from another angle with the same positioned in a setting on one of the flow functions.
FIG. 8 is a perspective view of an alternative embodiment of a selector switch.
DETAILED DESCRIPTION OF THE INVENTION
This invention relates to a sprayer with a water purifier, and to a valve system and a selector switch for the same.
FIG. 1 shows one embodiment of a sprayer 20 with a purifier. This sprayer 20 is an ergonomically-designed, hand-held hose end sprayer. It should be understood that the sprayer 20 shown in FIG. 1 has a unique configuration, and that the purifier, the valve system, and selector switch are not limited to use with a sprayer having such a configuration. The purifier, the valve system, and selector switch can be used with sprayers having any suitable configuration.
The sprayer 20 comprises a housing or structure 22 . Preferably, in the embodiment shown, water flows through the housing 22 when the sprayer 20 is connected to a hose 24 and is in use. The housing 22 comprises a barrel portion 26 and a handle 28 for gripping by a user that is disposed at an angle to the barrel portion 26 . The sprayer 20 further comprises at least one spray nozzle 30 that is operatively connected to the housing 22 , and a hose connection (or simply “connection”) 32 for the hose 24 . The sprayer 20 also comprises purifier, such as purifier cartridge 34 , and a selector switch 36 .
FIG. 2 shows that in this embodiment, the sprayer 20 comprises an opening 37 in a portion of the sprayer 20 , such as in the rear 38 of the barrel portion 26 of the sprayer 20 , for a purifer, such as purifier cartridge 34 . The purifier 34 can be removeable so that it need not comprise part of the sprayer 20 when the sprayer is not in use. The sprayer 20 can comprise any suitable receiving structure for the purifier cartridge 34 into which the purifier cartridge 34 fits. One non-limiting embodiment of a receiving structure for the purifier cartridge is described in U.S. patent application Ser. No. 10/713,460 filed on Nov. 14, 2003.
The sprayer housing 22 may also have a element, such as a clip 40 for retaining the purifier cartridge in place. The clip 40 can comprise an element that is joined to the housing, or it can comprise a portion of the housing 22 . In other embodiments, the purifier 34 can reside entirely inside the sprayer housing, in which case a door may cover the purifier 34 , and the clip may not be necessary. It should be understood, however, that in other embodiments the sprayer 20 need not include an opening therein for the purifier cartridge 34 . In such other embodiments, the purifier cartridge 34 may reside at least partially, or entirely, outside of the sprayer 20 . In still other embodiments, the sprayer 20 need not comprise a purifier at all.
FIGS. 1 and 2 show one non-limiting embodiment of a purifier cartridge 34 . The purifier cartridge 34 can be in any suitable configuration. The purifier cartridge 34 in the embodiment shown in the drawings is generally comprised of two side-by-side compartments. The compartments comprise cylindrical portions, and the cartridge 34 is more specifically is in the form of a structure comprised of two cylindrical portions 42 and 44 that are aligned along their axes and joined together to form a compound cylindrical structure with a cross-section that resembles the figure “8”. In this particular embodiment, the cartridge has inlet and outlet openings that are both located on the same end of the purifier cartridge, the end inserted into the sprayer housing 22 . When the purifier cartridge 34 is in use, water flows in the inlet opening into first cylindrical portion 42 . Water then flows from the first cylindrical portion 42 through a channel 46 connecting the first and second cylindrical portions, to the second cylindrical portion 44 . Water exits the purifier cartridge 34 at the outlet opening into a purified rinse spray conduit.
The purifier cartridge 34 can be permanent or replaceable. The purifier cartridge 34 can be inserted into and removed from the sprayer housing 22 through the opening 37 in the rear 38 of the barrel portion 26 of the sprayer 20 . The purifier cartridge 34 can comprise any suitable type of purifying material. In one non-limiting embodiment, the purifier cartridge 34 comprises an ion exchange resin medium. The ion exchange resin medium may have any of the properties described in U.S. Pat. No. 6,562,142 B2 issued to Barger, et al.
FIG. 3 shows the internal components of the sprayer 20 . In the non-limiting embodiment shown, these components comprise: an inlet tube 48 , a valve system or valve 50 , the selector switch 36 , a rinse conduit 52 , and a purifier conduit 54 . FIG. 4 shows that the valve 50 comprises: a bottom valve component 56 , an inner valve component 58 , a top valve component 60 , a selector spring 62 , a selector inner seal 64 , a click spring 66 , and a click pin 68 . The valve 50 may further comprise O-rings 70 as well as other components.
As shown in FIGS. 3 and 4 , the top portion 72 of the inlet tube 48 fits into a cylindrical extension 74 on the underside of the bottom valve component 56 . The upper portion 76 of the bottom valve component 56 comprises a cylindrical portion 78 . The inner valve component 58 also has an exterior with a cylindrical configuration. A portion of the inner valve component 58 fits inside the cylindrical portion 78 of the bottom valve component 56 . In the embodiment shown, the selector switch 36 is joined to the exterior of the inner valve component 58 and extends outward therefrom. In the embodiment shown, the selector switch 36 extends outward from the inner valve component 58 in a direction that is generally perpendicular to the axis of the cylindrical inner valve component 58 .
As shown in FIG. 5 , the inner valve component 58 has a top surface 80 with an opening 82 therein, and several depressions 84 therein. The opening 82 permits water from the hose to flow through the valve 50 . As shown in FIGS. 4 , 6 , and 7 , the selector inner seal 64 sits on top of the selector spring 62 , and fits at least partially into the opening 82 in the top surface 80 of the inner valve component 58 . The top surface 80 of the inner valve component 58 may also comprise one or more seals 86 . The seals 86 can be of any suitable configuration. In the embodiment shown, the seals 86 are in the form of raised ribs that radiate outward from the center of the top surface 80 of the inner valve component 58 . In other versions of the embodiment shown, the seals 86 can have any other suitable configuration. In still other embodiments, the seals can be located on the underside of the top valve component instead of, or in addition to, being located on the top surface 80 of the inner valve component 58 .
The top valve component 60 comprises a plate 87 and a pair of inflow conduits 88 and 90 . One of the inflow conduits directs incoming water that passes through the valve 50 to a conduit that by-passes the water purifier 34 , and thus comprises the rinse conduit. The other inflow conduit directs incoming water that passes through the valve 50 into the water purifier 34 . The purified water then flows out of the purifier in a conduit that leads to a purified rinse spray nozzle. As shown in FIG. 4 , the click pin 68 fits over the click spring 66 , and the click spring is inserted into the underside of the top valve component 60 . The top valve component 60 then rides on top of the inner valve component 58 to complete the assembly of the valve 50 .
FIG. 6 shows the selector switch 36 and valve system in the “off” position. As shown in FIG. 6 , when the system is in the “off” position, the opening 82 in the top surface 80 of the inner valve component 58 is located between the inflow conduits 88 and 90 of the top valve component 60 . In this position, the engagement of the seals 86 against the underside of the top valve component 60 will prevent water from flowing through the valve 50 into either of the inflow conduits 88 and 90 . In addition, the click pin 68 engages into the central depression 84 on the top surface 80 of the inner valve component 58 to provide a signal to the operator that the selector switch 36 is in the “off” position.
FIG. 7 shows the selector switch 36 and the valve system turned to one side. When the selector switch 36 is turned in this manner, the opening 82 in the top surface 80 of the inner valve component 58 aligns with one of the inflow conduits 88 and 90 of the top valve component 60 , and water will flow through the valve 50 into the inflow conduit. In this position, the click pin 68 engages into the depression 84 to the left of the central depression on the top surface 80 of the inner valve component 58 to provide a signal to the operator that the selector switch 36 is in a different position.
The selector switch 36 , in one non-limiting embodiment, has at least two positions. In the embodiment shown, the selector switch 36 has three positions, which are from left to right: “tap water spray”, “off”, and “purified rinse”. The multiple position selector switch 36 can be controlled by one of the operator's fingers, or by the operator's thumb, so that the operator can use the sprayer and select the sprayer setting with one hand. This will allow the operator to use their other hand for some other task, such as during a process of washing a vehicle, applying a cleaning composition to the surface of the vehicle. Alternatively, this may allow the operator to hold some article in their other hand, such as a cleaning mitt, or other cleaning implement.
The selector switch 36 can comprise any suitable type of switch. The selector switch 36 shown in FIGS. 1–7 comprises a paddle/rocker switch. This switch has a generally flat region 92 in the center that is sized to accommodate the operator's thumb, and a pair of spaced apart “paddles” 94 (see FIG. 5 ) that are joined at an angle to the generally flat region, and are a sufficient distance apart to create a space for the operator's thumb therebetween. The paddles 94 have an interior surface and an exterior surface. The operator can control this switch by placing their thumb in the generally flat region 92 , and applying force with their thumb from the interior of the switch to the interior surface of one of the paddles 94 on either side of the switch. Alternatively, the operator can place their thumb on the outside of the switch, and apply a force with their thumb on the exterior surface of one of the paddles 94 on either side of the switch. Different embodiments of such a switch can be provided with different width (or thickness) of the paddles measured in the direction of movement of the switch to provide different “throw” distances when changing between switch positions.
FIG. 8 shows an alternative embodiment of a selector switch. In FIG. 8 , the selector switch 36 is a thumb switch. The operator can control this switch by applying force on either side of the switch with their thumb. Other embodiments of this switch can also be provided that have different widths to provide different “throw” distances when changing from one switch setting to another setting. In other embodiments, the selector switch 36 can have any other suitable configuration.
Numerous other embodiments are possible. A few of these are as follows. In other embodiments, for example, the sprayer could be of the type described in U.S. patent application Ser. No. 10/137,748 filed on May 2, 2002, and published as US 2003/0034051 A1 on Feb. 20, 2003, or in the configuration of the sprayer shown in U.S. Design patent application Ser. No. 29/193,107 filed on Nov. 3, 2003. In other embodiments, the valve system 50 can be located in the barrel portion 26 of the sprayer 20 . In other embodiments, the components of the valve system 50 can be inverted. Therefore, the various parts of the valve system 50 that are referred to as “top” portions may be referred to as “first portions”, and the various parts of the valve system 50 that are referred to as “bottom” portions may be referred to as “second portions”.
The sprayer can be manufactured in any suitable manner. The housing 22 and many other components of the sprayer 20 can be made of any suitable material, such as plastic. In the embodiment shown, the housing can be comprised of two, or more pieces. The components of the sprayer 20 can be assembled inside of at least one of the pieces comprising the housing, and the pieces of the housing 22 can then be secured together.
To use the sprayer 20 , the end of the purifier cartridge 34 with the inlet and outlet openings is inserted into the receiving structure located within the sprayer housing 22 . The clip 40 will hold the cartridge 34 in place. After the ion exchange resin in the purifier cartridge is exhausted, the clip 40 is pressed downward and moved away from the cartridge 34 , and the cartridge 34 is removed and replaced with a new cartridge.
The sprayer 20 can be used in any suitable manner or process. In one non-limiting embodiment, the sprayer 20 can be used in a process of cleaning the external surface of a vehicle, such as a car. The process can include any suitable number of steps in any suitable order. In one such embodiment, the process includes a step of applying a cleaning composition to the external surface of the vehicle. Any suitable cleaning composition can be used, and the cleaning composition can be applied to the surface of the vehicle in any manner.
In one version of such an embodiment, the cleaning composition comprises a polymer that renders the surface of the vehicle hydrophilic. One suitable polymer is described in U.S. Pat. No. 6,593,288 B2 issued to Aubay, et al. on Jul. 15, 2003. A suitable cleaning composition is described in U.S. Patent Application Publication No. US 2002/01600224 A1, published in the name of Barger, et al. on Oct. 31, 2002. In one version of such an embodiment, the cleaning composition can be applied directly to the surface of the vehicle. In another version of such an embodiment, the cleaning composition can be applied by diluting a concentrated cleaning composition with water, such as in a bucket of water, and then applying the diluted cleaning composition to the surface of the vehicle. The cleaning composition can be applied to the surface of the vehicle in any suitable manner such as by pouring, or spraying the cleaning composition on the surface of the vehicle, or by using any suitable type of applicator (such as a sponge, a wash mitt, etc.) to apply the cleaning composition to the surface of the vehicle.
The sprayer 20 can then be set to the rinse setting and used to rinse off the cleaning composition. Following this, the sprayer 20 can be set to the purified rinse setting, and the surface of the vehicle can be rinsed with purified rinse water to remove any residue-forming substances that remain on the surface of the vehicle.
The disclosure of all patents, patent applications (and any patents which issue thereon, as well as any corresponding published foreign patent applications), and publications mentioned throughout this description are hereby incorporated by reference herein. It is expressly not admitted, however, that any of the documents incorporated by reference herein teach or disclose the present invention.
While particular embodiments of the subject invention have been described, it will be obvious to those skilled in the art that various changes and modifications of the subject invention can be made without departing from the spirit and scope of the invention. In addition, while the present invention has been described in connection with certain specific embodiments thereof, it is to be understood that this is by way of illustration and not by way of limitation and the scope of the invention is defined by the appended claims which should be construed as broadly as the prior art will permit.
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A sprayer with a water purifier, a valve system, and a selector switch for the same are disclosed. In one non-limiting embodiment, when the sprayer is in use, the sprayer includes a purifier for purifying water. The sprayer may be compact and ergonomic. The sprayer may include a valve system that provides a selection of water flow paths and/or nozzles or other output mechanisms for the sprayer, and a selector switch for controlling the valve system. In certain embodiments, the sprayer is provided with a multiple position selector switch that can be controlled by one of the operator's fingers, or by the operator's thumb so that the operator can use the sprayer and select the sprayer setting with one hand.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to amidinophenol derivatives, processes for the preparation thereof and the use thereof as leukotriene B 4 (LTB 4 )antagonists, phospholipase A 2 inhibitors, and trypsin inhibitors.
[0003] More particularly, it relates to LTB 4 antagonists containing an amidinophenol derivative of the formula (IA):
[0004] (wherein various symbols are the same meanings as hereafter described), as the active ingredient; to
[0005] amidinophenol derivatives of the formula (IB):
[0006] (wherein various symbols are the same meanings as hereafter described) and processes for the preparation thereof; and to LTB 4 antagonists, phospholipaseA 2 inhibitors and trypsin inhibitors containing a compound of formula (IB) as the active ingredient.
[0007] 2. Description of Related Art
[0008] The metabolic pathways by which various compounds are biosynthesized, in vivo, from arachidonic acid as a common starting material are called the arachidonic acid cascade.
[0009] Lipoxygenase, for example, 5-lipoxygenase, 12-lipoxygenase or 15-lipoxygenase, respectively, acts on arachidonic acid to produce 5-HPETE, 12-HPETE or 15-HPETE from arachidonic acid.
[0010] The above mentioned HPETEs are converted into 5-HETE, 12-HETE or 15-HETE, by converting a peroxy group into a hydroxy group by the action of peroxidase, and 5-HPETE is also converted into LTA 4 .
[0011] LTA 4 is converted into LTB 4 or LTC 4 by enzymatic reaction (see Biochem. Biophys. Res. Commun., 91, 1266 (1979), Prostaglandins, 19(5), 645).
[0012] Recently a number of properties of LTB 4 have been revealed.
[0013] It is understood that LTB 4 has strong chemotactic and adhesive activity and degranulation activity on leukocytes (see Nature, 286, 264 (1980), Proc. Nat. Acad. Sci. USA, 78, 3887 (1981)).
[0014] LTB 4 also has strong calcium ionophore action, and attacks various cells, and it is considered to accelerate release of metabolites of arachidonic acid from these cells (see J. Biol. Chem, 257, 4746 (1982)).
[0015] High levels of LTB 4 have also been found at sites of various inflammations, for example, rheumatism, spondyl arthritis, gout, psoriasis, ulcerative colitis and respiratory tract diseases, thereby demonstrating that LTB 4 is closely associated with various inflammations (see J. Clin. Invest., 66, 1166 (1980); Lancet 11 1122-1123 (1982); J. Invest. Dermatol., 82, 477-479 (1984); Gastroenterology 86, 453-460 (1984)).
[0016] It is therefore considered that LTB 4 antagonists are useful as anti-inflammatory agents or anti-allergic agents.
[0017] It is known that LTB 4 antagonists are also useful for the treatment of rheumatoid arthritis, inflammatory bowel diseases, psoriasis, nonsteroidal anti-inflammatory agent-induced stomach diseases, adult respiratory distress syndrome, cardiac infarction, allergic rhinitis, hemodialysis-induced neutropenia, anaphase asthma (see the specification of the Japanese Patent Kokai No. 5-239008).
[0018] Phospholipase A 2 (PLA 2 ) is an enzyme which acts on phospholipids existing in cell membranes. It hydrolyzes an ester bond at the second position of the phospholipids. There are two known kinds of PLA 2 , membrane-associated PLA 2 and pancreatic PLA 2 .
[0019] Membrane-associated PLA 2 acts on phospholipids to release arachidonic acid (AA) from the phospholipids. The AA is converted into prostaglandins, thromboxanes and leukotrienes, which are physiologically active substances inducing various inflammatory diseases and allergic diseases.
[0020] On the other hand, pancreatic PLA 2 degrades phospholipids and destroys cell membranes, thereby producing lysolecithin having strong cytotoxicity. Recently, much importance has been attached to pancreatitis, severity in pancreatitis and multiple organ failure induced by this destructive activity on cell membranes.
[0021] It is also reported that membrane-associated PLA 2 is also concerned with these diseases.
[0022] Accordingly, the inhibition of PLA 2 leads to the suppression of the release of AA, a precursor of various physiologically active substances, and therefore, it is considered to be useful for the prevention and/or the treatment of various inflammatory and allergic diseases. Furthermore, it is considered to be useful for the prevention and/or the treatment of pancreatitis, severity in pancreatitis and multiple organ failure due to the inhibition of the destructive activity on cell membranes.
[0023] It is also known that the inhibition of various proteases such as trypsin, plasmin, thrombin, kallilrein, especially trypsin is useful for the prevention and/or the treatment of disseminated intravascular coagulation, pancreatitis, severity in pancreatitis and multiple organ failure.
[0024] In the specifications of EP-A-588655 and 656349, it is disclosed that cetain amidinophenol compounds of the formula (IA) depicted hereinafter have an inhibitory activity on PLA 2 and an inhibitory activity on trypsin and are useful for the prevention and/or the treatment of various inflammatory or allergic diseases, disseminated intravascular coagulation, pancreatitis, severity in pancreatitis and multiple organ failure.
[0025] Several amidinophenol derivatives are known to be LTB 4 antagonists. They are disclosed in WO 94/11341, the specification of Japanese Patent Kokai No. 5-239008 and EP-518819. In these applications, it is disclosed that amidinophenyloxy (thio) alkyloxy (thio) benzamide is useful as an LTB 4 antagonist.
[0026] For example, it is described in the specification of EP-518819 that compounds of the formula (A):
[0027] wherein R 1a is amino which is mono- or disubstituted by a substituent selected from an aliphatic hydrocarbon radical, an araliphatic hydrocarbon radical, an aromatic radical, and a cycloaliphatic hydrocarbon radical or is amino which is disubstituted by a divalent aliphatic hydrocarbon radical; R 2a is hydrogen, halogen, trifluoromethyl, an aliphatic hydrocarbon radical, or is hydroxy which is etherified by an aliphatic alcohol, araliphatic alcohol, or aromatic alcohol or which is esterified by an aliphatic or araliphatic carboxylic acid;
[0028] R 3a is hydrogen or an acyl radical which is derived from an organic carbonic acid, an organic carboxylic acid, a sulfonic acid, or a carbamic acid; X 1a and X 3a , independently of one another, are oxygen (—O—) or sulphur (—S—);
[0029] X 2a is a divalent aliphatic hydrocarbon radical which may be interrupted by an aromatic radical;
[0030] wherein the phenyl rings of formula (A) may be, independently of one another, further substituted by one or more substituents selected from halogen, trifluoromethyl, an aliphatic hydrocarbon radical, hydroxy, and hydroxy which is etherified by an aliphatic alcohol or which is esterified by an aliphatic or araliphatic carboxylic acid;
[0031] wherein aryl moieties in the above definitions may be, independently of one another, further substituted by one or more substituents selected from halogen, trifluoromethyl, an aliphatic hydrocarbon radical, hydroxy, and hydroxy which is etherified by an aliphatic alcohol or which is esterified by an aliphatic or araliphatic carboxylic acid; and
[0032] wherein a cycloaliphatic hydrocarbon radical may be substituted by an aliphatic radical;
[0033] and pharmaceutically acceptable salts thereof are useful as LTB 4 antagonist.
[0034] 3. Comparison with the Related Arts
[0035] In the amidinophenyloxy(thio)alkoxy(thio)benzamide compounds represented by EP-518819 as prior art, it can be seen that —X 1a —X 2a —X 3a — must be —O(or S)-alkylene-O(or S)—, with the proviso that the alkylene may be interrupted by an aromatic group.
[0036] It has now been discovered that compounds in which it is essential that the amidinophenyl group is bonded to the phenyl group via an ester or amide group possess useful properties as LTB 4 antagonists and as inhibitors of phospholipase A 2 and/or trypsin.
SUMMARY OF THE INVENTION
[0037] The present invention relates to the discovery that amidinophenol derivatives defined by formulas (IA) and (IB) have a strong antagonistic activity on LTB 4 and thus are useful for the prevention or treatment of diseases induced by LTB 4 .
[0038] The present invention also relates to the discovery that compounds of formula (IB) have an inhibitory activity on phospholipase A 2 and an inhibitory activity on trypsin and thus are useful in preventing or treating conditions associated with the activity of these enzymes, such as various inflammatory and allergic diseases, disseminated intravascular coagulation, pancreatitis, severity in pancreatitits and multiple organ failure.
[0039] Compunds of formula (IA) and processes for the preparation thereof are known and disclosed in EP-A-588655 and EP-A-656349. Compounds of formula (IB) are novel and described below.
DESCRIPTION OF THE INVENTION
[0040] The present invention relates to
[0041] 1) a new amidinophenol derivative of the formula (IB):
[0042] is a group of the formula:
[0043] wherein R 0 is hydrogen, C1-4 alkyl, or C1-4 alkoxy,
[0044] T is NH or oxygen,
[0045] E is a single bond, or a group of the formula:
[0046] A 0 is selected from the group consisting of a single bond, C1-4 alkylene, -oxy-(C1-4)alkylene-, -thio-(C1-4)alkylene-, C2-8 alkenylene, and C2-8 alkenylene substituted by carboxy or C1-4 alkoxycarbonyl,
[0047] R 100 , R 200 , R 300 and R 400 each independently, is hydrogen or C1-4 alkyl, R is a group of the formula:
[0048] is a 4-10 membered hetero ring containing one or two nitrogen atoms, R 50 , R 60 and R 70 each independently, is,
[0049] (i) hydrogen,
[0050] (ii) C1-8 alkyl,
[0051] (iii) C2-8 alkenyl
[0052] (iv) —COOR 110 , wherein R 110 is hydrogen, C1-4 alkyl, or C1-4 alkyl substituted by phenyl,
[0053] (v) —(C1-8 alkylene)-COOR 110 , wherein R 110 has the same meaning as defined above,
[0054] (vi) —(C2-8 alkenylene)-COOR 110 , wherein R 110 has the same meaning as defined above,
[0055] (vii) C4-7 cycloalkyl,
[0056] (viii) —(C1-4 alkylene)-(4-7 membered hetero ring containing one oxygen),
[0057] (ix) —(C1-4 alkylene)-(4-7 membered hetero ring containing one nitrogen),
[0058] (x) phenyl,
[0059] (xi) C1-8 alkyl substituted by one or two phenyl,
[0060] (xii) —(C1-4 alkylene)-O-benzoyl,
[0061] (xiii) -(C1-4 alkylene)-CONH—(C1-4 alkylene)-NR 120 R 130 ,
[0062] (xiv) —(C1-4 alkylene)-COO—(C1-4 alkylene)-NR 120 R 130 ,
[0063] (xv) —(C1-4 alkylene)-COO-amidinophenyl,
[0064] (xvi) —(C1-4 alkylene)-CONH—(C1-4 alkyl substituted by one or two COOR 110 ), wherein R 110 has the same meaning as defined above,
[0065] (xvii) —(C1-4 alkylene)-CONR 120 R 130 , or
[0066] (xviii) (C1-4) alkoxy (C1-4) alkyl,
[0067] R 80 and R 90 each independently, is C1-4 alkyl or —(C1-4 alkylene)-phenyl,
[0068] R 120 and R 130 each independently, is hydrogen, C1-4 alkyl, or C2-8 alkenyl, with the provisos that:
[0069] (1) R 50 and R 60 in the formulae (i) and (iii), and R 50 , R 60 and R 70 in the formulae (ii) and (iv), do not represent hydrogen at the same time,
[0070] (2) when at least one substituent in R 50 , R 60 , R 70 and A 0 represents a substituent containing —COO-t-Bu, the other groups do not represent groups containing carboxy,
[0071] (3) R 120 and R 130 do not represent hydrogen at the same time,
[0072] (4) when
[0073] T is oxygen,
[0074] the group:
[0075] is the formula (i) as hereinbefore described,
[0076] E is a single bond,
[0077] A 0 is a single bond, C1-4 alkylene or vinylene which is optionally substituted by one or two C1-4 alkyl, and
[0078] R is the formula (i) as described above,
[0079] then at least one group in R 50 , R 60 and R 70 is
[0080] (viii) —(C1-4 alkylene)-(4-7 membered hetero ring containing one oxygen),
[0081] (ix) —(C1-4 alkylene)-(4-7 membered hetero ring containing one nitrogen),
[0082] (x) phenyl,
[0083] (xi) C1-8 alkyl which is substituted by one or two phenyl,
[0084] (xii) —(C1-4 alkylene)-O-benzoyl,
[0085] (xiii) —(C1-4 alkylene)-CONH—(C1-4 alkylene)-NR 120 R 130 ,
[0086] (xiv) —(C1-4 alkylene)-COO—(C1-4 alkylene)-NR 120 R 130 ,
[0087] (xv) —(C1-4 alkylene)-COO-amidinophenyl,
[0088] (xvi) —(C1-4 alkylene)-CONH—(C1-4 alkyl substituted by one or two COOR 110 ), wherein R 110 has the same meaning as defined above,
[0089] (xvii) —(C1-4 alkylene)-CONR 120 R 130 , or
[0090] (xviii) (C1-4) alkoxy (C1-4) alkyl;
[0091] (5) when
[0092] T is oxygen,
[0093] the group
[0094] is the formula (i) as hereinbefore defined,
[0095] E is a single bond,
[0096] A 0 is a single bond, C1-4 alkylene or vinylene optionally substituted by one or two C1-4 alkyl, and
[0097] R is the formula (ii) as defined above,
[0098] then R 50 , R 60 and R 70 do not represent hydrogen;
[0099] and non-toxic salts thereof or non-toxic acid addition salts thereof,
[0100] 2) a method for the prevention and/or treatment of diseases induced by leukotriene B 4 , which comprises the administration to a patient of an effective amount of a compound of the formula (IA):
[0101] wherein R 1 and R 2 each independently, is:
[0102] (i) hydrogen, or
[0103] (ii) —COOR 4 wherein R 4 is C1-3 alkyl;
[0104] A is
[0105] (i) a single bond,
[0106] (ii) C1-4 alkylene, or
[0107] (iii) —C(R 5 )═C(R 6 )—, wherein R 5 and R 6 each independently, is hydrogen or C1-4 alkyl;
[0108] R 3 is
[0109] (i) —CON(R 7 )R 8 ,
[0110] (ii) —CONR 9 -CH(R 7 )R 8 , or
[0111] (iii)
[0112] wherein R 7 and R 8 each independently, is
[0113] (1) hydrogen,
[0114] (2) phenyl,
[0115] (3) —(C1-4 alkylene)-phenyl,
[0116] (4)-(C1-4 alkylene)-phenyl is substituted by one or two —R 11 —COOR 12 , wherein R 11 is a single bond or C1-8 alkylene, and
[0117] R 12 is hydrogen or C1-4 alkyl,
[0118] (5) C1-5 alkyl,
[0119] (6) C2-10 alkenyl containing one to three double bonds,
[0120] (7) —R 11a —COOR 12 ,
[0121] wherein R 11a is
[0122] (a) a single bond,
[0123] (b) C1-8 alkylene,
[0124] (c) C2-8 alkenylene, or
[0125] (d) C4-8 alkenylene in which one or two carbon atoms in the main chain are replaced by sulfur, and R 12 has the same meaning as defined above, or
[0126] (8) C3-7 cycloalkyl;
[0127] R 9 is
[0128] (1) hydrogen,
[0129] (2) —R 1 1 —COOR 12 , wherein R 11 and R 12 have the same meanings as defined above, or
[0130] (3) C2-6 alkoxyalkyl;
[0131] the group:
[0132] is a 4-7 membered mono hetero ring contain one or two nitrogen;
[0133] R 10 is
[0134] (1) hydrogen, or
[0135] (2) —(C1-4 alkylene)-phenyl,
[0136] with the proviso that:
[0137] (1) both R 7 and R 8 do not represent hydrogen at the same time,
[0138] (2) when at least one group in R 7 , R 8 , and R 9 represent the group containing —COO-t-Bu, the other groups do not represent the groups containing carboxy;
[0139] or non-toxic salts thereof and non-toxic acid-addition salts thereof,
[0140] 3) processes for the preparation of the compound of the formula (IB),
[0141] 4) LTB 4 antagonists containing a compound of the formula (IB) and non-toxic salts thereof or non-toxic acid addition salts thereof, as the active ingredient, and
[0142] 5) phospholipaseA 2 and trypsin inhibitors containing a compound of the formula (IB) and non-toxic salts thereof or non-toxic acid addition salts thereof, as the active ingredient.
[0143] The compounds of the invention may form hydrates; it is to be understood that such hydrates form part of the present invention and that references to the compounds in this specification, including the accompanying claims, are to be understood as embracing the hydrates.
[0144] It will be understood that formulae (i) and (ii) for the symbol R may overlap: formula (ii) should be construed as excluding those groupings already embraced by formula (i).
[0145] Throughout the specification, it will be understood by those skilled in the art that all isomers are included in the present invention. For example, the alkyl, alkoxy, alkylene, alkenylene and alkynylene groups include straight-chain and also branched-chain ones, and the double bonds in the alkenylene group include E, Z and EZ mixtures. Accordingly, all isomers produced by the existence of asymmetric carbon atoms are included in the present invention when branched-chain alkyl, alkoxy, alkylene, alkenylene and alkynylene are present.
[0146] Explanation of various symbols in the formula (IB) is given below.
[0147] The C1-3 alkyl group means methyl, ethyl, propyl and the isomers thereof. C1-4 alkyl group means methyl, ethyl, propyl, butyl, and the isomers thereof. C1-5 alkyl group means methyl, ethyl, propyl, butyl, pentyl and the isomers thereof.
[0148] C1-4 alkylene group means methylene, ethylene, trimethylene, tetramethylene and the isomers thereof. C1-8 alkylene group means methylene, ethylene, trimethylene, tetramethylene, pentamethylene, hexamethylene, heptamethylene, octamethylene, and the isomers thereof.
[0149] C2-6 alkoxyalkyl group means ethylene, trimethylene, tetramethylene, pentamethylene, hexamethylene which are interrupted by oxygen except end.
[0150] C4-8 alkenylene group means tetramethylene, pentamethylene, hexamethylene, heptamethylene, octamethylene in which a —CH 2 —CH 2 — grouping (which is not at either end of the group) is replaced by a double bond.
[0151] C2-8 alkenylene group containing one to three double bonds means ethylene, trimethylene, tetramethylene, pentamethylene, hexamethylene, heptamethylene or octamethylene in which one to three groupings —CH 2 —CH 2 — (except those at each end of the group) are replaced by double bonds.
[0152] C3-7 cycloalkyl group means cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl and cycloheptyl.
[0153] The 4-7 membered hetero ring containing one or two nitrogen means, for example, pyrrolyl, pyrrolidinyl, imidazolyl, imidazolidinyl, pyridinyl, piperidinyl, pyrazinyl, piperazinyl or pyrimidinyl.
[0154] Further explanation of various symbols in the formula (IB) is given below.
[0155] In the formula (IB), C1-4 alkyl represented by R 0 , R 100 , R 200 , R 300 , R 400 , R 50 , R 60 , R 70 , R 80 , R 90 , R 120 and R 130 , and that in R 0 , R 100 , R 200 , R 300 , R 400 , R 50 , R 60 , R 70 , R 80 , R 90 , R 120 and R 130 , means methyl, ethyl, propyl, butyl and the isomers thereof.
[0156] In the formula (IB), C1-4 alkyl represented by R 0 and A 0 , and that in R 0 and A 0 means methoxy, ethoxy, propoxy, butoxy and the isomers thereof.
[0157] In the formula (IB), C1-4 alkylene represented by A 0 , and that in A 0 , means methylene, ethylene, trimethylene, tetramethylene and the isomers thereof.
[0158] In the formula (IB), C2-8 alkenylene represented by A 0 , and that in A 0 , means ethylene, trimethylene, tetramethylene, pentamethylene, hexamethylene, heptamethylene, octamethylene and the isomers thereof, having one, two or three double bonds.
[0159] In the formula (IB), C1-8 alkyl represented by R 50 , R 60 and R 70 , and that in R 50 , R 60 and R 70 , means methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl and the isomers thereof.
[0160] In the formula (IB), C2-8 alkenyl represented by R 50 , R 60 and R 70 , and that in R 50 , R 60 and R 70 , mean methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl and the isomers thereof, having one, two or three double bonds.
[0161] In the formula (IB), 4-7 cycloalkyl represented by R 50 , R 60 and R 70 , and that in R 50 , R 60 and R 70 , mean cyclobutyl, cyclopentyl, cyclohexyl and cycloheptyl.
[0162] In the formula (IB), examples of the 4-7 membered hetero ring containing one oxygen (which may be partially or fully saturated) represented by R 50 , R 60 and R 70 , and that in R 50 , R 60 and R 70 , are furyl, pyranyl, dihydrofuryl, dihydropyranyl, tetrahydrofuryl and tetrahydropyranyl.
[0163] In the formula (IB), examples of the 4-7 membered hetero ring containing one nitrogen (which may be partially or fully saturated) represented by R 50 , R 60 and R 70 , and that in R 50 , R 60 and R 70 , are pyrrolyl, pyridinyl, piperidinyl, pyrrolinyl, pyrrolidinyl and dihydropyridinyl.
[0164] In the formula (IB), when R is the formula represented by (vi), examples of the 4-10 membered hetero ring containing one or two nitrogen, (which may be partially or fully saturated) are pyrrolyl, pyridinyl, pyrrolinyl, pyrrolidinyl, dihydropyridinyl, imidazolyl, piperidinyl, imidazolinyl, imidazolidinyl, pyrimidinyl, pyridazinyl, pyrazinyl, indolyl and tetrahydroindolyl.
[0165] Preferred Compound
[0166] Preferred formula (IB) compounds of the present invention are those described in the Examples and the following compounds.
TABLE 1 Preferable groups as R
[0167] [0167] TABLE 2 Preferable groups as R
[0168] [0168] TABLE 3 Preferable groups as R
[0169] [0169] TABLE 4 Preferable groups as R
[0170] [0170] TABLE 5 Preferabie groups as R
[0171] [0171] TABLE 6 Preferabie groups as R
[0172] [0172] TABLE 7 Preferable groups as R
[0173] [0173] TABLE 8 Preferable groups as R
[0174] [0174] TABLE 9 Preferable groups as R
[0175] [0175] TABLE 10 Preferable groups as R
[0176] [0176] TABLE 11 Preferable groups as R
[0177] [0177] TABLE 12 Preferable groups as R
[0178] [0178] TABLE 13 Preferable groups as R
[0179] [0179] TABLE 14 Preferabel groups as R
[0180] [0180] TABLE 15 Preferable groups as R
[0181] [0181] TABLE 16 Preferable groups as R
[0182] Pharmaceutical compositions of the present invention can be prepared using one active ingredient or two or more active ingredients.
[0183] Salts and Acid-additon Salts
[0184] Compounds of the formulae (IA) and (IB) of the present invention may be converted into the corresponding salts and acid-addition salts by known methods. Nontoxic and water-soluble salts are preferred.
[0185] Suitable salts include the salts of alkali metals (sodium, potassium etc.), alkaline-earth metal (calcium, magnesium etc.), ammonium salts, salts of pharmacoligically acceptable organic amines (tetramethyl ammonium, triethylamine, methylamine, dimethylamine, cyclopentylamine, benzylamine, phenetylamine, piperidine, monoethanolamine, diethanolamine, tris (hydroxymethyl)aminomethane, lysine, arginine, N-methyl-D-gulcane etc).
[0186] Suitable acid-addition salts include the salts with inorganic acids such as hydrochloric acid, and the salts with organic acids such as acetic acid, trifluoroacetic acid, lactic acid, tartaric acid, oxalic acid, fumaric acid, maleic acid, citric acid, benzoic acid, methanesulfonic acid, ethanesulfonic acid, benzenesulfonic acid, toluenesulfonic acid, isethionic acid, glucuronic acid and gluconic acid. Preferred salts include the salts with acids such as hydrochloric acid, methanesulfonic acid, acetic acid and trifluoroacetic acid.
[0187] Preparation of Compounds
[0188] The compounds of the formula (IA) may be prepared by methods known per se, as defined in published applications EP-A-588655 and EP-A-656349. The formula (1B) compounds of the present invention may be prepared by forming an ester or amide bond between a compound of the formula (II):
[0189] (wherein the various symbols have the same meanings as hereinbefore defined) with a compound of the formula (III):
[0190] (wherein the various symbols have the same meanings as hereinbefore defined). The esterification reaction and the reaction to form an amide are known and can be carried out by known method, for example:
[0191] (1) using an acid halide,
[0192] (2) using a mixed acid anhydride or
[0193] (3) using a condensing agent.
[0194] Esterification can be carried out, for example, as follows:
[0195] (1) the method using an acid halide may be carried out, for example, by reacting a carboxylic acid with an acid halide (e.g., oxalyl chloride, thionyl chloride etc.) in an inert organic solvent (e.g., chloroform, methylene chloride, diethyl ether, tetrahydrofuran etc.) or without a solvent at from −20° C. to the reflux temperature of the solvent, and then by reacting the acid halide obtained with a corresponding alcohol in the presence of a tertiary amine (e.g., pyridine, triethylamine, diethylaniline, diethylaminopyridine etc.) in an inert organic solvent (e.g., chloroform, methylene chloride, diethyl ether, tetrahydrofuran etc.) at a temperature of from 0° C. to 40° C.;
[0196] (2) the method using a mixed acid anhydride may be carried out, for example, by reacting a carboxylic acid and an acid halide (e.g., pivaloyl chloride, tosyl chloride, mesyl chloride etc.) or an acid derivative (e.g., ethyl chloroformate, isobutyl chloroformate etc.) in the presence of a tertiary amine (e.g., pyridine, triethyamine, dimethylaniline, dimethylaminopyridine etc.) in an inert organic solvent (e.g., chloroform, methylene chloride, diethyl ether, tetrahydrofuran etc.) or without a solvent at a temperature of from 0° C. to 40° C., and then by reacting the mixture of acid anhydride obtained with a corresponding alcohol in an inert organic solvent (e.g., chloroform, methylene chloride, diethyl ether, tetrahydrofuran etc.), at a temperature of from O° C. to 40° C.; and
[0197] (3) the method using a condensing agent (e.g., 1,3-dicyclohexylcarbodiimide (DCC), 1-ethyl-3-[(dimethylamino)propyl] cabodiimide (EDC), 2-chloro-1-methypyridinium iodide etc.) may be carried out, for example, by reacting a carboxylic acid with a corresponding alcohol using a condensing agent in the presence or absence of a tertiary amine (e.g., pyridine, triethylamine, dimethylaniline, dimethylaminopyridine etc.) in an inert organic solvent (e.g., chloroform, methylene chloride, dimethyl formamide, diethyl ether etc.) or without a solvent at a temperature of from 0° C. to 40° C.
[0198] The formation of an amide may be accomplished by the same reactions as described above, except the corresponding alcohol is replaced by a corresponding amine.
[0199] The reactions (1), (2) and (3) hereinbefore described may be preferably carried out in an atmosphere of inert gas (e.g., argon, nitrogen etc.) under anhydrous conditions.
[0200] The compounds of the formula (III) may be prepared by the series of reactions depicted in the following Scheme A.
[0201] In the Scheme A,
[0202] R p is t-butyl or benzyloxycarbonyl,
[0203] X 10 , X 20 and X 30 each independently, is halogen,
[0204] Ms is methaneosulfonic acid,
[0205] A 00 is bond, C1-3 alkylene, oxy-(C1-3) alkylene, thio-(C1-3)alkylene, C2-7 alkenylene, C2-7 alkenylene substituted by carboxy or C1-4 alkoxycarbonyl, and the other symbols have the same meaning as hereinbefore described.
[0206] The reactions in the scheme hereinbefore depicted may be carried out by methods known per se. The compounds of the formulae (II), (IV), (V) and (VI) used as starting materials in this scheme are known per se or may be easily prepared by methods known per se.
[0207] Other starting materials and each of the reagents are known per se or may be prepared by known methods.
[0208] In each reaction in the present specification, products may be purified in a conventional manner. For example, purification may be carried out by distillation at atmospheric or reduced pressure, high performance liquid chromatography, thin layer chromatography or column chromatography using silica gel or magnesium silicate, washing or recrystallization. Purification may be carried out after each reaction, or after a series of reactions.
[0209] Physiological Effects
[0210] As mentioned above, it is understood that LTB 4 antagonist is useful as an anti-inflammatory and anti-allergic agent.
[0211] Therefore, compounds of the present invention of formulas (IA) and (IB), having LTB 4 antagonistic activity, may be used for the treatment of an animal, preferably a human, as an anti-inflammatory and anti-allergic agent.
[0212] It is known that an LTB 4 antagonist is also useful for the prevention and/or treatment of various diseases in animals, including humans. These diseases include rheumatoid arthritis, inflammatory bowel diseases, psoriasis, nonsteroidal anti-inflammatory agent-induced stomach diseases, adult respiratory distress syndrome, cardiac infarction, allergic rhinitis, hemodialysis-induced neutropenia and anaphase asthma.
[0213] The compounds of the formula (IB) also have inhibitory activity on phospholipase and inhibitory activity on trypsin in animals, including humans. Therefore compounds of formula (IB) are useful for the prevention and/or the treatment of various inflammatory, allergic diseases, disseminated intravascular coagulation, pancreatitis, severity in pancreatitis and multiple organ failure in animals, preferably humans.
[0214] Toxicity
[0215] It is confirmed that the toxicity of the active ingredients and non-toxic salts thereof and non-toxic acid addition salts thereof in the present invention is very weak. For example, LD 50 of Compound 1 was 117 mg/kg when administered intravenously to male mice. Accordingly, the active substances in the present invention may be considered to be sufficiently safe and suitable for pharmaceutical use.
[0216] For the purpose hereinbefore described, the active ingredient in the present invention and non-toxic salts thereof and non-toxic acid addition salts thereof may be normally administered systemically or partially, usually by oral or parenteral administration.
[0217] The doses to be administered are determined depending upon age, weight, symptom, the desired therapeutic effect, the route of administration, and the duration of the treatment, etc. In the human adult, the doses per person per dose are generally between 1 mg and 1000 mg, by oral administration, up to several times per day, or between 100 μg and 100 mg, by parenteral administration (preferably, intravenously) up to several times per day. As mentioned above, the doses to be used depend upon various conditions. Therefore, there are cases in which doses lower than or greater than the ranges specified above may be used.
[0218] Compounds of the present invention are administered in the form of solid compositions, liquid compositions or other compositions for oral administration, and as injections, liniments or suppositories, etc., for parenteral administration.
[0219] Solid compositions for oral administration include compressed tablets, pills, capsules, dispersible powders, and granules.
[0220] In such compositions, at least one of the active compounds is admixed with at least one inert diluent (such as lactose, mannitol, glucose, hydroxypropyl cellulose, microcrystalline cellulose, starch, polyvinylpyrrolidone, magnesium metasilicate aluminate, etc.).
[0221] These compositions may also comprise, as in normal practice, additional substances other than inert diluents: e.g., lubricating agents (such as magnesium stearate, etc.), disintegrating agents (such as cellulose calcium glycolate, etc.), assisting agents for dissolving (such as arginine, glutamic acid, asparaginic acid, etc.) and stabilizers (human serum albumin, lactose, etc.).
[0222] The tablets or pills may, if desired, be coated with a film of gastric or enteric material (such as sugar, gelatin, hydroxypropyl cellulose, hydroxypropylmethyl cellulose phthalate, etc.).
[0223] Capsules include hard capsules and soft capsules.
[0224] Liquid compositions for oral administration include solutions, emulsions, suspensions, syrups and elixirs.
[0225] These liquid compositions may comprise inert diluents commonly used in the art (purified water, ethanol, etc.).
[0226] Besides inert diluents, such compositions may also comprise adjuvants (such as wetting agents, suspending agents, etc.), sweetening agents, flavoring agents and preserving agents.
[0227] Other compositions for oral administration include spray compositions, which may be prepared by known methods and which comprise one or more of the active compound(s). Spray compositions may comprise additional substances other than inert diluents: e.g. stabilizing agents (sodium sulfate, etc.), isotonic stabilizing agents (sodium chloride, sodium citrate, citric acid, etc.). For preparation of such spray compositions, for example, the method described in the U.S. Pat. No. 2,868,691 or No. 3,095,355 may be used.
[0228] Injections for parenteral administration include sterile aqueous or non-aqueous solutions, suspensions and emulsions.
[0229] In such compositions, one or more of active compound(s) is or are admixed with at least one of inert aqueous diluent(s) (distilled water for injection, physiological salt solution, etc.) or inert non-aqueous diluent(s) (propylene glycol, polyethylene glycol, olive oil, ethanol, POLYSORBATE80 (registered trademark) etc.).
[0230] Injections may comprise furthermore assisting agents such as preserving agents, wetting agents, emulsifying agents, dispersing agents, stabilizing agents (such as human serum albumine, lactose, etc.) and assisting agents for dissolving (arginine, glutamic acid, asparaginic acid, polyvinylpyrrolidone, etc.).
[0231] Usually, they may be sterilized by filtration (a bacteria-retaining filter etc), by incorporation of sterilizing agents in the compositions or by irradiation, or after treated, they may also manufactured in the form of sterile solid compositions, for example, by freeze-drying, which may be dissolved in sterile water or some other sterile diluent(s) for injection immediately before used, and which may be used.
EXAMPLE
[0232] The following Reference Examples and Examples illustrarte the present invention.
[0233] The solvents in parentheses show the developing or eluting solvents used in chromatographic separations and the solvent ratios used are by volume.
Example 1 (A)
[0234] Binding Inhibition Against 3 H-LTB 4 on the Human Polymorphonuclear Leukocyte (PMN)
[0235] 0.049 ml Hanks balanced salt solution (HBSS), 0.001 ml test compound and 0.05 ml 3 H-LTB 4 (4 nM) were added to polypropylene tubes and mixed. The reaction was started by addition of a thoroughly mixed PMN cell suspension (1.6×10 6 cells), followed by incubation at 0° C. for 20 min. The reaction was terminated by the addition of ice-cold HBSS (2.5 ml). PMNs were harvested by vacuum filtration through Whatman GF/C glass fiber filters on a Brandel cell harvester (BRANDEL, M-24R). The filters were then washed 2 times to remove free 3 H-LTB 4 with 2.5 ml of the ice-cold PBS (−) solution. The filters were transferred to each vial, and equilibrated after adding 8 ml ACS II cocktail (Amersham). The radioactivity was measured by liquid scintillation counter (Aloka, LSC-5100).
[0236] Specific binding of 3 H-LTB 4 to the LTB 4 receptor was defined as total binding minus nonspecific binding. Nonspecific binding was the amount of 3 H-LTB 4 binding in the presence of 1.5 μM LTB 4 instead of the test compound. The inhibitory effect of test compound was calculated from the following equation.
The percentage of inhibition (%)=100−( B 1 /B 0 ×100)
[0237] B 1 : Specific 3 H-LTB 4 binding in presence of test compound
[0238] B 0 : Specific 3 H-LTB 4 binding in absence of test compound
[0239] Results
[0240] The results are shown in the following Table 17.
TABLE 17 European Patent Publication No. 588655 binding activity Compound No. Compound (Example No.) (%) 1 1 (i) 91.5 2 1 (m) 76.6 3 1 (p) 75.0 4 1 (aa) 63.7 5 1 (ii) 94.3 6 1 (pp) 71.6 7 1 (qq) 78.0 8 1 (hhh) 82.7 9 1 (lll) 91.6 10 1 (mmm) 86.5 11 2 (g) 76.8 12 2 (p) 95.2 13 2 (u) 100.2 14 2 (w) 96.5 15 2 (cc) 89.1 16 2 (gg) 83.6 17 2 (kk) 93.9 18 3 (f) 87.0 19 4 74.0 20 4 (a) 83.5 21 5 (r) 90.8 22 5 (w) 89.7 23 5 (ff) 78.0 24 European Patent Publication 61.2 No. 656349 Example 1 (b)
[0241] The structure of compounds used in the present invention are shown below.
Example 1 (B)
[0242] The compounds of the formula (IB), of the present invention have an antagonistic activity on LTB 4 . The results which are measured by method as hereinbefore described in Example 1 (A), are shown the following Table 18.
TABLE 18 binding activity Compound (Example No.) (%) 2 79.7 2 (a) 92.0 2 (b) 97.9 2 (c) 103.2 2 (d) 99.3 2 (e) 94.5 2 (f) 91.8 2 (g) 89.6 2 (h) 85.4 2 (i) 69.6 2 (j) 55.4 2 (k) 97.7 2 (l) 81.0 2 (m) 89.2 2 (n) 82.8 2 (o) 85.8 2 (p) 95.2 2 (q) 98.0 2 (r) 80.1 2 (s) 83.0 2 (t) 51.5 2 (u) 67.6 2 (v) 92.0 2 (w) 76.7 2 (x) 94.1 2 (y) 85.5 2 (z) 92.8 2 (aa) 94.4 2 (bb) 87.3 2 (cc) 76.7 2 (dd) 50.8 2 (ee) 65.3 2 (ff) 82.4 3 96.8 4 73.1 4 (a) 52.0 5 89.7 5 (a) 62.5 5 (b) 90.2 6 67.8
Example 1 (C)
[0243] Inhibitory Activity on Phospholipase A 2 and on Trypsin
[0244] It has been confirmed that compounds of formula (IB) of the present invention have inhibitory activities on phospholipaseA 2 (PLA 2 ) and on trypsin.
[0245] For example, in laboratory tests the following results were obtained.
[0246] Method
[0247] (1) Inhibitory Activity on PLA 2
[0248] A reaction solution including 50 mM tris-HCl buffer (pH7.5, 874 μl; containing 100 mM sodium chloride, 1 mM EDTA), 1M calciumchloride (6 μl), 1% bovine serum albumin (10 μl) and 2.5 mM 10PY-PC (10 μl), was prepared. To the solution were added a test compound in various concentration or water (50 μl), and a solution of 10 mU/ml PLA 2 (derived from hog pancreas) (50 μl). The appearance of fluorescence was measured (Ex=345 nm, Em=396 nm). Percentage (%) of the strength of fluorescence in the presence of a test compound was calculated when the strength of that in the absence thereof was regarded as 100%, and therefrom IC 50 value was calculated. The results are shown in the following Table19.
[0249] (2) Inhibitory Activity on Trypsin
[0250] To a mixture of a 0.2 M HEPES•sodium hydroxide buffer solution (pH 8.0, 100 μl) and distilled water (640 μl), were added a test compound in various concentration or water (10 μl), and a solution of 80 mU/ml trypsin (derived from bovine pancreas) (50 μl) and then the mixture was preincubated for one minute at 30° C. To the solution thus obtained was added 2.5 mM BAPNA (200 μl) and the mixture was incubated at 30° C. The absorbance at 405 nm was measured. Percentage (%) of the absorbance in the presence of a test compound was calculated when the absorbance in the absence thereof was regarded as 100%, and therefrom IC 50 value was calculated. The results are shown in the following Table 19.
TABLE 19 inhibitory activity inhibitory activity Compound on PLA 2 on trypsin (Example No.) IC 50 (μM) IC 50 (μM) 2 — 0.19 2 (a) 2.6 0.4 2 (b) 3.8 0.56 2 (c) 8.1 0.26 2 (d) 8.7 0.14 2 (e) 8.5 0.34 2 (f) 70 0.10 2 (g) 53 0.16 2 (h) 11 0.15 2 (i) 59 0.14 2 (j) — 0.12 2 (k) 20 0.10 2 (l) 94 0.12 2 (m) 18 0.17 2 (n) 10 0.16 2 (o) 12 0.14 2 (p) 29 0.13 2 (q) 34 0.16 2 (r) 46 0.16 2 (s) 44 0.16 3 4.7 0.12 4 41 0.16 4 (a) — 0.14 5 — 0.13 5 (a) — 0.15 6 4.5 0.17
[0251] In the methods hereinbefore described,
[0252] 10PY-PC represents 3′-palmitoyl-2-(1-pyrenedecanoyl)-L-(α-phosphatidycholine,
[0253] HEPES represents 4-2-hydroxyethyl)-1-piperazineethanesulfonic acid, and
[0254] BAPNA represents α-N-benzoyl-DL-arginine-p-nitroanilide hydrochloride.
[0255] Preparation of New Compounds
[0256] The following Reference Examples and Examples illustrate the preparation of new compounds of formula (IB).
Reference Examples 1
[0257] N-(2-Propenyl)-N-ethoxycarbonylmethyl-4-benzyloxycarbonylphenoxyacetamide.
[0258] A solution of 4-benzyloxycarbonylphenoxyacetic acid (4.29 g) in thionyl chloride (10 ml) was refluxed for 15 min. After an excess amount of solvent was distilled off, product was dissolved in dichloromethane. And this solution was added dropwise to a solution of N-(2-propenyl)-N-ethoxycarbonylmethylamine (2.14 g) in pyridine under cooling with ice. After the solution was stirred for 30 min at room temperature, the solution was poured into ice water. The mixture was extracted with ethyl acetate. The extract was washed with a solution of 1N hydrochloric acid, water and a saturated aqueous solution of sodium chloride, successively, and then evaporated. The residue was then purified by silica gel column chromatograhy to obtain the title compound (5.96 g) having the following physical data:
[0259] TLC:Rf 0.43 (hexane:ethyl acetate=3:2)
Reference Example 2
[0260] N-(2-Propenyl)-N-ethoxycarbonylmethyl-4-carboxyphenoxyacetamide
[0261] Methanesulfonic acid (28 ml) was added to the compound prepared in Reference Example 1 (5.69 g) under cooling at 0° C. After reaction, the solution was stirred for one hour at room temperature, poured into ice water and extracted with ethyl acetate. The organic layer was washed with water, and a saturated aqueous solution of sodium chloride, successively, and then evaporated. The residue was purified by silica gel column chromatography to obtain the title compound (4.31 g) having the following physical data.
[0262] TLC:Rf 0.35 (hexane:ethyl acetate=1:1)
Example 2
[0263] N-(2-propenyl)-N-ethoxycarbonylmethyl-4-(4-amidinophenoxycarbonyl)phenoxyacetamide acetate
[0264] To a pyridine solution of amidinophenol (1.72 g) and the compound prepared in Reference Example 2 (3.21 g) was added DCC (3.09 g) and stirred overnight at room temperature. The reaction solution was filtered and the filtrate was evaporated. The residue was purified by silica gel column chromatography and was formed into acetate by a conventional manner to obtain the title compound having the following physical data.
[0265] TLC:Rf 0.41 (chloroform:methanol:acetic acid=10:2:1),
[0266] NMR (CD 3 OD): δ 8.14(2H, d, J=9.0 Hz), 7.90(2H, d, J=9.0 Hz), 7.49(2H, d, J=9.0 Hz), 7.08(2H, d, J=9.0 Hz), 5.68-6.07(1H, m), 5.17-5.37(2H, m), 4.93 and 5.02(2H, s, ratio=7:10), 4.03-4.28(6H, m), 1.26 and 1.29(3H, t, J=7.0 Hz).
Example 2 (a)˜2 (ff)
[0267] By the same procedure as Reference Examples 1-2 and Example 2, the compound having the following physical data was obtained.
Example 2 (a)
[0268] [0268]
[0269] TLC:Rf 0.57 (chloroform:methanol:acetic acid=10:2:1),
[0270] NMR (CD 3 OD): δ 2.60(2H, t, J=8.0 Hz), 2.98(2H, t, J=8.0 Hz), 5.17(2H, s), 6.99-7.02(2H, m), 7.09-7.16(5H, m), 7.30(5H, s), 7.38(1H, d, J=9.0Hz), 7.43(1H, s), 7.48(2H, d, J=8.0 Hz), 7.98(2H, d, J=8.0 Hz).
Example 2 (b)
[0271] [0271]
[0272] TLC:Rf 0.60 (chloroform:methanol:acetic acid=10:2:1),
[0273] NMR (CD 3 OD): δ 2.41(2H, t, J=7.0 Hz), 3.00(2H, t, J=7.0 Hz), 4.69(2H, s), 5.23(2H, s), 7.09-7.42(14H, m), 7.43(2H, d, J=8.0 Hz), 7.98(2H, d, J=8.0 Hz).
Example 2 (c)
[0274] [0274]
[0275] TLC:Rf 0.53 (chloroform:methanol:acetic acid=10:2:1),
[0276] NMR (CD 3 OD): δ 8.0(2H, d, J=8.0 Hz), 7.50(2H, d, J=8.0 Hz), 7.46(1H, s), 7.40(1H, d, J=8.0 Hz), 7.24(5H, s), 7.12(1H, s), 7.10(1H, d, J=8.0 Hz), 4.61(2H, s), 4.22(2H, q, J=8.0 Hz), 3.00(2H, t, J=9.0 Hz), 2.61(2H, t, J=9.0 Hz), 1.30(3H, t, J=8.0 Hz).
Example 2 (d)
[0277] [0277]
[0278] TLC:Rf 0.45 (chloroform:methanol:acetic acid=10:2:1),
[0279] NMR (CD 3 OD): δ 8.00(2H, d, J=8 Hz), 7.80(1H, d, J=16 Hz), 7.75(2H, d, J=8 Hz), 7.50(2H, d, J=8 Hz), 7.35(2H, d, J=8 Hz), 7.30-7.20(5H, m), 6.70(1H, d, J=16 Hz), 4.65(2H, s), 4.25(2H, q, J=7 Hz), 1.30(3H, t, J=7 Hz).
Example 2 (e)
[0280] [0280]
[0281] TLC:Rf 0.45 (chloroform:methanol:acetic acid=10:2:1),
[0282] NMR (CD 3 OD): δ 1.30(3H, t, J=7.0 Hz), 2.18(3H, s), 4.31(2H, q, J=7.0 Hz), 4.77(2H, m), 5.02(1H, t, J=4.0 Hz), 7.39-7.61(8H, m), 7.89(2H, d, J=9.0 Hz), 8.02(2H, d, J=9.0 Hz), 8.22(2H, d, J=9.0 Hz).
Example 2 (f)
[0283] [0283]
[0284] TLC:Rf 0.43 (chloroform:methanol:acetic acid=10:2:1),
[0285] NMR (CD 3 OD): δ 8.00-7.80(7H, m), 7.50(2H, d, J=8.5 Hz), 6.90(1H, d, J=16 Hz), 4.60(1H, dd, J=4.5, 4.5 Hz), 4.20(2H, q, J=6.5 Hz), 4.15(2H, q, J=6.5 Hz), 2.50(2H, t, J=7.5 Hz), 2.30(1H, m), 2.10(1H, m), 1.30(3H, t, J=6.5 Hz), 1.25(3H, t, J=6.5 Hz).
Example 2 (g)
[0286] [0286]
[0287] TLC:Rf 0.46 (chloroform:methanol:acetic acid=10:2:1),
[0288] NMR (CD 3 OD): δ 8.00-7.90(5H, m), 7.65(2H, d, J=8 Hz), 7.50(2H, d, J=8 Hz), 4.65(1H, dd, J=4.5, 4.5 Hz), 4.20(2H, q, J=6.5 Hz), 4.15(2H, q, J=6.5 Hz), 2.50(2H, t, J=7.5 Hz), 2.30(1H, m), 2.25(3H, m), 2.10(1H, m), 1.30(3H, t, J=6.5 Hz), 1.25(3H, t, J=6.5 Hz).
Example 2 (h)
[0289] [0289]
[0290] TLC:Rf 0.48 (chloroform:methanol:acetic acid=15:2:1),
[0291] NMR (CD 3 OD): δ 8.24(2H, d, J=8.5 Hz), 7.95(2H, d, J=8.5 Hz), 7.62(2H, d, J=8.0 Hz), 7.55(2H, d, J=8.0 Hz), 7.35(1H, s), 6.85(1H, dt, J=7.5, 15.0 Hz), 5.93(1H, d, J=15.0 Hz), 4.28(4H, q, J=7.5 Hz), 4.18(2H, d, J=7.5 Hz), 3.23(2H, d, J=7.5 Hz), 2.14(3H, s), 1.26(6H, t, J=7.5 Hz), 1.23(3H, t, J=7.5 Hz).
Example 2 (i)
[0292] [0292]
[0293] TLC:Rf 0.43 (chloroform:methanol:acetic acid=10:2:1),
[0294] NMR (CD 3 OD): δ 8.24 and 8.26(2H, d, J=9.0 Hz), 7.81(1H, d, J=18.0 Hz), 7.75(2H, d, J=9.0 Hz), 7.58 and 7.66(2H, d, J=9.0 Hz), 7.37(2H, d, J=9.0 Hz), 6.73(1H, d, J=18.0 Hz), 5.77-5.96(1H, m), 5.22-5.34(2H, m), 4.12-4.28(4H, m), 3.96-4.00(2H, m), 1.20 and 1.30(3H, t, J=7.0 Hz).
Example 2 (j)
[0295] [0295]
[0296] TLC:Rf 0.44 (chloroform:methanol:acetic acid=10:2:1),
[0297] NMR (CD 3 OD): δ 8.18(2H, d, J=9.0 Hz), 7.90(2H, d, J=9.0 Hz), 7.50(2H, d, J=9.0 Hz), 7.17(2H, d, J=9.0 Hz), 4.70(2H, s), 4.55(1H, dd, J=9.5, 5.0 Hz), 4.18(2H, q, J=7.0 Hz), 4.11(2H, q, J=7.0 Hz), 2.40(2H, t, J=7.0 Hz), 1.97-2.32(2H, m), 1.27(3H, t, J=7.0 Hz), 1.23(3H, t, J=7.0 Hz).
Example 2 (k)
[0298] [0298]
[0299] TLC:Rf 0.48 (chloroform:methanol:acetic acid=15:2:1),
[0300] NMR (CD 3 OD): δ 8.22(2H, d, J=8.0 Hz), 7.92(2H, d, J=8.0 Hz), 7.60(2H, d, J=8.0 Hz), 7.56(2H, d, J=8.0 Hz), 7.37(1H, brs), 4.27(4H, q, J=7.5 Hz), 4.13(2H, q, J=7.5 Hz), 3.47(2H, s), 2.16(3H, s), 1.25(6H, t, J=7.5 Hz), 1.22(3H, t, J=7.5 Hz).
Example 2 (l)
[0301] [0301]
[0302] TLC:Rf 0.49 (chloroform:methanol:acetic acid=10:2:1),
[0303] NMR (CD 3 OD): δ 7.98(1H, s), 7.90(2H, d, J=9.0 Hz), 7.58(4H, m), 7.48(2H, d, J=9.0 Hz), 5.78-5.96(1H, m), 5.23-5.32(2H, m), 4.22(2H, q, J=7.0 Hz), 4.20(2H, s), 3.98-4.03(2H, m), 2.24(3H, s), 1.30(3H, t, J=7.0 Hz).
Example 2 (m)
[0304] [0304]
[0305] TLC:Rf 0.38 (chloroform:methanol:acetic acid=10:1:1),
[0306] NMR (CD 3 OD): δ 8.20(2H, d, J=8.4 Hz), 7.92(2H, d, J=8.8 Hz), 7.74(2H, d, J=8.4 Hz), 7.55(2H, d, J=8.8 Hz) 7.25(3H, m), 6.32(1H, d, J=14.6 Hz), 4.55(1H, m), 4.20(2H, q, J=7.2 Hz), 4.14(2H, q, J=7.0 Hz), 2.72(3H, s), 2.45(2H, t, J=7.4 Hz), 2.36-1.90(2H, m), 1.29(3H, t, J=7.2 Hz), 1.25(3H, t, J=7.0 Hz).
Example 2 (n)
[0307] [0307]
[0308] TLC:Rf 0.39 (chloroform:methanol:acetic acid=10:1:1),
[0309] NMR (CD 3 OD): δ 8.18(2H, d, J=8.4 Hz), 7.92(2H, d, J=8.8 Hz), 7.73(2H, d, J=8.4 Hz), 7.53(2H, d, J=8.8 Hz), 7.50-7.15(2H, m), 7.05(1H, d, J=14.5 Hz), 6.75-6.55(1H, m), 6.03-5.81(1H, m), 5.32-5.14(2H, m), 4.20(2H, q, J=7.2 Hz), 4.30-4.10(4H, m), 1.94(3H, s), 1.28(3H, t, J=7.2 Hz).
Example 2 (o)
[0310] [0310]
[0311] TLC:Rf 0.50 (chloroform:methanol:acetic acid=10:2:1),
[0312] NMR (CD 3 OD): δ 8.20(2H, d, J=8.5 Hz), 7.90(2H, d, J=11.5 Hz), 7.60(2H, d, J=8.5 Hz), 7.55(2H, d, J=11.5 Hz), 7.35(1H, br.s), 5.70(1H, m), 5.15(2H, m), 4.25(4H, q, J=7 Hz), 3.10(2H, d, J=7 Hz), 2.15(3H, s), 1.95(3H, s), 1.25(6H, t, J=7HZ).
Example 2 (p)
[0313] [0313]
[0314] TLC:Rf 0.50 (chloroform:methanol:acetic acid=10:1:1),
[0315] NMR (CD 3 OD): δ 7.94(2H, d, J=8.0 Hz), 7.89(2H, d, J=8.5 Hz), 7.72(2H, d, J=8.5 Hz), 7.44(2H, d, J=8.0 Hz), 6.49(1H, s), 4.64(1H, m), 4.23(2H, q, J=7.5 Hz), 4.14(2H, q, J=7.0 Hz), 2.74(3H, s), 2.66(3H, s), 2.52(2H, t, J=7.0 Hz), 2.32(2H, m), 2.14(2H, m), 1.30(3H, t, J=7.0 Hz), 1.25(3H, t, J=7.5 Hz).
Example 2 (q)
[0316] [0316]
[0317] TLC:Rf 0.50 (chloroform:methanol:acetic acid=10:1:1),
[0318] NMR (CD 3 OD): δ 7.89(2H, d, J=8.8 Hz), 7.73(2H, d, J=8.4 Hz), 7.56(2H, d, J=8.4 Hz), 7.44(2H, d, J=8.8 Hz), 6.49(1H, s), 5.88(1H, m), 5.35-5.20(2H, m), 4.30-4.10(4H, m), 4.00(2H, m), 2.65(3H, s), 1.93(3H, s), 1.31(3H, t, J=7.2 Hz).
Example 2 (r)
[0319] [0319]
[0320] TLC:Rf 0.46 (chloroform:methanol:acetic acid=10:2:1),
[0321] NMR (CD 3 OD): δ 8.18(2H, d, J=9.0 Hz), 7.93(2H, d, J=9.0 Hz), 7.82(2H, d, J=9.0 Hz), 7.80(1H, s), 7.52(2H, d, J=9.0 Hz), 4.66(1H, dd, J=8.5 Hz,4.0 Hz), 4.33(2H, q, J=7.0 Hz), 4.20(2H, q, J=7.0 Hz), 4.12(2H, q, J=7.0 Hz), 2.39(2H, t, J=7.0 Hz), 2.11-2.31(1H, m), 1.82-2.00(1H, m), 1.36(3H, t, J=7.0 Hz), 1.24(3H, t, J=7.0 Hz), 1.21(3H, t, J=7.0 Hz).
Example 2 (s)
[0322] [0322]
[0323] TLC:Rf 0.43 (chloroform:methanol:acetic acid=10:2:1),
[0324] NMR (CD 3 OD): δ 8.20 and 8.22(2H, d, J=8.0 Hz), 7.92(2H, d, J=9.0 Hz), 7.75-7.90(1.6H, m), 7.64(1H, d, J=8.0 Hz), 7.54(2H, d, J=9.0 Hz), 7.18 and 7.26(0.4H, m),5.54-5.72(0.4H, m), 5.10-5.31(2H, m), 4.17-4.40(6H, m), 3.98(2H, br), 1.08-1.38(6H, m).
Example 2 (t)
[0325] [0325]
[0326] TLC:Rf 0.15 (chloroform:acetic acid:H 2 O=3:1:1),
[0327] NMR (CD 3 OD): δ 8.23(2H, d, J=8 Hz), 7.93(2H, d, J=8 Hz), 7.58(2H, d, J=8 Hz), 7.53(2H, d, J=8 Hz), 6.80(1H, bs), 6.10-5.90(1H, b), 5.35-5.20(2H, m), 4.25-4.00(4H, m), 3.68-3.45(2H, m), 3.25-3.00(2H, m), 2.88(6H, s), 2.69(3H, s), 2.15(3H, s), 1.96(3H, s).
Example 2 (u)
[0328] [0328]
[0329] TLC:Rf 0.46 (chloroform:methanol:acetic acid=10:2:1),
[0330] NMR (CD 3 OD): δ 8.18(2H, d, J=9.0 Hz), 7.93(2H, d, J=9.0 Hz), 7.82(2H, d, J=9.0 Hz), 7.80(1H, s), 7.52(2H, d, J=9.0 Hz), 4.66(1H, dd, J=8.5 Hz,4.0 Hz), 4.33(2H, q, J=7.0 Hz), 4.20(2H, q, J=7.0 Hz), 4.12(2H, q, J=7.0 Hz), 2.39(2H, t, J=7.0 Hz), 2.11-2.31(1H, m), 1.82-2.00(1H, m), 1.36(3H, t, J=7.0 Hz), 1.24(3H, t, J=7.0 Hz), 1.21 (3H, t, J=7.0 Hz).
Example 2 (v)
[0331] [0331]
[0332] TLC:Rf 0.22 (chloroform:methanol:acetic acid=10:2:1),
[0333] NMR (CD 3 OD): δ 8.21(2H, d, J=8.0 Hz), 7.95(2H, d, J=8.0 Hz), 7.89(2H, d, J=8.0 Hz), 7.59(2H, d, J=8.0 z), 7.55(2H, d, J=8.0 Hz), 7.43(2H, d, J=8.0 Hz), 6.78(1H, s), 6.15-5.80(1H, m), 5.47-5.28(2H, m), 4.42(2H, s), 4.25(2H, d, J=5.0 Hz), 2.68(3H, S, CH 3 SO 3 H), 2.18(3H, s).
Example 2 (w)
[0334] [0334]
[0335] TLC:Rf 0.27 (chloroform:methanol:acetic acid=10:2:1),
[0336] NMR (CD 3 OD): δ 8.20(2H, d, J=8 Hz), 7.91(2H, d, J=8 Hz), 7.57(2H, d, J=8 Hz), 7.53(21, d, J=8 Hz), 6.73(1H, s), 5,8-6.0(1H, br), 5.2-5.35(2H, m), 4.8-4.9(1H, m), 4.0-4.3(8H, m), 2.12(3H, s), 1.91(3H, s)1.27(6H, t, J=7 Hz).
Example 2 (x)
[0337] [0337]
[0338] TLC:Rf 0.25 (chloroform:methanol:acetic acid=10:2:1),
[0339] NMR (CD 3 OD): δ 8.22(2H, d, J=8 Hz), 7.91(2H, d, J=8 Hz), 7.52 and 7.67(4H, d, J=8 Hz, rotamer), 6.65 and 6.78(1H, s, rotamer), 5.6-6.0(3H, br), 5.0-5.3(6H, m), 3.9-4.4(8H, m), 2.11 and 2.16(3H, s, rotamer), 1.92(3H, s).
Example 2 (y)
[0340] [0340]
[0341] TLC:Rf 0.41 (chloroform:methanol:acetic acid=20:2:1),
[0342] NMR (CD 3 OD): δ 8.22(2H, d, J=8.0 Hz), 7.94(2H, d, J=8.0 Hz), 7.55(4H, t, J=7.5 Hz), 6.71(1H, brs), 5.20-4.90(1H, m), 4.40-4.00(6H, m), 2.20-2.00(3H, m), 1.95-1.50(3H, m), 1.30(6H, t, J=7.5 Hz), 1.10-0.80(6H, m).
Example 2 (z)
[0343] [0343]
[0344] TLC:Rf 0.40 (chloroform:methanol:acetic acid=20:2:1),
[0345] NMR (CD 3 OD): δ 8.21(2H, d, J=8.5 Hz), 7.95(2H, d, J=8.5 Hz), 7.57(4H, t, J=8.0 Hz), 6.62(1H, s), 4.15(2H, q, J=7.0 Hz), 3.80-3.60(2H, m), 3.55-3.38(2H, m), 2.68(2H, t, J=7.5 Hz), 2.12(3H, s), 1.70-1.40(3H, m), 1.27(3H, t, J=7.5 Hz), 1.10-0.70(6H, m).
Example 2 (aa)
[0346] [0346]
[0347] TLC:Rf 0.55 (chloroform:methanol:acetic acid=10:2:1),
[0348] NMR (CD 3 OD): δ 8.23(2H, d, J=8 Hz), 7.93(2H, d, J=8 Hz), 7.57(2H, d, J=8 Hz), 7.54(2H, d, J=8 Hz), 6.60(1H, s), 3.92-3.50(3H, m), 2.70-2.55(2H, m), 2.13 and 2.11(3H, s), 1.93-1.00(10H, m).
Example 2 (bb)
[0349] [0349]
[0350] TLC:Rf 0.41 (chloroform:methanol:acetic acid=10:2:1),
[0351] NMR (CD 3 OD): δ 8.21(2H, d, J=8 Hz), 7.92(2H, d, J=8 Hz), 7.65-7.50(4H, m), 6.72 and 6.65(1H, s, rotamer), 4.2-4.1(4H, m), 3.8-3.6(2H, br), 3.6-3.5(2H, br), 3.34(3H, s), 2.17(3H, s), 1.91(AcOH), 1.35-1.15(3H, br).
Example 2 (cc)
[0352] [0352]
[0353] TLC:Rf 0.30 (chloroform:methanol:acetic acid=10:2:1),
[0354] NMR (CD 3 OD): δ 8.21(2H, d, J=8 Hz), 7.92(2H, d, J=8 Hz), 7.60-7.45(4H, m), 6.73 and 6.65(1H, s, rotamer), 4.5-4.3(1H, m), 4.3-4.0(2H, br), 4.0-3.7(3H, m), 3.7-3.5(1H, br), 2.70(3H, s), 2.17 and 2.10(3H, s, rotamer), 2.2-1.8(3H, m), 1.8-1.4(1H, m).
Example 2 (dd)
[0355] [0355]
[0356] TLC:Rf 0.10 (ethyl acetate:acetic acid:H 2 O=3:1:1),
[0357] NMR (CD 3 OD): δ 8.22(2H, d, J=8 Hz), 7.92(2H, d, J=8 Hz), 7.7-7.4(4H, m), 6.70(1H, s), 4.5-4.0(3H, br), 3.6-3.4(2H, m), 3.2-3.0(2H, m), 2.3-1.9(7H, br).
Example 2 (ee)
[0358] [0358]
[0359] TLC:Rf 0.43 (chloroform:methanol:acetic acid=3:1:1),
[0360] NMR (CD 3 OD): δ 9.20(1H, br. s), 8.70(1H, br. s), 8.05-7.95(4H, m), 7.85(2H, d, J=9 Hz), 7.75(2H, J=8 Hz), 6.75(1H,m), 5.95(1H, m), 5,30(2H, m), 4.20(4H, m), 2.75(3H, s, CH 3 SO 3 H), 2.20(3H, s).
Example 2 (ff)
[0361] [0361]
[0362] TLC:Rf 0.40 (chloroform:methanol:acetic acid=10:2:1),
[0363] NMR (CDCl 3 ): δ 8.02(1H, d, J=9 Hz), 7.90(1H, d, J=9 Hz), 7.64(1H, s), 7.50(1H, d, J=9 Hz), 7.40-7.00(1411, m), 6.95-6.80(2H, m), 6.80-6.72(1H, m), 6.48(1H, d, J=9 Hz), 4.00-3.80(1H, m), 3.88(3H, s), 3.70-3.30,(2H, m), 3.10-2.90(1H, m), 2.90-2.70(2H, m), 2.70-2.30(2H, m), 2.30-2.00(2H, m), 1.00-1.24(1H, m).
Reference Example 3
[0364] 2-(N-Benzyl-N-methylamino)-2-(4-t-butoxycarbonylphenylmethylimino)acetic Acid Ethyl Ester.
[0365] To a solution of 2-(N-benzyl-N-methylamino)-2-thioxoacetic acid ethyl ester (4.98 g) in dichloromethane under cooling with ice, was added dropwise BF 4 —Et 3 O (72 ml). The reaction solution was stirred for 30 min at room temperature and extracted with dichloromethane. The extract was evaporated. The resulting residue was purified by silica gel column chromatography to obtain the title compound having the following the physical data.
[0366] TLC:Rf 0.45 (hexane:ethyl acetate=3:1).
Reference Example 4
[0367] 2-(N-Benzyl-N-methylamino)-2-(4-carboxyphenylmethylimino)acetic Acid Ethyl Ester
[0368] To a solution of the compound prepared in Reference Example 3 (3.77 g) in anisole (10 ml) under cooling with ice bath, was added trifluoroacetic acid (20 ml) and stirred for two hours at room temperature. The reaction solution was evaporated, neutralizied by adding 1N aqueous solution of sodium hydroxide, and extracted with ethyl acetate. The extract was evaporated. The resulting residue was purified by silica gel column chromatography to obtain the title compound (1.87 g) having the following physical data.
[0369] TLC:Rf 0.36 (hexane:ethyl acetate=1:2).
Example 3
[0370] 2-[4-(4-Amidinophenoxycarbonyl)phenylmethylimino]-2-(N-benzyl-N-methylamino)acetic Acid Ethyl Ester Hydrochroride
[0371] By the same procedure as Example 2, the title compound having the following physical data was obtained.
[0372] TLC:Rf 0.34 (chloroform:methanol:acetic acid=10:2:1),
[0373] NMR (CD 3 OD): δ 1.26(3H, t, J=7.0 Hz), 2.88(3H, s), 4.36(2H, q, J=7.0 Hz), 4.49(2H, s), 4.50(2H, s), 7.27-7.35(5H, m), 7.48(2H, d, J=9.0 Hz), 7.52(2H, d, J=9.0 Hz), 7.92(2H, d, J=9.0 Hz), 8.12(21H, d, J=9.0 Hz).
Reference Example 5
[0374] Ethyl 1-(3-phenylpropyl)-1-(4-benzyloxycarbonylphenylmethyl)phosphinate.
[0375] A solution of ethyl phenylpropylphosphinate (1.2 g) and triethylamine (2.4 ml) in chloroform (30 ml) was cooled to 0° C., and a solution of trimethylsilylchloride (1.46 ml) and 4-bromomethylbenzoic acid benzyl ester (1.75 g) in chloroform (10 ml) was added thereof, and stirred at room temperature for 1.5 day. To the reaction mixture was added ice water and extracted with ethyl acetate. Organic layer was washed with water and a saturated aqueous solution of sodium chloride, successively evaporated. The residue was purified by silica gel column chromatography to give the title compound (900 mg).
Reference Example 6
[0376] Ethyl 1-(3-phenylpropyl)-1-(4-carboxyphenylmethyl)phosphinate
[0377] A mixture of the compound prepared in Reference Example 5 (900 mg), palladium carbon (180 mg, 10%) and ethanol (20 ml) was stirred for two hours under an atmosphere of hydrogen at room temperature. The reaction mixture was filtered. The filtrate was evaporated and the title compound (815mg) was obtained.
Example 4
[0378] Ethyl 1-(4-amidinophenoxycarbonylphenylmethyl)-1-(3-phenylpropyl)phosphinate acetate
[0379] By the same procedure as Reference Example 5,6 and Example 2, the title compound (805 mg) having the following physical data was obtained.
[0380] TLC:Rf 0.62 (chloroform:methanol:acetic acid=10:2:1),
[0381] NMR (CD 3 OD): δ 8.10(2H, d, J=8 Hz), 7.95(2H, d, J=9 Hz), 7.55(2H, d, J=9 Hz), 7.60-7.40(2H, m), 7.30-7.10(3H, m), 7.20(2H, d, J=8 Hz), 4.00(2H, m), 3.40(2H, d, J=24 Hz), 2.70(2H, t, J=6.5 Hz), 2.00-1.60(4H, m), 1.30(3H, t,J=7.5 Hz).
Example 4(a)
[0382] [0382]
[0383] By the same procedure as Example 4, the compound having the following physical data was obtained.
[0384] TLC:Rf 0.60 (chloroform:methanol:acetic acid=10:2:1),
[0385] NMR (CD 3 OD): δ 1.36(6H, t, J=7.0 Hz), 4.15(4H, quin, J=7.0 Hz), 6.68(1H, t, J=18.0 Hz), 7.54(2H, d, J=9.0 Hz), 7.56(1H, dd, J=23.0 Hz,18.0 Hz), 7.82(2H, d, J=9.0 Hz), 7.93(2H, d, J=9.0 Hz), 8.22(2H, d, J=9.0 Hz).
Reference Example 7
[0386] 4-Phenylpiperidine-1-ylmethylbenzoic Acid Methyl Ester
[0387] A solution of 4-formylbenzoic acid (3.5 g) and 4-phenylpiperidine (6.9 g) in methanol (35 ml) was stirred for one hour at room temperature. After the solution was cooled with ice bath, sodium borohydride (1.63 g) was added and the reaction solution was stirred. After the reaction finished, the reaction solution was poured into ice water and extracted with ethyl acetate. The organic layer was washed with water and a saturated aqueous solution of sodium chloride, successively, dried over and evaporated. The residue was washed with methanol to obtain the title compound (4.70 g).
Reference Example 8
[0388] 4-(4-Phenylpiperidine-1-ylmethyl)benzoic Acid
[0389] A solution of the compound prepared in Reference Example 7 (4.8 g) in dioxane (50 ml) was cooled with ice bath and 2N aqueous solution of sodium hydroxide (10 ml) was added thereof and stirred at 60° C. for two hours. The reaction mixture was cooled with ice bath and neutralized by adding 2N hydrochloric acid. Depositing solid was fittered and washed with water, ether successively, dried over. The title compound (4.29 g) was obtained.
Example 5
[0390] 4-(4-Phenylpiperidine-1-ylmethyl)benzoic Acid Amidinophenol Ester 2 Hydrochloride
[0391] By the same procedure as Example 2, the title compound having the following physical data was obtained.
[0392] TLC:Rf 0.33 (chloroform:methanol:acetic acid=5:1:1),
[0393] NMR (CD 3 OD): δ 8.32(2H, d, J=8.0 Hz), 7.95(2H, d, J-8.8 Hz), 7.88(2H, d, J=8.0 Hz), 7.55(2H, d, J=8.8 Hz), 7.28(5H, m), 4.52(2H, s), 3.62(2H, br.d), 3.25(2H, br.d), 2.94(1H, m), 2.12(4H, m).
Example 5(a)-5(b)
[0394] By the same procedure as Reference Example 7,8 and Example 5, the compounds having the following physical data were obtained.
Example 5 (a)
[0395] [0395]
[0396] TLC:Rf 0.3 (chloroform:methanol:acetic acid=50:10:1),
[0397] NMR (CD 3 OD): δ 8.20(2H, d, J=8.0 Hz), 7.95(2H, d, J=8.0 Hz), 7.81(1H, d, J=2.0 Hz), 7.79(1H, d, J=2.0 Hz), 7.69(5H, brs), 7.55(2H, d, J=8.5 Hz), 7.39(2H, d, J=8.5 Hz), 5.63(2H, s), 2.72(6H, s).
Example 5 (b)
[0398] [0398]
[0399] TLC:Rf 0.48 (chloroform:methanol:acetic acid=10:1:1),
[0400] NMR (CD 3 OD+CDCl 3 ): δ 8.05(2H, d, J=8.4 Hz), 7.89(2H, d, J=8.8 Hz), 7.71(1H, d, J=8.0 Hz), 7.46(2H, d, J=8.8 Hz), 7.40(1H, s), 7.37-7.30(2H, m), 7.17(1H, d, J=8.0 Hz), 7.16(2H, d, J=8.4 Hz), 5.95(2H, s), 4.30(2H, q, J=7.4 Hz), 2.73(3H, s), 1.33(3H, t, J=7.4 Hz).
Reference Example 9
[0401] 4-(N-Benzyl-N-ethoxycarbonylaminomethyl)benzoic Acid Benzyl Ester
[0402] A solution of 4-(N-benzylaminomethyl)benzoic acid benzyl ester (5.21 g) and bromoacetic acid benzyl ester (1.7 ml) in DMF (10 ml) was stirred for two hours at 80° C. and ice water was added thereto. The reaction solution was extracted with ethyl acetate. The organic layer was washed with a saturated aqueous solution of sodium hydrogen carbonate, water and a saturated aqueous solution of sodium chloride, successively. The organic layer was dried over and evaporated. The residue was purified by silica gel column chromatography to obtain the title compound (2.26 g).
Reference Example 10
[0403] 4-(N-Benzyl-N-ethoxycarbonylaminomethyl)benzoic Acid Hydrochloride
[0404] A mixture solution of the compound prepared in Reference Example 9 (2.26 g), methanesufonic acid (10.5 ml), and anisole (25 ml) was stirred for one hour at room temperature. To the reaction solution was added ice water and extracted with chloroform. The organic layer was washed with water, a saturated aqueous solution of sodium chloride, dried over and evaporated. The residue was purified by silica gel column chromatography to obtain amine. 4N hydrochloric acid-dioxane was added to the amine and the mixture was evaporated to obtain the title compound (1.76 g).
Example 6
[0405] N-(4-(4-Amidino-phenoxycarbonyl)phenylmethyl)-N-benzylaminoacetic Acid Ethyl Ester 2 Hydrochroride
[0406] By the same prodedure as Example 2, the title compound having the following physical data was obtained.
[0407] TLC:Rf 0.42 (chloroform:methanol:acetic acid=10:2:1),
[0408] NMR (CD 3 OD): δ 8.25(2H, d, J=8 Hz), 7.90(2H, d, J=8 Hz), 7.60(2H, d, J=8 Hz), 7.50(2H, d, J=8 Hz), 7.40-7.20(5H, m), 4.15(2H, q, J=7 Hz), 3.90(2H, s), 3.80(2H, s), 3.30(2H, s), 1.25(3H, t, J=7 Hz).
Formulation Example I The following components were admixed in a conventional manner and punched out to obtain 100 tables, each containing 100 mg of active ingredient. Compound number 1 10 g Cellulose calcium glycolate (disintegrating agent) 0.2 g Magnesium stearate (Lubricating agent) 0.1 g Microcrystaline cellulose 1.7 g Formulation Example 2 The following components were admixed conventional method and punched out to obtain 100 tables each containing 100 mg of active ingredient. Compound number 2 1 g Cellulose calcium glycolate (disintegrating agent) 0.2 g Magnesium stearate (Lubricating agent) 0.1 g Microcrystaline cellulose 1.7 g Formulation Example 3 The following components were admixed in conventional manner. The solution was sterilized conventional manner, placed 5 ml portions into 10 ml ampoules and obtained 100 ampoules each containing 10 mg of the active ingredient. Compound number 1 1 g Citric acid 0.2 g distilled water 500 ml Formulation Example 4 The following components were admixed in conventional manner. The solution was sterilized in conventional manner, placed 5 ml portions into 10 ml ampules to obtain 100 ampoules, each containing 10 mg of the active ingredient. Compound number 2 1 g Citric acid 0.2 g distilled water 500 ml
[0409] [0409] TABLE 1 Preferable groups as R
[0410] [0410] TABLE 2 Preferable groups as R
[0411] [0411] TABLE 3 Preferable groups as R
[0412] [0412] TABLE 4 Preferable groups as R
[0413] [0413] TABLE 5 Preferable groups as R
[0414] [0414] TABLE 6 Preferable groups as R
[0415] [0415] TABLE 7 Preferable groups as R
[0416] [0416] TABLE 8 Preferable groups as R
[0417] [0417] TABLE 9 Preferable groups as R
[0418] [0418] TABLE 10 Preferable groups as R
[0419] [0419] TABLE 11 Preferable groups as R
[0420] [0420] TABLE 12 Preferable groups as R
[0421] [0421] TABLE 13 Preferable groups as R
[0422] [0422] TABLE 14 Preferable groups as R
[0423] [0423] TABLE 15 Preferable groups as R
[0424] [0424] TABLE 16 Preferable groups as R
[0425] Pharmaceutical compositions of the present invention can be prepared using one active ingredient or two or more active ingredients.
[0426] Salts and Acid-additon Salts
[0427] Compounds of the formulae (IA) and (IB) of the present invention may be converted into the corresponding salts and acid-addition salts by known methods. Nontoxic and water-soluble salts are preferred.
[0428] Suitable salts include the salts of alkali metals (sodium, potassium etc.), alkaline-earth metal (calcium, magnesium etc.), ammonium salts, salts of pharmacoligically acceptable organic amines (tetramethyl ammonium, triethylamine, methylamine, dimethylamine, cyclopentylamine, benzylamine, phenetylamine, piperidine, monoethanolamine, diethanolamine, tris (hydroxymethyl)aminomethane, lysine, arginine, N-methyl-D-gulcane etc).
[0429] Suitable acid-addition salts include the salts with inorganic acids such as hydrochloric acid, and the salts with organic acids such as acetic acid, trifluoroacetic acid, lactic acid, tartaric acid, oxalic acid, fumaric acid, maleic acid, citric acid, benzoic acid, methanesulfonic acid, ethanesulfonic acid, benzenesulfonic acid, toluenesulfonic acid, isethionic acid, glucuronic acid and gluconic acid. Preferred salts include the salts with acids such as hydrochloric acid, methanesulfonic acid, acetic acid and trifluoroacetic acid.
[0430] Preparation of Compounds
[0431] The compounds of the formula (IA) may be prepared by methods known per se, as defined in published applications EP-A-588655 and EP-A-656349. The formula (1B) compounds of the present invention may be prepared by forming an ester or amide bond between a compound of the formula (II):
[0432] (wherein the various symbols have the same meanings as hereinbefore defined) with a compound of the formula (III):
[0433] (wherein the various symbols have the same meanings as hereinbefore defined). The esterification reaction and the reaction to form an amide are known and can be carried out by known method, for example:
[0434] (1) using an acid halide,
[0435] (2) using a mixed acid anhydride or
[0436] (3) using a condensing agent.
[0437] Esterification can be carried out, for example, as follows:
[0438] (1) the method using an acid halide may be carried out, for example, by reacting a carboxylic acid with an acid halide (e.g., oxalyl chloride, thionyl chloride etc.) in an inert organic solvent (e.g., chloroform, methylene chloride, diethyl ether, tetrahydrofuran etc.) or without a solvent at from −20° C. to the reflux temperature of the solvent, and then by reacting the acid halide obtained with a corresponding alcohol in the presence of a tertiary amine (e.g., pyridine, triethylamine, diethylaniline, diethylaminopyridine etc.) in an inert organic solvent (e.g., chloroform, methylene chloride, diethyl ether, tetrahydrofuran etc.) at a temperature of from 0° C. to 40° C.;
[0439] (2) the method using a mixed acid anhydride may be carried out, for example, by reacting a carboxylic acid and an acid halide (e.g., pivaloyl chloride, tosyl chloride, mesyl chloride etc.) or an acid derivative (e.g., ethyl chloroformate, isobutyl chloroformate etc.) in the presence of a tertiary amine (e.g., pyridine, triethyamine, dimethylaniline, dimethylaminopyridine etc.) in an inert organic solvent (e.g., chloroform, methylene chloride, diethyl ether, tetrahydrofuran etc.) or without a solvent at a temperature of from 0° C. to 40° C., and then by reacting the mixture of acid anhydride obtained with a corresponding alcohol in an inert organic solvent (e.g., chloroform, methylene chloride, diethyl ether, tetrahydrofuran etc.), at a temperature of from 0° C. to 40° C.; and
[0440] (3) the method using a condensing agent (e.g., 1,3-dicyclohexylcarbodiimide (DCC), 1-ethyl-3-[(dimethylamino)propyl] cabodiimide (EDC), 2-chloro-1-methypyridinium iodide etc.) may be carried out, for example, by reacting a carboxylic acid with a corresponding alcohol using a condensing agent in the presence or absence of a tertiary amine (e.g., pyridine, triethylamine, dimethylaniline, dimethylaminopyridine etc.) in an inert organic solvent (e.g., chloroform, methylene chloride, dimethyl formamide, diethyl ether etc.) or without a solvent at a temperature of from 0° C. to 40° C.
[0441] The formation of an amide may be accomplished by the same reactions as described above, except the corresponding alcohol is replaced by a corresponding amine.
[0442] The reactions (1), (2) and (3) hereinbefore described may be preferably carried out in an atmosphere of inert gas (e.g., argon, nitrogen etc.) under anhydrous conditions.
[0443] The compounds of the formula (III) may be prepared by the series of reactions depicted in the following Scheme A.
[0444] In the Scheme A,
[0445] RP is t-butyl or benzyloxycarbonyl,
[0446] X 10 , X 20 and X 30 each independently, is halogen,
[0447] Ms is methaneosulfonic acid,
[0448] A 00 is bond, C1-3 alkylene, oxy-(C1-3) alkylene, thio-(C1-3)alkylene, C2-7 alkenylene, C2-7 alkenylene substituted by carboxy or C1-4 alkoxycarbonyl, and the other symbols have the same meaning as hereinbefore described.
[0449] The reactions in the scheme hereinbefore depicted may be carried out by methods known per se. The compounds of the formulae (II), (IV), (V) and (VI) used as starting materials in this scheme are known per se or may be easily prepared by methods known per se.
[0450] Other starting materials and each of the reagents are known per se or may be prepared by known methods.
[0451] In each reaction in the present specification, products may be purified in a conventional manner. For example, purification may be carried out by distillation at atmospheric or reduced pressure, high performance liquid chromatography, thin layer chromatography or column chromatography using silica gel or magnesium silicate, washing or recrystallization. Purification may be carried out after each reaction, or after a series of reactions.
[0452] Physiological Effects
[0453] As mentioned above, it is understood that LTB 4 antagonist is useful as an anti-inflammatory and anti-allergic agent.
[0454] Therefore, compounds of the present invention of formulas (IA) and (IB), having LTB 4 antagonistic activity, may be used for the treatment of an animal, preferably a human, as an anti-inflammatory and anti-allergic agent.
[0455] It is known that an LTB 4 antagonist is also useful for the prevention and/or treatment of various diseases in animals, including humans. These diseases include rheumatoid arthritis, inflammatory bowel diseases, psoriasis, nonsteroidal anti-inflammatory agent-induced stomach diseases, adult respiratory distress syndrome, cardiac infarction, allergic rhinitis, hemodialysis-induced neutropenia and anaphase asthma.
[0456] The compounds of the formula (IB) also have inhibitory activity on phospholipase and inhibitory activity on trypsin in animals, including humans. Therefore compounds of formula (IB) are useful for the prevention and/or the treatment of various inflammatory, allergic diseases, disseminated intravascular coagulation, pancreatitis, severity in pancreatitis and multiple organ failure in animals, preferably humans.
[0457] Toxicity
[0458] It is confirmed that the toxicity of the active ingredients and non-toxic salts thereof and non-toxic acid addition salts thereof in the present invention is very weak. For example, LD 50 of Compound 1 was 117mg/kg when administered intravenously to male mice. Accordingly, the active substances in the present invention may be considered to be sufficiently safe and suitable for pharmaceutical use.
[0459] For the purpose hereinbefore described, the active ingredient in the present invention and non-toxic salts thereof and non-toxic acid addition salts thereof may be normally administered systemically or partially, usually by oral or parenteral administration.
[0460] The doses to be administered are determined depending upon age, weight, symptom, the desired therapeutic effect, the route of administration, and the duration of the treatment, etc. In the human adult, the doses per person per dose are generally between 1 mg and 1000 mg, by oral administration, up to several times per day, or between 100 μg and 100 mg, by parenteral administration (preferably, intravenously) up to several times per day. As mentioned above, the doses to be used depend upon various conditions. Therefore, there are cases in which doses lower than or greater than the ranges specified above may be used.
[0461] Compounds of the present invention are administered in the form of solid compositions, liquid compositions or other compositions for oral administration, and as injections, liniments or suppositories, etc., for parenteral administration.
[0462] Solid compositions for oral administration include compressed tablets, pills, capsules, dispersible powders, and granules.
[0463] In such compositions, at least one of the active compounds is admixed with at least one inert diluent (such as lactose, mannitol, glucose, hydroxypropyl cellulose, microcrystalline cellulose, starch, polyvinylpyrrolidone, magnesium metasilicate aluminate, etc.).
[0464] These compositions may also comprise, as in normal practice, additional substances other than inert diluents: e.g., lubricating agents (such as magnesium stearate, etc.), disintegrating agents (such as cellulose calcium glycolate, etc.), assisting agents for dissolving (such as arginine, glutamic acid, asparaginic acid, etc.) and stabilizers (human serum albumin, lactose, etc.).
[0465] The tablets or pills may, if desired, be coated with a film of gastric or enteric material (such as sugar, gelatin, hydroxypropyl cellulose, hydroxypropylmethyl cellulose phthalate, etc.).
[0466] Capsules include hard capsules and soft capsules.
[0467] Liquid compositions for oral administration include solutions, emulsions, suspensions, syrups and elixirs.
[0468] These liquid compositions may comprise inert diluents commonly used in the art (purified water, ethanol, etc.).
[0469] Besides inert diluents, such compositions may also comprise adjuvants (such as wetting agents, suspending agents, etc.), sweetening agents, flavoring agents and preserving agents.
[0470] Other compositions for oral administration include spray compositions, which may be prepared by known methods and which comprise one or more of the active compound(s). Spray compositions may comprise additional substances other than inert diluents: e.g. stabilizing agents (sodium sulfate, etc.), isotonic stabilizing agents (sodium chloride, sodium citrate, citric acid, etc.). For preparation of such spray compositions, for example, the method described in the U.S. Pat. No. 2,868,691 or No. 3,095,355 may be used.
[0471] Injections for parenteral administration include sterile aqueous or non-aqueous solutions, suspensions and emulsions.
[0472] In such compositions, one or more of active compound(s) is or are admixed with at least one of inert aqueous diluent(s) (distilled water for injection, physiological salt solution, etc.) or inert non-aqueous diluent(s) (propylene glycol, polyethylene glycol, olive oil, ethanol, POLYSORBATE80 (registered trademark) etc.).
[0473] Injections may comprise furthermore assisting agents such as preserving agents, wetting agents, emulsifying agents, dispersing agents, stabilizing agents (such as human serum albumine, lactose, etc.) and assisting agents for dissolving (arginine, glutamic acid, asparaginic acid, polyvinylpyrrolidone, etc.).
[0474] Usually, they may be sterilized by filtration (a bacteria-retaining filter etc), by incorporation of sterilizing agents in the compositions or by irradiation, or after treated, they may also manufactured in the form of sterile solid compositions, for example, by freeze-drying, which may be dissolved in sterile water or some other sterile diluent(s) for injection immediately before used, and which may be used.
Example
[0475] The following Reference Examples and Examples illustrarte the present invention.
[0476] The solvents in parentheses show the developing or eluting solvents used in chromatographic separations and the solvent ratios used are by volume.
Example 1 (A)
[0477] Binding Inhibition Against 3 H-LTB 4 on the Human Polymorphonuclear Leukocyte (PMN)
[0478] 0.049 ml Hanks balanced salt solution (HBSS), 0.001 ml test compound and 0.05 ml 3 H-LTB 4 (4nM) were added to polypropylene tubes and mixed. The reaction was started by addition of a thoroughly mixed PMN cell suspension (1.6×10 6 cells), followed by incubation at 0° C. for 20 min. The reaction was terminated by the addition of ice-cold HBSS (2.5 ml). PMNs were harvested by vacuum filtration through Whatman GF/C glass fiber filters on a Brandel cell harvester (BRANDEL, M-24R). The filters were then washed 2 times to remove free 3 H-LTB 4 with 2.5 ml of the ice-cold PBS (−) solution. The filters were transferred to each vial, and equilibrated after adding 8 ml ACS II cocktail (Amersham). The radioactivity was measured by liquid scintillation counter (Aloka, LSC-5100).
[0479] Specific binding of 3 H-LTB 4 to the LTB 4 receptor was defined as total binding minus nonspecific binding. Nonspecific binding was the amount of 3 H-LTB 4 binding in the presence of 1.5 μM LTB 4 instead of the test compound. The inhibitory effect of test compound was calculated from the following equation.
The percentage of inhibition (%)=100−( B 1 /B 0 ×100)
[0480] B 1 : Specific 3 H-LTB 4 binding in presence of test compound
[0481] B 0 : Specific 3 H-LTB 4 binding in absence of test compound
[0482] Results
[0483] The results are shown in the following Table 17.
TABLE 17 European Patent Publication No. 588655 binding activity Compound No. Compound (Example No.) (%) 1 1 (i) 91.5 2 1 (m) 76.6 3 1 (p) 75.0 4 1 (aa) 63.7 5 1 (ii) 94.3 6 1 (pp) 71.6 7 1 (qq) 78.0 8 1 (hhh) 82.7 9 1 (lll) 91.6 10 1 (mmm) 86.5 11 2 (g) 76.8 12 2 (p) 95.2 13 2 (u) 100.2 14 2 (w) 96.5 15 2 (cc) 89.1 16 2 (gg) 83.6 17 2 (kk) 93.9 18 3 (f) 87.0 19 4 74.0 20 4 (a) 83.5 21 5 (r) 90.8 22 5 (w) 89.7 23 5 (ff) 78.0 24 European Patent Publication 61.2 No. 656349 Example 1 (b)
[0484] The structure of compounds used in the present invention are shown below. Compound No. 1
Example 1 (B)
[0485] The compounds of the formula (IB), of the present invention have an antagonistic activity on LTB 4 The results which are measured by method as hereinbefore described in Example 1 (A), are shown the following Table 18.
TABLE 18 binding activity Compound (Example No.) (%) 2 79.7 2 (a) 92.0 2 (b) 97.9 2 (c) 103.2 2 (d) 99.3 2 (e) 94.5 2 (f) 91.8 2 (g) 89.6 2 (h) 85.4 2 (i) 69.6 2 (j) 55.4 2 (k) 97.7 2 (l) 81.0 2 (m) 89.2 2 (n) 82.8 2 (o) 85.8 2 (p) 95.2 2 (q) 98.0 2 (r) 80.1 2 (s) 83.0 2 (t) 51.5 2 (u) 67.6 2 (v) 92.0 2 (w) 76.7 2 (x) 94.1 2 (y) 85.5 2 (z) 92.8 2 (aa) 94.4 2 (bb) 87.3 2 (cc) 76.7 2 (dd) 50.8 2 (ee) 65.3 2 (ff) 82.4 3 96.8 4 73.1 4 (a) 52.0 5 89.7 5 (a) 62.5 5 (b) 90.2 6 67.8
Example 1 (C)
[0486] Inhibitory Activity on Phospholipase A 2 and on Trypsin
[0487] It has been confirmed that compounds of formula (IB) of the present invention have inhibitory activities on phospholipaseA 2 (PLA 2 ) and on trypsin.
[0488] For example, in laboratory tests the following results were obtained.
[0489] Method
[0490] (1) Inhibitory Activity on PLA 2
[0491] A reaction solution including 50 mM tris-HCl buffer (pH7.5, 874 μl; containing 100 mM sodium chloride, 1 mM EDTA), 1M calciumchloride (6 μl), 1% bovine serum albumin (10 μl) and 2.5 mM 10PY-PC (10 μl), was prepared. To the solution were added a test compound in various concentration or water (50 μl), and a solution of 10 mU/ml PLA 2 (derived from hog pancreas) (501 μl). The appearance of fluorescence was measured (Ex=345 nm, Em=396 nm). Percentage (%) of the strength of fluorescence in the presence of a test compound was calculated when the strength of that in the absence thereof was regarded as 100%, and therefrom IC 50 value was calculated. The results are shown in the following Table19.
[0492] (2) Inhibitory Activity on Trypsin
[0493] To a mixture of a 0.2 M HEPES•sodium hydroxide buffer solution (pH 8.0, 100 μl) and distilled water (640 μl), were added a test compound in various concentration or water (10 μl), and a solution of 80 mU/ml trypsin (derived from bovine pancreas) (50 μl) and then the mixture was preincubated for one minute at 30° C. To the solution thus obtained was added 2.5 mM BAPNA (200 μl) and the mixture was incubated at 30° C. The absorbance at 405 nm was measured. Percentage (%) of the absorbance in the presence of a test compound was calculated when the absorbance in the absence thereof was regarded as 100%, and therefrom IC 50 value was calculated. The results are shown in the following Table 19.
TABLE 19 inhibitory activity inhibitory activity Compound on PLA 2 on trypsin (Example No.) IC 50 (μM) IC 50 (μM) 2 — 0.19 2(a) 2.6 0.4 2(b) 3.8 0.56 2(c) 8.1 0.26 2(d) 8.7 0.14 2(e) 8.5 0.34 2(f) 70 0.10 2(g) 53 0.16 2(h) 11 0.15 2(i) 59 0.14 2(j) — 0.12 2(k) 20 0.10 2(l) 94 0.12 2(m) 18 0.17 2(n) 10 0.16 2(o) 12 0.14 2(p) 29 0.13 2(q) 34 0.16 2(r) 46 0.16 2(s) 44 0.16 3 4.7 0.12 4 41 0.16 4(a) — 0.14 5 — 0.13 5(a) — 0.15 6 4.5 0.17
[0494] In the methods hereinbefore described,
[0495] 10PY-PC represents 3′-palmitoyl-2-(1-pyrenedecanoyl)-L-α-phosphatidylcholine,
[0496] HEPES represents 4-2-hydroxyethyl)-1-piperazineethanesulfonic acid, and BAPNA represents α-N-benzoyl-DL-arginine-p-nitroanilide hydrochloride.
|
Novel amidinophenol derivatives of formula (IB)
and processes for the preparation thereof; compositions containing a compound of formula (IB) as active ingredient useful as antagonists of leukotine B 4 and inhibitors of phospholipase A 2 and/or trypsin; methods for preventing or treating diseases induced by phospholipase A 2 and/or trypsin comprising administering to a patient a compound of formula (IB); and methods for treating diseases induced by leukotine B 4 comprising administering to a patient a compound of formula (IB) or a known amidinophenol derivative of formula (IA)
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TECHNICAL FIELD OF THE INVENTION
[0001] The present invention relates to automatic gain controllers, and more particularly to automatic gain controllers for use with RF transceivers of the type utilized with the IEEE 802.15.4 standard.
BACKGROUND OF THE INVENTION
[0002] Portable RF transceivers such as those utilizing the IEEE 802.15.4 standard require the ability to easily detect signals of interest while minimizing the effects of noise and interferer signals within the wireless network. Interferer signals comprise other transmitted signals which may be received by an RF transceiver that are not of interest to the receiving RF transceiver but introduce energy within the desired operating band of the radio, and thus constitute an additional energy source, which the RF transceiver must take into account. In order to overcome this problem, RF transceivers may have associated therewith automatic gain controllers enabling the gain of various amplifiers associated with the RF transceiver to control the gain levels applied to the receive signals to maximize the receipt potential of signals of interest while minimizing the interference caused by both noise and interferer signals. These automatic gain controllers typically adjust the received signal strength of the in band signal to a desired analog level to primarily insure that there is no saturation of the radio front end. However, they adjust the gain of the front end based on the entire received signal comprised of the signal of interest, the possible interferer and the noise. If the gain is set too high, the interferer signal may be amplified to too large a value, potentially causing problems with the signal of interest. Likewise, if the gain level is set to low, unexpected spikes within the noise level at the RF transceiver may cause the signal of interest to be lost. Thus, there is a need for an effective method and apparatus for providing an automatic gain controller with an RF transceiver.
SUMMARY OF THE INVENTION
[0003] The present invention, as disclosed and described herein, comprises an automatic gain controller for an RF transceiver. The automatic gain controller consists of a dedicated digital engine configured to select a gain level responsive to a selected signal to noise ratio of a signal received by the RF transceiver. The signal that is the subject of the signal to noise ration is the expected received signal—the “signal of interest.” Any other received signals are treated as if it were noise. The digital engine is configured to select the gain level from a plurality of possible gain levels as a function of both the ratio of the signal of interest to the combined other received signals and noise and the dynamic range of the receiver.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] For a more complete understanding of the present invention and the advantages thereof, reference is now made to the following description taken in conjunction with the accompanying Drawings in which:
[0005] FIG. 1 illustrates wireless communication amongst a plurality of portable RF transceivers;
[0006] FIG. 2 is a block diagram of an RF transceiver chip;
[0007] FIG. 3 is a block diagram of an analog portion of the RF transceiver chip of FIG. 1 ;
[0008] FIG. 4 is a block diagram of the digital portion of the RF transceiver chip of FIG. 1 ;
[0009] FIG. 5 is an illustration of the automatic gain controller implemented in a digital signal processor;
[0010] FIG. 6 illustrates the signals potentially received by an RF transceiver;
[0011] FIG. 7 is a flow diagram illustrating the operation of the digital signal processor implementing the automatic gain controller;
[0012] FIG. 8 illustrates the margin level between the signal level of a signal of interest in the noise level of unwanted signals; and
[0013] FIG. 9 illustrates the manner in which a particular gain level may be selected to achieve a desired margin level for the signal to noise ratio.
DETAILED DESCRIPTION OF THE INVENTION
[0014] Referring now to the drawings, wherein like reference numbers are used herein to designate like elements throughout the various views, embodiments of the present invention are illustrated and described, and other possible embodiments of the present invention are described. The figures are not necessarily drawn to scale, and in some instances the drawings have been exaggerated and/or simplified in places for illustrative purposes only. One of ordinary skill in the art will appreciate the many possible applications and variations of the present invention based on the following examples of possible embodiments of the present invention.
[0015] Referring now to FIG. 1 , there is illustrated a low rate wireless personal area network (LR-WPAN) such as an 802.15.4 network. However, it should be realized that other wireless networks communicating between a number of RF transceiver devices may also utilize the improvements described herein. A low rate wireless personal network network (LR-WPAN) is a network designed for low cost and very low power short range wireless communications. A number of RF transceivers 102 may communicate with each other over various wireless links 104 . The RF transceivers 102 may comprise single chip devices which are associated with sensors or other portable devices that are moving around or located within a defined and limited area. WPANs are used to convey information over relatively short distances among the participant transceivers 102 . WPANs have little or no infrastructure enabling small power efficient inexpensive solutions to be implemented for a wide range of devices. Wireless transceiver devices 102 of this type may be used for various applications such as stick-on sensors, virtual wires, wireless hubs, or cable replacement. Other application are of course possible.
[0016] To achieve low power operation, each of the transceivers is operable to operate in a sleep mode, periodically “waking up” and either listening for some communication directed to itself or transmitting information to another one of the transceivers. When transmitting, the data is only transmitted in short bursts. Although asynchronous in operation, the timing between transceivers in a network is such that they wake up generally at a common time. The signal they are trying to listen for is referred to herein as a “signal of interest.” A problem arises when there are other transmitting devices operating in the same frequency band that are not in the network. For example, IEEE 802.11 wireless devices and Bluetooth wireless devices all operate in the 2.45 GHz band associated with the transceivers of the present disclosure. If one of these devices is transmitting during the data burst associated with the signal of interest, i.e., an interferer is present, the transceiver must account for this. The result is an overall increase in the inband spectral energy content, which can cause saturation if not accounted for. Additionally, it is possible for the interferer to be present for only a short period of time during the data burst.
[0017] Referring now to FIG. 2 , there is illustrated a block diagram of one potential configuration of an RF transceiver chip that may utilize the automatic gain controller of the present disclosure. The RF transceiver chip consists of an analog portion 202 and a digital portion 204 . The analog portion 202 includes the analog circuitry necessary for transmitting and receiving the RF signals, i.e., the RF front end. This portion is responsible for receiving the signal at the 2.45 GHz carrier frequency and dividing it into the I- and Q-quadrature signals at an intermediate or base band frequency. An antenna 206 connects with an antenna switch 208 . The antenna switch 208 switches the antenna between the RF receiver circuitry 210 and the RF transmitter circuitry 212 . The RF receiver circuitry 210 is responsible for receiving RF signals transmitted to the transceiver chip, and the RF transmitter circuitry 212 controls transmission operations from the chip. The receiver circuitry 210 is interfaced with the digital portion 204 of the chip through an analog-to-digital converter 214 . The analog-to-digital converter 214 converts received analog signals from the RF receiver 210 into a digital format. The RF transmitter circuitry 212 is interfaced with the digital portion 204 of the RF transceiver chip via a digital-to-analog converter 216 . The digital-to-analog converter 216 converts digital signals from the digital portion 204 into analog signals useable by the RF transmitter circuitry 212 .
[0018] The analog circuitry 202 additionally includes a frequency synthesizer 218 , external oscillator circuit 220 , sleep mode oscillator 222 , calibration and bias circuitry 224 and voltage regulators 226 . The frequency synthesizer 218 generates the frequencies necessary for performing RF modulation and demodulation operations within the RF receiver 210 and the RF transmitter 212 . The external oscillator circuitry 220 comprises the circuitry for generating the oscillator signals necessary for operation of the digital portion 204 and analog portion 202 responsive to an external oscillator crystal signal provided thereto. The sleep mode oscillator 222 provides oscillation signals to the digital portion 204 and analog portion 202 while the digital portion 204 is in a sleep mode of operation. This would be a mode between the receive and transmit operations of the RF transceiver chip. The sleep mode oscillator circuitry 222 minimizes power requirements of the RF receiver chip. The chip requires most power during transmitting and receiving periods of time, and the remainder of the time the chip is in a power down or sleep mode to conserve system power. The calibration and bias circuitry 224 provides the circuitry for controlling various calibration and biasing operations for the analog portion 202 of the RF transceiver chip. Voltage regulators 226 regulate an applied voltage of 1.8 volts to 3.6 volts to the levels necessary for operation within the analog and digital portions of the RF transceiver chip.
[0019] The digital portion 204 of the RF transceiver chip consists of the digital modem 228 and an embedded MCU 230 . The digital modem 228 provides for the modulation and demodulation of digital signals provided between the MCU 230 and the analog-to-digital controller 214 and digital-to-analog controller 216 of the analog portion 202 of the RF transceiver chip. The digital modem 228 is realized with a DSP. The embedded MCU 230 is an 8051 based microprocessor that controls processing operations within the RF transceiver chip. The embedded MCU 230 includes interfaces to the external world via a SPI interface 232 connected to an associated SPI port, a host sync interface 234 which may communicate with external devices via handshaking routines, and a test interface 236 providing for test and debugging of the chip.
[0020] Referring now to FIG. 3 , there is illustrated a block diagram of the analog portion 204 with respect to the RF receiver 210 and RF transmitter 212 . The antenna switch 208 operates responsive to control signals from the antenna control block 302 . The antenna switch 208 connects the antenna to either the RF transceiver input low noise amplifier 304 or to the power amplifier 306 . The native received RF signals is provided from the low noise amplifier 304 to inputs of mixers 308 and 310 , respectively. The low noise amplifier 304 also receives control signals from the antenna control block 302 for adjusting the gain thereof, this being a programmable gain amplifier. The mixer circuits 308 and 310 extract the quadrature I- and Q-components of the received RF signals using the 90 phase shifted local oscillator signals provided from the quadrature generator 312 . The quadrature generator 312 receives a voltage control oscillator signal from voltage control oscillator 314 which is responsive to signals from the phase lock loop and clock divider circuit 316 . The I- and Q-outputs of mixer circuits 308 and 310 are provided to the inputs of programmable gain amplifiers 320 and 322 . The output of programmable gain amplifiers 320 and 322 are filtered through low pass filters 324 and 326 before being provided to associated analog-to-digital converters 328 and 330 for conversion to digital signals.
[0021] Signals for transmission are received through the level shifter 318 to the digital-to-analog converters 332 and 334 associated with the I and Q components respectively where the signals are converted to analog format. The outputs of the digital-to-analog converters 322 and 334 are filtered through low pass filters 336 and 338 . The I and Q components of the composite signal are upconverted and combined within mixer circuits 340 and 342 responsive to the filtered signals from low pass filters 336 and 338 and mixing signals from the quadrature generator 312 . The I and Q components upconverted by the mixers 340 and 342 are summed together at the summer circuit 344 and passed through a harmonic filter 346 to provide the composite RF signal at 2 . 45 GHz. The harmonic filter 346 provides an output to a programmable gain power amplifier 306 connected to the output antenna switch 208 and controlled by the antenna control circuitry 302 . The programmable gain power amplifier 306 amplifies the signal to a desired level before being switched for output to the antenna.
[0022] The automatic gain control is implemented within the low noise amplifier 304 and/or the programmable gain amplifiers 320 and 322 via inputs provided to these amplifiers from a digital signal processor implemented within the digital portion 204 of the RF transceiver chip. By implementing the automatic gain control within one or both of these amplifiers to maximize desired signals while minimizing noise, the analog-to-digital converter 328 and 330 can avoid being placed in saturation conditions and provide for optimal reception of signals of interest being transmitted to the RF transceiver chip as will be described more fully herein below. This makes full use of the dynamic range of the overall RF front end. It is noted that the reason for the programmable gain amplifier 320 is to allow for a lower resolution analog-to-digital converter with a resulting lower power budget. However, it should be understood that a higher resolution data converter could be utilized with a much wider dynamic range, with the disadvantage of a much higher power budget.
[0023] Referring now to FIG. 4 , there is provided a block diagram of the digital portion 204 of the RF transceiver chip. Received RF signals from the analog-to-digital converter 214 are provided as I and Q components of the composite signal to an acquisition module 402 . The acquisition module 402 receives control signals from a synchronization module 404 enabling the module to determine frame boundaries for received signals detected by the RF circuitry. Likewise, transmitted RF signals are provided as I and Q components of the resultant composite signal from the frame generation module 404 to the digital-to-analog converter 216 . The frame generation module 404 also receives synchronization information from the synchronization module 404 . A DSP core 408 provides control signals to the synchronization module 404 and is also responsible for providing the automatic gain control to the low noise amplifier 304 and programmable gain amplifiers 320 and 322 of the analog portion 202 .
[0024] A memory manager 410 manages the various RAM memories 412 associated with the DSP core 408 . The memory manager 410 is also in communication with the embedded MCU 230 and a SPI port 232 . The MCU 230 also has associated RAM 420 , an MCU register file 422 , a non-volatile RAM 424 and an analog control interface 426 . Control signals may be provided to the MCU 230 via a control port 428 . A prefetch buffer 430 obtains MCU program memory instructions from program memory 432 when needed by the MCU 230 .
[0025] By implementing an automatic gain controller 502 within the digital signal processor 408 as illustrated generally at FIG. 5 , various signals of interest may be amplified while minimizing signals that are noise or interferer signals. In a preferred embodiment, the automatic gain controller 502 will provide a minimum of three different gain levels and a maximum of 5 different gain levels. The goal of the automatic gain controller 502 is to avoid any saturation of the devices within the RF transceiver in order to be able to filter out adjacent signal interferers which may be detected. If the input of the receiver filter 324 is saturated it cannot properly filter out interferer signals and the harmonics of the interferer signals will fall in band. The RF transceiver has a finite number of gain levels in the low noise amplifier 304 and receive filter 324 in order to reduce the complexity of the system. An accurate AGC algorithm is needed in order to set this gain level since an error in the choice of the gain level cannot be tolerated. The gain of the AGC 502 is established after receiving the signal of interest. Thus, the symbol synchronization must be known before changing the gain. Furthermore, the synchronization algorithm must not be sensitive to saturation as gain levels which may achieve saturation must be tested to determine their possible use.
[0026] Referring now also further to FIG. 6 , there are illustrated the different signals which may be received by the RF transceiver chip within the bandwidth of the receiver (noting that they are all overlapping, but illustrated as separate signals for clarification purposes). Signal 602 represents a signal of interest that is being transmitted to the RF transceiver. This is a spread spectrum signal utilizing single carrier QPSK modulation transmitted by a corresponding transmitter in the network, which signal, when demodulated, has a predetermined sequence of symbols. This is the signal which the RF transceiver is intended to receive, i.e., the signal of interest. Signal 604 represents a noise signal received by the RF transceiver. This is the general background noise that is often received over an RF channel and is of a substantially lower signal strength value than a signal of interest in most cases. Finally, an interferer signal 606 comprises a signal that is being transmitted on the same channel as the signal of interest 602 but is not intended for reception by the RF transceiver chip, although it also may be a QPSK signal. The interferer signal 606 is much larger than the noise signal 604 and in some cases may be strong enough to drown out or preempt the signal of interest 602 . The desire is to avoid saturation at the input of the Rx filter in order to filter out properly the interferers 606 . If the input signal already saturates the RF chain then an upcoming out of band interferer will create spur inband. In order to achieve these goals of minimizing the interferer signals 606 to maximize reception of signals of interest 602 , the automatic gain controller 502 is implemented as software within the digital signal processor 408 . It is important that the signal of interest be maintained at a sufficient signal level to adequately demodulate it, but also not allowing the interferer to cause saturation of the RF front end. Thus, it is the goal of the automatic gain control to seek a level that maximizes the ratio of the signal of interest to the sum of the interferer plus noise. In effect, the interferer is considered to be noise. As will be described in more detail herein below, what is necessary is to detect the presence of the signal of interest in the band and then with autocorrelation, determine the signal level thereof separate form the other received signals. With this signal level, the above noted ration can be determined and maximized.
[0027] The IEEE 802.15.4 signal is a constant envelope signal and thus very robust to saturation. Saturating the analog low pass filters 324 and 326 and the analog-to-digital converters 328 and 330 should be avoided as much as possible especially when an interferer signal 606 is present as this can potentially make the signal of interest and the interferer signal of similar strengths. The AGC 502 implemented within the DSP 408 provides gain control for the RF transceiver in a series of fixed steps. The DSP is always late by one buffer length when receiving and evaluating received RF signals. The AGC 502 always initially establishes the analog gain signal to a maximum gain value at wake up in order to reach the desired sensitivity level. If the analog gain is not at a maximum level when the DSP is trying to detect the presence of a signal, it is possible to miss some of the received signal, as this is a short burst of data. Therefore, it is important to wake up at maximum gain, as opposed to initiating the gain control from a medium level of gain.
[0028] The AGC algorithm relies upon the power levels of the signal of interest and the SNR of this signal. The following equation represents the model for the received signal z(k):
[0000] z ( k )= G AGC x ( k )exp(2 iπΔfk )+ G AGC i ( k )+ n RF ( k ) (1)
[0029] G AGC comprises the gain level of the automatic gain controller 502 . This gain level will of course vary depending upon which gain level is ultimately chosen. x(k) comprises the signal of interest. The power of the signal of interest depends upon the propagation conditions within which the signal is being transmitted. Δf is the frequency offset in base-band used by the receiver and the transmitter of the transceiver. i(k) comprises the received interferer signal within any received signal z(k). n RF (k) comprises any received noise signals received by the RF stage. The digital signal processor 408 within which the AGC 502 is implemented will have a sampling frequency at its input of 2 MHz.
[0030] Equation 2 represents the power Px of the signal of interest x(k).
[0000] P x =G 2 AGC E[x ( k ) x ( k )*] (2)
[0000] In order to estimate P x the periodicity of the preamble of the signal of interest is utilized. P x comprises the power of the received signal of interest. E is the expectation. As before x(k) comprises the signal of interest and x(k)* comprises the complex conjugate of the symbol of interest x(k).
[0031] In order to estimate the power of the received signal of interest, the periodicity of its preamble is determined utilizing using the following equation:
[0000] C 32 =E[z ( k ) z *( k+ 32)] (3)
[0032] This is an estimator of the 32-order self correlation. 32 samples correspond to 16 microseconds at 2 MHz. The value of C32 measures the periodicity of the received signal. C32 is maximal when the signal z(k) is periodical with a period 32 . In our case the received signal x(k) is periodical whereas the noise (RF and interferers) is a random signal which is not 32 periodical. As the noise is not 32-periodical the contribution of the noise in C32 defined in (3) becomes very small compared with the contribution of the signal of interest x(k). It can be demonstrated that the power of the preamble C32 calculated based upon samples belonging to the preamble are equal to the received signal power as soon as the interferer signal is non periodical or at least has a period greater than the 16 microsecond sampling period. This provides equation 4 as illustrated below:
[0000] C32=P x (4)
[0033] An estimation of the power of the preamble C32 and the power of the total received signal power Pz are used to estimate the signal to adjacent interferer ratio (SAIR) and signal to noise ration (SNR). Pz represents the power of the received signal and is defined by the following equation:
[0000] Pz=[z ( k ) z *( k )]= G 2 AGC ( P x +P i )+ P NRF
[0000] P i comprises the power of the interferer signal, P x comprises the power of the received signal of interest and P NRF comprises the power of the RF noise. P NRF depends upon the RF stage noise factor and to a small degree on the gain of the automatic gain controller that is selected so this value is fixed and known.
[0034] Referring now to FIG. 7 , there is illustrated the process for establishing a gain level using the automatic gain controller 502 within the digital signal processor 408 . The process is initiated at step 702 when the RF transceiver wakes up from sleep mode and attempts to detect received RF signals. At wake up, the AGC 502 sets the gain of the analog gain controller 502 to a maximum level at step 704 . The DSP sniffs at step 706 for an 802.15.4 signal at this maximum gain level with the expected symbol sequence periodicity. If an 802.15.4 signal is detected, the preamble of the detected signal is decoded such that synchronization estimators may be measured for the detected signal to detect the beginning of various data symbols within the detected signal, noting that the buffers may have one boundary and the actual data may and usually does have a different boundary at step 708 . Once synchronization for the signal has been established, the detected channel power estimation and SNR of the signal of intent may be made at step 710 enabling the analog gain controller 502 to make a first decision. This estimation is based on the estimation of C32 (equation 3) and Pz (equation 5). Once the detected signal is autocorrelated to itself, the autocorrelation order depends on the preamble periodicity. Within a 16 micro second sample period, an estimation may be made of the total signal strength of the received signal of interest separate from other received signals, as shown in equation 3, even other QPSK signals, such as those associated with 802.11 standards. Once the estimated received signal strength power has been determined for the signal of interest, the signal to noise ratio for the detected signal may be determined at step 710 . The signal to noise ratio (SNR) would equal the power of the signal of interest divided by the power of the noise plus any detected interferer signal.
[0035] The signal to noise ratio is determined according to the equation:
[0000]
SNR
=
C
32
P
z
-
C
32
(
6
)
[0000] The precision of the estimator of the SNR which depends on the choice of the estimator is taken into account by the choice of the SNR threshold which is utilized. The threshold is augmented by a factor which warrants that the targeted SNR will be reached after the gain setting is selected.
[0036] Inquiry step 712 determines the signal to noise ratio associate with the next gain is estimate by the DSP and if this “future” SNR is greater than a threshold SNR, the SNR associate with the next gain is determined at step 710 . The gain is decreased because of the desire to filter a new incoming interferer during the demodulation of the signal of interest. When the determined SNR is smaller than the threshold SNR, the gain is set to the minimal gain that exceeded the threshold SNR at step 714 . Thus, the gain is set to the minimal value in order to have a minimal SNR. This established gain level is used for controlling the LNA and/or PNA amplifiers using control signals provided by the automatic gain controller 502 within the DSP 508 . The goal is to keep the RF gain as low as possible with respect to the received signal while providing some minimal SNR level with some predetermined margin provided for.
[0037] Referring now to FIG. 8 , there is illustrated the margin range 802 that should be maintained between the detected signal power level 804 and the detected noise level 806 . The detected signal power level 804 represents the signal strength of the signal of interest which is being received by the RF transceiver chip. This is the signal with which the RF transceiver chip is most interested, and the one that the gain level of the automatic gain controller is intended to maximize its reception. The detected noise level 806 represents the normal channel noise received by the RF transceiver chip plus any interferer signals which may be received by the RF transceiver chip. The goal of the automatic gain controller is to minimize the detected noise level 806 while maximizing the signal power level 804 to provide a signal to noise ratio creating a particular margin range 802 between the detected signal power level 804 and the detected noise level 806 . This margin range 802 is intended to be of such a level that signal spikes caused by increases in the detected noise level which may arise from increased normal noise levels or increased interferer signal reception do not cause the noise to rise to such a level that the detected noise level 806 overwhelms and causes loss of the detected signal of interest. Thus, while spikes within the detected noise level may cause the noise to approach the signal strength levels of the detected signal, these levels will not usually match or exceed the received signal power level 804 if the desired margin range 802 is maintained. The precision of the estimation algorithm on the SNR fixes this margin. If the estimation algorithm gives the worst case precision of 3 dB and if we want to have an SNR more than 5 dB (at the demodulator input) the decision threshold is fixed at 8 dB. In fact if the estimator of the SNR gives 8 dB then in the worst case the SNR will be 5 dB which is the minimum SNR allowed to change the gain.
[0038] Referring now to FIG. 9 , there is illustrated the manner in which the selection of varying gain levels affects the margin provided by the automatic gain controller with respect to the dynamic range of the analog-to-digital converter to which the signals are provided. The goal of the automatic gain controller is to prevent the analog-to-digital controller from entering its saturation region. As can be seen in FIG. 9 , the full scale range 902 of the analog-to-digital converter goes from approximately −38 dbvrms to 0 at the input of the analog-to-digital converter. The diagonal lines 904 represent 5 different gain levels of the automatic gain controller 502 . Line 904 a represents the maximum gain level line and lines 904 b through 904 d respectively represent decreasing gain levels of the AGC. Line 906 represents the gain step delta G of a signal caused by lowering the gain to a next gain level. Line 908 represents the margin that must be provided above the signal to noise level 910 in order to assure that the reception of the signal of interest is maximized while minimizing the potential of interference arising from interferer signals or noise residing upon the receiving channel.
[0039] The bottom line 910 represents the noise level associated with the channel on which signals being received by the RF transceiver. Lines 912 and 914 and the area therebetween represent the potential signal strength levels associated with the signal of interest. The distance M between lines 910 and 912 represent the margin 908 which must be maintained between the signal level of the signal of interest and the noise level of the system. The gain of the automatic gain controller may not be lowered to such a level that the signal strength of the signal of interest received by the RF transceiver chip would drop below the level represented by line 912 or the detected signal level would drop below the permissible margin range. The space represented between lines 912 and 914 and indicated generally at 916 comprises the gain step delta G.
[0040] The gain step represents the amount that the signal strength of the signal of interest will decrease when gain is decreased from one gain level of the automatic gain controller to the next lower gain level. Thus, if the signal strength level of the signal of interest was approximately −24 dbvrms as indicated at point 918 for gain level 904 a the gain level associated with the automatic gain controller may be decreased from gain level 904 a to gain level 904 b. This will cause the signal strength of the received signal of interest to decrease from the point indicated at 918 to the point indicated at 920 of approximately −35 dbvrms. Similar decreases can be seen when moving from points on the gain levels of the automatic gain controller along line 912 . However, if the signal strength associated with gain level 904 a were instead at −30 dbvrms ( 922 ), the gain level of the automatic gain controller could not be decreased to the next gain level 904 b because this would take the signal strength of the detected signal of interest down to a point ( 924 ) below the desirable gain margin desired for operation of the transceiver. Thus, as can be seen, the gain step decrease caused by movement from a first gain level to a next lower gain level must maintain the signal strength of the received signal of interest above the margin level established for the system such that the signal to noise ratio will be maintained above a maximum desired level.
[0041] It will be appreciated by those skilled in the art having the benefit of this disclosure that this invention provides an automatic gain controller for use with an RF transceiver. It should be understood that the drawings and detailed description herein are to be regarded in an illustrative rather than a restrictive manner, and are not intended to limit the invention to the particular forms and examples disclosed. On the contrary, the invention includes any further modifications, changes, rearrangements, substitutions, alternatives, design choices, and embodiments apparent to those of ordinary skill in the art, without departing from the spirit and scope of this invention, as defined by the following claims. Thus, it is intended that the following claims be interpreted to embrace all such further modifications, changes, rearrangements, substitutions, alternatives, design choices, and embodiments.
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The present invention comprises an automatic gain controller for an RF transceiver that comprises a digital engine that selects a gain level responsive to a signal power level of a signal of interest received by the RF transceiver. The digital engine is configured to select the gain level from a plurality of possible gain levels to maximize the signal power of the signal of interest while providing at least a selected signal of interest to noise ratio. The digital engine provides a control signal enabling amplification of a received signal according to the selected gain level.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to limited slip differentials, and more particularly to limited slip differentials having an electromagnetically actuated clutch.
[0002] Differentials are well known in the prior art and allow each of a pair of output shafts or axles operatively coupled to a rotating input shaft to rotate at different speeds, thereby allowing the wheel associated with each output shaft to maintain traction with the road while the vehicle is turning. Such a device essentially distributes the torque provided by the input shaft between the output shafts.
[0003] The completely open differential, i.e., a differential without clutches or springs which restrict relative rotation between the axles and the rotating differential casing, is not well suited to slippery conditions in which one driven wheel experiences a much lower coefficient of friction than the other driven wheel: for instance, when one wheel of a vehicle is located on a patch of ice and the other wheel is on dry pavement. Under such conditions, the wheel experiencing the lower coefficient of friction loses traction and a small amount of torque to that wheel will cause a “spin out” of that wheel. Since the maximum amount of torque which can be developed on the wheel with traction is equal to torque on the wheel without traction, i.e. the slipping wheel, the engine is unable to develop any torque and the wheel with traction is unable to rotate. A number of methods have been developed to limit wheel slippage under such conditions.
[0004] Prior means for limiting slippage between the axles and the differential casing use a frictional clutch mechanism, either clutch plates or a frustoconical engagement structure, operatively located between the rotating case and the axles. Certain embodiments of such prior means provide a clutch element attached to each of the side gears, and which frictionally engages a mating clutch element attached to the rotating casing or, if the clutch is of the conical variety, a complementary interior surface of the casing itself. Such embodiments may also include a bias mechanism, usually a spring, to apply an initial preload between the clutch and the differential casing. By using a frictional clutch with an initial preload, a minimum amount of torque can always be applied to a wheel having traction, e.g., a wheel located on dry pavement. The initial torque generates gear separating forces between the first pinion gears and the side gears interneshed therewith. The gear separating forces urge the two side gears outward, away from each other, causing the clutch to lightly engage and develop additional torque at the driven wheels. Examples of such limited slip differentials which comprise cone clutches are disclosed in U.S. Pat. No. 4,612,825 (Engle), U.S. Pat. No. 5,226,861 (Engle) and U.S. Pat. No. 5,556,344 (Fox), each of which is assigned to Auburn Gear, Inc., the disclosures of which are all expressly incorporated herein by reference.
[0005] Certain prior art limited slip differentials provide, between the first of the two side gears and its associated clutch element, interacting camming portions having ramp surfaces or ball/ramp arrangements. In response to an initiating force, this clutch element is moved towards and into contact with the surface against which it frictionally engages, which may be a mating clutch element attached to the casing, or an interior surface of the casing itself, as the case may be, thereby axially separating the clutch element and its adjacent first side gear, the interacting camming portions slidably engaging, the rotational speed of the clutch element beginning to match that of the differential casing due to the frictional engagement. Relative rotational movement between the ramp surfaces induces further axial separation of the clutch element and the first side gear. Because the clutch element is already in abutting contact with the surface against which it frictionally engages, the first side gear is forced axially away from the clutch element by the camming portions.
[0006] Certain embodiments of such limited slip differentials utilize an electromagnet having an electrical coil to effect the initiating force and actuate the clutch, as disclosed in U.S. Pat. No. 5,989,147 (Forrest et al.), U.S. Pat. No. 6,019,694 (Forrest et al.), and U.S. Pat. No. 6,165,095 (Till et al.), each of which is assigned to Auburn Gear, Inc., the disclosures of which are all expressly incorporated herein by reference. Each of these references discloses that the differential casing, in which the clutches are disposed, rotates within the housing and is rotatably supported by a pair of bearings. An electromagnet, which actuates a primary cone clutch element, is mounted in fixed relationship to the axle housing and is rotatably supported by the differential casing. Alternatively, as disclosed in pending U.S. patent application Ser. No. 09/484,967, filed Jan. 18, 2000, which is assigned to Auburn Gear, Inc., the disclosure of which is expressly incorporated herein by reference, the electromagnet may be fixedly supported by the axle housing. In either case, activation of the electromagnet draws a primary cone clutch element into frictional engagement with the rotating differential housing.
[0007] The camming portions, described above, act between the primary cone clutch element and the first side gear to axially separate them, forcing the first side gear into abutment with a transfer block located intermediate the first and second side gears. Responsive to this force, the transfer block is moved into abutment with the second side gear, which is rotatably fixed to a secondary cone clutch element, which frictionally engages a mating interior surface of the rotating differential casing. The frictional engagement of the secondary cone clutch element and the differential casing effects further clutched engagement between the axles and the differential casing, enhancing the locking capability of the limited slip differential. Notably, the load carrying capability of the secondary cone clutch mechanism is usually significantly greater than that of the primary cone clutch mechanism, owing to a greater axial engagement force exerted thereon. Examples of prior limited slip differentials are described in more detail below, with reference to FIGS. 1 and 2.
[0008] [0008]FIG. 1 depicts an embodiment of prior axle assembly 10 having electrically or electromagnetically actuated limited slip differential assembly 12 . Axle assembly 10 may be a conventional axle assembly or comprise part of a transaxle assembly. Therefore, it is to be understood that the term “axle assembly” encompasses both conventional (rear wheel drive) axle assemblies as well as transaxle assemblies. Differential assembly 12 comprises electromagnet 14 , ferrous rotatable casing 16 constructed of joined first and second casing parts 16 a and 16 b , respectively, and providing inner cavity 18 , which is defined by the interior surface of the circumferential wall portion of first casing part 16 a and end wall portions 20 , 22 of first and second casing parts 16 a , 16 b , respectively. Casing part 16 a may be a machined iron or steel casting; casing part 16 b may also be such a casting, or a ferrous, sintered powdered metal part. Disposed within cavity 18 are side gears 24 , 26 and pinion gears 28 , 30 . The teeth of the side gears and pinion gears are intermeshed, as shown. Pinion gears 28 , 30 are rotatably disposed upon cylindrical steel cross pin 32 , which extends along axis 34 . The ends of cross pin 32 are received in holes 36 , 38 diametrically located in the circumferential wall of casing part 16 a.
[0009] Axles 40 , 42 are received through hubs 44 , 46 , respectively formed in casing end wall portions 20 , 22 , along common axis of rotation 48 , which intersects and is perpendicular to axis 34 . Axles 40 , 42 are respectively provided with splined portions 50 , 52 , which are received in splines 54 , 56 of side gears 24 , 26 , thereby rotatably fixing the side gears to the axles. The axles are provided with circumferential grooves 58 , 60 in which are disposed C-rings 62 , 64 , which prevent the axles from being removed axially from their associated side gears. The terminal ends of the axles 98 and 100 may abut against the cylindrical surface of cross pin 32 , thereby restricting the axles' movement toward each other along axis 48 .
[0010] Primary clutch element 66 is attached to side gear 24 and rotates therewith. Clutch element 66 is ferrous and of the cone clutch variety and has frustoconical surface 68 which is adjacent to, and clutchedly interfaces with, complementary surface 70 provided on the interior of casing part 16 a . Secondary clutch element 72 is also of the cone clutch variety and has frustoconical surface 74 which is adjacent to, and clutchedly interfaces with, complementary surface 76 also provided on the interior of casing part 16 a . Cone clutches 66 and 72 may be of the type described in U.S. Pat. No. 6,076,644 (Forrest et al.) or U.S. Pat. No. 6,261,202, each of which is assigned to Auburn Gear, Inc., the disclosures of which are both expressly incorporated herein by reference, or may also be of any other suitable structure.
[0011] Disposed between primary cone clutch element 66 and side gear 24 is annular cam plate 78 , which abuts thrust washer 82 adjacent end wall portion 22 . Ball and ramp arrangement 84 , 86 , 88 is comprised of a first plurality of paired spiral slots 84 , 86 located in cam plate 78 and primary cone clutch element 66 , respectively. Slots 84 , 86 define a helically ramping path followed by ball 88 , which may be steel, disposed in each slot pair and a first ramp angle. With electromagnet 14 de-energized, balls 88 are seated in the deepest portion of slots 84 , 86 by Belleville spring 90 . The actuation sequence is created by the momentary difference in rotational speed between cone clutch element 66 and cam plate 78 as frustoconical surfaces 68 and 70 seat against each other. A more detailed discussion of ball/ramp camming arrangements is disclosed in U.S. Pat. No. 5,989,147.
[0012] In operation, a variable coil current on electromagnet 14 induces a variable amount of magnetic clamping force between casing part 16 a and primary cone clutch element 66 , which induces a variable amount of torque to be exerted by casing part 16 a on clutch element 66 . As electromagnet 14 is activated, axial separation of primary cone clutch element 66 and cam plate 78 is induced as cone clutch element 66 is magnetically pulled to the left against the force of Belleville spring 90 into clutched engagement with casing part 16 a through frustoconical surfaces 68 and 70 . In response to the initial flow of magnetic flux, cone clutch element 66 is pulled by the magnetic field to the left and surfaces 68 and 70 abut, and enter frictional engagement. As cone clutch element 66 and cam plate 78 separate axially, balls 88 are caused to rotate along the ramping helical paths of slots 84 , 86 due to the relative rotation between clutch element 66 and cam plate 78 . Cam plate 78 is urged against thrust washer 82 by the force of Belleville spring 90 and gear separation forces between pinion gears 28 , 30 and side gear 24 . As balls 88 rotate further along the helical ramp paths, frustoconical surfaces 68 , 70 are forced into tighter frictional engagement and cam plate 78 , still abutting thrust washer 82 , reaches the end of its rotational travel relative to cone clutch member 66 .
[0013] First side gear 24 moves towards the right, forcing secondary cone clutch element 72 into abutment with casing part 16 a via transfer block 92 and second side gear 26 in the manner described above. Transfer block 92 , which may be steel, is disposed about cross pin 32 and adapted to move laterally relative thereto along axis 48 to transfer movement of first side gear 24 to second side gear 26 , thereby engaging secondary clutch element 72 . As shown, transfer block 92 is attached directly to cross pin 32 , and supports the cross pin in position within the differential casing as described in U.S. Pat. No. 6,254,505, assigned to Auburn Gear, Inc., the disclosure of which is expressly incorporated herein by reference. Alternatively, the transfer block may be loosely fitted about the cross pin, the cross pin being directly attached to the differential housing by a bolt extending through one end of the cross pin, as shown, for example, in U.S. Pat. No. 5,226,861. The shear loads associated with torque transmission are exerted on cross pin 32 near its opposite ends, particularly between the circumferential wall of casing part 16 a and the adjacent pinion gears 28 , 30 .
[0014] Transfer block 92 includes opposite bearing sides 94 , 96 which respectively abut first and second side gears 24 , 26 , and allows terminal ends 98 , 100 of axles 40 , 42 , respectively, to abut the cylindrical side surface of cross pin 32 . Transfer block 92 moves laterally relative to cross pin 32 , along axis 48 , such that rightward movement of side gear 24 , described above, is transferred to side gear 26 . Thus, during actuation of electromagnet 14 , first side gear 24 is urged rightward, as viewed in FIG. 1, into abutting contact with transfer block 92 . Transfer block 92 moves rightward, into abutting contact with second side gear 26 ; and second side gear 26 moves rightward, urging surface 74 of secondary clutch element 72 into frictional engagement with surface 76 of casing part 16 a , thereby providing additional torque transfer capacity to the differential than would otherwise be provided with single cone clutch element 66 .
[0015] Provided on the exterior surface of casing part 16 a , near electromagnet 14 , is flange 102 , to which ring gear 104 is attached. The teeth 136 of ring gear 104 are in meshed engagement with the teeth of pinion gear 106 which is rotatably driven by an engine (not shown), thus rotating differential casing 16 within axle housing 108 . As casing 16 rotates, the sides of holes 36 , 38 bear against the portions of the cylindrical surface of cross pin 32 in the holes. The rotation of cross pin 32 about axis 48 causes pinion gears 28 , 30 to revolve about axis 48 . The revolution of the pinion gears about axis 48 causes at least one of side gears 24 , 26 to rotate about axis 48 , thus causing at least one of axles 40 , 42 to rotate about axis 48 . Engagement of the clutches as described above arrests relative rotation between the side gears and the differential casing.
[0016] Differential casing 16 is rotatably supported within axle housing 108 by means of identical first and second bearings 110 , 112 . Because of the proximity of ring gear flange 102 to the end of casing 16 nearest first bearing 110 , in operation, that bearing is more heavily loaded than is second bearing 112 .
[0017] Electromagnet 14 is rotatably supported on second differential casing portion 16 b by third bearing 114 . Electromagnet 14 is rotatably fixed relative to axle housing 108 and disposed in close proximity to casing 16 , which rotates relative thereto. The voltage applied to electromagnet 14 to energize same and actuate primary clutch element 66 may be controlled by a control system (not shown) which is in communication with sensors (not shown) which indicate, for example, excessive relative rotation between axles 40 , 42 , and thus the need for traction control. Housing 108 includes hole 116 fitted with rubber grommet 118 through which extend leads 120 . Through leads 120 the control system provides voltage to electromagnet 14 . As electromagnet 14 is energized, a magnetic initiating force is applied to primary cone clutch element 66 by a toroidal electromagnetic flux path (not shown) which is established about the annular electromagnet coil 126 ; the flux path flows through ferrous casing portions 16 a and 16 b and through clutch element 66 . Clutch element 66 is thus magnetically drawn into engagement with casing 16 during operation of electromagnet 14 . Because it is made of a magnetic material (e.g., steel) and has a solid structure, primary cone clutch element 66 is better suited for conducting the magnetic flux path therethrough than would be a clutch comprising a series of interleaved discs, which may have gaps therebetween and which would likely be formed of materials which would not so readily transmit the magnetic flux. Further, casing part 16 b may include annular nonmagnetic portion 122 to help direct the toroidal magnetic flux path through primary cone clutch element 66 , as described in U.S. Pat. No. 6,019,694 (Forrest et al.), assigned to Auburn Gear, Inc., the disclosure of which is expressly incorporated herein by reference.
[0018] [0018]FIG. 2 depicts a second embodiment of a prior axle assembly which is identical in structure and operation to the above-described axle assembly 10 except as follows: Axle assembly 10 ′ comprises electromagnet 14 ′ which is fixed to the axle housing, rather than being rotatably supported by a bearing 114 disposed about casing part 16 b . Bearing 110 ′ is disposed in cup 124 which extends inwardly of the axle housing to engage and support electromagnet 14 ′ in the manner described in pending U.S. patent application Ser. No. 09/484,967, filed Jan. 18, 2000. Notably, bearing 110 ′ is somewhat smaller than bearing 110 (and identical bearing 112 ) and, as noted above, would be more heavily loaded during operation than larger bearing 112 due to the proximity of the ring gear.
[0019] Although cone clutches of the type disclosed above are better suited than disc-type clutches as primary clutch elements in electromagnetically-actuated limited slip differentials, for the reasons set forth above, their load carrying capability is limited, for a give axial engagement force, by the angle of the included angle formed by the cone clutch engagement surfaces. Typically, these angles range from 9° to 12.5°. The smaller this angle, the greater the torque capacity of the cone clutch. The smaller this angle, however, the harsher the clutch engagement, and the smaller the tendency for the clutch to release. Clutches having multiple interleaved discs, or “clutch packs,” are well known in the art and generally have greater torque capacity than a cone clutch of approximately equal package size. Moreover, the required tolerances associated with manufacturing cone clutches tend to be somewhat smaller than with disc clutches.
[0020] Further still, compared to the axial movement needed to engage disc clutches, a greater distance is needed when using cone clutches because a portion of the movement is absorbed by the casing as it is being radially stretched. Therefore, relatively more movement between the pinion and side gears is needed to accommodate proper movement of the cone clutch, and optimal gear mesh clearances therebetween, which are on the order of ±0.010 inch, may be compromised. An electromagnetically-actuated limited slip differential assembly which provides the respective benefits of cone clutches and clutch packs is highly desirable.
[0021] A further issue associated with electromagnetically-actuated limited slip differentials is that the electromagnet tends to magnetize ferrous components within the axle housing, particularly those in close proximity to the electromagnet. This can be of particular concern where relatively moving, interengaging components such as bearings or gears of the differential or axle assembly become magnetized and attract metal shavings or other ferrous debris, or where the shavings and debris are themselves magnetized and become attached to these interengaging components. The collection of such contamination on these components can substantially accelerate their wear and lead to premature failure.
[0022] One known approach to addressing this issue is to provide a magnetic drain plug in the axle housing, which may attract and retain some of the debris. However, the debris may be equally attracted to other magnetized components within the axle housing, rather than to only the drain plug. Another approach to addressing this issue is described in
[0023] U.S. Pat. No. 6,165,095, which discloses an apparatus and method for demagnetizing the components initially magnetized by the electromagnet. While effective, this means for demagnetization involves providing additional controls for directing current through the electromagnet(s). It is desirable to provide a simple and effective means for reducing the likelihood or severity of magnetization of at least some of the relatively moving, interengaging components within the axle housing.
[0024] Further, one way to reduce the cost and improve the reliability of an axle assembly is to reduce the number of components parts, or at least the number of complex, high precision parts. For example, reducing the number of ball or roller bearings may reduce the cost of material, the cost of assembly labor, and the number of moving parts, thereby improving durability and reliability. Reduction in the number of parts, however, may compromise the ability of the remaining parts to perform satisfactorily. For example, reducing the number of bearings may increase the load to be borne by the remaining bearings, which may adversely affect the durability of those remaining bearings. The reduction of costs without compromising performance is an ongoing and important goal in virtually every commercial endeavor, and means for accomplishing that goal are therefore highly desirable.
SUMMARY OF THE INVENTION
[0025] The present invention provides a differential assembly including a rotatable casing, first and second axially moveable side gears disposed within the casing, at least one pinion gear disposed within the casing and intermeshed with the side gears, a cone clutch operatively coupled to the first side gear, the cone clutch being frictionally coupled to the casing in response to being exposed to a magnetic field, and at least one clutch disc operatively coupled to the second side gear in response to axial movement of the second side gear.
[0026] The present invention also provides a differential assembly including a rotatable casing having opposite ends, a differential gear mechanism and a magnetically-activated clutch disposed within the casing, relative rotation of at least a portion of the gear mechanism being selectively frictionally engaged with the casing by the clutch, an electromagnet being disposed proximal to one of the casing ends, and a ring gear attached to the casing at a location proximal to the other of the casing ends.
[0027] The present invention also provides a differential assembly including a rotatable casing, a differential gear mechanism and a magnetically-activated clutch disposed within the casing, relative rotation of at least a portion of the gear mechanism being selectively frictionally engaged with the casing by the clutch, an electromagnet disposed proximal to the casing, the casing and the electromagnet having relative rotation therebetween, and a self lubricating bearing disposed between the electromagnet and the casing, the electromagnet being supported relative to the casing by the bearing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] The above mentioned and other features and objects of this invention, and the manner of attaining them, will become more apparent and the invention itself will be better understood by reference to the following description of the embodiments of the invention taken in conjunction with the accompanying drawings, wherein:
[0029] [0029]FIG. 1 is a sectional side view of a first embodiment of a prior art electrically actuated limited slip axle assembly having its clutch-activating electromagnet rotatably supported on the differential casing by a separate bearing;
[0030] [0030]FIG. 2 is a sectional side view of a second embodiment of a prior art electrically actuated limited slip axle assembly having its clutch-activating electromagnet rotatably supported by an extended bearing cup of a bearing which supports the differential casing within the axle housing;
[0031] [0031]FIG. 3 is a sectional side view of a first embodiment of an electrically actuated limited slip axle assembly according to the present invention having its clutch-activating electromagnet rotatably supported on the differential casing by a separate bearing;
[0032] [0032]FIG. 4 is a sectional side view of a second embodiment of an electrically actuated limited slip axle assembly according to the present invention having its clutch-activating electromagnet rotatably supported by an extended bearing cup of a bearing which supports the differential casing within the axle housing;
[0033] [0033]FIG. 5 is an enlarged, fragmentary view of the axle assembly of FIG. 3;
[0034] [0034]FIG. 6 is an enlarged, fragmentary view of an axle assembly according to a third embodiment of the present invention having its electromagnet supported by a self-lubricating bearing;
[0035] [0035]FIG. 7 is an enlarged, fragmentary view of an axle assembly according to a fourth embodiment of the present invention having its electromagnet supported by an alternative self-lubricating bearing;
[0036] [0036]FIG. 8 is an enlarged, fragmentary view of an axle assembly according to a fifth embodiment of the present invention having its electromagnet supported by another alternative self-lubricating bearing;
[0037] [0037]FIG. 9A is a plan view of a first embodiment of a ball spacer used in the axle assemblies of FIGS. 3 and 4; and
[0038] [0038]FIG. 9B is an oblique view of a second embodiment of a ball spacer used in the axle assemblies of FIGS. 3 and 4.
[0039] Corresponding reference characters indicate corresponding parts throughout the several views. Although the drawings represent embodiments of the present invention, the drawings are not necessarily to scale and certain features may be exaggerated in order to better illustrate and explain the present invention. The exemplification set out herein illustrates embodiments of the invention in several forms, and such exemplifications are not to be construed as limiting the scope of the invention in any manner.
DETAILED DESCRIPTION OF THE INVENTION
[0040] The embodiments disclosed below are not intended to be exhaustive or limit the invention to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may utilize their teachings.
[0041] [0041]FIGS. 3 and 4 respectively depict first and second embodiments of electrically or electromagnetically-actuated limited slip differentials according to the present invention. Axle assembly 210 (FIG. 3) is structurally and operationally similar to prior art axle assembly 10 (FIG. 1) except as described hereinbelow. Axle assembly 210 ′ (FIG. 4) is structurally and operationally similar to prior art axle assembly 10 ′ (FIG. 2) except as described hereinbelow. Identical parts between all of these axle assemblies are identically numbered.
[0042] Referring to FIG. 3, axle assembly 210 includes differential assembly 212 rotatable comprising casing 216 . Casing 216 includes first, second and third parts 216 a , 216 b and 216 c , respectively. At least casing parts 216 a and 216 b are ferrous, and may be machined iron or steel castings. Casing part 216 b may be a sintered powdered metal part having nonmagnetic annular portion 218 to facilitate the proper magnetic flux path as described above.
[0043] Rotatably supported on casing 216 is electromagnet 220 , which is rotatably fixed relative to axle housing 108 . As described above, current is supplied to electromagnet 220 via leads 120 .
[0044] Disposed within casing 216 and proximal to casing part 216 b is primary clutch element 222 which is ferrous and of the cone clutch variety. In the manner described above, frustoconical surface 224 of cone clutch 222 is magnetically drawn into frictional engagement with complementary interior surface 226 of differential casing part 216 a to initiate clutching and slows the relative rotation between casing 216 and cone clutch 222 .
[0045] A ball/ramp arrangement comprising spiral slots 230 provided in planar portion 232 of primary cone clutch 222 , spiral slots 234 provided in first side gear 236 , and balls 88 , act to axially force first side gear 236 , which is rotatably coupled to axle 42 via interfitted splined portions 52 and 56 therein, leftward as viewed in FIG. 3. Ball spacer 238 , also shown in FIGS. 9A and 9B, is provided between the interfacing axial surfaces of planar cone clutch element portion 232 and first side gear 236 . Ball spacer 238 is flat and annular, and provided with a plurality of circumferentially distributed identically-sized holes 238 within which balls 88 are disposed; the diameter of holes 238 is slightly larger than the diameter of balls 88 to facilitate free movement of the balls through the holes. Spacer 238 maintains proper positioning of balls 88 as the interfacing axial surfaces of planar cone clutch element portion 232 and first side gear 236 separate, and ensures that all the balls transmit and equal force between all paired surfaces of slots 230 and 234 . Should a ball 88 tend to lead or lag the revolution of the other balls 88 about axis 48 , it will contact a side of its spacer hole 240 and be urged thereby back into its proper circumferential position. Proper positional relationship between the balls 88 is thus maintained at all times. Spacer 238 may be flat, stamped sheet steel part. Alternatively, the ball spacer may be formed as a steel Belleville spring as shown in FIG. 9B. Ball spacer 238 ′ is provided with circumferentially distributed holes 240 like ball spacer 238 to maintain proper relative ball positions, but provides the additional function of facilitating the axial separation of primary cone clutch element 222 and first side gear 236 by urging them axially apart and more quickly effecting locking of the differential.
[0046] As first side gear 236 is moved leftward, as viewed in FIG. 3, it is brought into abutment with bearing side 96 of transfer block 92 , which moves laterally relative to cross pin 32 as described above. Opposite transfer block bearing side 94 abuts second side gear 242 , which is rotationally fixed to axle 40 via interfitted splined portions 50 and 54 therein. Leftward movement of second side gear 242 urges a plurality of interleaved discs 244 , 246 , which comprise secondary clutch 248 , into mutual frictional engagement. Discs 244 are rotatably fixed to side gear 242 , and discs 246 are rotatably fixed to casing 216 ; hence, their frictional engagement tends to slow their relative rotation, and lock the axle 40 into rotation with casing 216 . Because axles 40 and 42 are connected through side gears 234 , 242 and pinion gears 28 , 30 , once one axle is clutchedly engaged to casing 216 , both axles are so engaged.
[0047] In marked distinction from the differentials shown in FIGS. 1 and 2, differential 212 provides ring gear mounting flange 250 at the axial end of casing 216 which is opposite that at which electromagnet 220 is located, thereby substantially decreasing the likelihood that ring gear 104 will become magnetized, and thus minimizing the possibility that magnetic shavings or other debris which may be in cavity 18 will come between the intermeshed teeth of ring gear 104 and pinion 106 . As described above, the toroidal flux path about the annular electromagnet coil is directed through the adjacent portions of the ferrous casing parts, and the primary cone clutch. By greatly separating ring gear 104 from this flux path in accordance with the present invention, gear wear, and the durability of axle assembly 210 is improved vis-a-vis prior art electromagnetically-actuated limited slip axle assemblies which more proximally locate the ring gear and electromagnet.
[0048] [0048]FIG. 4 depicts a second embodiment of an axle assembly according to the present invention which is identical in structure and operation to above-described axle assembly 210 except as follows: Axle assembly 210 comprises electromagnet 220 ′ which is fixed to the axle housing 108 , rather than being rotatably supported about casing part 216 b ′. Bearing 110 ′ is disposed in cup 124 which extends inwardly of the axle housing to engage and support electromagnet 220 ′. Notably, bearing 110 ′ is somewhat smaller than bearing 112 , or bearing 110 of FIG. 3. By moving the electromagnet to the axial end of casing 216 ′ opposite that at which ring gear 104 is located, however, larger bearing 112 , located near the ring gear 104 , is more heavily loaded during operation.
[0049] With reference now to FIGS. 5 - 8 , there are shown various bearing means for axially and radially supporting electromagnet 220 in axle assembly 210 . FIG. 5, which is an enlarged fragmentary view of FIG. 3, shows electromagnet 220 (which comprises coil 252 ) is separated from casing 216 by flat annular roller thrust bearing 254 , and by annular bearing 256 molded of a self-lubricating, SP polyimide resin such as, for example, Vespel®, manufactured by DuPont. Bearing 256 has an L-shaped partial cross section providing integral cylindrical portion 258 and flat annular portion 260 . Snap ring 262 disposed in annular groove 264 provided in hub 266 of casing part 216 b retains electromagnet 220 to casing 216 . Notably, line 268 indicates the toroidal magnetic flux path of electromagnet coil 252 .
[0050] [0050]FIG. 6 shows an alternative to the electromagnet mounting scheme of FIG. 5 which eliminates roller thrust bearing 254 , and replaces bearing 256 with bearing 270 . Bearing 270 , which may also be molded of Vespel®, has a U-shaped partial cross section providing integral annular flat portions 272 and 274 located on opposite sides of central cylindrical portion 276 . Effectively, the function of roller thrust bearing 254 (FIG. 5) is performed by bearing portion 272 .
[0051] [0051]FIG. 7 shows a further alternative to the electromagnet mounting scheme of FIG. 5 which eliminates roller thrust bearing 254 , and replaces it with flat, annular Vespel® bearing 278 . Further, bearing 256 (FIG. 5) is replaced with individual Vespel® bearings 280 , 282 which are respectively substituted for portions 258 and 260 of bearing 256 . Flat annular bearing 278 of FIG. 7, and annular L-shaped bearing 256 of FIG. 5, are both used in the variant shown in FIG. 8.
[0052] While this invention has been described as having exemplary designs, the present invention may be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains.
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A differential assembly including a rotatable casing, first and second axially moveable side gears disposed within the casing, at least one pinion gear disposed within the casing and intermeshed with the side gears, a cone clutch operatively coupled to the first side gear, the cone clutch being frictionally coupled to the casing in response to being exposed to a magnetic field, and a disc clutch having at least one clutch disc operatively coupled to the second side gear in response to axial movement of the second side gear.
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BACKGROUND OF THE INVENTION
[0001] Neoplastic diseases, characterized by the proliferation of cells which are not subject to normal cell proliferating controls, are a major cause of death in humans and other mammals. Cancer chemotherapy has provided new and more effective drugs to treat these diseases and has also demonstrated that drugs which disrupt microtubule synthesis are effective in inhibiting the proliferation of neoplastic cells.
[0002] Microtubules play a key role in the regulation of cell architecture, metabolism and division. The microtubule systems of eukaryotic cells comprises a dynamic assembly and disassembly matrix in which heterodimers of tubulin polymerize to form microtubules in both normal and neoplastic cells. Within neoplastic cells, tubulin is polymerized into microtubules which form the mitotic spindle. The microtubules are then depolimerized when the mitotic spindle's use has been fulfilled. Agents which disrupt the polymerization or depolymerization of microtubules in neoplastic cells, thereby inhibiting the proliferation of these cells, comprise some of the most effective cancer chemotherapeutic agents in use.
[0003] Combretastatin A-4 (CA-4), isolated from the African bush willow, Combretum caffrum (Combretaceae) (Pettit, G. R., et al.; Experientia, 1989, 45, 209) shows exciting potential as an anticancer agent binding strongly to tubulin at a site shared with, or close to, the colchicine binding site (Lin, C. N., et al; Biochemistry, 1989, 28, 6984). The bond to tubulin prevents its polymerization into microtubules with anti-mitotic effect. CA-4 inhibits cell growth at as low as nanomolar concentrations and shares many structural features common to other tubulin-binding agents such as colchicine and podophyllotoxin.
[0004] The phosphate salt [CA-4P] (Pettit, G. R., et al.; Anticancer Drug Des., 1995, 10, 299), which has better water solubility than CA-4, has entered Phase II clinical trials.
[0005] It is the ability of combretastatins to damage tumor vasculature, thereby effectively starving tumors of nutrients, which makes them such exciting molecules.
[0006] Recently many studies have shown that a number of antiangiogenic agents, like CA-4P, can inhibit retinal neovascularization in a well-characterized murine model of ischemia-induced proliferative retinopathy.
[0007] These studies suggest that as CA-4P or new derivatives as other antiangiogenic agents, could be useful in the treatment of non-neoplastic diseases like ischemia-induced proliferative retinopathy (Griggs, J., et al., Am. J. Pathol., 2002, 160(3), 1097-103).
[0008] The spatial relationship between the two aromatic rings of combretastatin, colchicine and similar drugs is an important structural feature that determines their ability to bind to tubulin (McGown, A. T., et al., a) Bioorg. Med. Chem. Lett., 1988, 8(9), 1051-6; b) Bioorg. Med. Chem. Lett., 2001, 11(1), 51-4).
[0009] Since '80s researchers have discovered that the selective introduction of fluorine into biologically active molecules exerts an influence on activity. Therefore, important endeavour in drug design has been described and a number of compounds incorporating fluorine as a bioisosteric replacement for hydrogen were reported (Giannini, G., Current Medicinal Chemistry, 2002, 9, 687-712).
SUMMARY OF THE INVENTION
[0010] It has now been found that without any modification of the cis-stilbene motif the introduction of the strongly electron-withdrawing fluorine atom in olefin bond allows the biological activity to increase or, in case of the same activity, to influence the pharmacodynamics activity.
[0011] Fluoro and bromofluoro stilbenes have been synthesized.
[0012] Accordingly, it is an object of the present invention a compound of formula (I)
wherein:
R 1 , R 2 and R 3 , which can be the same or different, are H, OMe, NO 2 , NHR′;
Z=H or halogen
X and Y, different each other, are halogen or H;
R═OH, OPO 3 Na 2 , OCH 2 OPO 3 Na 2 , OR′, NO 2 , NHR′;
R′═H, alkyl (C 1 -C 6 ), (COCHR″NH) n —H;
R″═H, an amino acid side chain, Ph;
n an integer comprised between 1 and 3;
their pharmaceutically acceptable salts, racemates and single enantiomers.
[0013] Other objects of the present invention are processes for the preparation of the compounds of the above Formula (I).
[0014] Another object of the present invention is the use of the compounds of Formula (I) as test compounds in a biological assay for microtubule polymerization.
[0015] The compounds of Formula (I) have antitubulin activity at least comparable to that of CA-4 ( J. Med. Chem, 2002, 45:1697-1711).
[0016] Another object of the present invention is the use of the compounds of Formula (I) as medicaments, in particular for the preparation of a medicament for treating pathological states which arise from or are exacerbated by cell proliferation.
[0017] A further object of the present invention are pharmaceutical compositions comprising at least a compound of Formula (I) as active ingredient in admixture with at least one pharmaceutically acceptable carrier and/or excipient.
[0018] These and other objects of the present invention shall be illustrated in detail also my means of Examples and Drawings, wherein, in the latter:
[0019] FIG. 1 : synthesis of difluorocombretastatin;
[0020] FIG. 2 : synthesis of difluoronitro- and difluoroamino-combretastatin;
[0021] FIG. 3 : synthesis of monofluorocombretastatin;
[0022] FIG. 4 : synthesis of difluorocombretastatin disodium-phosphate;
[0023] FIG. 5 : synthesis of mono-difluorocombretastatin disodium-oxymetil-phosphate;
[0024] FIG. 6 : synthesis of mono-difluoroaminocombretastatin aminoacid amide derivatives.
[0025] FIG. 7 : synthesis of bromofluorocombretastatin
[0026] It shall be understood by the skilled person that in the FIGS. 1-7 synthetic schemes are provided for the preferred compounds of the present invention, but the skilled reader will understand that these schemes are applicable to the whole range of the invention, just selecting the appropriate starting materials, depending on the meanings in Formula (I), and resorting to the general common knowledge for the obvious modifications of the reaction conditions and reactants.
DETAILED DESCRIPTION OF THE INVENTION
[0027] According to the present invention, halogen means fluoro, chloro and bromo.
[0028] According to the present invention, R″ is preferably the side chain of a natural amino acid, and in particular Ala, Asn, Asp, Cys, Gly, Gln, Glu, His, Ile, Leu, Lys, Met, Phe, Pro, Ser, Thr, Tyr, Try, Val.
[0029] Particularly preferred compounds are those of formula (I) wherein:
[0000] at least one of X and Y is halogen, R 1 -R 3 are methoxy, and R is hydroxy;
[0000] at least one of X and Y is halogen, R 1 -R 3 are methoxy, R is amino or substituted amino;
[0000] at least one of X and Y is halogen, R 1 -R 3 are different from methoxy, R is hydroxy;
[0000] Z is hydrogen or halogen;
[0000] R is OPO 3 Na 2 or OCH 2 OPO 3 Na 2 ;
[0000] R′ is (COCHR″NH) n —H.
[0030] Particularly preferred compounds are those wherein:
[0000] X═Y═F; R═OPO 3 Na 2 : difluorocombretastatin;
[0000] X═Y═F; R═NH 2 : difluoroaminocombretastatin;
[0000] X═H; Y═F; R═OPO 3 Na 2 : monofluorocombretastatin;
[0000] X═F; Y═H; R═OPO 3 Na 2 : monofluorocombretastatin;
[0000] X═H; Y═F; R═NH 2 : monofluoroaminocombretastatin;
[0000] X═F; Y═H; R═NH 2 : monofluoroaminocombretastatin.
[0000] X═Br; Y═F; R═OPO 3 Na 2 bromofluorocombretastatin
[0031] Processes for the preparation of the compounds of the present invention shall be described in details, by making reference to the synthetic schemes appended as Figures.
[0032] The compounds of the present invention can be prepared by conventional synthetic methods, however, in some preferred embodiments of the present invention, the starting compound is a compound of formula (I), wherein both X and Y are hydrogen.
[0033] A process for the preparation of compounds of Formula (I), wherein X and Y are both F comprises the following steps:
[0000] a) reaction of 1-bromo-1,2-difluoro-2-(4-methoxy-3-(protected OH)-phenyl)ethene with 3-R 1 -4-R 2 -5-R 3 -phenylboronic acid, and
[0000] b) restoring the 3-(protected OH) group.
[0034] For step a), 1-bromo-1,2-difluoro-2-(4-methoxy-3-(protected OH)-phenyl)ethene can be obtained by synthetic methods available in the art. For example, isovanillin, with OH group suitably protected, is transformed into 1-bromo-1,2-difluoro-2-(4-methoxy-3-(protected OH)-phenyl)ethene.
[0035] Isovanillin is a commercially available product, as well as the 3,4,5-trisubstituted-phenyl-boronic acid is commercially available, or can be obtained by conventional methods. Also many other mono-, di-, and tri-substituted-phenyl-boronic acids are commercially available. However, the starting materials can be obtained by conventional methods.
[0036] Reaction of step a) is carried out in a suitable reaction medium, for example an organic solvent, or a mixture of water and the solvent, in the presence of aqueous base, for example an alkaline carbonate. The use of a catalyst can be advisable, and a preferred example is Pd(Ph 3 P) 4 . The reaction temperature is selected according to the starting materials, the solvent and the catalyst used. Preferably, the reaction temperature is at the reflux temperature of the reaction medium.
[0037] Removal of the protecting moiety from the hydroxy group is absolutely conventional and is normally performed by the person skilled in the art. A preferred protecting group is found among commercially available organosilyloxy derivatives, for example tert-butyl-dimethyl-syliloxyphenyl. Removal of such groups is done with conventional methods.
[0038] A process for the preparation of compounds of Formula (I), wherein one of the X and Y is F and the other one is hydrogen, comprises the following steps:
[0000] a) bromofluorination of the compound of Formula (I), wherein X and Y are H, and
[0000] b) base-promoted HBr elimination.
[0039] This process is disclosed in Giannini, G., Gazz. Chim. It., 1997, 127, 545; Thakker D. R., et al., J. Org. Chem., 1989, 54, 3091.
[0040] Compounds of Formula (I), wherein one of the X and Y is F can be also prepared by a process comprising the following steps:
[0000] a) transformation of compound of Formula (I), wherein X and Y are H into the respective bromohydrin, and
[0000] b) base-promoted HBr elimination.
[0041] This process is disclosed in Giannini, G., Gazz. Chim. It., 1997, 127, 545; Thakker D. R., et al., J. Org. Chem., 1989, 54, 3091.
[0042] In alternative, compounds of Formula (I), wherein one of the X and Y is F can be prepared by a process comprising the following steps:
[0000] a) transformation of compound of Formula (I), wherein X and Y are H into the respective epoxide;
[0000] b) epoxide opening to give the respective bromohydrin, and
[0000] c) base-promoted HBr elimination, or in alternative,
[0000] d) epoxide opening to give the respective fluorohydrin, and
[0000] e) elimination of the opportune hydroxyl derivative.
[0043] This process is disclosed in Giannini, G., Gazz. Chim. It., 1997, 127, 545; Thakker D. R., et al., J. Org. Chem., 1989, 54, 3091.
[0044] Compounds of Formula (I), wherein one of the X or Y is F and the other is Br are prepared by a process comprising the following steps:
[0000] a) transformation of compound of Formula (I), wherein X and Y are H into the respective bromohydrin, and
[0000] b) base-promoted HBr elimination.
[0045] This process is disclosed in Giannini, G., Gazz. Chim. It., 1997, 127, 545; Thakker D. R., et al., J. Org. Chem., 1989, 54, 3091.
[0046] In a preferred embodiment, the starting compound is Combretastatin A (Formula I, R 1 , R 2 , R 3 ═OMe, X and Y═H, R═OH).
[0047] In alternative, the monofluorocombretastatin derivatives, wherein one of the X or Y is F, can be prepared by a total synthesis.
[0048] A process for the preparation of compounds of Formula (I), wherein X is Br and Y is F, is disclosed in Scheme 7.
[0049] Pharmaceutically acceptable salts are obtained with conventional methods reported in the literature and do not require any further description.
[0050] As above disclosed, the compounds of the present invention are useful as medicaments, and, due to their activity on tubulin site, they can be used for the preparation of a medicament for the treatment of pathological states which arise from or are exacerbated by cell proliferation.
[0051] An example of said pathological state is a tumour, and among them, both solid and haematic tumors can be treated, for example sarcoma, carcinoma, carcinoid, bone tumour, neuroendocrine tumour, lymphoid leukaemia, acute promyelocytic leukaemia, myeloid leukaemia, monocytic leukaemia, megakaryoblastic leukaemia and Hodgkin's disease.
[0052] In another aspect according to the present invention, said medicament is used for treating a pathological state caused by abnormal angiogenesis, such as, for example, tumour metastases; arthritic disease; diabetic retinopathy; psoriasis; chronic inflammatory diseases or arteriosclerosis.
[0053] In a further embodiment of the present invention, said medicament is used for treating a non-neoplastic disease, such as for example ischemia-induced proliferative retinopathy.
[0054] The pharmaceutical compositions will contain at least one compound of Formula (I) as an active ingredient, in an amount such as to produce a significant therapeutic effect. The compositions covered by the present invention are entirely conventional and are obtained with methods which are common practice in the pharmaceutical industry, such as, for example, those illustrated in Remington's Pharmaceutical Science Handbook, Mack Pub. N.Y .—latest edition. According to the administration route chosen, the compositions will be in solid or liquid form, suitable for oral, parenteral or intravenous administration. The compositions according to the present invention contain, along with the active ingredient, at least one pharmaceutically acceptable vehicle or excipient. These may be particularly useful formulation coadjuvants, e.g. solubilising agents, dispersing agents, suspension agents, and emulsifying agents.
[0055] The present invention shall now be further illustrated by means of Examples.
[0056] General Remarks: 1 H- and 13 C-NMR spectra were recorded in CDCl 3 solution as indicated, at 200 or 300 MHz, respectively. The chemical shift values are given in ppm and the coupling constants in Hz. Optical rotation data were obtained with a Perkin-Elmer model 241 polarimeter. Thin-layer chromatography (TLC) was carried out using Merck precoated silica gel F-254 plates. Flash chromatography was carried out using Macherey-Nagel silica gel 60, 230-400 mesh. Solvents were dried according to standard procedures, and reactions requiring anhydrous conditions were performed under nitrogen. Solutions containing the final products were dried with Na 2 SO 4 , filtered, and concentrated under reduced pressure using a rotatory evaporator.
[0057] Same abbreviation used in the experimental part: TBDMSiCl (tert-butyldimethylchlorosilane); Hex (Hexane); DAST (Diethylaminosulfur trifluoride); DIPEA (diisopropylethylamine); PyBroP (Bromo-tris-pyrrolidino-phosphonium-hexafluoro-phospate); TAEA (tris(2-aminoethyl)amine).
EXAMPLE 1
Synthesis of difluorocombretastatin (Scheme 1)
Synthesis of tert-butyl-dimethyl-sylil isovanillin (1)
[0058] To a solution of 6.09 g (40 mmol) of Isovanillin in 50 mL of CH 2 Cl 2 , were added 6.64 g of TBDMSiCl (44 mmol, 1.1 eq.) and 2.95 g (44 mmol, 1.1 eq) of Imidazole. The solution was stirred at room temperature for three hours and then washed with 0.5 M HCl. The crude product was purified on a silica gel column using Hexane/Ethyl Acetate 9:1, to give 9 g (33 mmol, 83%) of a colourless oil. Rf=0.27 (Hex./Ethyl Acetate 95:5)
[0059] MS (IS): [MH] + =267.2 [M+Na] + =289.2 (main peak)
[0060] 1 H NMR (300 MHz, CDCl 3 , δ): 0.2 (s, 6H, 2×CH 3 ), 1.0 (s, 9H, tBu), 3.9 (s, 3H, OCH 3 ), 6.9-6.95 (d, 1H, CH), 7.4 (s, 1H, CH), 7.45-7.5 (d, 1H, CH), 9.8 (s, 1H, CHO).
[0061] 13 C NMR (75 MHz, CDCl 3 , δ): −4.4; 18.6; 25.9; 55.6; 111.9; 120.0; 126.5; 130.0; 146.0; 157.1; 191.0.
Synthesis of 2,2-dibromo-2-fluoro-1-(4-methoxy-3-tert-butyl-dimethyl-syliloxyphenyl)ethanol (2)
[0062] A mixture of 2.66 g (10 mmol) of TBDMS-Isovanillin and 2.98 g (11 mmol, 1.1 eq) of CFBr 3 in 80 mL of Et 2 O/THF (1:1) was brought to T=−130° C.; 4.4 mL (11 mmol, 1.1 eq) of a 2.5 M BuLi solution in hexane was added to the mixture in 10 minutes. After two hours at T=−70° C., it was necessary to add 1.3 mL of BuLi solution and 0.3 mL of CFBr 3 to drive the reaction to completion.
[0063] The reaction was quenched with 60 mL of NH 4 Cl saturated solution and diluted with 20 mL of diethyl ether. The aqueous phase was back-extracted with 2×20 mL of diethyl ether, the organic fractions were collected and dried over anhydrous sodium sulfate and then purified on a silica gel column using Hexane/Ethyl Acetate 95:5 to give 3.1 g (6.8 mmol, 68%) of a waxy solid. Rf=0.5 (Hex./AcOEt 85:15).
[0064] MS (IS): [M+Na] + =479.1; 481.1; 483.1 (1:2:1) [M−1]−=457.2
[0065] 1 H-NMR (300 MHz, CDCl 3 , δ): 0.2 (s, 6H, 2×CH 3 ), 1.0 (s, 9H, tBu), 3.8 (s, 3H, OCH 3 ), 5.0 (d, 1H, CH, 3JHF=10 Hz), 6.8-6.9 (d, 1H, CH ar ), 7.0-7.1 (t, 2H, 2×CH).
[0066] 13 C-NMR (75 MHz, CDCl 3 , δ): 4.4; 18.6; 25.9; 55.6; 82.7; 83.0; 101.3; 105.6; 111.5; 121.3; 122.2; 127.5; 144.9; 152.2.
Synthesis of 1,1-dibromo-1,2-difluoro-2-(4-methoxy-3-tert-butyl-dimethyl-syliloxyphenyl)ethane (3)
[0067] (Diethylamino)sulfur trifluoride 1.5 mL (11.2 mmol; 1.8 eq) in 10 mL CH 2 Cl 2 was added to a solution of 2.84 g (6.2 mmol) alcohol DA 59 in 14 mL CH 2 Cl 2 at −78° C. The reaction mixture was allowed to warm up to 0° C. over a period of 2 h, quenched with 25 mL of NaHCO 3 saturated solution and diluted with 20 mL of diethyl ether. The organic phase was dried over anhydrous sodium sulfate and purified on preparative TLC using Hexane/Ethyl Acetate 98:2 to give 1.8 g (4 mmol; 64.5%) of a yellow oil. Rf=0.43 (Hex./AcOEt 97:3).
[0068] MS (IS): [M+Na] + =483.1; 485.1; 487.1 (1:2:1)
[0069] 1 H-NMR (300 MHz, CDCl 3 , δ): 0.2 (s, 6H, 2×CH 3 ), 1.0 (s, 9H, tBu), 3.8 (s, 3H, OCH 3 ), 5.6 (dd, 1H, CH, 3JHF=10 Hz, 2JHF=44 Hz), 6.8-6.9 (d, 1H, CH ar ), 7.0-7.1 (t, 2H, 2×CH).
[0070] 13 C-NMR (75 MHz, CDCl 3 , δ): -4.4; 18.6; 25.9; 55.7; 96; 82.5; 82.8; 95.8; 96.1; 98.3; 98.7; 111.5; 121.1; 121.2; 122.4; 122.5; 124.4; 144.9; 152.8.
Synthesis of 1-bromo-1,2-difluoro-2-(4-methoxy-3-tert-butyl-dimethyl-syliloxyphenyl)ethene (4)
[0071] Step 1. Preparation of the tetramethylpiperidide solution. 1.9 mL (11.7 mmol; 3 eq.) of 2,2,6,6-tetramethylpiperidine was dissolved in 4 mL of anhydrous THF; the solution was cooled to −80° C. and then 3.9 mL (9.8 mmol; 2.5 eq) of a 2.5 M solution BuLi in Hexane were added. The mixture was stirred for 2 h at 0° C.
[0072] Step 2. Dehydrobromination. A solution of 1.8 g (3.9 mmol) of DA 62 in 5 mL of anhydrous THF was added to the tetramethyl piperidide solution previously cooled down to −100° C. After 1 h the reaction was washed with 10 mL HCl 0.1 N, the aqueous phase was back-extracted with 2×10 mL Et 2 O. The organic extracts were collected and dried over anhydrous sodium sulfate and then purified on preparative silica plates with n-Hexane/Ethyl acetate 97:3 to give 857 mg (2.3 mmol; 59%) of product. Rf=0.8 in Hex./Acetone 8:2.
[0073] MS (IS): [M+Na] + =401.4; 403.4 (1:1)
[0074] 1 H-NMR (300 MHz, CDCl 3 , δ): 0.2 (s, 6H, 2×CH 3 ), 1.0 (s, 9H, tBu), 3.8 (s, 3H, OCH 3 ), 6.8-6.9 (d, 1H, CH), 7.1-7.15 (d, 1H, CH), 7.2-7.3 (dd, 1H, CH).
[0075] 13 C-NMR (75 MHz, CDCl 3 , δ): -4;4; 18.6; 25.9; 55.7; 111.7; 120.5; 121.9; 122.0; 122.1; 124.3; 144.7; 151.9.
Synthesis of (Z)-1,2-difluoro-1-(3,4,5-trimethoxyphenyl)-2-(4-methoxy-3-tert-butyl-dimethyl-syliloxyphenyl)ethene (5)
[0076] A mixture of 750 mg (1.98 mmol; 1 eq.) of DA 63, 1.260 g (5.94 mmol; 3 eq.) of 3,4,5-trimethoxyphenyl-boronic acid, 4 mL of Na 2 CO 3 2M aqueous solution and 104 mg (0.09 mmol; 0.05 eq.) of Pd(Ph 3 P) 4 in 20 mL toluene was refluxed overnight. The solution was then cooled down to room temperature, dried over anhydrous sodium sulfate and the crude mixture was passed through a short silica gel column to remove catalyst. The crude product was purified by chromatography on silica gel plates with Hexane/Acetone 8:2 to give 740 mg (1.6 mmol; 81%) of an oil. Rf=0.36 in Hex./Acetone 8:2.
[0077] MS (IS): [M+NH 4 ] + =484.1; [2M+NH 4 ] + =950.1
[0078] 1 H-NMR (300 MHz, CDCl 3 , δ): 0.5 (s, 6H, 2×CH 3 ), 1.0 (s, 9H, tBu), 3.65 (s, 6H, 2×OCH 3 ), 3.8 (s, 3H, OCH 3 ), 3.9 (s, 3H, OCH 3 ), 6.5-6.7 (t, 2H, 2×CH), 6.75-7.0 (dq, 3H, 3×CH).
[0079] 13 C-NMR (75 MHz, CDCl 3 , δ): −4.6;1; 18.6; 25.8; 25.9; 55.7; 56.2; 56.3; 56.4; 61.0; 61.1; 103.4; 105.5; 111.9; 121.0; 122.5; 122.6; 123.8; 145.1; 153.3; 153.8.
Synthesis of (Z)-1,2-difluoro-1-(3,4,5 trimethoxyphenyl)-2-(3-hydroxy-4-methoxyphenyl)ethene (ST2303]
[0080] A 1M solution of Tetrabutylammonium fluoride in THF (9.4 mmol; 2 eq.) was dropped, at 0° C. and under inert atmosphere, to a solution of 2.2 g (4.7 mmol) of stilbene DA 64 in 10 mL of anhydrous THF (stored on molecular sieves). The reaction mixture was allowed to warm up to room temperature and after 4 h the reaction was complete. The mixture was poured into ice and the aqueous phase extracted with Et 2 O (3×20 mL); the organic extracts were collected and dried over anhydrous Na 2 SO 4 .
[0081] The crude mixture was purified by chromatography on silica gel with n-Hexane/Acetone 8:2 to give 1.361 g (3.9 mmol; 83%).
[0082] M.p.=135° C.
[0083] MS (IS): [M+H] + =353.0
[M+NH 4 ] + =370.0 [M+Na] + =375.0 [M−1] − =351.0
[0087] 1 H NMR (300 MHz, CDCl 3 , δ): 3.75 (s, 6H, 2×OCH 3 ), 3.8 (s, 3H, OCH 3 ), 3.9 (s, 3H, OCH 3 ), 5.6 (broad, 1H, OH), 6.6 (s, 2H, 2×CH), 6.75-6.8 (d, 1H, CH), 6.85-6.9 (dd, 1H, CH), 7.0 (dd, 1H, CH).
[0088] 13 C NMR (75 MHz, CDCl 3 , δ): 56.2; 61.1; 105.3; 105.4; 110.4; 114.5; 114.6; 121.1; 123.1; 123.6; 125.1; 125.6; 142.1; 145.6; 147.3; 147.5; 147.6; 153.1.
[0089] 19 F NMR (282 MHz, CDCl 3 , δ): −126.2 (d, J FF =14.8 Hz), −130.3 (d, J FF =14.8 Hz).
EXAMPLE 2
Synthesis of difluoronitro- and difluoroaminocombretastatin (Scheme 2)
Synthesis of 2,2-dibromo-2-fluoro-1-(3-nitro-4-methoxy-phenyl)ethanol (7)
[0090] A mixture of 978 mg (5.4 mmol) of 3-nitro-4-methoxy-benzaldehyde(6) and 1.6 g (5.9 mmol, 1.1 eq) of CFBr 3 in 40 mL of Et 2 O/THF (1:1) was brought to T=−130° C.; 3.7 mL (5.9 mmol, 1.1 eq) of a 1.6 M BuLi solution in hexane was added to the mixture in 10 minutes.
[0091] The reaction was quenched with 25 mL of NH 4 Cl saturated solution and diluted with 20 mL of diethyl ether. The aqueous phase was back-extracted with 2×20 mL of diethyl ether, the organic fractions were collected and dried over anhydrous sodium sulfate and then purified on a silica gel column using Hexane/Ethyl Acetate 95:5 to give 1.146 g (3.1 mmol, 57.4%) of a yellow oil. R f =0.53 (Hex./AcOEt 6:4).
[0092] MS (IS): [M−1] − =371.8
[M+AcO] − =431.7
[0094] 1 H-NMR (300 MHz, CDCl 3 , δ): 3.2 (bs, 1H, OH), 4.0 (s, 3H, OCH 3 ), 5.1-5.2 (m, 1H, CH), 7.05-7.15 (d, 1H, CH ar ) 7.7-7.8 (d, 1H, CH ar ), 8.05 (s, 1H, CH ar ).
[0095] 13 C-NMR (75 MHz, CDCl 3 , δ): 56.9; 81.5; 81.8; 98.9; 100.3; 104.6; 113.3; 126.3; 127.3; 134.3; 153.8.
Synthesis of 1,1-dibromo-1,2-difluoro-2-(3-nitro-4-methoxy-phenyl)ethane (8)
[0096] (DAST 730 μL (5.58 mmol; 1.8 eq) in 5 mL CH 2 Cl 2 was added to a solution of 1.146 g (3.1 mmol) of the alcohol (7) in 7 mL CH 2 Cl 2 at −78° C. The reaction mixture was allowed to warm up to 0° C. over a period of 2 h, quenched with 15 mL of NaHCO 3 saturated solution and diluted with 20 mL of diethyl ether. The organic phase was dried over anhydrous sodium sulfate and purified by chromatography on SiO 2 using Hexane/Ethyl Acetate 7:3 to give 960 mg (2.6 mmol; 84%) of a yellow oil. R f =0.493 (Hex./AcOEt 7:3)
[0097] 1 H-NMR (300 MHz, CDCl 3 , δ): 4.0 (s, 3H, OCH 3 ), 5.55-5.80 (dd, 1H, CH,), 7.1-7.2 (d, 1H, CH ar ), 7.7-7.8 (d, 1H, CH ar ), 8.1 (s, 1H, CH ar ).
[0098] 13 C-NMR (75 MHz, CDCl 3 , δ): 29.9; 56.9; 94.4; 94.8; 97.0; 97.2; 97.4; 113.6; 124.1; 124.4; 126.2, 134.0, 139.4; 154.5.
Synthesis of (E)-1-bromo-1,2-difluoro-2-(3-nitro-4-methoxy-phenyl)ethene (9)
[0099] Step 1 Preparation of the Tetramethyl-piperidide solution. 1.3 mL (7.8 mmol; 3 eq.) of 2,2,6,6-tetramethyl-piperidine was dissolved in 3 mL of anhydrous THF.; the solution was cooled to −80° C. and then 3.9 mL (9.8 mmol; 2.5 eq) of a 2.5 M solution BuLi in Hexane were added. The mixture was stirred for 2 h at 0° C.
[0100] Step 2 Dehydrobromination. A solution of 960 mg (2.6 mmol) of (8) in 5 mL of anhydrous THF was added to the tetramethyl piperidide solution previously cooled down to −100° C. After 1 h the reaction was washed with 10 mL HCl 0.1 N, the aqueous phase was back-extracted with 2×10 mL Et 2 O. The organic extracts were collected and dried over anhydrous sodium sulfate and then purified on silica gel with n-Hexane/Ethyl acetate 8:2 to give 100 mg (0.34 mmol; 13%) of product. R f =0.36 in Hex./Acetone 8:2.
[0101] 1 H-NMR (300 MHz, CDCl 3 , δ): 4.0 (s, 3H, OCH 3 ), 7.1-7.2 (d, 1H, CH ar ), 7.8-7.9 (d, 1H, CH ar ), 8.2 (s, 1H, CH ar ).
[0102] 13 C-NMR (75 MHz, CDCl 3 , δ): 57.0; 113.6; 113.8; 120.5; 120.9; 124.6; 125.1; 125.4; 126.2; 126.3; 128.8; 129.3; 133.3; 134.0; 141.1; 141.3; 144.4; 144.6; 154.0.
Synthesis of (Z)-1,2-difluoro-1-(3,4,5-trimethoxyphenyl)-2-(3-nitro-4-methoxy-phenyl)ethene (10)
[0103] A mixture of 90 mg (0.31 mmol; 1 eq.) of (9), 198 mg (0.93 mmol; 3 eq.) of 3,4,5-trimethoxyphenyl-boronic acid, 0.6 mL of Na 2 CO 3 2M aqueous solution and 19 mg (0.0016 mmol; 0.05 eq.) of Pd(Ph 3 P) 4 in 4 mL toluene was refluxed for 2.5 h. The solution was then cooled down to room temperature, dried over anhydrous sodium sulfate and the crude mixture was passed through a short silica gel column to remove catalyst. The crude product was purified by chromatography on silica gel with Hexane/Acetone 8:2 to give 57 mg (0.15 mmol; 48%) of a yellow oil. R f =0.17 in Hex./Acetone 8:2.
[0104] MS (IS): [M+H] + =382.4; [M+NH 4 ] + =399.3.
[0105] 1 H-NMR (300 MHz, CDCl 3 , δ): 3.75 (s, 6H, 2×OCH 3 ), 3.85 (s, 3H, OCH 3 ), 4.0 (s, 3H, OCH 3 ), 6.6 (s, 2H, 2×CH ar ), 6.95-7.05 (dq, 1H, CH ar ), 7.4-7.5 (d, 1H, CH ar ), 7.9 (s, 1H, CH ar ).
[0106] 13 C-NMR (75 MHz, CDCl 3 , δ): 29.9; 56.4; 56.9; 61.2; 105.9; 113.6; 125.1; 133.3; 153.7.
Synthesis of (Z)-1,2-difluoro-1-(3,4,5-trimethoxyphenyl)-2-(3-amino-4-methoxyphenyl)ethene (ST2578)
[0107] To a solution of 40 mg (0.105 mmol) of nitro-stilbene (10) in AcOH (5 mL) was added zinc powder 75 mg (1.15 mmol; 11 eq.); the mixture was stirred at room temperature for 1.5 h. The reaction mixture was filtered over Celite and the filtrate evaporated to dryness.
[0108] The crude product was purified by chromatography on silica gel with CH 2 Cl 2 , then on preparative HPLC to give 32 mg (0.091 mmol; 87%) of a white solid. R f =0.31 in CH 2 Cl 2 .
[0109] A small portion (4 mg) of the trifluoroacetate salt obtained from the prep. HPLC was passed through an ion-exchange column IRA402*Cl − to give 3 mg of the corresponding HCl salt (ST2578).
[0110] MS (IS): [M+H] + =352.3; [2M+H] + =703.1.
[0111] 1 H-NMR (300 MHz, CDCl 3 , δ): 3.7 (s, 6H, 2×OCH 3 ), 3.85 (s, 3H, OCH 3 ), 4.0 (s, 3H, OCH 3 ), 6.6 (s, 2H, 2×CH ar ), 6.7-6.8 (t, 1H, CH ar ), 6.85-6.90(d, 1H, CH ar ), 6.95 (s, 1H, CH ar ).
[0112] 13 C-NMR (75 MHz, CDCl 3 , δ): 29.9; 55.9; 56.3; 56.5; 61.1; 105.0; 105.4; 110.5; 116.6; 121.6; 122.8; 123.1; 125.5; 125.9; 133.0; 143.1; 143.9; 146.6; 149.5; 153.3; 153.7.
EXAMPLE 3
Synthesis of monofluorocombretastatins (Scheme 3)
[0113] Convenient approaches to the synthesis of both of the regioisomeric monofluorocombretastatins, starting from the natural CA-4, are the following:
[0000] A) Bromofluorination of the CA-4, followed by base-promoted HBr elimination (Giannini, G., Gazz. Chim. It., 1997, 127, 545; Thakker D. R., et al., J. Org. Chem., 1989, 54, 3091).
[0000] B) Fluorination, by DAST, of the bromohydrin obtained from the CA-4, followed by base-promoted HBr elimination.
[0000] C) Synthesis of the epoxide from the CA-4, epoxide opening to obtain:
[0000]
the bromohydrin and to continue as point B), or
the fluorohydrin followed by elimination of opportune hydroxyl derivative.
[0116] Alternatively, the monofluorocombretastatins can be obtained by total synthesis according to Scheme 3a
[0117] Key intermediates for this approach can be prepared as exemplified below for the 3,4,5-trimethoxybenzaldheyde.
Synthesis of (E/Z)-1-fluoro-2-(3,4,5-trimethoxyphenyl)ethene
[0118] 1.63 g (6 mmol, 1.2 eq,) of CFBr 3 have been added to a solution of 2.9 g (11 mmol, 2.2 eq.) of Ph 3 P in 30 mL CH 2 Cl 2 kept in an ice bath. After 30 minutes at this temperature, 980 mg of 3,4,5-trimethoxybenzaldheyde have been added to the mixture and the reaction has been allowed to warm up to room temperature over 2 hours. The mixture has been diluted with 50 mL CH 2 Cl 2 and washed with brine. The crude product has purified by silica gel chromatography with Hexane(EtOAc 9:1 to give 758 mg (2.6 mmol; 52%) of a 53:47 Z/E mixture of the desired product as a colourless oil. Rf=0.23 in Hex/EtOAc 9:1.
[0119] MS (IS): [M+H] + =291.0/293.0
[0120] (Z)-Isomer (obtained by preparative HPLC)
[0121] 1 H-NMR (200 MHz, CDCl 3 , δ): 3.88 (s, 3H, OCH 3 ), 3.89 (s, 6H, 2×OCH 3 ), 6.66 (d, J=15.4 Hz, 1H, CH), 6.75 (s, 2H, 2×CH ar ).
[0122] (E)-Isomer (obtained by preparative HPLC)
[0123] 1 H-NMR (200 MHz, CDCl 3 , δ): 3.87 (s, 9H, 3×OCH 3 ), 5.93 (d, J=32.2 Hz, 1H, CH), 6.65 (s, 2H, 2×CH ar ).
[0124] This intermediates can undergo a classical Suzuki-like coupling with the proper boronic acid. (see Scheme 3a)
EXAMPLE 4
Synthesis of Disodium-Phosphate Prodrug of Difluorocombretastatin (Scheme 4)
[0125] A typical procedure for the synthesis of the disodium-phosphate prodrug is well known in the literature (Pettit, G. R., et al., Anti - Cancer Drug Design 1998, 13, 183-191) and is intended to be generally applicable to all the compounds here described, possessing a free phenolic moiety. As an example, the synthesis of the disodium-phosphate prodrug of compound (6) is here reported.
Synthesis of (Z)-1,2-difluoro-1-(3,4,5-trimethoxyphenyl)-2-(3-hydroxy-4-methoxyphenyl)ethene o-dibenzyl-phosphate (11)
[0126] To a solution of 30 mg of (6) (0.09 mmol) in 1 mL dry CH 3 CN, cooled down to −25° C., 44 μL (0.45 mmol; 5 eq.) CCl 4 were added. After 5 minutes mixing 33 μL (0.19 mmol; 2.1 eq.) diisopropyl-ethyl amine, 1 mg (0.009; 0.1 eq.) DMAP and 29 μL of di-benzyl phosphite were added to the solution and the reaction mixture was stirred for 1.5 h at −10° C.
[0127] The reaction was quenched by pouring 5 mL KH 2 PO 4 0.5 M; the aqueous phase was washed with AcOEt (3×10 mL) and the organic phase was back-extracted with 10 mL H 2 O and then with 10 mL NaCl saturated solution. The crude mixture was purified by silica gel chromatography with Hexane/AcOEt 6:4 to give 55 mg of a colourless oil (0.088; 98%). R f =0.32 in Hex./AcOEt 6:4
[0128] MS (IS): [M+H] + =613.4; [M+NH 4 ] + =630.2; [M+Na] + =635.0.
[0129] 1 H-NMR (300 MHz, CDCl 3 , δ): 3.70 (s, 6H, 2×OCH 3 ); 3.80 (s, 3H, OCH 3 ); 3.85 (s, 3H, OCH 3 ); 5.65 (s, 2H, CH 2 ); 5.70 (s, 2H, CH 2 ); 6.55 (s, 2H, 2×CHar.); 6.80-6.85 (d, 1H, CHar.); 7.10-7.15 (dd, 1H, CHar.); 7.25 (s, 1H, CHar.); 7.35-7.45 (m, 10H, CHar.).
[0130] 13 C-NMR (75 MHz, CDCl 3 , δ): 29.6; 29.9; 56.1; 56.3; 56.4; 61.1; 70.1; 70.3; 104.3; 105.4; 106.4; 109.1; 112.6; 115.1; 121.7; 125.0; 126.6; 128.1; 128.2; 128.8; 128.9; 129.2; 130.9; 132.3; 135.7; 145.5; 153.2; 153.4.
Synthesis of (Z)-1,2-difluoro-1-(3,4,5-trimethoxyphenyl)-2-(3-hydroxy-4-methoxyphenyl)ethene o-disodium phosphate [ST2493]
[0131] To a solution of 50 mg (0.08 mmol) of (11) in 1.5 mL dry CH 3 CN in a three-necked round-bottom flask and under an Ar atmosphere, 24 mg (0.16 mmol; 2 eq.) of NaI were added. The mixture was stirred at room temperature for 10 minutes and then a solution of 20 μL (CH 3 ) 3 SiCl (0.16 mmol; 2eq.) in 1 mL CH 3 CN was dropped in.
[0132] After 1.5 h one equivalent of NaI and one equivalent of (CH 3 ) 3 SiCl were added to complete the reaction. Water (just enough to dissolve the salts) was added and the pale yellow colour removed by the addition of 10% aq. Na 2 S 2 O 3 (1 mL). The organic phase was separated and the aqueous phase extracted with AcOEt (4×4 mL). The combined organic extracts were concentrated to give a yellow waxy solid.
[0133] The solid was dissolved in 1.5 mL dry MeOH (stored on molecular sieves) and 9 mg (0.16 mmol; 2 eq.) of sodium methoxide were added and the solution stirred at room temperature for 12 h. The methanol was removed in vacuo and the solid recrystallized from water-acetone and methanol-acetone to give 35 mg (0.073 mmol; 91%) of compound (ST2493) as a white solid.
[0134] 1 H-NMR (200 MHz, D 2 O, δ): 3.60 (s, 6H, 2×OCH 3 ); 2.70 (s, 3H, OCH 3 ); 3.8 (s, 3H, OCH 3 ); 6.70 (bs, 2H, 2×CHar.); 6.85 (bs, 2H, 2×CHar.); 7.55 (s, 1H, CHar.).
EXAMPLE 5
Synthesis of disodium mono difluorocombretastatin-4-O-methyloxyphosphate [12]
[0135] The prodrug 12 were prepared by the route described in Scheme 5.
[0136] Typical methyloxy-phosphorylation method was first treated the phenolic residue with sodium hydride followed by protected chloromethyl phosphate prepared as a described method [Mantyla A. et al. Tetrahedron Lett. 2002, 43, 3793-4). The protecting group was removal by a saturated EtOAc/HCl solution, followed by a disodium salt preparation in NaOH/H 2 O solution.
EXAMPLE 6
Synthesis of mono-difluoroaminocombretastatin aminoacid amide derivatives [13]
[0137] Starting with aminostilbene derivatives, the coupling with aminoacids has been produced by Fmoc route, followed by cleavage of the α-amino protecting group [G. R. Pettit et al., J. Med. Chem 2002, 46, 525-31], according to Scheme 6.
EXAMPLE 7
Synthesis of bromofluoroaminocombretastatin [14]
[0138] According to procedure in Scheme 7, have been isolated, after flash chromatographic separation, the two isomers (E and Z) of the bromofluorocombretastatin.
[0000] Cell Culture and Cytotoxicity Assay
[0139] Primary cultures of bovine microvascular endothelial cells (BMEC) were obtained from bovine adrenal glands as described by Folkman (Folkman J., Haudenschild C. C., Zetter B. R. Long - term culture of capillary endothelial cells. Proc. Natl. Acad. Sci. USA, 1979 October; 76(10): 5217-21). BMEC were maintained in DMEM supplemented with 20% fetal calf serum (FCS), 50 units/ml heparin (Sigma, St. Louis, Mo.), 50 μg/ml bovine brain extract, 100 units/ml gentamycin. HUVEC (Human umbilical vein endothelial cells) were obtained from BioWhittaker (Walkersville, Md.) and grown in EGM-2 (BioWhittaker). EA-hy 926 cell line, a HUVEC-adenocarcinoma immortalized cell hybrid, was obtained from the Dipartimento di Scienze Biomediche e Oncologia Umana (Universita di Bari, Italy), and cultured in DMEM supplemented with 10% serum and 50 μg/ml gentamycin sulfate.
[0140] The following cell lines were purchased from ATCC and cultured according to manufacturer's instructions: NCIH460 human lung carcinoma, MeWo human melanoma, MES-SA human uterine sarcoma and HCT116 human colorectal carcinoma. HT-29 human colon adenocarcinoma cells and A2780 human ovarian carcinoma, obtained from Istituto Nazionale Tumori (Milan, Italy), were grown in RPMI 1640 (GIBCO) containing 10% fetal bovine serum (GIBCO) and 50 μg/ml gentamycin sulfate.
[0141] To test the effects of ST2303 on growth, cells were seeded in 96-well tissue culture plates (Corning) at approximately 10% confluence and were allowed to attach and recover for at least 24 h. Varying concentrations of the compound were then added to each well. The plates were incubated for 24 h and then washed before incubating them for additional 48 h. The number of surviving cells was then determined by staining with sulforhodamine B as described by Skehan et al. (1990). ST2303 inhibitory concentration 50 (IC 50 )±SD on different cell lines, evaluated by “ALLFIT” computer program, are shown in Table 1.
TABLE 1 (ST2303) Cell line IC 50 ± SE (nM) BMEC 1 ± 0.5 HUVEC 1 ± 0.3 EAHY.926 5 ± 0.5 NCI-H460 3 ± 0.005 HT29 >200 MeWo 3.6 ± 0.0003 A2780 3 ± 0.001 MES-SA <1 HCT 116 2.2 ± 0.05
Tumor Growth Evaluation
[0142] NCI-H460 human lung carcinoma from in vitro cell cultures were injected s.c. (3×10 6 cells/100 μl/mouse) into the right flank of CD-1 nude mice. Four days after tumor implant mice started to be treated with ST2493 at the dose of 50 mg/kg intraperitoneally according to the following schedule: qdx5/w/3wks. CA-4P (combretastatin A-4 P) at the same dose was used as positive control.
[0143] All animals were weighed during the whole treatment period, in order to adjust the volume of drug administration and to record the percent of body weight loss due in the course of treatment.
[0144] In a following experiment with the same animal model ST2493 (prodrug of ST2303) was administered intravenously at the doses of 25 and 50 mg/kg according to a q2dx6 schedule.
[0145] Tumor growth was assessed by twice a week measurements of the shortest (width) and the longest (length) diameters of each tumor by a Vernier caliper and the antitumor activity was evaluated in terms of percent inhibition of tumor growth. Tumor volume (or tumor weight*) was calculated according to the following formula using caliper measurements: tumor volume or TV (mm 3 )=[length (mm)×width (mm) 2 ]/2.
[0146] Tumor volume inhibition percent (% TVI) was calculated according to the equation: 100−[(mean tumor volume of treated group/mean tumor volume of control group)×100]. A P value≦0.05 was considered statistically significant.
[0147] Results, reported in Table 2, show that both intraperitoneal and intravenous administration of ST2493 determined a significant TVI compared to vehicle. In the intraperitoneal treatment the comparison of ST2493 with the same dose of CA-4P demonstrated a significant difference between the two compounds (p=0.0095 at day 11 and p=0.0180 at day 28, Mann Whitney's test).
TABLE 2 % TVI Days after cell % injection Treatment n BWL mortality 11 28 Vehicle (saline) 8 0 0/8 / / ST2493 i.p. 8 8 0/8 68** 73*** 50 mg/kg CA-4P i.p. 8 3 0/8 47** 61*** 50 mg/kg ST2493 i.v. 8 8 0/8 63** 64*** 25 mg/kg ST2493 i.v. 8 8 0/8 73** 73** 50 mg/kg *P < 0.05, **P < 0.01, ***P < 0.001 vs vehicle (Mann Whitney's test)
Tubulin Polymerisation Inhibition Test
[0148] The tubulin polymerisation test was performed by CytoDINAMIX Screen™. Turbidity from tubulin polimerisation was measured with a Victor2 from Wallac. HTS-tubulin was diluted to 3 mg/ml in buffer PEM [100 mM PIPES (pH 6.9), 1 mM EGTA and 1 mM MgCl 2 ] containing 1 mM GTP (GPEM) plus 5% glycerol, and kept on ice. Aliquots of this solution was then placed at 37° C. in presence of taxol (3 μM) or colcemid (3 μM) or combretastatin (ST1986) or compounds to examinate, and absorbance was measured at 340 nm. The IC 50 values were determined by non-linear regression analysis using “Prism GraphPad” software.
[0149] The value indicated in Table 3 is the mean of 3 independent determinations.
TABLE 3 Compound IC50 ± SE (μM) ST2303 7.7 ± 0.12 ST1986 14.4 ± 5.8
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The present invention is related to new derivatives of Combretastatin, of Formula
obtained by total synthesis. The strategy developed for each of the compounds is to i) replace a halogen (i.e. fluorine atom) to hydrogen on olefinic bound; ii) replace an aromatic ring in a natural product with an amino-aromatic ring. Said compounds recognize and bind the tubulin site: are useful for treating pathological states which arise from or are exacerbated by cell proliferation—as anticancer and/or antiangiogenic activity, in a mammal—to pharmaceutical compositions comprising these compounds.
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CLAIM OF PRIORITY
This application is a nonprovisional of and claims the priority benefit of commonly owned, U.S. Provisional Patent Application No. 61/737,273, to John Gerling et al., filed Dec. 14, 2012, and entitled “APPARATUS AND METHOD FOR OPTICAL INSPECTION, MAGNETIC FIELD AND HEIGHT MAPPING” the entire disclosures of which are incorporated herein by reference.
FIELD OF THE INVENTION
Embodiments of the present invention relate to metrology systems employed in fabrication processes, and more particularly, to an apparatus and a method for obtaining optical images, magnetic field and height topology maps for an electromagnet or permanent magnet.
BACKGROUND OF THE INVENTION
Monitoring and evaluation of fabrication processes on the circuit structures and other types of structures is necessary to ensure the manufacturing accuracy and to ultimately achieve the desired performance of the finished electronic device. With the development trend in miniature devices, the ability to examine microscopic structures and to detect microscopic defects becomes crucial to the fabrication processes.
Various technologies and methods of defect inspection on patterns or structures formed on semiconductor wafers or magnetic arrays have been developed and employed with varying degrees of success. For example, optical inspection methods employ optical inspection tools such, as an optical microscope, the inspect pattern shapes for defects. This type of device usually involves collecting radiation emitted from a target or scattered by a target from an incident beam of radiation directed at the structure. The collected radiation is converted to signals that can be measured or used to form an image. Such measurements or images can be used to determine various characteristics, such as the profile of the structure. Additionally, for wafer topography, electric sensors, such as capacitive sensors, have been employed to measure variations in substrate height. Such sensors detect changes in capacitance due to variations in topography as a sensor element is scanned across a target. The height of the sensor is typically controlled by a height transducer such as a piezoelectric element, which keeps the sensor element at a fixed height above the target structure. Changes in the signals that drive the height transducer can be analyzed to determine the profile of the structure.
With respect to magnetic samples, magnetic microscopy has been widely used in many areas of research for imaging and characterizing the samples. Suitable applications for the magnetic microscope include failure analysis, fault isolation, inspection of semiconductor integrated circuit, manufacturing monitoring and other biological, chemistry, physics and materials research applications. Specifically, many physical objects (e.g., conductors or semiconductors) generate magnetic fields near the objects surfaces when a current flows inside them. The magnetic microscope can obtain images of the magnetic fields by scanning a magnetic sensor on the surface of the object of interest. With the images of the magnetic fields, it is possible to reconstruct the path followed by the currents and consequently localize any defects. Additionally, the magnetic field is not perturbed by non-ferromagnetic materials, and thus, a map of the currents may be produced without de-processing the device. Accordingly, it avoids the risk of losing the defect by de-packaging the component in the localization stage. There are currently a number of techniques for imaging magnetic fields at surfaces. The conventional scanning magnetic microscope has a microscopic field sensor, typically a superconducting quantum interference device (SQUID), a Hall probe or simply a magnetic tip. This type of microscope scans the magnetic sensor relative to a sample to obtain a local field image. The magnetic sensor is typically controlled by a magnetic transducer such as a piezoelectric element.
It is within this context that aspects of the present disclosure arise.
SUMMARY
According to aspects of the present disclosure, a system comprises an optical inspection tool configured to provide image information of a sample, a magnetic sensor configured to provide magnetic field information of the sample, and a height sensor configured to provide height information of the sample. The optical inspection tool, the magnetic sensor and the height sensor are mounted to a system head. A stage is configured to hold the sample. The stage and system head are configured to move relative to each other. The stage includes one or more fiducial features for determining relative positions of the optical inspection tool, the magnetic sensor and the height sensor.
The system may further include a processor coupled to the optical inspection tool, the magnetic sensor, and the height sensor. The processor may be configured to collect the image information, the magnetic field information and the height information of the sample and use alignment information from the one or more fiducial features to determine one or more relative offsets between two or more of the optical inspection tool, the magnetic sensor, and the height sensors.
The processor may be configured to use the or more relative offsets to obtain magnetic field and sample height information at a given position on the sample
In some implementations, the optical inspection tool is an optical microscope, scanning capacitance microscope or scanning electron microscope.
In some implementations, the magnetic sensor is a Hall probe, magnetoresistive sensor, giant magnetoresistance sensor (GMR) or magneto optical Kerr effect (MOKE).
In some implementations, the height sensor is a capacitive sensor, laser interferometry, inductive sensor, drop gauge, atomic force microscope (AFM), scanning tunneling microscope (STM) or stylus profilometer.
In some implementations, the magnetic sensor and the height sensor are provided in a bracket mounted on the system head.
According to certain aspects of the disclosure, a method comprises imparting relative movement between a stage which holds a sample and a system head. An optical inspection tool, a magnetic sensor and a height sensor are mounted to the system head. Relative positions of the optical inspection tool, the magnetic sensor and the height sensor are determined with one or more fiducial features on the stage.
The method may further include imparting relative movement between a stage which holds a sample and a system head. An optical inspection tool, a magnetic sensor and a height sensor are mounted to the system head. Relative positions of the optical inspection tool, the magnetic sensor and the height sensor are determined with one or more fiducial features on the stage.
The method may also further include acquiring image information of the sample with the optical inspection tool; acquiring magnetic field information of the sample with the magnetic sensor; acquiring height information of the sample with the height sensor; and using the or more relative offsets to obtain magnetic field and sample height information at a given position on the sample
In some implementations of the method, the magnetic sensor and the height sensor are provided in a bracket mounted on the system head.
In some implementation of the method, the calibration device includes an optical calibration slide having features of known dimension for position or dimensional calibration for the optical inspection tool.
In some implementation of the method, the calibration device includes a magnetic calibration piece having a permanent magnet fixed underneath the magnetic calibration piece, wherein the magnetic calibration piece has a slit where magnetic flux of the permanent magnet leaks through.
BRIEF DESCRIPTION OF THE DRAWINGS
Objects and advantages of the invention will become apparent upon reading the following detailed description and upon reference to the accompanying drawings in which:
FIG. 1A is a three-dimensional view of a metrology system according to an aspect of the present disclosure.
FIG. 1B is a schematic view of a metrology system according to an aspect of the present disclosure.
FIG. 2 is a schematic view of a sensor bracket employed in a system according to an aspect of the present disclosure.
FIG. 3A is an enlarged view of a magnetic calibration piece in a system according to an aspect of the present disclosure.
FIG. 3B is a cross-sectional view of a portion of the calibration piece of FIG. 3A .
FIG. 4 is a graph showing a vertical magnetic field measured from a magnetic calibration piece in a system according to an aspect of the present disclosure.
DETAILED DESCRIPTION
In the following Detailed Description, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. The drawings show illustrations in accordance with examples of embodiments, which are also referred to herein as “examples”. The drawings are described in enough detail to enable those skilled in the art to practice the present subject matter. Because components of embodiments of the present invention can be positioned in a number of different orientations, directional terminology is used for purposes of illustration and is in no way limiting. It is to be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope of the present invention.
In this document, the terms “a” and “an” are used, as is common in patent documents, to include one or more than one. In this document, the term “or” is used to refer to a nonexclusive “or,” such that “A or B” includes “A but not B,” “B but not A,” and “A and B,” unless otherwise indicated. The following detailed description, therefore, is not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims.
For an electromagnet or permanent magnet array as workpiece, the conventional metrology system lacks an off-the-shelf solution that can obtain optical images, three-dimensional magnetic field and height topology maps of the workpiece and provide data from the optical field, magnetic field and height information in order to correlate defects in the manufacturing process of the workpiece. Aspects of this disclosure relate to a metrology system configured to provide visual inspection of the workpiece (e.g., obtain high resolution optical images), three-dimensional magnetic field map, and height measurement (i.e., workpiece topology mapping). Specifically, an optical inspection tool provides images of the sample, a 3D Hall probe (or other type of magnetic sensors) provides simultaneous x,y,z field information, and a capacitive sensor (or other type of height sensors) provides the sample height information. A software controlled mechanical stage is used to bring sample points of interest under the desired tool for measurement. The metrology system according to the embodiments includes a calibration device/method to verify stage fiducials in x, y, z positions. The optical field, magnetic field, and height information can all be used independently or together in order to correlate defects in the manufacturing process of the workpiece. According to the embodiments of the disclosure, for a magnetic workpiece, the magnetic field in three dimensions at a given position, the height information at that position and an image of those features can be obtained.
As seen in FIGS. 1A-1B , a metrology system 100 according to an aspect of the present disclosure may include a system head 110 to which is mounted and an optical inspection tool 120 and a sensor bracket 130 held by the system head 110 . The sensor bracket 130 includes a magnetic sensor 132 , (e.g., a Hall probe) and a height sensor 134 (e.g., a capacitive sensor) as shown in FIG. 2 . The metrology system 100 further includes a stage 140 for holding the workpiece (e.g., a magnet array) 141 . The workpiece may include features that are either co-planar or not co-planar.
The stage 140 and system head 110 are configured for relative movement with respect to each other. By way of example, and not by way of limitation, the stage 140 may be configured to move the workpiece 141 in x, y, and (optionally) z directions. By way of example, the stage 140 may include suitably configured bearings that allow the stage to move along x, y and z directions and corresponding actuators that impart movement to the stage along these directions in response to input signals. Furthermore, the stage 140 may include position sensing mechanisms that can sense the relative position of the stage with respect to the x, y, and z axes and produce corresponding output signals. The positioning and sensing mechanisms may provide the stage 140 with sub-micron resolution in the X, Y, and Z directions. By way of example, the positioning mechanisms may provide the stage with resolution in the X-Y position of about 5 nanometers (nm) or better and resolution of about 20 nm or better in the Z position.
In the example above, the system head 110 may be fixed while the stage 140 is moved with respect to the system head to impart the relative movement. Alternatively, the stage may be fixed while the system head is moved relative to the stage, e.g., using bearings and actuators responsive to signals from the controller 150 to impart the relative movement. In yet other implementations, both the system head 110 and stage 140 may be configured to move with respect to a fixed frame to impart relative movement between the system head and the stage.
On the stage 140 , there are an optical calibration slide 142 and a magnetic calibration piece 144 . In the example shown in FIGS. 1A-1B , the magnetic calibration piece 144 is also configured to act as the height sensor calibration piece. However, aspects of the present disclosure include implementations in which a separate calibration piece may be included on the stage 140 for alignment of the height sensor 134 . It is also possible for the magnetic calibration piece 144 to include a visible fiducial feature that can be used to align the optical inspection tool 120 .
The system 100 may include a controller 150 having a processor 152 and memory 154 coupled to the optical inspection tool 120 , magnetic sensor 132 , height sensor 134 and the stage 140 (e.g., the actuator(s) and position sensing mechanism(s)). The system 100 may be configured to use the optical calibration slide 142 and the magnetic calibration piece 144 as fiducials to determine the relative offsets between two or more of the optical inspection tool 120 , magnetic sensor 132 , and height sensor 134 . By way of example, and not by way of limitation, the stage 140 may be moved with respect to the x and y directions to align each tool over its respective calibration piece. The position of the stage 140 can recorded at each alignment position and differences in the alignment positions for different sensors can provide offsets between the sensors. For example, an optical alignment position (x o ,y o ) of the stage 140 may be recorded when the optical inspection tool 120 is aligned over a centering mark (e.g., a visible fiducial feature on the magnetic calibration piece 144 . A magnetic alignment position (x m , y m ) may be recorded when the magnetic sensor 132 is centered over a fiducial feature on the magnetic calibration piece 144 . A height alignment position (x h , y h ) may be recorded when the height sensor is 134 centered over a fiducial feature on a height calibration piece.
The processor 152 can obtain the three alignment positions from position sensors on the stage 140 and calculate an offset Δ mo between the magnetic sensor 132 and the optical inspection tool 120 as Δ mo =(x o −x m , y o −y m ) and an offset Δ ho between the height sensor 134 and the optical inspection tool 120 as Δ ho =(x o −x h , y o −y h ). During measurements of the workpiece 141 , the stage 140 is translated as signals from the optical inspection tool, magnetic sensor, and height sensor are recorded as functions of stage position. Positions of the optical inspection tool, magnetic sensor and height sensor can be correlated to the stage position by applying the appropriate offset(s). Those skilled in the art will be able to devise suitable modifications to the above-described procedure to address situations where spatially separate fiducial features are used for aligning two or more of the optical inspection tool 120 , magnetic sensor 132 , and height sensor 134 . For example, a separate fiducial feature on the optical calibration slide 142 may be used to align the optical inspection tool. This fiducial feature may have a known displacement (Δx, Δy) with respect to the fiducial feature on the magnetic calibration piece that is used to align the magnetic sensor 132 and height sensor 134 . In such a case the offset Δ mo may be calculated as Δ mo =(x o −x m +Δx, y o −y m +Δy) and the offset Δ ho may be similarly calculated as Δ ho =(x o −x h +Δx, y o −y h +Δy).
The optical inspection tool 120 may be used to obtain high resolution optical images. By way of example but not by way of limitation, the optical inspection tool 120 may be an optical microscope, a scanning capacitance microscope (SCM), or electron microscope such as critical dimension-scanning electron microscope (CD-SEM). In one example, the optical inspection tool 120 is an Edmund Optics optical microscope (1.3 Megapixel CCD, EO-1312C) with 2× and 5× long working distance objectives and co-axial illumination. The objectives have an optical blur of 5 μm and 2 μm for the 2× and 5× lens, respectively. The microscope is supported by optical post-processing for feature recognition and feature size extraction. Additionally, the 2× and 5× lens have different fields of view, and thus, it will be advantageous to use the 5× lens for higher resolution inspection versus the 2× lens.
The magnetic sensor 132 may include a Hall probe configured to sense the magnetic flux density that is present in a given area. A Hall probe is usually a wand-shaped device placed at or near the surface of the magnet and reads the magnetic flux density in that area. The Hall probe is connected to a flux density meter or a gaussmeter, which converts the magnetic flux readings collected from the Hall probe into a voltage. The voltage is proportional to the magnitude of the magnetic field in that given area. In one embodiment, the magnetic sensor 132 may be a Hall probe (or other magnetic sensor) having a minimum resolution of 10 microns in the field and may be positioned on a workpiece to within 5-10 microns. In one embodiment, the magnetic sensor 132 may measure magnetic field to within 2 Gauss. Moreover, an optional temperature sensing function may be built into the magnetic sensor to facilitate calibration of temperature-dependent performance. In one example, the magnetic sensor 132 may be a Senis three-axis Hall transducer with 10 μm×150 um×150 μm spatial resolution, ±1 T measurement range and sensitivity of 2 G at 14 bits. The Senis field transducer has a differential signal output of ±10 V per axis in addition to a temperature sensing output for a total of 7 outputs. A differential-to-single ended converter is used to reduce the connections to accommodate the limited general purpose input/output (GPIO) connections on the stage. These transducers are pre-calibrated prior to installation for different field ranges and resolution requirements. In alternative embodiments, the magnetic sensor 132 may some other type of magnetic sensor, such as a magnetoresistive sensor, giant magnetoresistance sensor (GMR), or magneto optical Kerr effect (MOKE).
The height sensor 134 is used for height mapping of a workpiece. In one embodiment, the height sensor 134 is a capacitive sensor having nm-scale resolution in the height. In addition, the X-Y position of the height sensor 134 may be located to within slit dimensions (typically 50-100 microns). In one embodiment, the height sensor 134 may be a MicroSense capacitive displacement sensor with 250 μm standoff and ±125 μm measurement range. The resolution is 15 nm at 1 kHz bandwidth. The output signal is ±10 V with 0 V corresponding to the standoff distance of 250 μm. Like Hall probes, capacitive sensors can be pre-calibrated to a desired working range. In alternative embodiments, the height sensor 134 may be a laser interferometer, inductive sensor, drop gauge, atomic force microscope (AFM), scanning tunneling microscope (STM), or stylus profilometer.
The system head position can be determined by the stage 140 . The optical inspection tool 120 , the magnetic sensor 132 and the height sensor 134 are in different locations and thus position calibration for these tools is required. The positions of the optical inspection tool 120 , magnetic sensor 132 and the height sensor 134 can be cross-referenced using offsets determined from one or more fiducial features the stage 140 , such as the optical calibration slide 142 and/or magnetic calibration piece 144 . In addition, the sizes of features in images obtained with the optical inspection tool 120 or distances between such features can be calibrated using the optical calibration slide. The apparent size of features of known size on the optical calibration slide can be measured in pixels in an image of these features obtained with the optical inspection tool. The ratio of the apparent size to the known size can be used to provide a calibration factor to determine the actual size of other features in the image or the actual distance between two or more such features, e.g., by converting pixels to distances. By way of example, and not by way of limitation, the optical calibration slide 142 may include features of known dimension (e.g., circles of known diameter) for such calibration of the optical inspection tool 120 .
In some implementations, the optical inspection tool 120 may be an optical microscope having an objective with both brightfield and darkfield capability. In brightfield microscopy, the sample is illuminated, direct illumination is collected and the image is formed as a result of absorption of illumination by the sample. In darkfield microscopy, direct illumination is blocked from being collected by the objective and the image is formed by illumination scattered by the sample. According to aspects of the present disclosure, the same calibration method described above may be used for calibration in both brightfield and darkfield modes. The calibration values for brightfield and darkfield modes may differ.
FIGS. 3A-3B illustrate a possible configuration for the magnetic calibration piece 144 on the stage 140 . In one embodiment, the magnetic calibration piece 144 includes a magnet 146 sandwiched between top and bottom plates 147 , 149 made of stainless steel. The top plate 147 has across-shaped opening/slit 145 . The slit 145 may include two slits 145 x , 145 y respectively aligned with the x and y axes in a cross or “L” shape. A magnetic flux of the permanent magnet 146 leaks through the slit 145 . A position calibration for the Hall probe 132 can be obtained by measuring the magnetic field as a function of X-Y position and identifying the coordinates of the magnetic alignment position (x m , y m ) from the zero crossing in the vertical composition of the magnetic field. For example, x m is the location where B z (x)=0 in the example shown in FIG. 4 . In one embodiment, the magnetic calibration piece 144 consists of an XY corner fiducial with 50-100 μm wide features that can be seen optically. The corner fiducials or the slit 145 may provide a fiducial feature for alignment the optical inspection system 120 .
In some implementations, the magnetic calibration piece 144 may also serve as a calibration piece for the height sensor 134 . For example, as the height sensor 134 , (e.g., a capacitive sensor) is moved over the slit 145 the signal from the height sensor abruptly changes as it passes over the slit. In addition, when the magnetic sensor 132 sweeps across the slit 145 , the magnetic alignment position (x m , y m ) can be extracted from the zero crossing in a plot of the field slope, e.g., as shown in FIG. 4 . In a similar manner, the height alignment position (x h , y h ) can be determined from an abrupt change in the height sensor signal as the height sensor 134 passes over the same slit 145 . The slit 145 , can also be used as a fiducial feature for determining the optical alignment position (x o ,y o ) for alignment of the optical inspection tool 120 . This simplifies the calculation of the offsets of the magnetic sensor 132 and the height sensor 134 with respect to the optical inspection tool.
A metrology system according to an aspect of the present disclosure may collect optical images of a workpiece (e.g., a magnet array) as a function of sample position, i.e., Image(x, y), magnetic field information in the form of x, y and z components as a function of sample position, i.e., Bfield(x,y,z), and height information as a function of sample position, i.e., Height (x, y). In addition, the above discussed fiducial features can be used to account for physical offsets between these tools to ensure correlation between the optical, magnetic and height data sets. In addition, a metrology system according to an aspect of the present disclosure may have a large sampling volume, for example, of 300 mm×400 mm×5 mm depending on the stage motion.
The appended claims are not to be interpreted as including means-plus-function limitations, unless such a limitation is explicitly recited in a given claim using the phrase “means for.” Any element in a claim that does not explicitly state “means for” performing a specified function, is not to be interpreted as a “means” or “step” clause as specified in 35 USC §112, ¶6. In particular, the use of “step of” in the claims herein is not intended to invoke the provisions of 35 USC §112, ¶6.
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A metrology system is configured to provide visual inspection of a workpiece, three-dimensional magnetic field map, and height measurement. A stage is configured to bring points of interest at the workpiece under the desired tool for measurement. The optical field, magnetic field, and height information can be used independently or together in order to correlate defects in the manufacturing process of the workpiece. This abstract is provided to comply with 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.
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RELATED APPLICATIONS
This application is a continuation in part of non-provisional application Ser. No. 10/164,963, filed Jun. 7, 2002, now U.S. Pat. No. 6,718,599, which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
This invention relates to spring fasteners characterized by a structure having a cavity in which an extension or rib of a first part, such as a plastic panel for example, may be engaged, and they are also suitable to be engaged reversibly in a slot of second part, such as a metal sheet or the frame of a car for example. The invention also pertains an assembly of the first and the second part as connected to each other through the fastener, as well as vehicles comprising such assemblies.
BACKGROUND OF THE INVENTION
A number of fasteners have been used in the past for securing one object on another object, as for example, securing an article such as for example a plastic sheet on a metal or other rigid plastic sheet. However, the fasteners of the type, which are improved by the advances of the present invention, and being used presently, have a rather low ratio of insertion force to removal force. In other words, they require considerable force to be inserted into a slot in order to provide adequate removal resistance in order to be removed from the slot. This is ergonomically inferior performance, and the operators may suffer miscellaneous ailments, while productivity is also considerably undermined.
Examples of conventional fasteners are disclosed in U.S. Pat. No. 5,987,714 (Smith); U.S. Pat. No. 5,887,319 (Smith); U.S. Pat. No. 5,542,158 (Gronau et al.); U.S. Pat. No. 5,422,789 (Fisher et al.), U.S. Pat. No. 5,373,611 (Murata); U.S. Pat. No. 5,314,280 (Gagliardi); U.S. Pat. No. 5,095,592 (Doerfling); U.S. Pat. No. 4,792,475 (Bien); U.S. Pat. No. 4,683,622 (Ohelke); U.S. Pat. No. 4,609,170 (Schnabl); U.S. Pat. No. 4,245,652 (Kelly et al.); U.S. Pat. No. 3,864,789 (Leitner); U.S. Pat. No. 3,673,643 (Kindell); U.S. Pat. No. 3,525,129 (Holton); U.S. Pat. No. 2,825,948 (Parkin); U.S. Pat. No. 2,607,971 (Bedford, Jr.); U.S. Pat. No. 2,542,883 (Tinnerman); U.S. Pat. No. 2,329,688 (Bedford, Jr.); U.S. Pat. No. 2,322,656 (Murphy), among others.
U.S. Pat. No. 5,919,019 (Fisher) provides fasteners which can only be permanently installed into a slot; they can only be inserted but not extracted without damage to parts of the fastener. The major engagement is performed by spring strips, while frictional portions of the fastener pass through the slot with at most slight compression, and immediately after the insertion of the fastener they are located in slightly spaced or barely contacting relation with the edges of the slot. They are only activated for engagement after the insertion of a bolt into a hole at the base plate. Thus, the profound effect of the increased removal to insertion ratio (explained in detail hereinbelow) is not recognized, mentioned, or implied. Thus, the intentionally provided distance of the frictional portions away from the edges of the slot by Fisher, during insertion and before use of the bolt, teaches actually away from the instant invention, which recognizes and takes full advantage of the increased removal to insertion ratio by an engagement region having a hindrance portion. As a matter of fact, if the engagement surfaces of the instant invention were located in slightly spaced or barely contacting relation with the edges of the slot, no engagement at all would take place upon insertion of the fastener of this invention into the slot.
U.S. Pat. No. 6,141,837 (Wisniewski) describes a spring fastener comprising bulbous and outwardly projecting portions, which assist in preventing withdrawal of the clip and associated molding from an aperture of a vehicle frame. However, “bulbous projections” are necessarily voluminous, take most of the space between the “reverse bents”, and unless they are manufactured within tight tolerances with regard to the thickness of the frame, the “base plates” do not sit on the frame (see also the Figures), rendering the structure unstable.
U.S. Pat. Nos. 6,203,240 B1 (Hironaka et al.), 5,129,768 (Hoyle et al.), 5,092,550 (Bettini), 4,981,310 (Belissaire), 4,712,341 (Harris, Jr. et al.), 4,595,325 (Moran et al.), 4,431,355 (Junemann), 4,133,246 (Small), and 2,424,757 (F. Klump, Jr.) are directed to plastic or metal fasteners which are designed to be just inserted into the slot of a panel, but not extracted without damage to the fastener (if such extraction would be attempted from the front side; the side from which the fastener is inserted into the panel, since the back part of the panel is not reachable in the cases, wherein such types of fasteners are used).
SUMMARY OF THE INVENTION
As aforementioned, this invention relates to spring fasteners characterized by a structure having a cavity in which the rib of a first part, such as a plastic panel for example, may be engaged, and they are also suitable to be engaged reversibly in a slot of second part, such as a metal sheet or the frame of a car for example. The invention also pertains an assembly of the first and the second part as connected to each other through the fastener, as well as vehicles comprising such assemblies.
More particularly, the invention pertains a spring fastener comprising a first side and a second side opposite the first side, the first side connected to the second side thereby forming a U-shaped structure having a cavity between the first side and the second side, a bottom portion wherein the first side and the second side are connected, and a top portion, the first side comprising first barbs having first front ends, and a first engagement spring, the first engagement spring connected to the first side in the vicinity of the bottom portion, the second side comprising second barbs second front ends, and a second engagement spring, the second engagement spring connected to the second side in the vicinity of the bottom portion, each of the first and second engagement springs having an optional recess and a free end in the vicinity of the top portion, each spring also comprising a peak and an engagement region with a hindrance portion between the optional recess, or the free end if the recess is absent, and the peak, the hindrance portion providing increased removal force, when the fastener is pulled by a rib of a first part engaged to the first and second barbs, after the fastener has been inserted into a slot of a second part, the slot having a slot width and edges on which edges the engagement region is engaged, the increased removal force being due to the hindrance portion, and wherein the fastener can be extracted when pulled by the rib without damage to said fastener.
This invention further pertains an assembly comprising:
a spring fastener comprising a first side and a second side opposite the first side, the first side connected to the second side thereby forming a U-shaped structure having a cavity between the first side and the second side, a bottom portion wherein the first side and the second side are connected, and a top portion, the first side comprising first barbs having first front ends, and a first engagement spring, the first engagement spring connected to the first side in the vicinity of the bottom portion, the second side comprising second barbs second front ends, and a second engagement spring, the second engagement spring connected to the second side in the vicinity of the bottom portion, each of the first and second engagement springs having an optional recess and a free end in the vicinity of the top portion, each spring also comprising a peak and an engagement region with a hindrance portion between the optional recess, or the free end in absence of the recess, and the peak; a first part comprising a rib inserted into the cavity of the spring fastener and engaged to the first and second barbs; and a second part comprising a slot, the slot having a width and edges, the fastener being disposed in the slot in a manner that the edges of said slot are engaged to the engagement regions of the spring fastener; with the requirement that by pulling the rib, the fastener is extracted from the slot without damage to the fastener, and with a higher force than a force required in the absence of the hindrance portion.
In addition, this invention is related to a vehicle which comprises an assembly, the assembly comprising:
a spring fastener comprising a first side and a second side opposite the first side, the first side connected to the second side thereby forming a U-shaped structure having a cavity between the first side and the second side, a bottom portion wherein the first side and the second side are connected, and a top portion, the first side comprising first barbs having first front ends, and a first engagement spring, the first engagement spring connected to the first side in the vicinity of the bottom portion, the second side comprising second barbs second front ends, and a second engagement spring, the second engagement spring connected to the second side in the vicinity of the bottom portion, each of the first and second engagement springs having an optional recess and a free end in the vicinity of the top portion, each spring also comprising a peak and an engagement region with a hindrance portion between the optional recess, or the free end in the absence of a recess, and the peak; a first part comprising a rib inserted into the cavity of the spring fastener and engaged to the first and second barbs; and a second part comprising a slot, the slot having a width and edges, the fastener being disposed in the slot in a manner that the edges of said slot are engaged to the engagement regions of the spring fastener; with the requirement that by pulling the rib, the fastener is extracted from the slot without damage to the fastener, and with a higher force than a force required in the absence of the hindrance portion.
According to this invention, and particularly for ergonomic purposes combined with practical aspects, it is highly preferable that the force to insert the rib of the first part into the cavity of the spring fastener should be less than 40 lbs, preferably less than 15 lbs, and even more preferably less that 10 lbs; the force to insert the spring fastener into the slot should be less that 30 lbs, preferably less than 15 lbs, and even more preferably less than 10 lbs; and the force to extract the spring fastener from the slot should be in the range of 30-100 lbs, and preferably in the range of 50-70 lbs.
To achieve the above results, in a preferred embodiment of this invention, the hindrance portion comprises one structure selected from ripple, side rib, upward solid bent extension parallel to the peak and the optional recess (or the free end in the absence of the recess), knurled region, bent teeth, each having a depth, and a combination thereof.
It is preferable that the depth of the ripple, the side rib, the upward solid bent extension which is parallel to the peak, the knurled region, and the bent teeth is smaller than 0.2 mm.
It is further preferable that each ripple is in the form of a depression, the depression having a deepest part, a front side, a back side and a width, and the hindrance portion has a surface, comprises not more than three ripples, and wherein the depth of each ripple is the distance between the surface of the hindrance portion and the deepest part of the respective ripple.
It is more preferable that the hindrance portion comprises not more than two ripples, and even more preferable one ripple.
For better performance, the ripple width is larger than the depth of the ripple, and preferably the ripple width is at least twice the size of the depth of the ripple.
The ripple width is preferably in the range of 0.1 to 0.5 mm and the ripple depth is in the range of 0.01 to 0.1 mm.
In a preferred embodiment, the back side of the ripple has a slope in the range of 15 to 30 degrees with regard to the general plane of the hindrance portion, and it is also preferable that the front side has a higher slope than the back side.
In the case that the hindrance portion comprises a single ripple, it is highly preferable that the ripple has only a back side, and substantially lacks a front side. It is also highly preferable that the back side has the form of a curvature with a gradually decreasing slope. For example, the gradually decreasing slope may have the shape of an arc in the range of 50-70 degrees with a radius in the range of 0.03-0.05 mm.
The barbs are preferably selected from a group consisting essentially of:
first barbs being outer barbs and second barbs being inner barbs; first barbs being outside outer barbs and second barbs being inside outer barbs; and first barbs being inner barbs and second barbs being inner barbs.
It is preferable that the barbs are cut from their respective side, are flexible, and bent in the vicinity of their respective front end as described for example in U.S. Pat. No. 6,279,207 B1, which is incorporated herein by reference, and more particularly in FIG. 1 of said patent, with an angle of bent in the range of 5-25 degrees.
The barbs are considered to be flexible if they do not cause the width W 3 ( FIG. 1A ) to increase more than 30%, preferably 20%, and more preferably 10%, when the rib 46 is inserted into the cavity 19 of the fastener 10 ( FIG. 4A ), and provided that the first object 46 is adequately hard to hinder the barbs 36 from substantially digging into it.
Regarding the outside outer barbs, it is preferable that their front points are at a distance from the second side smaller than the thickness of the material from which the spring fastener was made. This is to avoid interconnection of the fasteners, when said fasteners are stored in bulk.
The barbs may have variable width along their length, or they may have substantially the same width along their length. Further, the front points of the barbs may be toothed.
It is also preferable that the fastener has a width in the vicinity of the top portion of the fastener which is at least 60%, and more preferably at least 70%, as wide as the slot width.
With respect to the engagement region it is preferable that it is at least partially wider than the rest of the engagement spring.
The spring fasteners of the instant invention may have two engagement springs at the edges of each side instead of one engagement spring in substantially the middle portion of each side.
The spring fastener may further comprise additional lower barbs pointing inwardly and originating form the vicinity of the bottom portions of the first side and the second side of the fastener. In another embodiment, each side of the spring fastener has only one upper barb and one lower barb, the upper barb of one side facing the lower barb of the other side and vice versa. In still another embodiment, the fastener may further comprise a relief opening in the vicinity of the bottom of the spring fastener.
The spring fastener of the instant invention may further comprise a molded elastic body under the top portion of said spring fastener. Such arrangements are disclosed in U.S. Pat. No. 6,353,981 B1, which is incorporated herein by reference.
In another embodiment, the spring fastener of the instant invention may further comprise:
an elastic body comprised of at least a gasket, the gasket extending away from the closed cavity in the vicinity of the top portion of the fastener and enclosing at least partially the cavity; and a casing surrounding at least partially the spring fastener under the top portion, except at least the engagement section of each engagement spring, the casing also at least partially surrounding the cavity and such portion of the elastic body which at least partially encloses the cavity; wherein the casing has lower ultimate elongation, higher Shore hardness, and higher shear strength than the elastic body. Such arrangements are disclosed in U.S. Pat. No. 6,381,811 B2, which is incorporated herein by reference
According to the present invention, any embodiments of fasteners described above and their equivalents may be used in any assembly in which the first part and the second part are connected with the fastener, as well as in any vehicle comprising such an assembly or such a fastener or its equivalents.
DESCRIPTION OF THE DRAWING
The reader's understanding of practical implementation of preferred embodiments of the invention will be enhanced by reference to the following detailed description taken in conjunction with perusal of the drawing figures, wherein:
FIG. 1 illustrates a perspective view of a spring fastener according to a preferred embodiment of the present invention, wherein the hindrance portion comprises a single-sided ripple and bent barbs.
FIG. 1A shows a side view of the spring fastener of FIG. 1 .
FIG. 2 illustrates a perspective view of a spring fastener according to another preferred embodiment of the present invention, wherein the hindrance portion comprises one two-sided ripple and bent barbs.
FIG. 3A illustrates a fragmental cross-sectional view of an engagement spring, wherein the hindrance portion comprises a single-sided ripple.
FIG. 3B illustrates a fragmental cross-sectional view of an engagement spring, wherein the hindrance portion comprises one two-sided ripple.
FIG. 3C illustrates a fragmental cross-sectional view of an engagement spring, wherein the hindrance portion comprises two two-sided ripples.
FIG. 3D illustrates a fragmental cross-sectional view of an engagement spring, wherein the hindrance portion comprises three two-sided ripples.
FIG. 4 illustrates two parts, which can be connected with the fastener according to the present invention.
FIG. 4A illustrates the side view of the fastener of FIG. 1 and a cross section of the rib of a first part, such as a panel for example, inserted into the cavity of the fastener.
FIG. 4B illustrates the same elements shown in FIG. 4A after insertion of the fastener into the slot of a second part, such as the frame of an automobile for example.
FIG. 4C illustrates a fragmental cross section of the second part of FIG. 4B and the edges of the slot in relation with the engagement regions of the engagement springs of the fastener.
FIG. 5 illustrates a detailed diagram of a ripple in the hindrance portion according to preferred embodiments of the instant invention.
FIG. 5A illustrates a detailed diagram of a single-sided ripple having a back side in the form of a curvature in the hindrance portion according to a highly preferred embodiment of the instant invention.
FIG. 6 illustrates a stamped fastener before final formation according to another embodiment of the present invention, wherein the fastener comprises outer and inner barbs, as well as relief portions in the vicinity of the bottom of the fastener.
FIG. 6A illustrates a side view of the fastener of FIG. 6 after final formation.
FIG. 7 illustrates a stamped fastener before final formation according to another embodiment of the present invention, wherein the fastener comprises outside outer barbs on the first side and inside outer barbs on the second side.
FIG. 8 illustrates a stamped fastener before final formation according to another embodiment of the present invention, wherein the fastener comprises only inner barbs.
FIG. 9 illustrates a stamped fastener before final formation according to another embodiment of the present invention, wherein the fastener comprises upper and lower outer and inner barbs.
FIG. 10 illustrates a stamped fastener before final formation according to another embodiment of the present invention, wherein the fastener comprises two engagement springs per side of the fastener, and only one upper and one lower barb per side.
FIG. 11 illustrates a stamped fastener before final formation according to another embodiment of the present invention, wherein the barbs have uniform width along their length.
FIG. 12 illustrates a stamped fastener before final formation according to another embodiment of the present invention, wherein the barbs have uniform width along their length, and they are toothed at their front ends.
FIG. 13 illustrates a cross-sectional view of the middle portion of a spring fastener, according to another embodiment of the instant invention, wherein a molded elastic body 54 is disposed at least under the top portion of said spring fastener.
FIG. 14 is a perspective view of a fastener, according to still another embodiment of the instant invention, wherein the lower portion of the fastener is covered by a casing, while an elastic body is disposed in the vicinity of the top portion and encloses the cavity, at least partially
DETAILED DESCRIPTION OF THE INVENTION
As aforementioned, this invention relates to spring fasteners characterized by a structure having a cavity in which the rib of a first part, such as a plastic panel for example, may be engaged, and they are also suitable to be engaged reversibly in a slot of second part, such as a metal sheet or the frame of a car for example. The invention also pertains an assembly of the first and the second part as connected to each other through the fastener, as well as vehicles comprising such assemblies.
More particularly, as better shown in FIGS. 1 and 1A , the invention pertains a spring fastener 10 comprising a first side 12 and a second side 14 opposite the first side 12 . The first side 12 is connected to the second side 14 forming a U-shaped structure which has a cavity 19 between the first side 12 and the second side 14 . The fastener 10 also has a bottom portion 16 , wherein the first side 12 and the second side 14 are connected. It further has a top portion 18 a and 18 b (collectively 18 ).
In all cases, numerals referring to the first side 12 contain the letter “a”, while numerals referring the second side 14 contain the letter “b”. The same numerals without the letters “a” or “b”, refer collectively to the respective elements of both sides.
The first side 12 comprises first barbs 36 a , which in this case are outer barbs, since they are disposed in an outer portion of the first side 12 . The barbs 36 a have first front ends 38 a . In this particular case the first barbs 36 a are bent inwardly in the vicinity of the front ends 38 a , as it will be explained in more detail at a later point.
The first side 12 also comprises a first engagement spring 20 a , which is connected to the first side 12 in the vicinity of the bottom portion 16 .
The second side 14 comprises second barbs 36 b , which in this case are inner barbs, since they are disposed in an inner portion of the second side 14 . The second barbs have second front ends 38 b . In this particular case the first barbs 36 b are also bent inwardly in the vicinity of the front ends 38 b , as it will be explained in more detail at a later point.
The second side 14 comprises a second engagement spring 20 b , which is connected to the second side 14 , also in the vicinity of the bottom portion.
Each of the first and second engagement springs 20 a and 20 b have a first and second optional recess, 24 a and 24 b , respectively, and a first and second free end, 22 a and 22 b , respectively, in the vicinity of the top portion 18 ( 18 a and 18 b , respectively). Each spring also comprises a first and a second peak, 26 a and 26 b , respectively, and a first and second engagement region, 28 a and 28 b , respectively, with a first and second hindrance portion, 29 a and 29 b , respectively, between the optional recesses 24 and the peaks 26 .
The hindrance portions providing increased removal force, when the fastener 10 is pulled by a rib or extension 46 ( FIG. 4B ) of a first part 44 ( FIG. 4 ) engaged to the first and second barbs, 36 a and 36 b , respectively, after the fastener 10 has been inserted into a slot 50 of a second part 48 ( FIG. 4 ), the slot 50 having a slot width W 2 ( FIGS. 4 and 4C ) and edges 51 ( FIG. 4C ) on which edges the engagement regions 28 a and 28 b are engaged. The increased removal force is due to the hindrance portions 29 a and 29 b ( FIG. 4C ), which in this particular case comprise single ripples with only back sides 34 , as it will be explained at a later point in more detail. According to this invention, the engagement portions 28 a and 28 b and the hindrance regions 29 a and 29 b are required to be such that the fastener 10 can be extracted from the slot 50 when pulled by the rib 46 without damage to said fastener 10 , and with a higher force than a force required in the absence of the hindrance portions 29 a and 29 b.
This invention further pertains an assembly 11 , as better shown in FIG. 4B , comprising a spring fastener as described above or in the embodiments presented hereinbelow; a first part 44 ( FIG. 4 ) comprising a rib 46 ( FIG. 4A ) inserted into the cavity 19 of the spring fastener 10 and engaged to the first and second barbs 36 a and 36 b ; and a second part 48 ( FIGS. 4 and 4B ) comprising a slot 50 , which slot 50 has a width W 2 and edges 51 ( FIG. 4C ), so that the edges 51 of said slot are engaged to the engagement regions 28 a and 28 b of the spring fastener 10 . In this case also, the requirement exists that by pulling the rib 46 , the fastener 10 is extracted from the slot 50 without damage to the fastener 10 , and with a higher force than a force required in the absence of the hindrance portions 29 a and 29 b.
In addition, this invention is related to a vehicle which comprises an assembly 11 , as described above.
In operation of the above embodiments, the spring fastener 10 of the present invention is intended to connect a first part, such as a panel 44 for example, which panel may have a rib 46 , with a second part, such as a frame 48 of a car for example, having a slot 50 , as illustrated in FIG. 4 .
The rib 46 of the panel 44 is preferably first inserted into the cavity 19 of the fastener 10 (see FIG. 4A ), where, it is secured by barbs 36 a and 36 b . Then, the fastener 10 , which has been secured on the extension 46 of the panel 44 , is inserted into the slot 50 of the frame 48 , as better shown in FIG. 4B .
In this manner, the first part, exemplified by panel 44 , has been connected on the second part, exemplified by frame 48 , through the fastener 10 of the instant invention.
In most practical applications, the length Le (see FIG. 4A ) of the engagement regions 28 is not higher than 2-4 mm, while the thickness T f of the frame 48 (see FIG. 4B ) may vary in most occasions in the range of 0.5 to 2 mm. This fact makes it rather difficult to form large hindrance portions. Thus, The “bulbous projections” suggested by U.S. Pat. No. 6,141,837 (Wisniewski) are necessarily too bulky and voluminous, take most of the space between the “reverse bents” (engagement regions between the peak and the optional recess or free end in the case of the instant invention), and unless they are manufactured within tight tolerances with regard to the thickness of the frame (which in practice may vary considerably), the “base plates” (top portions in the case of the present invention) do not sit on the frame (see also Wisniewski's Figures), rendering the structure considerably unstable.
According to this invention, and particularly for ergonomic purposes combined with practical aspects, it is highly preferable that the force to insert the rib of the first part into the cavity of the spring fastener should be less than 40 lbs, preferably less than 15 lbs, and even more preferably less that 10 lbs; the force to insert the spring fastener into the slot should be less that 30 lbs, preferably less than 15 lbs, and even more preferably less than 10 lbs; and the force to extract the spring fastener from the slot should be in the range of 30-100 lbs, and preferably in the range of 50-70 lbs.
It was unexpectedly found by the inventors that in order to achieve the above results, the hindrance portions should comprise rather minute elements, and not the huge structural components disclosed in the art. Such huge structural components render respective fasteners to be irreversibly inserted into slots. Any attempt to extract these fasteners from the side of the panel that they were inserted would result in destruction of the fasteners.
According to this invention, the hindrance portions 29 a and 29 b may comprise minute elements, such as ripples, upward solid bent extensions parallel to the peaks and the optional recesses (or free ends in the absence of recesses), knurled regions, bent teeth, each having a depth, the depth of which does not exceed preferably 0.2 mm, and more preferably 0.1 mm. Any person of ordinary skill in the art would not expect that elements having such minute depths would have such great impact in force balances as the aforementioned ones.
The depth for any element is substantially defined in the same manner as defined at a later point for the ripples.
Although this invention includes any structure which satisfies the claims, such as for example upward solid bent extensions parallel to the peaks and the optional recesses (or free ends in the absence of recesses), knurled regions, bent teeth, as described in at least one of the provisional patent applications 60/301,364, filed Jun. 25, 2001, 60/327,815, filed Oct. 9, 2001, and 60/353,515, filed Feb. 1, 2002, all of which are incorporated herein by reference, and as long as their depth does not exceed 0.2 mm, the most preferable configuration is one that comprises at most three ripples having a preferable depth not exceeding 0.2 mm, and more preferably not exceeding 0.1 mm. It is more preferable that the hindrance portion comprises not more than two ripples, and even more preferable one ripple. Structures with one to three two-sided ripples 30 are shown in FIGS. 3B to 3D , respectively.
FIG. 2 illustrates a spring fastener 10 according to this invention, wherein the hindrance portion 29 comprises one two-sided ripple 30 and bent barbs 36 .
The most efficient and effective case, however, according to this invention, is the use of only one single-sided ripple 30 , as shown for example in FIGS. 1 and 3A .
The operation of these embodiments is substantially the same as the operation of the previous embodiments.
It is preferable that each ripple 30 is in the form of a depression, as better shown in FIG. 5 . The depression has a deepest part Z, a front side 32 , a back side 34 , and a width W 1 . The hindrance portion 29 has a surface E, and the depth D of each ripple 30 is defined as the distance between the surface E of the hindrance portion 29 and the deepest part Z of the respective ripple 30 .
For better performance, the ripple width is larger than the depth of the ripple, and preferably the ripple width is at least twice the size of the depth of the ripple. The ripple width is preferably in the range of 0.1 to 0.5 mm and the ripple depth is in the range of 0.01 to 0.1 mm, as aforementioned.
In a preferred embodiment, the back side 34 of the ripple 30 is substantially linear and has a slope S in the range of 15 to 30 degrees with regard to the general plane of the surface E of the hindrance portion 29 , and it is also preferable that the front side 32 has a higher slope than the back side. The slope of the front side is measured in the same manner as the slope of the back side. Thus, if the front side 32 is substantially perpendicular to the surface E, the slope is substantially 0 degrees, while if the front side 32 is substantially parallel to the plane of surface E and the continuation of the deepest part Z, it is substantially 90 degrees.
It is, however, highly preferable that the back side 34 has the form of a curvature with a gradually decreasing slope. For example, the gradually decreasing slope of back side 34 may have the shape of an arc corresponding to an angle A 1 , preferably in the range of 50-70 degrees, with a radius R, preferably in the range of 0.03-0.05 mm., as better shown in FIG. 5A .
This configuration is of extreme importance in most occasions, because during vibrations, the edges 51 of the slot 50 ( FIG. 4C ) slide smoothly on the engagement regions 28 as well as the hindrance portions 29 during operation, and when they reach the back sides 34 of the single-sided ripples 30 ( FIG. 5A ), they continue sliding smoothly finding increasingly higher resistance in a continuous manner, which eliminates any rattling noises. Such rattling noises would be present in a case that the edges 51 would hit abrupt obstacles or would suddenly jump down, even without hitting such obstacles.
The barbs are preferably selected from a group consisting essentially of:
first barbs 36 a being outer barbs, and second barbs 36 b being inner barbs, as better shown in FIGS. 6 (blank before forming) and 6 A (side view); first barbs 36 a being outside outer barbs, and second barbs 36 b being inside outer barbs, as better shown in FIG. 7 (blank before forming); and first barbs 36 a being inner barbs, and second barbs 36 b being inner barbs, as better shown in FIG. 8 (blank before forming).
In operation, the barbs engage on the rib 46 of the first part 44 , and when an adequate pulling force is applied on the firs part 44 , the fastener remains on said first part 44 , but is extracted from the slot 50 .
The spring fastener 10 may also comprise relief openings 42 a and 42 b in the vicinity of the bottom 16 of the spring fastener 10 , as better shown in FIG. 6 (blank before forming). These relief openings facilitate the insertion of the fastener into the slot 50 .
The spring fastener 10 may further comprise additional lower barbs 40 a and 40 b pointing inwardly and originating form the vicinity of the bottom portion 16 of the first side and the second side, respectively, of the fastener 10 , as better shown in FIG. 9 (blank before forming).
In another embodiment, better illustrated in FIG. 10 (blank before forming), the first side of the spring fastener 10 has only one upper barb 36 a and one lower barb 40 a , while the second side also has also only one upper barb 36 b and only one lower barb 40 b , in a manner that the upper barb of one side faces the lower barb of the other side and vice versa.
The barbs 36 may have variable width along their length, as illustrated in for example in FIGS. 6-10 , or they may have substantially the same width along their length as better shown in FIG. 11 . Further, the front points of the barbs 36 may be toothed, as illustrated in FIG. 12 .
Regarding outside outer barbs 36 , it is preferable that their front points 38 are at a distance C from the second side 14 smaller than the thickness T of the material from which the spring fastener 10 is made, as better shown in FIG. 1A . This is to avoid interconnection of the fasteners, when said fasteners are stored in bulk.
It is preferable that the barbs are cut from their respective side, are flexible, and bent in the vicinity of their respective front end as described for example in U.S. Pat. No. 6,279,207 B1, which is incorporated herein by reference, and more particularly in FIG. 1 of said patent, with an angle of bent in the range of 5-25 degrees.
It is also preferable that the fastener 10 has a width W 3 ( FIG. 1A ) in the vicinity of the top portion 18 of the fastener 10 , which is at least 60%, and more preferably at least 70%, as wide as the slot width W 2 ( FIG. 4C ). Thus, it is preferable that the whole fastener complies with this requirement, or at least a portion in the vicinity of the top. This is to avoid reversal of the direction and failure of the barbs 36 , when and if the rib 46 is forcefully pulled away from the second part 48 ( FIG. 4B ).
With respect to the engagement regions 28 , it is preferable that these regions are at least partially wider than the rest of the respective engagement springs 20 (see for example FIG. 6 ).
The more barbs are present, or the more bent their front points are, the stronger the engagement of the rib 46 in the cavity 19 . However, in many occasions it is desirable that this engagement is not so strong so as to destroy the integrity of the fastener or the rib, when an adequate force is applied to separate the fastener 10 from the rib 46 .
The spring fasteners 10 of the instant invention may have two engagement springs 20 at the edges of each side instead of one engagement spring 20 in substantially the middle portion of each side (see for Example FIG. 10 ).
The spring fastener 10 of the instant invention may further comprise a molded elastic body 54 at least under the top portion 18 of said spring fastener 10 , as better shown in FIG. 13 . Such arrangements are disclosed in U.S. Pat. No. 6,353,981 B1, which is incorporated herein by reference.
The operation of this embodiment is similar to the operation of the previously described embodiments with the difference that the elastic body provides moderate sealing properties to the fastener when the fastener is inserted into the slot.
In another embodiment, the spring fastener of the instant invention may further comprise:
an elastic body 54 comprised of at least a gasket 56 , the gasket 56 extending away from the closed cavity 19 in the vicinity of the top portion 18 of the fastener 10 and enclosing at least partially the cavity 19 ; and a casing 58 surrounding at least partially the spring fastener under the top portion 18 , except at least the engagement region 28 of each engagement spring 20 , the casing 58 also at least partially surrounding the cavity 19 and such portion of the elastic body 54 which at least partially encloses the cavity; wherein the casing 58 has lower ultimate elongation, higher Shore hardness, and higher shear strength than the elastic body 54 ; as better shown in FIG. 14 .
The presence of lips 60 improves considerably the sealing properties of the elastic body.
Such arrangements are also disclosed in U.S. Pat. No. 6,381,811 B2, which is incorporated herein by reference.
The operation of this embodiment is similar to the operation of the previously described embodiments with the difference that the combination of the elastic body 54 with the casing 58 provide outstanding sealing properties to the fastener 10 when the fastener 10 is inserted into the slot 50 , and the casing itself facilitates the insertion of the fastener 10 into the slot 50 .
According to the present invention, any embodiments of fasteners described above and their equivalents may be used in any assembly in which the first part and the second part are connected with the fastener, as well as in any vehicle comprising such an assembly or such a fastener or its equivalents.
It should also be understood that the miscellaneous embodiments and features of the instant invention may be used in any combination or by themselves in other articles or devices, where they may be needed.
Examples of embodiments demonstrating the operation of the instant invention, have been given for illustration purposes only, and should not be construed as restricting the scope or limits of this invention in any way.
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This invention relates to a spring fastener, which comprises engagement springs in opposite sides of the fastener. Each engagement spring has an engagement region comprising a hindrance portion, which increases considerably the removal to insertion force ratio as compared to such ratio in the absence of the hindrance portion, thus permitting very easy insertion with considerably more difficult removal of the fastener from the slot of a panel, which provides an efficient ergonomically balanced removal to insertion force ratio. The hindrance portion comprises ripples or other hindrance elements of unexpectedly minute dimensions for providing this efficient ergonomic force balance. The combination of the above structures with the presence of barbs being bent at their front portion improves immensely the ergonomic character of the devices.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention pertains to a travel drive apparatus for a hydraulic drive work vehicle and a control method therefor, and more particularly to a travel drive apparatus for a hydraulic drive work vehicle, and a control method therefor, designed for a hydraulic drive vehicle that travels by driving a hydraulic motor with pressure oil from a variable delivery hydraulic pump for traveling that is driven by an engine.
2. Description of the Related Art
Variable delivery hydraulic pumps (hereinafter called hydraulic pumps) are conventionally used as pumps for generating oil under pressure for driving hydraulic shovels and other working machines or traveling equipment. These hydraulic pumps are equipped with power control mechanisms (hereinafter called regulators) to prevent the engine that drives the pump from stalling. Such a regulator controls the flow rate Q in response to the discharge pressure P, so that equipment is run with roughly constant torque (P×Q=constant). When the discharge pressure P is low, the force generated by a piston (not shown in the drawings) is smaller than the force of an opposing spring, wherefore the piston does not move, so that the cylinder block of the pump is in the position of maximum tilt angle, and the pump discharge quantity is also at maximum. When the load acting on the pump, that is, either the load of the working machine or the load when traveling, increases, the piston moves to a position that balances the force of the spring, decreasing the cylinder block tilt angle, and control is effected so that torque becomes constant. As described above, the spring used in the regulator pushes the cylinder block in the direction of maximum tilt angle. Alternatively, in another known example, the spring used in the regulator pushes the cylinder block in the direction wherein the tilt angle is minimized. Thus, when the engine is started, the load driving the pump becomes small, making engine startup easy.
Also known are hydraulic drive apparatuses, which use hydraulic pumps and hydraulic motors, for enabling hydraulic shovels and other construction equipment to travel. Among these known hydraulic drive apparatuses are those wherein the hydraulic pumps and hydraulic motors are connected in a closed circuit, and those wherein the hydraulic pumps and hydraulic motors are connected in an open circuit with changeover valves inserted between the hydraulic pumps and hydraulic motors. An example of such an open circuit is disclosed in Utility Model Registration No. 2543146, in gazette. According to this model, as diagrammed in FIG. 9, this hydraulic circuit comprises a hydraulic pump 201 for driving various actuators in the work vehicle, compound control valves 202 A, 202 B that are collection of control valves for controlling the supply of pressure oil from the hydraulic pump 201 to each of various actuators, and a travel hydraulic motor 204 that is drive-controlled by travel control valves 203 a , 203 b for the compound control valves 202 A, 202 B. To a main line 205 for the travel hydraulic motor 204 are connected crossover relief valves 206 , counterbalance valves 207 , and lower makeup valves 208 . The lower makeup valves 208 and an oil tank 210 are connected by a makeup circuit 212 , and an oil cooler 211 is provided in the return oil line of the compound control valve 202 A. A center joint CJ is also provided for circulating oil between an upper revolving structure and a lower revolving structure.
As based on the present invention, furthermore, while one end of the makeup circuit 212 A is connected to the main lines 205 A, 205 B via a lower makeup valve (second makeup valve) 208 , the other end thereof is connected to a line 222 upstream of a cooler relief valve 221 via the makeup circuit 212 B. The upstream line 222 is the return line for the compound control valves 202 A, 202 B. Also, upper main lines 205 C, 205 D between the center joint CJ and the travel control valves 203 a , 203 b built into the compound control valves 202 A, 202 B is connected to the makeup circuit 212 B via an upper makeup valve (first makeup valve) 223 , and makeup oil is replenished from various portions to the upper main lines 205 C, 205 D. A hydraulic pump 201 D is a steering hydraulic pump, connected to a hydraulic steering cylinder 225 via a steering valve 224 . The return oil from the steering valve 224 is connected to the upstream line 222 of the cooler relief valve 221 via the return line 226 and the makeup circuit 212 B. Thus makeup oil is introduced to the upper main lines 205 C, 205 D on the side of the upper revolving structure that connects the center joint CJ and the compound control valves 202 A, 202 B. Accordingly, if a large flow rate of makeup oil is introduced, a large flow rate of makeup oil will be conveyed all the way to the travel hydraulic motor 204 installed in a lower traveling body. Also, the return oil from the steering hydraulic pump 201 D is merged into the makeup circuit 212 , wherefore an adequate makeup flow rate can be secured. Accordingly, cavitation can be definitely prevented in the travel hydraulic motor 204 . In addition, makeup oil is also replenished directly to a lower main line from the makeup circuit 212 . The pressure of the makeup oil can be set by the cooler relief pressure, and it is stated that replenishment efficiency is improved.
With a hydraulic drive apparatus for effecting travel in a hydraulic shovel or other construction machine, however, there are problems. Namely, when decelerating, descending a slope, or changing either from forward travel to reverse travel or from reverse travel to forward travel, cavitation occurs which damages the hydraulic motor, and, when descending a slope, due to overrun, the vehicle ceases to be controllable. Therefore, when a closed circuit configuration is used, in order to prevent overruns, the inertial energy of the working vehicle (roughly 125% of the d vehicle speed) must absorb the inertial energy generated by the reverse drive torque of the engine. Hence, in order to absorb this with the travel hydraulic pump and travel hydraulic motor, the capacity (discharge volume per revolution, in cc/rev) has to be made large. With the closed circuit configuration, moreover, oil is supplied from a charge pump on the intake side of the closed circuit so that cavitation does not occur, and the supply volume of this charge pump must also be made large. Thus, the charge pump drive force must become large, and the engine output horsepower must be increased. The engine will become large, and wasted energy will be developed when traveling normally. The maximum traveling speed is determined by the capacities of the hydraulic pump and hydraulic motor, wherefore, at the very least, it is necessary to use a hydraulic pump having large capacity from the outset. In a large working vehicle, a hydraulic pump having larger discharge capacity will become necessary, and, together therewith, it will be necessary to increase the engine output horsepower, which is uneconomical. Next, according to Utility Model Registration No. 2543146, in gazette, configured with an open circuit, makeup oil is replenished from the makeup valve when normally moving forward, moving in reverse, accelerating, or descending a slope, and cavitation is prevented. However, when changing from forward travel to reverse travel or from reverse travel to forward travel, cavitation develops, damaging the hydraulic motor, and rendering control of the vehicle impossible. Suppose, for example, that an operator moves travel control valves 203 a , 203 b from the forward position (A) past neutral to the reverse position (C), thereby changing the vehicle from forward travel to reverse travel. While moving forward, pressure oil passes through the upper main line 205 A and reaches the intake 204 A in the travel hydraulic motor 204 , turning the travel hydraulic motor 204 , and moving the vehicle forward. When reverse travel is changed to, the pressure oil, from the reverse position (C) of the travel control valves 203 a , 203 b , passes through the upper main circuit 205 D, reaches the counterbalance valve 207 , and switches the counterbalance valve 207 to the reverse position (C). The pressure oil from the hydraulic pump 201 , from the counterbalance valve 207 in the reverse position (C), passes through the lower main circuit 205 B, reaches the intake 204 B in the travel hydraulic motor 204 , and tries to turn the travel hydraulic motor 204 and make the vehicle move in reverse. At this time, the travel hydraulic motor 204 is still turning in the forward direction due to the inertial energy of the vehicle, and oil is being discharged from the intake 204 B in the travel hydraulic motor 204 . For this reason, the pressure oil from the hydraulic pump 201 and the oil from the travel hydraulic motor 204 are discharged to the lower main circuit 205 B and put under high pressure, whereupon the crossover relief valve 206 is activated. With the oil from this crossover relief valve 206 , makeup oil is replenished to the lower main circuit 205 B via the upper makeup valve (first makeup valve) 223 , and cavitation is prevented. At this time, however, the oil discharged from the hydraulic pump 201 is at high pressure, wherefore, in the conventional hydraulic circuit, a regulator is used to reduce the discharge quantity of the hydraulic pump, so makeup oil is not adequately replenished to the lower main circuit 205 B, and cavitation occurs. When the inertial energy of the vehicle is large, the discharge quantity of the hydraulic pump will become smaller while the crossover relief valve 206 is operating, cavitation will occur, and the vehicle will not stop within the designated range, which is a problem. Accordingly, in a hydraulic drive apparatus configured with an open circuit, there is a problem in that the operations of changing over from forward travel to reverse travel and from reverse travel to forward travel are very difficult.
In view of the problems set forth above, the present invention pertains to a travel drive apparatus for a hydraulic drive work vehicle, and an object thereof is to provide a travel drive apparatus for a hydraulic drive work vehicle exhibiting good acceleration performance, and a control method therefor, wherewith, particularly for a hydraulic drive work vehicle wherein a work machine is loaded on a hydraulic drive vehicle, it is possible to perform switching operations from forward travel to reverse travel or from reverse travel to forward travel.
SUMMARY OF THE INVENTION
In order to attain the object set forth above, a first invention is a travel drive apparatus for a hydraulic drive work vehicle including: a travel hydraulic pump driven by the power of an engine; a hydraulic motor that receives discharged oil from the travel hydraulic pump and causes the vehicle to travel; a travel changeover valve that receives the discharged oil from the travel hydraulic pump, supplies the discharged oil to the hydraulic motor and discharges return oil from the hydraulic motor to a tank, wherein the apparatus comprises: acceleration means for controlling engine rotational speed; operation means for selecting vehicle forward travel, stop, and reverse travel; the travel changeover valve being adapted for receiving signals from the operation means, switching the discharge oil supplied from the travel hydraulic pump to the hydraulic motor, and controlling vehicle forward travel, stop, and reverse travel; a relief valve that regulates pressure for controlling the hydraulic motor when the vehicle has decelerated, positioned between the travel changeover valve and the hydraulic motor; and pressurizing means for raising the set pressure at a relief valve controlling the hydraulic motor when engine rotational speed has been increased and lowering the set pressure on a relief valve controlling the hydraulic motor when engine rotational speed has been decreased, while switching the vehicle from forward travel to reverse travel, or from reverse travel to forward travel.
As based on the configuration described in the foregoing, when an operator switches the vehicle from forward travel to reverse travel, or from reverse travel to forward travel, and has increased engine rotational speed, the set pressure at the relief valve controlling the hydraulic motor rises, the braking force is increased, and both stopping time and stopping distance are shortened. Also, since engine rotational speed is being increased, the pressure on the braking side is being raised, wherefore the takeoff torque from stop to forward travel becomes large, and acceleration speed rises rapidly. When engine rotational speed has been reduced, on the other hand, the set pressure at the relief valve controlling the hydraulic motor is lowered, the braking force is reduced, and both stopping time and stopping distance are lengthened.
Accordingly, the changeover operations from forward travel to reverse travel and from reverse travel to forward travel that are very difficult with the conventional open circuit become possible, while the engine rotational speed at such times can be increased, shortening stopping times and stopping distances. In addition, takeoff acceleration performance is improved, thus improving work efficiency. Also, the work vehicle responds to and follows the will of the operator, so operability is improved. Switching from forward travel to reverse travel or from reverse travel to forward travel can be done with hydraulic equipment, moreover, so operations can be done inexpensively with a simple structure. Also, when engine rotational speed has been reduced, the braking force is reduced, lengthening stopping time and stopping distance, thus reducing jolting, and making the braking distance roughly constant irrespective of engine rotational speed.
In a second invention based on the first invention, the pressurizing means comprise an unloading valve for adjusting the discharge pressure of the travel hydraulic pump to low pressure while switching the vehicle from forward travel to reverse travel or from reverse travel to forward travel, and a restrictor valve, positioned between the relief valve and the tank, for restricting and raising the pressure on the oil discharged from the travel hydraulic pump via the unloading valve, while switching the vehicle from forward travel to reverse travel or from reverse travel to forward travel, and raising the set pressure at the relief valve.
As based on the configuration described above, the discharged oil from the travel hydraulic pump that is increasing with the increase in engine rotational speed is supplied via the unloading valve to the restrictor valve, and restricted by the restrictor valve so that its pressure increases. This pressure acts on the relief valve, increases the braking force, shortens the stopping time and stopping distance, and increases takeoff acceleration performance.
Accordingly, the discharge quantity from the travel hydraulic pump that is increasing as the engine rotational speed increases is restricted by the restrictor valve so that its pressure increases, wherefore the set pressure at the relief valve increases automatically due to the hydraulic equipment, and the hydraulic circuit becomes simple and inexpensive. Also, since control is performed with hydraulic equipment, there cease to be malfunctions, and both maintainability and safety are enhanced.
In a third invention based on the first invention, the pressurizing means comprise a control hydraulic pump that is driven by engine power, for discharging a discharge quantity in response to engine rotational speed, and a restrictor valve, positioned between the relief valve and the tank, for restricting and raising the pressure on the oil discharged from the control hydraulic pump, while switching the vehicle from forward travel to reverse travel or from reverse travel to forward travel, and raising the set pressure at the relief valve.
As based on the configuration described above, the discharged oil from the travel hydraulic pump that is increasing with the increase in engine rotational speed is supplied to the restrictor valve, and restricted by the restrictor valve so that its pressure increases.
This pressure acts on the relief valve, increases the braking force, shortens the stopping time and stopping distance, and increases takeoff acceleration performance.
Accordingly, the discharge quantity from the travel hydraulic pump that is increasing as the engine rotational speed increases is restricted by the restrictor valve so that its pressure increases, wherefore the set pressure at the relief valve increases automatically due to the hydraulic equipment, and the hydraulic circuit becomes simple and inexpensive. Also, since control is performed with hydraulic equipment, there cease to be malfunctions, and both maintainability and safety are enhanced.
In a fourth invention based on the third invention, the pressurizing means comprise a control hydraulic pump driven by engine power, and a restrictor valve that connects with the control hydraulic pump, restricting the discharged oil, whereupon a control pressure responsive to engine rotational speed is produced, and that supplies the control pressure to the relief valve and raises the pressure.
As based on the configuration described above, the discharged oil from the travel hydraulic pump that is increasing with the increase in engine rotational speed is supplied to the restrictor valve, and restricted by the restrictor valve so that its pressure increases.
This pressure acts on the relief valve, increases the braking force, shortens the stopping time and stopping distance, and increases takeoff acceleration performance.
Accordingly, as noted earlier, the discharge quantity from the travel hydraulic pump that is increasing as the engine rotational speed increases is restricted by the restrictor valve so that its pressure increases, wherefore the set pressure at the relief valve increases automatically due to the hydraulic equipment, and the hydraulic circuit becomes simple and inexpensive. Also, since control is performed with hydraulic equipment, there cease to be malfunctions, and both maintainability and safety are enhanced.
In a fifth invention based on any one of the first to the fourth inventions, the relief valve comprises a piston unit that is connected to the relief valve and can make variable the pressure regulation of the relief valve, and a control valve that is connected to the piston unit, detects that the relief valve has been activated and switches it, cuts off the circuit from the piston unit to the tank, and makes the relief valve variable.
As based on the configuration described above, when switching over from forward travel to reverse travel or from reverse travel to forward travel, the return oil from the hydraulic motor oppositely driven by the inertial energy of the work vehicle is restricted by the travel changeover valve so that it attains high pressure. However, a relief valve inserted between the travel changeover valve and the hydraulic motor, by means of the piston unit and the control valve that controls the operation of the piston unit, variably adjusts the pressure acting on the hydraulic motor. This pressure that acts on the hydraulic motor is made variable so that it becomes higher when the inertial energy of the work vehicle is great.
Accordingly, by making the pressure variable in response to the inertial energy of the work vehicle, the vehicle braking distance becomes roughly constant. Also, the pressure varies in response to the inertial energy of the work vehicle, so jolting during braking is reduced.
In a sixth invention based on the first invention, the travel hydraulic pump comprises a variable delivery hydraulic pump equipped with a regulator, and the regulator comprises a servo valve that is activated, receiving pressure that drives the hydraulic motor at one end and signals responsive to engine rotational speed at the other end, and a piston cylinder that receives pressure that drives the hydraulic motor in one chamber, and pressure that drives the hydraulic motor via the servo valve in the other chamber, that houses a spring, and that discharges, from the travel variable delivery hydraulic pump, a discharge quantity such that the pressure driving the hydraulic motor is made less than a prescribed value by the force of the spring, when engine rotational speed is below a prescribed value and the hydraulic motor is driven oppositely from the vehicle.
As based on the configuration described above, the servo valve is activated upon receiving the low pressure driving the hydraulic motor and the low engine rotational speed, and the regulator supplies the pressure driving the hydraulic motor to the piston cylinder. The piston cylinder is activated, receiving in one cylinder the pressure driving the hydraulic motor, and in the other chamber the pressure driving the hydraulic motor and the force of the spring, so that, when engine rotational speed is below a prescribed value and the hydraulic motor is driven oppositely from the vehicle, a discharge quantity is discharged from the travel variable delivery hydraulic pump such that the pressure driving the hydraulic motor becomes lower than a prescribed value due to the force of the spring.
Accordingly, when the hydraulic motor is acted on by an opposite drive and the driving pressure is low, there is no need to use other hydraulic equipment to prevent cavitation, it being necessary only to increase the discharge volume of the travel variable delivery hydraulic pump, making it possible to operate inexpensively with a simple structure.
A first invention that is a control method for a travel drive apparatus for a hydraulic drive work vehicle according to the present invention is a method for controlling a travel drive apparatus for a hydraulic drive work vehicle comprising: a travel hydraulic pump driven by the power of an engine; a hydraulic motor that receives discharged oil from the travel hydraulic pump and causes the vehicle to travel; and a travel changeover valve that receives discharged oil from the travel hydraulic pump, supplies the discharged oil to the hydraulic motor and discharges return oil from the hydraulic motor to a tank; wherein: the set pressure at a relief valve which controls the hydraulic motor is raised when engine rotational speed has been increased while switching the vehicle from forward travel to reverse travel or from reverse travel to forward travel.
Based on the method described in the foregoing, when the vehicle is switched over from forward travel to reverse travel or from reverse travel to forward travel, the hydraulic motor is driven backward by the inertial energy of the work vehicle, and the return oil from the hydraulic motor is restricted by the travel changeover valve, making it high-pressure, whereupon the relief valve is activated. Braking torque develops as a result of this high-pressure braking pressure. At this time, when engine rotational speed is increased, the discharge quantity from the hydraulic pump also increases according to the increase in engine rotational speed This discharge quantity from the hydraulic pump is restricted so that its pressure rises, and this pressure acts on the relief valve to further raise the braking pressure that brakes the hydraulic motor.
Accordingly, even when switching over from forward travel to reverse travel or from reverse travel to forward travel, a high-pressure braking pressure develops so that the vehicle decelerates and stops, and the vehicle begins moving in the opposite direction. At this time, due to the fact that the engine rotational speed increases, the high-pressure braking pressure becomes even higher, increasing the braking force, so that stopping time and stopping distance can be shortened. And, both because the engine rotational speed is being increased and because the pressure on the braking side is being raised, the startup torque when departing from a standstill becomes larger, the acceleration speed rises rapidly at takeoff, and work efficiency is improved. The work vehicle responds to and follows the will of the operator, moreover, so operability is improved. It is also possible now to use hydraulic equipment to make the switchover from forward travel to reverse travel or from reverse travel to forward travel, so this can be performed inexpensively with a simple structure.
A second invention that is a control method for a travel drive apparatus for a hydraulic drive work vehicle according to the present invention is a method for controlling a travel drive apparatus for a hydraulic drive work vehicle comprising: a travel hydraulic pump driven by the power of an engine; a hydraulic motor that receives discharged oil from the travel hydraulic pump and causes the vehicle to travel; and a travel changeover valve that receives discharged oil from the travel hydraulic pump, supplies the discharged oil to the hydraulic motor and discharges return oil from the hydraulic motor to a tank; wherein: when engine rotational speed has been increased while switching the vehicle from forward travel to reverse travel or from reverse travel to forward travel, the discharge oil from the control pump is increased to accord with the engine rotational speed, that discharge oil is restricted, thereby raising its pressure, that pressure is sent to the relief valve, the set pressure at the relief valve is raised, and the hydraulic motor is braked.
Based on the method described in the foregoing, when the vehicle is switched over from forward travel to reverse travel or from reverse travel to forward travel, the return oil from the hydraulic motor being driven backward by the inertial energy of the work vehicle is restricted by the travel changeover valve, making it high-pressure, whereupon the relief valve is activated, so that a braking torque acts on the vehicle. This braking torque increases engine rotational speed, and increases the discharge oil from the control pump to match the engine rotational speed This discharge oil is restricted to further raise its pressure, making it possible to shorten stopping time and stopping distance, and to increase acceleration performance at takeoff.
Accordingly, the pressure acting on the hydraulic motor becomes variable in response to the inertial energy of the work vehicle, and this pressure is maintained during this time, wherefore the vehicle braking distance becomes roughly constant. During this time also the discharge oil from the travel variable delivery hydraulic pump is being increased, so cavitation is prevented from occurring. The same benefits are realized, moreover, as with the first control method described above.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a hydraulic diagram for a first embodiment of the travel drive apparatus for a hydraulic drive work vehicle;
FIG. 2 is an enlarged diagram of the travel valve and pilot pressure supply valve noted in FIG. 1;
FIG. 3 is an enlarged diagram of the modulation relief valve noted in FIG. 1;
FIG. 4 is a graph plotting the relationship between travel speed and stopping time;
FIG. 5 is a graph plotting the relationship between the pressure acting on the travel hydraulic motor and time;
FIG. 6 is a hydraulic diagram for a second embodiment of the travel drive apparatus for a hydraulic drive work vehicle;
FIG. 7 is a hydraulic diagram for a third embodiment of the travel drive apparatus for a hydraulic drive work vehicle;
FIG. 8 is a hydraulic diagram for a fourth embodiment of the travel drive apparatus for a hydraulic drive work vehicle; and
FIG. 9 is a hydraulic diagram for a conventional travel hydraulic motor.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiments of the present invention are now described, making reference to the drawings. FIG. 1 is a hydraulic circuit diagram representing an embodiment of a travel drive apparatus for a hydraulic drive work vehicle according to the present invention; FIG. 2 is an enlarged diagram of the travel valve and pilot pressure supply valve noted in FIG. 1; and FIG. 3 is an enlarged diagram of the modulation relief valve noted in FIG. 1 .
As diagrammed in FIG. 1, an engine 1 drives a variable delivery type travel hydraulic pump 2 and a fixed capacity type control hydraulic pump 3 . The discharge line 2 a from the travel hydraulic pump 2 is connected to a travel valve 5 . To the travel valve 5 are connected a first main circuit 7 and a second main circuit 8 leading to the travel hydraulic motor, and a return circuit 11 leading to a tank 9 . The travel valve 5 switches the pressure oil from the travel hydraulic pump 2 to either the first main circuit 7 or the second main circuit 8 going to the travel hydraulic motor 6 , and returns the return oil from the travel hydraulic motor 6 to the tank 9 . To the first main circuit 7 and second main circuit 8 , respectively, are connected intake valves 12 and 12 . These intake valves 12 and 12 are connected, respectively, to a return circuit 11 going to the tank 9 by an intake circuit 13 . The intake valves 12 supply oil to either the first main circuit 7 or the second main circuit 8 when either the first main circuit 7 or second main circuit 8 falls below a prescribed pressure, thus preventing the occurrence of cavitation in the oil supplied to the travel hydraulic motor 6 .
To the first main circuit 7 and the second main circuit 8 , respectively, are connected check valves 14 and 14 acting as relief valves, and, via a relief circuit 15 a , a modulation relief valve 50 . A return relief circuit 15 b for the modulation relief valve 50 passes through the intake circuit 13 and is connected to the return circuit 11 going to the tank 9 . The modulation relief valve 50 is activated when either the first main circuit 7 or the second main circuit 8 reaches or exceeds a prescribed pressure, regulating the circuit pressure and applying a brake to the vehicle. The return oil from the modulation relief valve 50 , moreover, passes through the intake circuit 13 and is supplied either to the first main circuit 7 or the second main circuit 8 by the intake valves 12 and 12 .
A back-pressure valve 17 is inserted in the return circuit 11 going to the tank 9 . As necessary, the pressure is raised on the oil returning to the tank 9 from the travel valve 5 , intake circuit 13 , or return relief circuit 15 b and supplied from the intake valves 12 and 12 to either the first main circuit 7 or the second main circuit 8 , wherefore the oil volume is increased and cavitation is prevented.
An oil line splitting off from the discharge line 3 a from the control hydraulic pump 3 communicates with the tank 9 via a variable restrictor 18 , so as to generate pressure in response to the discharge quantity from the control hydraulic pump 3 , that is, pressure produced by the turning speed of the engine 1 .
As diagrammed in FIG. 2, the travel valve 5 comprises four ports, namely a pump port 21 , tank port 22 , and first and second actuator ports 23 and 24 . To the pump port 21 is connected the discharge line 2 a from the travel variable delivery hydraulic pump 2 . To the tank port 22 is connected the tank 9 . To the first actuator port 23 is connected the first main circuit 7 . And to the second actuator port 24 is connected the second main circuit 8 .
The travel valve 5 is provided on one end with a first spring 25 and a first pressure unit 26 , and on the other end with a second spring 27 and a second pressure unit 28 . The travel valve 5 is made in a pilot pressure switching configuration wherein it is held in a neutral position A by the first and second springs 25 and 27 , switched to a forward position B by the pressure in the first pressure unit 26 , and switched to a reverse position C by the pressure in the second pressure unit 28 . The neutral position A of the travel valve 5 is provided with first and second check valves 29 a and 29 b and with a restrictor 29 c , the first check valve 29 a being located between the pump port 21 and the first main circuit 7 , and the second check valve 29 b being located between the pump port 21 and the second main circuit 8 . The first and second check valves 29 a and 29 b are provided so as to block flows both from the pump port 21 toward the first and second actuators 23 and 24 , and from the first and second actuators 23 and 24 toward the pump port 21 . The restrictor 29 c is positioned between the pump port 21 and the tank port 22 to restrict flow to the tank 9 so as to prevent the pressure in the first main circuit 7 and second main circuit 8 going to the travel hydraulic motor 6 from falling below a prescribed pressure (from becoming a negative pressure, for example). To the first and second pressure units 26 and 28 of the travel valve 5 is supplied, as pilot pressure, the pressure in the first and second main circuits 7 and 8 , via a pilot pressure supply valve 30 (described below).
The pilot pressure supply valve 30 comprises seven ports, namely first, second, third, fourth, fifth and sixth ports 31 , 32 , 33 , 34 , 35 and 36 , and a tank port 37 . The first port 31 is connected to the first main circuit 7 by a first pilot circuit 38 , the second port 32 is connected to the first pressure unit 26 by a second pilot circuit 39 , the third port 33 is connected to the second main circuit 8 by a third pilot circuit 40 , and the fourth port 34 is connected to the second pressure unit 28 by a fourth pilot circuit 41 . The fifth port 35 is connected to the modulation relief valve 50 by a fifth pilot circuit 42 . The sixth port 36 is connected to the control hydraulic pump 3 via the discharge line 3 a . The tank port 37 is connected to the tank 9 by a second return circuit 43 .
The pilot pressure supply valve 30 has three positions, namely a neutral position D, a forward position E, and a reverse position F. The pilot pressure supply valve 30 is provided at one end with a first spring 44 and a first solenoid 45 , and at the other end with a second spring 46 and a second solenoid 47 . The pilot pressure supply valve 30 has an electromagnetic switching configuration wherewith it is maintained in the neutral position D by the first spring 44 and second spring 46 , moved to the forward position E by the first solenoid 45 , and moved to the reverse position F by the second solenoid 47 . Current is supplied to the first solenoid 45 and the second solenoid 47 by manipulating an operation unit 48 (described below).
In the neutral position D, the first port 31 and third port 33 are closed off, while the other ports (i.e. the second port 32 , fourth port 34 , fifth port 35 , sixth port 36 , and tank port 37 ) are all connected, and the discharge oil from the control hydraulic pump 3 has back pressure applied to it by a back-pressure check valve 49 (cf. FIG. 1) in front of the tank 9 .
In the forward position E, the third port 33 and sixth port 36 are closed off, while either the first port 31 , second port 32 , and fifth port 35 , or the fourth port 34 and tank port 37 , respectively, are connected. When activated, the pressure in the first main circuit 7 is supplied to the first pressure unit 26 in the travel valve 5 , while the oil in the second pressure unit 28 is returned to the tank 9 .
In the reverse position F, the first port 31 and sixth port 36 are closed off, while the third port 33 , fourth port 34 , and fifth port 35 , or the second port 32 and tank port 37 , respectively, are connected. When activated, the pressure in the second main circuit 8 is supplied to the second pressure unit 28 in the travel valve 5 , while the oil in the first pressure unit 26 is returned to the tank 9 .
The operation unit 48 (cf. FIG. 1) is used when selecting either forward travel or reverse travel. When selecting forward travel, for example, the operation unit 48 is manipulated to the right in the figure (FIG. 1 ), sending current to the first solenoid 45 and changing the pilot pressure supply valve 30 to the forward position E. The pilot pressure supply valve 30 supplies the pressure in the first main circuit 7 to the first pressure unit 26 in the travel valve 5 , as a pilot pressure, switching the travel valve 5 to the forward position B. The pressure in the travel hydraulic pump 2 is supplied via the travel valve 5 in the forward position B, and the first main circuit 7 , to the travel hydraulic motor 6 , turning the motor so as to drive the vehicle forward. When selecting reverse travel, the procedure is the opposite. That is, the operation unit 48 is manipulated to the left, as diagrammed, current is sent to the second solenoid 49 , and the pilot pressure supply valve 30 is switched over to the reverse position F. As diagrammed in FIG. 1, the modulation relief valve 50 comprises a variable relief valve 51 , control valve 60 , first restrictor unit 57 , and second restrictor unit 58 .
The variable relief valve 51 , as diagrammed in FIG. 1 and FIG. 3, comprises a variable relief valve 52 , a piston unit 53 , a check valve 54 , and a restrictor 55 .
The variable relief valve 52 is connected to the first main circuit 7 and the second main circuit 8 via the check valves 14 and 14 , acting as relief valves, and the relief circuit 15 a , and is also connected to the return circuit 11 going to the tank 9 via the return relief circuit 15 b and the intake circuit 13 . The pressure in the relief circuit 15 a is led to and acts on one end of the variable relief valve 52 , while the pressure in the return relief circuit 15 b is led to and acts on the other end, which is also provided with a spring 52 a . The piston unit 53 is linked to the spring 52 a , and the force of this piston unit 53 acts on the spring 52 a . Thus the load of the spring 52 a acting on the other end of the variable relief valve 52 can be made variable, and the regulating pressure at the variable relief valve 52 can be made variable. The pressure in the relief circuit 15 a is led to and acts in a piston bottom chamber 53 a in the piston unit 53 , and the piston unit 53 compresses the spring 52 a . The piston head chamber 53 b of the piston unit 53 is connected via the check valve 54 and the restrictor 55 to the return relief circuit 15 b.
The variable relief valve 52 is set up so that, when the vehicle is traveling normally, either the pressure developed in the first main circuit 7 or the pressure developed in the second main circuit 8 acts on one end of the variable relief valve 52 and in the piston bottom chamber 53 a of the piston unit 53 , so that the pressure produced in the first main circuit 7 or second main circuit 8 due to travel becomes at or lower than a prescribed regulated pressure (say 420 kg/cm 2 , for example). The variable relief valve 52 , in addition, during vehicle braking or deceleration, restricts the oil returning to the return relief circuit 15 b from the piston head chamber 53 b by the restrictor 55 , raising the pressure thereon, and retarding and weakening the compression of the spring 52 a by the piston unit 53 , so as to make the pressure generated in the first main circuit 7 or second main circuit 8 become a control pressure (pressure variable from 150 to 420 kg/cm 2 , for example) following the inertial energy of the vehicle.
The variable relief valve 52 , furthermore, when the vehicle is braking or decelerating, raises the pressure by the manipulation of the accelerator pedal 110 when it is desired to increase vehicle speed.
If a control input is made during reverse travel to effect forward travel, and the accelerator pedal 110 is depressed, when it is desired to increase the vehicle speed in the forward direction, the pressure is raised, shortening the braking time (braking distance), and the vehicle speed in the forward direction is increased.
The control valve 60 , as diagrammed in FIG. 1 and FIG. 3, is configured with three positions and six ports, provided at one end with a third pressure unit 61 and spring 62 , and tenth pressure unit 61 A and provided at the other end with a fourth pressure unit 63 and spring 64 . The three positions are a neutral position G positionally determined by the springs 62 and 64 , a travel position H for forward or reverse travel, and a relief position I for braking. A first port 66 is connected by the fifth pilot circuit 42 to the fifth port 35 of the pilot pressure supply valve 30 . The second port 67 is connected to the third pressure unit 61 . A third port 68 is connected by a sixth pilot circuit 75 to the intake circuit 13 . A fourth port 69 is connected by a seventh pilot circuit 76 to a regulator 80 (described below) in the travel hydraulic pump 2 . A fifth port 70 is connected to the return relief circuit 15 b . The sixth port 71 is connected by an eighth pilot circuit 77 to the piston head chamber 53 b . And the fourth pressure unit 63 is connected by an eighth pilot circuit 78 to the return relief circuit 15 b.
The tenth pressure unit 61 A is connected to the return relief circuit 15 b and the unloading valve 100 described below.
The control valve 60 , furthermore, is in the relief position I when the vehicle is braking, cutting off the oil returning from the piston head chamber 53 b to the return relief circuit 15 b via the eighth pilot circuit 77 and the control valve 60 . At this time, the oil returning from the piston head chamber 53 b to the return relief circuit 15 b is restricted by the restrictor 55 so that its pressure is raised, thereby both retarding and weakening the contraction of the spring 52 a by the piston unit 53 , and the pressure developed in the first main circuit 7 or second main circuit 8 becomes a braking pressure (for example, a pressure variable from 150 to 420 kg/cm 2 ) that is caused by the inertial energy of the vehicle.
The first restrictor unit 57 comprises a first restrictor 57 a and a check valve 57 b . The first restrictor 57 a increases the resistance to the return oil flowing to the return relief circuit 15 b , while a prescribed pressure (2 kg/cm 2 , for example) is generated by the check valve 57 b . This prescribed pressure acts from the eighth pilot circuit 78 and the fourth pressure unit 63 , switching the control valve 60 to the relief position I when the variable relief valve 52 is activated.
The second restrictor unit 58 , when the accelerator pedal is depressed, while braking, so that the discharge quantity QA from the travel hydraulic pump 2 is increased, increases resistance to the return oil flowing to the return relief circuit 15 b , raises the adjustment pressure at the variable relief valve 52 , and raises the braking force.
As diagrammed in FIG. 1, a regulator 80 is attached to the travel hydraulic pump 2 to make the pump discharge volume (i.e., the discharge volume per revolution, in cc/rev) variable. This regulator 80 comprises a piston cylinder 81 , a servo valve 82 , a restrictor 83 , and a check valve 84 . The piston cylinder 81 is connected to an inclined plate (not shown), receives oil from the servo valve 82 for controlling the tilt angle, and makes the discharge volume of the pump variable. On the bottom side of the piston cylinder 81 a spring 85 is inserted to compress the piston 81 a in order to increase both the tilt angle and the pump discharge volume. The pilot pressure (Pac) from either the first main circuit 7 or second main circuit 8 is received on the head side of the piston cylinder 81 via the control valve 60 .
The servo valve 82 is configured with two positions and three ports. A first port 86 is connected to the seventh pilot circuit 76 , and receives the pilot pressure (Pac) from either the first main circuit 7 or second main circuit 8 via the control valve 60 . A second port 87 is connected to the second return circuit 43 . A third port 88 is connected to the piston cylinder 81 via the restrictor 83 and check valve 84 . The servo valve 82 is connected by a link 89 to the piston cylinder 81 and moves together therewith.
The servo valve 82 is provided at one end with a fifth pressure unit 90 and spring 91 , and at the other end with a sixth pressure unit 92 .
The fifth pressure unit 90 receives the pilot pressure (Pac) from the seventh pilot circuit 76 via the control valve 60 . The sixth pressure unit 92 receives the pressure developed in response to the turning speed of the engine 1 , via an oil line 93 branching off from the discharge line 3 a of the control hydraulic pump 3 .
The servo valve 82 is in the J position when, while traveling, the drive pressure is high in either the first main circuit 7 or second main circuit 8 that drives the travel hydraulic motor 6 , moving the piston cylinder 81 to the right, as diagrammed, against the force of the spring 91 , and reducing the discharge volume (cc/rev). When the drive pressure is low during travel, and the engine turning speed is high, the servo valve 82 is in the K position, moving the piston cylinder 81 to the left, as diagrammed, working with the spring 91 , to increase the discharge volume (cc/rev). When the travel hydraulic motor 6 is driven backward by the inertial energy of the vehicle, the drive pressure during travel is low, and the turning speed of the engine 1 is also low, the servo valve 82 is in either the K or J position, the piston cylinder 81 is moved to the left, as diagrammed, by the spring 91 , and the discharge volume (cc/rev) is increased so that cavitation does not occur.
An unloading valve 100 is placed in the line 99 that branches off from the discharge line 2 a of the travel hydraulic pump 2 . On one end of the unloading valve 100 acts the discharge pressure from the travel hydraulic pump 2 , while the other end is acted on by the drive pressure, during travel, of the first main circuit 7 or second main circuit 8 , via the seventh pilot circuit 76 , and by the force of a spring 101 .
When the unloading valve 100 is activated, the return oil passes through the return lines 103 and 103 a , and flows to the return relief circuit 15 b from between the first restrictor unit 57 and the second restrictor unit 58 . The line 103 is connected to the tenth pressure unit 61 A of the control valve 60 .
The unloading valve 100 is not activated while the control valve 60 is in the neutral position G and the travel valve 5 is in the neutral position A, and the discharge oil from the travel hydraulic pump 2 passes through the travel valve 5 in the neutral position A, opens the back-pressure valve 17 , and returns to the tank 9 .
When the control valve 60 is in the travel position H, the drive pressure during travel in the first main circuit 7 or second main circuit 8 acts on the other end of the unloading valve 100 , via the seventh pilot circuit 76 , matching the force of the spring 101 , and raising the discharge pressure from the travel hydraulic pump 2 to or above the drive pressure during travel in the first main circuit 7 or second main circuit 8 .
When the control valve 60 is in the relief position I due to the activation of the variable relief valve 52 , the other end of the unloading valve 100 is connected to the tank 9 via the seventh pilot circuit 76 , the relief position I, the sixth pilot circuit 75 , and the intake circuit 13 , and is at low pressure. When the pressure acting on the one end is low (at a low pressure when traveling forward or in reverse and the travel hydraulic motor 6 is driven backward by the inertial energy of the vehicle), that is, when the direction of travel, either forward or reverse, is in agreement with the control position of the travel valve 5 (i.e. the forward position B or reverse position C), the unloading valve 100 is not activated, and the discharge oil from the travel hydraulic pump 2 is sent to either the first main circuit 7 or the second main circuit 8 via the control position of the travel valve 5 , whereupon cavitation is prevented.
When the vehicle is being operated in forward travel or reverse travel, or being switched to forward while in reverse, the unloading valve 100 configures a pressurizing unit 105 that raises the braking pressure even higher. This pressurizing unit 105 comprises the unloading valve 100 and the second restrictor unit 58 . As described in the foregoing, when the variable relief valve 52 is activated and the control valve 60 is in the relief position I, the other end of the unloading valve 100 is at low pressure, and the pressure acting on the first end of the unloading valve 100 is high, that is, when the vehicle operation is being switched to reverse while moving forward, or to forward while traveling in reverse, the unloading valve 100 is activated, and the discharge oil from the travel hydraulic pump 2 flows from the intake circuit 13 to the tank 9 via the unloading valve 100 , the return line 103 , the return relief circuit 15 b , and the second restrictor unit 58 . At this time, the discharge oil from the travel hydraulic pump 2 that is unloaded is restricted by the second restrictor unit 58 , so that its pressure rises, and this pressure acts on the variable relief valve 52 , raising the adjustment pressure and making the braking force large.
To the engine 1 , an accelerator pedal 110 for controlling a fuel supply apparatus (not shown) is provided. When the accelerator pedal 110 is depressed, increasing its volume, the fuel supplied to the engine 1 increases and its rotational speed increases.
In the discharge line 2 a of the travel hydraulic pump 2 is placed a check valve 2 b , so that, when changing forward-reverse directions on a slope, the vehicle does not descend the slope even when the unloading valve 100 unloads. This is also so that high pressure does not act on the travel hydraulic pump 2 . When switching from forward travel to reverse travel or from reverse travel to forward travel, for example, the hydraulic pressure generated in the main circuit, that is, either the first main circuit 7 or the second main circuit 8 , does not act on the travel hydraulic pump 2 .
The travel operation is next described. The operation unit 48 is manipulated to run the work vehicle in the forward direction, for example, sending current to the first solenoid 45 of the pilot pressure supply valve 30 , and thereby switching the pilot pressure supply valve 30 over to the forward position E. The pilot pressure supply valve 30 blocks the return to the tank 9 of oil from the discharge line 3 a of the control hydraulic pump 3 , whereupon the oil from the control hydraulic pump 3 returns to the tank 9 via the variable restrictor 18 , producing a pressure responsive to the turning speed of the engine 1 , detecting the turning speed of the engine 1 , and supplying that pressure to the sixth pressure unit 92 in the servo valve 82 of the travel hydraulic pump 2 via the oil line 93 branching off from the discharge line 3 a of the control hydraulic pump 3 . The pilot pressure supply valve 30 receives the pressure driving the travel hydraulic motor 6 at the first port 31 from the first main circuit 7 connecting the travel valve 5 and the travel hydraulic motor 6 , via the first pilot circuit 38 , and supplies the drive pressure from the first main circuit 7 to the third pressure unit 61 of the control valve 60 , as the pilot pressure (Pac), via the first port 31 to the fifth port 35 , the fifth pilot circuit 42 , and the control valve 60 , switching the control valve 60 over to the travel position H. The pilot pressure supply valve 30 also supplies pilot pressure to the first pressure unit 26 of the travel valve 5 from the first port 31 via the second port 32 and the second pilot circuit 39 , while the pilot pressure of the second pressure unit 28 is returned to the tank 9 via the fourth pilot circuit 41 and the pilot pressure supply valve 30 , whereupon the travel valve 5 is switched over to the forward position B. The control valve 60 receives the drive pressure from the first main circuit 7 , via the fifth pilot circuit 42 , in the first port 66 , and supplies the drive pressure as a pilot pressure (Pac) to the fifth pressure unit 90 in the travel hydraulic pump 2 via the fourth port 69 and the seventh pilot circuit 76 .
When the pilot pressure supply valve 30 is switched over to the forward position E, the prescribed pressure in the first main circuit 7 restricted by the restrictor 29 c in the travel valve 5 moves the travel valve 5 to the forward position B and the control valve 60 to the travel position H, being supplied to the fifth pressure unit 90 in the servo valve 82 of the travel hydraulic pump 2 , whereupon the pressure oil discharged from the travel hydraulic pump 2 is supplied to the first main circuit 7 , and the oil in the second main circuit 8 flows to the tank 9 , turning the travel hydraulic motor 6 in the forward direction. At this time, the drive pressure driving the travel hydraulic motor 6 is at high pressure in order to start traveling, wherefore the servo valve 82 of the travel hydraulic pump 2 is in the J position, and the drive pressure moves the piston cylinder 81 to the right, as diagrammed, against the spring 91 , reducing the discharge volume (cc/rev). Accordingly, the work vehicle begins traveling at a slow speed without jolting. At this time, furthermore, the control valve 60 is slowly activated and switched over by the restriction in the neutral position and by the restrictor 83 of the regulator 80 , so that travel can be started without jolting.
At this time, moreover, the control valve 60 is in the travel position H, wherefore the oil in the piston head chamber 53 b returns to the return relief circuit 15 b via the eighth pilot circuit 77 and the sixth port 71 and fifth port 70 in the control valve 60 , so that the return from the piston head chamber 53 b to the return relief circuit 15 b is rapid. For this reason, the drive pressure in the first main circuit 7 acts through the relief circuit 15 a on one end of the variable relief valve 52 and in the piston bottom chamber 53 a in the pressure unit 53 , rapidly activating the piston unit 43 , and causing the pressure due to travel in the first main circuit 7 to become the designated regulated pressure (420 kg/cm 2 , for example).
When next, to raise the speed of travel, when the operator steps on the accelerator pedal 110 and increases its volume, the turning speed of the engine 1 rises, wherefore the discharge pressure of the control hydraulic pump 3 increases, and this high discharge pressure is supplied to the sixth pressure unit 92 of the servo valve 82 in the travel hydraulic pump 2 . Meanwhile, when the travel speed increases, the drive pressure in the first main circuit 7 driving the travel hydraulic motor 6 decreases. This decreased drive pressure is supplied to the fifth pressure unit 90 of the servo valve 82 in the travel hydraulic pump 2 via the pilot pressure supply valve 30 , control valve 60 , and seventh pilot circuit 76 . Thus the servo valve 82 moves the piston 81 a to the left as diagrammed (FIG. 1) together with the spring 91 by the pressure oil flowing from the seventh pilot circuit 76 through the K position to the bottom side of the piston cylinder 81 , thereby increasing the discharge volume (cc/rev) and increasing the speed of the vehicle. At this time, the high discharge pressure of the control hydraulic pump 3 acts on the back-pressure valve 17 to reduce the pressure on the oil returning from the travel hydraulic motor 6 .
Next is described the case where the vehicle is decelerated while traveling at high speed. When the operator eases up on the accelerator pedal 110 , the discharge pressure of the control hydraulic pump 3 decreases because the turning speed of the engine 1 decreases, and that decreased discharge pressure is supplied to the sixth pressure unit 92 of the servo valve 82 in the travel hydraulic pump 2 . Because the work vehicle is traveling at high speed, moreover, the drive pressure driving it is also low. Nevertheless, in order to decelerate further, the travel hydraulic motor 6 receives a drive force opposite to the inertial energy of the vehicle, whereupon the drive pressure in the first main circuit 7 becomes a low pressure, and the pressure supplied to the fifth pressure unit 90 in the servo valve 82 also becomes lower. The servo valve 82 , therefore, moves from the J position to the K position, and the oil on the bottom side of the piston cylinder 81 returns to the tank 9 via the restrictor 83 of the regulator 80 and the servo valve 82 in the K position. Thus the piston 81 a is moved to the right as diagrammed (FIG. 1 ), reducing the discharge volume (cc/rev), but when it has moved a prescribed amount the piston 81 a comes up against the spring 85 and stops, whereupon the discharge volume (cc/rev) of the travel hydraulic pump 2 is maintained at the prescribed value. The prescribed volume of oil discharged from this travel hydraulic pump 2 is sent via the discharge line 2 a and the travel valve 5 in the forward position B to the first main circuit 7 , thus maintaining the prescribed pressure (20 kg/cm 2 , for example), whereupon cavitation is definitely prevented from occurring in the travel hydraulic motor 6 . At this time, the oil returning to the tank 9 from the travel hydraulic motor 6 increases the oil volume supplied from the intake valve 12 to the first main circuit 7 .
The case of traveling down a slope is next described.
When traveling down a slope, the inertial energy of the work vehicle increases, and the turning speed of the travel hydraulic motor 6 seeks to exceed a speed commensurate with the discharge quantity supplied from the travel hydraulic pump 2 , that is to say, an overrun occurs, whereupon the pressure in the first main circuit 7 decreases. Accordingly, the pilot pressure acting from the first main circuit 7 on the first pressure unit 26 in the travel valve 5 , via the first pilot circuit 38 , the pilot pressure supply valve 30 in the forward position E, and the second pilot circuit 39 , decreases.
The travel valve 5 , therefore, is returned to the neutral position A from the forward position E by the first spring 25 . When the travel valve 5 is returned to the neutral position A, the return oil discharged from the travel hydraulic motor 6 being driven by the inertial energy of the work vehicle is blocked from returning to the tank 9 by the second check valve 29 b of the travel valve 5 , and the pressure of the oil returning from the travel hydraulic motor 6 rises. Due to this rise in the pressure of the return oil of the travel hydraulic motor 6 , a braking torque is produced which causes the turning speed of the travel hydraulic motor 6 to decelerate. Also, the pilot pressure that acts, from the first main circuit 7 , on the third pressure unit 61 in the control valve 60 , via the first pilot circuit 38 , the pilot pressure supply valve 30 in the forward position E, the fifth pilot circuit 42 , and the control valve 60 in the travel position H, is reduced. Therefore the control valve 60 is returned to the neutral position G from the forward position E by the spring 64 .
The control valve 60 connects the seventh pilot circuit 76 connected to the servo valve 82 in the travel hydraulic pump 2 with the sixth pilot circuit 75 connected to the tank 9 via the intake circuit 13 , and reduces the pilot pressure acting on the servo valve 82 in the travel hydraulic pump 2 . The servo valve 82 is switched over to the K position by the discharge pressure of the control hydraulic pump 3 acting on the sixth pressure unit 92 , and the oil on the bottom side of the piston cylinder 81 returns to the tank 9 via the restrictor 83 of the regulator 80 and the servo valve 82 in the K position. Thus the piston 81 a is moved to the right, as diagrammed (FIG. 1 ), reducing the discharge volume (cc/rev), but when it moves a prescribed amount the piston 81 a comes up against the spring 85 and stops, whereupon the discharge volume (cc/rev) of the travel hydraulic pump 2 is maintained at the prescribed value. This prescribed volume of oil discharged from the travel hydraulic pump 2 is sent via the discharge line 2 a and the first check valve 29 a of the travel valve 5 in the neutral position A to the first main circuit 7 , and the prescribed pressure (20 kg/cm 2 , for example) is maintained, while the oil returning to the tank 9 from the travel hydraulic motor 6 increases the oil volume supplied from the intake valve 12 to the first main circuit 7 .
As a result of all this, the work vehicle will be braked, and overrun in the work vehicle will be prevented. When the work vehicle is braked and its speed decreases, the pressure in the first main circuit 7 will again rise, the travel hydraulic motor 6 will be balanced at a speed commensurate with the discharge quantity supplied from the travel hydraulic pump 2 , and the work vehicle will travel down the slope.
Next will be described the case of the work vehicle being stopped from a traveling state.
The operator eases up on the accelerator pedal 110 and at the same time manipulates the operation unit 48 from the forward position to the neutral position. The turning speed of the engine 1 decreases, wherefore the discharge pressure of the control hydraulic pump 3 also decreases, and this lowered discharge pressure is supplied to the sixth pressure unit 92 of the servo valve 82 in the travel hydraulic pump 2 . Due to the manipulation of the operation unit 48 , the current that had been flowing to the first solenoid 45 stops, and the pilot pressure supply valve 30 returns to the neutral position D from the forward position E. As a result, the pressure driving the travel hydraulic motor 6 supplied to the first port 31 from the first main circuit 7 via the first pilot circuit 38 is shut off by the first port 31 . Also, the supply of the pilot pressure (Pac) from the first main circuit 7 that had been acting on the third pressure unit 61 in the control valve 60 via the first port 31 is stopped, and the control valve 60 is returned to the neutral position G from the travel position H. Also, the supply of the pilot pressure to the first pressure unit 26 in the travel valve 5 via the first port 31 is stopped, and the travel valve 5 is returned to the neutral position A from the forward position B.
At this time, when the inertial energy of the work vehicle is large due to the cargo being carried, etc., the travel hydraulic motor will be subjected to the large opposite drive force caused by the inertial energy of the vehicle. The return oil in the second main circuit 8 discharged from the travel hydraulic motor 6 driven by the inertial energy of the work vehicle is prevented from returning to the tank 9 by the second check valve 29 b in the travel valve 5 , and the pressure on the oil returning from the travel hydraulic motor 6 rises. Due to the rise in pressure on the return oil of the travel hydraulic motor 6 , a braking torque is developed which acts to slow down the turning speed of the travel hydraulic motor 6 . This braking torque is generated by the pressure that is produced by the variable relief valve 52 when the return oil from the second main circuit 8 acts thereon via the check valve 14 acting as a relief valve. This pressure that is produced is determined by the size of the opposite drive force caused by the inertial energy of the vehicle.
In other words, since the control valve 60 is in the neutral position G, the oil returning to the return relief valve 15 b from the piston head chamber 53 b via the eighth pilot circuit 77 and the control valve 60 is shut off. At this time, the oil returning to the return relief circuit 15 b from the piston head chamber 53 b has its pressure raised by the restriction of the restrictor 55 , the compression of the spring 52 a by the piston unit 53 is retarded and weakened, and the pressure generated in the second main circuit 8 is adjusted by the variable relief valve 52 so that it becomes a braking pressure (a pressure variable from 150 to 420 kg/cm 2 , for example) caused by the inertial energy of the vehicle. The pressure oil in this relief circuit 15 a , after adjustment, flows to the return relief circuit 15 b , and is supplied to the first main circuit 7 from the intake valve 12 via the intake circuit 13 .
Also, because the control valve 60 is in the neutral position G, the discharge quantity of the travel hydraulic pump 2 acts in the same manner as when the vehicle is traveling down a slope, as described earlier.
The control valve 60 connects the seventh pilot circuit 76 connected to the servo valve 82 of the travel hydraulic pump 2 with the sixth pilot circuit 75 connected to the tank 9 via the intake circuit 13 , and lowers the pilot pressure acting on the servo valve 82 of the travel hydraulic pump 2 . The servo valve 82 is switched over to the K position by the discharge pressure of the control hydraulic pump 3 acting on the sixth pressure unit 92 , and the oil on the bottom side of the piston cylinder 81 returns to the tank 9 via the restrictor 83 in the regulator 80 and the servo valve 82 in the K position. Therefore the piston 81 a is moved to the right, as diagrammed, reducing the discharge volume (cc/rev). When it has moved the prescribed amount, the piston 81 a comes up against the spring 85 and stops, and the discharge volume (cc/rev) of the travel hydraulic pump 2 is maintained at the prescribed value. The oil discharged from this travel hydraulic pump 2 in the prescribed volume (20 kg/cm 2 , for example) is sent to the first main circuit 7 , via the discharge line 2 a and the first check valve 29 a of the travel valve 5 in the neutral position A, wherefore cavitation is definitely prevented from occurring in the travel hydraulic motor 6 . At this time, the oil returning to the tank 9 from the travel hydraulic motor 6 increases the oil volume supplied from the intake valve 12 to the first main circuit 7 .
As a result of these operations, the work vehicle is braked, and the work vehicle can be stopped in a prescribed braking distance by a braking pressure caused by the inertial energy of the vehicle.
Next is described the case of changing the work vehicle from traveling forward to traveling in reverse.
FIG. 4 is a graph plotting the relationship between travel speed V (km/h) and time. Vehicle speed V (km/h) is plotted on the vertical axis, and both stopping time and starting time (sec) are plotted on the horizontal axis. The solid curve in the graph represents the condition of manipulating (stepping on) the accelerator pedal when changing to the state of traveling in reverse from the state of traveling forward, while the dashed curve represents the condition wherein the accelerator pedal is not manipulated.
FIG. 5 is a graph plotting the relationship between the pressure P (adjustment pressure (kg/cm 2 ) at variable relief valve) acting on the travel hydraulic motor 6 and time. Pressure(kg/cm 2 ) is plotted on the vertical axis, and both stopping time and takeoff time (sec) on the horizontal axis. The solid curve in the graph represents the condition of manipulating (stepping on) the accelerator pedal either in the period during which reverse travel is changed to from a condition of forward travel, or in the period during which forward travel is changed to from a condition of reverse travel, while the dashed curve represents the condition wherein the accelerator pedal is not manipulated.
The operator eases up on the accelerator pedal 110 and, at the same time, manipulates the operation unit 48 from the forward position to the reverse position. The turning speed of the engine 1 decreases, so the discharge pressure of the control hydraulic pump 3 also decreases. This lowered discharge pressure is supplied to the sixth pressure unit 92 in the servo valve 82 of the travel hydraulic pump 2 . The current that is flowing in the first solenoid 45 is stopped by the manipulation of the operation unit 48 , and, at the same time, current begins flowing in the second solenoid 47 , and the pilot pressure supply valve 30 is switched over from the forward position E to the reverse position F. The pilot pressure supply valve 30 receives, at the third port 33 , the pressure driving the travel hydraulic motor 6 from the second main circuit 8 connecting the travel valve 5 and the travel hydraulic motor 6 , and, from the third port 33 , supplies the drive pressure from the second main circuit 8 as a pilot pressure (Pac) to the third pressure unit 61 in the control valve 60 , via the fifth port 35 , the fifth pilot circuit 42 , and the control valve 60 , switching the control valve 60 to the travel position H. Also, the pilot pressure supply valve 30 supplies pilot pressure from the third port 33 to the second pressure unit 28 in the travel valve 5 , via the fourth port 34 and the fourth pilot circuit 41 . The pilot pressure of the first pressure unit 26 is returned to the tank 9 via the second pilot circuit 39 and the pilot pressure supply valve 30 , switching the travel valve 5 over to the reverse position C. The control valve 60 receives the drive pressure from the second main circuit 8 at the first port 66 , via the fifth pilot circuit 42 , and supplies the drive pressure as a pilot pressure (Pac) via the fourth port 69 and seventh pilot circuit 76 to the fifth pressure unit 90 in the servo valve 82 of the travel hydraulic pump 2 .
The pilot pressure supply valve 30 is moved to the reverse position F, the travel valve 5 to the reverse position C, and the control valve 60 to the travel position H, while the drive pressure is supplied to the fifth pressure unit 91 in the servo valve 82 of the travel hydraulic pump 2 . The discharge pressure of the travel hydraulic pump 2 is supplied to the second main circuit 8 and, at the same time, the oil in the first main circuit 7 flows to the tank 9 and turns the travel hydraulic motor 6 in the reverse position. However, by the changeover at reverse travel time, the pressure oil for reverse travel is supplied to the second main circuit 8 in which return oil is flowing during forward travel. At this time, the work vehicle is not stopped, so the travel hydraulic motor 6 is subjected to the opposite drive force caused by the inertial energy of the vehicle, the drive pressure in the first main circuit 7 becomes a low pressure, and a high pressure is developed in the second main circuit 8 due to the merging of the pressure oil for reverse travel from the travel hydraulic pump 2 and the return oil that discharges, acted upon by the opposite drive force of the travel hydraulic motor 6 . The high pressure generated in the second main circuit 8 acts on the variable relief valve 52 via the check valve 14 acting as a relief valve, the variable relief valve 52 is activated by the high pressure so generated, the rotational speed in the forward direction is gradually reduced, and the vehicle is stopped.
For example, as indicated in FIG. 4, the vehicle moving forward at a travel speed of 20 (km/h) is switched over to travel in the reverse direction by manipulating the operation unit 48 from the forward position to the reverse position. In this case, when the operator eases up his or her foot pressure on the accelerator pedal, the vehicle stops at the 3-second position, as indicated by the dashed curve, and, as will be described in greater detail below, the control valve 60 is switched, so that the vehicle travels next in the forward direction.
When the variable relief valve 52 is activated and the oil, after adjustment, flows into the return relief circuit 15 b , it is restricted by the restrictor unit 57 , producing the prescribed pressure, which acts on the fourth pressure unit 63 from the eighth pilot circuit 78 , and the control valve 60 is switched over to the relief position I when the variable relief valve 52 is activated.
As a result of this changeover, the control valve 60 is in the relief position I, so the oil returning from the piston head chamber 53 b to the return relief circuit 15 b via the eighth pilot circuit 77 and the control valve 60 is shut off. At this time, the oil returning from the piston head chamber 53 b to the return relief circuit 15 b has its pressure raised by the restriction of the restrictor 55 , whereupon the compression of the spring 52 a by the piston unit 53 is retarded and weakened, and the pressure produced in the second main circuit 8 is regulated by the variable relief valve 52 so that it becomes a braking pressure (a pressure variable from 150 to 420 kg/cm 2 , for example) caused by the inertial energy of the vehicle. The pressure oil in this relief circuit 15 a , after adjustment, flows into the return relief circuit 15 b , and is supplied to the first main circuit 7 from the intake valve 12 via the intake circuit 13 .
For example, as indicated in FIG. 5, the pressure of the return oil that the travelling hydraulic motor 6 discharges upon receipt of the reverse drive force gradually raises from roughly zero at the initial state to 200 kg/cm 2 , due to the restrictor 55 in the variable relief valve unit 51 , so that, the vehicle does not stop suddenly and develop jolting due to the braking pressure by the variable relief valve 52 .
This pressure (200 kg/cm 2 ) continues for 3 seconds and stops the vehicle. After that, as will be described below in greater detail, the vehicle begins moving in reverse, and the pressure driving the travel hydraulic motor 6 in reverse rises further to 420 kg/cm 2 .
When the control valve 60 is in the relief position I, the seventh pilot circuit 76 connecting to the servo valve 82 in the travel hydraulic pump 2 is connected with the sixth pilot circuit 75 connecting to the tank 9 via the intake circuit 13 , whereupon the pilot pressure acting on the servo valve 82 of the travel hydraulic pump 2 is reduced.
The servo valve 82 is switched over to the K position by the discharge pressure of the control hydraulic pump 3 acting on the sixth pressure unit 92 , and the oil on the bottom side of the piston cylinder 81 returns to the tank 9 via the restrictor 83 of the regulator 80 and the servo valve 82 in the K position. The piston 81 a is thereby moved to the right, as diagrammed (FIG. 1 ), reducing the discharge volume (cc/rev). When it moves a prescribed amount, the piston 81 a comes up against the spring 85 and stops, and the discharge volume (cc/rev) of the travel hydraulic pump 2 is maintained at the prescribed value.
At this time, the pilot pressure (Pac) described earlier acts at low pressure on the other end of the unloading valve 100 , and the pressure acting on the first end of the unloading valve 100 rises because the discharge oil from the travel hydraulic pump 2 is cut off by the check valve 2 b . For this reason, the unloading valve 100 is activated, and the discharge oil from the travel hydraulic pump 2 flows from the intake circuit 13 to the tank 9 via the unloading valve 100 , return line 103 , return relief circuit 15 b , and second restrictor unit 58 . At this time, the unloaded travel hydraulic pump 2 discharge oil is restricted by the second restrictor unit 58 , which raises its pressure. This pressure acts on the variable relief valve 52 , raising the adjustment pressure and making the braking force large. In addition to flowing from the intake circuit 13 to the tank 9 , it is supplied from the intake valve 12 to the first main circuit 7 , and cavitation ceases to occur in the first main circuit 7 .
As explained in the foregoing, the oil volume supplied from the travel hydraulic pump 2 to the travel hydraulic motor 6 is maintained securely as a prescribed volume by the spring 85 provided in the regulator 80 , wherefore, even when a switching operation is done, from forward travel to reverse travel or from reverse travel to forward travel, the oil volume supplied to the travel hydraulic motor 6 increases, and cavitation ceases to occur. Thus the back-and-forth manipulations that were very difficult with conventional open-circuit hydraulic drives become possible, and damage to hydraulic equipment is prevented. The variable relief valve 52 is used, and, in conjunction therewith, the braking pressure and braking time thereof is made so as to follow the inertial energy of the vehicle, so the braking distance can be made roughly constant irrespective of vehicle speed.
The pressure regulation with this second main circuit 8 , and the supply of return oil to the first main circuit 7 , are conducted until the work vehicle stops. When the work vehicle stops, the pressure regulation by the variable relief valve 52 stops, and the oil volume flowing to the return relief circuit 15 b disappears. Thus the prescribed pressure acting on the fourth pressure unit 63 disappears, and the control valve 60 is returned to the neutral position G. At this time, the pilot pressure supply valve 30 is in the reverse position F, wherefore the control valve 60 supplies the pressure driving the travel hydraulic motor 6 to the third port 33 from the second main circuit 8 connecting the travel valve 5 and the travel hydraulic motor 6 via the third pilot circuit 40 , and further supplies the drive pressure from the second main circuit 8 , as pilot pressure (Pac), to the third pressure unit 61 from the pilot pressure supply valve 30 and the third port 33 via the fifth port 35 and the fifth pilot circuit 42 , and switches the control valve 60 to the travel position H. The control valve 60 receives the drive pressure from the second main circuit 8 , via the fifth pilot circuit 42 , at the first port 66 , and supplies the drive pressure as pilot pressure (Pac) to the fifth pressure unit 90 of the servo valve 82 in the travel hydraulic pump 2 , via the seventh pilot circuit 76 .
At this time, the drive pressure driving the travel hydraulic motor 6 is at high pressure for starting the vehicle traveling from forward to reverse, wherefore the servo valve 82 of the travel hydraulic pump 2 is in the J position, and the drive pressure acts against the spring 91 to move the piston cylinder 81 to the right, as diagrammed, thus reducing the discharge volume (cc/rev). Accordingly, the work vehicle begins to travel at a slow speed without jolting. At this time, furthermore, the control valve 60 is activated and switched over slowly by the restriction in the neutral position and the restrictor 83 in the regulator 80 , wherefore travel in the reverse direction can be started without jolting. For example, as indicated by the dashed curve in FIG. 5, the pressure of the return oil that the travelling hydraulic motor 6 discharges upon receipt of the reverse drive force gradually raises from roughly zero at the initial state to 200 kg/cm 2 , due to the restrictor 55 in the variable relief valve unit 51 , so that, the vehicle does not stop suddenly and develop jolting due to the braking pressure by the variable relief valve 52 . This pressure (200 kg/cm 2 ) continues for 3 seconds and stops the vehicle, after which, continuing on therefrom, it slowly rises to 380 kg/cm 2 and travel in the reverse direction is started. There is no sudden changeover, so the hydraulic equipment is not damaged.
At this time, moreover, because the control valve 60 is in the travel position H, the oil in the piston head chamber 53 returns to the return relief circuit 15 b via the eighth pilot circuit 77 , and the sixth port 71 and fifth port 70 in the control valve 60 , wherefore that oil returns rapidly from the piston head chamber 53 b to the return relief circuit 15 b . For this reason, the drive pressure in the first main circuit 7 acts via the relief circuit 15 a on one end of the variable relief valve 52 and in the piston bottom chamber 53 a of the piston unit 53 , whereupon the piston unit 53 is rapidly activated, so that the pressure due to travel in the first main circuit 7 becomes the prescribed adjustment pressure (420 kg/cm 2 for example).
In the foregoing description, the operator, in the example assumed, manipulates the operation unit 48 from the forward position to the reverse position, effecting a changeover to travel in the reverse direction, at which time, moreover, foot pressure on the accelerator pedal 110 is eased. Next, however, is described a case where, at such time, foot pressure on the accelerator pedal 110 is increased.
When foot pressure on the accelerator pedal 110 is increased, the rotational speed of the engine 1 is increased, along with which the discharge quantity QB from the travel hydraulic pump 2 increases. At this time, the discharge quantity QB, as described earlier, is secured at the prescribed volume by the spring 85 in the regulator 80 . This discharge quantity QB from the travel hydraulic pump 2 flows from the intake circuit 13 to the tank 9 via the unloading valve 100 , return line 103 , return relief circuit 15 b , and second restrictor unit 48 , as in the previous description. At this time, the unloaded travel hydraulic pump 2 discharge oil is restricted by the second restrictor unit 58 so that its pressure rises. This pressure acts on the variable relief valve 52 , raising the adjustment pressure and making the braking force large.
As indicated by the solid curve in FIG. 5, for example, when the operator manipulates the operation unit 48 from the forward position to the reverse position, switching over so as to travel in the reverse direction, the pressure of the return oil that the travelling hydraulic motor 6 discharges upon receipt of the reverse drive force gradually raises from roughly zero at the initial state to 200 kg/cm 2 , due to the restrictor 55 in the variable relief valve unit 51 , so that, the vehicle does not stop suddenly and develop jolting due to the braking pressure by the variable relief valve 52 . And, as diagrammed, if foot pressure on the accelerator pedal 110 is increased 1 second later, for example, this pressure (200 kg/cm 2 ) is such that the discharge quantity QB from the travel hydraulic pump 2 increases along with the further increase in the rotational speed of the engine 1 , whereby, as described earlier, the variable relief valve 52 increases the adjustment pressure to approximately 300 kg/cm 2 and increases the braking force. Due to this increase in braking force, should the foot pressure on the accelerator pedal 110 be eased, the vehicle stopping time, which was 3 seconds, is shortened to 2.5 seconds. After the vehicle has stopped, moreover, it will begin traveling in reverse. At that time, however, the discharge quantity QB from the travel hydraulic pump 2 has increased, wherefore, continuing therefrom, the pressure will increase to around 420 kg/cm 2 in a shorter time than when operated as described earlier, and the vehicle will begin traveling in reverse. For this reason, if foot pressure on the accelerator pedal 110 is increased, the stopping time is shortened, while, at the same time, the startup torque at reverse takeoff rises, vehicle acceleration performance rises, and takeoff performance is improved. At this time, furthermore, the oil returning via the second restrictor unit 58 is such that, because the discharge quantity QB from the travel hydraulic pump 2 is increased, the flow rate from the intake circuit 13 to the tank 9 is also increased, wherefore a large volume of oil is supplied from the intake valve 12 to the first main circuit 7 , whereupon cavitation ceases to be produced in the first main circuit 7 . As described earlier, the oil pressure going to the regulator 80 controlling the discharge quantity from the travel hydraulic pump 2 is received either from the first main circuit 7 connecting the travel valve 5 and the travel hydraulic motor 6 , or from the second main circuit 8 , via the control valve 60 , wherefore, even should the discharge pressure of the travel hydraulic pump 2 be high, the discharge quantity from the hydraulic pump will no longer be reduced, whereupon cavitation will no longer be produced in the travel hydraulic motor 6 . When the hydraulic pressure driving the travel hydraulic motor 6 is below the prescribed value, because a spring is provided in the hydraulic pump regulator to secure the prescribed discharge quantity, cavitation is no longer produced in the travel hydraulic motor 6 , even when the vehicle is acted on by an opposite drive force.
The variable relief valve 52 , moreover, when the vehicle is braking or decelerating, raises the pressure on the oil returning to the return relief circuit 15 b from the piston head chamber 53 b by restricting it by the restrictor 55 , delaying and weakening the compression of the spring 52 a by the piston unit 53 , and makes the pressure generated in either the first main circuit 7 or second main circuit 8 a braking pressure (pressure variable from 150 to 420 kg/cm 2 , for example) that is caused by the inertial energy of the vehicle, so that the direction of travel can be changed without jolting. The servo valve 82 in the travel hydraulic pump 2 , furthermore, acts against the spring 91 to move the piston cylinder 81 to the right, as diagrammed (FIG. 1 ), reducing the discharge volume (cc/rev), wherefore the work vehicle can be made to begin traveling at a slow speed without jolting. At this time, moreover, the control valve 60 is slowly activated and switched, due to the restriction of the neutral position and the restrictor 83 in the regulator 80 , wherefore travel can be commenced without jolting. When switching over from forward travel to reverse travel or from reverse travel to forward travel, while increasing foot pressure on the accelerator pedal 110 , the variable relief valve 52 increases the adjustment pressure and increases the braking force. The stopping time is shortened by this increase in braking force, and, at the same time, the startup torque when starting off in reverse rises, improving the takeoff performance of the vehicle. By using a variable relief valve 52 that generates braking pressures that follow the inertial energy of the vehicle, the braking distance can be made roughly constant irrespective of vehicle speed, and work vehicle jolting during braking or deceleration can be eliminated. When foot pressure on the accelerator pedal 110 is reduced, the variable relief valve 52 reduces the adjustment pressure and reduces the braking force. Due to this reduction in braking force, the stopping time is lengthened, the braking distance can be made roughly constant irrespective of vehicle speed, and work vehicle jolting during braking or deceleration can be eliminated.
FIG. 6 is a hydraulic diagram of a travel drive apparatus for a hydraulic drive work vehicle in a second embodiment of the present invention. The same components as in the first embodiment are designated by the same symbols and their description is omitted.
A pressurizing unit 120 by which the pressure on the variable relief valve 52 is raised is driven by the engine 1 , and comprises a control hydraulic pump 3 that discharges a discharge quantity QB according to the rotational speed of the engine 1 , and a second restrictor unit 58 , connected to the discharge line 3 a from the control hydraulic pump 3 , for producing control pressures according to the rotational speed of the engine 1 .
With the pressurizing unit 105 of the first embodiment, the discharge pressure from the travel hydraulic pump 2 was supplied via the unloading valve 100 and return line 103 to a return relief circuit 15 b between the variable relief valve 52 and second restrictor unit 58 . With the pressurizing unit 120 in the second embodiment, however, the discharge oil from the control hydraulic pump 3 driven by the engine 1 is supplied, via a control line 121 that branches off from the discharge line 3 a , to the return relief circuit 15 b between the variable relief valve 52 and second restrictor unit 58 . Thus the second restrictor unit 58 generates a control pressure in response to the discharge quantity from the control hydraulic pump 3 , that is, a control pressure in response to the rotational speed of the engine 1 , raises the return pressure at the variable relief valve 52 by this control pressure, and thus, by this return pressure, makes the adjustment pressure at the variable relief valve 52 variable in response to the rotational speed of the engine 1 . When the vehicle is switched over from forward travel to reverse travel or from reverse travel to forward travel, for example, and, at the same time, the foot pressure on the accelerator pedal 110 is increased, the variable relief valve 52 increases the adjustment pressure in response to the rotational speed of the engine 1 , thereby increasing the braking force. When foot pressure on the accelerator pedal 110 is reduced, the variable relief valve 52 reduces the adjustment pressure, thereby reducing the braking pressure.
The operation is the same as in the first embodiment and so is not further described here.
FIG. 7 is a hydraulic diagram of a travel drive apparatus for a hydraulic drive work vehicle in a third embodiment of the present invention. The same components as in the first embodiment are designated by the same symbols and their description is omitted.
A pressurizing unit 130 , wherewith the pressure at the variable relief valve 52 is raised, comprises a control hydraulic pump 3 driven by the engine 1 , and a variable restrictor 18 , connected to the discharge line 3 a from the control hydraulic pump 3 , for producing control pressures in response to the rotational speed of the engine 1 .
With the pressurizing unit 105 of the first embodiment, the discharge pressure from the travel hydraulic pump 2 was supplied via the unloading valve 100 and return line 103 to a return relief circuit 15 b between the variable relief valve 52 and second restrictor unit 58 . With the pressurizing unit 130 in the third embodiment, however, a control line 131 branching off from the discharge line 3 a from the control hydraulic pump 3 is connected to a pressure unit 52 c at the other end of the variable relief valve 52 , and control pressures responsive to the rotational speed of the engine 1 , working with the piston unit 53 and spring 52 a , compress the variable relief valve 52 . Therefore the variable restrictor 18 produces control pressures responsive to the discharge quantity of the control hydraulic pump 3 , which is to say control pressures responsive to the rotational speed of the engine 1 . By these control pressures the return pressure at the variable relief valve 52 is raised. By this return pressure the adjustment pressure of the variable relief valve 52 A is made variable in response to the rotational speed of the engine 1 . When the vehicle is switched over from forward travel to reverse travel or from reverse travel to forward travel, and, at the same time, foot pressure on the accelerator pedal 110 is increased, the variable relief valve 52 increases the adjustment pressure and increases the braking pressure. When foot pressure on the accelerator pedal 110 is reduced, the variable relief valve 52 reduces the adjustment pressure and reduces the braking pressure.
The operation is the same as in the first embodiment and so is not further described here.
FIG. 8 is a hydraulic diagram of a travel drive apparatus for a hydraulic drive work vehicle in a fourth embodiment of the present invention. The same components as in the first embodiment are designated by the same symbols and their description is omitted.
In the fourth embodiment, as in the third embodiment, when the vehicle is switched over from forward travel to reverse travel or from reverse travel to forward travel, and, at the same time, foot pressure on the accelerator pedal 110 is increased, the variable relief valve 52 increases the adjustment pressure, and the braking force is increased, but the configuration is different.
In the fourth embodiment, the pressure in the relief circuit 15 a is led in so that it acts on one end of the variable relief valve 52 A, while at the other end thereof is installed a first pressure chamber 52 d , spring 52 e , and second pressure chamber 52 f . To the first pressure chamber 52 d is connected a pilot circuit 76 a that branches off from the seventh pilot circuit 76 , which, together with the servo valve 82 of the travel hydraulic pump 2 , is acted on by drive pressure from either the first main circuit 7 or second main circuit 8 . To the second pressure chamber 52 f is connected a control line 131 that branches off from the discharge line 3 a from the control hydraulic pump 3 , which is acted on by control pressures in response to the rotational speed of the engine 1 .
The variable relief valve 52 A, when the vehicle is traveling normally in the forward or reverse direction, is acted on by the spring 52 e , the drive pressure received in the first pressure chamber 52 d , and the control pressure responsive to rotational speed that is received in the second pressure chamber 52 f , and maintains high pressure, causing the vehicle to travel. When the variable relief valve 52 A is activated while the vehicle is stopped, decelerating, or being switched over from forward travel to reverse travel or from reverse travel to forward travel, it is acted on by the spring 52 e and the control pressure response to rotational speed received in the second pressure chamber 52 f , and maintains the prescribed pressure, causing the vehicle to brake.
The control valve 60 in the first embodiment is configured with three positions and six ports, but the control valve 60 a in the fourth embodiment is configured with three positions and four ports. In the fourth embodiment, furthermore, the sixth port 71 connected to the piston head chamber 53 B by the eighth pilot circuit 77 and the fifth port 70 connecting to the relief circuit 15 b of the first embodiment are done away with.
A pressurizing unit 140 is such that the control pressure responsive to the rotational speed of the engine 1 , via the control line 131 branching off from the discharge line 3 a from the control hydraulic pump 3 , acts on the second pressure chamber 52 f at the other end of the variable relief valve 52 A, while the drive pressure from the first main circuit 7 or second main circuit 8 act on the first pressure chamber 52 d , and, by the compression of the spring 52 e , raises the pressure at the variable relief valve 52 A.
At this time, the variable restrictor 18 produces a control pressure responsive to the discharge quantity from the control hydraulic pump 3 , that is to say a control pressure responsive to the rotational speed of the engine 1 . This control pressure acts on the second pressure chamber 52 f , making the adjustment pressure of the variable relief valve 52 A variable in response to the rotational speed of the engine 1 . Accordingly, when the vehicle is switched over from forward travel to reverse travel or from reverse travel to forward travel, and, at the same time, foot pressure on the accelerator pedal 110 is increased, the variable relief valve 52 increases the adjustment pressure and increases the braking force. When foot pressure on the accelerator pedal 110 is reduced, the variable relief valve 52 reduces the adjustment pressure and reduces the braking force.
The operation is the same as in the first embodiment and so is not further described here.
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A travel drive apparatus for a hydraulic drive work vehicle and control method therefor, the apparatus including: a travel hydraulic pump driven by the power of an engine; a hydraulic motor that receives discharged oil from the travel hydraulic pump and causes the vehicle to travel; a travel changeover valve that receives the discharged oil from the travel hydraulic pump, supplies the discharged oil to the hydraulic motor and discharges return oil from the hydraulic motor to a tank, in which the travel drive apparatus comprises; an accelerator for controlling an engine rotational speed; an operation unit for selecting vehicle forward travel, stop, and reverse travel; the travel changeover valve being adapted for receiving signals from the operation unit, switching the discharge oil supplied from the travel hydraulic pump to the hydraulic motor, and controlling vehicle forward travel, stop and reverse travel; a relief valve that regulates pressure for controlling the hydraulic motor when the vehicle has decelerated, positioned between the travel changeover valve and the hydraulic motor; and a pressurizing unit for raising the set pressure at the relief valve controlling the hydraulic motor when the engine rotational speed is increased, while switching the vehicle from forward travel to reverse travel, or from reverse travel to forward travel, so that the work vehicle may switch over from forward to reverse travel; or vice versa, while exhibiting good acceleration performance.
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BACKGROUND
[0001] 1. Field of the Invention
[0002] The present invention relates to credit/debit cards, and more specifically, a method and system offering immediate replacement of lost or stolen credit/debit cards.
[0003] 2. Related Art
[0004] The potential for fraud in case a credit/debit card is lost or stolen has been a major concern for the credit card companies and financial institutions as well as the customers and the providers of the goods and services. Hereinafter, reference to “credit” cards, unless otherwise noted, encompasses both credit and debit cards. There have been many developments in an effort to overcome this fundamental problem of fraud. The credit card companies have an efficient credit card fraud protection system which is working well to block a lost or stolen credit card. The credit card companies also have an efficient credit card replacement system which has been working well to issue and send a new credit card to the customer in case their card has been lost or stolen. Most credit card companies claim that they can replace a lost or stolen credit card within 24 to 48 hours, if the customer carries the emergency replacement feature. But this replacement time period of 24 to 48 hours can be critical in many situations where the customer might need his/her card immediately, for example, while traveling out of town or being in an emergency situation. Therefore, a need exists for an improved system for replacement of lost or stolen credit cards.
OBJECTS AND SUMMARY OF THE INVENTION
[0005] The present invention is directed towards improving the existing credit card replacement system, by providing immediate replacement of a lost or stolen card. The problem for credit card replacement as noted above can be minimized in accordance with the principles of the present invention, by providing an additional “deactivated” credit card (spare credit card) to the customer.
[0006] The credit card company opens one account with two different card numbers, first card number for the “main credit card” and second card number for the “spare credit card”. The credit card company provides the customer with two credit cards, a “Main Credit Card” and a “Spare Credit Card”. The “Main Credit Card” will be the master credit card and will function identically as the existing credit cards. The “spare credit card” will also function identical to the existing credit cards, but will be “activated” for use, only when the “main credit card” is reported as lost or stolen by the customer to the credit card company. Both credit cards will never be activated at the same time. The credit card company will only “activate” the master card (main credit card) (unless otherwise indicated the term “master card” is a general term for “main card” and does not refer to and is not limited to the trademark MasterCard®) after receiving confirmation from the customer that he/she has received the two credit cards. The “spare credit card” will remain “deactivated”.
[0007] When the customer reports his/her lost or stolen credit card to the company, then the credit card company blocks (Deactivates) the first credit card number (main credit card) and activates the second credit card number (spare credit card), to be used as the master credit card (main credit card). The credit card company will then replace the blocked (Deactivated) credit card number (first credit card number) with a new number and will send a new credit card (New Spare Credit Card) for the customer. The new credit card (New Spare Credit Card) will remain “deactivated”.
[0008] The “deactivated” credit card (spare credit card) which will only be “activated” for use when the master credit card (main credit card) is reported as lost/stolen, should always be kept in a separate place. The two credit cards (“main credit card” and “spare credit card”) should never be carried together.
[0009] Differentiation of Main and Spare Credit Cards: The two credit cards (“Main Credit Card” and “Spare Credit Card”) should be distinguished from one another, in-order for the customer not to carry and use the wrong credit card (spare credit card) which is “deactivated”. The distinguishable factor used for the two credit cards can be; a: sticker, b: color, c: name, other recognizable indicia or any other means. The following methods are examples of such distinguishing elements between the two cards:
a. Sticker: The credit card provider can place a sticker on the “spare credit card” in-order for the “spare credit card” to be distinguished from the “main credit card” and only when the “spare credit card” is to be used (activated), the customer will simply remove the sticker. The sticker can be in any color or form, or a special word such as, “spare” which can be written on the sticker. b. Color: The two credit cards (“Main Credit Card” and “Spare Credit Card”) can also be distinguished from one another by color. For example, the “Main Credit Card” can be in any color except Red and the “Spare Credit Card” will always come in Red. c. Name: The two credit cards (“Main Credit Card” and “Spare Credit Card”) can be distinguished from one another by name. For example the “Main Credit Card” can be named as “Credit Card” and the “Spare Credit Card” can be named as “Credit Card-T” as shown in FIG. 12 .
[0013] If the customer already has a credit card, then the credit card company will add an additional new card number to the existing credit card account, to be used as the second credit card number (spare credit card). After receiving confirmation from the customer that he/she has received the “Spare Credit Card”, the Credit card provider will instruct the customer to use the “Spare Credit Card” in the same manner as described above.
[0014] The “Spare Credit Card” sent to the customer will be distinguished from the “Main Credit Card”, in-order for the customer not to carry and use the wrong credit card (spare credit card) which is “deactivated”. As mentioned under “Differentiation of Main and Spare Credit Cards”, the distinguishable factors used for the two credit cards (“Main” and “Spare”) can be a sticker, color, name, general indicia or any other means.
[0015] Generally the present invention comprises a credit card use and security system method with immediate replacement capability comprising two credit cards issued to a single user by a financial institution. A first of the cards is active as a main card for transactions and a second spare card is inactive from transactions. With loss or theft of the first active main card, the first main card is deactivated by the financial institution and the second spare card is activated for immediate transaction use as a main card with an account. The financial institution issues at least one additional card according to one of the following options:
i) a new inactive spare card; ii) a new active main card with the activated spare card being deactivated for use as a spare; and iii) a new active main card and a new deactivated spare card with the original activated spare card being destroyed.
[0019] Embodiments of the present invention include cards for one or two accounts as will be described.
[0020] The above and other objects, features and advantages of the present invention will become apparent from the following description of illustrative embodiments thereof to be read in conjunction with the accompanying drawings, in which like reference numerals represent the same or similar elements.
[0021] It is to be understood, however, that the drawings are designed solely for purpose of illustration and not as a definition of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The foregoing, and other, objects, features and advantages of the present invention will be more readily understood upon reading the following detailed description in conjunction with the drawings in which:
[0023] FIG. 1 is a front side view of the two credit cards, “Main Credit Card” and “Spare Credit Card” showing the same name (card holder) and validity date on both cards, with different credit card numbers. The “Main Credit Card” is shown as “Activated” and the “Spare Credit Card” is shown as “Deactivated”.
[0024] FIG. 2 is a back side view of the two credit cards, “Main Credit Card” and “Spare Credit Card” showing card holder signature space and customer service contact numbers. Main Credit Card is shown as “Activated” and Spare Credit Card is shown as “Deactivated”.
[0025] FIG. 3 is a front side view of the “Main Credit Card” shown as “Lost/Stolen” and a back side view of the “Spare Credit Card” showing card holder signature space and customer service contact numbers. “Spare Credit Card” is shown as “Deactivated”.
[0026] FIG. 4 is a front side view of the “Main Credit Card” shown as “Lost/Stolen” and a front side view of the “Spare Credit Card” showing name (card holder), validity date and card number as shown in FIG. 1 . “Spare Credit Card” is shown as “Activated”.
[0027] FIG. 5 is a front side view of the two credit cards. A “New Spare Credit Card” showing new card number with the same name and validity date and the old “Spare credit card” which is now used as the “Main Credit Card”. The “New Spare Credit Card” is shown as “Deactivated” and the “Main Credit Card” (Old Spare Credit Card) is shown as “Activated”.
[0028] FIG. 5A is a front side view of the two credit cards. A “New Main Credit Card” showing new card number with the same name and validity date and a “Spare Credit Card” with the same credit card number, name and validity date as shown in FIG. 1 . The “New Main Credit Card” is shown as “Activated” and the “Spare Credit Card” is shown as “Deactivated”.
[0029] FIG. 6 is a front side view of the two credit cards. A “New Main Credit Card” showing new card number with same name and new validity date and a “New Spare Credit Card” with new credit card number, name and new validity date. The “New Main Credit Card” is shown as “Activated” and the “New Spare Credit Card” is shown as “Deactivated”.
[0030] FIG. 7 is a front side view of the two credit cards. A “Main Credit Card” showing credit card number with the same name and validity date, and a “Spare Credit Card” with a different credit card number, the same name but without validity date. The “Main Credit Card” is shown as “Activated” and the “Spare Credit Card” called “Temporary” is shown as “Deactivated”.
[0031] FIG. 8 is a back side view of the two credit cards, “Main Credit Card” and “Spare Credit Card” showing card holder signature space and customer service contact numbers. The “Main Credit Card” is shown as “Activated” and the “Spare Credit Card” is shown as “Deactivated”.
[0032] FIG. 9 is a front side view of the credit card (Main Credit Card) shown as “Lost/Stolen” and a back side view of the credit card (Spare Credit Card) showing card holder signature space and customer service contact numbers. Credit card (Spare Credit Card) is shown as “Deactivated”.
[0033] FIG. 10 is a front side view of the “Main Credit Card” shown as “Lost/Stolen” and a front side view of the “Spare Credit Card” showing the same name (card holder), credit card number, but without validity date as shown in FIG. 7 . The “Spare Credit Card” is called “temporary” and is shown as “Activated”.
[0034] FIG. 11 is a front side view of the two credit cards. A “New Main Credit Card” showing new card number with the same name and validity date and a “Spare Credit Card” with the same credit card number, same name, but without validity date as shown in FIG. 7 . The “New Main Credit Card” is shown as “Activated” and the “Spare Credit Card” is called “Temporary” and shown as “Deactivated”.
[0035] FIG. 12 is a front side view of the two credit cards, (“Main Credit Card” and “Spare Credit Card”) showing the same name (card holder) and validity date but with different card numbers. The “Main Credit Card” is called the “credit card” and the “Spare Credit Card” is called the “credit card-T ”. The “Main Credit Card” is shown as “Activated” and the “Spare Credit Card” is shown as “Deactivated”.
[0036] FIG. 13 is a procedural flow chart of the credit card system with options of a single account embodiment; and
[0037] FIG. 14 is a procedural flow chart of the credit card system with options of an embodiment with two accounts.
DETAILED DESCRIPTION
[0038] In this specification the term “credit card” refers to credit cards (Master Card®, Visa®, Diners Club®, etc.) as well as charge cards (e.g., American Express®, some department store cards), debit cards such as usable at ATMs and many other locations or cards that are associated with a particular account, and hybrids thereof (e.g., extended payment American Express®, bank debit cards with the Visa® logo, etc.).
[0039] Referring to FIG. 1 , two credit cards are shown from the front side, (“Main Credit Card” and “Spare Credit Card”) with basic identification information such as, a card number, name (card holder) and validity date. Both terms “Main Credit Card” and “Spare Credit Card” refer to credit cards as generally understood, namely, that which are allocated by the credit card provider to the customer. Each credit card has a different card number, but the name of the card holder and the validity dates on both cards are the same. Because each credit card company (credit card provider) has a different card numbering system, the structure of both credit card numbers vary depending on the credit card company system.
[0040] The credit card (Main Credit Card) will be “Activated” as soon as the customer confirms the receipt of both credit cards “Main Credit Card” and “Spare Credit Card” to the Credit card provider. The credit card “Spare Credit Card” will remain “Deactivated” as shown in FIG. 1 .
[0041] Referring again to FIG. 1 , the credit card provider will open one account with two different card numbers, first card number for the “main credit card” and second card number for the “spare credit card”. Then the Credit card provider will send a package with two credit cards to the customer, a “Main Credit Card” and a “Spare Credit Card”. Upon receipt of the package, the customer will call the Credit card provider to inform them that he/she has received the two credit cards. Then the Credit card provider will “Activate” only the “Main Credit Card”. The “Spare Credit Card” will remain “Deactivated”.
[0042] The two credit cards (“Main Credit Card” and “Spare Credit Card”) should be distinguished from one another, in-order for the customer not to carry and use the wrong credit card (spare credit card) which is “deactivated”. As mentioned under “Differentiation of Main and Spare Credit Cards”, the distinguishable factors used for the two credit cards (“Main” and “Spare”) can be a sticker, color, name or any other means.
[0043] According to the company policy the credit card company (Credit card provider) will either provide one Personal Identification number (PIN) for both credit cards or two different Personal Identification numbers (PIN) allocated to each one of the credit cards.
[0044] After the completion of this process, the customer will be instructed to carry and use only the “Main Credit Card” which is “Activated” and keep the “Spare Credit Card” which is “Deactivated” in a separate and safe place, such as at home. In case the customer is traveling out of town, again the customer should keep the credit card (Spare Credit Card) which is “Deactivated” in a separate and safe place, such as the hotel room or any place he/she is residing at that time. The customer should never carry both credit cards together.
[0045] After the validity dates on the two credit cards (“Main Credit Card” and “Spare Credit Card”) have expired, the credit card provider will issue and send two new credit cards “Main Credit Card” and “Spare Credit Card” for the customer.
[0046] If the customer already has a credit card, then the credit card company will add an additional new card number to the existing credit card account, to be used as the second credit card number (spare credit card). Upon receipt of the package, the customer will call the Credit card provider to inform them that he/she has received the “Spare Credit Card”. Then the Credit card provider will instruct the customer to use the “Spare Credit Card” in the same manner as described above.
[0047] The “Spare Credit Card” sent to the customer will be distinguished from the “Main Credit Card”, in-order for the customer not to carry and use the wrong credit card (spare credit card) which is “deactivated”. As mentioned under “Differentiation of Main and Spare Credit Cards”, the distinguishable factors used for the two credit cards (“Main” and “Spare”) can be a sticker, color, name or any other means.
[0048] Referring to FIG. 2 , the same two credit cards are shown from the back side, (Main Credit Card) and (Spare Credit Card) with basic information such as, card holder signature space and customer service contact numbers. The Main Credit Card will be “Activated” as soon as the customer confirms the receipt of both credit cards (“Main Credit Card” and “Spare Credit Card”) to the Credit card provider as shown and described in FIG. 1 . The “Spare Credit Card” will remain “Deactivated”.
[0049] If the customer already has a credit card, then the credit card company will add an additional new card number to the existing credit card account, to be used as the second credit card number (“spare credit card”) for the customer. The customer confirms the receipt of the “Spare Credit Card” to the credit card provider as shown and described in FIG. 1 . The “Spare Credit Card” will remain “Deactivated”.
[0050] The “Spare Credit Card” sent to the customer will be distinguished from the “Main Credit Card”, in-order for the customer not to carry and use the wrong credit card (spare credit card) which is “deactivated”. As mentioned under “Differentiation of Main and Spare Credit Cards”, the distinguishable factors used for the two credit cards (“Main” and “Spare”) can be a sticker, color, name or any other means.
[0051] Referring to FIG. 3 , the Main Credit Card is shown as “Lost/Stolen”. The “Spare Credit Card” is shown from back side as described and shown in FIG. 2 . The customer service contact numbers are listed on the back side of the “Spare Credit Card” as shown and described in FIG. 2 and FIG. 3 . The “Spare Credit Card” remains “Deactivated”.
[0052] Referring again to FIG. 3 , the customer (card holder) calls the listed customer service contact numbers on the back side of the “Spare Credit Card” to report his/her “Lost/Stolen” credit card (Main Credit Card). For security check, the credit card provider will ask the customer (card holder) to provide information such as, name, validity date, card number, PIN number, etc. Because both credit cards (“Main Credit Card” and “Spare Credit Card”) are issued to one person, then the credit card provider will ask for the “Spare Credit Card” number in-order to block and “Deactivate” the Credit card (Main Credit Card). There is no need to keep a copy of the credit card (Main Credit Card) in case the credit card provider needs any information for blocking the credit card (Main Credit Card).
[0053] Referring to FIG. 4 , the Main Credit Card is shown as “Lost/Stolen” and “Deactivated”. The “Spare Credit Card” is also shown from the front side with basic identification information such as, a card number, name (card holder) and validity date as shown and described in FIG. 1 . The “Spare Credit card” is “Activated” as shown in FIG. 4 .
[0054] Referring again to FIG. 4 , once the customer (card holder) reports his/her “Lost/Stolen” credit card (Main Credit Card) to the credit card provider as described and shown in FIG. 3 , the credit card company blocks (Deactivates) the first credit card number (main credit card) and activates the second credit card number “spare credit card”, to be used as the main credit card.
[0055] If the credit card provider has decided to place a sticker on the “spare credit card” as the distinguishing factor between the two credit cards (“Main Credit Card” and “Spare Credit Card”), then the customer will simply remove the sticker from the “spare credit card” and use the “spare credit card” as the main credit card “main credit card”. As mentioned under “Differentiation of Main and Spare Credit Cards”, the distinguishable factors used for the two credit cards (“Main” and “Spare”) can be a sticker, color, name or any other means.
[0056] Depending on the company policy, as described and shown in FIG. 1 ., the Personal Identification number (PIN) used for the old “Spare Credit Card” which is now the “Main Credit Card” can be the same Personal Identification number (PIN), or a different Personal Identification number (PIN) can be allocated.
[0057] Now the customer can use the “Spare Credit Card” as the “Main Credit Card”.
[0058] Referring to FIG. 5 , the “New Spare Credit Card” is shown from the front side, with a new card number, but with the same validity date (depending on the credit card company policy the validity date can remain the same or can be changed). The “Spare Credit Card” which is now used as the “Main Credit Card” is also shown from the front side with the same card number and validity date as shown in FIGS. 1 and 4 . The “New Spare Credit Card” is “Deactivated” and the “Main Credit Card” (Old Spare Credit Card) is “Activated”.
[0059] Referring again to FIG. 5 , after the customer (card holder) reports his/her “Lost/Stolen” credit card (Main Credit Card) to the credit card provider as described and shown in FIGS. 3 and 4 , the credit card company will then replace the blocked (deactivated) credit card number (first credit card number) with a new number and will send a new credit card (New Spare Credit Card) to the customer. The new credit card (New Spare Credit Card) will remain “deactivated”.
[0060] The credit card (New Spare Credit Card) sent to the customer will be distinguished from the “Main Credit Card” (Old Spare credit card), in-order for the customer not to carry and use the wrong credit card (New Spare credit card) which is “deactivated”. As mentioned under “Differentiation of Main and Spare Credit Cards”, the distinguishable factors used for the two credit cards (“Main” and “Spare”) can be a sticker, color, name or any other means.
[0061] Depending on the company policy, as described and shown in FIGS. 1 and 4 , the Personal Identification number (PIN) to be used for the “New Spare Credit Card” can be the same Personal Identification number (PIN), or a different Personal Identification number (PIN) can be allocated.
[0062] Upon receipt of the new credit card (New Spare Credit Card), the customer will call the credit card provider to confirm that he/she has received the new credit card (New Spare Credit Card).
[0063] Now the customer can use the “old Spare Credit Card” as the “Main Credit Card” and keep the “New Spare Credit Card” which is “Deactivated” in a separate and safe place, as shown and described in FIG. 1
[0064] After the validity dates on the two credit cards (“Main Credit Card” and “Spare Credit Card”) have expired, the credit card provider will issue and send two new credit cards (“Main Credit Card” and “Spare Credit Card”) to the customer.
Option 1
SUMMARY
[0000]
The credit card company opens One account with two different credit card numbers for each customer
When the credit card is lost/stolen, the customer uses the credit card (Spare Credit Card) until a new credit card (New Main credit Card) is issued and sent to the customer.
Upon receipt of the package, the customer will call the Credit card provider to inform them that he/she has received the new credit card (New Main Credit Card). Then the Credit card provider will activate the new credit card number (New Main Credit Card) and will block (Deactivate) the second credit card number (spare credit card). The “Spare Credit Card” will be “Deactivated”.
The customer can now use the new credit card (New Main Credit Card) and keep the credit card (Spare Credit Card) which is “Deactivated” in a separate and safe place. The “Spare Credit Card” does not get replaced.
[0069] In this specification the term “credit card” refers to credit cards (Master Card®, Visa®, Diners Club®, etc.) as well as charge cards (e.g., American Express®, some department store cards), debit cards such as usable at ATMs and many other locations or that are associated with a particular account, and hybrids thereof (e.g., extended payment American Express®, bank debit cards with the Visa® logo, etc.).
[0070] Referring to FIG. 1 , two credit cards are shown from the front side, (Main Credit Card) and (Spare Credit Card) with basic identification information such as, a card number, name (card holder) and validity date. Both terms “Main Credit Card” and “Spare Credit Card” refer to credit cards as generally understood, namely, that which are allocated by the credit card provider to the customer. Each credit card has a different card number, but the name of the card holder and the validity dates on both cards are the same. Because each credit card company (credit card provider) has a different card numbering system, the structure of both credit card numbers vary depending on the credit card company system.
[0071] The credit card (Main Credit Card) will be “Activated” as soon as the customer confirms the receipt of both credit cards “Main Credit Card” and “Spare Credit Card” to the Credit card provider. The credit card “Spare Credit Card” will remain “Deactivated” as shown in FIG. 1 .
[0072] The two credit cards (“Main Credit Card” and “Spare Credit Card”) should be distinguished from one another, in order for the customer not to carry the wrong credit card (spare credit card) which is “deactivated”. As mentioned under “Differentiation of Main and Spare Credit Cards”, the distinguishable factors used for the two credit cards (“Main” and “Spare”) can be a sticker, color, name or any other means. In option 1 the sticker on the “spare credit card” will never be removed.
[0073] Referring again to FIG. 1 , The credit card provider will open one account with two different card numbers, first card number for the “main credit card” and second card number for the “spare credit card”. Then the Credit card provider will send a package with two credit cards to the customer, a “Main Credit Card” and a “Spare Credit Card”. Upon receipt of the package, the customer will call the Credit card provider to inform them that he/she has received the two credit cards. Then the Credit card provider will “Activate” only the “Main Credit Card”. The “Spare Credit Card” will remain “Deactivated”.
[0074] The credit card company (Credit card provider) will also provide one Personal Identification number (PIN) for both credit cards or, two different Personal Identification number (PIN) allocated to each one of the credit cards, according to the credit card company policy.
[0075] After the completion of this process, the customer will be instructed to carry and use only the “Main Credit Card” which is “Activated” and keep the “Spare Credit Card” which is “Deactivated” in a separate and safe place, such as at home. In case the customer is traveling out of town, again the customer should keep the credit card (Spare Credit Card) which is “Deactivated” in a separate and safe place, such as the hotel room or any place he/she is residing at that time. The customer should never carry both credit cards together.
[0076] After the validity dates on the two credit cards (“Main Credit Card” and “Spare Credit Card”) have expired, the credit card provider will issue and send two new credit cards “Main Credit Card” and “Spare Credit Card” for the customer.
[0077] If the customer already has a credit card, then the credit card company will add an additional new card number to the existing credit card account, to be used as the second credit card number (spare credit card). Upon receipt of the package, the customer will call the Credit card provider to inform them that he/she has received the “Spare Credit Card”. Then the Credit card provider will instruct the customer to use the “Spare Credit Card” in the same manner as described above.
[0078] The “Spare Credit Card” sent to the customer will be distinguished from the “Main Credit Card”, in-order for the customer not to carry and use the wrong credit card (spare credit card) which is “deactivated”. As mentioned under “Differentiation of Main and Spare Credit Cards”, the distinguishable factors used for the two credit cards (“Main” and “Spare”) can be a sticker, color, name or any other means. In option 1 the sticker on the “spare credit card” will never be removed.
[0079] Referring to FIG. 2 , the same two credit cards are shown from the back side, (Main Credit Card) and (Spare Credit Card) with basic information such as, card holder signature space and customer service contact numbers. The credit card (Main Credit Card) will be “Activated” as soon as the customer confirms the receipt of both credit cards (“Main Credit Card” and “Spare Credit Card”) to the Credit card provider as shown and described in FIG. 1 . The credit card “Spare Credit Card” will remain “Deactivated”.
[0080] If the customer already has a credit card, then the credit card company will add an additional new card number to the existing credit card account, to be used as the second credit card number (spare credit card). The customer confirms the receipt of the credit “Spare Credit Card” to the Credit card provider as shown and described in FIG. 1 . The credit card (Spare Credit Card) will remain “Deactivated”.
[0081] The “Spare Credit Card” sent to the customer will be distinguished from the “Main Credit Card”, in-order for the customer not to carry and use the wrong credit card (spare credit card) which is “deactivated”. As mentioned under “Differentiation of Main and Spare Credit Cards”, the distinguishable factors used for the two credit cards (“Main” and “Spare”) can be a sticker, color, name or any other means. In option 1 the sticker on the “spare credit card” will never be removed.
[0082] Referring to FIG. 3 , the credit card (Main Credit Card) is shown as “Lost/Stolen”. The “Spare Credit Card” is shown from back side as described and shown in FIG. 2 . The customer service contact numbers are listed on the back side of the “Spare Credit Card” as shown and described in FIG. 2 and FIG. 3 . The “Spare Credit Card” remains “Deactivated”.
[0083] Referring again to FIG. 3 , the customer (card holder) calls the listed customer service contact numbers on the back side of the “Spare Credit Card” to report his/her “Lost/Stolen” credit card (Main Credit Card). For security check, the credit card provider will ask the customer (card holder) to provide information such as, name, validity date, card number, PIN number, etc. Because both credit cards (“Main Credit Card” and “Spare Credit Card”) are issued to one person, then the credit card provider will ask for the “Spare Credit Card” number in-order to block and “Deactivate” the Credit card (Main Credit Card). There is no need to keep a copy of the credit card (Main Credit Card) in case the credit card provider needs any information for blocking the credit card (Main Credit Card).
[0084] Referring to FIG. 4 , the credit card (Main Credit Card) is shown as “Lost/Stolen” and “Deactivated”. The “Spare Credit Card” is also shown from the front side with basic identification information such as, a card number, name (card holder) and validity date as shown and described in FIG. 1 . The “Spare Credit card” is “Activated” as shown in FIG. 4 .
[0085] Referring again to FIG. 4 , once the customer (card holder) reports his/her “Lost/Stolen” credit card (Main Credit Card) to the credit card provider as described and shown in FIG. 3 , the credit card company blocks (Deactivates) the first credit card number (main credit card) and activates the second credit card number (spare credit card), to be used as the spare credit card (spare credit card).
[0086] The Personal Identification number (PIN) to be used for the credit card (Spare Credit Card) can be the same Personal Identification number (PIN), or a different Personal Identification number (PIN) can be allocated, depending on the company policy, as described and shown in FIG. 1 .
[0087] Now the customer can use the credit card (Spare Credit Card) until a new credit card (New Main credit Card) is issued and sent to the customer.
[0088] Referring to FIG. 5A , the new credit card (New Main Credit Card) is shown from the front side, with a new card number, but with the same validity date (the validity date can remain the same or can be changed according to the credit card company policy). The “Spare Credit Card” is also shown from the front side with the same card number and validity date as shown in FIGS. 1 and 4 . The new credit card (New Main Credit Card) is “Activated” and the “Spare Credit Card” is “Deactivated”.
[0089] Referring again to FIG. 5A , after the customer (card holder) reports his/her “Lost/Stolen” credit card (Main Credit Card) to the credit card provider as described and shown in FIGS. 3 and 4 , the credit card company will then replace the blocked (Deactivated) credit card number (first credit card number) with a new number and will send a new credit card (New Main Credit Card) to the customer.
[0090] Upon receipt of the package, the customer will call the Credit card provider to inform them that he/she has received the new credit card (New Main Credit Card). Then the Credit card provider will activate the new credit card number (New Main Credit Card) and will block (Deactivate) the second credit card number (spare credit card). The “Spare Credit Card” will be “Deactivated”.
[0091] The Personal Identification number (PIN) to be used for the new credit card (New Main Credit Card) can be the same Personal Identification number (PIN), or a different Personal Identification number (PIN) can be allocated, depending on the company policy, as described and shown in FIGS. 1 and 4 .
[0092] Now the customer can use the new credit card (New Main Credit Card) and keep the credit card (Spare Credit Card) which is “Deactivated” in a separate and safe place, as shown and described in FIG. 1
[0093] After the validity dates on the two credit cards (“Main Credit Card” and “Spare Credit Card”) have expired, the credit card provider will issue and send two new credit cards (“Main Credit Card” and “Spare Credit Card”) for the customer.
Option 1 A
SUMMARY
[0000]
The credit card company opens One account with two different credit card numbers for each customer
When the credit card is lost/stolen, the customer uses the credit card (Spare Credit Card) until two new credit cards (New Main Credit Card and New Spare Credit Card) are issued and sent to the customer.
Upon receipt of the package, the customer will call the credit card provider to inform them that he/she has received the two new credit cards. Then the Credit card provider will activate the (New Main Credit Card) and will block (Deactivate) the (Old spare credit card). The “New Spare Credit Card” will remain “Deactivated”.
The customer (card holder) will be asked to destroy the “Old Spare Credit Card” and keep the “New Spare Credit Card” which is “Deactivated”, in a separate and safe place.
The Credit card provider sends two new credit cards to the customer, a “New Main Credit Card” and a “New Spare Credit Card”.
[0099] Referring to FIG. 6 , the new credit card (New Main Credit Card) is shown from the front side, with a new card number and a new validity date. A new credit card (New Spare Credit Card) is also shown from the front side with a new card number and a new validity date. The new credit card (New Main Credit Card) is “Activated” and the new credit card (New Spare Credit Card) is “Deactivated”.
[0100] Referring again to FIG. 6 , after the customer (card holder) reports his/her “Lost/Stolen” credit card (Main Credit Card) to the credit card provider as described and shown in FIGS. 3 and 4 , the Credit card provider will send a package with two new cards to the customer, a “New Main Credit Card” and a “New Spare Credit Card”.
[0101] Upon receipt of the package, the customer will call the Credit card provider to inform them that he/she has received the two new credit cards. Then the Credit card provider will activate the first new credit card number (New Main Credit Card) and will block (Deactivate) the second credit card number (Old spare credit card). The “New Spare Credit Card” will be “Deactivated”.
[0102] The customer (card holder) will be asked to destroy the “Old Spare Credit Card” and keep the “New Spare Credit Card” which is “Deactivated”, in a separate and safe place, as shown and described in FIG. 1 .
[0103] This option provides the customer with a feature in which the Credit card provider sends two new credit cards to the customer, a “New Main Credit Card” and a “New Spare Credit Card”. The validity dates on both credit cards can remain the same or can be changed according to the credit card company policy.
[0104] After the validity dates on the two credit cards (“Main Credit Card” and “Spare Credit Card”) have expired, the credit card provider will issue and send two new credit cards “Main Credit Card” and “Spare Credit Card” for the customer.
Option 1 B
SUMMARY
[0000]
The credit card company opens One account with two different credit card numbers for each customer
When the credit card is lost/stolen, the customer uses the credit card (Spare Credit Card) which has no validity date, until a new credit card (Main Credit Card) is issued and sent to the customer.
Upon receipt of the package, the customer will call the Credit card provider to inform them that he/she has received the new credit card (New Main Credit Card). Then the Credit card provider will activate the “New Main Credit Card” and will block (Deactivate) the “spare credit card”.
The customer can now use the new credit card (New Main Credit Card) and keep the “Spare Credit Card” which is “Deactivated” in a separate and safe place.
The “Spare Credit Card” which has no validity date, allows the customer to use the “Spare Credit Card” without receiving a new “Spare Credit Card” from the credit card provider. The customer will only receive a new “Main Credit Card” when the credit card (Main Credit Card) is lost/stolen or the validity date on the credit card “Main Credit Card” has expired.
[0110] Referring to FIG. 7 , the two credit cards are shown from the front side, (Main Credit Card) and (Spare Credit Card). The credit card (Main Credit Card) is issued with the basic identification information such as, a card number, name (card holder) and validity date. The “Spare Credit Card” has no validity date, but is issued with the basic identification information such as, a card number, name (card holder). Both terms “Main Credit Card” and “Spare Credit Card” refer to a credit card as generally understood, namely, that which is allocated by the credit card provider to the customer. Each credit card has a different card number, but the name of the card holder on both cards are the same. Because each credit card company (credit card provider) has a different card numbering system, the structures of both credit card numbers vary depending on the credit card company system.
[0111] The credit card (Main Credit Card) will be “Activated” as soon as the customer confirms the receipt of both credit cards (“Main Credit Card” and “Spare Credit Card”) to the Credit card provider. The “Spare Credit Card” will remain “Deactivated” as shown in FIG. 7 .
[0112] The two credit cards (“Main credit card” and “Spare Credit Card”) will be distinguished from one another in-order for the customer not to carry and use the wrong credit card (spare credit card) which is “deactivated”. As mentioned under “Differentiation of Main and Spare Credit Cards”, the distinguishable factors used for the two credit cards (“Main” and “Spare”) can be a sticker, color, name or any other means. In option 1 B the sticker on the “spare credit card” will never be removed.
[0113] Referring again to FIG. 7 , the credit card provider will open one account with two different card numbers, first card number for the “main credit card” and second card number for the “spare credit card”. Then the Credit card provider will send a package with two credit cards to the customer, a “Main Credit Card” and a “Spare Credit Card”. Upon receipt of the package, the customer will call the Credit card provider to inform them that he/she has received the two credit cards. Then the Credit card provider will “Activate” only the credit card “Main Credit Card”. The credit card “Spare Credit Card” will remain “Deactivated”.
[0114] The card company (Credit card provider) will also provide one Personal Identification number (PIN) allocated to both credit cards or two different Personal Identification numbers (PIN) allocated to each one of the credit cards, depending on the company policy.
[0115] After the completion of this process, the customer will be instructed to carry and use only the “Main Credit Card” which is “Activated” and keep the “Spare Credit Card” which is “Deactivated” in a separate place, for example, at home. In case the customer is traveling out of town, again the customer should keep the “Spare Credit Card” which is “Deactivated” in a separate place, such as the hotel room or any place he/she is residing at that time. The customer should never carry both credit cards together.
[0116] If the customer already has a credit card, then the credit card company will add an additional new card number to the existing credit card account, to be used as the second credit card number (spare credit card). Upon receipt of the package, the customer will call the Credit card provider to inform them that he/she has received the “Spare Credit Card”. Then the Credit card provider will instruct the customer to use the “Spare Credit Card” in the same manner as described above.
[0117] The “Spare Credit Card” sent to the customer will be distinguished from the “Main Credit Card”, in-order for the customer not to carry and use the wrong credit card (spare credit card) which is “deactivated”. As mentioned under “Differentiation of Main and Spare Credit Cards”, the distinguishable factors used for the two credit cards (“Main” and “Spare”) can be a sticker, color, name or any other means. In option 1 B the sticker on the “spare credit card” will never be removed.
[0118] Referring to FIG. 8 , the same two credit cards are shown from the back side, (“Main Credit Card” and “Spare Credit Card”) with basic information such as, card holder signature space and customer service contact numbers. The credit card (Main credit Card) will be “Activated” as soon as the customer confirms the receipt of both credit cards “Main Credit Card” and “Spare Credit Card” to the Credit card provider as shown and described in FIG. 7 . The credit card “Spare Credit Card” will remain “Deactivated”.
[0119] If the customer already has a credit card, then the credit card company will add an additional new card number to the existing credit card account, to be used as the second credit card number (spare credit card). The customer confirms the receipt of the credit card (Spare Credit Card) to the Credit card provider as shown and described in FIG. 7 . The credit card “Spare Credit Card” will remain “Deactivated”.
[0120] The “Spare Credit Card” sent to the customer will be distinguished from the “Main Credit Card”, in-order for the customer not to carry and use the wrong credit card (spare credit card) which is “deactivated”. As mentioned under “Differentiation of Main and Spare Credit Cards”, the distinguishable factors used for the two credit cards (“Main” and “Spare”) can be a sticker, color, name or any other means. In option 1 B the sticker on the “spare credit card” will never be removed.
[0121] Referring to FIG. 9 , the credit card (Main Credit Card) is shown as “Lost/Stolen”. The “Spare Credit Card” is shown from back side as described and shown in FIG. 8 . The customer service contact numbers are listed on the back side of the “Spare Credit Card” as shown and described in FIG. 8 and FIG. 9 . The “Spare Credit Card” remains “Deactivated”.
[0122] Referring again to FIG. 9 , the customer (card holder) calls the listed customer service contact numbers on the back side of the “Spare credit Card” to report his/her “Lost/Stolen” credit card (Main Credit Card). For security check, the credit card provider will ask the customer (card holder) to provide information such as, name, validity date, card number, PIN number, etc. Since both credit cards (“Main credit Card” and “Spare Credit Card”) are issued to one person, the credit card provider will ask for the “Spare Credit Card” number in-order to block and “Deactivate” the Credit card (Main Credit Card). There is no need to keep a copy of the credit card (Main Credit Card) in case the credit card provider needs any information for blocking the credit card (Main Credit Card).
[0123] Referring to FIG. 10 , the credit card (Main Credit Card) is shown as “Lost/Stolen” and “Deactivated”. The “Spare Credit Card” is also shown from the front side without a validity date, but has the basic identification information such as, a card number, name (card holder) as shown and described in FIG. 7 . The “Spare Credit Card” is “Activated” as shown in FIG. 10 .
[0124] Referring again to FIG. 10 , once the customer (card holder) reports his/her “Lost/Stolen” credit card (Main Credit Card) to the credit card provider as described and shown in FIG. 9 , the credit card company blocks (Deactivates) the first credit card number (main credit card) and activates the second credit card number “spare credit card”, to be used as the spare credit card (spare credit card).
[0125] The Personal Identification number (PIN) to be used for the “Spare Credit Card” can be the same Personal Identification number (PIN), or a different Personal Identification number (PIN) can be allocated, depending on the company policy, as described and shown in FIG. 7 .
[0126] Now the customer can use the “Spare Credit Card” until a new credit card (Main Credit Card) is issued and sent to the customer.
[0127] Referring to FIG. 11 , the new credit card (New Main Credit Card) is shown from the front side, with a new card number, but with the same validity date (the validity date can remain the same or can be changed according to the credit card company policy). The “Spare Credit Card” is also shown from the front side with the same card number but without a validity date as shown in FIGS. 7 and 10 . The new credit card (New Main Credit Card) is “Activated” and the “Spare Credit Card” is “Deactivated”.
[0128] Referring again to FIG. 11 , after the customer (card holder) reports his/her “Lost/Stolen” credit card (Main Credit Card) to the credit card provider as described and shown in FIGS. 9 and 10 , The credit card company will then replace the blocked (Deactivated) credit card number (first credit card number) with a new number and will send a new credit card (New Main Credit Card) to the customer.
[0129] Upon receipt of the package, the customer will call the Credit card provider to inform them that he/she has received the new credit card (New Main Credit Card). Then the Credit card provider will activate the first new credit card number (New Main Credit Card) and will block (Deactivate) the second credit card number (spare credit card). The “Spare Credit Card” will be “Deactivated”.
[0130] The Personal Identification number (PIN) to be used for the new credit card “New main Credit Card” can be the same Personal Identification number (PIN), or a different Personal Identification number (PIN) can be allocated, depending on the company policy, as described and shown in FIGS. 7 and 10 .
[0131] Now the customer can use the new credit card (New Main Credit Card) and keep the “Spare Credit Card” which is “Deactivated” in a separate and safe place, as shown and described in FIG. 7
[0132] This option provides the customer with a feature in which the “Spare Credit Card” has no validity date. This option has the advantage where the customer can always keep the “Spare Credit Card” without receiving a new “Spare Credit Card” from the credit card provider. The customer will only receive a new “Main Credit Card” when the credit card (Main Credit Card) is lost/stolen or the validity date on the credit card “Main Credit Card” has expired.
[0133] After the validity date on the credit card (Main Credit Card) has expired, the credit card provider will issue and send a new credit card (Main Credit Card) for the customer.
[0134] Referring to FIG. 12 , two credit cards are shown from the front side, (Main Credit Card and Spare Credit Card) with basic identification information such as, a card number, name (card holder) and validity date. Both terms (“Main Credit Card” and “Spare Credit Card”) refer to a credit card as generally understood, namely, that which is allocated by the credit card provider to the customer. Each credit card has a different card number, but the name of the card holder and the validity dates on both cards are the same. Because each credit card company (credit card provider) has a different card numbering system, the structure of both credit card numbers vary depending on the credit card company system.
[0135] In-order to distinguish the two credit cards (Main Credit Card and Spare Credit Card) from each other, the credit card “Main Credit Card” is named as “Credit Card” and the “Spare Credit Card” is named as “Credit Card-T”. This feature also applies to FIGS. 1 , 4 , 5 , 5 A and 6
Option 2
SUMMARY
[0000]
The credit card company opens Two accounts with two different card numbers, first account for the “main credit card” and second account for the “spare credit card”.
When the customer reports his/her lost or stolen credit card to the company, then the credit card company blocks (Deactivates) the first account (main credit card) and transfers the whole account (balance of credit) in the main credit card into the “spare credit card” and the “spare credit card” is activated to be used as the main credit card.
The credit card company will then replace the blocked (deactivated) first account with a new account and will send a new credit card (New Spare Credit Card) for the customer. The new credit card (New Spare Credit Card) will remain “deactivated”.
[0139] The credit card company opens two accounts with two different card numbers, first account for the “main credit card” and second account for the “spare credit card”. Then the credit card company provides the customer with two credit cards, a “main credit card” and a “spare credit card”. The “main credit card” will be the master credit card and will function identically as the existing credit cards. The “spare credit card” will also function identical to the existing credit cards, but will be “activated” for use, only when the “main credit card” is reported as lost or stolen by the customer to the credit card company. Both credit cards will never be activated at the same time. The credit card company will only “activate” the master card “main credit card” after receiving confirmation from the customer that he/she has received the two credit cards. The “spare credit card” will remain “deactivated”.
[0140] When the customer reports his/her lost or stolen credit card to the company, then the credit card company blocks (Deactivates) the first account (main credit card) and transfers the whole account (balance of credit) in the master card (main credit card) into the “spare credit card” and the “spare credit card” is activated to be used as the master credit card (main credit card). The credit card company will then replace the blocked (deactivated) first account with a new account (or reactivate the first account) and will send a new credit card (New Spare Credit Card) for the customer. The new credit card (New Spare Credit Card) will remain “deactivated”.
[0141] The “deactivated” credit card (spare credit card) which will only be “activated” for use when the master credit card (main credit card) is reported as lost/stolen, should always be kept in a separate place. The two credit cards (“main credit card” and “spare credit card”) should never be carried together.
[0142] The two credit cards (“Main Credit Card” and “Spare Credit Card”) should be distinguished from one another, in-order for the customer not to carry and use the wrong credit card (spare credit card) which is “deactivated”. As mentioned under “Differentiation of Main and Spare Credit Cards”, the distinguishable factors used for the two credit cards (“Main” and “Spare”) can be a sticker, color, name or any other means.
[0143] If the customer already has a credit card, then the credit card company will open an additional new card account with a new card number, to be used as the second account (spare credit card). After receiving confirmation from the customer that he/she has received the “Spare Credit Card”, the Credit card provider will instruct the customer to use the “Spare Credit Card” in the same manner as described above.
[0144] The “Spare Credit Card” sent to the customer will be distinguished from the “Main Credit Card”, in-order for the customer not to carry and use the wrong credit card (spare credit card) which is “deactivated”. As mentioned under “Differentiation of Main and Spare Credit Cards”, the distinguishable factors used for the two credit cards (“Main” and “Spare”) can be a sticker, color, name or any other means.
[0145] Referring to FIG. 1 , two credit cards are shown from the front side, (“Main Credit Card” and “Spare Credit Card”) with basic identification information such as, a card number, name (card holder) and validity date. Both terms “Main Credit Card” and “Spare Credit Card” refer to credit cards as generally understood, namely, that which are allocated by the credit card provider to the customer. Each credit card has a different card number, but the name of the card holder and the validity dates on both cards are the same. Because each credit card company (credit card provider) has a different card numbering system, the structure of both credit card numbers vary depending on the credit card company system.
[0146] The credit card (Main Credit Card) will be “Activated” as soon as the customer confirms the receipt of both credit cards “Main Credit Card” and “Spare Credit Card” to the Credit card provider. The credit card “Spare Credit Card” will remain “Deactivated” as shown in FIG. 1 .
[0147] Referring again to FIG. 1 , the credit card provider will open two accounts with two different card numbers, first account for the “main credit card” and second account for the “spare credit card”. Then the Credit card provider will send a package with two credit cards to the customer, a “Main Credit Card” and a “Spare Credit Card”. Upon receipt of the package, the customer will call the Credit card provider to inform them that he/she has received the two credit cards. Then the Credit card provider will “Activate” only the “Main Credit Card”. The “Spare Credit Card” will remain “Deactivated”.
[0148] The two credit cards (“Main Credit Card” and “Spare Credit Card”) should be distinguished from one another, in-order for the customer not to carry and use the wrong credit card (spare credit card) which is “deactivated”. As mentioned under “Differentiation of Main and Spare Credit Cards”, the distinguishable factors used for the two credit cards (“Main” and “Spare”) can be a sticker, color, name or any other means.
[0149] According to the company policy the credit card company (Credit card provider) will either provide one Personal Identification number (PIN) for both credit cards or two different Personal Identification numbers (PIN) allocated to each one of the credit cards.
[0150] After the completion of this process, the customer will be instructed to carry and use only the “Main Credit Card” which is “Activated” and keep the “Spare Credit Card” which is “Deactivated” in a separate and safe place, such as at home. In case the customer is traveling out of town, again the customer should keep the credit card (Spare Credit Card) which is “Deactivated” in a separate and safe place, such as the hotel room or any place he/she is residing at that time. The customer should never carry both credit cards together.
[0151] After the validity dates on the two credit cards (“Main Credit Card” and “Spare Credit Card”) have expired, the credit card provider will issue and send two new credit cards “Main Credit Card” and “Spare Credit Card” for the customer.
[0152] If the customer already has a credit card, then the credit card company will open an additional new card account with a new card number, to be used as the second account (spare credit card). Upon receipt of the package, the customer will call the Credit card provider to inform them that he/she has received the “Spare Credit Card”. Then the Credit card provider will instruct the customer to use the “Spare Credit Card” in the same manner as described above.
[0153] The “Spare Credit Card” sent to the customer will be distinguished from the “Main Credit Card”, in-order for the customer not to carry and use the wrong credit card (spare credit card) which is “deactivated”. As mentioned under “Differentiation of Main and Spare Credit Cards”, the distinguishable factors used for the two credit cards (“Main” and “Spare”) can be a sticker, color, name or any other means.
[0154] Referring to FIG. 2 , the same two credit cards are shown from the back side, (“Main Credit Card” and “Spare Credit Card”) with basic information such as, card holder signature space and customer service contact numbers. The Main Credit Card will be “Activated” as soon as the customer confirms the receipt of both credit cards (“Main Credit Card” and “Spare Credit Card”) to the Credit card provider as shown and described in FIG. 1 . The “Spare Credit Card” will remain “Deactivated”.
[0155] If the customer already has a credit card, then the credit card company will open an additional new card account with a new card number, to be used as the second account (spare credit card). The customer confirms the receipt of the “Spare Credit Card” to the credit card provider as shown and described in FIG. 1 . The “Spare Credit Card” will remain “Deactivated”.
[0156] The “Spare Credit Card” sent to the customer will be distinguished from the “Main Credit Card”, in-order for the customer not to carry and use the wrong credit card (spare credit card) which is “deactivated”. As mentioned under “Differentiation of Main and Spare Credit Cards”, the distinguishable factors used for the two credit cards (“Main” and “Spare”) can be a sticker, color, name or any other means.
[0157] Referring to FIG. 3 , the Main Credit Card is shown as “Lost/Stolen”. The “Spare Credit Card” is shown from back side as described and shown in FIG. 2 . The customer service contact numbers are listed on the back side of the “Spare Credit Card” as shown and described in FIG. 2 and FIG. 3 . The “Spare Credit Card” remains “Deactivated”.
[0158] Referring again to FIG. 3 , the customer (card holder) calls the listed customer service contact numbers on the back side of the “Spare Credit Card” to report his/her “Lost/Stolen” credit card (Main Credit Card). For security check, the credit card provider will ask the customer (card holder) to provide information such as, name, validity date, card number, PIN number, etc. Because both credit cards (“Main Credit Card” and “Spare Credit Card”) are issued to one person, the first account number for the “main credit card” will display the second account number for the “spare credit card” and the second account number for the “spare credit card” will display the first account number for the “main credit card”. Then the credit card provider will ask for the “Spare Credit Card” number in-order to block and “Deactivate” the Credit card (Main Credit Card). There is no need to keep a copy of the credit card (Main Credit Card) in case the credit card provider needs any information for blocking the credit card (Main Credit Card).
[0159] Referring to FIG. 4 , the Main Credit Card is shown as “Lost/Stolen” and “Deactivated”. The “Spare Credit Card” is also shown from the front side with basic identification information such as, a card number, name (card holder) and validity date as shown and described in FIG. 1 . The “Spare Credit card” is “Activated” as shown in FIG. 4 .
[0160] Referring again to FIG. 4 , once the customer (card holder) reports his/her “Lost/Stolen” credit card (Main Credit Card) to the credit card provider as described and shown in FIG. 3 , the credit card company blocks (Deactivates) the first account (main credit card) and transfers the whole account (balance of credit) in the master card (main credit card) into the “spare credit card” and the “spare credit card” is activated to be used as the master credit card (main credit card).
[0161] If the credit card provider has decided to place a sticker on the “spare credit card” as the distinguishing factor between the two credit cards (“Main Credit Card” and “Spare Credit Card”), then the customer will simply remove the sticker from the “spare credit card” and use the “spare credit card” as the master credit card (main credit card). As mentioned under “Differentiation of Main and Spare Credit Cards”, the distinguishable factors used for the two credit cards (“Main” and “Spare”) can be a sticker, color, name or any other means.
[0162] Depending on the company policy, as described and shown in FIG. 1 ., the Personal Identification number (PIN) used for the old “Spare Credit Card” which is now the “Main Credit Card” can be the same Personal Identification number (PIN), or a different Personal Identification number (PIN) can be allocated.
[0163] Now the customer can use the “Spare Credit Card” as the “Main Credit Card”.
[0164] Referring to FIG. 5 , the “New Spare Credit Card” is shown from the front side, with a new card number, but with the same validity date (depending on the credit card company policy the validity date can remain the same or can be changed). The “Spare Credit Card” which is now used as the “Main Credit Card” is also shown from the front side with the same card number and validity date as shown in FIGS. 1 and 4 . The “New Spare Credit Card” is “Deactivated” and the “Main Credit Card” (Old Spare Credit Card) is “Activated”.
[0165] Referring again to FIG. 5 , after the customer (card holder) reports his/her “Lost/Stolen” credit card (Main Credit Card) to the credit card provider as described and shown in FIGS. 3 and 4 , the credit card company will then replace the blocked (Deactivated) first account with a new account (or reactivate the first account) and will send a new credit card (New Spare Credit Card) for the customer. The new credit card (New Spare Credit Card) will remain “deactivated”.
[0166] The credit card “New Spare Credit Card” sent to the customer will be distinguished from the “Main Credit Card” (Old Spare Credit Card) in-order for the customer not to carry and use the wrong credit card (new spare credit card) which is “deactivated”. As mentioned under “Differentiation of Main and Spare Credit Cards”, the distinguishable factors used for the two credit cards (“Main” and “Spare”) can be a sticker, color, name or any other means.
[0167] Depending on the company policy, as described and shown in FIGS. 1 and 4 , the Personal Identification number (PIN) to be used for the “New Spare Credit Card” can be the same Personal Identification number (PIN), or a different Personal Identification number (PIN) can be allocated.
[0168] Upon receipt of the new credit card (New Spare Credit Card), the customer will call the credit card provider to confirm that he/she has received the new credit card (New Spare Credit Card).
[0169] Now the customer can use the old “Spare Credit Card” as the “Main Credit Card” and keep the “New Spare Credit Card” which is “Deactivated” in a separate and safe place, as shown and described in FIG. 1
[0170] After the validity dates on the two credit cards (“Main Credit Card” and “Spare Credit Card”) have expired, the credit card provider will issue and send two new credit cards (“Main Credit Card” and “Spare Credit Card”) for the customer.
Option 2 A
SUMMARY
[0000]
The credit card company opens Two accounts with two different card numbers, first account for the “main credit card” and second account for the “spare credit card”.
When the credit card is lost/stolen, the customer uses the credit card (Spare Credit Card) until a new credit card (New Main credit Card) is issued and sent to the customer.
Upon receipt of the package, the customer will call the Credit card provider to inform them that he/she has received the new credit card (New Main Credit Card). Then the Credit card provider will “Activate” the new credit card (New Main Credit Card) and will transfer the whole account (balance of credit) from the “Spare Credit Card” into the new credit card (New Main Credit Card). The “Spare Credit Card” will be “Deactivated”.
The customer can now use the new credit card (New Main Credit Card) and keep the credit card (Spare Credit Card) which is “Deactivated” in a separate and safe place.
[0175] In this specification the term “credit card” refers to credit cards (Master Card®, Visa®, Diners Club®, etc.) as well as charge cards (e.g., American Express®, some department store cards), debit cards such as usable at ATMs and many other locations or that are associated with a particular account, and hybrids thereof (e.g., extended payment American Express®, bank debit cards with the Visa® logo, etc.).
[0176] Referring to FIG. 1 , two credit cards are shown from the front side, (Main Credit Card) and (Spare Credit Card) with basic identification information such as, a card number, name (card holder) and validity date. Both terms “Main Credit Card” and “Spare Credit Card” refer to credit cards as generally understood, namely, that which are allocated by the credit card provider to the customer. Each credit card has a different card number, but the name of the card holder and the validity dates on both cards are the same. Because each credit card company (credit card provider) has a different card numbering system, the structure of both credit card numbers vary depending on the credit card company system.
[0177] The credit card (Main Credit Card) will be “Activated” as soon as the customer confirms the receipt of both credit cards “Main Credit Card” and “Spare Credit Card” to the Credit card provider. The credit card “Spare Credit Card” will remain “Deactivated” as shown in FIG. 1 .
[0178] The two credit cards (“Main Credit Card” and “Spare Credit Card”) should be distinguished from one another, in order for the customer not to carry the wrong credit card (spare credit card) which is “deactivated”. As mentioned under “Differentiation of Main and Spare Credit Cards”, the distinguishable factors used for the two credit cards (“Main” and “Spare”) can be a sticker, color, name or any other means. In option 2 A the sticker on the “spare credit card” will never be removed.
[0179] Referring again to FIG. 1 , the Credit card provider will send a package with two credit cards to the customer, a “Main Credit Card” and a “Spare Credit Card”. Upon receipt of the package, the customer will call the Credit card provider to inform them that he/she has received the two credit cards. Then the Credit card provider will “Activate” only the “Main Credit Card”. The “Spare Credit Card” will remain “Deactivated”.
[0180] The credit card company (Credit card provider) will also provide one Personal Identification number (PIN) for both credit cards or, two different Personal Identification number (PIN) allocated to each one of the credit cards, according to the credit card company policy.
[0181] After the completion of this process, the customer will be instructed to carry and use only the “Main Credit Card” which is “Activated” and keep the “Spare Credit Card” which is “Deactivated” in a separate and safe place, such as at home. In case the customer is traveling out of town, again the customer should keep the credit card (Spare Credit Card) which is “Deactivated” in a separate and safe place, such as the hotel room or any place he/she is residing at that time. The customer should never carry both credit cards together.
[0182] After the validity dates on the two credit cards (“Main Credit Card” and “Spare Credit Card”) have expired, the credit card provider will issue and send two new credit cards “Main Credit Card” and “Spare Credit Card” for the customer.
[0183] If the customer already has a credit card, then the credit card company will open a new account with a new card number, to be used as the second account (spare credit card). Upon receipt of the package, the customer will call the Credit card provider to inform them that he/she has received the “Spare Credit Card”. Then the Credit card provider will instruct the customer to use the “Spare Credit Card” in the same manner as described above.
[0184] The “Spare Credit Card” sent to the customer will be distinguished from the “Main Credit Card”, in-order for the customer not to carry and use the wrong credit card (spare credit card) which is “deactivated”. As mentioned under “Differentiation of Main and Spare Credit Cards”, the distinguishable factors used for the two credit cards (“Main” and “Spare”) can be a sticker, color, name or any other means. In option 2 A the sticker on the “spare credit card” will never be removed.
[0185] Referring to FIG. 2 , the same two credit cards are shown from the back side, (“Main Credit Card” and “Spare Credit Card”) with basic information such as, card holder signature space and customer service contact numbers. The credit card (Main Credit Card) will be “Activated” as soon as the customer confirms the receipt of both credit cards (“Main Credit Card” and “Spare Credit Card”) to the Credit card provider as shown and described in FIG. 1 . The credit card “Spare Credit Card” will remain “Deactivated”.
[0186] If the customer already has a credit card, then the credit card company will open a new card account with a new card number, to be used as the second account (spare credit card). The customer confirms the receipt of the credit “Spare Credit Card” to the Credit card provider as shown and described in FIG. 1 . The credit card “Spare Credit Card” will remain “Deactivated”.
[0187] The “Spare Credit Card” sent to the customer will be distinguished from the “Main Credit Card”, in-order for the customer not to carry and use the wrong credit card (spare credit card) which is “deactivated”. As mentioned under “Differentiation of Main and Spare Credit Cards”, the distinguishable factors used for the two credit cards (“Main” and “Spare”) can be a sticker, color, name or any other means. In option 2 A the sticker on the “spare credit card” will never be removed.
[0188] Referring to FIG. 3 , the credit card (Main Credit Card) is shown as “Lost/Stolen”. The “Spare Credit Card” is shown from back side as described and shown in FIG. 2 . The customer service contact numbers are listed on the back side of the “Spare Credit Card” as shown and described in FIG. 2 and FIG. 3 . The “Spare Credit Card” remains “Deactivated”.
[0189] Referring again to FIG. 3 , the customer (card holder) calls the listed customer service contact numbers on the back side of the “Spare Credit Card” to report his/her “Lost/Stolen” credit card (Main Credit Card). For security check, the credit card provider will ask the customer (card holder) to provide information such as, name, validity date, card number, PIN number, etc. Because both credit cards (“Main Credit Card” and “Spare Credit Card”) are issued to one person, the first account for the “main credit card” will display the second account for the “spare credit card” and the second account for the “spare credit card” will display the first account for the “main credit card”. Then the credit card provider will ask for the “Spare Credit Card” number in-order to block and “Deactivate” the Credit card (Main Credit Card). There is no need to keep a copy of the credit card (Main Credit Card) in case the credit card provider needs any information for blocking the credit card (Main Credit Card).
[0190] Referring to FIG. 4 , the credit card (Main Credit Card) is shown as “Lost/Stolen” and “Deactivated”. The “Spare Credit Card” is also shown from the front side with basic identification information such as, a card number, name (card holder) and validity date as shown and described in FIG. 1 . The “Spare Credit card” is “Activated” as shown in FIG. 4 .
[0191] Referring again to FIG. 4 , once the customer (card holder) reports his/her “Lost/Stolen” credit card (Main Credit Card) to the credit card provider as described and shown in FIG. 3 , the credit card company blocks (Deactivates) the first account (main credit card) and transfers the whole account (balance of credit) in the master card (main credit card) into the “spare credit card” account and the “Spare Credit Card” is “Activated”.
[0192] The Personal Identification number (PIN) to be used for the credit card (Spare Credit Card) can be the same Personal Identification number (PIN), or a different Personal Identification number (PIN) can be allocated, depending on the company policy, as described and shown in FIG. 1 .
[0193] Now the customer can use the credit card (Spare Credit Card) until a new credit card (New Main credit Card) is issued and sent to the customer.
[0194] Referring to FIG. 5A , the new credit card (New Main Credit Card) is shown from the front side, with a new card number, but with the same validity date (the validity date can remain the same or can be changed according to the credit card company policy). The “Spare Credit Card” is also shown from the front side with the same card number and validity date as shown in FIGS. 1 and 4 . The new credit card (New Main Credit Card) is “Activated” and the “Spare Credit Card” is “Deactivated”.
[0195] Referring again to FIG. 5A , after the customer (card holder) reports his/her “Lost/Stolen” credit card (Main Credit Card) to the credit card provider as described and shown in FIGS. 3 and 4 , the credit card company will then replace the blocked (Deactivated) first account with a new account (or reactivated first account) and will send a new credit card (New Main Credit Card) to the customer.
[0196] Upon receipt of the package, the customer will call the Credit card provider to inform them that he/she has received the new credit card (New Main Credit Card). Then the Credit card provider will “Activate” the new credit card (New Main Credit Card) and will transfer the whole account (balance of credit) from the “Spare Credit Card” into the new credit card (New Main Credit Card). The “Spare Credit Card” will be “Deactivated”.
[0197] The Personal Identification number (PIN) to be used for the new credit card (New main Credit Card) can be the same Personal Identification number (PIN), or a different Personal Identification number (PIN) can be allocated, depending on the company policy, as described and shown in FIGS. 1 and 4 .
[0198] Now the customer can use the new credit card (New Main Credit Card) and keep the credit card (Spare Credit Card) which is “Deactivated” in a separate and safe place, as shown and described in FIG. 1
[0199] After the validity dates on the two credit cards (“Main Credit Card” and “Spare Credit Card”) have expired, the credit card provider will issue and send two new credit cards (“Main Credit Card” and “Spare Credit Card”) for the customer.
Option 2 B
SUMMARY
[0000]
The credit card company opens Two accounts with two different card numbers, first account for the “main credit card” and second account for the “spare credit card”.
When the credit card is lost/stolen, the customer uses the credit card (Spare Credit Card) until two new credit cards (“New Main Credit Card” and “New Spare Credit Card”) are issued and sent to the customer.
Upon receipt of the package, the customer will call the Credit card provider to inform them that he/she has received the two new credit cards. Then the credit card provider will “Activate” the new credit card (New Main Credit Card) and will transfer the whole account (balance of credit) from the old credit card (Old Spare credit Card) into the new credit card (New Main Credit Card). The “New Spare Credit Card” will remain “Deactivated”.
The customer (card holder) will be asked to destroy the “Old Spare Credit Card” and keep the “New Spare Credit Card” which is “Deactivated”, in a separate and safe place.
The Credit card provider sends two new credit cards to the customer, a “New Main Credit Card” and a “New Spare Credit Card”.
[0205] Referring to FIG. 6 , the new credit card (New Main Credit Card) is shown from the front side, with a new card number and a new validity date. A new credit card (New Spare Credit Card) is also shown from the front side with a new card number and a new validity date. The new credit card (New Main Credit Card) is “Activated” and the new credit card (New Spare Credit Card) is “Deactivated”.
[0206] Referring again to FIG. 6 , after the customer (card holder) reports his/her “Lost/Stolen” credit card (Main Credit Card) to the credit card provider as described and shown in FIGS. 3 and 4 , the Credit card provider will send a package with two new cards to the customer, a “New Main Credit Card” and a “New Spare Credit Card”.
[0207] Upon receipt of the package, the customer will call the Credit card provider to inform them that he/she has received the two new credit cards. Then the credit card provider will “Activate” the new credit card (New Main Credit Card) and will transfer the whole account (balance of credit) from the old credit card (Old Spare credit Card) into the new credit card (New Main Credit Card). The “New Spare Credit Card” will be “Deactivated”.
[0208] The customer (card holder) will be asked to destroy the “Old Spare Credit Card” and keep the “New Spare Credit Card” which is “Deactivated”, in a separate and safe place, as shown and described in FIG. 1 .
[0209] This option provides the customer with a feature in which the Credit card provider sends two new credit cards to the customer, a “New Main Credit Card” and a “New Spare Credit Card”. The validity dates on both credit cards can remain the same or can be changed according to the credit card company policy.
[0210] After the validity dates on the two credit cards (“Main Credit Card” and “Spare Credit Card”) have expired, the credit card provider will issue and send two new credit cards “Main Credit Card” and “Spare Credit Card” for the customer.
Option 2 C
SUMMARY
[0000]
The credit card company opens Two accounts with two different card numbers, first account for the “main credit card” and second account for the “spare credit card”.
When the credit card is lost/stolen, the customer uses the credit card (Spare Credit Card) which has no validity date, until a new credit card (Main Credit Card) is issued and sent to the customer.
Upon receipt of the package, the customer will call the Credit card provider to inform them that he/she has received the new credit card (New Main Credit Card). Then the Credit card provider will “Activate” the new credit card (New Main Credit Card) and will transfer the whole account (balance of credit) from the “Spare Credit Card” into the new credit card (New Main Credit Card). The “Spare Credit Card” will be “Deactivated”.
The customer can use the new credit card (New Main Credit Card) and keep the “Spare Credit Card” which is “Deactivated” in a separate and safe place.
The “Spare Credit Card” has no validity date, allows the customer to use the “Spare Credit Card” without receiving a new “Spare Credit Card” from the credit card provider. The customer will only receive a new “Main Credit Card” when the credit card (Main Credit Card) is lost/stolen or the validity date on the credit card “Main Credit Card” has expired.
[0216] Referring to FIG. 7 , the two credit cards are shown from the front side, (Main Credit Card) and (Spare Credit Card). The credit card “Main Credit Card” is issued with the basic identification information such as, a card number, name (card holder) and validity date. The credit card (Spare Credit Card) has no validity date, but is issued with the basic identification information such as, a card number, name (card holder). Both terms “Main Credit Card” and “Spare Credit Card” refer to a credit card as generally understood, namely, that which is allocated by the credit card provider to the customer. Each credit card has a different card number, but the name of the card holder on both cards are the same. Because each credit card company (credit card provider) has a different card numbering system, the structures of both credit card numbers vary depending on the credit card company system.
[0217] The credit card (Main Credit Card) will be “Activated” as soon as the customer confirms the receipt of both credit cards (“Main Credit Card” and “Spare Credit Card”) to the Credit card provider. The “Spare Credit Card” will remain “Deactivated” as shown in FIG. 7 .
[0218] The two credit cards (“Main Credit Card” and “Spare Credit Card”) will be distinguished from one another, in-order for the customer not to carry and use the wrong credit card (spare credit card) which is “deactivated”. As mentioned under “Differentiation of Main and Spare Credit Cards”, the distinguishable factors used for the two credit cards (“Main” and “Spare”) can be a sticker, color, name or any other means. In option 2 C the sticker on the “spare credit card” will never be removed.
[0219] Referring again to FIG. 7 , the Credit card provider will send a package with two credit cards to the customer, a “Main Credit Card” and a “Spare Credit Card”. Upon receipt of the package, the customer will call the Credit card provider to inform them that he/she has received the two credit cards. Then the Credit card provider will “Activate” only the credit card “Main Credit Card”. The credit card “Spare Credit Card” will remain “Deactivated”.
[0220] The card company (Credit card provider) will also provide one Personal Identification number (PIN) allocated to both credit cards or two different Personal Identification numbers (PIN) allocated to each one of the credit cards, depending on the company policy.
[0221] After the completion of this process, the customer will be instructed to carry and use only the “Main Credit Card” which is “Activated” and keep the “Spare Credit Card” which is “Deactivated” in a separate place, for example, at home. In case the customer is traveling out of town, again the customer should keep the “Spare Credit Card” which is “Deactivated” in a separate place, such as the hotel room or any place he/she is residing at that time. The customer should never carry both credit cards together.
[0222] If the customer already has a credit card, then the credit card company will open a new account with a new card number, to be used as the second account (spare credit card). Upon receipt of the package, the customer will call the Credit card provider to inform them that he/she has received the “Spare Credit Card”. Then the Credit card provider will instruct the customer to use the “Spare Credit Card” in the same manner as described above.
[0223] The “Spare Credit Card” sent to the customer will be distinguished from the “Main Credit Card”, in-order for the customer not to carry and use the wrong credit card (spare credit card) which is “deactivated” As mentioned under “Differentiation of Main and Spare Credit Cards”, the distinguishable factors used for the two credit cards (“Main” and “Spare”) can be a sticker, color, name or any other means. In option 2 C the sticker on the “spare credit card” will never be removed.
[0224] Referring to FIG. 8 , the same two credit cards are shown from the back side, (“Main Credit Card” and “Spare Credit Card”) with basic information such as, card holder signature space and customer service contact numbers. The credit card (Main credit Card) will be “Activated” as soon as the customer confirms the receipt of both credit cards “Main Credit Card” and “Spare Credit Card” to the Credit card provider as shown and described in FIG. 7 . The credit card “Spare Credit Card” will remain “Deactivated”.
[0225] If the customer already has a credit card, then the credit card company will open a new card account with a new card number, to be used as the second account (spare credit card). The customer confirms the receipt of the credit card (Spare Credit Card) to the Credit card provider as shown and described in FIG. 7 . The credit card “Spare Credit Card” will remain “Deactivated”.
[0226] The “Spare Credit Card” sent to the customer will be distinguished from the “Main Credit Card”, in-order for the customer not to carry and use the wrong credit card (“pare credit card) which is “deactivated”. As mentioned under “Differentiation of Main and Spare Credit Cards”, the distinguishable factors used for the two credit cards (“Main” and “Spare”) can be a sticker, color, name or any other means. In option 2 C the sticker on the “spare credit card” will never be removed.
[0227] Referring to FIG. 9 , the credit card (Main Credit Card) is shown as “Lost/Stolen”. The “Spare Credit Card” is shown from back side as described and shown in FIG. 8 . The customer service contact numbers are listed on the back side of the “Spare Credit Card” as shown and described in FIG. 8 and FIG. 9 . The “Spare Credit Card” remains “Deactivated”.
[0228] Referring again to FIG. 9 , the customer (card holder) calls the listed customer service contact numbers on the back side of the “Spare credit Card” to report his/her “Lost/Stolen” credit card (Main Credit Card). For security check, the credit card provider will ask the customer (card holder) to provide information such as, name, validity date, card number, PIN number, etc. Since both credit cards (“Main credit Card” and “Spare Credit Card”) are issued to one person, the first account for the “main credit card” will display the second account for the “spare credit card” and the second account for the “spare credit card” will display the first account for the “main credit card”. Then the credit card provider will ask for the “Spare Credit Card” number in-order to block and “Deactivate” the Credit card (Main Credit Card). There is no need to keep a copy of the credit card (Main Credit Card) in case the credit card provider needs any information for blocking the credit card (Main Credit Card).
[0229] Referring to FIG. 10 , the credit card (Main Credit Card) is shown as “Lost/Stolen” and “Deactivated”. The “Spare Credit Card” is also shown from the front side without a validity date, but has the basic identification information such as, a card number, name (card holder) as shown and described in FIG. 7 . The “Spare Credit Card” is “Activated” as shown in FIG. 10 .
[0230] Referring again to FIG. 10 , once the customer (card holder) reports his/her “Lost/Stolen” credit card (Main Credit Card) to the credit card provider as described and shown in FIG. 9 , the credit card company blocks (Deactivates) the first account (main credit card) and transfers the whole account (balance of credit) in the master card (main credit card) into the “spare credit card” and the “Spare Credit Card” is “Activated”.
[0231] The Personal Identification number (PIN) to be used for the “Spare Credit Card” can be the same Personal Identification number (PIN), or a different Personal Identification number (PIN) can be allocated, depending on the company policy, as described and shown in FIG. 7 .
[0232] Now the customer can use the “Spare Credit Card” until a new credit card (Main Credit Card) is issued and sent to the customer.
[0233] Referring to FIG. 11 , the new credit card (New Main Credit Card) is shown from the front side, with a new card number, but with the same validity date (the validity date can remain the same or can be changed according to the credit card company policy). The “Spare Credit Card” is also shown from the front side with the same card number but without a validity date as shown in FIGS. 7 and 10 . The new credit card (New Main Credit Card) is “Activated” and the “Spare Credit Card” is “Deactivated”.
[0234] Referring again to FIG. 11 , after the customer (card holder) reports his/her “Lost/Stolen” credit card (Main Credit Card) to the credit card provider as described and shown in FIGS. 9 and 10 , the credit card company will then replace the blocked (Deactivated) first account with a new account (or reactivate the first account) and will send a new credit card (New Main Credit Card) to the customer.
[0235] Upon receipt of the package, the customer will call the Credit card provider to inform them that he/she has received the new credit card (New Main Credit Card). Then the Credit card provider will “Activate” the new credit card (New Main Credit Card) and will transfer the whole account (balance of credit) from the “Spare Credit Card” into the new credit card (New Main Credit Card). The “Spare Credit Card” will be “Deactivated”.
[0236] The Personal Identification number (PIN) to be used for the new credit card “New main Credit Card” can be the same Personal Identification number (PIN), or a different Personal Identification number (PIN) can be allocated, depending on the company policy, as described and shown in FIGS. 7 and 10 .
[0237] Now the customer can use the new credit card (New Main Credit Card) and keep the “Spare Credit Card” which is “Deactivated” in a separate and safe place, as shown and described in FIG. 7
[0238] This option provides the customer with a feature in which the “Spare Credit Card” has no validity date. This option has the advantage where the customer can always keep the “Spare Credit Card” without receiving a new “Spare Credit Card” from the credit card provider. The customer will only receive a new “Main Credit Card” when the credit card (Main Credit Card) is lost/stolen or the validity date on the credit card “Main Credit Card” has expired.
[0239] After the validity date on the credit card (Main Credit Card) has expired, the credit card provider will issue and send a new credit card (Main Credit Card) for the customer.
[0240] Referring to FIG. 12 , two credit cards are shown from the front side, (Main Credit Card and Spare Credit Card) with basic identification information such as, a card number, name (card holder) and validity date. Both terms (“Main Credit Card” and “Spare Credit Card”) refer to a credit card as generally understood, namely, that which is allocated by the credit card provider to the customer. Each credit card has a different card number, but the name of the card holder and the validity dates on both cards are the same. Because each credit card company (credit card provider) has a different card numbering system, the structure of both credit card numbers vary depending on the credit card company system.
[0241] In-order to distinguish the two credit cards (“Main Credit Card” and “Spare Credit Card”) from each other, the credit card “Main Credit Card” is named as “Credit Card” and the “Spare Credit Card” is named as “Credit Card-T”. This feature also applies to FIGS. 1 , 4 , 5 , 5 A and 6 .
[0242] FIG. 13 and FIG. 14 summarize, in respective flow charts, the system of the present invention as applied to two cards with active main card and deactived or inactive spare card for a single account and active main card for a first active account and an inactive spare card in a second inactive account. The flow charts of FIGS. 13 and 14 summarize all the above options for issuing of additional cards, with their respective status and account status, as triggered by the loss or theft of an original active main card.
[0243] While the foregoing description makes reference to particular illustrative embodiments, these examples should not be construed as limitations. Thus, the present invention is not limited to the disclosed embodiments.
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A credit card use and replacement security system and method comprising two credit cards issued to a single user by a financial institution, with a first of the cards being active as a main card for transactions and a second spare card being inactive from transactions. Loss or theft of the first active main card, is reported to the financial institution with the original main card being deactivated by the financial institution and the spare card is activated for immediate transaction use as a main card with an account. The financial institution issues at least one additional card according to one of the following options: a new inactive spare card; a new active main card with the activated spare card being deactivated for use as a spare; and a new active main card and a new deactivated spare card with the original activated spare card being destroyed.
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CROSS REFERENCE TO RELATED APPLICATION
This is a divisional of U.S. Application Ser. No. 10/061,189 filed on Feb. 1, 2002, which is a non-provisional application based on provisional application Ser. No. 60/265,714, filed Feb. 1, 2001.
BACKGROUND
1. Field of the Invention
This invention relates generally to switch-mode power converters and more particularly it provides simple a drive circuit and an enable function with isolation and having high performance in full-bridge topologies using synchronous rectification.
2. Background Discussion
A switch-mode power converter is a circuit that uses an inductor, a transformer, or a capacitor, or some combination, as energy storage elements to transfer energy from an input source to an output load in discrete pulses. Additional circuitry is added to maintain a constant voltage within the load limits of the circuit. The basic circuit can be configured to step up (boost), step down (buck), or invert output voltage with respect to input voltage. Using a transformer allows the output voltage to be electrically isolated from the input voltage.
Switch-mode converters have changed very little over the past 15 years, most using Schottky diodes to rectify their output. However, newer challenges in the industry for dc/dc power supply designers demand lower voltages required by digital circuits, and also higher frequencies. Since converters using Schottky diodes for rectification experience a large forward voltage drop relative to the output voltage, their efficiency is generally relatively low. Lower efficiencies result in more dissipated heat that has to be removed using a heat sink, which takes up space. A dramatic increase in converter efficiency can be accomplished by replacing the Schottky diodes with “synchronous rectifiers” realized in practice with MOSFET transistors. Synchronous rectifiers are not new, but they have previously been too expensive to justify, primarily due to high “on” resistance. However, as costs fall and performance improves, synchronous rectifiers have quickly become a viable component, especially for low voltage converters.
Using self-driven synchronous rectifiers in various converter topologies is very attractive and popular because there is no need for additional isolation between drive signals. It has the advantage of simplicity. However, it has the disadvantage of cross conduction between synchronous rectifiers and primary side switches, as well as reverse recovery current of the parasitic anti-parallel diode of the MOSFETs used for synchronous rectification. In order to minimize these shoot-through currents, an inductance (or saturable inductor) is usually placed in series with the synchronous rectifier. While this may be a solution for lower switching frequencies, for example, 100 kHz-200 kHz, it is not suitable for higher switching frequencies (200 kHz and above). Especially at switching frequencies of 300-400 kHz this is not an optimum solution. The reason for this is that increased inductance in series with a synchronous rectifier reduces the effective duty cycle on the secondary side of the power transformer due to slower di/dt of the secondary current. As a result, more voltage headroom is required in the power transformer, implying a smaller effective turns ratio and lower efficiency.
A second reason why self-driven synchronous rectification is not suitable for higher switching frequencies is the potential loss due to reverse recovery current in the body diode of the synchronous rectifiers (MOSFETs) and increased turn-on current in the primary side switches (usually MOSFETs).
A third reason why self driven synchronous rectifiers have not been a preferred solution is that the drive voltage, being derived from a power transformer, depends on input voltage and therefore could vary significantly (200% to 300%). As a consequence, power consumption of the drive circuit, which varies exponentially with input voltage, can vary even more (400% to 900%) and decrease overall converter efficiency.
A much more preferred solution is to use direct drive to power synchronous rectifiers with well-controlled timing between drive signals for the main switches (primary side) and synchronous rectifiers (secondary side). This solution thus allows for very efficient operation of the synchronous rectifiers even at high switching frequencies. Yet another benefit of direct driven synchronous rectifiers is that the drive voltage (gate to source) is constant and independent of input voltage, which further improves efficiency over a wide input voltage range.
It is necessary to provide delays between drive signals for primary side switches and secondary side switches in order to avoid cross conduction (simultaneous conduction which would result in a short circuit). When power converters are operated at lower switching frequencies (for example, 100 kHz), cross conduction of the switches can be acceptable since the percentage of the time during which cross conduction occurs relative to the switching period is small (typically 40 ns/10 μs). Also, a transformer designed to operate at lower frequencies will have a larger leakage inductance, which will reduce cross conduction currents. In the case of higher switching frequencies (above 100 kHz), cross-conduction becomes more unacceptable (40 ns/2 μs for a 500 kHz switching frequency). Also for higher switching frequencies, the leakage inductance in the transformer as well as in the whole power stage should be minimized for higher efficiency. Consequently, currents due to cross conduction time can become significant and degrade overall converter efficiency and increase heating of the power components significantly.
SUMMARY OF THE INVENTION
In an embodiment of the invention, one drive transformer is used for providing appropriate delays as well as providing power for driving primary switches, particularly high side switches in a full-bridge topology. The leakage inductance of the drive transformer is used to delay turn-on of the main switches (primary side) while turn-off is with no significant delay. The number of windings on the drive transformer is minimized to four, when the control circuit is referenced to the output of the converter, and minimized to five when the control circuit is referenced to the input of the converter. In the full-bridge converter, having the control circuit referenced to the output of the converter, four windings are for: (1) the control and drive circuit (pulse width modulated (PWM) type, for example) signal referenced to the output and providing proper waveforms for driving synchronous rectifiers; (2) driving two bottom primary side switches; (3) driving one top primary side switch; and (4) driving second top primary side switch. If the control circuit is referenced to the input of the converter, there are five windings for: (1) the control and drive circuit signal referenced to the input of the converter; (2) providing proper waveforms for driving synchronous rectifiers; (3) driving one top primary side switch; (4) driving a second top primary side switch; and (5) driving two bottom primary side switches. It is an additional object of the invention to provide means to enable/disable the module due to a condition sensed on either the input or the output side via a controller or protection circuit located on either the input or the output side of the converter.
BRIEF DESCRIPTION OF THE DRAWING
The objects, advantages and features of the invention will be more clearly perceived from the following detailed description, when read in conjunction with the accompanying drawing, in which:
FIGS. 1A and 1B comprise a circuit diagram of an embodiment of the invention using a full-bridge converter with the control and drive circuit referenced to the input side of the converter and a drive transformer that includes five windings;
FIG. 1C is an embodiment of the invention similar to FIG. 1A, having four windings on the drive transformer and two external inductances for driving two bottom switches;
FIG. 2 shows the salient waveforms of an embodiment of the invention, taken at several locations in the circuit from FIGS. 1A and 1B;
FIG. 3 shows the turn-on waveforms of a primary side switch in the FIGS. 1A and 1B circuit with reduced leakage inductance of one winding;
FIG. 4 shows the turn-off waveforms of a primary side switch in FIGS. 1A and 1B;
FIGS. 5A and 5B comprise circuit diagram of an embodiment of the invention using a full-bridge converter with the control and drive circuit referenced to the output side of the converter;
FIG. 5C is an alternative circuit embodiment of the invention to facilitate disabling the control circuit, referenced to the output, from a condition sensed on the input side of the converter;
FIG. 5D is another alternative circuit embodiment similar to FIG. 5C;
FIG. 6 is a partial circuit diagram for a possible realization of a driver for the synchronous rectifiers of an embodiment of the invention using bipolar transistors;
FIG. 7 is an alternative circuit diagram for a possible realization of a driver for the synchronous rectifiers of an embodiment of the invention using MOSFETs;
FIG. 8 is yet another partial circuit diagram for a possible realization of a driver for synchronous rectifiers of an embodiment of the invention with MOSFETs;
FIGS. 9A and 9B are alternative partial circuit diagrams for a possible realization of drivers for the top primary side switches with n-channel MOSFETs;
FIGS. 10A-10D are partial circuit diagram for possible realizations of the drivers for primary side switches using p-n-p bipolar transistors; and
FIGS. 11A and 11B comprise an alternative circuit embodiment to facilitate disabling the control circuit, referenced to the input side, from a condition sensed on the output side of the converter.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1A and 1B demonstrate a full-bridge topology with synchronous rectifiers using an isolated drive circuit according to an embodiment of the invention. Four primary switches (transistors) Q 10 , Q 20 , Q 30 and Q 40 , power transformer T 2 , synchronous rectifiers S 1 and S 2 , output inductor L 0 , and capacitor C 0 form the power stage of the full-bridge converter. Switches Q 10 and Q 20 form one leg of the bridge, while switches Q 30 and Q 40 form the other leg of the bridge. Both legs of the bridge are connected across the input voltage, with Q 10 and Q 40 connected to the positive side and Q 20 and Q 30 connected to the negative side. Switches in the same leg (Q 10 and Q 20 , and Q 30 and Q 40 ) always conduct out of phase, while diagonal switches conduct simultaneously (Q 10 and Q 30 , and Q 20 and Q 40 ). Primary winding N p of power transformer T 2 is connected between the mid-points of the two legs. Two secondary windings, N S1 and N S2 , are preferably identical and are connected in series. The common point between two windings N S1 and N S2 is connected to one end of output inductor L 0 . The second end of the inductor is connected to output capacitor C 0 . The second end of winding N S1 is connected to synchronous rectifier S 1 while the second end of winding N S2 is connected to synchronous rectifier S 2 . For a basic full-bridge converter, the polarity of the windings is chosen such that: (a) when switches Q 10 and Q 30 are on, S 1 is on and S 2 is off; (b) when switches Q 20 and Q 40 are on, synchronous rectifier S 2 is on and synchronous rectifier S 1 is off; and (c) when all four primary side switches, Q 10 , Q 20 , Q 30 and Q 40 , are off both S 1 and S 2 are on and all three windings of power transformer T 2 are shorted.
Output voltage V OUT is compared with reference voltage V R in block 100 (comprising reference V R and an error amplifier with a compensation network) as shown in FIG. 1 B. The output of block 100 is fed into isolation circuit 101 (usually an opto-coupler or isolation transformer) and error signal V E is fed into controller block 102 which comprises, for example, but is not limited to, a PWM controller, two driver stages generating out-of-phase outputs OUTA and OUTB, and ON/OFF logic. Block 102 may also contain additional protection features very often found in converters. However, they are not relevant for the purpose of this description, and are thus omitted. Driver outputs OUTA and OUTB are capable of driving two primary side switches simultaneously (Q 10 and Q 30 , and Q 20 and Q 40 ) as well as supplying magnetizing current to drive transformer T 1 . Note that in FIG. 1A the controller and drivers OUTA and OUTB are referenced to −V IN and thus to the input of the converter.
Drive transformer T 1 has five windings, N 1 to N 5 (FIG. 1 A). Their leakage inductances are illustrated explicitly in FIG. 1A as external inductances L 1 , L 2 , L 3 , L 4 and L 5 . Winding N 5 is driven from block 102 with signals OUTA and OUTB. Capacitor C 1 serves as a dc blocking capacitor. Winding N 1 is connected with one end to the source of transistor Q 10 and the second end is connected to the gate of transistor Q 10 via series diode D 10 and resistor R 5 . Resistor R 5 is connected in series with diode D 10 in order to dampen oscillations on the gate of Q 10 caused by resonance between leakage inductance L 1 and the input capacitance of transistor Q 10 . Transistor Q 1 , shown as a p-channel MOSFET, is connected across the gate and source of Q 10 with its gate connected via resistor R 3 to the end of winding N 1 marked with dot polarity. Resistor R 10 , connected across the gate and source of transistor Q 10 , is used to increase the noise immunity of Q 10 when the voltage across winding N 1 is zero. Resistor R 3 is connected in series with the gate of transistor Q 1 in order to dampen any undesirable oscillations caused between the input capacitance of transistor Q 1 and the leakage inductance L 1 of winding N 1 .
Similarly, winding N 2 is connected with one end to the source of transistor Q 40 and the second end is connected to the gate of transistor Q 40 via series diode D 40 and resistor R 41 . Resistor R 41 is connected in series with diode D 40 in order to dampen oscillations on the gate of transistor Q 40 caused by resonance between leakage inductance L 2 and input capacitance of transistor Q 40 . Transistor Q 4 , shown as a p-channel MOSFET, is connected across the gate and source of transistor Q 40 with its gate connected via resistor R 9 to the end of winding N 2 without the dot marking. Resistor R 40 , connected across the gate and source of transistor Q 40 , is used to increase the noise immunity of Q 40 when the voltage across winding N 2 is zero. Resistor R 9 is connected in series with the gate of transistor Q 4 in order to dampen any undesirable oscillations caused between the input capacitance of Q 4 and the leakage inductance L 2 of winding N 2 .
Winding N 4 is used to drive the two bottom primary switches Q 20 and Q 30 connected to the negative side of the input voltage (−V IN ). Each end of winding N 4 is connected to −V IN with diodes D 50 and D 60 . The end of winding N 4 marked with dot polarity (and also marked as point “A” in FIG. 1A) is connected via a series connection with diode D 30 and resistor R 8 to the gate of transistor Q 30 . Transistor Q 3 , shown as a p-channel MOSFET, is connected across the gate and source of transistor Q 30 with its gate connected via resistor R 7 to end “A” of winding N 4 . Resistor R 8 is connected in series with diode D 30 in order to dampen oscillations on the gate of transistor Q 30 caused by resonance between leakage inductance L 4 and input capacitance of primary switch Q 30 . Resistor R 30 , connected across the gate and source of transistor Q 30 , is used to increase the noise immunity of Q 30 when the voltage across winding N 4 is zero. Resistor R 7 is connected in series with the gate of Q 3 in order to dampen any undesirable oscillations caused between the input capacitance of Q 3 and leakage inductance L 4 of winding N 4 . Resistor R 60 is connected in order to keep Q 3 off by connecting its gate to its drain when the voltage on winding N 4 is zero.
The end of winding N 4 not marked by dot polarity (and also marked as point “B” in FIG. 1A) is connected via a series connection of diode D 20 and resistor R 6 to the gate of transistor Q 20 . Resistor R 6 is connected in series with diode D 20 in order to dampen oscillations on the gate of Q 20 caused by resonance between leakage inductance L 4 and the input capacitance of primary switch Q 20 . Transistor Q 2 , shown as a p-channel MOSFET, is connected across the gate and source of transistor Q 20 with its gate connected via resistor R 4 to end “B” of winding N 4 . Resistor R 20 , connected across the gate and source of transistor Q 20 , is used to increase noise immunity of Q 20 when the voltage across winding N 4 is zero. Resistor R 4 is connected in series with the gate of transistor Q 2 in order to dampen any undesirable oscillations caused between the input capacitance of Q 2 and leakage inductance L 4 of winding N 4 . Resistor R 70 is used in order to keep transistor Q 2 off by connecting its gate to its drain when the voltage on winding N 4 is zero.
Winding N 3 is connected to the drive circuitry for synchronous rectifiers S 1 and S 2 . The end of winding N 3 marked by dot polarity (also marked as point “D” in FIGS. 1A and 1B) is connected to one input of logic OR gate U 3 and to one end of resistor R 22 . The second end of resistor R 22 is connected to the ground of U 3 . The other end of winding N 3 , not marked by a dot (also marked as point “C” in FIGS. 1A and 1B) is connected to one input of logic OR gate U 1 and to one end of resistor R 21 . The second end of resistor R 21 is connected to the ground of U 1 .
It is assumed that each input of logic gates U 1 and U 3 has protection diodes from ground to input and from input to supply voltage V CCS . Capacitor C 4 serves as a bypass capacitor across V CCS . If logic gates without these protection diodes are used, then external diodes need to be added for proper operation of the circuit (diodes D 3 -D 10 are shown as external diodes in FIG. 1 B). Supply voltage V CCS is usually generated from the windings of main transformer T 2 or from a separate bias circuit from the primary side with proper isolation. Drive transformer T 1 can also provide the necessary supply voltage V CCS via winding N 3 and diodes D 5 , D 6 , D 8 and D 11 . The second input of logic gate U 1 is connected through resistor R 23 to the drain of synchronous rectifier S 1 , and similarly, the second input of logic gate U 3 is connected through resistor R 24 to the drain of synchronous rectifier S 2 . These two inputs provide break-before-make turn-on for both S 1 and S 2 . The voltages on the inputs of U 1 and U 3 are clamped to V CCS with diodes D 4 and D 7 , respectively. The output of U 1 is connected to the input of inverting driver U 2 , which drives S 1 , while the output of U 3 is connected to the input of inverting driver U 4 , which drives S 2 . Resistors R 21 , and R 22 are used for dampening possible oscillations between leakage inductance L 3 and the input capacitance of logic gates U 1 and U 3 .
As mentioned previously, L 1 , L 2 and L 4 are the leakage inductances associated with windings N 1 , N 2 and N 4 , of drive transformer T 1 , respectively. These three inductances are purposely made larger than usual in order to delay turn-on of primary switches Q 10 , Q 20 , Q 30 and Q 40 . They are carefully designed to have leakage inductances that are very close in value to further increase the efficiency and simplicity of the circuit. This is relatively easy to do if the transformer windings are formed on a multi-layer printed circuit board (PCB). In addition, repeatability and control in manufacturing are excellent. Typical values for these inductances are approximately 100 nH and higher. They are designed so that one-fourth of the period of oscillation caused by the input capacitance of primary switches Q 10 , Q 20 , Q 30 and Q 40 and leakage inductances of corresponding windings N 1 , N 4 and N 2 (L 1 , L 4 and L 2 ) is longer than the turn-off time of the secondary synchronous rectifying switches S 1 and S 2 .
The leakage inductance L 3 of winding N 3 of drive transformer T 1 is not critical since winding N 3 is loaded with a high impedance load (resistors R 21 and R 22 have a typical value of at least few kOhms), and also taking into consideration the input capacitance of logic gates U 1 and U 3 (5 pF-10 pF being typical). Thus, inductance L 3 will not have a significant impact on the rising and falling edges of the voltage waveforms across winding N 3 and consequently will not add any additional delay in turning off synchronous rectifiers S 1 and S 2 . The leakage inductance L 5 of winding N 5 is designed such that in conjunction with leakage inductances L 1 , L 2 and L 4 , proper delay is achieved in turning on the primary switches.
An alternative embodiment to the invention illustrated in FIG. 1A is shown in FIG. 1 C. In this circuit, drive transformer T 3 has four windings. Winding N 4 is connected to OUTA and OUTB of controller 102 via series dc blocking capacitor C 1 and has combined the functions of windings N 5 and N 4 from FIG. 1 A. Two bottom primary side switches, Q 30 and Q 20 , are driven from OUTA and OUTB via series inductors L 30 and L 20 , respectively. External inductors L 20 and L 30 have the same value for leakage inductance as L 4 from FIG. 1 A. The rest of the circuitry is the same as in FIG. 1 A. An advantage of the embodiment in FIG. 1C, as compared to that of FIG. 1A, is that the drive transformer is simpler with only four windings versus five. On the other hand, two extra components, inductances L 20 and L 30 are needed. In applications in which a multilayer PCB is used, the drive transformer T 1 from FIG. 1A may be preferable since it eliminates the need for inductances L 20 and L 30 , and their associated cost and space on the PCB. Operations of the FIGS. 1A and 1C circuits are very similar.
The salient waveforms for operational understanding of the circuit from FIGS. 1A and 1B are provided in FIG. 2 . For simplicity, it is assumed that all primary switches Q 10 , Q 20 , Q 30 and Q 40 are identical, and that synchronous rectifiers S 1 and S 2 are identical as well as are leakage inductances L 1 , L 2 and L 4 . It should be noted that the invention is not limited to these assumptions. Also, for simplicity it is assumed that leakage inductance L 5 ≈0. In these waveforms:
t d1 —time between turning-off synchronous rectifier S 2 and turning-on switches Q 10 and Q 30 . This is determined by leakage inductances L 1 and L 4 of windings N 1 and N 4 of transformer T 1 and the input capacitances of Q 10 and Q 30 .
t d2 —time delay between turning-off switches Q 10 and Q 30 and turning-on synchronous rectifier S 2 . The drive signal for turning on S 2 is applied when the voltage V S2 across S 2 is below the threshold of logic gate U 3 . Resister R 24 and the input capacitance of U 3 provide fine-tuning of the delay. During this time the output capacitance of S 2 is discharged with the output inductor current, thus S 2 has a near zero voltage.
t x —time during which all primary side switches are off, both S 1 and S 2 are on and all windings of T 2 are shorted. Inductor current splits in between S 1 and S 2 .
t d3 —time between turning-off S 1 and turning-on switches Q 20 and Q 40 . It is determined by the leakage inductances L 2 and L 4 of windings N 2 and N 4 of drive transformer T 1 and input capacitances of Q 20 and Q 40 . In practice, td 1 ≈td 3 .
t d4 —time delay between turning-off switches Q 20 and Q 40 and turning-on synchronous rectifier S 1 . The drive signal for turning on S 1 is applied when the voltage V S1 across S 1 is below the threshold of logic gate U 1 . Resistor R 23 and the input capacitance of logic gate U 1 provide fine tuning of this delay. The output capacitance of S 1 is discharged by the output inductor current during this time, thus S 2 is turned-on at near zero voltage. In practice, td 2 ≈td 4 .
t y —time during which all primary side switches are off, both S 1 and S 2 are on and all windings of T 2 are shorted. The inductor current splits between S 1 and S 2 . In practice, t x ≈t y .
At t=0, OUTA (of the controller, for example PWM type) becomes high, while OUTB is low. The voltage across all windings of T 1 is positive. Note that the dot polarity next to one end of the windings of the transformer is used for reference and is now positive with respect to other side of the windings. The voltage across winding N 3 is positive and the end of winding N 3 connected to the input of U 1 (marked as point “C” in FIG. 1B) is clamped with an internal diode (shown as external diode D 6 ) to the negative voltage equal to the forward voltage drop of the diode. Since the voltage at point “D” is positive, the output of U 3 goes high and the output of U 4 goes low, causing turn-off of synchronous rectifier S 2 with minimum delay. On the other hand, since the voltage at point “C” is low, the output of U 1 is low and U 2 is high which keeps synchronous rectifier S 1 on. At the same time a positive voltage is applied across windings N 1 and N 4 . Due to the positive voltage on winding N 1 , diode D 10 becomes forward biased and the input capacitance of primary switch Q 10 starts to be charged in resonant manner via leakage inductance L 1 of winding N 1 , resistor R 5 and diode D 10 . Due to positive voltage on its gate, transistor Q 1 is off. At the same time, positive voltage across winding N 4 makes diode D 50 forward biased while diode D 60 is reverse biased. The end of winding N 4 marked with point “B” is connected to −V IN via diode D 50 . The input capacitance of primary switch Q 30 starts to be charged in a resonant manner via leakage inductance L 4 , resistor R 8 and diode D 50 . Transistor Q 3 is off due to a positive voltage on its gate. At t=t d1 , voltages V G10 and V G30 have reached the threshold level and switches Q 10 and Q 30 are fully on. Positive voltages across windings N 4 and N 2 keep transistors Q 2 and Q 4 on and consequently Q 20 and Q 40 are kept off. The body diode of transistor Q 2 clamps a negative voltage across primary switch Q 20 to near zero during time DT S /2, while D 20 is reverse biased. Similarly, the body diode of transistor Q 4 clamps negative voltage across Q 40 to near zero during time DT S /2, while D 40 is reverse biased. Clamping negative voltage on transistors Q 20 and Q 40 during off time is preferred in order to reduce gate drive losses. During time DT S /2− d1 , the voltage across the windings of transformer T 2 is positive and output inductor current is supplied from input to output through winding N S1 . The voltage across S 2 is also positive.
At t=DT S /2, OUTA becomes low (OUTB is still low), winding N 5 is shorted and voltages across the other four windings of T 1 are near zero. Zero voltage across winding N 1 connects the gate to drain of transistor Q 10 via resistor R 3 , while the gate of Q 3 is connected via resistor R 60 to its drain. Transistors Q 1 and Q 3 are turned-on, diodes D 10 and D 30 are reverse biased, the input capacitances of Q 10 and Q 30 are discharged very quickly via ON resistance of Q 1 and Q 3 and voltages V G10 and V G30 rapidly drop to zero, resulting in turn-off of Q 10 and Q 30 . The current in output inductor L 0 splits between synchronous rectifier S 1 and the body diode of synchronous rectifier S 2 , which as a consequence, has shorted windings of transformer T 2 . As soon as the voltage across S 2 drops down to the logic zero threshold of U 3 , the output of U 3 goes low (since the input connected to winding N 3 is zero), and the output of U 4 goes high and synchronous rectifier S 2 is turned-on (time interval t d2 ). Both S 1 and S 2 are on during the rest of the half of the switching period and the voltages across the windings of T 1 and T 2 are zero (time interval t x ).
At t=T S /2, OUTB goes high while OUTA is still low. The voltage across all windings of T 1 is negative (referenced to the dot marking). The voltage across winding N 3 is negative and the end of winding N 3 connected to the input of U 3 (marked as point “D” in FIG. 1B) is clamped with an internal diode (shown as external diode D 11 ) to the negative voltage equal to the forward voltage drop of the diode. Since the voltage at point “C” is positive, the output of U 1 goes high and the output of U 2 goes low, causing turn-off of S 1 with minimum delay. On other hand, since the voltage at point “D” is low, the output of U 3 is low and U 4 is high which keeps S 2 on. At the same time negative voltage is applied across windings N 2 and N 4 . Due to negative voltage on winding N 2 , diode D 40 becomes forward biased and the input capacitance of Q 40 starts to be charged in a resonant manner via leakage inductance L 2 of winding N 2 , resistor R 41 and diode D 40. Due to a positive voltage on its gate, transistor Q 4 is off. At the same time, negative voltage across winding N 4 (point “B” is more positive than point “A”) makes diode D 20 forward biased while diode D 50 is reverse biased. The end of winding N 4 marked as point “A” is connected to −V IN via diode D 60 . The input capacitance of Q 20 starts to be charged in resonant manner via leakage inductance L 4 of winding N 4 , resistor R 6 and diode D 60 . Due to a positive voltage on its gate, transistor Q 2 is off. At t=t d1 , voltages V G10 and V G30 are positive and transistors Q 10 and Q 30 are fully on. The negative voltage across windings N 1 and N 4 keeps transistors Q 1 and Q 3 on and consequently Q 10 and Q 30 are off. The body diode of Q 1 clamps a negative voltage across Q 10 to near zero during time DT S /2, while diode D 10 is reverse biased. Similarly, the body diode of Q 3 clamps negative voltage across Q 30 to near zero during time DT S /2, while D 30 is reverse biased. Clamping a negative voltage on Q 10 and Q 30 during off time is desirable in order to reduce gate drive losses. During time DT S /2−t d3 , the voltage across the windings of transformer T 2 is negative and the output inductor current is supplied from input through winding N S2 . The voltage across synchronous rectifier S 1 is positive.
At t=T S /2+DT S /2, OUTB becomes low (OUTA is still low), winding N 5 is shorted and the voltages across the other four windings of T 1 are near zero. Zero voltage across winding N 2 connects the gate to drain of transistor Q 4 via resistor R 9 , while the gate of Q 2 is connected via resistor R 70 to its drain. Transistors Q 2 and Q 4 are turned-on, diodes D 20 and D 40 are reverse biased, input capacitances of Q 20 and Q 40 are discharged very quickly via the ON resistance of Q 2 and Q 4 , and voltages V G20 and V G40 rapidly drop to zero resulting in turn-off of Q 20 and Q 40 . Switches Q 10 and Q 30 are kept off. The current in output inductor L 0 splits between synchronous rectifier S 2 and the body diode of S 1 , which as a consequence has shorted the windings of transformer T 2 . As soon as voltage across synchronous rectifier S 1 drops down to the logic zero threshold of logic gate U 1 , the output of U 1 goes low (since the input connected to winding N 3 is zero), the output of U 2 goes high and synchronous rectifier S 1 is turned-on (time interval t d2 ). Both synchronous rectifiers S 1 and S 2 are on during rest of the half of the switching period and voltages across the windings of T 1 and T 2 are zero (time interval t y ). The overshoot in gate voltage waveforms of the primary side switches, as shown in FIG. 2, is due to the resonant charging of input capacitances of these switches. The amplitude of the overshoot depends on the Q-factor of the resonant circuit formed by the leakage inductance of the winding, the input capacitance of the switch and the series connection of the resistor and diode in the drive circuit.
The turn-on waveforms of primary switch Q 10 (as an example) are shown in more detail in FIG. 3 for two different values of leakage inductance L 1 , L 1(1) and L 1(2) , in order to explain the turn-on delay of primary switch Q 10 due to the finite rise time of the current in leakage inductance L 1 of winding N 1 . It is assumed that there is no overshoot in gate voltage. Note that the other three primary switches, Q 20 , Q 30 and Q 40 have the same gate drive waveforms. The lower value of leakage inductance L 1 , denoted L 1(2) , allows a higher peak current for charging the input capacitance of Q 10 and consequently it allows for a faster turn-on of Q 10 and shorter delay between turning-off of S 2 and turning-on of Q 10 . Note that voltage level V ON in waveform (C) in FIG. 3 represents the voltage level of V G10 at which Q 10 is fully on, and t d1 (either t d1(1) or t d1(2) ) is the so called “dead time” and represents time during which both synchronous rectifier S 2 and primary switch Q 10 are off. This dead time is necessary in order to avoid cross conduction of synchronous rectifier S 2 and primary switch Q 10 and Q 30 (and S 1 and Q 20 and Q 40 ). Dead time, t d1 (equivalently, t d2 ), should be minimized because, during this time the body diode of S 2 (equivalently, S 1 ) is carrying half of the output inductor current, thus decreasing efficiency of the converter. If the dead time is too short, that is Q 10 and Q 30 are turned-on before S 2 is turned-off, there will be cross-conduction that would result in efficiency drop. Therefore, it is important to have well-controlled dead times in order to have the highest efficiency. With proper design of leakage inductances and repeatability in manufacturing, dead time is optimized for highest efficiency.
The turn-off waveforms for primary switch Q 10 (the same apply for Q 20 , Q 30 and Q 40 ) are shown in more detail in FIG. 4 . Since diode D 10 becomes reverse biased when OUTA goes low, the discharging current of the input capacitance of Q 10 is going through transistor Q 1 and is limited, in first approximation, only by the ON resistance and turn-on characteristic of Q 1 , but not affected by leakage inductance L 1 . The presence of leakage inductance is desirable during the turn-off transient since the leakage inductance generates a negative spike, which improves the turn-on of Q 1 . In this manner, a very fast and well-controlled turn-off of Q 10 (as well as of Q 20 , Q 30 and Q 40 ) is achieved. By varying the resistance of switches Q 1 through Q 4 , the turn-off performance of switches Q 10 , Q 20 , Q 30 and Q 40 can be adjusted to a preferred value.
While the turn-on of primary switches Q 10 ,Q 20 , Q 30 and Q 40 are delayed (slowed down) by leakage inductances L 1 , L 2 , and L 4 respectively, turn-off is very fast due to switches Q 1 through Q 4 and their low on resistances. By placing switches Q 1 through Q 4 physically close to primary switches Q 10 , Q 20 , Q 30 and Q 40 , respectively, maximum speed for turning off switches Q 10 , Q 20 , Q 30 and Q 40 can be achieved. Note that the turn-off performance of switches Q 10 , Q 20 , Q 30 and Q 40 is not significantly affected by the leakage inductances L 1 , L 2 , L 4 which allows independent control of turn-on and turn-off transients. Also, it is preferable for EMI (electromagnetic interference) purposes to have the turn-on of switches Q 10 , Q 20 , Q 30 and Q 40 slowed down.
As an alternative, if the control and drive circuit is referenced to the output of the converter, winding N 5 (from the FIG. 1A embodiment) is not needed, as shown in FIGS. 5A and 5B. In this case, OUTA and OUTB are generated from controller 104 referenced to the output side of the converter and are directly connected to one input of logic gates U 3 and U 1 . Winding N 3 is connected via dc blocking capacitor C 3 to the inputs of the two inverting drivers DRIVER_A and DRIVER_B which are controlled by OUTA and OUTB, respectively. The salient waveforms shown in FIG. 2 are still valid for the circuit in FIGS. 5A and 5B. For simplicity, diodes D 3 through D 10 shown in FIG. 1B are omitted and it is assumed that they are integrated into logic gates U 1 , and U 3 . Also, only block 104 incorporating the controller, drive and protection circuitry as well as regulation circuitry, is shown in FIG. 5 B and its specific realization is insignificant to the description. Supply voltage for controller 104 and U 1 through U 4 is referenced to the output of the converter and can be generated in different ways which are not relevant for the operation of the drive circuit and thus not shown in FIG. 5 B. FIGS. 5B and 5C are to be discussed later herein.
Illustrated in FIGS. 6, 7 and 8 are partial circuitry embodiments for possible realization of drivers U 2 and U 4 . In FIG. 6, logic gate U 1 (U 3 ) is a NOR gate instead of an OR gate since driver stage U 2 (U 4 ) is non-inverting. The drivers operate the same way so only U 2 (and not U 4 ) is shown. In FIGS. 7 and 8, driver stage U 2 (U 4 ) is inverting and logic gate U 1 (U 3 ) is an OR gate as in FIGS. 1B and 5B. In FIG. 8, driver stage U 2 (U 4 ) allows synchronous rectifier S 1 (S 2 ) to be driven with a voltage higher than the supply voltage for logic gate U 1 (U 3 ). Practical realizations of drivers U 2 and U 4 , different from those in FIGS. 6, 7 and 8 , are also possible.
Even though transistors Q 1 through Q 4 are shown as p-channel MOSFETs, it is possible to use n-channel MOSFETs instead, as well as bipolar transistors. The former are more practical due to an easier drive and an integrated body diode, which would be needed as an external component if Q 1 through Q 4 were bipolar transistors. One possible realization using n-channel MOSFETs as Q 1 and Q 4 for example from FIGS. 1A, 1 C and 5 A is shown in FIGS. 9A and 9B. When p-n-p bipolar transistors are used for Q 1 and Q 4 , two additional diodes, D 70 and D 80 , respectively, are used as shown in FIGS. 10A and 10B. Diodes D 70 and D 80 prevent windings N 1 and N 2 from shorting via the collector-emitter junction of Q 1 and Q 4 , respectively. One possible realization using p-n-p transistors for Q 2 and Q 3 is shown in FIGS. 10C and 10D. Since diodes D 50 and D 60 already exist (FIGS. 1 A and 5 A), extra diodes are not needed as was the case in FIGS. 10A and 10B.
If the control circuit is referenced to the input side of the converter, as is controller 102 in FIG. 1A, there must be means to disable the converter from a condition sensed on the output side, for example, in case of output over-voltage, under-voltage or over-current conditions. Similarly, if the feedback and control circuit is referenced to the output of the converter, as is controller 104 in FIG. 5B, there must be means to disable the converter from the input side of converter, for example, in case of input over-voltage, under-voltage conditions or in order to turn the converter off. A previous solution which has been employed uses an opto-coupler. This solution has several disadvantages:
Opto-couplers cannot operate at temperatures above 85° C. (some are limited to 100° C.), and therefore will impose serious temperature limitations of the printed circuit board (PCB) which is also used as a means for cooling semiconductor devices and magnetic devices;
Unless it is fast (digital), the opto-coupler will not provide a fast enough disable of the control circuit, particularly in the case of output over-voltage condition when the controller is on the input side and the converter operates at high switching frequency;
Opto-couplers are not available in small, low profile packages. Thus, it will be the tallest component and will impose a limit on the low-profile design of the converter.
Another prior art solution has been to have a separate pulse transformer that will be used only for this function. The main drawbacks of this alternative are:
An additional component which needs to meet all safety requirements;
Extra space is required on the PCB, thus imposing limits on the minimum size of the PCB;
If there is no other use of this transformer it is not a practical solution.
An alternate solution disclosed herein provides, as shown in FIGS. 11A and 11B, means for disabling the control circuit on the input side from a condition sensed on the output side of the converter, as described in detail below. The principle idea is to short winding N 3 of drive transformer T 3 , detect excessive current in winding N 5 due to shorted winding N 3 , and disable the control circuit and drivers OUTA and OUTB (controller 102 in FIG. 11 A), thus resulting in turn-off the converter. Different circuit realizations are possible as is known to one of ordinary skill in the art. Protection logic 200 (FIG. 11 B), referenced to the output of the converter, generates signal DSS whenever the converter needs to be disabled (for example, in case of over-voltage on the output, under-voltage, over-current or any other non regular operating condition). Active signal DSS turns-on switches Q 5 and Q 6 (shown as a possible realization with n-channel MOSFETs in FIG. 11 B), which in turn shorts winding N 3 of drive transformer T 3 . Current in winding N 5 is indirectly measured with resistor R 12 that is connected to the positive rail of the supply voltage of controller 102 and measures the total current into controller 102 . Note that resistor R 12 could be placed in different locations such as in series with winding N 3 , for example. The voltage across resistor R 12 is sensed with comparator U 6 that has a threshold set such that in normal operation the voltage drop across resistor R 12 will not trip U 6 , but when winding N 3 is shorted, comparator U 6 is tripped, and generates signal DSB which disables controller 102 and both OUTA and OUTB are disabled (that is, they are in the low state).
An alternate embodiment disclosed herein provides, as shown in FIGS. 5A through D, a means for disabling the control circuit referenced to the output side of the converter from a condition sensed on the input side of converter as described in detail below. Protection logic 201 on the input side of the converter, shown in FIGS. 5C and 5D, initially senses a fault condition on the input side and generates a disable signal DSP that is active (high). Switch Q 100 , shown as an n-channel MOSFET as one possible practical realization in FIG. 5C, is connected to one end (either at point “A” or “B”) of winding N 4 (FIG. 5 A). In response to an active disable signal DSP, transistor Q 100 is turned-on and winding N 4 is shorted via Q 100 and diode D 60 , if Q 100 is connected to end “A” of N 4 . Similarly, winding N 4 is shorted via transistor Q 100 and diode D 50 if Q 100 is connected to end “B” of N 4 . By shorting winding N 4 , two primary side switches (specifically Q 20 and Q 30 ), that were on before the DSP signal became active, are turned-off. In addition, increased current in winding N 3 is sensed with resistor R 11 connected between supply voltage V CCS and drivers DRIVER_A and DRIVER_B referenced to the output of the converter. DRIVER_A and DRIVER_B are shown in FIG. 5B explicitly with a possible realization as complementary pairs of p- and n-channel MOSFETs. The voltage across resistor R 11 is sensed with comparator U 5 that has a threshold set such that in normal operation the voltage drop across resistor R 11 will not trip U 5 , but when winding N 4 is shorted, comparator U 5 is activated, causing controller 104 to disable OUTA and OUTB, and consequently the converter. Note that switch Q 100 can be connected in parallel with either primary switch Q 20 or Q 30 in which case the gate of transistor Q 20 or Q 30 will be shorted in response to the active disable signal. As a consequence, winding N 4 will be shorted via transistor Q 100 and diodes D 20 and D 60 or diodes D 30 and D 50 , causing again increased current through windings N 4 and N 3 . A possible drawback of this solution is that the capacitance of transistor Q 100 may affect the turn-on performance of primary switches Q 20 or Q 30 . In order for Q 20 or Q 30 to have similar turn-on characteristics with Q 40 and Q 10 , respectively, leakage inductance L 4 is needed to be less then L 1 or L 2 , thus resulting in a more complicated drive transformer design. Note that the disable circuit from FIG. 5C has an inherent delay of one switching period since winding N 4 is shorted only during the on-time of either transistors Q 10 and Q 30 or transistors Q 20 and Q 40 . In most applications this should not be a problem.
As an additional embodiment, two switches shown as n-channel MOSFETs Q 5 and Q 6 in FIG. 5D are used to short winding N 4 when the DSP signal is high in order to stop controller 104 and disable OUTA and OUTB, immediately, whenever a fault condition on the input side of converter is detected. The body diodes of Q 5 and Q 6 can replace diodes D 50 and D 60 , respectively, thus further simplifying the circuit. In addition, this circuit provides an inherent delay of one half of the switching period.
In the invention, winding N 4 has the best coupling with winding N 3 , while windings N 2 and N 1 are placed in layers above and below in the PCB. This is the preferred structure because it provides enough leakage between N 3 and N 1 and N 2 , and also decouples N 1 and N 2 from N 3 when N 4 is shorted. Other arrangements of windings in the drive transformer of the invention are also possible.
It should be understood that the foregoing embodiments are exemplary for the purpose of teaching the inventive aspects of the present invention that are covered solely by the appended claims and encompass all variations not regarded as a departure from the scope of the invention. It is likely that modifications and improvements will occur to those of ordinary skill in the art and they are intended to be included within the scope of the following claims and their equivalents.
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A drive transformer and associated circuitry for providing power and appropriate delays to primary switches and synchronous rectifiers in switch-mode power converters in a full-bridge topology. The invention takes advantage of the leakage inductances of the drive transformer windings as well as the input capacitance of the primary switches (MOSFETs) to provide the delays. No separate circuitry is needed to provide such delays, thereby providing reliability. Exemplary embodiments further disclose means to disable or enable the primary winding from a condition sensed on the secondary side even with a control and feedback circuit located on the secondary side. The invention further discloses means to use one drive transformer winding to control two switches completely out of phase.
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CROSS REFERENCE TO RELATED APPLICATIONS
This is a continuing application of PCT/EP/96/01648 filed Apr. 19, 1996, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a method for controlling and surveying the operation of an elevator system. In addition, an antifriction bearing for use in the method is also the subject matter of the present invention.
2. Description of the Prior Art
The control of an elevator system must meet two demands. On one hand, a control of the operation must occur in correspondence with the signals inputted by the users, wherein also special motion programs can be made use of, on the other hand safety of operation must be surveyed continually, this primarily including surveillance of closing condition of the doors, surveillance of speed of movement and protection against overload.
Such a control and surveillance presupposes the detection and processing of certain input values which have to be continually detected during operation. This usually is done using controls and checking circuitry permitting detection of operating data depending on time and path and evaluation thereof. Therein it is the essential point that the elevator cage is detected in its position and/or movement, respectively, in the elevator shaft as exactly as possible and to bring it to a standstill in a given position.
Detection of the position and/or movement condition, respectively, generally is effected by mechanical arrangements, like tracer systems or belts, ropes or the like directly connected to the elevator cage, by which a direct checking function can be executed. Due to the mechanical construction, however, the possibility of using such systems in case of high moving speeds and large lift heights is limited.
In addition, also meters of different construction are known, which generate pulses or analogue voltages from a rotational movement using frictional engagement, belt drive, chain drive or other kinds of transmission, which values serve as input values for the control. Mostly, it Is a matter of add-on devices with attachments which mostly are subject to a certain amount of slippage and thus e.g. do not permit direct final switch-off in a holding position. Thereby, further switch-off and/or changing circuitry or doubling of the comparatively expensive systems become necessary.
SUMMARY OF THE INVENTION
It is, therefore, the main object of the present invention to provide a method for controlling and surveying an elevator system and an antifriction bearing for effecting the method which enable improved control and surveillance of the elevator system.
In order to achieve this object, it is a feature of the invention to detect signals indicating the operation condition of an elevator system by pulse generators in antifriction bearing and by alternative means for signal detection integrated in the antifriction bearings, e.g. reacting to noise frequencies of the bearing or pressure waves. This has the advantage that the accuracy of the detection of failures in the elevator system is improved.
The antifriction bearing for effecting the method the invention is characterized in that the bearing includes a sensor or a pulse generator for signal detection as well as alternative means for signal detecting, such as sensors reacting to noise frequencies.
The invention is based on the fact that in an elevator system there exists a plurality of rotational drives for actuating the different groups of components, in particular the elevator cage as well as the elevator and shaft doors. The rotational parts of such rotational drives, e.g. the shaft of the drive motor or a part of a transmission, therein as a rule are supported in antifriction bearings. The rotational displacement condition of a rotational part, either statically or dynamically, thus represents a value which corresponds to the static or dynamic condition of the driven part.
For example, driving of the elevator cage mostly is effected by a pulley over which the track ropes are running. If the number of revolutions of the pulley is counted each single counted value corresponds to a certain position of the elevator cage in the shaft. If, however, the speed of rotation of the pulley is measured, this is a value representing the moving speed of the elevator cage.
Antifriction bearings with integrated pulse generators are known, e.g. from EP 0 631 140 A1. Therein, an encoder in form of a ring made from magnetic material is mounted on the circumferential ring of the bearing, onto which north and south poles are magnetized which generate a sinusoidal magnetic field. A sensor provided with an electrical terminal, in which pulses are generated upon rotation of the magnet ring is located in one position of the stationary bearing ring. The number of pulses generated per revolution corresponds to the number of poles located on the magnet ring. By counting the pulses in a suitable evaluation circuitry, the number of revolutions and the respective angular position of the rotating part can be calculated. The pulse frequency during rotation is a measure for the speed of rotation.
The use of such bearings opens a great variety of possibilities for control and surveillance of an elevator system. Thus, the speed of movement of the elevator cage can be detected by a pulse generator in a bearing of the main engine, the pulley or a deflection sheave. In addition, the speed can also be directly measured on the elevator cage by measuring the speed of rotation of one or several guide rolls in the above described manner. Finally, also the bearing at the deflection sheave is suitable for detecting the speed of the elevator, for a speed limiting rope which for safety reasons is present additionally and independently from the track ropes.
In the same manner in which the speed of the elevator cage was detected, it also is possible to detect its position in the shaft by counting and converting by calculation the number of pulses from at least one of the above bearings. As the number of pulses can be very high depending on the bearing questioned and thus one single pulse is the measure for a very short interval of the path of the elevator cage, an extremely sensible path control can be effected. Moreover, rope slippage and rope lengthening can be balanced by separate detection of elevator cage path, e.g. by guide rolls and the pulley, and by comparing the measured values.
Furthermore, the cabin and shaft doors can be controlled and surveyed in the manner in accordance with the present invention. The drive of the doors mostly is effected using cable control with respective rotational drives, into which at least one antifrictional bearing with a pulse generator can be incorporated. From the counted number of pulses, the opening condition of the respective door can be detected and included into the operation and safety control.
Since the bearings with integrated pulse generators have the dimensions of common standardized bearings, also retrofitting of existing elevator systems to the control and surveillance method in accordance with the present invention is possible without extensive labor.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an elevator system in a schematical principle view;
FIG. 2 shows an antifriction bearing usable in the method in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The elevator system comprises a main drive engine 1 located above the uppermost floor, with a pulley 2 coupled thereto by means of a transmission. The parallelly extending ropes put thereover on one hand carry the elevator cage 5 and on the other hand the counterweight 6, the rope side carrying the counterweight being guided over a deflection sheave 7. The elevator cage 5 is provided with guide rolls 8 on two sides as well as on top and bottom, which run on the shaft guides under spring pressure.
The elevator system further includes a safety apparatus for limitation of speed. For being capable of being efficient even in the unprobable event of breaking of all ropes or the rope fixation, the safety apparatus is independent from drive, suspension and guide of the elevator cage. In the shown embodiment it consists of a rope 9 which with both ends is fixed to the elevator cage and guided around an upper deflection sheave 10 and a lower deflection sheave 11 for forming a loop. The rope 9 forms a safety rope or speed limitation rope. In addition to the prescribed function of communicating excess speed to the safety circuit, in known systems the running speed is detected by means of additionally inserted devices, like speedometers and pulse generators.
The elevator cage 5 has a mechanically actuable cabin door whose drive is arranged on the elevator cage roof and a.o. includes rolls 12 for moving the door as well as for actuating a lock. In each floor a shaft door 13 whose drive is of similar construction and which has not been shown in the drawing for better outlay, exists opposite to the cabin door.
The control and surveillance of all courses takes place in a central control system 14 connected to the drive, the elevator cage and the service fields at the shaft doors by means of current, control and signal lines (not shown).
As can be seen from the above description, the to that extent conventional elevator system comprises a plurality of rotating components, like the shafts of electromotors, pulleys and rope rolls, rollers and the like. These rotating components as a rule are supported in antifrictional bearings, roller bearings in particular, wherein either the inner bearing ring is stationary and the outer one is rotating or vice versa. These bearings can be made use of for control and/or surveillance of the elevator system in manifold manner by incorporation of a pulse generator.
Thus, the bearing of the shaft of the main drive motor 1 and/or the bearing of the pulley 2 and/or the bearing of the deflecting sheave 7 is suited for detection of pulse frequency and calculatory conversion thereof into speed of movement by means of a computer 13 existing in the control system 14. Detection and processing of the pulses therein is effected in dependence on direction.
Furthermore, detection of pulse frequency can be effected at one or both deflection sheaves 10 and 11 for the rope 9 of the speed limitation. A comparison of the detected values with one another and with the speed values received from the drive system reveals occurrence of rope slippage directly and quantitatively so that the required control measurements can be initiated automatically.
Similar to the speed of the elevator cage 5, also the position thereof in the shaft can be detected using pulse generators in certain antifriction bearings. For doing so, it is necessary the detect the number of pulses instead of the frequency or in addition thereto and to add them in an adding device in dependence on direction. For detection of pulse number in principle the same bearings can be used as for detection of speed of motion by measuring the pulse frequency. Here, too, a comparison of the values obtained from the main drive system with those of the apparatus for speed limitation is possible for balancing rope slippage and rope lengthening.
Motion path measurement can be carried out by selection of suitable bearings with pulse generators and by a correspondingly drafted computer program so accurately that thereby also the stop positions can be determined and approached without mechanical contact generators in the shaft being required.
A further possibility for speed and path measurement is offered by the bearings of guide rolls 8 by means of which the elevator cage 5 is guided on the guide rails in the shaft. The number of revolutions and the speed of these guide rolls is in direct relation to the path covered by the elevator cage 5 so that pulse values derived from the pulse generators 21 (FIG.2) in these bearings can be processed into path and speed values. Possibly occurring inaccuracies can be corrected in that the measuring values of at least two guide rolls are detected and differences are eliminated.
Pulse generators in the guide rolls 8 also are well suitable for detecting values for comparison with measured values from the main drive system and the safety apparatus.
Also the control and surveillance of the elevator doors can be carried out using pulse generators in bearings suited for this purpose. Here the bearings of rolls 12 are particularly suitable which are intended for driving the doors for opening and closing as well as actuation of locking members. By processing of the measured values therein the operation of the cabin door can be harmonized to that of the shaft doors 13.
It is generally known that most malfunctions in an elevator system are located in the area of the doors. The method in accordance with the present invention permits to recognize an approaching malfunction in time. Thus it can e.g. be detected from a comparison of all door actions whether a pulley repeatedly has different pulse sequences. Therefrom it can then be concluded that either the bearing itself or the rope tension is defective. By communicating such malfunction in time, an inspection or repair can be carried out before standstill of the entire system will be required.
The method in accordance with the present invention needs not be restricted to one single elevator system but can also detect several elevators operated one beside the other or in different places. Thus it also is possible e.g. in larger building complexes to survey a plurality of elevators centrally.
The antifriction bearings with integrated pulse generators with their installation requirements correspond to common bearings. In known antifriction bearings with stationary outer ring the installation measures correspond to common bearing dimensions. Only room must be available for installation of the signal line leaving the sensor. In a total system as just described also bearings with reverse function are used, i.e. bearings with stationary inner ring and rotating outer ring.
Such a bearing is shown in FIG. 2. The inner ring 16 in this case is stationary while the outer ring 18 can be turned by bearing balls 19 and e.g. carries a guide roll 8. On the left-hand side in FIG. 2 the bearing is sealed with a sealing ring 20. With these components and the dimensions D for the outer diameter, d for the inner diameter and b for the axial length the bearing is identical to those of conventional construction.
On the left-hand side in FIG. 2 the standard sealing ring is substituted for by a special sealing ring 21 which is fixed to the inner ring and into which the sensor for signal detection is integrated. The sensor receives the induction pulses of the magnet ring circulating together with the outer bearing ring 18. The pulses are transmitted to the control system 14 by signal line 22. The bearing thus is enlarged by the dimension a only as compared to the dimensions of conventional bearings. This area in the longitudinal extension of the bearing usually is not located in the area for fixation of the bearing within a construction and thus can be utilized for signal detection and for the electric connection.
In case of the embodiment with rotating inner ring the magnet ring is fixed on the inner ring 16 and circulates together therewith, while the sealing ring 21 with the sensor is fixed to the outer ring 18.
The method in accordance with the present invention, when combined with a bearing embodied therefor, also permits to use alternative signal detection, like pressure waves and noise frequencies of a bearing with a pressure or noise detector 24 (FIG.2) and to convert those into logically utilizable pulses supplied via a line 26, which can be an optical line, connected to the control system 14. The invention in addition also permits a direct scanning of the orbiting balls, ball cages or roller cages with a micro laser beam through a glass fiber line.
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For controlling and surveying the operation of elevator systems pulse generators are used which are integrated into antifriction bearings of mutually pivotable structural members of the elevator system. By measuring pulse numbers and pulse frequency, conditions of movement and positions of moving parts, like e.g. the elevator cage (5) and the doors (13), can be detected and evaluated in a computer.
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This is a division of application Ser. No. 115,517 filed Nov. 2, 1987 which is a division of application Ser. No. 922,355 filed Oct. 23, 1983 now U.S. Pat. No. 4,735,266.
BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
The invention relates to a method and apparatus for isolating a pluralityt of vertically spaced sets of perforations provided in a well conduit adjacent production formations to permit the concurrent treatments of such formations with predetefrmined amounts of a treatment fluid, either liquid or gas. In many oil and gas wells, the well conduit may traverse a plurality of vertically spaced production formations or zones. The well conduit is generally perforated to provide communication with each of the production zones. If the need arises for chemical treatment of the production zones, it is highly desirable that each of the set of perforations be insolated from each other so that treatment may be selectively applied to only one or more of the production zones. Similarly, in many oil and gas fields, a plurality of wells located in close proximity to each other traverse common production formations. When the initial production from such wells reach an unacceptably low level, it has been a common practice to perform secondary recovery operations on the wells. The secondary operation comprises taking a centrally located one of a group of wells and applying either water or carbon dioxide to the production zones traversed by such well. Such water or gas flooding drives the hydrocarbons in the production formation towards the remaining active wells and enhances their productivity. In both recovery operations, it is highly desirable that the supplied fluid be confined to the production zones and thus be capable of substantial recovery from the producing wells. This is particularly important in recovery operations where pressurized carbon dioxide is utilized. Here again, the necessity arises for effectively isolating each set of a plurality of vertically spaced sets of perforations in the well conduit carrying the treatment fluid from the adjoining sets of perforations.
The prior art has not provided a simple, inexpensive method and apparatus for isolating a plurality of sets,of perforations in a well conduit from each other so as to permit the selective application of predetermined amounts of treatment or flooding fluid concurrently to each of the sets of perforations.
SUMMARY OF THE INVENTION
The method and apparatus of this invention may be applied to a new well built for the purpose of supplying treatment fluid to production zones traversed by the well or to previously completed wells, including wells completed by the openhole method referred to technical paper SPE 15009, copyrighted in 1981 by the Societyt of Petroleum Engineers. In the case of a new well, a steel liner is conventionally suspended from the bottom end of a casing to traverse the various production zones for which fluid treatment is desired. The liner is then cemented in place and perforated in the vicinity of each of the production zones by conventional methods, thrs providing a plurality of vertically spaced sets of perforations respectively communicating only with the production zones. In the case of a previously completed will, the well is filled with a permeable sand-resin mixture and then redrilled to permit a new liner to be inserted therein, traversing the various production zones for which treatment is desired. The liner is cemented in the new hole and perforated by conventional methods. To minimize cost, a relatively small-diameter liner is employed having an ID on the order of 2.5 inches. With such a small diameter liner, it is possible to utilize threadably connected tubular sections fabricated from a fiberglass-reinforced plastic. The employment of such reinforced plastic as a liner material substantially increases the life of the liner because of its greater resistance to the acid environment created by the infection of carbon dioxide, but it is not possible to utilize conventional packers within the bore of the fiberglass liner due to the damage to the bore walls which would be inflicted through the employment of conventional slips.
In accordance with this invention, at least one metallic section is incorporated in the fiberglass sections, preferably near the botton of the threadably interconnected fiberglass sections, and such metallic section defines an internal annular locking groove which receives a plurality of radially expandable locking dogs carried by a tension set packer inserted in the bore of the fiberglass liner on a tubular assembly which is run into the well on a tubular work string.
The tubular assembly is provided with a plurality of vertically spaced, radial ports which are respectively alignable with the various sets of perforations provided in the liner, with the exception of the lowermost set of perforations for which no radial port is required. In addition to the packer carried by the tubular assembly, a plurality of vertically spaced, tension set packing units are mounted on the tubular assembly and are expandable into sealing engagement with the bore of the liner by manipulation of the tubing string, thus providing an annulus seal intermediate each of the sets of perforations to isolate each set of perforations from the adjacent set.
Adjacent each radial port in the tubular assembly, a flow dividing, adjustable valve is removably mounted. Such valve carries axially spaced seals which are disposed in straddling relationship to the adjacent radial port. The valve divides the fluid flow coming down the bore of the tubular member into a radial and an axial component, with the amount of flow going into the radial component being adjustable. Thus, when a treatment fluid, either water or CO 2 , is supplied through the tubing string, a preselected proportion of the treatment fluid will be diverted from the main axial flow by each of the flow-dividing valves and the selected proportion will be directed into the adjacent production formation by flowing through the radial port and through the adjacent set of perforations. The remaining treatment fluid in the bore of the tubular member reaching the bottom of such tubular member can flow directly into the lowermost set of perforations by flowing out of the open bottom end of the tubular assembly.
If the well casing is of a size to permit thfe insertion therein of a side pocket mandrel, then in a modification of this invention, a side pocket mandrel may be employed at the upper end of the tubular assembly. An adjustable orifice valve is mounted in the side pocket of the side pocket mandrel and a fluid conduit is provided connecting the bottom end of the side pocket with the exterior of the tubular assembly. Thus, a predetermined proportion of the axially flowing treatment fluid entering the bore of the tubular assembly may be diverted through the orifice valve mounted in the side pocket mandrel to flow directly into the uppermost set of perforations provided in the tubular liner. The tubular liners employed are, as mentioned above, of such small diameter as to not accommodate side pocket mandrels and hence the internally nounted, adjustable flow-dividing valves are employed to effect the diversion of a predetermined amount of the axially flowing treatment fluid into each of the vertically spaced sets of perforations, hence into each of the vertically spaced production zones.
Thus, by adjustment of the flow-dividing valves, and the orifice valve, if used, which are readily wireling removable and insertable, a desired flow rate of the treatment fluid into each of the production zones may be obtaoned and such desired flow rates concurrently respectively applied to each of the production zones. No treatment fluid is lost by penetration into porous strata between the production zones due to the cementing of the liner in the bore hole. Thus, by adjustment of the flow dividing valves, which are readily wireline removable and insertable, a desired flow rate of the treatment fluid into each of the isolated production zones may be obtained and such desired flow rates concurrently respectively applied to each of the priduction zones. No treatment fluid is lost by penetration into the porous strata between the production zone due to the cementing of the liner in the bore hole. It follows that a substantial improvement in the amount of treatment fluid recovered from akjacent producing wells will be inherently realized.
The method and apparatus of this invention is equally applicable to a conventional well to effect the isolation of a plurality of sets of perforations provided in a well conduit from each other for any purpose, and the herein described utilization of the method and apparatus of this invention for controlling the application of flooding fluids through a fiberglass liner to a plurality of production zones represents only one potential application of this invention.
Further advantages of the invention will be reasily apparent to those skilled in the art from the following detailed description, taken in conjunction with the annexed sheets of drawings, on which is shown several embokiments of the invention.
BRIEF DESCRIPTION OF DRAWINGS
FIGS. 1A, 1B, and 1C collectively represent a vertical quarter sectional view of a treatment tool embodying this invention inserted and set within a well bore.
FIGS. 2A, 2B, 2C, and 2D collectively represents a quarter sectional view of a modified tool embodying this invention showing the tool inserted and set in a well bore.
FIGS. 3A and 3B collectively represent an enlarged scale, quarter sectional view of the lowermost packer unit utilized in all mokifications of this invention, with the components of a lowermost packer unit shown in their initial run-in positions.
FIGS. 4A and 4B respectively constitute views similar to FIGS. 3A and 3B but showing the lowermost packer unit in its set position.
FIGS. 5A and 5B, are views respectively similar to FIGS. 3A and 3B, but showing the components of the lowermost packer unit in the positions assumed during the unsetting of such packer.
FIGS. 6A, 6B, and 6C collectively constitute an enlarged-scale, vertical quarter section view of the upper packing elements utilized in two modifications of this invention, with the components in their initial run-in positions.
FIGS. 7A, 7B, and 7C respectively correspond to FIGS. 6A, 6B, and 6C but show the components of the upper packing elements in their set positions.
FIGS. 8A, 8B, and 8C are views respectively corresponding to FIGS. 6A, 6B, and 6C but showing the components of the upper packing elements in the positions assumed during the unsetting of such packer elements.
FIG. 9 is a developed view of the J-slot employed in the lowermost packing unit.
FIGS. 10A and 10B collectively constitute a vertical quarter section view of a modified upper packing element in its run-in position.
FIGS. 11A and 11B are views similar to FIGS. 10A and 10B but with the upper packing element in a set position.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to FIGS. 1A-1C of the drawings, there is shown one embodiment of the invention for effecting the concurrent supply of treatment fluid to four vertically spaced production zones with the amount of such treatment fluid supplied to each of the zones being respectively predetermined.
The apparatus embodying this invention is shown in FIGS. 1A-1C to comprise a tubular liner 10 which is suspended within the bottom portions of the well casing 1 by a conventional hanger 5 having slips 5a and 5b respectively engaged with the interior wall of casing 2. To minimize costs, the liner 10 is preferably of relatively small diameter, such as 2.5 inches ID. Liner 10 is fabricated by the threaded assemblage of tubular sections 10a, 10b, 10c, etc. . The liner is conventionally secured by threads 2e provided on the lower portion of the body 5d of the hanger 5.
After the liner is run into place by a conventional setting tool (not shown) which is engagable with internal lefthand threads (not shown) conventionally provided on an upper sleeve bore portion 5c of the hanger 5, and the hanger 5 is set in the bore of casing 2, a conventional cementing operation is provided to fill the annulus between the exterior of the liner 10 and the well bore with cement 6, thus preventing fluid communicatilon along the exterior of liner 10 between vertically spaced production zones P1, P2, and P3. A wireline perforating gun is then inserted in the bore of liner 10 and a plurality of vertically spaced sets of perforations 11a, 11b, 11c, and 11d are produced in the wall of liner 10 and also passages 6a, 6b, 6c, and 6d through the cement layer 6.
Because of the small diameter of liner 10, and the fact that such liner will be subjected to acid corrosion during the introduction of carbon dioxide as a treatment fluid for the production zones P1, P2, and P3, it becomes feasible to fabricate the liner sections 10a, 10b, 10c, etc. from a reinforced plastic such as fiberglass-reinforced plastic pipe. Such material is, of course, highly resistant to corrosion and has sufficient tensile strenth for the particular application so long as the diameter of the liner is small and the length of the liner is not excessive.
Since the treatment apparatus embodying this invention requires the setting of a packer in the bore of liner 10 at a position immediately above the lowermost set of perforations 11c, a metallic section 12 is threadably incorporated in the length of fiberglass-reinforced pipe as by conventional threaded connections 12a and 12b. The metallic liner section 12 is further provided with an internal annular locking groove 12c for the purpose of receiving the locking lugs of a packer unit 25 to be hereinafter described.
A tubular assemblage 20, which is conventionally secured at its upper end by threads 20f to a tubing string TS leading to the surface of the well, is then inserted in the bore of the liner 10. Tubular assemblage 20 includes a packer unit 25 which, as previously mentioned, is disposed near the bottom of the assemblage to cooperate with the locking groove 12c provided in the metallic section 12 of the liner. Packer 25 is provided with a plurality of peripherally spaced locking lugs 26 which are expandable into engagement with the locking groove 12c by an apparatus to be hereinafter described. Packer unit 25 further comprises an annular elastomeric packing element 27 which is expandable through the application of compressive force thereto to effect a sealing engagement of the annulus defined between the bore of the liner 10 and the exterior of the tubular assemblage 20. As will be described, packer unit 25 is set by the application of tension to the tubing string, and the expansion of packing element 27 effectively isolates the lowermost set of perforations 11d from the other perforations.
At locations immediately above the remaining sets of perforations 11a, 11b, and 11c, a packing unit 30 is mounted on the tubular assemblange 20 in a manner to be hereinafter described in detail, and incorporates an annular elastomeric sealing element 34 which is expandable into sealing engagement with the bore of the mandrel 10 through the application of tension to the tubing string. Thus each of the sets of perforations 11a, 11b, 11c, and 11d are isolated from each other.
Immediately adjacent each of the sets of perforations 11a, 11b, and 11c, a plurality of peripherally spaced radial ports 21a, 21b, and 21c are respectively provided, thus providing communication between the perforations and thef internal bore 20a of the tubular assemblage 20.
Immediately below the ports 21a, 21b, and 21c, the tubulat assemblage 20a is provided with internal valve retention grooves 22a, 22b, and 22c, respectively. Such grooves mount a conventional adjustable flow valving unit 40 which is provided with axially spaced external seals 40a and 40b which straddle the radial ports 21a, 21b, or 21c as the case may be, and with radially outwardly biased retention dogs 40c which respectively engage the internal valve retention grooves 22a, 22b, and 22c.
The valve units 40 are a standard commercial unit, and may comprise, for example, the DANIEL RO-1-C valve which is sold by DANIEL EQUIPMENT. INC. of Houston, Texas. Valve 40 is provided with an internal adjustable orifice for dividing fluid flow through the valve into two components, namely an axial component and radial component, and the amount of fluid being diverted into the radial component and hencfe passing through the ports 21a, 21b or 21c and the respective sets of perforations 11a, 11b, and 11c, may be preselected prior to insertion of the valve into the tubular assemblage 20. Each valve 40 is provided with a fishing neck 40d by which the valve may be conveniently removed by wireline from the tubular assemblage 20 for adjustment of the radial flow rate, in the event that the initially selected adjustment is not satisfactory. The valves 40 can then be reinserted bu wireline, thus eliminating any necessity for pulling the entire tubing string to make adjustments to produce the proper flow rate into each of the respective production formations P1, P2, or P3. Since the valve 40 is a standard commercial item, further description of the structure of the valve is deemed unnecessary.
It will be noted that no orifice valve is provided for the lowermost set of perforations 11d. These perforations are supplied with treatment fluid by the residual axial flow. Adjustment of the initial flow rate of treatment fluid introduced into the tubing string will adjust the residual axial flow rate.
Referring now to FIGS. 3A and 3B, the detailed construction of the lowermost packing element 25 will now be described. As shown in the aforementioned figures of the drawings, the lowermost packing element 25 comprises a tubular inner body member 25a provided with internal threads 25b for convbentional securement to the bottom end of a sleeve 28 which extends upwardly to form part of thfe tubular assemblange 20 which is suspended at its top end from the main tubing string TS (FIG. 1A) extending to the well surface. The lower end of the tubllar inner body 25a is provided with external threads 25c which are engaged by the internally threaded upper end of a connecting sub 29. The lower end of connecting sub 29 is provided with internal threads 29a which are engaged with threads provided on the top end of an extension sleeve 28b which extends downwardly to a position adjacent the lowermost set of perforations 21c.
Surrounding the medial portion of the inner tubular body 25a is a lock support sleeve 25d. Lock support sleeve 25d is conventionally milled out to provide a plurality of peripherally spaced recesses 25e for respectively accommodating a plurality of locking elements 26. Each locking element is biased in a radially outward derection by a pair of leaf springs 26a and 26b which are suitably mounted to the lock-supporting sleeve by bolts 26c. Thus, when the lowermost packing element is run into the liner 10 and the lock elements 26 are positioned adjacent the annular locking recess 12c provided in the metallic insert 12 in the liner 10, the locking lugs 26 will be urged outwardly into engagement with locking recess 12c, but may be cammed otu of such engagement by the inclined surfaces 12d and 12e provided at the top and bottom ends of the locking recess 12c. Thus, the preferred initial run-in position of the lowermost packing unit 25 places the locking lugs 26 at a position slightly below the annular locking recess 12c as shown in FIG. 3A.
The lock support sleeve 25d is connected to the inner tubular body 25a for run-in purposes by an inwardly projecting J-pin 25g which is threadably mounted in the lock support sleeve 25d and cooperates with a J-slot 25h (FIG. 9) provided on the exterior surface of the inner tubular body 25a. In the run-in position, the J-pin 25g is engaged in the horizontial leg of the J-slot 25h and hence the lock support sleeve 25d moves concurrently with the tubular inner body 25a to the run-in position illustrated in FIG. 3A.
The tubing string is then rotated in a counter clockwise direction a sufficient amount to move the J-pin 25g into alignment with the vertically extending portion of the J-slot 25h and tension is then applied to the tubing string to elevate same and this brings the locking lugs 26 upwardly into alignment with the lock receiving recess 12c provided in the metallic liner section 12. The application of tension to the tubing string is continued, resulting in the upward movement of the tubular inner body 25a relative to the lock support sleeve 25d. Such upward movement brings an enlarged-diameter portion 25f of the tubular inner body into a portion adjacent the locking lugs 26 and prevents such locking lugs from being cammed out of the lock receiving recess 12c, thus effectively locking the lock support sleeve in a fixed axial position (FIG. 4A).
Below the lock support sleeve 25d, a pair of axially spaced abutment rings 27a and 27b are mounted on the tubular inner body 25a in axially spaced relationship, and respectively abut the top and bottom faces of the annular elastomeric sealing element 27. The upper abutment ring 27a is secured to the inner body 25a by shear screws 27c. The lower abutment ring 27b is shearably secured to the tubular inner body 25a by a shear ring 27d. When the locking lugs 26c are engaged with the annular locking recess 12c, the upper abutment ring 27a is in abutting engagement with the bottom end of the lock support sleeve 25d, and thus prevents further upward movement of the annular elastomeric sealing element 27 until shear screws 27c are severed. As the upward movement of the tubular inner body 25a then continues, the annular elastomeric seal element 27 is axially compressed and expands into sealing engagement with the bore 12f of the liner section 12 and the external surface 25k provided on the inner tubular body 25a, as illustrated in FIG. 4A. Thus, the packing element 25 is fully set and is not only anchored to the liner 10 by the locking lugs 26 but also effects a sealing engagement of the annulus between the bore of the liner 10 and the external surface of the tubular inner body 25a, thus isolating the lowermost set of perforations 11d from all of the other perforations.
In order to permit the tension applied through the tubing string to the lowermost packing element 25 to be relaxed, a body lock ring 35 is mounted in the bore of the top end portion of the lock support sleeve 25d. Such body lock ring cooperates with conventional wicker threads 25m provided on the top portion of the inner tubular body 25a. Thus, the tension may be released in the tubing string without effecting the unsetting of the lowermost packing element 25.
To effect the unsetting of the lowermost packing element 25, a substantially higher degree of tension is applied to the inner tubular body 25a than required to effect the setting of the lowermost packing element 2k. This degree of tension is selected to exceed the shear strength of thfe shear ring 27d which holds the lower abutment ring 27b in compressing relationship with respect to the annular elastomeric element 27. Once the shear ring 27d separates, the lower abutment ring 27b is free to move downwardly and thus remive the compressive forces on the annular elastomeric sealing element 27 (FIGS. 5A, 5B, and 5C). Upward movement of the tubing string will then bring a second smaller diameter surface 25k of the inner tubular body 25a into alignment with the inner faces of the locking lugs 26. Such locking lugs will be cammed out of the locking recess 12c by an inclined upper shoulder 12d, thus releasing the lowermost packing element 25 from its locked relation with respect to the liner section 12. All of the outer components of the lowermost packing assembly 25 are then removable from the well with the inner tubular body portion 25a through the engagement of the top surface 29b of the connecfting sub 29 with the shear ring 27d.
Referring now to FIGS. 6A, 6B, and 6C there is shown in enlarged detail the construction of the upper packing elements 30. Such units comprise an upper connecting sub 31 having internal threads 31a for connection to either the bottom of the tubing string (not shown) or the botton of a tubing element forming part of the tubular assemblage 20. Connecting sub 31 is provided with internal threads 31b by which it is connected to the upper end of an axially split, two-piece mandrel assemblage 32. The threaded connection is sealed by an O-ring 31b and secured by a set screw 31c. The upper piece 31a has a bottom end surface 32c a(FIG. 6B) lying in abutment with the top end surface 32d of the lower mandrel portion 32b. Immediately adjacent the abutting surfaces 32c and 32d, the top and bottom sections 32a and 32b are both provided with an annular recess 32e. A shear ring 32f is contoured to engage both annular recesses 32e and thus secure the upper and lower mandrel pieces 32a and 32b for co-movement. Shear ring 32f may be fabricated as a split C-ring construction in order to facilitate assemblage.
The lower portion of lower mandrel portion 32b is radially enlarged as indicated at 32p and such lower portion mounts an O-ring 32g which sealable engages the external surface of a connecting sleeve 33. Connecting sleeve 33 has an enlarged-diameter lower portion 33a which is provided with external threads 33b for engagement with the next tubing portion of the tubular assemblage 20.
The radially enlarged portion 32p of the lower mandrel piece 32b abuts the bottom face of an annular elastomeric sealing element 34. The upper face of the annular elastomeric sealing element 34 is abutted by the bottom end face 36a of a compressing sleeve 36. Sleeve 36 mounts a plurality of peripherally spaced, inwardly projecting bolts 36a each of which extends through a vertical slot 32h provided in the lower mandrel piece 32b and engages a recess 33c formed in the medial portions of the connecting sleeve 33. The top end of connecting sleeve 33 mounts an O-ring 33d which is desposed in sealing relationship with the internal surface of the upper mandrel piece 32a .
The top end of the compression sleeve 36 is shearably secured to the bottom end of the connecting sub 31 by a plurality of peripherally spaced shear screws 31d. Additionally, the compression sleeve 32 conventionally mounts a body lock ring 37 which is engagable with wicker threads 32m provided on the exterior of the upper mandrel piece 32a .
The operation of the upper packing units 30 may now be described. FIGS. 6A, 6B, and 6C illustrate the run-in position of the elements wherein they are disposed in the manner heretofore described. After setting of the lowermost packing unit 25, any tensile forces imparted to the lowermost packing unit must pass through the upper packing elements 30. When such tension reaches a degree to effect thef shearing of shear bolts 31d, the severance of such shear bolts permits the mandrel assemblage 32 to move upwardly relative to the compression sleeve 36 and thus effect an axial compression of the annular elastomeric sealing element 34, causing such element to radially expand to seal the annulus between the bore of the liner 10 and the external surface 32n of the lower mandrel piece 32b (FIGS. 7A, 7B, and 7C). The sealing of the annulus is completed by O-ring seal 32g below the elastomeric sealing elemefnt 34 and O-ring seal 33d above the elastomeric sealing element 34. Upward movement of the compression sleeve 36 is prevented by the bolts 36b which traverse the vertically extending slots 32h provided in the lower mandrel piece 32b.
When the desired degree of expansion of the annular elastomeric sealing element 34 has been accomplished, the body lock ring 37 will prevent any return movement of the mandrel in a downward direction to release the compressive forces on the annular elastomeric sealing element 34. Thus, the elements of the upper packing units 30 assume the configuration illustrated in FIGS. 7A, 7B, and 7C.
Each upper packing unit 30 may be unset through the application of a tension force through the tubing string substantially greater than the force required to effect the setting of such packing unit. Such force should be sufficient to effect the separation of the shear ring 32f, which effects the immediate release of the lower mandrel piece 32b, thus removing the compressive force on the annular elastomeric sealing element 34 (FIGS. 8A, 8B, and 8C).
The shear strength of the shear ring 32f should be less than that required to effect the shearing of the shear ring 27d of the lowermost packer unit 25. The lowermost packer unit 25 must remain in an anchored position relative to the liner 10 until all of the shear rings 32f of the upper packing elements 30 are sheared to unset each of the upper packing elements 30 prior to unsetting of the lowermost packing element 25, which provides the required resistance to tension applied through the tubing string to effect the shearing of the unsetting shear rings 32f of the upper packing elements 30.
Those skilled in the art will recognize that the aforedescribed method and apparatus provides an unusually simple and economical solution to the problem of concurrently supplying treatment fluid, be it liquid or gas, to a plurality of vertically spaced production zones traversed by a well bore. Not only is such treatment fluid concurrently applied, to all production zones, but the amount or flow rate of the treatment fluid supplied to each of the production zones may be selectively adjusted.
Referring now to FIGS. 2A, 2B, 2C, and 2D there is shown a modification of this invention which is useful whenever the interior diameter of the casing 1 is large enough to accommodate a conventional side pocker mandrel in the tubing string. Referring to these drawings, wherein similar numbers indicate components similar to those previously described, it will be noted that the liner 10 is identical to that previously described and is suspended from the hanger 5 in the same manner as described. The tubular assemblage 20, however, is now connected at its upper end by threads 20f to a lower inner portion 60a of a conventional side pocket mandrel 60. Side pocket mandrel 60 is in turn connected in series relationship to the lower end of the tubing string (not shown). An extension sleeve 62 connected by threads 62a to the outer bottom end of the side pocket mandrel 60 and sleeve 62 is provided at its bottom end with a radially thickened portion 62b in which are mounted a plurality of axially spaced seals 62c. Seals 62c effect a sealing engagement with the extension sleeve 5c provided on the hanger 5. Thus the side pocket mandrel 60 may move axially with respect to the hanger 5, but maintains sealing engage,ent with the bore of the extension sleeve 5c.
Side pocket mandrel 60 is provided with a conventional interior side pocket 65 within which is conventionally mounted an adjustable axial flow-controlling valve 70. Such valve is entirely conventional and may comprise the DANIEL RO-1-C valve sold by DANIEL EQUIPMENT, INC. Houston, Texas, but midified with respect to the same valve utilized in the midifications of FIGS. 1A, 1B, and 1C to provide an adjustable axial flow outlet instead of a radial flow outlet. Thus the treatment fluid introduced through the tubing string will be divided by the adjustable flow valve 70 into an inner axile component which proceeds down the bore 20a of the tubular assemblage 20, and a second axially flowing component which proceeds down the annulus 20g defined between the exterior of the tubular assemblage 20 and the internal bores of the hanger 5 and the liner 10.
In this modification, the uppermost packing element 30 which was previously disposed above the uppermost set of perforations is eliminated and the axial flow component of treatment fluid enters the perforations 11a directly from the annular flow passage 20g. The amount of this flow is adjustable by adjustment of the adjustable flow valve 70. For this purpose, the adjustable flow valve 70 is is provided with a fishing neck 70a by which the valve may be conveniently retrieved by wireline for adjustment purposes and then reinserted in the side pocket 65 of the side pocket mandrel 60.
It will be noted that the annular flow passage 20g is sealed off at its lower end by the packing element 30 sealably located in such annulus above the next set of perforations 11b.
The modification of FIGS. 2A, 2B, and 2C is particularly useful whenever only tow or three perforating zones are to be concurrently treated. With such arrangement, the adjustable flow valve 70 may be directly removed by wireline for adjustment purposes. In contrast, in the modification of FIGS. 1A, 1B, and 1C, it is necessary to remove any flow valves 40 located above the particular valve requiring adjustment before that valve can be reached by wireline and removed for adjustment purposes.
The modification of FIGS. 2A, 2B, 2C, and 2D incorporates a lower packer unit 25 which is set above the lowermost set of perforations in the same manner as described in the modification of 1A, 1B, and 1C, as well as upper packing units 30. Bothe the packer unit 25 and all upper packing units 30 are set through the application of tension through the tubing string in the manner previously described.
Referring now to FIGS. 10A, 10B, 11A, and 11B, there is shown a modified construction of a packing unit 100. Unit 100 incorporates an upper tubular body member 102 having internal threads 102a for conventional engagement with the tubular assemblage 20. The lower end of the tubular body 102 is provided with internal threads 102b which are threadably engaged with an abutment sleeve 104. Abutment sleeve 104 secures a shear ring 106 in a radially projecting position immediately below the end of the body sleeve 102.
An inner body sleeve 110 is mounted in concentric telescopic relationship to body sleeve 102 and is provided at its lower end with external threads 110a for securement to the next section of the tubular body assemblage 102. An O-ring seal 112 is provided on the exterior of the inner body member 110 adjacent the upper end of such body member and a second O-ring 114, which is on somewhat larger diameter is secured to a medial portion of the inner body member 110. Such seals engage the bore surfaces 102c and 102d of the inner body member 102 in slidable and sealable relationship.
An annular elastomeric seal 120 surrounds the lower portions of the outer body member 102. A seal compressor sleeve 122 also surrounds the lower end of the outer tubular body 102 and is secured by internal threads 122a to the top end of a shear pin ring 124. Shear pin ring 124 slidably surrounds the exterior of the inner tubular body 110 and is provided with one or more radially inwardly projecting shear screws 126 which engage an annular groove 110c provided on the exterior of the inner tubular body 110.
An abutment sleeve 130 is mounted in surrounding relationship to the upper portions of the outer tubular body 102 and is secured in a fixed axial position relative to the inner tubular body 110 by one or more radially disposed bolts 132 which are threadably secured in the abutment sleeve 130 but project through axially extending slots 102e formed in the outer tubular body 102. The anchor bolts 132 snugly engage an annular groove 110d formed in the upper portions of the inner tubular body 110.
Assuming that the lower end of the tubular body assembly is anchored by a lower packing element in the manner heretofor described, the exertion of an upward tensile force on the outer tubular body 102 will first effect a shearing of the shear screws 126, thus permitting the outer tubular body 102 to move upwardly relative to the inner tubular body 110 and the abutment sleeve 130. The compression sleeve 122 is therefore carried upwardly by the outer tubular body 102 and effects a compression of the annular elastomeric seal element 120 into sealing engagement with the adjacent wall of the fiberglass reinforced liner 10, as illustrated in FIGS. 11A and 11B, thus setting the upper packing element 100. The packing element is retained in a set position through the co-operation of a body lock ring 140 which is conventially mounted between internally projecting threads 130b formed on the interior of the abutment sleeve 130 and wicker threads 102f formed on the exterior of the outer tubular body 102. Thus, tension can be relieved on the outer tubular body 102. and the packer will remain in its set, sealed relationship with the bore of the thermoplastic liner 10.
To unset the mosified upper packer 100, it is only necessary to apply a greater degree of tension than that employed in setting the packer. Such larger tensile force will effect the shearing of the shear ring 106 and thus immediately permit the compression sleeve 120 to shift downwardly to relax the compressive forces on the annular elastomeric seal element 120. All of the elements of the packer can then be removed with the tubing assemblage 20, if desired.
Although the invention has been described in terms of specified embodiments which are set forth in detail, it should be understood that this is by illustration only and that the invention is not necessarily limited thereto, since alternative embodiments and operating techniques will become apparent to those skilled in the art in view of the disclosure. Accordingly, modifications are contemplated which can be made without departing from the spirit of the described invention.
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A plurality of packing elements are mounted in vertically spaced relationship on a tubing string with the spacing of the elements corresponding generally to the spacing of a plurality of sets of perforations in a well conduit. The lowermost packing unit is provided with radially expanding locking elements which engage a locking groove provided in the well conduit. All packing units incorporate expandable elastomeric sealing members and are set by the application of tension to the tubing string and are unset by the subsequent application of a higher degree of tension to the tubing string.
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FIELD OF THE INVENTION
This invention relates to optical systems and devices and, in particular, to optical systems and devices employing long period spectral shaping devices.
BACKGROUND OF THE INVENTION
Optical fibers are key components in modern telecommunications. Optical fibers are thin strands of glass capable of transmitting an optical signal containing a large amount of information over long distances with very low loss. In essence, an optical fiber is a small diameter waveguide characterized by a core with a first index of refraction surrounded by a cladding having a second (lower) index of refraction. Light rays which impinge upon the core at an angle less than a critical acceptance angle undergo total internal reflection within the fiber core. These rays are guided along the axis of the fiber with minimum attenuation. Typical optical fibers are made of high purity silica with minor concentrations of dopants to control the index of refraction.
A typical optical fiber communications system comprises a source of optical input signals, a length of optical fiber coupled to the source and a receiver for optical signals coupled to the fiber. One or more amplifying devices are disposed along the fiber for amplifying the transmitted signal. Pump energy must be supplied to operate the amplifier. Contemplated optical fiber systems use digitally modulated optical signals at a wavelength of 1.55 micrometers and erbium-doped fiber amplifiers.
Such systems present a number of difficulties. One problem is the disposition of unused pump energy in a counter-pumped fiber amplifier (with two pump sources). If unused pump energy from one source is permitted to propagate down the fiber towards the other pump source, it can deteriorate the performance of the amplifier. Also, in any amplifier, amplified spontaneous emission generated by the interaction of the pump power with the rare-earth ions can act as noise and adversely affect system performance. In both these cases, it would be useful to have an in-fiber device that can effectively introduce a wavelength-dependent loss to increase the efficiency of the amplifier.
Another problem limiting the capacity of such systems is that the erbium-doped fiber amplifier has a characteristic spectral dependence providing different gain for different wavelengths. This spectral dependence poses a problem for contemplated multichannel wavelength division multiplexed (WDM) systems because different gains for different channels would lead to high bit error rates in some of the channels. In this case, a spectral shaping device would help flatten the gain spectrum of the amplifier.
SUMMARY OF THE INVENTION
In accordance with the present invention, optical fiber communications systems are provided with one or more long period spectral shaping devices to shift light of unwanted wavelength from guided modes into non-guided modes. Such devices can be used for removing unused laser pump energy, for removing amplified spontaneous emission, and for flattening the spectral response of an erbium amplifier. Such devices can also provide optical fiber sensing systems with inexpensive shift detectors.
BRIEF DESCRIPTION OF THE DRAWINGS
The advantages, nature and various additional features of the invention will appear more fully upon consideration of the illustrative embodiments now to be described in detail in connection with the accompanying drawings. In the drawings:
FIG. 1 is a schematic cross section of a long period spectral shaping device;
FIG. 2 is a graphical plot of center wavelength versus period useful in making the device of FIG. 1;
FIG. 3 is a typical transmission spectrum of a long-period shaping device used for removal of light in a wavelength region around λp.
FIG. 4 illustrates apparatus useful in making the device of FIG. 1;
FIG. 5 shows an optical transmission system using long period spectral shaping devices to remove unused pump energy;
FIG. 6 shows the characteristic gain vs wavelength spectrum of a typical erbium-doped fiber amplifier;
FIG. 7 shows an optical transmission system using a long period spectral shaping device to reduce the spectral dependence of an erbium amplifier;
FIG. 8 is a typical transmission spectrum of long period shaping device useful for flattening the gain of an erbium amplifier; and
FIG. 9 shows an optical fiber sensing system using a long period shaping device to provide frequency shift detection.
It is to be understood that these drawings are for purposes of illustrating the concepts of the invention and, except for graphical illustrations, are not to scale.
DETAILED DESCRIPTION
Referring to the drawings, FIG. 1 is a schematic cross section of a first embodiment of a long period spectral shaping device in accordance with the invention comprising a length of optical fiber 10 for transmitting light in a guided mode having a core 11 surrounded by a lower index cladding 12. The core 11 includes one or more long period gratings 13 each comprising a plurality of index perturbations 14 of width w spaced apart by a periodic distance Λ where, typically, 50 μm≦Λ≦1500 μm. Advantageously 1/5Λ≦w≦4/5Λ and preferably w=1/2Λ. The perturbations are formed within the glass core of the fiber and preferably form an angle of 74 (2°≦θ≦90°) with the longitudinal axis of the fiber. The fiber is designed to transmit broad band light of wavelength centered about λ.
The spacing Λ of the perturbations is chosen to shift transmitted light in the region of a selected wavelength λp from the guided mode into a non-guided mode, thereby reducing in intensity a band of light centered about λp. In contrast with conventional short period gratings which reflect light, these long period devices remove the light without reflection by convening it from a guided mode to a non-guided mode. FIG. 2 is a graph illustrating the periodic spacing Λ for removing light centered about a wavelength λp. Thus, to make a device for removing light centered around 1540 nm, one chooses a spacing of about 760 μm as shown in FIG. 2. FIG. 3 shows the transmission spectrum of a grating with λp at approximately 1550 nm indicating removal of most of the light at λp to non-guided radiation modes.
Preferably the optical fiber is single mode optical fiber having a silica core doped with photosensitive material such as germanium. Further, the fiber may be loaded with molecular hydrogen to enhance its photosensitivity. The long period grating 13 can then be formed by selectively exposing the core to beams of intense light of width w at locations separated by the distance Λ.
The preferred exposure source is UV radiation from a KrF excimer laser. Proper spacing can be effected by exposing through a slit of width w and then moving the fiber to the next exposure site. Alternatively, as shown in FIG. 4, the fiber 10 can be exposed to a wide beam from laser 40 through an amplitude mask 41 providing a plurality of transparent slits 42 at spacing A and opening widths w. Preferably the exposure dosage for each slit is on the order of 1000 pulses of >100 mJ/cm 2 fluence/pulse, and the number of perturbations is in the range 10-100 depending on the specific application.
FIG. 5 illustrates an optical transmission system 50 using a long period spectral shaping device to remove unused pump energy. Specifically, the system 50 comprises a transmitter source 51 of optical signals such as a digitally modulated 1.55 μm signal, an optical signal path comprising a length of optical fiber 52 for transmitting the signal, and a receiver 53 for receiving and demodulating the signal. An optical amplifier such as an erbium-doped fiber amplifier 54 is disposed in the optical signal path for amplifying the transmitted signal. The amplifier is pumped by pump sources 55, 56 of optical energy of pump wavelengths λp 1 and λp 2 . Unused pump energy of each pump wavelength will pass through amplifier 54. The energy is advantageously removed from the system so that it will not deteriorate the performance of the pump sources 55, 56 and transmission and receiving equipment 51, 53. To remove unused pump energy, a long period spectral shaping device 57 is disposed in the path of the energy from pump 55 after it has passed through amplifier 54. Specifically, in the dual-pumped laser of FIG. 5, device 57 has its spacing Λ chosen to remove energy of wavelength λp 1 . A second long period grating 58 has its spacing chosen to remove energy of wavelength λp 2 . In a typical application, λ s is 1.55 μm, λp 1 is 9.780 μm and λp 2 is 9.840 μm. Thus, for example, device 57 could comprise a hydrogen-loaded germanosilicate fiber with core index and diameter chosen such that it allows the propagation of only the fundamental mode at λ≧9.70 μm. For this application the perturbations should be exposed by a dosage ≧100 mJ/cm 2 and there should be at least 20 perturbations in each grating.
Another preferred use of the device of FIG. 1 is to reduce spectral dependence in the gain output of an optical amplifier. The characteristic gain spectrum of an erbium-doped optical fiber amplifier is shown in FIG. 6. As can be seen, the amplifier has a pair of gain peaks at about 1.53 μm and at about 1.56 μm. So a signal at 1.53 μm will be amplified more than one at 1.54 μm, which would be disadvantageous in a WDM system.
FIG. 7 illustrates an optical transmission system 70 using a long period shaping device 72 to reduce the spectral dependence of an optical amplifier such as erbium-doped fiber amplifier 54. Specifically, the device 72 is serially disposed in the output path of the amplifier 54. The shaping device 72 has one set of spacings Λ chosen to remove energy of wavelength 1.53 μm corresponding to the gain peak wavelength of the amplifier and another set of spacings to remove energy of wavelength 1.56 μm at the other gain peak. By proper choice of the number of perturbations and the dosage of exposure, the gain spectrum of the amplifier device combination can be made substantially flat over a range of wavelengths 1530 to 1560 nm. For a typical erbium amplifier, the shaping device exposed by a dosage ≦100 mJ/cm 2 , 1000 pulses per slit will produce a more uniform gain response over the range of wavelengths 1530-1560 nm. The transmission spectrum of such a device is shown in FIG. 8. Advantageously, system 70 can be a WDM system using a plurality of different wavelength signals, e.g. λs 1 and λs 2 .
Another useful application of the FIG. 1 device pertains to optical fiber sensing systems. Conventional fiber sensing systems typically use an optical fiber including one or more narrow spacing reflective gratings. In the absence of strain, the reflective grating will reflect light of wavelength λ. But if the grating region is subject to strain, the spacing d will change by an amount Δd producing a reflected wavelength shift Δλ. This shift Δλ can be detected in a spectrum analyzer and the strain can be determined from Δλ. The problem, however, is that spectrum analyzers are expensive.
FIG. 9 illustrates an optical fiber sensing system 90 using a long period grating to provide an inexpensive wavelength shift detector. In essence, the sensing device comprises a source 91 of optical energy around wavelength λ, a length of optical fiber 92 including a short period reflective sensing grating 93 for reflecting light of wavelength λ, a long period grating 94 coupled to fiber 92 for receiving light reflected from short period grating 93 and a photodetector 95 for detecting the intensity of light through device 94. More specifically, device 94 has spacing Λ chosen so that λ in the output intensity spectrum is in a region of substantially linear slope. In such a region, a shift Δλ in the reflected wavelength will produce a linear shift in the intensity output of device 94 which can be detected by photodetector 95. The system thus substitutes inexpensive components 94, 95 for the high cost spectrum analyzer of the prior art.
It is to be understood that the above-described embodiments are illustrative of only a few of the many possible specific embodiments which can represent applications of the principles of the invention. Numerous and varied other arrangements can be readily devised by those skilled in the art without departing from the spirit and scope of the invention.
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In accordance with the present invention, optical fiber communications systems are provided with one or more long period spectral shaping devices to shift light of unwanted wavelength from guided modes into non-guided modes. Such devices can be used for removing unused laser pump energy, for removing amplified spontaneous emission, and for flattening the spectral response of an erbium amplifier. Such devices can also provide optical fiber sensing systems with inexpensive shift detectors.
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BACKGROUND OF THE INVENTION
The invention relates to means of enclosing a vehicle, such as an automobile, truck or the like, for the purpose of protecting it from the destructive elements of the environment, for example, moisture, acid rain, sunlight, dust and dirt.
The need for an enclosure such as claimed in this invention arises from the recent popularity and growth of the collector car market. There is an increasing need to shelter such collector cars, especially outdoors, since indoors garage space is becoming increasingly scarce and expensive to obtain. Numerous shelters and protective devices are presently used for protection of vehicles, including car covers, car tents, protective bags and enclosed trailers or buildings. A few types of car covers can acceptably protect the upper part of an automobile from rain and sunlight but they offer very limited protection for the lower parts of a vehicle, namely the wheels, chassis parts, rocker panels and bumpers, from splashing water, blowing snow and rising moisture from the ground. Further, a car cover will physically contact the painted surfaces of a vehicle, casing possible damage from abrasion. A car tent such as cited in J. F. Oliver, Collapsible Housing Structure, U.S. Pat. No. 2,798,501 (1957), can also protect an automobile from rain and sunlight but being of an open construction at the bottom, it cannot protect from rising ground moisture. Also, since a car tent is normally not ventilated, it has a tendency under certain temperature conditions to accumulate condensation on its inside walls which can cause water droplets to form and drip on the vehicle. The resulting high humidity conditions can cause severe corrosion damage to steel and chrome plated parts. Enclosed bags of flexible material are also known to exist for the storage of automobiles. Such bags are only intended for indoor use and are inconvenient to use since they are openable only from one end. Enclosed trailers or garages are generally relatively very expensive compared to this invention and are not easily disassembled, moved or transported. Although air supported structures have been heretofore utilized for the containment of vehicles; such structures have not been as ideally suited for the task of protection and preservation of vehicles as the protective enclosure claimed herein. Prior air supported structures have employed extensive means to anchor the perimeter of the structure to the ground or to a pre-fabricated base. Such anchors must necessarily bear heavy tension loads developed by upward air pressure on the roof of the structure and must therefore be of heavy construction and costly. Examples of such construction are shown in Malet, Inflatable Structure For Use As A Shelter, U.S. Pat. No. 4,567,696 (1986), FIGS. 4 and 5 and in W. W. Bird, Weather-Tight Enclosure System, U.S. Pat. No. 3,496,686 (1970) FIG. 5. In addition, methods must be employed to seal the perimeter of such air supported structures either to a special base member or to an underlying surface, increasing cost of manufacture further. This type of construction is shown in Hickey, U.S. Pat. No. 3,929,178 (1975) as well as Patents of Malet and W. W. Bird referenced above, wherein the perimeter of a cover part is being sealed to a base member. In contrast, the portable protective enclosure claimed herein does not require means for sealing nor anchoring its perimeter. Further, Hickey's Patent referenced above would not be as suitable as this invention for housing vehicles with fine paint finishes, since its flexible cover interior is not pressurized, and thus self supporting, but opposingly is drawn tightly in contact with the vehicle by means of suction applied to its interior, thereby possibly causing damage to the paint finish of the vehicle.
OBJECTS OF THE INVENTION
It is an object of this invention to overcome the disadvantages cited above and provide a protective enclosure for a vehicle which totally encloses the vehicle including the bottom surface to prevent evaporating moisture from the ground from causing corrosion damage to parts of the vehicle such as bare steel chassis parts and chrome plated parts.
It is a further object of this invention to provide a protective enclosure for a vehicle which is ventilated for nearly equalizing the temperature inside the enclosure compared with the temperature outside the enclosure, therefore minimizing condensation formation on the vehicle.
It is another object of this invention to provide a protective enclosure for a vehicle which eliminates, in an air supported structure, the need for expensive sealing methods between a base members and an upper cover member by providing a shell that continuously encircles the vehicle, including the bottom.
It is a further another object of this invention to provide a protective enclosure for a vehicle which under normal conditions remains free of the vehicle, preventing damage to painted surfaces of the vehicle from abrasion.
It is another object of this invention to provide a protective enclosure for a vehicle which is convenient to use and which allows rapid entry and exit along with the ability to store or transport the enclosure in a small space.
It is yet another object of this invention to provide a protective enclosure for a vehicle which, when in use is firmly held in place due to the weight of the vehicle resting upon it and therefore, does not need extensive anchoring techniques to attach it to the ground and is resistant to wind and other forces attempting to move it.
Further objects and advantages of the invention will become apparent from the following summary, specifications and drawings.
SUMMARY OF THE INVENTION
In accordance with the invention, an air supported enclosure is provided, fabricated of lightweight vinyl sheeting, which when inflated encloses a vehicle on all sides including the bottom. A slide fastener in the form of a zipper is provided on three sides of the enclosure for access to its interior. The zipper closure is protected from entry of moisture by an overflap of the vinyl material covering the fastener.
Located in the interior of the front part of the enclosure is a fan which functions to inflate and pressurize the enclosure. The pressure differential thus developed is sufficient to support the enclosure and stabilize it so that it remains unaffected by strong wind velocities. The fan also functions to ventilate the enclosure so the temperature within the enclosure remains nearly equal to the temperature outside the enclosure. The air inlet port of the fan is connected through an opening in the vinyl sheeting to an S shaped duct which at the other end connects to a filter housing containing a washable filter element to filter fine dust particles from the incoming air stream and a coarse screen to exclude larger dirt particles, falling leaves, bugs, snowflakes and the like. Due to the configuration of the S shaped duct, the filter housing is located in a relatvely high position and in an inverted manner to place the open end of the housing facing down. This prevents entry of water and keeps the air intake port free of snow accumulations.
A supporting frame, fabricated preferentially of round steel tubing, rests on the vinyl sheeting at the bottom surface of the enclosure and encircles the vehicle. Supports, made of sheet metal rest loosely on the supporting frame and extend under at least four wheels of the enclosed vehicle, placing the full weight of the vehicle on the supporting frame. This holds the bottom of the enclosure firmly on the ground and directs the vinyl sheeting away from the vehicle. The frame is fabricated in sections attached by connectors which enable it to be disassembled and transported or stored conveniently. The vinyl sheeting can be folded around the fan assembly to create a small transportable package.
Although one particular embodiment of this invention is shown, it is understood that many different sizes, shapes and configurations of the invention may be fabricated within the scope of the claim set forth.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a left front partial cut-away view of the inflated enclosure also showing the filter housing and duct.
FIG. 2 is a left rear view of the inflated enclosure showing the zipper closure and overflap.
FIG. 3 is a detail sectional view of the zipper closure and weather protective overflap taken along lines 3--3 of FIG. 2.
FIG. 4 is a top view of the enclosure prior to inflation with the slide fasteners open and the top portion of the flexible sheeting rolled up.
FIG. 5 is a close-up view of the front wheel of a vehicle resting upon a support member which engages the supporting frame of the enclosure.
FIG. 6 shows a cross sectional view of the filter housing.
FIG. 7 is a view from the interior of the enclosure showing the ventilator fan and duct.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to the figures, in FIG. 1 a flexible sheeting 1 preferably made of lightweight, watertight, reinforced vinyl material, encloses totally within it a vehicle 2, such as an automobile. The sheeting 1 comprises a rectangular top portion 3, a rectangular bottom portion 4 and essentially bread-loaf shaped sides 5 joined by sewing or electronic welding technique to form a completely watertight enclosure surrounding the vehicle on all sides, including bottom.
A closure means, preferably a heavy duty zipper 6 extending on two sides 5 and rear 7 allows when opened access to the interior of the enclosure. An overlapping strip of sheeting material 8 covers the zipper 6 so that water entry is not possible.
Located within the front part of the enclosure 9 a ventilating fan 10 is mounted on a bracket 11 and situated so that its air intake port faces an opening in the enclosure sheeting having a fitting 12 connecting to a flexible ducting 13 leading to a filter housing 14. Referring to FIGS. 6 and 7, when the motor 15 driving the impeller of ventilating fan 10 is electrically energized, air is drawn in through a screen 16, enters the filter housing 14, flows through filter 17, duct 13, and is discharged by the fan 10 into the interior of the enclosure causing it to become inflated. Once inflated and an equilibrium condition is attained, the airflow is of such magnitude that it equals the leakage through small openings in the enclosure and through the zipper 6 which is designed to leak an amount of air sufficient to ventilate the enclosure. The fan 10 is sized to develop pressure against this fixed airflow to keep the enclosure firmly inflated. In this equilibrium condition the flexible sheeting 1 assumes a semicircular shape in cross section. The fan 10 is mounted on the bracket 11 whose lower edge is attached to frame 19 by clamps 20. Clamps 20 allow the bracket 11 to pivot about frame 19 to adjust its position to conform to the position of the flexible sheeting 1 when inflated. Included on bracket 11 is an electrical inlet box 22 containing means for connecting to a source of electrical current, and an electrical outlet box 23 containing means for connecting an extension cord to power additional enclosures or other accessories. The S shaped flexible duct 13 is connected, as in FIG. 1, to the filter housing 14 and fitting 12 by hose clamps 24 and is retained in an upright position by strap 25 attached to the sheeting material. The relatively high position of the filter housing 14 with its open end with screen 16 (FIG. 6) facing in a downward direction prevents entry of water and snow into the enclosure.
As in FIG. 1, the perimeter of the enclosure is retained firmly on the ground by the weight of the vehicle 2 bearing on the support members 18 and supporting frame 19. Since the enclosure is self-supporting, it is completely free of the vehicle 2 at all points and under normal operating conditions cannot scratch or otherwise injure the finish of the vehicle. Further, since the enclosure assumes a semi-rigid airfoil-like shape, it is stable under windy outdoor conditions. The supporting frame 19 consists of several sections of circular steel tubing rigidly held together by screw-lock type connectors 20 which allow the frame to be quickly disassembled and stored or transported. As in FIG. 4, the frame sections at each end of the enclosure pass through pockets 21 formed by an additional thickness of the sheeting material. This locates the frame 19 precisely in the enclosure. The wheels 26 (FIG. 5) of the vehicle 2 rest upon support members 18 incorporating tabs 27 which engage frame 19 and hold frame 19 firmly against the inflation pressure which tends to lift the frame from the ground. As in FIG. 1, support members 18 can be adjustably positioned fore and aft along frame 19 corresponding to the wheelbase and length of the vehicle. As in FIG. 5, the front support members 18 contain a raised section 28 which functions as a stop when the vehicle is driven onto the enclosure.
To place a vehicle into the enclosure the sheeting material is spread out and positioned as shown in FIG. 4 with the sides 5 laying folded on each side and the top portion 3 rolled up at the forward end. The frame 19 is placed on the bottom sheeting 4 and connected using connectors 20. The support members 18 are then positioned according to the size of the vehicle 2 and the vehicle 2 is driven onto the enclosure with the front of the vehicle 2 toward fan 10 until the front wheels contact stop 28. The top portion 3 of the enclosure is rolled over the vehicle 2 and the slide fasteners 6 closed. The fan motor 15 is then energized causing the enclosure to inflate to its operating configuration.
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An air supported enclosure for the protection of a vehicle from the harmful effects of the outdoor environment comprising a flexible sheeting totally surrounding but not touching the vehicle. Access into the enclosure is gained by a slide fastener which extends around three sides of the enclosure. The enclosure is ventilated to minimize temperature differentials between its interior and its exterior therefore also minimizing the formation of condensation in its interior.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention lies in the field of printing presses. The present invention relates generally to a sheet-conveying apparatus, for example, for conveying newspapers, and, more particularly, to a sheet conveying apparatus having collating pockets moving on a track. In particular, the invention relates to an adjustable gripping device for holding folded sheet material sections in such a collating pocket and for separating folded ends of the sections from one another to allow nesting of inserted other sections.
2. Background Information
Sheet-conveying devices, in particular, devices for conveying newspapers, are required to be able to insert or nest or collate various sets of sheets inside one another. Specifically, to create a finished newspaper, a first folded section of the paper, taking the form of a folded sheet section, is opened and at least one second section of the newspaper is inserted between the two sides of the folded sheet section. It is possible that the second section is, itself, a section having third, fourth, or more other sections nested therein in the same manner as the first section. To process such sheets, in particular, newspapers, prior art conveying devices have an angle-shaped pocket that first picks up a first section, opens the first section, and then conveys the opened first section to a delivery station. Prior art systems including pockets include, for example, U.S. Pat. No. 4,133,521 to Müller and U.S. Pat. No. 5,213,318 to Newhall. A delivery unit drops the second section into the opened first section to create a nested paper with two sections. This process can be repeated for many different sections to create an entire newspaper.
There is a difficulty associated with the pocket properly opening the first section to the appropriate opening position. To facilitate proper opening, each section is formed with a lap. In other words, the two ends of the folded sheet section are not even. Typically, in a sheet-processing direction, the forward-most end of the folded sheet section is longer than the rear-most end of the folded sheet section. Thus, if the fold of the sheet section is at the bottom of the pocket, when viewing the ends of the folded sheet section in the pocket from above, the forward lap is higher than the rear lap.
In such a position, the folded sheet section can be opened if the forward, higher lap is secured by a device (applying a physical contact and/or air suction) and the pocket or folded sheet section is moved or tilted to allow gravity (possibly assisted with suction) to let the rear lap fall away from the forward lap. After the rear lap has fallen or is moved away from the forward lap, there exists an opening into which a second section can be inserted. Accordingly, a second section can be inserted into or nested within the first section. This combined section can then be inserted into a further section, and so on, to create a multiply nested set of sheets, typically, forming a common newspaper.
The securing device typically takes the form of a finger-shaped gripper. In the opening process, such a gripper is rotated or lowered onto the forward lap to secure the forward lap, and the forward sheet section, to a front wall of the pocket. Some examples of prior art gripper systems in such pockets include U.S. Pat. No. 4,723,770 to Seidel et al., U.S. Pat. No. 4,988,086 to Schlough, and U.S. Pat. No. 5,024,432 to Thünker et al.
However, lap sizes are neither consistent nor equal. Therefore, there is a need to adjust such grippers in a vertical direction with respect to a pocket so that the forward lap is gripped in the most efficient place. Prior art pocket systems solve this positioning problem by vertically adjusting the lowermost surface of the pocket holding the folded sheet section. If such a surface is lowered, the folded section resting thereon is also lowered. Similarly, if the lowermost surface is raised, the folded section resting thereon is also raised. What is needed is more precise lap-gripping adjustment system that is independent of the lowermost surface of the pocket.
U.S. Pat. No. 5,911,416 to Klopfenstein describes a sheet material conveying apparatus with a plurality of pockets moveable around a track to accept sheet material from sheet material feeders. These pockets permit, for example, a first outer section of a newspaper to first be fed into the pockets by a first sheet material feeder, and then an inner newspaper section to be inserted between the folds of the first outer newspaper section. The Klopfenstein apparatus uses a lift cam 20 to move a semicircular actuator gear 150 to rotate a drive shaft 110 so as to set a height for pocket feet 90 disposed on racks 80 . A pawl and ratchet mechanism prevents the pocket from opening. The sheet material can then be accepted and inserted into the pockets. To deliver the sheet material, a trip cam 22 can release the pawl and ratchet mechanism. Tracks 80 move to a lower position through a biasing spring, so that feet 90 release through operation of a driver cam 130 . The sheet material in the pocket can, thus, move out of the pocket from the bottom to be further conveyed or to be stacked. The entirety of Klopfenstein is hereby incorporated by reference.
U.S. Pat. No. 5,251,888 to Eugster purports to describe pockets moveable along an endless path. Each pocket is provided with two vertically adjustable stops 14 mounted displaceably in a pocket carrier 8 . A guide member 28 purportedly can be set to vertically adjust the stops 14 as the pockets are moved along the endless path.
Other examples of adjustment devices for the bottom of a pocket can be found in U.S. Pat. No. 3,891,202 to Kircher, U.S. Pat. No. 4,373,710 to Hansen et al., and U.S. Pat. No. 6,311,968 to Linder et al.
These prior art pocket systems do not provide an adjustment device for setting placement of grippers at the top of the pocket or at the gripper location itself.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide an adjustable gripping device for adjustable sheet-receiving pockets that overcomes the hereinafore-mentioned disadvantages of the heretofore-known devices of this general type and that better separates the forward lap from the rearward lap by adjusting grippers in a vertical direction with respect to a pocket so that the forward lap is gripped in the most efficient place.
Commonly assigned U.S. patent application Ser. No. 09/662,277, entitled “SHEET MATERIAL CONVEYING APPARATUS WITH INDIVIDUALLY-ADJUSTABLE POCKETS” filed on Sep. 14, 2000, describes a plurality of manually-adjustable pockets, each having a setting device for adjusting a height of the pocket.
Commonly assigned U.S. patent application Ser. No. 09/702,012, entitled “SHEET MATERIAL CONVEYING APPARATUS WITH HEIGHT-ADJUSTABLE POCKETS” filed on Oct. 30, 2000, describes a plurality of manually adjustable pockets, each having a setting device for adjusting a height of the pocket so as to define a set height.
Commonly assigned U.S. patent application Ser. No. 10/178,645, entitled “ADJUSTABLE GRIPPING DEVICE FOR ADJUSTABLE SHEET-RECEIVING POCKETS AND METHOD FOR ADJUSTING SHEET-RECEIVING POCKETS” and filed concurrently herewith, describes a different gripper adjusting system 70 where each gripper 71 is individually adjustable through a gripper plunger 73 having a plunger body 75 with a nose, a rod 76 , and a cam follower 77 attached to the end of rod 76 . The nose directly contacts and holds forward lap 61 of a section 6 , or holds the entire section 6 , 61 , 63 . Depending on a setting of a vertically adjustable cam 26 the nose moves away from or towards an upper edge of the rearward lap 63 .
Commonly assigned U.S. patent application Ser. No. 10/178,642, entitled “LAP SEPARATOR FOR SHEET-RECEIVING POCKETS AND METHOD FOR SEPARATING LAPS IN SHEET-RECEIVING POCKETS” and filed concurrently herewith, describes a lap separator system 70 for extending a window of time for allowing grippers 53 , 55 to engage a forward lap 61 . The lap separating system 70 includes at least one lap separator 72 moveably disposed on a lap separator carrier system 74 , preferably in the form of an endless belt that follows pockets 10 , but moves at a different speed. Lap separator 72 contacts a rearward side of upper rear wall 54 and forces it against upper front wall 52 , thereby clamping a folded section 6 therebetween. As lap separator 72 is traveling with but faster than pocket 10 , it first lets go of upper rear wall 54 , then of rearward lap 63 , and, finally, of upper front wall 52 by dragging over the uppermost edge of each, similar to a fanning of a deck of cards.
A setting device of some of the commonly assigned applications is manually operated by an operator, who turns a knob gear and sets a lock ring for a desired pocket height. It may be desirable to provide a less time consuming, one-step setting device for each pocket.
Each of these commonly assigned applications is hereby incorporated by reference herein.
With the foregoing and other objects in view, there is provided, in accordance with the invention, an adjustable gripper system for releasably holding at least one sheet against a surface, including a pivotable gripper shaft with a pivot axis and at least one gripper having a gripper body defining a plunger cavity, the gripper body connected to the gripper shaft for pivoting the gripper about the pivot axis, a gripper plunger slidably disposed in the plunger cavity and configured to hold the at least one sheet against the surface, and a cam follower to be actuated by a cam, the cam follower connected to the gripper plunger to displace the gripper plunger along the plunger cavity dependent upon a position of the cam.
In accordance with another feature of the invention, the gripper is a plurality of grippers spaced apart from one another on the gripper shaft.
In accordance with a further feature of the invention, the gripper body is releasably connected to the gripper shaft.
In accordance with an added feature of the invention, the gripper plunger has a nose for holding the sheet against the surface.
In accordance with an additional feature of the invention, the cam follower has a follower to be actuated by the cam and a cam rod connecting the gripper plunger to the follower.
In accordance with yet another feature of the invention, the plunger cavity has a plunger body portion with a given diameter and a cam rod portion having a diameter smaller than the given diameter, the gripper plunger has a plunger body with a body diameter, the cam rod has a cam rod diameter smaller than the body diameter, the plunger body is slidably disposed in the plunger body portion, and the cam rod is slidably disposed in the cam rod portion.
In accordance with yet a further feature of the invention, there is provided a bias device connected to the gripper body and the plunger body, the bias device biasing the plunger body with respect to the gripper body. Preferably, the bias device is a spring.
In accordance with yet an added feature of the invention, the bias device is disposed in the plunger body portion.
In accordance with yet an additional feature of the invention, the gripper body has a wall between the plunger body portion and the cam rod portion and the bias device is disposed between the wall and the plunger body. The bias device can also be disposed around the cam rod. Preferably, the wall is disk-shaped.
In accordance with again another feature of the invention, the cam rod has an end and the follower is a wheel and an axle rotatably connecting the wheel to the end.
With the objects of the invention in view, there is also provided a sheet-collating pocket, including a forward wall having an upper end portion, a rearward wall pivotably connected to the forward wall for moving towards and away from the forward wall, the rearward wall and the forward wall together defining an opening for receiving at least one sheet, and an adjustable gripper system for releasably holding the sheet against the forward wall, the gripper system disposed at the upper end portion and having a pivotable gripper shaft with a pivot axis and at least one gripper having a gripper body defining a plunger cavity, the gripper body connected to the gripper shaft for pivoting the gripper about the pivot axis, a gripper plunger slidably disposed in the plunger cavity and configured to hold the sheet against the forward wall, and a cam follower to be actuated by a cam, the cam follower connected to the gripper plunger to displace the gripper plunger along the plunger cavity dependent upon a position of the cam.
In accordance with again a further feature of the invention, the pocket travels in a given direction and the forward wall is disposed downstream of the rearward wall with respect to the given direction.
In accordance with again an added feature of the invention, the upper end portion is an upper third, an upper fourth, or an upper fifth of the forward wall. Preferably, the forward wall has a top and the gripper system is disposed substantially at the top.
With the objects of the invention in view, in a sheet-collating pocket having a top, a forward wall, and a rearward wall pivotably connected to the forward wall, the rearward and forward walls together defining an opening for receiving at least one sheet from the top, there is also provided an adjustable gripping system for setting placement of grippers at the top of the pocket, the gripping system including a pivotable gripper shaft with a pivot axis and at least one gripper having a gripper body defining a plunger cavity, the gripper body connected to the gripper shaft for pivoting the gripper about the pivot axis, a gripper plunger slidably disposed in the plunger cavity and configured to hold the at least one sheet against the forward wall, and a cam follower to be actuated by a cam, the cam follower connected to the gripper plunger to displace the gripper plunger along the plunger cavity dependent upon a position of the cam.
With the objects of the invention in view, there is also provided a sheet-collating machine, including a conveyor traveling along a transport direction, at least one sheet feeding device disposed at the conveyor for feeding at least one sheet towards the conveyor to a plurality of sheet-collating pockets, and a cam having an adjustment device placing the cam in different positions with respect to the pockets, the cam disposed at the conveyor and selectively contacting each of the pockets as each pocket respectively passes thereby. Each of the pockets is connected to the conveyor, receives the sheet from the sheet feeding device, and transports the sheet along at least a portion of the conveyor in the transport direction. Each of the pockets has a forward wall with an upper end portion, a rearward wall pivotably connected to the forward wall, and an adjustable gripper system for releasably holding the at least one sheet against the forward wall. The rearward wall and the forward wall together define an opening for receiving the sheet. The gripper system is disposed at the upper end portion and has a pivotable gripper shaft with a pivot axis and at least one gripper having a gripper body defining a plunger cavity, the gripper body connected to the gripper shaft for pivoting the gripper about the pivot axis, a gripper plunger slidably disposed in the plunger cavity and configured to hold the at least one sheet against the forward wall, and a cam follower actuated by the cam, the cam follower connected to the gripper plunger to displace the gripper plunger along the plunger cavity dependent upon a position of the cam.
In accordance with again an additional feature of the invention, the conveyor is an endless conveyor.
In accordance with still another feature of the invention, the sheet feeding device is disposed above the conveyor and the pockets.
In accordance with a concomitant feature of the invention, the forward wall is disposed downstream of the rearward wall with respect to the transport direction.
The present invention permits the grippers to be set to a set height while moving and to operate for a relevant distance at the set height. To change a gripper height, a movable setting cam is set for a new height and may also include a lock engagement device. The present invention provides a simple device for resetting gripper height and allows for manual re-setting of the gripper height.
“Rod” as defined herein can be any elongated structure. “Slide gear” as defined herein specifically includes any type of slidable interlocking structure, and may include a gear with an exterior star gearing, a single key or tooth exterior structure, or any other structure with which a ring gear may be fixed rotationally and with which a lock ring may be selectively fixed or free to rotate, include one having a ball-detent mechanism.
Other features that are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in an adjustable gripping device for adjustable sheet-receiving pockets, it is, nevertheless, not intended to be limited to the details shown because various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The construction and method of operation of the invention, however, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic perspective view of a sheet material conveying apparatus according to the invention;
FIG. 2A is a side view of a pocket according to the invention with certain elements omitted for clarity;
FIG. 2B is a side view of an enlarged detail of a gripper of the pocket of FIG. 2A;
FIG. 3 is a fragmentary perspective view of the pocket of FIG. 2A with certain elements omitted for clarity;
FIG. 4 is a different, fragmentary perspective view of the pocket of FIG. 3;
FIG. 5 is a fragmentary, partially exploded, cross-sectional view of a setting device for setting a finger height according to the invention;
FIG. 6 is a fragmentary, exploded, perspective view of the setting device of FIG. 5;
FIG. 7 is an enlarged side view of a detail of the setting device of FIG. 5;
FIG. 8A is a diagrammatic, partially cross-sectional, side view of a gripper system according to the invention; and
FIG. 8B is a diagrammatic, partially cross-sectional, side view of the gripper system of FIG. 8A in a different cam-adjusted position.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the figures of the drawings in detail and first, particularly to FIG. 1 thereof, there is shown a diagrammatic representation of a sheet material conveying apparatus 100 having an endless track 101 for transporting a plurality of pockets 10 in transport direction 17 . Each pocket 10 includes moveable fingers 90 for defining a pocket height, an individual height setting mechanism 8 , and a releasable lock mechanism 9 for height setting mechanism 8 .
At a setting area 1 , each pocket 10 can be set manually by setting mechanism 8 to move fingers 90 to at least one of two desired heights, for example, a setting for receiving 10½-inch folded products. Pockets 10 are stationary during setting, and the setting can occur outside setting area 1 as well, for example, by an operator moving about track 101 .
Alternatively, pockets 10 can be moved to setting area 1 , the apparatus can be stopped, and each pocket can be set. An automated robot for interacting with setting mechanism 8 also could be located at setting area 1 to move each pocket 10 to the proper height, as a pocket 10 is moved to and stopped at setting area 1 .
After a pocket is set to a desired height, setting mechanism 8 is then locked in place by lock mechanism 9 so that the pocket height is set. After all the pockets 10 are set, the pockets are moved to pass beneath a first sheet material feed station 2 where, for example, a folded cover section 6 of a newspaper or other printed product, also referred to as a jacket, is delivered into pocket 10 . At a second and optional sheet material feed station 3 , a second section 7 may be inserted between forward and rear portions of cover section 6 to form a final printed product 12 . This process can be repeated for any number of feed stations 2 , 3 to create a final product 12 having many nested sections 6 , 7 .
After receiving sections 6 , 7 , pockets 10 can then pass a release station 4 , which releases lock mechanism 9 . Setting mechanism 8 , which is, preferably, spring-loaded, then releases fingers 90 so that the bottom of pocket 10 opens, and finished products 12 are delivered, for example, to a conveyor belt 11 .
As pockets 10 continue past release station 4 , pockets 10 pass through a reset station 5 , which can include a movable incline reset ramp 25 for interacting with a reset cam follower 156 (see FIG. 3) of setting mechanism 8 and a lock engagement device 35 for locking lock mechanism 9 . Pockets 10 , which are preferably all set to a common height, are then reset to the common height by reset ramp 25 , and locked into place by lock engagement device 35 engaging lock mechanism 9 .
FIGS. 2A, 3 , and 4 show more details of pocket 10 .
Pocket 10 has an upper rear wall 54 and an upper front wall 52 , in between which is an opening 56 for accepting sheet material, for example, cover section 6 . Pocket 10 also has a side wall 44 . Pocket 10 also may have a lower rear wall 64 and a lower front wall 62 .
FIG. 2B is an enlarged view of the upper portion of pocket 10 illustrated in FIG. 2 A. FIG. 2B shows the area where forward lap 61 of a cover section 6 is held. To hold cover section 6 in place, a set of grippers 53 , 55 are located at the top of upper front wall 52 . Grippers 53 , 55 are shown coaxially disposed on a single shaft 57 , albeit in different rotational positions. However, alternatively, different sets of grippers can be disposed on different shafts, each being independently controlled. For example, grippers of one set can be longer than grippers of another set. Also, grippers 53 , 55 are shown at the top of upper front wall 52 . However, grippers 53 , 55 can be located at the upper third, fourth, or fifth of upper front wall 52 , depending upon the distance between the top of section 6 and a top of upper front wall 52 .
A non-illustrated control device pivots the shaft 57 holding the grippers 53 , 55 between an engaged position and a disengaged position. In FIG. 2B, one gripper 53 is shown in the disengaged position and the other gripper 55 is shown in the engaged position. In the engaged position, the gripper 55 holds the forward lap 61 of the cover section 6 so that it is fixed with respect to the upper front wall 52 . A cover section 6 being so held is shown diagrammatically in FIG. 2B with a dashed line. See also FIGS. 8A and 8B.
When the cover section 6 is first deposited in the opening 56 , the bottom (lowermost) edge of the cover section 6 rests at the junction between the fingers 90 and the upper rear wall 54 . In the open position of the pocket 10 shown in FIG. 2A, gravity causes the cover section 6 to rest entirely against the upper rear wall 54 . To grip the cover section 6 with the grippers 53 , 55 , the upper rear wall 54 is pivoted about axis 51 to contact the upper front wall 52 . Alternatively and/or additionally, the entire rear wall 54 , 64 can be displaced towards the front wall 52 , 62 . When the cover section 6 rests against the upper front wall 52 , the grippers 53 , 55 can be rotated into the engaged position and hold the cover section 6 in place against the upper front wall 52 . If the grippers 53 , 55 are adjusted so that they extend no further than the top edge of the rearward lap 63 of the cover section 6 (see FIGS. 8 A and 8 B), then the grippers 53 , 55 only grip the forward lap 61 of the cover section 6 . After engaging the forward lap 61 , when the upper rear wall 54 is moved back to the position shown in FIG. 2A, the forward lap 61 is held against the upper front wall 52 and gravity carries the rearward lap 63 of the cover section 6 along with the upper rear wall 54 , thus creating an opening between the forward lap 61 and rearward lap 63 for receiving another section 7 therein, for example, from the second sheet material feed station 3 .
Slidable with respect to upper front wall 52 is a rack 80 , on which the fingers 90 are supported. The fingers 90 are supported on the rack 80 by a pivot 96 attached to a first section 92 of the finger 90 . A second section 94 of the finger 90 can define a pocket bottom when the fingers 90 are in a closed position (as illustrated in FIG. 2 A). As most clearly shown in FIG. 4, rack 80 includes teeth 82 that interact with a gear 122 of a pinion 120 (FIGS. 3 and 4 ), which also includes a release cam 130 . Pinions 120 are located on a shaft 110 rotatably supported in wall 44 and wall 46 (only partially shown in FIG. 4 ).
At the wall 46 , an end 111 of shaft 110 passes through a setting ring gear 140 , of which only a first part is shown in FIG. 3 . Ring gear 140 has an interior surface that ensures rotation of ring gear 140 in a fixed relationship with a slide gear 180 (FIG. 5) that is in a fixed rotational relationship with shaft 110 . Slide gear 180 , however, can slide axially with respect to shaft 110 for selective interlocking with the lock ring 160 (interior to gear 140 and visible in FIG. 6) that forms part of lock mechanism 9 . Lock mechanism 9 also includes a pawl 209 for interacting with a single ratchet 164 on the exterior of ring 160 . Ring gear 140 is shown in FIGS. 2A, 3 , and 4 only in part, with a second outer gear section 182 (FIGS. 5 and 6) for interacting with a non-illustrated setting rod. The details of slide gear 180 and its interaction with ring gear 140 and lock ring 160 will be described in more detail with respect to FIGS. 5 and 6.
FIG. 3 shows how fingers 90 extend through the front wall. Release cam 130 can interact with a release surface 100 (FIG. 4) of finger 90 located in an opening 86 between teeth 82 when fingers 90 are fully lowered, so that the fingers 90 rotate away from the rear wall 54 , 64 and release any products in the pocket 10 . Release of the fingers 90 is similar to the release of the feet in U.S. Pat. No. 5,911,416 to Klopfenstein, which has been incorporated herein by reference.
FIG. 2A shows ring gear 140 interacting with a semicircular setting gear 150 . On one side of semicircular gear 150 is a reset cam follower 156 held rotationally at an axis 154 . The setting gear 150 pivots about an axis 152 .
As shown in FIG. 4, the semicircular gear 150 is attached to a spring 158 to spring-load the gear 150 in a direction 151 , as also shown in FIG. 2 A.
FIG. 5 shows an exploded view of certain details of the setting mechanism. End 111 of shaft 110 fits, passing through interior holes in ring gear 140 and lock ring 160 , into an interiorly toothed hole 147 of slide gear 180 . End 111 is fixed to a screw 145 that abuts slide gear 180 through a spring 146 . Thus, slide gear 180 can be moved against the force of spring 146 in the direction of arrow 240 so as to slide axially with respect to shaft 110 , however always remaining rotationally fixed with the shaft 110 .
Slide gear 180 has exterior star gearing 141 that matches interior star gearing 183 of ring gear 140 . Slide gear 180 and ring gear 140 thus rotate together at all times. Interior to slide gear 180 and ring gear 140 is lock ring 160 , which selectively engages, through an interior star gear 163 , exterior star gearing 141 of slide gear 180 when slide gear 180 is not moved axially against the spring force of spring 146 .
When moved axially against the spring force in direction 240 (see FIG. 5 ), slide gear 180 releases from lock ring 160 , which then is held only by pawl 209 but is freely rotatable with respect to shaft 110 due to a smooth inner surface section 162 that rests on shaft 110 .
Slide gear 180 has a raised portion 142 for interacting with a disengaging device of a non-illustrated setting rod to permit the slide gear 180 to be moved against the spring force of spring 146 .
Ring gear 140 has external gear teeth 181 for interacting with semicircular gear 150 (FIG. 2 A), as well as external gear teeth of the second outer gear section 182 for interacting with the setting rod.
Lock ring 160 has a single ratchet 164 on an external surface, which interacts with pawl 209 , as shown in FIG. 7 . An extension 210 extends outwardly from pawl 209 , for permitting pawl 209 to move between an upward and a downward position. The pawl 209 may be spring-loaded to favor one position, or to click into both positions.
As stated above, after a pocket 10 is set to a desired height, the setting mechanism 8 is then locked in place by the lock mechanism 9 so that the pocket height is set. After all the pockets 10 are set, the pockets 10 are moved to pass beneath at least one sheet material feed station 2 , 3 where, for example, sections 6 , 7 of a newspaper or other printed product are delivered into the pocket 10 .
Once the pocket 10 is set to a desired height, it typically cannot be adjusted to account for variations in the size of the sections 6 , 7 being placed therein. Prior art devices have been created to adjust for such variations by only adjusting the level or location of the bottom of the pocket. Thereby, raising or lowering the section 6 , 7 placed therein from below. However, no prior art device has used an adjustment of the grippers 53 , 55 to compensate for section 6 , 7 size variation.
As set forth above, up until the invention, there was a difficulty associated with separating the forward lap 61 of a first section 6 from the rearward lap 63 to create a pocket therebetween into which the second section 7 can be inserted or nested.
The invention adds a new adjustment mechanism to the grippers 53 , 55 .
FIGS. 8A and 8B diagrammatically illustrate a gripper adjusting system 70 . A single gripper 71 is depicted in FIGS. 8A and 8B for the sake of clarity. Nonetheless, system 70 can be expanded to many or all of the grippers used to grip forward lap 61 in a pocket 10 . Gripper 71 has a gripper body 72 , a gripper plunger 73 , and a reset spring 74 . Gripper plunger 73 includes a plunger body 75 with a nose, a rod 76 , and a cam follower 77 . The nose directly contacts and holds forward lap 61 of a section 6 , or holds the entire section 6 , 61 , 63 . Gripper body 72 is attached, preferably, fixedly but adjustably, to gripper shaft 57 , which is diagrammatically illustrated in FIGS. 2A and 2B. Thus, when shaft 57 rotates about its axis 58 in either rotation direction 59 , gripper 71 is rotated as well, and the nose of plunger body 75 either lifts away from upper front wall 52 to let go of or make room to grasp forward lap 61 or moves towards upper front wall 52 to grasp forward lap 61 of section 6 .
Gripper body 72 defines a cavity 78 having forward and rearward openings (with respect to an insertion direction of gripper plunger 73 ). The larger forward opening is sized to slidably fit the outer circumference of plunger body 75 . The smaller rearward opening is sized to slidably fit the outer circumference of rod 76 . Cavity 77 also has a rear, disk-shaped wall 79 to hold the rearmost end of reset spring 74 . Thus, while reset spring 74 can slidably fit into cavity 78 , it can only be inserted until it hits rear wall 79 . Alternatively, reset spring 74 can be integral with rear wall 79 .
Rod 76 of gripper plunger 73 is inserted into cavity 78 . Rod 76 has an outer diameter that is smaller than an inner diameter of reset spring 74 and, therefore, rod 76 passes through reset spring 74 unobstructed. Rod 76 also passes rear wall 79 and exits the second smaller opening of cavity 78 to project out of the top (with respect to the views of FIGS. 8A and 8B) of gripper body 72 . A cam follower 77 is attached to the end of rod 76 .
The other, forward, end of reset spring 74 contacts a rearward disk-shaped wall of plunger body 75 . As such, when plunger body 75 enters cavity 78 , reset spring 74 is compressed. In such an embodiment, plunger body 75 is biased to travel out of cavity 78 .
The rod 76 and cam follower 77 combination and connection can take various forms. For example, rod 76 can have an axle hole (extending into the plane of the views of FIGS. 8A and 8B) for receiving an axle or shaft that is then attached to a wheel-shaped cam follower 77 . Other equivalent attachment embodiments can be used as well.
FIGS. 8A and 8B illustrate how gripper system 70 works. A vertically adjustable gripper bite adjustment cam 26 is placed in the path of pockets 10 as they travel in transport direction 17 . Adjustment cam 26 is placed in a position similar to incline reset ramp 25 , in that, a portion of pocket 10 must contact adjustment cam 26 as the portion passes thereby. Before any pocket 10 reaches adjustment cam 26 , the bias of reset spring 74 pushes plunger body 75 out of the cavity 78 , for example, until the connection of rod 76 and cam follower 77 abuts the upper surface of gripper body 72 or to the fullest extent of an uncompressed reset spring 74 , whichever is smaller. In such a position, the nose of plunger body 75 is disposed at a given first distance 65 from the end of rearward lap 63 . Such an embodiment is illustrated in FIG. 8 A.
Adjustment cam 26 can be set to any vertical distance with respect to gripper body 72 .
In the view of FIG. 8A, adjustment cam 26 is set to a lowermost activating position. In such a position, when pocket 10 , including gripper system 70 , passes by adjustment cam 26 , cam follower 77 merely rolls along the upper surface 27 of adjustment cam 26 and does not contact ramp 29 . Such a position is called a lowermost activating position because adjustment cam 26 has no affect upon cam follower 77 if adjustment cam 26 is lowered any more than that shown in FIG. 8 A. In the lowermost activating position, the nose of plunger body 75 is at a distance 65 from the uppermost edge of rearward lap 63 .
In the view of FIG. 813, adjustment cam 26 is set to a position Δh higher than the lowermost activating position. In such a raised position, when pocket 10 , including gripper system 70 , passes by adjustment cam 26 , cam follower 77 first contacts ramp 29 and then rolls up and off ramp 29 onto upper surface 27 of adjustment cam 26 . This raised position of adjustment cam 26 has a specific affect upon cam follower 77 —cam follower 77 , attached to rod 76 , pulls rod 76 and, therefore, plunger body 75 further into cavity 78 of gripper body 72 . As such, the nose of plunger body 75 is raised vertically along the surface of upper front wall 52 to a distance 67 away from the uppermost edge of the rearward lap 63 .
In the lowermost activating position of FIG. 8A, the nose of plunger body 75 is shown at a distance 65 from the uppermost edge of rearward lap 63 . However, it is possible, due to a variation in size of rearward lap 63 , that the nose of plunger body 75 actually contacts rearward lap 63 and prevents rearward lap 63 from falling away from forward lap 61 to create the pocket for receiving an inserted section 7 . In such a situation, the printing press operator can use the invention and prevent this undesired condition by raising adjustment cam 26 such that the nose of plunger body 75 no longer contacts rearward lap 63 . Therefore, the invention allows an operator to raise a gripper system 70 of each of pocket 10 without having to manually adjust each gripper 71 of each pocket 10 .
The gripper system 70 shown is a linear raising system. In other words, if adjustment cam 26 is raised by Δh, then plunger body 75 will be pulled into cavity 78 along a distance equal to Δh. Thus, the difference between 65 and 67 is Δh. Gripper system 70 does not have to be a linear raising system, however. It is envisioned to have, if desired, a more complex lever system such that a small raising of the adjustment cam 26 results in a correspondingly larger or smaller raising of the plunger body 75 .
Ramp 29 of adjustment cam 26 is depicted as being relatively small and shallow. Of course, ramp 29 can have any length or be at any angle greater than 0 degrees and less than 90 degrees. However, preferably, the length of ramp 29 is at least equal to a radius of the cam follower 77 . Also preferable is for the ramp angle to be between 30 and 60 degrees, in particular, to be between 30 and 45 degrees. Adjustment cam 26 is also shown in FIGS. 8A and 8B with a flat front surface 30 . In alternative embodiments, the forward-most end of the ramp 29 can be even lower than the illustration of FIGS. 8A and 8B. Preferably, the forward-most end of ramp 29 is approximately level with lower surface 28 of adjustment cam 26 and, where cam follower 77 is wheel-shaped, the forward-most portion 30 of adjustment cam 26 is rounded to permit smooth contact between ramp 29 and cam follower 77 .
Vertical movement of the adjustment cam 26 , therefore, determines how far gripper plunger 73 is pulled into cavity 78 , thus, pulling the nose of plunger body 75 upward along front upper wall 52 and upward along section 6 , preferably along forward lap 61 .
Vertical movement of adjustment cam 26 can be effected by any device that can raise or lower rod 76 .
In the embodiment shown, the bottom of cam follower 77 contacts upper surface 27 of adjustment cam 26 . Alternatively, the top of cam follower 77 can contact lower surface 28 of adjustment cam 26 . The above-noted example including an axle hole and wheel-shaped cam follower 77 can be used both for contacting upper surface 27 and bottom surface 28 of adjustment cam 27 . But, an embodiment can be made so that cam follower 77 only contacts lower surface 28 . For example, rod 76 can have a groove with a width and cam follower 77 can be a wheel rotatably disposed in such a groove, the wheel 77 having a width less than the groove width. Wheel 77 can be attached to rod 76 with an axle and cotter pin assembly, for example. In such an embodiment, the reset spring 74 could be positioned not to bias the gripper plunger away from the cam follower 77 , but, instead, to bias the gripper plunger 73 in the direction of the cam follower 77 . Alternatively, the reset spring 74 could have an adjustment device that limits a bias thereof.
The invention better separates the forward lap from the rearward lap by adjusting grippers in a vertical direction with respect to a pocket so that the forward lap is gripped in the most efficient place.
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An adjustable gripper system for releasably holding at least one sheet against a surface includes a pivotable gripper shaft with a pivot axis and at least one gripper having a gripper body defining a plunger cavity, the gripper body connected to the shaft for pivoting the gripper about the axis, a gripper plunger slidably disposed in the cavity and holding the sheet against the surface, and a cam follower actuated by a cam. The cam follower is connected to the gripper plunger to displace the gripper plunger along the cavity dependent upon a position of the cam. The system can be part of a sheet-collating pocket having a forward wall and a rearward wall pivotally connected thereto and, together, defining an opening for receiving the sheet, which can be part of a sheet-collating machine having the cam, a conveyor, at least one sheet feeding device, and many of the pockets.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention concerns a method and a device in order to automatically determine a perfusion with a magnetic resonance system. Moreover, the present invention concerns a magnetic resonance system designed with the inventive device as well as an electronically readable data medium encoded with programming instructions that cause the method to be executed by a computer.
[0003] 2. Description of the Prior Art
[0004] MR perfusion methods (methods to determine perfusion by means of a magnetic resonance system) are used, for example, in order to measure a blood flow in various body regions, for example in the head (cerebral blood flow (CBF)). CBF is the volume of arterial blood (mL) which flows in 100 g of tissue per minute; in humans a typical value for CBF in the brain is
[0000]
60
mL
100
g
×
min
.
[0000] If the density of the brain is set near to 1 g/mL, CBF in humans is 0.6
[0000]
mL
mL
×
min
or
0.01
s
-
1
.
[0000] With reference to a volume, the dimensions of the CBF are simply the reciprocal of the time, i.e. a rate constant that defines the supply of a tissue volume with arterial blood. CBF has no causal connection with the quantity of the blood within a volume (blood velocity). According to the prior art, ASL methods (“Arterial Spin Labeling” methods) are used during a determination of the perfusion by means of a magnetic resonance system, wherein the water contained in blood is shifted into a particular magnetic state (normally an inverted magnetization); in short: the blood is “labeled” in order to be able to differentiate these blood particles which flow into a considered volume element from other tissue in this volume element. MR images are thereby generated with a perfusion-sensitive image sequence, and MR control images are generated with a control imaging sequence. The perfusion information is thereby represented only by a slight alteration in an image contrast which is present between the labeled blood particles flowing into a region of interest (which labeled blood particles exhibit the particular magnetic state) and the tissue in this region from which the MR images are acquired. A perfusion signal typically exhibits an intensity in the range of only a few percent of the entire intensity of the corresponding MR image. The acquisition of images of a relative perfusion or of images for calculation of a quantitative perfusion is therefore prone to artifacts. For this reason, at present multiple MR images for acquisition of a slight perfusion signal must be generated over multiple minutes, from which a series of MR images characterized with perfusion information and control images (without perfusion information) result over time. An image with perfusion information and a corresponding control image are respectively generated in alternation.
[0005] In order to generate MR images in which the perfusion is shown from these images with perfusion information and the corresponding control images, according to the prior art the difference is taken between an image embodying perfusion information and its corresponding control image. The difference value thereby obtained is then averaged over the series of images. A scaling or calibration factor is determined in order to arrive at a relative or quantitative perfusion information in the resulting MR images.
[0006] The quality of the conventionally calculated MR images shown perfusion information is low since the methods for determination of perfusion according to the prior art are very error-prone, for example with regard to artifacts or other interferences.
SUMMARY OF THE INVENTION
[0007] An object of the present invention is to improve the quality of the MR images depicting perfusion information.
[0008] The object is achieved In accordance with the present invention by a method for automatic determination of perfusion with the use of a magnetic resonance system, wherein multiple first MR data sets are generated in succession which are determined with a perfusion-sensitive imaging sequence of a volume element in a body of an organism. Multiple second MR data sets are determined in succession from the same volume element in a similar manner with a control imaging sequence, in particular with a perfusion-insensitive imaging sequence. The first MR data sets and the second MR data sets are evaluated by means of a statistical analysis in order to determine the perfusion in the volume element.
[0009] As used herein, a perfusion-sensitive imaging sequence means that particles subject to a perfusion are shifted into a first magnetic state such that these particles, when they flow into the volume element, differ from other particles (for example from the tissue not subject to a perfusion) upon acquisition of the first MR data by the magnetic resonance system. The particles subjected to the perfusion are shifted into a second magnetic state by the control imaging sequence, this second magnetic state being easy to differentiate from the first magnetic state in the determination of the second MR data by the magnetic resonance system, and being advantageously insensitive to perfusion effects.
[0010] In contrast to the prior art, in the method according to the invention no difference is taken between the first MR data sets and the second MR data sets in order to determine the perfusion; rather, the entirety of the first MR data sets and second MR data sets is subjected to a statistical analysis. Because, according to the invention, no difference is taken between the first MR data and the second MR data, a corresponding absolute value can advantageously also be calculated from the first MR data and the second MR data sets, and this absolute value can be used to determine the perfusion.
[0011] In the method according to the invention, a sequence of MR images is generated in particular starting from the first MR data sets and the second MR data sets, and a signal curve is determined for individual, respectively corresponding image points or voxels within these MR images. This signal curve is then advantageously evaluated by means of statistical analysis. The statistical analysis determines coefficients which are then analyzed in order to determine information about the perfusion.
[0012] In a preferred exemplary embodiment, a first MR data set followed by second MR data set followed again by first MR data set, etc. are acquired in alternation for the volume element. In other words, an MR image is generated by the magnetic resonance system with the perfusion-insensitive imaging sequence and an MR image with the control imaging sequence, are respectively generated in alternation. The signal curve of a voxel exhibiting a perfusion relative to a perfusion-sensitive value detected by the magnetic resonance system then exhibits a zigzag shape since the value in the first MR data set exhibits a high measurement value, for example, and correspondingly exhibits a comparatively low measurement value in the second MR data set. This zigzag signal curve can then be evaluated with statistical analysis in order to determine the perfusion information for the corresponding voxel.
[0013] The statistical analysis can be conducted according to the General Linear Model or according to the Student's t-Test. Other statistical methods such as, for example, a cross-correlation can alternatively be used.
[0014] A relative perfusion information or even a quantitative perfusion information can thereby be determined with the General Linear Model while the Student's t-Test is in particular used in order to draw a conclusion of whether the intensity of an image element in the first MR data set differs from the intensity of a corresponding image point in the second MR data set. Moreover, conclusions can be drawn about the quality of the first and second MR data which can then advantageously be used in order to exclude specific first and/or second MR data from the determination of the perfusion information (for example due to poor quality) and/or to assign an operator to acquire additional first and second MR data since sufficient first and second MR data of a satisfactory quality are not yet present.
[0015] Statistical measured values of a contrast within inventively generated MR images which correlate directly with a contrast-to-noise ratio with regard to the perfusion information in the MR images can specifically be calculated with the Student's t-Test. A display of these measured values or of the contrast-to-noise ratio occurring in real time enables an operator to track a quality of the perfusion information within the inventively generated MR images dependent on the time in which the first and second MR data are acquired.
[0016] To improve the perfusion information by statistical analysis, at least one model function or a function modality can be added to the statistical analysis as at least one regressor. The at least one regressor corresponds to one or more regressor from a group that includes the following regressors:
Regressors that are derived from measurement results acquired by the magnetic resonance system. For example, if systematic errors of the magnetic resonance system can be deduced from the measurement results, these errors can be taken into account by the statistical analysis via a corresponding model function. Movements of an organism for which the determination of the perfusion is implemented can be detected via the measurement results as long as movements are of a rigid body (thus no deformation of the body occurs in the movement). Regressors that are detected by devices not belonging to the magnetic resonance system. If interferences which influence the acquisition of the first and second MR data are detected by these devices, these interferences can be taken into account by the statistical analysis by a corresponding model function. Regressors that are derived from functional changes or variations of the organism. The “functional change” is in particular a change of a physiological state of the organism or a functional activity of the organism. An example of a functional activity is a periodic movement of a body part (for example a finger) of the organism. The functional activity can thereby be detected via variations of the perfusion, via variations of a cerebral blood flow or via variations in the BOLD (“Blood Oxygenation Level Dependent”) effect.
[0020] By a regressor, what is thereby understood (corresponding to the statistical analysis) is an explanatory variable which exhibits an explanatory influence on a variable to be explained (in particular on the perfusion in the present invention). There are unwanted or interfering regressors such as, for example, unplanned movements of the organism, but also desired or, respectively, useful regressors such as, for example, a planned functional activity of the organism. Although both unwanted and desired regressors can be taken into account by the statistical analysis in the determination of the perfusion according to the invention, the desired regressors can be planned better or more precisely in the General Linear Model, for example, since it known beforehand that the corresponding regressor exists and when it occurs.
[0021] These model functions, together with a perfusion model with which a conclusion can be drawn about the perfusion, form an input for a multi-dimensional statistical analysis according to the General Linear Model.
[0022] According to the invention, the group of regressors can also include the following regressors:
A movement of the organism. This means an unplanned movement. A scanning stability of the magnetic resonance system. The acquisition of the first and second MR data sometimes undergoes certain fluctuations if a stability with which the magnetic resonance system acquires the first and second MR data is not constant. A breathing of the organism. At least one part of the organism moves dependent on the breathing. A heart beat of the organism. At least the heart of the organism moves dependent on the heart beat, and on the other hand a flow speed of the blood also depends on the heart beat, for example.
[0027] The method according to the invention is not only able to generate perfusion information, but also can determine the following additional results:
Information about a reliability of results determined by the inventive method for the corresponding volume element. For example, a quality declaration of how good specific quantitative information determined according to the invention (for example) can be made by means of the Student's t-Test. Information about a contrast-to-noise ratio for a specific image point within the volume element. A conclusion about the quality of the perfusion information determined by the method according to the invention is thereby advantageously possible. Information about the following artifacts:
a breathing of the organism a heart beat of the organism a movement of the organism a functional activity of the organism the BOLD effect.
[0036] The information about the artifacts thereby comprise a conclusion about the scope or the extent of the artifacts, for example, which in turn allows a conclusion of the quality of the determined perfusion information. For example, if it is detected through the statistical analysis that the breathing and/or the movement of the organism was disproportionately severe in the acquisition of the first and second MR data, such that the quality of the perfusion information could thereby be affected, this information can be valuable for an evaluation of the perfusion information.
[0037] According to the invention, images (maps) can also be generated that represent an intensity and/or statistical significance of the various regressors separated per regressor. Which voxels within a specific MR image are influenced by the breathing, the heart beat, a movement, etc. can be derived via this images, for example.
[0038] A quality control of the acquired first and second MR data sets can be effected with the aid of the results described in the preceding. For example, depending on the results, already generated first and/or second MR data sets can additionally be excluded from the method, i.e., they are not analyzed. Moreover, further first and/or second MR data can be generated if the results suggest this. For example, this can be the case when the statistical analysis detects that a scope or an extent of one or more artifacts lies above a predetermined threshold. The quality of the detected first and second MR data sets is strongly influenced by a too-severe movement of the organism that is too severe, for example, wherein this movement itself is detected in the evaluation of the MR data. A false positive or a false negative perfusion information can also be derived from the results described above and be used for quality control.
[0039] With the method according to the invention, MR images which contain the following information can also be generated through the statistical analysis:
A change of the blood oxygenation of a tissue of the considered volume element. Since the BOLD effect has an effect on the results acquired by a magnetic resonance system, the change of the blood oxygenation can be derived from the first and second MR data. A functional activity of the organism. Since the functional activity of the organism likewise exhibits an effect on the results acquired by the magnetic resonance system, a scope of a functional activity can also be derived from the first and second MR data. A result of a correlation between the BOLD effect and a specific functional activity. Since the statistical analysis is already used to determine the perfusion information, it is advantageously no great additional effort to also determine the correlation between the BOLD effect and a specific functional activity.
[0043] According to the invention, MR images that contain the perfusion information and are generated starting from the first and second MR data can be continuously generated in real time so that they are continuously updated with new first and second MR data acquired according to the invention. In other words, a first series of MR images which represent the perfusion information is in particular generated when the statistical analysis has determined in advance that the perfusion information shown in this first series possesses a corresponding quality. This first series is then updated continuously starting from the already determined first and second MR data and further newly acquired first and second MR data.
[0044] The first and second MR data sets can naturally also be first evaluated after the conclusion of the acquisition of all first and second MR data sets.
[0045] The MR images generated by the method according to the invention and which exhibit the perfusion information can be generated either starting from the entirety of the first and second MR data which were acquired according to the invention or can be generated starting from a specific sub-set of the first and second MR data sets. If the MR images are generated from a sub-set of the first and second MR data sets, this sub-set in particular contains no first and second MR data sets, which are unusable according to the statistical analysis for determination of the perfusion information. Moreover, this sub-set comprises as up-to-date as possible first and second MR data sets, such that the oldest first and second MR data sets can be periodically removed from this sub-set, for example.
[0046] If the statistical analysis is executed with the General Linear Model, coefficients of this General Linear Model can be scaled such that a declaration about a relative perfusion and/or a declaration about an absolute perfusion can be made with these coefficients.
[0047] The present invention also encompasses a device for a magnetic resonance system for automatic determination of perfusion. This device has a control unit to control the magnetic resonance system, a receiver device to receive multiple first and second MR data sets which are acquired by the magnetic resonance system (in particular by local coils), and an evaluation device in order to evaluate these first and second MR data sets and to generate MR images therefrom. The device is designed such that it controls the magnetic resonance system to cause the magnetic resonance system to acquire or record the first and second MR data sets. The control device controls the magnetic resonance system such that the magnetic resonance system effects a perfusion-sensitive imaging sequence with regard to the volume element for the acquisition of the first MR data sets and effects a control imaging sequence, in particular a perfusion-insensitive imaging sequence with regard to the volume element, for the acquisition of the second MR data set. The device is able to conduct a statistical analysis of the first and second MR data sets with the aid of its evaluation device in order to determine the perfusion in the volume element.
[0048] The advantages of the device according to the invention significantly corresponding to the advantages of the method according to the invention.
[0049] The present invention also encompasses a magnetic resonance system that embodies the device described above.
[0050] The present invention also encompasses an electronically readable data medium (for example a DVD) on which is stored electronically-readable control information (in particular programming instructions). All embodiments of the method described above can be implemented when this control information is read from the data medium and stored in a controller of a magnetic resonance system.
[0051] The acquisition and the evaluation of MR images that contain perfusion information are significantly improved with the present invention compared to the prior art. According to the invention, information about the precision of the determined results (for example quantitative perfusion information), about a contrast-to-noise ratio and about a scope of specific artifacts can also be determined in addition to perfusion information. This information can be presented in the form of images.
[0052] The present invention is in particular suitable for a determination of perfusion or flows of liquids in the body of an organism by means of a magnetic resonance system in order to make the perfusion visible in MR images. Naturally, the present invention is not limited to this preferred application field; rather it can also be used in order to determine further information or results such as, for example, a change of the blood oxygenation of a tissue, an extent of a functional activity or the quality of information presented in an MR image. In general the method according to the invention can be used when information is to be determined from data sets which contain this information and from control data sets which primarily differ from the data sets in that they do not exhibit information.
BRIEF DESCRIPTION OF THE DRAWINGS
[0053] FIG. 1 shows a magnetic resonance system according to the invention with a device according to the invention.
[0054] FIG. 2A shows a time series of first and second MR data sets or MR images, obtained in accordance with the invention.
[0055] FIG. 2B shows a corresponding General Linear Model of the first and second MR data sets.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0056] FIG. 1 shows an exemplary embodiment for a magnetic resonance system 5 with which an automatic determination of perfusion is possible. The core of this magnetic resonance system 5 is a scanner (MR data acquisition unit) 3 in which is positioned a patient O on a recumbent board 2 in an annular basic field magnet (not shown) which surrounds a measurement volume 4 .
[0057] The recumbent board 2 can be displaced in the longitudinal direction, i.e. along the longitudinal axis of the scanner 3 . A whole-body coil (not shown), with which radio-frequency pulses can be emitted and also received is located within the basic field magnet in the scanner 3 . Moreover, the scanner 3 contains gradient coils (not shown) in order to be able to apply a magnetic field gradient in each of the three spatial directions.
[0058] The scanner 3 is controlled by a control device 6 which here is shown separate from the scanner 3 . A terminal 7 that includes a screen 8 , a keyboard 9 and a mouse 10 is connected to the control device 6 . The terminal 7 in particular serves as a user interface via which an operator operates the control device 6 and therefore the scanner 3 . Both the control device 6 and the terminal 7 are components of the magnetic resonance system 5 .
[0059] Moreover, a DVD 14 is shown in FIG. 1 on which software is stored with which the method according to the invention can be executed when the software has been loaded into the control device 6 .
[0060] Furthermore, the magnetic resonance system 5 has all further typical components or features such as, for example, interfaces for connection of a communication network (for example of an image information system) or the like. All of these components are not shown in FIG. 1 for better clarity.
[0061] An operator can communicate with the control device 6 via the terminal 7 and thus provide for an implementation of desired measurements in that, for example, the scanner 3 is controlled by the control device 6 such that required radio-frequency pulse sequences are emitted by the antenna and the gradient coils are switched in a suitable manner. First MR data sets 21 and second MR data sets 22 from the scanner 3 are also acquired by the control device 9 and converted into corresponding images (MR images) in an evaluation unit 13 (which is a module of the control device 6 ). These images are then shown on the screen 8 and/or stored in a memory or sent over a network, for example.
[0062] The recumbent board 2 can be moved by motors within the scanner 3 by means of the control device 6 . The control device 6 has an activation unit 11 that automatically moves the recumbent board 2 through scanner 3 so that it occupies various positions within the scanner 3 . Moreover, the activation device 11 ensures that a defined magnetic field gradient is applied a radio-frequency shield which essentially corresponds to the magnetic resonance frequency is simultaneously emitted by the whole-body coil. Alternatively, the radio-frequency signal can be emitted with a specially designed local coil (transmission/reception coil).
[0063] The first MR data set 21 and the second MR data set 22 from a corresponding volume element 15 in the body of the patient O are then determined and acquired with a local coil 1 with the aid of an acquisition channel 12 , or a measurement device of the control device 6 . MR images in which a perfusion is shown are generated in the evaluation device 13 from these first MR data set or MR images 21 and second MR data set or MR images 22 .
[0064] A time series of first MR images 21 and second MR images 22 is shown in FIG. 2 a . Arterial blood within a head of the organism O which flows in a considered voxel 19 was thereby labeled by means of ASL (“Arterial Spin Labeling”) in the acquisition of the first MR images 21 , such that blood flowing into the voxel is differentiable from the tissue within the volume element. In contrast to this, no such labeling of the arterial blood occurs in the acquisition of the second MR images. As shown in FIG. 2A , a second MR image 22 is respectively acquired after an acquisition of a first MR image 21 , and a first MR image 21 is acquired after each second MR image 22 . In other words: the series of first and second MR images 21 , 22 acquired over time alternates: first MR image 21 , second MR image 22 , etc.
[0065] The white rectangle labeled with the reference character 19 corresponds to the voxel in which the perfusion is currently determined. It s noted that the volume element 15 in FIG. 1 is shown within a leg of the patient I while the voxel 19 in FIG. 2A is arranged within the head of the patient.
[0066] The General Linear Model is shown in FIG. 2B . Individual component values of the left vector Y (y 1 , y 2 , y 3 , etc.) thereby correspond to individual measurement values with regard to the voxel 19 of correspondingly many first and second MR images 21 , 22 in chronological order. In other words: the vector Y corresponds to a signal curve over time of an image point or voxel 19 of successive MR images 21 , 22 .
[0067] The matrix standing directly to the right of the equals sign contains a perfusion model 18 on the one hand and three function models 17 on the other hand. The perfusion model 18 is thereby a vector which possesses the values 1, 0, 1, 0, etc., such that a grey line corresponds to a 1 and a white line corresponds to a 0 in FIG. 2B . A value of 1 thereby means that the corresponding component of the Y-vector contains perfusion information and the value 0 states that the corresponding component of the Y-vector contains no perfusion information.
[0068] The three function models 17 are a function model to depict a stability or, respectively, instability of a scanning behavior of the acquisition device 12 . A function model to depict the heart beat of the patient O and a function model to depict a functional activity (such as, for example, a periodic movement of a finger of the patient O) can likewise be used here. The vectors 17 representing a corresponding function model thereby normally respectively exhibit a 1 as a component value when the instability exists or, respectively, the heart beats just then, or the finger is moved or a 0 when this is not the case. For example, if the BOLD effect exhibits an increased value for some time during the acquisition of the first and second MR images 21 , 22 , a corresponding vector (not shown) of a function model representing the BOLD effect would have a 1 as a component value in this time period both for the corresponding first MR images 21 and for the corresponding second MR images 22 .
[0069] The matrix composed of the perfusion model 18 and the three function models 17 is also designated as a design matrix.
[0070] It is noted that a component value −1 can also be used instead of a component value of 0 in the General Linear Model, such that the vectors of the design matrix 17 , 18 then exhibit the component values −1 and +1.
[0071] The vector with which the design matrix 17 , 18 is multiplied contains coefficients μ, T 1 , T 2 , T 3 or, respectively, quantitative parameters to be determined by the statistical analysis with the General Linear Model 16 . The parameter μ indicates a quantitative value for the perfusion in the voxel 19 . In the same manner the parameter T 1 indicates a quantitative value for the stability of the scanning behavior of the acquisition device 12 , the parameter T 2 of a quantitative value for the heart beat of the patient O and the parameter T 3 indicates a quantitative value for the functional activity of the patient O with regard to the voxel 19 .
[0072] A vector U (u 1 , u 2 , u 3 , . . . ) contains (represents) remainder errors which are caused by noise or are formed by errors that are not depicted by the function model 17 .
[0073] The determination of the perfusion or, respectively, of the parameter Ξ as well as of the parameters T 1 , T 2 , T 3 thereby ensues by means of the General Linear Model adapted due to the design of the design matrix 17 , 18 , starting from the corresponding measurement values for different voxels, such that ultimately information about the perfusion (and about the stability of the scanning behavior, the heart beat and the functional activity) can be determined and presented in a larger volume segment. The parameter μ can the be scaled such that it represents a relative or even and absolute perfusion value (unit:
[0000]
(
unit
:
mL
100
g
×
min
)
.
[0074] With an appropriate selection of a function model 17 , probabilities and other statistical measured values which represent a measured value of the reliability or of the quality of the results (for example perfusion) determined per voxel can also be determined with the General Linear Model by the corresponding coefficients T 1 , T 2 , T 3 .
[0075] Although modifications and changes may be suggested by those skilled in the art, it is the intention of the inventors to embody within the patent warranted hereon all changes and modifications as reasonably and properly come within the scope of their contribution to the art.
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In a method and a device for automatic determination of perfusion by using a magnetic resonance system, multiple first MR data sets are thereby acquired from a volume element over time with a perfusion-sensitive imaging sequence, and multiple second MR data sets of the same volume element are acquired over time with a control imaging sequence, in particular a perfusion-insensitive imaging sequence. These first MR data sets and the second MR data sets are subjected to a statistical time series analysis in order to determine the perfusion in the volume element.
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BACKGROUND OF THE INVENTION
This invention relates to a device for dispensing medicaments.
Conventional administration of drugs takes two general forms--periodic injection or ingestion, or continuous infusion. Periodic administration has the disadvantage that the drug level within the body varies from above optimum initially and falls below optimum, resulting in poor maintenance of the patient and inefficient use of the drug. Increasing the number of applications minimizes the adverse effects of high dosages and improves efficiency but results in higher costs and more inconvenience to the patient. Infusion therapy can provide a relatively constant dose level but is limited by the bulky nature of the medicament preparation and by the expert care needed for safe administration.
In recent years, polymeric membranes have been used to encapsulate medicament preparations to slow and control the release of the active substance, allowing the body to be maintained at the optimum level over a relatively long time. Controlled release formulations have two deficiencies which limit their use--the amount of drug that can be encapsulated and implanted is relatively small, and it is not possible to vary the rate of release of the drug. The inability to vary the release rate limits the use to those agents which have a constant demand rate or a constant clearance rate, and is not entirely satisfactory for insulin therapy.
Insulin is required by the body in varying amounts with a greater amount being required during and immediately after a meal when the glucose level rises. The controlled release formulation while maintaining a basal amount of insulin in the blood, cannot increase the amount of insulin to counteract the increased glucose level after a meal.
It has been proposed, for example, in U.S. Pat. No. 3,923,060 to E. H. Ellinwood, Jr., to provide an implantable apparatus for dispensing medications within the body over a long period of time in accordance with the needs of the patient by providing sensors which monitor a particular body condition and powered dispensing means responsive to the sensed data. The aforesaid patent also describes a device specifically for dispensing insulin, having two dispensing elements, one to dispense a daily average dose on a regular basis and one to dispense intermittently when the need arises. The device described requires that each dispensing element is provided with a separate pump, pump driving means and associated logic circuit. This arrangement requires two separate dispensing units and associated energizing means, and in the event of an interruption of energy, no medication would be dispensed.
SUMMARY OF THE INVENTION
It has been found that a relatively simple medicament dispensing device can be provided with the use of a permeable elastic material in which delivery of the medicament can be increased by repeated compression of the permeable elastic material to provide a controllable delivery rate.
It has also been found that repeated compression of the permeable material can increase delivery without the use of check valves for preventing back flow. Although the reason for this is not understood with certainty, it is believed that as the piston compresses the elastic permeable material, the portion of the material in contact with and near the piston surface is compressed to a degree that it is rendered relatively impermeable in comparison with the material at the opposite outlet end, and thereby reduces backflow while allowing flow in the direction of the outlet.
The present invention provides a device for dispensing a medicament comprising: an elastic material permeable to the medicament; a housing for confining the elastic material, said housing having an inlet for connection with a supply of the medicament, and an outlet for delivery; a reciprocatable piston for repeatedly compressing the elastic material, and means for activating said piston; the device being operative to deliver a basal rate of the medicament when the piston is inoperative, and an augmented rate when the elastic material is compressed.
The present invention is well suited for delivering a highly concentrated medicament preparation thereby facilitating the design and use of an implanted device.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partly sectional view of a device for dispensing a medicament in accordance with the present invention.
FIGS. 2 and 3 are partly sectional views of alternative embodiments of a dispensing device.
FIG. 4 is a schematic illustration of a system incorporating the dispensing device of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, the medicament dispensing device 1 includes an elastic material 2 that is permeable to the medicament. The permeable elastic material 2 is contained by a suitable housing 3 having an inlet 4, for connecting with a supply of the medicament, and an outlet 5. Reciprocatably disposed within a cylindrical portion 6 of the housing 3 is a piston 7 for compressing the elastic permeable material 2. The piston 7 is made of a magnetic material and compression of the elastic material 2 is effected by means of a solenoid coil 8. The permeable material 2 is confined at the outlet by a suitable porous or apertured plug 9. Means, in the form of a passageway 10, is provided for allowing the medicament to bypass the piston 7 to the permeable material 2.
In operation, with the inlet 4 connected to a suitable supply of a medicament, the concentration difference and/or the pressure difference across the permeable elastic material 2 results in diffusion or bulk transport through the material 2. The medicament flows through the passageway 10, and also around the outside of the piston if sufficient clearance is provided, and exits at outlet 5. Hereinafter, the flow that takes place while the solenoid-piston is inactive is referred to as basal delivery. The basal rate for a particular medicament is a function of the concentration and/or pressure difference across the permeable elastic material, and the permeability of the material.
Augmented delivery is achieved by repeated compression and decompression of the material 2 by means of the piston 7. Compression is effected by the magnetic piston 7 when current is applied to the solenoid coil and decompression occurs when current supply is interrupted. The augmented delivery rate is a function of the permeability and mechanical properties, such as the modulus of elasticity, of the material, and also on the solenoid design. For a given device the augmented delivery rate is a function of the frequency of compression and the displacement of the material with each cycle of compression. The displacement can be varied by varying the current through the solenoid coil.
FIG. 2 illustrates another embodiment of the present invention. The device 20 is basically similar to that of FIG. 1, and has a piston 21 connected to solenoid core 22 for compressing the permeable elastic material 23, an inlet 24 and outlet 25 within a housing 26.
For basal delivery, the piston 23 is in the upper position, as shown, and the medicament enters at inlet 24, diffuses through the material 23 and exits at outlet 25. The inlet 24 is positioned in the housing 26 so as to be alternately blocked and unblocked by the piston 21 in the augmented delivery mode. As the piston 21 travels downward, it blocks the inlet 24 reducing backflow as the material 23 is compressed and thereby increasing efficiency.
FIG. 3 shows another embodiment of the invention in which the outlet portion 31 of the device, including the piston 32 and permeable elastic material 33, has a cross-sectional size smaller than that of the inlet portion 34 including the solenoid core 35. This embodiment is particularly suitable for the administration of a medicament directly into a small vessel.
Preferably the permeable elastic material will have a tensile modulus of elasticity of not greater than 10 4 psi in order to minimize power consumption. Examples of suitable materials include: polyvinyl alcohol hydrogels, polyhydroxyethyl methacrylate hydrogels, polyacrylamide gels, agarose gels, gels made from polyelectrolytes, acrylic polymers, vinyl pyridine, vinyl pyrrolidone, cellulose and cellulose derivatives, or polyurethane and other polymeric foams.
FIG. 4 illustrates schematically a complete system for administering a medicament, which could, for example, be insulin to treat diabetes mellitus. In this system the dispensing device 40, which may be of the type illustrated in FIGS. 1, 2 or 3, has its outlet 41 positioned in the body to be treated. Alternatively the entire dispensing device may be implanted in the body 42. The dispensing device 40 is supplied with a medicament from a suitable reservoir 43 which may also be implanted in the body.
In operation, a basal rate of a medicament, such as insulin for example, is delivered while the solenoid-piston is inoperative. When increased insulin delivery is required, such as during and after meals, the solenoid-piston is activated by control means 44 which provides a periodic pulse of current of selected magnitude and frequency to provide the desired augmented flow. The controller 44 may be activated manually or by a suitable programer 45. The programer 45 may, for example, provide for progressively decreasing delivery of insulin from the beginning of a meal to a predetermined time later. Alternatively, or in addition, the glucose concentration may be monitored by a suitable sensor 46 to control the amount of insulin delivered.
In addition to treating diabetes mellitus, the present invention may be used for various other conditions where variable delivery rate is required, such as cardiac function control or cancer chemotherapy.
EXAMPLE
A 7 mm outside diameter glass tube was capped at one end with a sintered glass disc. A 3 mm thick cylindrical section of flexible polyurethane foam (HYPOL®, W. R. Grace & Co.) made from 100 parts FHP 3000, 70 parts water, and 1.0 part L520 (Union Carbide) was forced into the tube. A 2.5 cm long mild steel rod (4.8 mm diameter) with a 1.4 mm diameter central bore was used as piston. Two thousand turns of number 36 enamelled copper wire was wrapped about the outside of the tube, so that there was a 2 mm offset between the end of the coil and the end of the piston. A piece of transformer iron was then wrapped about the coil to make an external field path.
A feed solution consisting of 143 ppm amaranth (a tracer molecule) and 0.35 units/ml of insulin in phosphate buffered saline (pH 7.4) was prepared within a sterile infusion bottle. The concentration of amaranth was determined by quantitative ultraviolet spectroscopy, at a wavelength of 220 nm, comparing the absorption of a test solution with the absorption of a set of standards. The addition of a small quantity of insulin labelled with radioactive iodine (I 125 ), enabled changes in the concentration of insulin to be determined. The activity of an insulin solution measured in a gamma counter was compared with that of the feed solution.
The remainder of the glass tube was filled with the solution as was a tube connecting with the inverted feed bottle. The outlet end of the glass tube was placed in 100 ml of well stirred saline, the level of which was maintained a constant amount (17 cm) below the level of the feed solution.
Characterization of the device consisted of following the amaranth concentration and insulin activity in the product receiver as a function of time in the absence of any current through the coil (basal delivery) and in the presence of such a current (augmented delivery).
For the particular device described above, the basal delivery rate of amaranth was 18.5 micrograms per minute or 0.027 grams/day and the basal delivery rate of insulin was 5.5×10 -2 units/minute or 79 units/day. With a current of 620 mA passing through the coil (60 volts), and the foam compressed 26 times per minute, the delivery rate of amaranth was increased to 54.5 micrograms per minute. The delivery rate of insulin was increased under these conditions to 0.17 units/minute. The amaranth delivery rate was augmented by a factor of 2.95 and the insulin delivery rate was augmented by a factor of 3.06. Since the power is on for about 0.1 seconds per cycle, the average power utilization is approximately 1.7 watts for augmented delivery and no power consumption for basal delivery.
Additional experiments, under different conditions, indicate that augmentation factors higher than those given above are obtainable. For example, a shorter offset of the piston with respect to the solenoid coil produced larger forces and higher augmented delivery. It was also found that higher degrees of augmentation are obtained by lowering supply pressure. However, it appears desirable to maintain a small positive pressure across the permeable elastic material.
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An implantable device for dispensing a medicament in two modes; a basal delivery rate and an augmented rate. The device includes a permeable elastic material adapted to be repeatedly compressed by a solenoid operated piston. The device delivers a basal rate when the piston is inoperative and an augmented rate when the permeable elastic material is compressed. The device is suitable for delivering insulin in an "artificial endocrine pancreas".
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THE INVENTION
The present invention is generally concerned with electronics and more specifically concerned with a system for controlling a stepper motor.
A stepper motor can run at a step rate that far exceeds the step rate at which they can start or stop. Thus, it is most desirable that the step rate start at a low value and increase to a maximum before decreasing the step rate as the system comes to rest.
Prior art systems have either limited the step rate to a value at which the stepper motor never misses the full advancement in response to a step pulse or else have disregarded the errors that are involved when a stepper motor cannot adequately respond in position change to a given input pulse.
The present system provides a linear increase in pulse and resulting step rate and a linear decrease in the pulse and resulting step rate. This linear change is accomplished by summing an analog command signal with an analog position feedback signal from the motor along with an analog signal which is proportional to the square of the step rate of the stepper motor. The sum of these signals is limited to a given maximum amount before being integrated. The integrated value is then used to actuate a duty cycle converter whose outputs are used both to provide stepping pulses to the motor at a frequency dependent upon the amplitude of the input and to provide a feedback signal indicative of the square of the input signal. As designed, the output of the integrator is proportional to velocity, thus, the output from the converter is proportional to the square of the velocity. Using this squared signal instead of a signal proportional directly to velocity, a system is achieved where the deceleration is constant as the position error goes to zero and overshoot is eliminated.
It is, thus, an object of the present invention to provide an improved stepper motor control system.
Other objects and advantages will be apparent from a reading of the specification and appended claims in conjunction with the drawings, wherein:
FIG. 1 is a block schematic diagram of a first preferred embodiment of the invention;
FIG. 2 is a second block schematic diagram of a second preferred embodiment of the invention; and
FIG. 3 is a set of waveforms describing the operation of both of the circuits of FIGS. 1 and 2.
DETAILED DESCRIPTION
In FIG. 1, an analog signal input 10 is connected through a resistor 12 to a first input 14 of a differential amplifier 16 at the inverting input thereof. A pair of zener diodes generally designated as 22 are connected between an output 20 of amplifier 16 and input 14. A resistor 24 is connected between ground or reference potential 26 and a non-inverting or positive input to amplifier 16. A resistor 28 is connected between output 20 of amplifier 16 and an inverting input 30 of a further differential amplifier 32 having an output 34. A capacitor 36 is connected between output 34 and input 30. A resistor 38 is connected between ground 26 and a further non-inverting input of amplifier 32. It will be noted as illustrated, amplifier 16 along with diodes 22, form a limiting device for preventing more than a predetermined change in step rate from the attached step motor. The amplifier 32 in combination with feedback capacitor 36 forms an integrator such that the output is an integration of the total signals received at input 30 over a period of time.
Apparatus within a dash line block generally designated as 40 constitutes the subject matter of my U.S. Pat. No. 4,005,284 issued Jan. 25, 1977. The disclosure of this referenced patent forms a part of the disclosure of the present application. However, a brief description will be provided as to the duty cycle converter contained within dash line block 40. A resistor 42 is connected to an input of the converter and to the output 34 of amplifier 32. The other end of resistor 42 is connected to an inverting input of an integrating amplifier 44 having a feedback capacitor 46. A resistor 48 is connected between ground 26 and a non-inverting input of amplifier 44. The output from amplifier 44 is divided between two resistors 50 and 52 and applied to inputs 54 and 56 of a dual D flip-flop which may be similar to that sold to RCA under Part Number CD4013 A. A positive power supply 58 supplies current through a resistor 61 to form a voltage dividing network in conjunction with resistor 50. Power supply 58 also supplies current directly to the dual D converter as well as supplying power to a set of switches 60. This set of switches 60 may be similar to that sold by RCA under Part Number CD4016A. Block 60 contains four switches wherein inputs 4, 8, 11 and 1 are connected respectively to 3, 9, 10 and 2 upon application of control signals to 13, 6, 12 and 5, respectively. The power supply 58 also supplies a reference potential to the block 60 for use in the feedback portion thereof. A negative power terminal 62 supplies current directly to the dual D converter and to block 60 as well as supplying signals through a resistor 64 to form a portion of a voltage dividing network with resistor 52. A clock signal input on a terminal 66 is supplied to clock inputs of the dual D flip-flop as well as being supplied to one input of each of two AND gates 68 and 70. An output Q1 designated as 72 supplies a signal to the other input of AND gate 68 as well as to two inputs of block 60. These two inputs are control inputs for two of the switches within block 60. The Q2 output of the dual D flip-flop designated as 74 is connected to the other input of AND gate 70 as well as being connected to two further switch control inputs of block 60. Output 34 from amplifier 32 is connected to two further switch inputs of block 60 wherein the output 72 connects a lead 76 to a lead 78 when 72 is a logic 1 and 74 accomplishes the same end result when it is a logic 1. A further output of block 60 is illustrated on lead 80 and passes signals through resistor 82 to the inverting input of amplifier 44. Actuation of the output 72 to a logic 1 condition will connect lead 80 to the positive power supply 58 while actuation of the switch within block 60 by output 74 becoming a logic 1 will connect lead 80 to receive its signals from negative power supply designated as 62. An output of AND gate 68 produces one input to a motor controller 84 which may be of the type sold by IMC Magnetics Corporation under the designation Model 0128 15 3312-01. An output from AND gate 70 produces a second input to the motor controller 84. As illustrated, a stepper motor designated as 86 will have three-phase inputs and the motor controller 84 will provide a first phase sequence upon receiving inputs from AND gate 68 and will provide the other phase sequence upon receiving inputs from AND gate 70. A potentiometer or other position feedback detector 88 is connected by mechanical linkage 90 to ascertain the position of stepper motor 86. An output is supplied on a lead 90 through a resistor 92 to the input 14 of amplifier 16. The lead 78 is connected through a resistor 94 to a first inverting input 96 of a smoothing filter amplifier generally designated as 98. A resistor 100 and a capacitor 102 are connected in parallel between input 96 and an output 104 of amplifier 98. A resistor 106 is connected between 26 and a non-inverting input of amplifier 98. Output 104 is connected through a resistor 106 to input 14.
FIG. 2 is substantially identical with that of FIG. 1 with the sole exception that the duty cycle converter is designed such that it does not require clock pulses and thus the AND gates 68 and 70 are not required in the stepping motor controller. Since the duty cycle converter of FIG. 2 is also illustrated in the referenced co-pending application C-7136, no further discussion is believed necessary and only the major portions of FIG. 2 have been numbered with the same numbers being used as are used in FIG. 1.
In FIG. 3, the waveforms correspond in number designation to the points illustrated in FIGS. 1 and 2 and will be used in the Description of Operation.
OPERATION
As may be ascertained from reading the referenced co-pending application, the duty cycle converter 40 provides a switching operation to the set of switches 60 which switches are operated at a pulse density or frequency in correspondence to or representative of the amplitude signals applied to input 42. The signal applied on lead 76 is indicative also of the amplitude of the input signal. If it is then output as a controlling amplitude at a frequency or pulse repetition in conjunction with its input, the resultant signal appearing on lead 78 will be representative of that amplitude times a pulse density representative of that amplitude and thus will be indicative of the signal on lead 76 times itself, or in other words, will be a squared function. As illustrated in FIG. 3, the signal at point 34 is a triangular function and is a result of the integration of the input illustrated on waveform 20. The multiplication of a triangular waveform times itself results in a waveform as illustrated in 96 or its inverse as illustrated in 104. In actuality, the waveform 96 is merely representative of a series of pulses slowly increasing in value and is not truly representative of the signal appearing at input 96. However, the amplifier 98 and its accompanying resistor and capacitor 100 and 102, respectively, perform a smoothing function such that the pulses represented by waveform 96 are smoothed out and waveform 104, as inverted by amplifier 98, is truly representative of the signal obtained. Waveform 90 is merely indicative of the position of motor 86 with respect to a reference point at time T o .
If at time T o , the input on 10 is suddenly increased or altered to a different value, this signal will be reflected through amplifier 16 to an output signal of the opposite polarity. With the high gain obtained and the limiting by diodes 22, the output signal will appear as a much smaller signal at output 20. This output will be integrated by amplifier 32 to obtain the waveform 34. With the action above-described in duty cycle converter 40, a feedback signal will appear on 78 which is smoothed by amplifier 98 to obtain a squared function at output 104 which is fed back to amplifier 16. As previously mentioned, the output of limiter 16 restricts the amplitude of the signal being integrated by amplifier 32. The velocity of stepper motor 86 is directly proportional to the signal output of integrator 32. This will be apparent since the motor is driven by pulses the frequency or density of which is dependent upon the amplitude of the signal appearing on 34. Thus, the squared signal on lead 78 is proportional to the velocity squared. Since deceleration is also constant, a proper assignment of values to resistors 12, 92 and 106 will produce a system where the position error as illustrated in 90 will go to a zero difference with respect to signal 10 without overshoot.
While I have shown and described a preferred embodiment of my inventive concept using two types of duty cycle converters for providing the constant acceleration and deceleration as well as providing a velocity squared feedback, I wish to be limited not by the specific embodiment illustrated, but only by the scope of the appended claims describing a stepper motor control system as claimed.
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A control system using a duty cycle converter to convert an analog input into both a second order or velocity squared feedback as well as a set of clockwise and counterclockwise pulse trains the frequency of which is dependent upon the amplitude of the input signal. The velocity squared feedback is augmented by a position feedback from a stepper motor to provide optimum operation. To obtain optimum performance from a stepper motor, the rate of change of input pulses must not exceed a predetermined value for starting or stopping or the motor will react improperly to some of the pulses. The present system provides a linear increase in the step rate to a maximum and then a linear decrease in the step rate such that there is no overshoot beyond the requested analog input signal.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to roof ventilator in general, and more particularly, to a device and method for filtering foreign matter from external air passing through the roof ventilator.
[0003] 2. Background
[0004] Roof ridge ventilators permit circulation of air through the roof of a building to decrease the temperature within the building and to allow for air circulation under the roof. Such ventilators are also desirable for the removal of moisture build-up within the enclosed cavity of the roof to prevent rotting of wooden and/or composite members. Commonly, ridged roofs will have an opening at the ridge communicating with the cavity. Ideally, the roof ridge ventilators protect the opening from the external environment while allowing air to freely circulate through the cavity.
[0005] Some currently available roof ventilators have external baffles used to deflect airflow away from the vents of the roof ventilator. That is, the external baffles do not filter air as it flows through the roof ventilator and, moreover, tend to be unsightly. In addition, other currently available ventilators use adhesives to attach various parts of the ventilator. Using adhesive tends to increase the complexity and cost of fabricating the ventilator. Moreover, adhesives tend to degrade relatively quickly over time due to the temperature cycling experienced by ventilators when installed, thereby decreasing the reliability of the ventilator.
[0006] One proposed ventilator to overcome these problems is set forth in U.S. Pat. No. 5,070,771, issued to Mankowski. Mankowski discloses a ventilator that includes a pair of flap covers hingedly connected by a hinge member integrally formed with each flap cover. Extending at an angle from the lower surface of each flap cover is a set of internal louvers (i.e., the louvers are under the covers when the ventilator is installed on a roof. Each louver includes openings extending there-through to permit the exchange of air. In addition, the louvers serve to filter the air as it flows through the ventilator. Although such a ventilator effectively vents the enclosed cavity of a roof, of course, further improvements are desirable.
[0007] One improvement that is desirable stems from recent changes in some state building codes. In response to extremely severe weather conditions, some state building codes have been amended to require that roof ventilators prevent infiltration of foreign matter into the enclosed roof cavity to which the ventilator is attached. A ventilator as disclosed in the aforementioned Mankowski patent meets such requirements for normal and even severe weather conditions. However, in extremely severe weather conditions (e.g., hurricanes), that ventilator may undesirably experience water leakage.
[0008] Thus, there exists a need for a roof ventilator that permits the free exchange of air within the roof cavity at a relatively low cost and with a high degree of performance and reliability under extreme weather conditions.
SUMMARY OF THE INVENTION
[0009] In accordance with the present invention, a roof ventilator is provided. The roof ventilator includes a cover member having a flap with a first surface over which shingles are secured and a second surface. The roof ventilator also includes a first set of louvers for deflecting airflow and reducing airflow velocity while maintaining minimum free area for air passage. Supports and a filter device are coupled to the cover member second surface. The supports extend from the second surface of the cover member flap at a height substantially equal to that of the first set of louvers to minimize interference with the first set of louvers by the supports. The filter device filters external air passing through the first set of louvers.
[0010] In accordance with other aspects of this invention, the filter device is a band of fibrous material and has a thickness that is substantially equal to the height of the supports.
[0011] In accordance with additional aspects of this invention, the filter device includes slits cut so as to be aligned with the supports when the filter device is attached to the cover member. The filter device is attached over the supports by the supports fitted into slits of the filter device.
[0012] In accordance with still yet other aspects of this invention, the roof ventilator further includes a second set of louvers located inboard of the supports. The second set of louvers have openings for further deflecting and reducing air flow velocity while maintaining a minimum free area for air passage.
[0013] A roof ventilator formed in accordance with the present invention has several advantages over roof ventilators used in the past. First, the filter device minimizes the passage of rain, insects, and dirt particles from entering the ventilated space while retaining the compact size and low cost of the roof ventilator. Second, the louvers deflect airflow while maintaining a minimum free area for air passage, such that the air flowing through the roof ventilator is substantially reduced in velocity to further limit the infiltration of foreign matter. Finally, because of its integrated design, a roof ventilator formed in accordance with the present invention can easily be manufactured and installed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] [0014]FIG. 1 is a perspective view of a roof ventilator formed in accordance with one embodiment of the present invention.
[0015] [0015]FIG. 2 is a partial bottom planar view of a roof ventilator formed in accordance with one embodiment of the present invention showing the filter device, louvers, and supports.
[0016] [0016]FIG. 3 is a cross-sectional end view of a roof ventilator formed in accordance with one embodiment of the present invention, showing placement and attachment of a filter device.
[0017] [0017]FIG. 4 is a cross-sectional end view of a roof ventilator formed in accordance with another embodiment of the present invention, showing alternative attachment of the filter device.
[0018] [0018]FIG. 4A is a cross-sectional end view of a roof ventilator formed in accordance with another embodiment of the present invention, showing other alternative attachment of the filter device.
[0019] [0019]FIG. 4B is a cross-sectional end view of a roof ventilator formed in accordance with another embodiment of the present invention, showing yet another alternative attachment of the filter device.
[0020] [0020]FIG. 5 is a cross-sectional end view of a roof ventilator formed in accordance with another embodiment of the present invention, showing alternative placement and attachment of the filter device.
[0021] [0021]FIG. 6 is a cross-sectional end view of a roof ventilator formed in accordance with another embodiment of the present invention, showing other alternative placement and attachment of the filter device.
[0022] [0022]FIG. 6A is a cross-sectional end view of a roof ventilator formed in accordance with yet another embodiment of the present invention, showing another alternative placement and attachment of the filter device.
[0023] [0023]FIG. 7 is a cross-sectional end view of a support of a roof ventilator formed in accordance with another embodiment of the present invention, showing sidewall serrations.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0024] [0024]FIGS. 1 and 2 illustrate one embodiment of a roof ventilator 20 constructed in accordance with the present invention. The roof ventilator 20 includes a cover member 22 , first and second louvers 24 A and 24 B, supports 26 , and a filter device 28 . Except for filter device 28 (described further below), roof ventilator 20 is suitably formed from a thermal plastic, such as polypropylene, or other materials such as nylon, epoxy resin, polyurethane or other plastics. Alternatively, roof ventilator 20 may be formed from a suitable metal such as aluminum or sheet steel.
[0025] The cover member 22 includes first and second flaps 30 A and 30 B and a hinge 32 extending longitudinally between the first and second flaps 30 A and 30 B. The hinge 32 is suitably integrally formed with the first and second flaps 30 A and 30 B to form a unitary body. The construction of the cover member 22 permits use of the roof ventilator 20 on roof ridges of varying pitches and angles. The roof typically contains an opening for venting the roof cavity. The roof ventilator 20 may be of any length, but is suitably four to five feet. In one embodiment, the roof ventilator 20 may be secured to a roof ridge by a cap shingle (not shown) by a well-known fastener (e.g., a nail, screw, tack, staple or other types of fasteners) extending through both the cap shingle and the roof ventilator 20 .
[0026] The first and second set of louvers 24 A and 24 B are suitably integrally formed with the cover member 22 and include openings 34 . Each opening 34 permits air circulation through the roof ventilator 20 . Further, each opening 34 deflects airflow while maintaining a minimum free area for air passage, such that air flowing through the louvers 24 A and 24 B is substantially reduced in velocity to limit the infiltration of foreign matter. The openings 34 change the direction of airflow through the roof ventilator 20 , such that airflow velocity within the roof ventilator 20 is reduced to substantially zero under normal conditions.
[0027] Still referring to FIGS. 1 and 2, the supports 26 will now be described in greater detail. Each of the supports 26 are substantially rectangular and are integrally formed with the lower surface of the cover member 22 , such that, in this embodiment, each support 26 is substantially normal to the cover member 22 . The supports 26 are spaced at predetermined locations along the length of the roof ventilator 20 to minimize their impact on air flowing through the roof ventilator 20 . In this embodiment, at least one side of the roof ventilator 20 includes two rows of aligned supports, such that an inboard and outboard row of supports are disposed in space relationship on the lower surface of the cover member 22 . As configured, filter device 28 may be disposed between the spaced inboard and outboard rows of supports. Although in this embodiment, the supports 26 are rectangular in shape and extend normally from the surface of the cover member 22 , in other embodiments, the supports can extend from the cover member at any suitable angle or shape so long as the configuration does not interfere with the roof ventilator 20 being properly mounted to the roof.
[0028] The filter device 28 is suitably formed from various fibrous materials, such as fiberglass, plastic fibers, natural fibers and coated natural fibers. The fibers may be loosely woven, or may be unwoven and held together with a binding material. In one embodiment, the fibrous material is the same as that used in SPEEDVENT vent products available from Northwest Building Products, Madison Heights, Mich. The fibrous material may include a backing or mesh on one or both sides to provide additional structural support for the filter device to hold its shape. In this particular embodiment, the filter device 28 is substantially rectangular in shape and may be adhesively or mechanically fastened between the inboard and outboard rows of the supports 26 . As fastened between supports of the supports 26 , the filter device 28 extends the length of the roof ventilator 20 . The filter device 28 further minimizes infiltration of foreign matter into the roof to which the roof ventilator 20 is mounted, while still allowing ventilation. In this embodiment, the filter device 28 is advantageously placed away from the opening in the roof ridge so that the fibrous material will not sag or otherwise fall into the roof ridge opening.
[0029] Operation of the roof of ventilator 20 may be best understood by referring to FIG. 3. For clarity, this description is for one half of the ventilator (i.e., the half containing louvers 24 A), with the operation for the other half (i.e., the half containing louvers 24 B) being essentially identical. In ventilation operation (i.e., when conditions tend to allow air to flow out of the ventilator), air tends to flow from the roof ridge opening toward the cover member 22 . This airflow is typically caused by convection and/or external airflow over the roof (i.e., the shape of the ventilator along with the orientation of the louvers can cause a pressure differential that facilitates airflow out of the ventilator). In normal ventilation, air flows through the filter device 28 as indicated by the arrow 52 . The air passes through the filter device 28 and then through the louvers 24 , as indicated by an arrow 50 .
[0030] Because the airflows and pressure differentials involved with ventilation are relatively small compared to those experienced during extreme weather conditions, it is desirable that the filter device impedes the ventilation airflow as little as possible while still providing the desired infiltration protection. Therefore, in accordance with the present invention, filter device 28 is formed into a relatively narrow band or strip of fibrous material. In conjunction with the internal louvers (e.g., louvers 24 A), the relatively narrow width of the band is sufficient to achieve infiltration performance to meet current extreme weather building codes while minimizing obstruction of ventilation airflow out of the roof. In one embodiment, the band is about 1.25 inches wide, but the width can be smaller or larger, depending on the density of the filter material, louver performance, and building code infiltration requirements. In view of the present disclosure, those skilled in the art can determine the suitable filter parameters to meet these requirements. The filter thickness preferably matches the height of the louvers. One advantage of this embodiment is that the louvers tend to filter out solid matter so that the filter device will not become clogged. Under extreme weather conditions when water may leak past the louvers, the filter device prevents this water from leaking into the roof ridge opening.
[0031] In infiltration operation (i.e., when conditions tend to cause air to flow into the roof ventilator), as air passes through the openings 34 of the louvers 24 A, this air is deflected upward, following a course in the opposite direction of the arrow 50 . As a result, the free area through which air is permitted to pass is minimized, thereby substantially reducing both the velocity and infiltration of foreign matter of air passing through the louvers 24 A.
[0032] After air passes through the louvers 24 A, this air passes through the filter device 28 , following a course that is opposite that of the arrow 52 . The filter device 28 further reduces passage of airborne foreign matter through the roof ventilator 20 . As a result, airborne matter within air passing through the roof ventilator 20 is filtered out through the louvers 24 A and the filter device 28 . As previously described, the louvers 24 A and the filter device 28 operate together to meet current extreme weather building codes while minimizing obstruction of ventilation airflow out of the roof.
[0033] Referring now to FIG. 4, an alternate embodiment of a roof ventilator 120 formed in accordance with the present invention is illustrated. The roof ventilator 120 of this alternate embodiment is substantially identical in materials and operation as roof ventilator 20 (FIG. 3) described above, except that roof ventilator 120 includes a retainer 136 . Except for retainer 136 , the reference numbers used in describing features and elements of roof ventilator 120 are the same as those of roof ventilator 20 (FIG. 3), but preceded by a numeral “ 1 ” so that the description of roof ventilator 20 can be easily applied to roof ventilator 120 . Attachment of the filter device 128 may be had by a retainer 136 extending normally from the free end of the inboard row of supports 126 . The retainer 136 extends outboard from the free end of the inboard row of supports 126 to further assist in retaining the filter device 128 within the roof ventilator 120 .
[0034] [0034]FIG. 4A illustrates a roof ventilator 120 A that is substantially similar to roof ventilator 120 (FIG. 4), except that roof ventilator 120 A has a retainer 166 that extends to the opposite support 126 (adjacent to louver 124 a ) instead of the shorter retainer 136 (FIG. 4). Support 126 A includes a fitting 168 that fits into a slot (not shown) on retainer 166 . In this embodiment, the fitting 168 has the shape of a tapered or angled flange and is formed from a substantially rigid yet resilient material. The flange is formed so that one side is tapered toward the distal end of the fitting 168 but the other side facing cover member 122 is flat. The resilient material and tapered side of the flange allows the fitting 168 to be fitted through the slot in retainer 166 , while the flat side of the flange prevents the retainer 166 from being moved away from support 126 A. This feature further aids in retaining filter device 128 in roof ventilator 120 A. Further, this feature can advantageously eliminate the need for adhesive to bond filter device 128 to the cover member 122 . Alternatively, the fitting 168 and the slot may be formed on the retainer 166 and support 126 A, respectively.
[0035] [0035]FIG. 4B shows another alternative embodiment similar to that of FIG. 4A except that the retainer 155 does not overlap the support 126 A. Instead, in this embodiment, the retainer 166 is formed as integrally with support 126 and is folded over so that the end of the retainer 166 contacts the support 126 A. In this embodiment, a lip 170 is formed on the support 126 A. In this embodiment, the lip 170 , the retainer 166 , and the supports 126 and 126 A are formed from a resilient material, such as a plastic or polymer, that allows the retainer 166 to be bent over past the lip 170 after the filter device 128 is placed between the supports 126 and 126 A. That is, the end of the retainer 166 is forced past the lip 170 to be “snapped” into place, contacting and flush with the support 126 A. The retainer 166 together with the lip 170 serve to hold the filter device 128 in place.
[0036] Referring now to FIG. 5, a second alternate embodiment of a roof ventilator 220 formed in accordance with the present invention is illustrated. The roof ventilator 220 is identical in materials and operation as the embodiment described above with the following exceptions described below. Except for the second set of louvers 270 , the reference numbers used in describing features and elements of roof ventilator 220 are the same as those of roof ventilator 20 (FIG. 3), but preceded by a numeral “ 2 ” so that the description of roof ventilator 20 (FIG. 3) can be easily applied to roof ventilator 220 .
[0037] In this alternate embodiment, a second set of louvers 270 , a mirror image of the first set of louvers 228 a, is located in a V-shaped configuration, such that the second set of louvers 270 extend from the base of the outboard set of supports at a predetermined angle to intersect the inboard set of supports. In this embodiment, the angle is about 25°, but any angle up to 90° can be used depending on the height and intersection point of the outboard set of supports. In this embodiment, the band of fibrous material for the filter device 228 includes slits 248 that are cut to a depth that is substantially equal to the height of the support, or deeper, or even all the way through the filter device 228 . The slits 248 run longitudinally and are suitably cut at a distance spaced from each other equal to the distance between each support. The filter device 228 is attached over the supports, with the slits 248 fitting snugly over each support 226 . Alternatively, the filter device may be attached to the cover member adjacent to or in the second set of louvers so that airflow into the roof ventilator must pass through two sets of louvers before flowing through the filter device.
[0038] [0038]FIG. 6 illustrates a roof ventilator 320 formed in accordance with another embodiment of the present invention. The roof ventilator 320 is identical in materials and operation as roof ventilator 220 (FIG. 5) described above except that the single row of supports 226 adjacent to louvers 224 A is replaced with two rows of supports 326 A and 326 B. Except for these supports, the reference numbers used in describing features and elements of roof ventilator 320 are the same as those of roof ventilator 220 (FIG. 5), but incremented by 100 , so that the description of roof ventilator 220 (FIG. 5) can be easily applied to roof ventilator 320 .
[0039] In this alternate embodiment, the row of supports 326 A is formed on part of the first set of louvers 324 A while the other row of supports 326 B is formed on the second set of louvers 370 . In this embodiment, the band of fibrous material for the filter device 328 is disposed between the rows of supports 326 A and 326 B. The filter device can be attached to the roof ventilator 320 by adhesive or mechanical fasteners. In a further refinement, retainers (not shown) as described above in conjunction with FIGS. 4 and 4B can be added.
[0040] [0040]FIG. 6A illustrates a refinement of the embodiment of FIG. 6, with the supports 326 A and 326 B placed closer together. In this embodiment, the supports 326 A and 326 B are about 0 . 5 inches apart, although other distances can be used in other embodiments as required to match the width of the filter device. The fibrous material of the filter device 328 is placed between the supports. It is believed that the two sets of louvers in this embodiment allow the filter device 228 to be relatively narrow while still achieving the desired infiltration protection.
[0041] [0041]FIG. 7 illustrates a support 426 formed in accordance with another embodiment of the present invention. As shown in FIG. 7, support 426 includes serrations 480 along a sidewall. The serrations 480 can have a spine-like, barb-like, spike-like shape, etc., with sharp points directed generally toward the cover member 422 . When the roof filter is assembled, the filter device (omitted for clarity) is adjacent to and contacting the serrations 480 of the support 426 . The serrations 480 tend to allow the filter device to move towards cover member 422 during assembly. In addition, the serrations 480 tend to prevent the filter device from moving away from cover member 422 by becoming enmeshed in the fibrous material of the filter device, thereby helping to fasten the filter device securely to the support 426 . These serrations can be provided in one or more of the supports of the embodiments depicted in FIGS. 3 - 6 .
[0042] From the foregoing descriptions, it may be seen that a roof ventilator formed in accordance with the present invention incorporates many novel features and offers significant advantages over currently available roof ventilators. While the presently preferred embodiments of the invention have been illustrated and described, it is to be understood that within the scope of the appended claims, various changes can be made therein without departing from the spirit and scope of the invention.
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A roof ridge ventilator with filtering device to be installed under a cap shingle includes a one piece cover member of an elongated shape including a pair of flaps, each flap having one upper surface over which cap shingles are secured and also having downwardly facing lower surfaces, a pair of vents respectively secured to the lower surface of the cover member flaps, each vent including at least one set of shielded louvers having openings for deflecting air flow while maintaining a minimum free area for air passage such that the air flowing therethrough is substantially reduced in velocity to limit the infiltration of foreign matter. Longitudinally spaced supports extend substantially vertically to permit nailing onto the roof such that the vent does not collapse during installation and such that the net free area remains intact. A band of fibrous material positioned inboard of the vent to further prevent foreign matter for entering the attic.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an active-matrix liquid crystal color display panel having a triangular pixel arrangement, and more particularly to an improvement for high quality color image.
2. Description of the Related Art
Recently, a liquid crystal color display panel has been remarkably progressed and is demanded to image a high quality color picture. An active-matrix liquid crystal display panel using thin film field effect transistors (hereinafter, referred to TFT) as switches has been recognized, in recent years, as preferable to image a fine high quality color image.
One pixel element is formed of a TFT and a display electrode. A plurality of pixel elements are disposed in a matrix form on a transparent glass substrate. The TFT's are driven by access signal buses (or scanning buses) and data signal buses (or video signal buses) disposed between pixel elements to form a lattice. Scanning signals are applied to TFT's through the access buses. Video signals are applied to the data buses to be supplied to selected display electrodes through TFT's which are turned on by the scanning signals.
In a color display, one color pixel element has three or four pixel elements (hereinafter, referred to cell element for imaging primary color components. Therefore, compared to a black-and-white display, number of cell elements required is more than three times. The larger the number of color pixel elements (that is, the number of cell elements), the higher the resolution of the obtained color image becomes. However, if the number of cell elements is increased, the time duration for driving one cell element becomes short to decrease the effective voltage applicable to liquid crystal, resulting in a poor quality of imaged picture. In this point of view, the activematrix liquid crystal color display panel is superior to other types of liquid crystal display panel. The activematrix type is small in decrease of the effective voltage applied to liquid crystal, if the driving time duration becomes short. However, in a case where the number of cell elements are greatly increased for obtaining a high quality color image, the driving time duration becomes too short to apply the sufficient effective voltage to the liquid crystal in the active-matrix type color display panel.
An arrangement for prolonging this driving time duration is to form one cell element with one display electrode and two TFT's and to successively drive those two TFT's by adjacent two access buses. By this arrangement, the time duration for applying a video signal to one display electrode becomes double, compared to the case where one TFT is coupled to one display electrode. However, since one access bus simultaneously drives adjacent two cell elements in the direction parallel with data signal bus, all the cell elements in the direction parallel with the data bus have to receive a video signal of the same color. This means the primary color pixel arrangement is limited to be a stripe type. The stripe type color pixel arrangement has the same color cell elements in a line and is poor in image quality.
The image quality is improved by the triangular color pixel arrangement. K. Noguchi et al. proposed one improvement for the triangular color pixel element in U.S. patent application (Ser. No. 823,104) filed on Jan. 27, 1986. One cell element in one color is divided into two parts each having one TFT and one display electrode. The drain electrodes and gate electrodes of the two TFT's are connected to the same data bus and the same access bus. The two-part-set cell elements are connected to every access buses. But every other two-part-set cell elements are disposed on one side of the access buses, while the other two-part-set cell element are disposed on the other side of the access buses. Two two-part-set cell elements on one side of the access bus and one two-part-set cell element on the other side of the access bus form one color pixel element having a triangular shape. The arrangement of the color pixel elements along the access buses is shifted with a half pitch of one color pixel element between adjacent two access buses. This arrangement images a high quality picture. However, there is one drawback of a line-defect which appears if one access bus or data bus has an opencircuit introduced in a manufacturing process. This linedefect spoils the imaged picture.
SUMMARY OF THE INVENTION
It is a primary object of the present invention to provide an active-matrix liquid crystal color display panel having a high density of pixel elements and imaging a high quality picture which is not spoiled by a small number of open-circuits in access buses.
According to the present invention, there is provided an active-matrix liquid crystal color display panel comprising a plurality of access signal buses (or scanning lines), a plurality of data signal buses (or video signal lines) orthogonaly crossing but separated from the access buses, a matrix of display electrodes formed of a plurality of columns parallel with the access buses and rows parallel with the data buses, each of the display electrodes being disposed in a space surrounded by two adjacent access buses and two adjacent data buses, a plurality of switching transistors having a gate electrode, a drain electrode and a source electrode, each of the display electrodes being connected to the source electrodes of two switching transistors, the gate electrodes of the two switching transistors being connected to the adjacent two access buses running both sides of the display electrode which is connected to the source electrodes of the two switching transistors, and the drain electrodes of the switching transistors having source electrodes connected to a pair of adjacent two display electrodes along the access buses being connected to the same data bus running between the pair of two display electrodes, each pair of two display electrodes in every other columns of the display electrode matrix being formed of two display electrodes on both sides of every other data buses and each pair of two display electrodes in the other columns being formed of two display electrodes on both sides of the other data buses, and a color filter having a plurality of filters each covering the pair of display electrodes and transmitting predetermined color components, filters transmitting different color components being repeatedly arranged in lines above the columns of display electrodes, the arrangement of the filters being shifted between adjacent lines with a half of total length of the filters to form a color pixel.
In the present invention, one display electrode is supplied with video signals from the same data bus through two switching transistors driven by adjacent two access buses. The time duration for being supplied with video signal is prolonged. Therefore, in an active-matrix liquid crystal color display panel having an increased number of pixel elements, high effective voltage can be applied to the liquid crystal to image a high quality picture. Furthermore, since one display electrode is connected to adjacent two access buses through switching transistors, small number of open-circuits in access buses does not affect the imaged picture. The display electrodes coupled to the open-circuited access bus can be made access from the other access bus having no open-circuit. Thus, the present invention images a high-quality natural picture with increased number of color pixel elements driven by a high effective signal voltage, even if small number of open-circuits exist in access buses.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and further objects, features and advantages of the present invention will become more apparent from the following detailed description taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a schematic plan view of a part of an active-matrix liquid crystal color display panel in the prior art;
FIG. 2 is a schematic plan view of a part of another active-matrix liquid crystal color display panel in a prior art;
FIG. 3 is a schematic plan view of a part of an active-matrix liquid crystal color display panel according to a first preferred embodiment of the present invention;
FIG. 4 is a plan view of a part of TFT array board used in the first preferred embodiment of the present invention;
FIG. 5 is a sectional view taken along A--A' of FIG. 4;
FIG. 6 is a timing chart of scanning pulses and a voltage applied to the liquid crystal in a non-interlacing operation of the first preferred embodiment;
FIGS. 7(a) and 7(b) are schematical diagrams of a part of first preferred embodiment shown in FIGS. 3, 4 and 5, for explaining an interlacing operation;
FIG. 8 is a timing chart of scanning pulses and a voltage applied to the liquid crystal in an interlacing operation of the first preferred embodiment; and
FIG. 9 is a schematic plan view of the active-matrix liquid crystal color display panel according to the second preferred embodiment of the present invention.
First prior art of an active-matrix liquid crystal color display panel has display electrodes 80 supplied with video signals through two TFT's 83 and 84 driven by adjacent two access buses 82, as shown in FIG. 1. A plurality of sets of the display electrode 80 and a pair of TFT's 83 and 84, a plurality of parallely arranged access buses 82 and a plurality of data buses 81 disposed orthogonally to the access buses 82 are formed on a transparent glass substrate. Every one display electrode 80 positions in every one space surrounded by two access buses 82 and two data buses 81 and connected to source electrodes of the pair of TFT's 83 and 84. Source electrodes of the pair of the TFT's 83 and 84 are connected to their left-side data bus 81. The display electrodes 80 labeled as "C 1 ", "C 2 " and "C 3 " form one color pixel element by covered respectively with red, green and blue filters. In the lines of the access buses 82, the red, green and blue filters cover repeatedly the display electrodes 80.
The access buses 82 are scanned to drive selected TFT's. Video signal is supplied to the display electrodes 80 through the data buses 81 and the driven TFT's. Therefore, one display electrodes 80 are supplied with the video signal for a time period when the TFT's 83 and 84 are driven. The time periods are double, compared to a time period when one TFT is driven. This results in that a sufficient effective voltage for driving liquid crystal is applied to the display electrode. In other words, the number of color pixel element can be increased without lowering the effective video voltages at the display electrodes 80.
However, since the video signal is supplied through the data buses 81 and one access bus drives two TFT's coupled to two display electrodes on both sides of the access bus, all the filters covering display electrodes 80 aligned in parallel with data buses must be same color. Thus color filter is limited to a stripe type. The image displayed by the stripe type color filter is poor in quality and is not natural.
The natural image can be improved by use of a color filter having a triangular color pixel elements. An active-matrix liquid crystal color display using the color filter having a triangular color pixel elements is drawn in FIG. 2. One cell element has a pair of TFT's 73 and 74 and a pair of display electrodes 75 and 76. Each display electrode is supplied with a video signal through a bus 71 and a TFT. The display electrodes are disposed on both sides of one bus 72. Gate electrodes of a pair of TFT's 73 and 74. The pairs of display electrodes coupled to every other data buses are disposed on one side of the access bus 72 while the other pairs of display electrodes coupled to the other data buses are disposed on the other side of the access bus. The display electrodes labeled as "C 1 ", "C 2 " and "C 3 " form one color pixel element by covered with red, green and blue filters, respectively. On lines of display electrodes aligned in parallel with access buses, an arrangement of an order of red (C 1 ), red (C 1 ), blue (C 3 ), blue (C 3 ), green (C 2 ) and green (C 2 ) filters is repeated. The filter arrangement is shifted between adjacent two lines of display electrodes with a half pitch of the the repetition cycle of the color filters to form triangular color pixel elements which are formed of two pairs of display electrodes in one line and one pair of display electrodes in an adjacent line.
Each color pixel element overlaps with adjacent color pixel elements in plan view. Repetition of primary colors is not clear to image a natural picture. However, there is a drawback that one open-circuit in an access bus results in a loss of operability of all TFT's coupled to the defective access bus. Thus, two lines of display electrodes on both sides of the defective bus are not supplied with video signal. A line defect appears on a imaged picture.
DESCRIPTION OF PREFERRED EMBODIMENT
One cell element in an active-matrix liquid crystal color display panel according to a first preferred embodiment has a pair of display electrodes 15 and 16, as shown in FIG. 3. The display electrodes 15 is connected to a source electrode of a TFT 13 which has a gate electrode connected to a gate bus 12 running on an upper side of the pair of display electrodes 15 and 16 and a drain electrode connected to a data signal bus 11 running between the pair of display electrodes 15 and 16. The display electrode 15 is also connected to a source electrode of a TFT 17 which has a gate electrode connected to an access signal bus 12 running on a lower side of the pair of display electrodes 15 and 16 and a drain electrode connected to the same data signal bus 11. Similarly, the other display electrode 16 is connected to source electrodes of two TFT's 14 and 18. The gate electrodes of the two TFT's 14 and 18 are respectively connected to gate buses 12 running on upper and lower sides of the pair of display electrodes 15 and 16. The drain electrodes of the two TFT's 14 and 18 are connected commonly to the same data bus 11 running between the pair of display electrodes 15 and 16.
A plurality of the cell elements are formed at every other data bus and form a line of cell elements. The lines of cell elements are formed in every region between two adjacent access buses 12. The data buses connected to the pixel elements are different between the neighbouring lines of cell elements.
The cell elements, the data buses and the access buses are formed on a transparent glass substrate to form a TFT array board. A layer of liquid crystal and a common electrode thereon connected to a reference potential cover the TFT array board and a layer of color filter is formed thereon. The color filter includes red filter elements "R", green filter elements "G" and blue filter elements "B" which are respectively positioned above the respective display electrodes. Each filter element may have an area covering each of the display electrodes 15 and 16 or each pair of the display electrodes 15 and 16. On a line of cell elements, the arrangement of the red filter element(s), the green filter element(s) and the blue filter element(s) is repeated. The repetition of the filter element arrangement is shifted between neighbouring lines of the cell elements with a half of a repetition pitch. This shift forms a triangular color pixel element as shown by hatched display electrodes.
The active-matrix liquid crystal color display panel will be further explained in more practical form. A part of TFT array board and a partial section of the color display panel are shown in FIGS. 4 and 5 with same reference numerals. A plurality of access buses 125 serving as gate electrodes are formed in parallel with one another on a transparent glass substrate 126 with chromium (Cr) of 1500 Å and covered with an insulator film 127 of silicon nitride of 3,000 Å. Amorphous Si films 122 of n - -type are formed with a thickness of 2,000 Å on the insulator film 127 above the access buses 125 to operate as channel regions of TFT's. N + -amorphous Si films 124 are formed with a thickness of 200 Å as source and drain regions on the amorphous Si films 122. Drain electrodes 121 and data buses 111 are formed on the N + -amorphous Si films 124 and on the insulator film 127, with Cr of 3,000 Å. The data buses 111 are arranged to be in parallel with one another and to cross orthogonally the access buses 125. The source electrodes 123 is formed with Cr of 3,000 Å to cover the N + -amorphous Si films 124 of the source regions and side wall of the amorphous Si films 122. A plurality of display electrodes 129 of ITO having a thickness of 1,500 Å are formed on regions of the insulator film 127 surrounded by two access buses 125 and two data buses 111. The peripheral portion of each display electrode 129 is overlapped with the source electrode 123 to which the display electrode is to be connected. The TFT's and the display electrodes 129 are covered with a protection film 128 of polyimide. Liquid crystal 135 is interposed between the TFT array board 120 and a common electrode 134 which is connected to ground. A color filter 130 is located thereon. The color filter 130 has a plurality of red, green and blue filter elements 132 on a transparent glass board 131. The arrangement of the red, green and blue filter elements 132 is as explained with reference to FIG. 3.
The color pixel elements have a triangular form and overlap with their side color pixel elements in plan view. The imaged picture does not generate moire-image interference fringes. Color uniformity is superior to feel the imaged picture natural. Thus, since the color display panel has a triangular color pixel arrangement, a high quality image can be produced. Furthermore, one display element is supplied with video signal through two TFT's having gates connected to different access buses. Therefore, if one access bus has an open-circuit, the display electrode can be made access by means of the other access bus. A line defect does not appear on an imaged picture. The open-circuit may occur in a manufacturing process of the TFT array board. The allowance of the small number of open-circuits in access buses raises a production yield and lowers the production cost.
The two-TFT structure has another merit. A scanning pulse of +15 volts is sequentially applied to the access buses 12 from upper one to lower one, while video signals of +(8±x) volts are supplied to the data buses 11 in synchronism with the scanning pulse. The value x is varied depending on the tone of the picture. For imaging color picture, red, green and blue video signals are supplied. As apparent from FIG. 3, respective data buses 11 may be supplied with only one of the red, green and blue video signals. This fact simplifies the peripheral circuit for operating the color display panel.
Furthermore, in a non-interlacing operation, the access buses 12 are successively driven by a scanning pulse in an order from upper one to lower one. FIG. 6 shows a timing chart of the scanning pulses applied to the even number of access bus V G2n and the next access bus V G2n+1 and voltage V LC applied to the liquid crystal. Since the video signals are supplied to one display electrode for succeeding two periods (2t) when the scanning pulses 151 and 152 are applied to succeeding two access buses, the time 2t for supplying the video signal to one display electrode becomes double, as compared to a case where one TFT is connected to one display electrode. The voltage applied to the liquid crystal decreases with a time constant CR off after the pulse 152 disappears. Since the liquid crystal is sufficiently charged for the elongated charging time 2t, the voltage V LC is kept at high for scanning period T to increase the effective voltage applied to the liquid crystal. The contrast of imaged picture is improved to obtain a high quality picture. In other words, the picture quality is not deteriorated by increasing the number of color pixel elements. Although an access time to one access bus decreases by increasing the cell element number, the access time to one display electrode does not become short. A fine, high contrast and wide image can be obtained.
The invention is also advantageous in interlacing operation. An odd number of field is schematically shown in FIG. 7(a), an even number of field being schematically shown in FIG. 7(b). FIGS. 7(a) and 7(b) are simplified diagram of FIG. 3 for explaining the interlacing operation. In an odd number of field, access buses G 1 , G 3 , G 5 . . . are sequentially supplied with scanning pulses. Each access bus turns on TFT's on both sides to supplied video signals to the display electrodes P m ,1 . . . P m ,4 and P m+1 ,1 . . . P m+1 , 4 . . . on both sides through data buses D 1 . . . D 5 . . . . Finally, all the display electrodes P 11 , . . . P 44 . . . are supplied with video signals in on even number field. In an odd number field, the other access buses G 2 , G 4 . . . are sequentially supplied with the scanning pulse. Similarly to the even number field, all the display electrodes P 11 . . . P 44 . . . are supplied with video signals in one odd number field.
The scanning pulses applied to the even number access buses V G2n and applied to the next access buses V G2n+1 is shown in FIG. 8 together with the voltage V LC applied to the liquid crystal. The video signals are twice applied to the liquid crystal by the scanning pulses 153 and 154.
The liquid crystal is not fully charged during the period of the first scanning pulse 153 which has shortened pulse width for increasing pixel elements. After the first scanning pulse 153, the charges in the liquid crystal are discharged with a time constant CR off . Since the charges are not completely discharged until the second scanning pulse 154, charges are added to the liquid crystal by the second scanning pulse 154 to fully increase the voltage V LC , resulted in an application of a high effective voltage to the liquid crystal. The increased effective voltage improves a contrast of imaged picture to obtain a high quality. This high quality picture has been maintained in a display panel having 480 scanning lines (i.e. 480 access buses) operated by a frame frequency of 60 Hz with an access time of 35μ sec.
The second preferred embodiment of the present invention shown in FIG. 9 has a constructional feature similar to the first preferred embodiment. Each cell element includes a pair of display electrodes 215 and 216 and four TFT's 213, 214, 217 and 218. The display electrode 215 is connected to the TFT 213 controlled by an upper access bus 212 and to the TFT 217 controlled by a lower access bus 212'. The other display electrode 216 is connected to the TFT 214 controlled by the upper access bus 212 and to the TFT 218 controlled by the lower access bus 212'. Red, green and blue filter elements in a color filter cover the display electrodes via a liquid crystal layer and a common electrode to form triangular color pixel elements (one being shown by hatching), similarly to the first preferred embodiment.
A distinctive feature of the second preferred embodiment is an interconnection 219 between the pair of display electrodes 215 and 216. This interconnection 219 may be formed of an ITO film formed on a data bus 211 through additional insulator film of silicon nitride to connect the pair of display electrodes 215 and 216 made of ITO.
The same advantages, merits and features as the first preferred embodiment may be obtained in this second preferred embodiment. Additionally, the interconnections 219 give a redundancy to the TFT array board. Since the pair of display electrodes 215 and 216 are electrically connected, even if one of TFT's 213 and 214 and one of TFT's 217 and 218 are defective and not operable in a manufactured TFT array board, the TFT array board may be employed with or without separating the defective TFT's from data bus and/or display electrode by a trimming technique such as a laser beam trimming.
The present invention provides an active-matrix liquid crystal color display panel in which the number of pixel element may be increased without decreasing a high quality imaged picture, a small number of opencircuits does not lower the imaged quality, a simplified peripheral circuit is required for imaging a color picture.
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An active-matrix liquid crystal color display panel includes lines of color pixel elements composed of first, second and third types of cell elements, each cell element having two display electrodes each connected to a video signal bus running therebetween through parallely connected two thin film FET's (TFT's) having gates connected to different scanning signal buses, the first, second and third types of cell elements having different one of three primary color filters, and repetition of the color pixel elements in adjacent line being shifted with a half length of the color pixel element to form triangular color pixel arrangement.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a female physical condition managing apparatus which is capable of making a decision about the female physical condition which appears periodically in a female, for example, on the ovulation day, at the time of appearance of the premenstrual syndrome (hereinafter abbreviated as “PMS”) for menstruation period or for the pregnancy-possible period.
2. Prior Art
The women's periodic body condition is related closely with their body temperature. The body temperature transfers from the low-temperature period to the high-temperature period on the ovulation day, and from the high-temperature period to the low-temperature period on the menstruation starting day, as shown in FIG. 1 . Women take their body temperature every morning in bed to make manually a graphic record or table showing how the body temperature varies each and every day, thereby making it possible to determine which stage has been reached in the periodic physical condition.
It is necessary that women take their body temperature while laying themselves in bed, and it takes them about five minutes to measure their body temperature with body thermometers. This, however, is difficult to continue for a long time, and women often fall in sleep while taking their body temperature in bed.
A reliable decision can be made about some particular types of female physical condition on the basis of the body temperature, such as determination of the ovulation day, the menstruation period and the pregnancy-possible period, all of which are useful factors for birth control. Determination about whether women undergo the PMS has been increasingly in concern from the point of women's daily life, but such decision is impossible with recourse to the recording of body temperature. The PMS starts seven days earlier than the beginning of the menstruation period, causing women to suffer from headache, irritation, stomachache, swell or any other unpleasing symptom. When they realize that their unpleasing symptoms are caused simply by the PMS, they can be released from their sufferings significantly.
As a matter of fact determination of the female physical condition from the graphic record of body temperature is difficult, and such determination is apt to be dependent on her discretion.
SUMMARY OF THE INVENTION
One object of the present invention is to provide a female physical condition managing apparatus which provides a quick decision on the periodic physical condition including the PMS.
To attain this object a female physical condition managing apparatus according to the present invention comprises: a bioelectrical impedance-meter for determining value of bioelectrical impedance; a memory for storing the so determined values of bioelectrical impedance; a decision-making unit for making a decision about the physical or mental condition of a female on the basis of the time series analysis made on the variation of determined values of bioelectrical impedance; and a display showing the physical or mental condition of the female in the form of graphs. Hereinafter, the word, “bioelectrical impedance” is abbreviated as “BI”.
The mental condition includes at least one of the feeling, the skin condition and the emission of pheromone whereas the physical condition includes at least one of the swell and the body condition.
The graphs may include bar graphs, circle graphs, line graphs and radar charts.
The bar graphs, circle graphs, line graphs and radar charts may be given in two- or three-dimensional form.
Other objects and advantages of the present invention will be understood from the following description of some preferred embodiments of the present invention.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 shows how the monthly periodic physical condition of women, the body temperature and the secretion of hormone are related with each other;
FIG. 2 illustrates how the body temperature and BI vary with day;
FIG. 3 illustrates how the weight varies with day;
FIG. 4 illustrates how the weight and BI are correlated;
FIG. 5 illustrates how the weight-modified BI varies with day;
FIG. 6 illustrates how the weight-modified BI and the body temperature are correlated;
FIG. 7 illustrates how the weight-modified BI, the monthly periodic physical condition and the body temperature are related;
FIG. 8 illustrates how the weight-modified BI, the monthly periodic physical condition and the body temperature are related;
FIG. 9 illustrates how a female physical condition managing apparatus according to a first embodiment looks in appearance;
FIG. 10 is a block diagram showing the functions of the female physical condition managing apparatus;
FIG. 11 is a perspective view of a female physical condition managing apparatus according to a second embodiment of the present invention;
FIG. 12 is a flow chart showing the proceeding by which a decision is made on the monthly periodical physical condition;
FIG. 13 is a flowchart according to which the initialization is performed;
FIG. 14 is a flowchart showing the pregnancy-possible period presenting mode;
FIG. 15 is a flow chart according to which required measurements and estimations are made;
FIG. 16 is a flow chart showing a series of steps for displaying the physical condition;
FIG. 17 shows what icons are displayed for selection;
FIG. 18 is a flow chart showing the proceeding by which cyclic body conditions and related advice are given;
FIG. 19 shows how different items can be transferred from one to another in graphic presentation;
FIG. 20 is a flow chart showing the proceeding by which a diary is logged and read;
FIG. 21 is a flow chart showing the proceeding by which an inquiry is made;
FIG. 22 is the initial image appearing in the display;
FIG. 23 illustrates how the pregnancy-possible day is indicated on a given page of the calendar;
FIG. 24 illustrates how the expected beginning day of the menstruation period is indicated on a given page of the calendar;
FIG. 25 shows one example of a message describing what the user is requested to do at the start of a required measurement;
FIG. 26 illustrates a screen appearing in the display during the measurement;
FIG. 27 illustrates how the display indicates a decision made on the physical condition;
FIG. 28 illustrates how the cyclic messages are given in the display;
FIG. 29 shows the advice messages appealing in the display;
FIG. 30 shows a message informing the user of pregnancy possibility in the display;
FIG. 31 illustrates how the measurement results of weight and percent fat are shown in the display;
FIG. 32 shows the 28 days' cycle measurements of weight and percent fat;
FIG. 33 shows one example of tomorrow's message in the display;
FIG. 34 shows how the weight varies within one month;
FIG. 35 illustrates how the percent fat varies within one month;
FIG. 36 illustrates how BI values vary within one month;
FIG. 37 shows some items to be selected in logging a diary;
FIG. 38 shows the selected items for confirmation;
FIG. 39 shows the diary content of the day in question;
FIG. 40 shows the diary content of the day in question in the previous month;
FIG. 41 shows an inquiry making screen;
FIG. 42 shows which days are Date Days;
FIG. 43 illustrates the practice of the decisions being given in the display;
FIG. 44 illustrates animation-like figures appearing in the display while a required measurement is being made;
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Before entering the description of a female physical condition managing apparatus according to the present invention the relation between the BI and the women's periodic physical condition is described by referring to the data of actual measurement. Women took their body temperatures every morning when getting up, and the values of BI were measured between both feet.
First, described is the periodic BI variation. FIG. 2 shows how the body temperature and BI of a selected woman A vary with day. The graphs were made by plotting the average values of two adjacent ones, which average values were determined according to the method of moving average. As a general tendency the values of BI remain high while the body temperature remains low. The values of BI remain low while the body temperature remains high, and the BI curve descends in the early half of the menstruation period after rising before the beginning of the menstruation period.
Next, the relation between the values of BI and the weight is described. FIG. 3 shows how the weight of the woman A varies while her physical condition was being monitored. The weight decreased gradually during measurement. FIG. 4 shows how the weight is correlated with the values of BI. A significant negative correlation between the weight and the values of BI was found (correlation coefficient R=0.527). As shown, the weight decreases with the increase of the values of BI, and vice versa. This inclination appears to be attributable to the fact that the water content of the female body increases (decreases) with the increase (decrease) of the weight and the value of BI decreases (increases) with the increase (decrease) of the water content. It appears that the BI curve of FIG. 2 is affected by the decreasing weight of the woman A as shown in FIG. 3 and that the BI curve needs to be corrected by modifying the values of BI with weight.
FIG. 5 shows the weight-modified BI curve, so that it may be made independent from the weight variation. Specifically the BI curve of FIG. 2 is modified according to Equation of Correction 1 or 2:
BI modified with weight= BI+A ×(difference of weight from the initial weight) (1),
or
BI modified with weight= BI+B ×(difference of weight from the preceding weight) (2),
where “A” and “B” stand for correction coefficients.
The weight-modified BI curve of FIG. 5 shows the periodic variation of BI more clearly than the BI curve of FIG. 2, which is affected more or less by the variation of the weight.
Next, the BI-to-body temperature relationship and the BI-to-PMS relationship are described. As seen from FIGS. 2 and 5, the values of BI decrease for a specific period spanning from the proximity to the menstruation beginning to the end of the early half of the menstruation period, for which specific period the body temperature decreases, too. Except for the specific period the values of BI remain high while the body temperature remains low. Because of this inconsistency there is little significant correlation between the body temperature and the values of weight-modified BI (correlation coefficient R=0.424) as shown in FIG. 6 .
The decending of BI curve for the specific period (the body temperature descending) appears to be attributable to the swell of women's bodies; the water content of women's body is so high that the BI value may decrease significantly. Thus viewed, the values of BI and the swell are related as follows: as the swell appears, the values of BI decrease, and as the swell disappears, the values of BI increase. This suggests that a decision as to whether the swell appears in women's bodies can be made in terms of the values of BI. Apparently such a decision is impossible on the basis of the variation of body temperature. It is well known that appearance of the swell prior to the menstruation period is closely related with the PMS. Specifically the PMS accompanies the swell in women's bodies, and the PMS is liable to get worse as the swell increases in size. This suggests that a decision as to whether the woman undergoes the PMS can be made on the basis of the variation of BI, as is the case with the swell.
FIGS. 7 and 8 illustrate how the weight-modified values of BI and the body temperature are related with the monthly variation of female physical condition. These graphs show clearly that the BI curve is closely related with the monthly variation of female physical condition. This suggests that a decision on the monthly variation of female physical condition can be made on the basis of the BI curve, as for instance, follows: the ovulation day can be expected from the high-to-low transition of BI curve. Likewise, appearance of the swell or the PMS can be expected. Termination of the PMS can be decided from the rise of the BI curve. Also, termination of the menstruation period can be decided from the BI curve remaining stable at high level. There appear three different phases noticeable from the BI curve in the PMS-prevailing period. As seen from FIG. 7, the BI curve rises and falls just before the beginning of the menstruation period (noticeable from women of Type A). From the rise-and-fall of the BI curve it may be expected that this type of women undergo the PMS. The BI curve remains constant for women of Type B whereas the BI curve decreases for women of Type C. The descendent of the BI curve accompanies an irritation characteristic of PMS and appearance of the swell.
The values of BI were determined by measuring bioelectrical impedance appearing between woman's feet. The same results as described above were confirmed on so numerous women that the proposed method may be justly applied to diagnosis of women's periodical physical and mental condition. Measurement of bioelectrical impedance between both hands or one hand and one foot may be permitted, but measurement of bioelectrical impedance between both feet is most appropriate for the purpose because of the symptoms being clearly discernible from the BI curve provided by such inter-feet measurements.
Now, some embodiments of the present invention are described below with reference to drawings.
FIG. 9 shows the appearance of a female physical condition managing apparatus 10 according to a first embodiment. It comprises a scale-and-bioelectrical impedance meter 20 and a control box 40 connected to the scale-and-bioelectrical impedance via infrared or radio wave or via an electric cable. The scale-and-bioelectrical impedance meter 20 has constant current feeding electrodes 21 a and 21 b and voltage measuring electrodes 22 a and 22 b provided on its front side whereas the control box 40 has a group of operation buttons 41 a to 41 j and a display 42 provided on its front side. The group of operation buttons include a power source button 41 a , a measurement button 41 b , a registration button 41 c , a transmission button 41 d , a menstruation button 41 e , a decision button 41 f , a mode selection button 41 g , a cancel button 41 h , a reset button 41 i and a direction button 41 j . The direction button 41 j has four button sector bearing directional indications →, ←, ↑ and ↓ thereon.
FIG. 10 is a block diagram showing the functional structure of the female physical condition managing apparatus 10 . The scale-and-bioelectrical impedance meter 20 comprises a high-frequency constant current circuit 23 for supplying a weak high-frequency constant current of fixed value to the constant current feeding electrodes 21 a and 21 b , a voltage measuring circuit 24 for measuring the voltage appearing between the voltage measuring electrodes 22 a and 22 b , a weight measuring unit 25 , an A/D converter 28 for converting the measured voltage and weight to digital values and a wireless transmitter section 29 .
In addition to the data-inputting buttons 41 a to 41 j and the display 42 for displaying the variation of BI, the determined physical condition and such like, the control box 40 comprises a clock 43 for showing on what day and time the measurement is effected, a memory 44 for storing the measured values of BI, the day and time at which measurements are effected, a CPU 45 for making a decision on the female physical condition on the basis of data pertaining to the menstruation period inputted by the data input device 41 and the measured values of BI, and a wireless communication section 46 .
In this particular embodiment the scale-and-bioelectrical impedance meter 20 and the control box 40 make up the female physical condition managing apparatus. The scale-and-bioelectrical impedance meter 20 and the control box 40 may be combined as a whole.
Now, the manner in which the female physical condition managing apparatus works is described.
FIGS. 12 to 18 , 20 and 21 show the flowcharts describing the operation of the apparatus. FIG. 19 shows how selected phases of operation are shifted to each other by depressing selected operation buttons. First, referring to FIG. 12 showing the main program, the power button 41 a is depressed at STEP S 1 , thereby putting the apparatus in circuit with the power supply. The apparatus is initialized at STEP S 2 as later described in detail. All the days of the present month are shown in the form of calendar in the display 42 at STEP S 3 , as seen from FIG. 22 . Different icons for commands appear on the heading of the screen. The figure encircled with a rectangle represents the present day.
By depressing the button sector ↑ of the direction button 41 j , the measurement button 41 b , the selection button 41 g . the menstruation button 41 e or the button sector ← or → of the direction button 41 j , S 4 , S 5 , S 6 , S 7 , S 8 or S 9 is executed, respectively.
At STEP S 4 the apparatus works in the pregnancy-possible period presenting mode, thus displaying days corresponding to the expected start of the menstruation period and the possibility of pregnancy in the form of calendar. At STEP S 5 the apparatus works in the measurement mode in which: the value of bioelectrical impedance and other factors are determined; and the results of the measurements are displayed. Some details are described later. At STEP S 6 the apparatus works in the icon mode, in which any command selected by marking which one of the icons appearing in the calendar page may be executed. Some details are described later.
At STEP S 7 the day of menstruation is specified on the calendar page. At STEP S 8 the calendar page of the previous month appears on the screen. At STEP S 9 the calendar page of the next month appears on the screen. At STEP S 10 the auto-power-off timer is counted up. The timer permits disconnection from the power supply after the predetermined length of time has passed, and is reset in response to the turning-on of the power supply or to key depression. At STEP S 11 a decision is made as to whether the predetermined length of time has passed. In the negative case the proceeding returns to STEP 10 . At STEP S 12 the power supply is made to turn off.
Referring to FIG. 13, the initializing process (STEP S 2 ) can start only when the power supply button is depressed for the first time or when the resetting button is depressed. A decision can be made as to whether the power supply has turned on before (in the affirmative case no initialization required); an initializing flag is set when the initialization has been completed, and therefore, at the first step it is necessary to check whether the flag has been set, and in the affirmative case no initialization is required.
At STEP S 21 all inner variables are initialized. At STEP S 22 the clock 43 is set for the present day and time. At STEP S 23 the beginning day of the latest menstruation period or latest menstruation date is inputted.
Referring to FIG. 14, the pregnancy-possible period displaying mode (STEP S 4 ) is described below. No corresponding icon appears in the screen because the relevant information needs to be kept confidential. At STEP S 31 the pregnancy-possible period and the beginning day of the menstruation period (or beginning of menstruation) are shown on the screen, as seen from FIGS. 23 and 24. Specifically in FIG. 23 the ovulation day is indicated by a double circle ⊚, and the words, “GOOD” sandwiching the double circle ⊚ represent the pregnancy-possible period. The double-circle and the words appear alternately with the days hidden behind, blinking all the time. The Figure encircled with a rectangle represents the present day.
Referring to FIG. 24, the expected menstruation beginning day is indicated by the letter M, and the letter and the expected day appear alternately, and blink. In a case where the pregnancy-possible period and the menstruation beginning day span two months, the arrow icon → blinks at the upper, right corner (see FIG. 23 ). The arrow button sector is depressed so that the next month calendar page appears (see FIG. 24 ). The next month calendar page has an arrow icon blinking on its upper left corner. In this example the pregnancy-possible period is five days long, including two days before and after the ovulation day. In another example the pregnancy possible period is determined to be nine days long, including the nineteenth to eleventh days counted backward from the day previous to the subsequent expected menstruation beginning day.
At STEP S 32 a decision is made as to whether the cancel button 41 h or ↓ button sector was pushed or not. In the affirmative the proceeding returns to the STEP S 3 , and then, the pregnancy-possible period presenting mode is finished. At STEP S 33 the timer reaches the set count. At STEP S 34 a decision is made as to whether the predetermined length of time has passed or not. In the negative the proceeding returns to STEP S 32 . In the affirmative the proceeding goes to STEP S 35 , where the power supply is disconnected.
Referring to FIG. 15, the measurement processing (STEP 5 ) is described in detail. At STEP S 41 a message reading “Please step on the bioelectrical impedance meter.” appears and blinks in the display, as seen from FIG. 25 . At the same time the date and time appear at the heading of the screen. When the cancel button 41 h is pushed, the proceeding returns to STEP S 3 .
At STEP S 42 the user stands on the bioelectrical impedance meter 20 equipped with the weight scale. Specifically she stands on the bioelectrical impedance meter with the toes and heels of the left and right feet put on the constant current feeding electrodes 21 a and 21 b and the voltage measuring electrodes 22 a and 22 b respectively. Now, the measurement starts with the weight of the user. At STEP S 43 a high-frequency, constant current circuit 23 makes a high-frequency, weak current flow in her body via the constant current feeding electrode 21 a , the toe of the left foot, the left leg, the lower part of her abdomen, the right leg, the toe of the right foot and the constant current feeding electrode 21 b . A voltage measuring circuit 24 determines the voltage appearing between the voltage measuring electrodes 22 a and 22 b , thus determining the value of BI. The CPU 45 allows the display to show a sinusoidal wave of monthly-period curve as seen from FIG. 26. A chick character and a white square move on the sinusoidal curve back and force. A linear or circular curve may be used in place of the sinusoidal curve. The chick character may be replaced by another lovely animal shape. Some measurement data may be retrieved from the memory 44 to be shown by means of television opaque projector. This has the effect of releasing from the boring condition while waiting for the result. The white square □ may be replaced by the circle ◯ or . The chick character may be changed in color or shape each and every month or day. The value of BI determined at STEP S 44 is modified according to the weight-modification equation (1) or (2) as described above to provide the weight-modified BI value.
At STEP S 45 the present physical condition is determined in consideration of the female physical condition-and-bioelectrical impedance relationship. The required determination can be made on the basis of the present weight-modified BI (which is determined at STEP S 44 ), the previous weight-modified BI (which is retrieved from the memory 24 ) and data collected for the menstruation period as follows:
the menstruation beginning day has been specified at STEP 7 in FIG. 12, and is regarded as the beginning day of the menstruation period, and the week counted forward from the beginning day of the menstruation period is called “First Period” (menstruation period). The “Second Period” (Good Condition Period) spans from the day following the termination of the “First Period” to the day previous to the first day on which the BI value is measured to be 4% less than the average BI value of the Second Week of the previous monthly record. The “Third Period” (Steady Period) spans from the day following the termination of the “Second Period” to the day one week backward from the beginning day of next menstruation period, which beginning day is presumed to be from the history or past record of female physical condition. Finally, the “Fourth Period” (PMS period) spans from the day following the termination of the Third Period to the specified beginning day of the next menstruation period. Appearance of PMS can be determined by making a decision as to which type of graphic variation appears at the transition to the rise of BI curve, TYPE A, B or C (see FIG. 7 ). Specifically when the present physical condition is found to be of TYPE A, the appearance of PMS may be presumed. The ovulation day may be justly determined as falling on the fourteenth day counted backward from the beginning day of next menstruation period, which beginning day is determined from the past record of data. The ovulation day is the last day of the “Good Condition Period”, and if the ovulation day should fall on the day following the last day, the pregnancy-possible day needs to be corrected accordingly.
The practice of a decision being made as described requires the past record of data, which was made at least one month previous to the decision making. In a case where no prior record is available, the message which reads “required data unavailable” appears in the display.
Now, the manner in which a decision is made as to whether the swell characteristic of PMS appears is described below. The average value of BI is determined from those recorded for a selected PMS period in the past, and the so determined average BI value is used as the STANDARD. Specifically the degree of swell is determined as SWELL LEVEL 1 when the BI value decreases 1% down with respect to the STANDARD, and the degree of swell rises one level high each time the BI value has decreased 1%
At STEP S 46 the measurement and decision is completed to show the so decided physical condition in the display, as later described in detail. At STEP S 47 the → button sector is depressed, or otherwise, the predetermined length of time has passed, and then, the message which reads “Push the record button to record the data.” appears in the display. The record button 41 c is pushed to store in the memory 44 the weight-modified BI value and the weight, both of which are determined this time. Then, the proceeding returns to the main program.
Referring to FIG. 16, the physical condition presenting processing is described (STEP S 46 ). Referring to FIG. 27, a circle ◯ on the sinusoidal curve stays on the day on which the measurement is made, and it blinks there. At the same time, the message describing the present physical condition such as “PMS” appears and blinks, too. After a while the blinking stops, allowing the word to appear still. The letter “M” appearing at the lower left and right corners indicates the menstruation period. At STEP S 142 the → button sector is depressed, or otherwise, the predetermined length of time has passed, and then, the message which describes the physical condition appears in the display, as shown in FIG. 28 . The message contains “Swell level”, “Feeling”, “Body condition”, “Skin condition” and “Pheromone”. The “Swell level” is given by the number of reversed marks, each representing one level high. The levels of “Feeling”, “Body condition”, “Skin condition” and “Pheromone” in “First Period” (Menstruation Period) “Second Period” (Good Condition Period) and “Third Period” (Steady Period) are given in terms of the number of days counted from the beginning of each period. As for the PMS period the levels of “Feeling” and “Body condition” are determined from the swell level, which is determined from the variation of BI values as described at STEP S 45 . The increase of swell in size indicates the intracerebral edema. Then, the woman may be impatient, and the level of “Feeling” lowers. Also, she feels lassitude, and accordingly the “Body condition” remains at a low level. The “Pheromone” will increase to the maximum level (100%) on the ovulation day. In this particular example these mental or physical conditions are given in the form of bar graphs, but they may be given in the form of circular or line graph or in the form of radar chart. A three-dimensional presentation is possible. At STEP S 143 the → button sector is depressed or otherwise, a predetermined length of time has passed, advisory messages in connection with the physical or mental condition are given, as seen from FIG. 29 . At STEP S 144 the → button sector is depressed or otherwise, a predetermined length of time has passed, and then, if a decision is made on the pregnancy possibility, the message is given in the display 42 , as seen from FIG. 30 . At STEP S 145 the → button sector is depressed or otherwise, a predetermined length of time has passed. Then, the weight and the percent fat are given with indications (↑) and (↓), as seen from FIG. 31 . At STEP S 146 the → button sector is depressed or otherwise, a predetermined length of time has passed. Then, the display shows the average of the days included in the menstruation cycle each of the previous six months, the average the menstruation cycle beginning and ending days, the number of the days included in the weight, the menstruation cycle and the average weight for the menstruation cycle, all counted or calculated in selected menstruation cycles in the past.
Referring to FIG. 17, icon mode processing (at STEP S 6 ) is described below. First, the body cycle icon (see the top of FIG. 22) is selected by the selection button 41 g , and then the decision making button 41 f is depressed, allowing the proceeding to advance to STEP S 51 , at which the processing of body cycle presentation is effected. The graphic presentation icon is selected by the selection button 41 g , and then the decision making button 41 f is depressed, thereby giving the graphic presentation in the display. The diary logging-and-reading icon is selected by the selection button 41 g , and then the decision making button 41 f is depressed, allowing the proceeding to advance to STEP S 53 , at which the diary logging-and-reading is permitted. Likewise, the inquiry icon is selected, and the decision making button 41 f is depressed, thereby allowing the proceeding to advance to STEP S 54 , at which the inquiry is permitted. Now, the alarm setting icon is selected, and the decision making button 41 f is depressed, so that the proceeding may advance to STEP S 55 , at which the required alarm setting is effected. By this processing, the date and time that are famous for alarm sound are set. The sound setting icon is selected by the selection button 41 g , and then the decision making button 41 f is depressed, thereby allowing the proceeding to advance to STEP S 56 , at which the sound setting is effected. The on-and-off operation for producing sound other than alarming sound can be set. Some details of each processing are described below by referring to FIGS. 18 to 21 .
Referring to FIG. 18, the body cycle presentation processing (STEP S 51 ) is described. The cyclic curve (see FIG. 27) appears as is the case with STEP S 141 (see FIG. 16 ). When the cancel button is depressed, the proceeding returns to STEP S 3 . The → button sector is depressed or otherwise, a predetermined length of time has passed. As is the case with STEP S 142 , the cycle message appears (see FIG. 28) as described at STEP S 142 . Depression of the cancel button permits the proceeding to return to STEP S 3 . The → button sector is depressed or a predetermined length of time has passed. As is the case with STEP S 143 , advice messages (see FIG. 29) are given at STEP S 63 . Depression of the cancel button permits the proceeding to return to STEP S 3 . The → button sector is depressed or a predetermined length of time has passed. Then, the “Tomorrow's Prospect” message appears at STEP S 64 . Depression of the cancel button permits the proceeding to return to STEP S 3 . The → button sector is depressed or a predetermined length of time has passed. Then, the Tomorrow's Advice messages (FIG. 33) are given at STEP S 65 . Depression of the cancel button permits the proceeding to return to STEP S 3 . In a case where a decision is made on the pregnancy possibility, the → button sector is depressed or a predetermined length of time has passed. Then, the woman is informed of the possibility of being pregnant (FIG. 30) at STEP S 66 , as is the case with STEP S 144 .
Referring to FIG. 19, the graphic presentation processing (STEP S 52 ) is described. The graph given in the STATE ST 71 shows the variation of the weight in a selected month and the average weight (see FIG. 34 ). Depression of the ← button sector makes the presentation transfer to the STATE ST 72 , where the variation of the weight in the preceding month and the average weight are shown. Depression of the → button sector makes the presentation transfer to the STATE ST 71 . Other state transfers equally, too. In the STATE ST 73 the variation of the weight in the following month and the average weight are shown. In the STATE ST 74 the variation of the percent fat in the selected month and the average percent fat are shown. In the STATE ST 75 the percent fat in the preceding month and the averagee percent fat are given. In the STATE ST 76 the variation of the percent fat in the following month and the average value are given. In the STATE ST 77 the graphic presentation of BI values in the selected month and the average value are given. In the STATE ST 78 the graphic presentation of BI values in the preceding month and the average value are given. In the STATE ST 79 the graphic presentation of BI values in the following month and the average value are given. A predetermined length of time has passed without depressing the → or ← button sector, and then, the power supply is made to turn off.
Referring to FIG. 20, the diary logging-and-reading processing (STEP S 53 ) is described. At STEP S 81 a selected date and the diary page of the selected date appear in the display 42 , as seen from FIG. 37 . At STEP S 82 the woman answers each question by selecting YES or NO. In selecting YES the ↑ button sector is depressed, and then, the decision making button 41 f is depressed. In selecting NO the ↓ button sector is depressed, and then, the decision making button 41 f is depressed. Desired entry in the selected previous diary page (or backlogging) may be permitted by using the ← button sector. When the cancel button is depressed, the proceeding returns to STEP S 3 . At STEP S 83 a confirmation screen appears, as seen from FIG. 38 . The woman can say, “YES” or “NO” by pushing the ↑ button sector or ↓ button sector, and by pushing the decision making button 41 f . When “NO” is selected, the proceeding returns to STEP S 81 . At STEP 84 the selected diary page appears (see FIG. 39 ). When the ← button sector is depressed, another selected diary page is shown (see FIG. 40 ). Depression of the → button sector makes the proceeding go back.
Referring to FIG. 21, an inquiry processing (STEP S 54 ) is described. At STEP S 91 a message which reads “What do you want to know?” appears along with some items to be selected, as shown in FIG. 41 . At STEP S 92 the woman pushes the ↑ button sector or the ↓ button sector to scroll, and then the decision making button 41 f is depressed. Examples of the items to be selected are: “Date Day”, “Abnormal Bleeding Day”, “Beginning Day of Menstruation Period”, “Beginning Day of Next Menstruation Period”, “Ovulation Day and Expected Date of Becoming Pregnant”, “Expected Day of Next PMS”, “Suitable Day of Dieting” and such like.
“Suitable Day (Period) of Dieting” can be determined as follows: the “Period” starts three days earlier than the expected Ovulation Day. Assuming that the woman's menstruation cycle has 28 days. The “Period” starts three days earlier than the fourteenth day from the day the menstruation is depressed. As a matter of course the start of the “Period” depends on the average menstruation cycle of the woman in question.
The swell disappears before the ovulation day, and the woman grows slim more or less while the body temperature has not risen yet. It is said that while the woman's body remains in such condition, the dieting can be effectively performed by taking care of food and exercise.
Termination of the “Period” is determined as follows: the BI curve descends to level off. The “Period” terminates on the fourth day counted forward from the beginning of the leveling-off period. Stated otherwise, the “Suitable Day of Dieting (Period)” terminates on the fourth day from the rise of the body temperature. The reason is that the consumption of energy increases while the body temperature remains at a high level.
At STEP S 93 there appears the calendar page containing the day selected at STEP S 92 , which day blinks. Alternatively only the selected date may be displayed with character. Depression of the → button sector makes the proceeding return to STEP S 91 . Otherwise, if a predetermined length of time has passed, the proceeding returns to STEP S 91 . Depression of the cancel button 41 h makes the proceeding return to STEP S 3 . Referring to FIG. 11, a female physical condition managing apparatus 50 according to the second embodiment has a scale-and-bioelectrical impedance meter and a control box both combined as a whole, and is capable of measuring the body temperature of the user. In these respects the apparatus 50 can be distinguished from the first embodiment of FIG. 9 . The female physical condition managing apparatus 50 has constant current feeding electrodes 51 a and 51 b , voltage measuring electrodes 52 a and 52 b , an operating push button 53 and a display 54 arranged on its front. Body temperature measuring sensors 55 a and 55 b are placed at the upper parts of the constant current feeding electrodes 51 a and 51 b . These sensors 55 a and 55 b are so constructed that they may be pinched between selected fingers of both feet. Alternatively an ear measuring type of infrared thermometer may be connected to the female physical condition managing apparatus 50 . A sublingual type of thermometer may be connected for precision measurement. The body temperatures thus measured can be used along with BI values for the CPU to make a decision on the women's monthly physical condition. Therefore, precision decision of the physical condition can be performed.
The female physical condition managing apparatus according to the first and second embodiments are so constructed that BI appealing between both hands or between one hand and one foot may be measured.
A selection button may be provided for selecting individual personal data among those stored in the memory, so that the apparatus may be used by two or more women in common.
It may be possible that the percent fat be determined from the measured BI values, and that the so determined percent fat be given in the display. On the basis of the body temperature and weight thus determined a decision can be made on the woman's periodic physical condition. These data may be given in the display.
Referring to FIG. 43, the display of FIG. 27 is modified as shown in FIG. 43 according to another embodiment. The circular mark ◯ stays on the day in question, blinking and encircling a message describing the present day's physical condition, as is in FIG. 27 . In this particular embodiment the physical conditions on other specified days are shown along with the dates. Examples of such physical conditions are menstruation, “good condition” period, ovulation and next menstruation. A chick appears on the position at which the present day's physical condition is described. The weight appears on the lower, left side.
Referring to FIG. 44, the display of FIG. 26 is modified as shown according to still another embodiment. While measuring and making a decision on a selected subject an egg is rolling rightward, and the egg break. A chick appears from the broken egg just before termination of the decision-making. This animation may be replaced by a monthly incidence such as the transition from the crescent to full moon.
As may be understood from the above, a female physical condition managing apparatus according to the present invention shows the swell, feeling, body condition, skin condition, pheromone and such like in the form of line graph, thereby permitting women to realize the mental and physical conditions of the present day instantly.
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Disclosed is a female physical condition managing apparatus comprising: a bioelectrical impedance-meter; a memory for storing the so determined values of bioelectrical impedance; a decision-making unit for making a decision about the physical or mental condition of a woman on the basis of the time series analysis, which is made on the variation of the determined values of bioelectrical impedance; and a display showing the physical or mental condition of the woman in the form of graphs. This permits women to realize quickly what physical or mental condition they are put in. The female physical condition includes the premenstrual syndrome.
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BACKGROUND ART
This invention relates to a method for introducing a pipe into the ground as well as a drill pipe. U.S. Pat. No. 3,485,052 describes a pipe which is provided with an auger-like screw over the entire length thereof. To prevent upward transport of material, a number of obstructing partitions are provided, which obstructing partitions extend between successive screw threads essentially parallel to the center line of the pipe. The obstructing partitions extend perpendicular to the pipe surface in the radial direction. After a hole has been bored using this device, grouting material is poured into the space left behind as the pipe is withdrawn. This device is best suited for soils which consist of material having a relatively loose granular structure. A problem is that material which is shifted by the screws will be moved over and along the obstructing partition as the latter approaches, as a result of which the obstructing partition exerts only a braking action. Consequently, certainly when withdrawing the pipe and introducing the grouting material, an appreciable amount of soil material, which may or may not be mixed with the grouting material, will be brought to the top. This is undesirable in many applications.
Patent publication WO 95/12050 proposes a construction in which the pipe widens out conically frogs the drill point and then conically tapers again. A screw having a pitch opposite to the pitch of the drill section is provided in the conically tapering section. Furthermore, displacement elements are provided, which extend over a few turns of the screw. The upward shifting of soil material is effectively prevented in this way. The drawback of this device is that it is relatively expensive and particularly complicated to produce. Moreover, a high torque and thus a great deal of energy is required for driving.
Belgian Patent publication 881 598 describes a drill pipe which has a drill head at the free end, which drill head is provided with displacement elements. In this publication it is assumed that the soil moves back to a limited extent after the displacement elements have passed through. However, there is no guarantee whatsoever that this is the case, whilst, furthermore, there is the drawback that, if the soil material does move back, a hole has to be made which is larger than the final diameter of the bore hole. Finally, U.S. Pat. No. 3,540,225 describes a construction with which a pipe is introduced into the ground by driving, that is to say not by rotating.
The aim of the present invention is to provide an improved method with which the soil material can be effectively displaced such that upward transport of large amounts of material is prevented, without a high drive torque being required, it being possible to carry out this method in a particularly simple manner using relatively simple means.
SUMMARY OF THE INVENTION
According to a first aspect the invention relates to a method for introducing into the ground an element consisting of set fluid material, comprising the introduction of a pipe into the ground by screwing with simultaneous displacement of the soil material, wherein during the downward screwing movement a setting fluid is introduced at least in the vicinity of the free end of the pipe, in that screwing takes place exclusively in the vicinity of the free end of the pipe and in that the displacement takes place over essentially the entire length of the pipe.
The fluid material assists in displacement during the downward movement. Furthermore, this holds the displaced soil material at a distance. The various aspects are further promoted because the displacment takes over the entire length of the pipe. In contrast to the construction disclosed in U.S. Pat. No. 3,485 052, screwing takes place exclusively in the vicinity of the free end of the pipe. With the method according to the invention soil material is actually displaced and not impeded.
Using the drive unit described above, pipes having a diameter of between, for example, approximately 30 and 120 cm can be installed, depending on the drive power.
The length over which such pipes can be introduced can be up to 30 meters or more.
As a result of the lower power needed to rotate the (drill) pipe and to introduce to it into the grounds it is also possible to restrict the nuisance inflicted on the surroundings. This relates not only to nuisance in view of the size of the drive installation but also to noise and motor emissions and the nuisance caused by vibration.
There is an essential difference between the method proposed according to the invention for displacement of the soil and techniques and methods with which soil is moved upwards by a spiral with the aid of auger-like components. In the present invention, the soil surrounding the pipe is displaced in a radial direction. In the latter case the friction between the underlying sail and the drill pipe will increase and additional drilling torque and pulling force for removal are needed compared with those required for the construction with a smooth drill pipe. It is possible to restrict the casing friction of the drill pipe with the aid of the method according to the present invention.
If the setting fluid is injected at the same time as the pipe is introduced, it is possible for the fluid to exert a lubricating action, in addition to any groundwater which may be present, between the outside of the pipe and the surrounding soil.
It is possible to leave the pipe permanently in the ground after it has been introduced or to remove it from the ground again. In the latter case, the hole produced on removal must preferably be filled with setting fluid and/or water.
The method described above is suitable both for the production of a foundation pile and for the production of water-retaining barriers, pre-drilling work, jet grouting or the like.
For the production of barriers, the drill pipe is moved successively downwards and then up again in a number of positions located in a series. During this operation a mixture of a fluid which subsequently sets or stiffens is introduced into the ground. This gives rise to a build-up such that a relatively large concentration of setting fluid is present close to the center of the location in which the drill pipe is introduced, which concentration of fluid becomes increasingly lower in the radial direction from the position. However, in combination with the soil already present, an adequate seal is produced.
According to a further aspect the invention relates to a device for introducing a setting fluid material into the ground over an appreciable depth, in order to form an element, with the aid of a pipe of essentially constant diameter introduced into the ground by rotating. The pipe is provided with means for introducing a setting fluid via the means outside the circumscription of the pipe. The pipe is provided on the outside with at least one displacement element. The displacement element extends either parallel to the center line of the pipe or at an angle therewith, the pitch being at least five times the external diameter of the pipe. The pipe is provided with a drill element at the free end, wherein from the drill element the pipe is essentially smooth over the entire length thereof and is provided only with the at least one displacement element. The displacement element or elements extend essentially over the entire length of the pipe.
In order to provide for optimum displacement, the angle between the displacement element and the outer circumference of the pipe viewed in the direction of flow is in the range between 120° and 150°. The displacement element preferably extends over a restricted portion of the circumference of the pipe and the portion makes up at most 1/6 of the circumference thereof.
The displacement elements and the drill pipe can each be of any shape conceivable by those skilled in the art, Preferably, however, the displacement elements are constructed as ribs. In this context it is possible for the displacement elements to be fitted such that they are retractable with respect to the pipe. The displacement elements can, moreover, be of any length. This length can vary from a few centimeters to a length equal to that of the drill pipe.
The drill pipe according to the invention can be provided with a so-called drill point close to the free end at the bottom. It is essential only that displacement elements are provided over part of or the entire length of the pipe.
The radial height of the displacement elements or ribs is preferably between approximately 15 and 150 mm. The height depends on the application and diameter of the drill pipe and the composition of the soil. Moreover, it is possible for the height to increase or decrease towards the bottom, viewed over the length of the drill pipe.
It is also possible to construct the rib or the displacement element such that a cavity for transport of the setting fluid is formed inside it, that is to say within the bounds between the rib and the drill pipe. It is, of course, also possible for setting fluid to move, in addition or exclusively, through the interior of the drill pipe. Optimum lubrication is obtained if outlet openings for the fluid are made in the ribs. This opening can be elongated or circular close to the bottom of the drill pipe, but can likewise comprise a number of openings distributed over the height of the drill pipe. With this arrangement it must, of course, be possible for the openings located higher up to be closed off in some way or other, if such openings extend above ground level. For some applications the drill pipe will be built up during operation by coupling various pipe sections.
DETAILED DESCRIPTION OF THE INVENTION
These and other features of the present invention will become more apparent upon reading the following description taken in conduction with the accompanying drawings, wherein
FIG. 1 shows diagrammatically, in cross-section, a drill pipe according to the invention introduced into the ground;
FIG. 2 shows a cross-section along the line II--II in FIG. 1;
FIGS. 3a to 3e show further embodiments of the drill pipe according to the invention;
FIG. 4 shows the distribution of grouting material following introduction of a drill pipe according to the invention into the ground, and
FIG. 5 shows a top view of a method for the production of a barrier with the aid of the drill pipe according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1 the drill pipe according to the invention, which is indicated in its entirety by 1, has been introduced into ground 7. Although this pipe is shown in the figure as a single part, it is readily possible that this pipe is built up of several parts. Drill pipe 1 is provided with a point 2 which has screw and/or displacement means 5. The screw and/or displacement means 5 serve to render penetration into the soil possible when shifting soil material. Above the screw and/or displacement means 5 the drill pipe 1 is of essentially circular construction, as can be seen from FIG. 2. The pipe is, however, provided with three displacement elements or ribs 3. In the embodiment shown the ribs are of triangular construction and a channel 4 is delimited inside them, which channel is joined, in a manner which is not shown in more detail, to a feed for setting fluid, such as grouting material. This feed is formed by the space between jacket 16 and drill pipe 1. As can be seen by reference to FIGS. 1 and 2, the ribs 3 are provided with outlet openings 6. In FIG. 2 an arrow 8 indicates the direction of rotation of the pipe 2 during introduction and it can be seen from this that the discharge of grouting material through opening 6 is rendered possible by the leading edge of rib 3.
As can be seen from FIG. 2, the flow angle α, that is to say the angle between the contact surface of the pipe and the contact face of rib 3, is in the range between 120° and 150°. The diameter of the pipe used can be between 20 and 100 cm.
In the embodiment shown in FIGS. 1 and 2, the ribs extend only in the vertical direction over the entire length of the pipe.
However, it is also possible for these ribs to make a small angle with the center line 10 of the pipe 11, as is shown in various variants in FIGS. 3a-3d. In FIG. 3a the rib which extends spirally is indicated by 13. It can be seen that the pitch of a rib of this type is particularly large and of the order of from a few to tens of meters. In FIG. 3d the rib extends in a straight line, whereas in FIG. 3e a number of short ribs 15 is arranged which form a continuous series and are offset with respect to one another.
FIG. 4 shows the pipe from FIG. 1 after introduction of grouting material has been completed.
It can be seen that the section 9 of the ground 7 in which grouting material is present is many times larger than the size of the pipe. In this way a large surface area of the ground can be covered in a particularly efficient manner.
FIG. 5 shows a number of such sections 9 located alongside one another. A barrier can be built up in this way. With this procedure the drill pipe is removed after making the opening.
In the construction described above the rib is of triangular design. However, it must be understood that the rib can have any other acceptable shape, for example sinusoidal. The shape chosen for the rib is partly dependent on the type of ground to be bored through. This applies in particular to that portion of the rib which first comes into contact with the soil material. The portion on the trailing side can be chosen virtually arbitrarily, but in view of the fact that the direction of rotation can or must also be reversed, this side of the displacement element or rib can be of the same construction as the leading side just described. The rib can be fixed with respect to the drill pipe in any manner known from the prior art. For instance, the rib can be of retractable construction, but it is likewise possible to fix the rib by welding to the drill pipe. With this arrangement both the drill pipe and the triangular rib can be made of steel. However, preference is given to the use of a relatively high grade material for the ribs because the ribs are exposed to an appreciable load when effecting displacement. As a result it is also possible to keep the thickness of the material of the rib relatively small. With the aid of the drill pipe described above it is possible to use a larger pipe diameter for the same power or the same pipe diameter at a lower power. With this arrangement it is not necessary further to increase the thickness of the wall of the pipe. The friction between the drill pipe and the surrounding soil is limited by the displacement elements, which effect can be even further promoted by the lubricating action of the setting fluid which is introduced.
The construction according to the invention can be produced simply, that is to say at low cost, it still being possible to recover the pipe after use.
Outflow of the grouting mixture through the outflow openings can be realised by means of an open system or can be controlled with the aid of valves. Any setting fluid can be used with the method described above. In this context preference is given to grout and the introduction pressure can be between 2 and 600 atm.
Although the invention has been described above with reference to a circular opening in the drill pipe, it will be understood that said opening can have any other shape, such as square, rectangular, etc. Similar variations in the various components likewise apply for other constructions of the drill pipe. Such variations can comprise all construction details known from the prior art.
It must be understood that these and other variants obvious to a person skilled in the art lie within the scope of the appended claims.
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Method and device for introducing a pipe into the ground. In order to restrict the drive power necessary to the greatest possible extent and to optimize the diameter of the pipe, it is proposed that the soil surrounding the pipe is displaced in the radial direction. To this end the pipe is provided with one or more displacement elements.
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BACKGROUND OF THE INVENTION
The invention relates to a hinge, preferably for furniture, comprising a hinge arm or a fixed-body hinge section and a pivotable hinge section flexibly connected thereto, whose movement to the closed position is at least damped over part of the closure path by a rotation damper.
Hinges of this type are known, for example, from DE 201 04 100 U1. In these known hinges, conventional rotation dampers are used wherein the rotation body damped by a damping fluid is located in a cylindrical housing and on at least one axial pin of the rotation body supported in the covers of the housing there is fixedly positioned a pinion which meshes with a toothed segment of one of the pivotable hinge sections. This known hinge can only be produced with relatively high manufacturing costs because a pinion-toothed segment arrangement is required to transmit the damping force.
SUMMARY OF THE INVENTION
The object of the invention is thus to provide a hinge of the type specified initially which can be manufactured with a reduced expenditure.
This object is solved according to the invention by the rotation damper being an axial damper whose axis forms a hinge axis of the hinge and whose cylinder is fixedly connected to the hinge section pivotably supported on the axis.
The damping device of this known hinge can be manufactured with very much lower expenditure because the axis of the axial damper forms a hinge axis of the hinge and the cylinder of the axial damper is fixedly connected to the pivotable hinge section so that the axial damper is integrated in a hinge axis of the hinge and special gearing means to transmit the damping force from the rotation damper to the pivotable hinge section are dispensed with.
Rotation dampers in the form of axial dampers suitable for incorporation in the hinge according to the invention are inherently known and are manufactured and distributed in various embodiments. Thus, a detailed description of the design of such known axial dampers is dispensed with here.
Double guide hinges can be damped particularly advantageously by axial dampers in the fashion according to the invention by the axis of the axial damper forming the joint pin of one of the four hinges and the end of the guide supported thereon being fixedly connected to the cylinder.
In a further development of the invention it is provided that one of the fixed joint pins is formed by the axis of the axial damper and the axis is thereby specified by the legs of a U-shaped hinge arm such that one end of the axis projecting beyond the cylinder has a non-circular or polygonal, e.g. square cross-section and engages in a complementary recess of one leg of the hinge arm and the other end bears a circular disk whose diameter is as large as the diameter of the cylinder which is held in a complementary hole of the other leg. In this embodiment the axial damper can be assembled in a simple fashion by sliding it through the hole until the non-circular or polygonal axial pin is inserted in the complementary recess of one leg and the circular disk is inserted in the corresponding complementary hole of the other legs. In this fashion the axis of the axial damper is held non-rotatably on the hinge arm.
According to a preferred embodiment it is provided that one of the pivotable joint pins is formed by the axis of the axial damper and an axial pin is held in a wall of the pivotable hinge section, that the cylinder is connected non-rotatably to an outer end of the guide and the other axial pin is provided with a radial extension with a hole in which the pivotable bolt of the other guide engages. Since the axis of the axial damper is held non-rotatably by the radial extension, the axial pin located at the front during insertion into the pivotable hinge section can be cylindrical.
In order that the axial damper can be inserted simply from one side between the walls of the pivotable hinge section supporting it, it is provided in a further development of the invention that the wall of the pivotable hinge section which lies opposite the wall holding the axial pin, is provided with a hole in which the end region of the cylinder of the axial damper is pivoted with clearance.
In order to fix the pushed-through axial pin of the axial damper in its recess or hole, this can be provided with a rivet head.
The pivotable hinge section or one end of a guide can easily be fixed to the cylinder of the axial damper by providing the cylinder with at least one flattened area for its fixing between the legs of a U-shaped guide or to a pivotable hinge section and providing the legs or the pivotable hinge section with a corresponding complementary recess.
BRIEF DESCRIPTION OF THE DRAWINGS
Exemplary embodiments of the invention are explained in detail below with reference to the drawings. In the figures:
FIG. 1 shows a longitudinal section through a double guide hinge with the damping device according to the invention in its opened position,
FIG. 1 a shows an enlarged view of the circled part in FIG. 1 ,
FIG. 2 shows a diagram of the double guide hinge corresponding to FIG. 1 in its closed position,
FIG. 3 shows a top view of the double guide hinge from FIG. 1 , partly in cross-section,
FIG. 4 shows a longitudinal section through a second embodiment of a double guide hinge with the damping device according to the invention in the closed state,
FIG. 5 shows a top view of a third embodiment of a double guide hinge with the damping device according to the invention, partly in cross-section,
FIG. 6 shows a side view of the axial damper as can be used in the embodiments from FIGS. 1 to 4 , and
FIG. 7 shows a side view of the axial damper built into the double guide hinge from FIG. 5 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The double guide hinges from FIGS. 1 and 5 comprise conventional double guide hinges which, however, have the feature that they are fitted with a rotation damper in the form of an axial damper to damp the closure movement of doors or flaps.
The double guide hinges shown in the drawings consist of a U-shaped hinge arm 1 made of Zamak or a stamped metal part, which is affixed to a cupboard wall or a body section 2 in a usual fashion. Supported between the legs of the hinge arm 1 are the ends of guides 3 , 4 of which the guide 3 at both its ends and the guide 4 at its rear end are provided with U-shaped, inclined bearing lugs which are provided with holes. At its outer end the guide 3 is provided with a rolled-up eye 5 which is supported on a bolt 7 held in the hinge cup 6 . On the bearing bolt 8 which is held between the legs of the hinge arm 1 and on which the inner end of the outer guide 3 is supported, there is mounted a double hairpin-shaped curved leaf spring 9 which is supported with its one leg on the web section of the hinge arm 1 and with its other leg on a control curve constructed at the inner end of the inner guide 4 . The outer end of the outer guide 3 is supported on a bolt 10 held in the hinge cup 6 . The hinge cup 6 is fixed as shown in a blind hole of a door or flap 11 . In this respect the double guide hinges shown in the drawing are of known design so that a more detailed description can be dispensed with.
In the exemplary embodiment from FIGS. 1 to 3 the inner end of the inner guide 4 is supported via the lugs 12 bent from it in a U-shaped fashion on an axial damper 13 , which is shown in detail in FIG. 6 and whose axial pins 15 , 16 which project beyond the cylinder 14 at both ends, are held in the legs of the hinge arm 1 . The leg 17 of the hinge arm 1 located at the back in FIG. 1 is provided with a square opening in which the square axial pin 15 of the axial damper 13 matched thereto and inserted therein is held non-rotatably. Adjacent to the square axial pin 15 the axis 18 of the axial damper 13 is provided with an annular step 19 via which the axis 18 is supported on the edge of the square opening in the rear leg 17 of the hinge arm 1 . The cylinder 14 of the axial damper 13 is provided with flattened areas 20 on the opposite sides. The lugs 12 of the inner guide 4 are provided with openings corresponding to the profile of the cylinder 14 so that the axial damper 13 can be slid through these openings such that the inner guide 4 is connected non-rotatably to the cylinder 14 . In order to allow the axial damper 13 to be slid through the lugs 12 , on the right axial pin of the axial damper 13 which can be seen from FIG. 6 there is placed a circular disk 16 which is held in a complementary hole 22 of the front leg 23 of the hinge arm 1 . The diameter of the disk 16 corresponds to the diameter of the cylinder 14 or is slightly larger than this. In order to fix the axis 18 of the axial damper 13 the end of the square axial pin 15 which passes through the square opening in the leg 17 is provided with a rivet head 24 .
In the exemplary embodiment from FIG. 4 the inner end of the outer guide 3 is supported between the legs of the hinge arm 1 on an axial damper 13 in the fashion described with reference to FIGS. 1 to 3 and 6 . Since in the exemplary embodiment from FIG. 4 the closing spring cannot be held on the axis formed by the axial damper, between the legs of the hinge arm 1 there can be arranged an additional bolt 25 on which a spring clip 26 can be mounted.
In the exemplary embodiment from FIG. 5 the outer end of the outer guide 3 is supported between the walls 29 , 30 of the hinge cup 6 on an axis which is formed by the axial damper 28 which can be seen from FIG. 7 . The cylinder 14 of the rotation damper 28 is held non-rotatably in the fashion described in openings of the lugs bent in a U shape from the web section of the guide 3 . The right axial pin of the axial damper 28 which can be seen from FIG. 7 is provided with a radial extension 32 which is provided with a hole 33 into which engages one end of the bearing bolt 34 on which the rolled-up eye 5 of the inner guide 4 is supported on the hinge cup 6 . Since the axis 18 of the axial damper 28 is held non-rotatably by the radial extension 32 , the other axial pin 34 of the axial damper 28 can be constructed as round and inserted in a hole in the wall 30 of the hinge cup 6 . The axial pin 34 is again provided with a rivet head 35 to hold it.
In order that the axial damper 28 can be slid from the slide-in side formed by the wall 29 of the hinge cup 6 between the walls of the hinge cup 6 and the lugs of the outer guide 3 , the wall 29 situated opposite the wall 30 of the hinge cup 6 which holds the axial pin 34 , is provided with a hole in which a cylindrical disk-shaped section 34 is held, which is connected non-rotatably to the axis 18 , is constructed integrally with the extension 32 and whose diameter is at least as large as the diameter of the cylinder 14 .
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The movement of a hinge, preferably for furniture, comprising a hinge arm or a fixed-body hinge section and a pivotable hinge section flexibly connected thereto, is damped by a rotation damper at least damped over part of the closure path to the closed position. In order that the hinge can be manufactured at reduced cost, the rotation damper is an axial damper whose axis forms a hinge axis of the hinge and whose cylinder is fixedly connected to the hinge section which is pivotably supported on the axis.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to Taiwan Patent Application No. 101130908, filed on Aug. 24, 2012, the contents of all of which are incorporated herein by reference in their entirety.
BACKGROUND
[0002] 1. Technical Field
[0003] The disclosure relates to power apparatuses, and particularly to a power adapter and a power connector.
[0004] 2. Description of Related Art
[0005] Power connectors (e.g., power adapters) connect electronic devices to a power supply, to supply power to the electronic devices. Most of the power connectors consume a small amount of electricity even if no electronic device is connected to the power connectors, which wastes energy. Therefore, there is room for improvement in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The accompanying drawings are included to provide a better understanding of the disclosure, and are incorporated in and constitute a part of this application. The drawings illustrate embodiments of the disclosure and, together with the description, serve to explain the principles of the disclosure.
[0007] FIG. 1 is a schematic view of one embodiment of a power connector connecting an electronic device and a power supply.
[0008] FIG. 2 is a plan view of a power adapter according to an exemplary embodiment.
[0009] FIG. 3 is a cross-sectional view of the power adapter along II-II line of FIG. 2 .
[0010] FIG. 4 is a cross-sectional view of the power adapter along III-III line of FIG. 2 .
DETAILED DESCRIPTION
[0011] Examples of the present embodiments are illustrated in the accompanying drawings. Wherever possible, the same or similar reference numbers are used, in the drawings and the description, to refer to the same or like parts.
[0012] Referring to FIG. 1 , a power connector 900 is configured to electrically connect a first device 51 and a second device 52 , to transmit electrical power therebetween. In the embodiment, the first device 51 may be a power source (e.g., a movable power supply device). The second device 52 may be an electronic device (e.g., a mobile phone or other device). In the embodiment, the power connector 900 includes a connection port 910 , a main portion 920 , and an electrical wire 930 connected between the connection port 910 and the main portion 920 . The connection port 910 is configured to connect to the first device 51 . The main portion 920 is configured to connect to the second device 52 . The electrical wire 930 includes a connection terminal 931 and a movable conductive member 980 .
[0013] The main portion 920 includes an insulating holding body 921 having a switch 970 within an inner space of the insulating holding body 921 . The insulating holding body 921 defines a receiving space 924 for receiving the switch 970 . The receiving space 924 has an opening 925 . The second device 52 is electrically connected to the power connector 900 by insertion partial of the second device 52 in the opening 925 . The insulating holding body 921 defines two protrusions 926 protruding from opposite inner sidewalls of the insulating holding body 921 , respectively. The connection terminal 931 of the electrical wire 930 is fixed on an inner sidewall of the insulating holding body 921 and spaced a certain distance from one of the protrusions 926 . The switch 970 includes a first magnet 971 and a second magnet 972 . The first magnet 971 and the second magnet 972 are arranged to repel each other. The second magnet 972 is arranged at a side of the first magnet 971 adjacent to the opening 925 . The protrusions 926 prevent the second magnet 972 from moving out of the receiving space 924 . The connection terminal 931 is arranged adjacent to the first magnet 971 , and the movable conductive member 980 is located above the second magnet 972 . At rest, the movable conductive member 980 is disconnected and distanced from the connection terminal 931 due to repulsion between the first magnet 971 and the second magnet 972 . When a portion of the second device 52 is inserted into the insulating holding body 921 through the first opening 924 , the second magnet 972 is pushed to drive the movable conductive member 980 to connect with the connection terminal 931 . Then, the main portion 920 receives power from the first device 51 and the main portion 920 starts working, and power is transmitted from the first device 51 to the second device 52 . When the second device 52 is moved out of the receiving space 924 , the repulsion between the first magnet 971 and the second magnet 972 drives the movable conductive member 980 away, to disconnect the movable conductive member 980 from the connection terminal 931 . Thereupon, the main portion 920 stops working because of the lack of power.
[0014] The main portion 920 of the power connector 900 is thus activated only when the second device 52 is inserted into the inner space of the main portion 920 , and energy waste is avoided.
[0015] Referring to FIG. 2 to FIG. 4 , a power adapter 100 according to an exemplary embodiment is shown. The power adapter 100 is configured to convert alternating current (AC) into direct current (DC) to power other electronic devices (not shown). The power adapter 100 includes a plug 110 , an AC to DC converter 120 , a switch 130 , a DC output member 150 , a first electrical wire 181 , and a second electrical wire 182 . The first electrical wire 181 is electrically connected between the AC to DC converter 120 and the plug 110 . The second electrical wire 182 is electrically connected between the AC to DC converter 120 and the DC output member 150 . In the embodiment, the AC to DC converter 120 converts external AC input from the plug 110 into DC, and outputs the DC via the DC output member 150 to other electronic devices.
[0016] In the embodiment, the power adapter 100 further includes a third electrical wire 183 and a fourth electrical wire 184 . The third electrical wire 183 is also electrically connected between the plug 110 and the AC to DC converter 120 . The first and third electrical wires 181 , 183 carry live and neutral supplies. Particularly, the first electrical wire 181 is a live wire and the third electrical wire 183 is a neutral wire. The fourth electrical wire 184 is a ground line. The first electrical wire 181 includes a first terminal 186 and a second terminal 187 which are normally connected with each other when an external device is connected to the DC output member 150 . When no external device is connected to the DC output member, the first terminal 186 and the second terminal 187 are disconnected and spaced from each other. The first electrical wire 181 is divided into two disconnected portions by the first and second terminals 186 , 187 . The switch 130 controls the connection and disconnection between the first terminal 186 and second terminal 187 .
[0017] The power adapter 100 further includes a first shell 170 made of plastic, which is configured to house the DC output member 150 and electrical wires connected to the DC output member 150 . A portion of the DC output member 150 extends out of the first shell 170 to connect to external devices (not shown), thus supplying power for the external devices. In the embodiment, the switch 130 is accommodated within an inner space of the DC output member 150 .
[0018] The DC output member 150 includes a second shell 190 , a holding structure 160 , and a conductive element 140 . The holding structure 160 accommodates the conductive element 140 , and a portion of the holding structure 160 is accommodated in the second shell 190 . The second shell 190 is made of electrically conductive materials, and a portion of the second shell 190 is accommodated within the first shell 170 . The second shell 190 defines a first opening 191 away from the first shell 170 . The second shell 190 is electrically connected to the fourth electrical wire 184 , and is connected to the ground via the fourth electrical wire 184 . In the embodiment, the second shell 190 is columnar and has a column shaped receiving space. Most of the holding structure 160 is accommodated in the receiving space of the second shell 190 .
[0019] The holding structure 160 , including a sidewall 161 and a bottom wall 162 , is made of insulating materials. The sidewall 161 and the sidewall 162 corporately form a first receiving space 164 to receive the switch 130 . The bottom wall 162 is located at an inner side of the second shell 190 away from the first opening 191 . In the embodiment, the sidewall 161 and the bottom wall 162 corporately form a column shaped structure. A resisting wall 166 extending towards the DC output member 150 is defined on the sidewall 161 , to resist a side of the second shell 190 where the first opening 191 is formed. The first receiving space 164 defines a second opening 165 at a side away from the bottom wall 162 . The holding structure 160 further includes a second receiving space 169 which is formed in the sidewall 161 and the bottom wall 162 and partially surrounds the first receiving space 164 . The second receiving space 169 accommodates the conductive element 140 . A through hole 168 is formed adjacent to the second opening 165 to communicate between the first receiving space 164 and the second receiving space 169 . The sidewall 161 defines at least one protrusion 167 to fix the switch 130 within the first receiving space 164 . The through hole 168 is defined at a side of the at least one protrusion 167 adjacent to the second opening 165 . An end 186 ′ of the first terminal 186 and an end 187 ′ of the second terminal 187 extend into the first receiving space 164 through the sidewall 161 . The ends 186 ′ and 187 ′ are positioned between the bottom wall 162 and the at least one protrusion 167 .
[0020] The conductive element 140 includes a body (not labeled), and a first contact end 142 and a second contact end 143 located at opposite ends of the body. The first contact end 142 extends into the first receiving space 164 through the through hole 168 . The second contact end 143 passes through the bottom wall 162 and extends out of the holding structure 160 , to be electrically connected to the AC to DC converter. In the embodiment, the conductive element 140 may be integrated with the holding structure 160 , and exposed at the through hole 168 . The conductive element 140 is electrically insulated from the second shell 190 .
[0021] The switch 130 includes a first magnet 131 and a second magnet 132 , which are arranged to repel each other. A movable conductive member 133 is arranged on the second magnet 131 . In the embodiment, the movable conductive member 133 is a made of conductive materials. The first magnet 131 is fixed on the bottom wall 162 . The at least one protrusion 167 prevents the second magnet 132 from moving out of the first receiving space 164 .
[0022] In use, the plug 110 is connected to an external power source (e.g., a 110V AC source) and an external device is inserted into the first receiving space 164 through the second opening 165 , thus the first contact end 142 is electrically connected to the external device. Then, the external device forces the second magnet 132 to move until the movable conductive member 133 on the second magnet 132 is electrically connected between the first end 186 ′ of the first terminal 186 and the second end 187 ′ of the second terminal 187 . Thereby, power from the external power source is transmitted to AC to DC converter 120 through the first electrical wire 181 , because the first terminal 186 and the second terminal 187 of the first electrical wire 181 are electrically connected to each other through the movable conductive member 133 .
[0023] When the external device is moved out of the first receiving space 164 , the movable conductive member 133 is driven away by the repulsion between the first magnet 131 and the second magnet 132 and so disconnects from the first end 186 ′ and the second end 187 ′. Thereupon, the external power source cannot pass power to the AC to DC converter 120 , and the AC to DC converter 120 stops working. Therefore, the AC to DC converter 120 of the power adapter 100 works only when the external device is inserted into the inner space of the DC output member 150 , and energy waste is avoided.
[0024] Although numerous characteristics and advantages of the present embodiments have been set out in the foregoing description, together with details of the structures and functions of the embodiments, the disclosure is illustrative only; and changes may be made in detail, especially in the matters of shape, size and arrangement of parts within the principles of the disclosure to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.
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A power adapter between an alternating current (AC) source and an external direct current (DC) consumer device consumes no electrical power until the DC device is connected to the power adapter. The power adapter includes a first magnet, a second magnet which is repelled by the first magnet, and a movable conductive member arranged on the second magnet. The insertion of the external DC device pushes the second magnet towards the first magnet and establishes a connection between the AC power source and the power adaptor. When the external device is removed, the movable conductive member is driven away by a repulsive force between the magnets to disconnect the external AC power source from the power adapter.
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TECHNICAL FIELD
[0001] The present invention pertains generally to adhesives and more particularly to paste adhesives for bonding dissimilar materials (e.g., steel and aluminum) in automotive vehicle structures.
BACKGROUND
[0002] In the automotive vehicle field there is an ongoing need for reducing weight of vehicle components. Traditionally, many vehicle body components have been made from steel. Joining such parts typically has been done by welding. In recent years, vehicle manufacturers have sought to substitute other materials for steel. For example, due to its relatively high strength to weight ratio, aluminum has been examined as a substitute material. When steel and aluminum are employed in combination, unfortunately, welding is an impractical solution. There is thus a need for forming a relatively high integrity joint between steel and aluminum for such applications.
[0003] One particular application that involves forming joints between steel and aluminum is the formation of vehicle roof structures. For these structures, efforts have been made to join an aluminum roof panel structure to a steel frame structure using rivets. When aluminum is attached to steel using rivets as mechanical fasteners, and the assembly is subjected to thermal cycling (such as under paint bake conditions), there results a potential for distortion of the assembly due to differing coefficients of thermal expansion. For instance, the aluminum experiences a bowing effect that increases any gap that may exist between aluminum and steel components.
[0004] Efforts have been made to employ pumpable adhesives between steel and aluminum. By their nature, pumpable adhesives tend to have a relatively low viscosity. As a result, when employed between steel and aluminum, there is a propensity for the steel and aluminum to come into contact with each other during riveting. This creates the potential for galvanic corrosion at the points of contact. Such adhesives also have made it necessary is some instances to employ secondary applications of sealant for assuring moisture protection at the joints.
[0005] What is needed is an adhesive and system for applying it that has characteristics sufficient for allowing riveting while still maintaining a separation between the steel and aluminum components during riveting.
SUMMARY OF THE INVENTION
[0006] The teachings herein meet the above need by providing an improved adhesive and a method for robotically applying the adhesive. Though the teachings find application in riveting aluminum roof panels to steel frames, other applications are possible as well. As can be appreciated, the teachings herein provide a way to avoid galvanic corrosion between aluminum and steel when those materials are riveted in an assembly. The teachings herein also provide for assuring that a bond is maintained between aluminum and steel structures during thermal cycling (e.g., as part of a paint bake operation), which would otherwise cause the aluminum and steel to separate from each other. As a result, it is possible to achieve good water sealing performance in the resulting assemblies during paint bake operations, and the need for subsequent sealing operations can be avoided.
[0007] The advantages herein are made possible by the use of a paste adhesive that is thermally activatable to expand and fill any gaps between aluminum and steel components during a paint bake operation.
[0008] In one aspect, the teachings envision a rivetable adhesive for use in a joint between dissimilar materials, comprising a liquid epoxy resin, an expoxidized polysulfide, a flexibilizer, a solid epoxy CTBN adduct based upon bisphenol A, a phenoxy resin, an impact modifier including methacrylate-butadiene-styrene, a curing agent; and a blowing agent.
[0009] In a more specific example, the teachings herein contemplate a rivetable adhesive for use in a joint between dissimilar materials, comprising an admixture of about 15 to about 25 parts by weight of a liquid epoxy resin reaction product of epichlorohydrin and bisphenol A having an epoxide equivalent weight per ASTM D-1652-11e1 of about 182 to about 192; about 10 to about 20 parts by weight of an epoxidized polysulfide; about 3 to about 20 parts by weight of a liquid epoxy resin reaction product of an epichlorohydrin and a polypropylene glycol; about 1 to about 5 parts by weight of a flexibilizer; about 3 to about 15 parts by weight of a solid epoxy carboxyl terminated butadiene-acrylonitrile (CTBN) adduct based upon bisphenol A: about 15 to about 25 parts by weight of an impact modifier of methacrylate-butadiene-styrene about 15 to about 30 parts by weight of phenoxy resin; about 1 to about 5 parts by weight of a dicyandiamide curing agent; an aromatic substituted urea curing agent accelerator in an amount of about 0.3 to about 1 parts by weight; and a blowing agent having a decomposition temperature of about 190 to about 220° C.
[0010] The adhesives herein may be robotically applied to a substrate. For example, the adhesives may be applied to a steel structure, an aluminum structure or both (or between some other combination of dissimilar materials), and the structures may be bonded together with the adhesive (e.g., after subjecting the adhesive to heat from a paint bake operation as described herein). A rivet may join the dissimilar materials.
DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 illustrates performance data in accordance with the present teachings.
DETAILED DESCRIPTION
[0012] This application claims the benefit of the filing date of U.S. Provisional Application Ser. No. 61/816,394 filed Apr. 26, 2013, the contents of such application being hereby incorporated by reference for all purposes.
[0013] The explanations and illustrations presented herein are intended to acquaint others skilled in the art with the teachings, its principles, and its practical application. Those skilled in the art may adapt and apply the teachings in its numerous forms, as may be best suited to the requirements of a particular use. Accordingly, the specific embodiments of the present teachings as set forth are not intended as being exhaustive or limiting of the teachings. The scope of the teachings should, therefore, be determined not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. Other combinations are also possible as will be gleaned from the following claims, which are also hereby incorporated by reference into this written description.
[0014] The teachings herein make advantageous use of an improved composition for bonding dissimilar materials, and particularly for bonding steel and aluminum. The teachings herein also make advantageous use of an improved method for bonding dissimilar materials, where the method employs robotic application of a paste adhesive between components (e.g., components made of dissimilar materials, such as steel and aluminum) to be joined. Use of a rivet for joining is also contemplated.
[0015] The adhesive material may be a polymeric material that is activated to flow, seal, expand or any combination thereof. It may be a material that forms a foam (e.g., an acoustic foam or a structural foam). It may expand from its original volume to at least 50%, or even at least about 100% (e.g., in the range of about 80 to about 100%) or larger of its original volume.
[0016] The adhesive material may be applied through a die associated with a robot arm. It may be applied at about room temperature. The adhesive may be heated to be applied above room temperature, but below a temperature at which it would be activated for curing, expanding or both.
[0017] The adhesive material may be activated when subjected to heat during paint shop baking operations. In applications where the adhesive material is a heat activated, thermally expanding material, an important consideration involved with the selection and formulation of the material comprising the adhesive material is the temperature at which a material reaction or expansion, and possibly curing, will take place. For instance, in most applications, it is undesirable for the material to be reactive at room temperature or otherwise at the ambient temperature in a production line environment. More typically, the adhesive material becomes reactive at higher processing temperatures, such as those encountered in an automobile assembly plant, when the material is processed along with the automobile components at elevated temperatures or at higher applied energy levels, e.g., during paint or e-coat curing or baking steps. While temperatures encountered in an automobile assembly operation may be in the range of about 148.89° C. to 204.44° C. (about 300° F. to 400° F.), body and paint shop applications are commonly about 93.33° C. (about 200° F.) or slightly higher. Following activation of the adhesive material, the material will typically cure. Thus, it may be possible that the adhesive material may be heated, it may then expand, and may thereafter cure to form a resulting foamed material.
Examples
[0018] Among the following examples are examples that illustrate materials that may are rivetable and exhibit attractive characteristics for the present application. The amounts shown are in preferred parts by weight. The teachings herein contemplate such amounts as well as amounts that are +/−10%, 20%, 30%, 40% or even 50% of those shown. Examples 2 and 3 exhibit particularly attractive viscosity characteristics and exhibit good riveting characteristics. Example 1 is included by way of comparison. The compositions need not necessarily employ the specific commercial examples as set forth in the following Table 1. The compositions may employ the general components as described in the following Table 1. The composition may employ ingredients that exhibit the characteristics set forth in the following Table 1. Even if not explicitly specified, relative proportions of ingredients are within the scope of the teachings herein.
[0000]
TABLE 1
Example 1
Example 2
Example 3
Commercial
(in parts
(in parts
(in parts
Component
Characteristic
Example
by weight)
by weight)
by weight)
Liquid epoxy resin
Epoxide
DER 331
—
16.48
20.60
reaction product
equivalent
from The
of epichlorohydrin
weight (g/eq)
Dow
and bisphenol A
per ASTM D-
Chemical
1652 of about
Company
182-192
Expoxidized
Epoxide
Thioplast
8.00
17.01
15.36
Polysulfide
equivalent
EPS-350
including epoxy
weight (g/eq)
from Akzo
terminated
per ASTM D-
Nobel
polymer with
1652-11e1 of
diglycidyl ether of
about 320
bisphenol A and
chains with
polysulfide
Liquid epoxy resin
Epoxide
DER 732
6.70
6.70
12.92
reaction product
equivalent
from The
of epichlorohydrin
weight (g/eq)
Dow
and
per ASTM D-
Chemical
polypropylene
1652-11e1 of
Company
glycol
about 310-330
Flexibilizer
Polyurethane
DY 965 from
2.50
2.50
2.25
polyol
Huntsman
Solid epoxy resin
Epoxide
DER 662
11.00
—
—
reaction product
equivalent
from The
of epichlorohydrin
weight (g/eq)
Dow
and bisphenol A
per ASTM D-
Chemical
1652-11e1 of
Company
about 590-630
Solid epoxy
Epoxide
Araldite
16.00
5.00
4.52
carboxyl
equivalent
1522 ES
terminated
weight (g/eq)
butadiene-
per ASTM D-
acrylontirile
1652-11e1 of
(CTBN) adduct
about 1560-
based upon
1820
bisphenol A
Impact modifier of
Paraloid
20.98
20.98
18.73
methacrylate-
2691A from
butadiene-styrene
the Dow
(core-shell)
Chemical
company
Phenoxy Resin
TMEP-70
24.77
24.77
19.35
from
Springfield
Indus.
Dicyandiamide
Dycanex
2.85
3.40
3.40
curing agent
1400B from
Air Products
Aromatic
Melting point
Omicure U-
0.76
0.76
0.69
substituted urea
of 220-230° C.
52M from
curing accelerator
Emerald
(e.g., [4,4′-
Methylene bis
(Phenyl Dimethyl
Urea])
Calcined kaolin
pH of about 6
Satintone W
5.49
1.47
1.25
and average
from BASF
particle size of
about 1.3 μm
Blowing agent of
Decomposition
Celogen
0.90
—
—
Activated
temperature of
754A from
azodicarbonamide
about 165 to
Lion
180° C.
Copolymer
Blowing agent of
Decomposition
Celogen AZ-
—
0.90
0.90
Activated
temperature of
120 from
azodicarbonamide
about 190 to
Lion
220° C.
Copolymer
Colorant
Pigment
0.05
0.03
0.03
[0019] FIG. 1 illustrates capillary viscosity data obtainable using the compositions of the teachings herein. As seen, the Example 1 formulation has a much higher viscosity than the viscosity of the Example 2 and 3 formulations. Two different test temperatures are used to cover the range of viscosities among the three materials. The reference test method for capillary viscosity employed is ASTM D 3835-08, pursuant to which the test parameters for the capillaries are as follows: diameter=1 mm, length=16 mm.
[0020] As seen from FIG. 1 , Examples 2 and 3 exhibit a capillary viscosity well below 1000 PaS at temperatures of 70 or 90° C. and a shear rate (sec−1) of 200 or higher. For use herein, it is desirable for materials to exhibit a capillary viscosity in the range of about 100 to about 700 PaS for a shear rate (sec−1) of about 100 to about 1000 at a temperature of 70 or 90° C. For example, it is desirable for materials to exhibit a capillary viscosity in the range of about 100 to about 700 PaS for a shear rate (sec−1) of about 100 to about 1000 at a temperature of 70 or 90° C. Materials may exhibit a capillary viscosity in the range of about 100 to about 400 PaS for a shear rate (sec−1) of about 400 to about 1000 at a temperature of 70 or 90° C. For certain applications it is desirable that the materials (at 70 or 90° C.) will have a capillary viscosity at shear rate (sec−1) in the range of about 200 to about 400 that is less than 700 PaS, or even less than 500 PaS. The materials (at 70 or 90° C.) will typically exhibit a capillary viscosity of at least about 100 PaS at a shear rate (sec−1) of about 200 to about 1000.
[0021] As used herein, unless otherwise stated, the teachings envision that any member of a genus (list) may be excluded from the genus; and/or any member of a Markush grouping may be excluded from the grouping.
[0022] Unless otherwise stated, any numerical values recited herein include all values from the lower value to the upper value in increments of one unit provided that there is a separation of at least 2 units between any lower value and any higher value. As an example, if it is stated that the amount of a component, a property, or a value of a process variable such as, for example, temperature, pressure, time and the like is, for example, from 1 to 90, preferably from 20 to 80, more preferably from 30 to 70, it is intended that intermediate range values such as (for example, 15 to 85, 22 to 68, 43 to 51, 30 to 32 etc.) are within the teachings of this specification. Likewise, individual intermediate values are also within the present teachings. For values which are less than one, one unit is considered to be 0.0001, 0.001, 0.01 or 0.1 as appropriate. These are only examples of what is specifically intended and all possible combinations of numerical values between the lowest value and the highest value enumerated are to be considered to be expressly stated in this application in a similar manner. As can be seen, the teaching of amounts expressed as “parts by weight” herein also contemplates the same ranges expressed in terms of percent by weight. Thus, an expression in the of a range in terms of “x parts by weight of the resulting polymeric blend composition” also contemplates a teaching of ranges of same recited amount of “x” in percent by weight of the resulting polymeric blend composition.”
[0023] Unless otherwise stated, all ranges include both endpoints and all numbers between the endpoints. The use of “about” or “approximately” in connection with a range applies to both ends of the range. Thus, “about 20 to 30” is intended to cover “about 20 to about 30”, inclusive of at least the specified endpoints.
[0024] The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for ail purposes. The term “consisting essentially of to describe a combination shall include the elements, ingredients, components or steps identified, and such other elements ingredients, components or steps that do not materially affect the basic and novel characteristics of the combination. The use of the terms “comprising” or “including” to describe combinations of elements, ingredients, components or steps herein also contemplates embodiments that consist of, or consist essentially of the elements, ingredients, components or steps.
[0025] Plural elements, ingredients, components or steps can be provided by a single integrated element, ingredient, component or step. Alternatively, a single integrated element, ingredient, component or step might be divided into separate plural elements, ingredients, components or steps. The disclosure of “a” or “one” to describe an element, ingredient, component or step is not intended to foreclose additional elements, ingredients, components or steps.
[0026] It is understood that the above description is intended to be illustrative and not restrictive. Many embodiments as well as many applications besides the examples provided will be apparent to those of skill in the art upon reading the above description. The scope of the invention should, therefore, be determined not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. The omission in the following claims of any aspect of subject matter that is disclosed herein is not a disclaimer of such subject matter, nor should it be regarded that the inventors did not consider such subject matter to be part of the disclosed inventive subject matter.
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A rivetable adhesive for use in a joint between dissimilar materials, comprising a liquid epoxy resin, an expoxidized polysulfide, a flexibilizer, a solid epoxy CTBN adduct based upon bisphenol A, a phenoxy resin, an impact modifier including methacrylate-butadiene-styrene, a curing agent; and a blowing agent. The adhesive finds particular suitability for use in riveting aluminum panels to steel structures, such as for forming automotive vehicle roof structures.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation-in-part application of pending prior application Ser. No. 10/685,941, filed on Oct. 14, 2003 for COMBINATION OF BRIMONIDINE AND TIMOLOL FOR TOPICAL OPHTHALMIC USE, which is continuation application of application Ser. No. 10/126,790, filed on Apr. 19, 2002 for COMBINATION OF BRIMONIDINE AND TIMOLOL FOR TOPICAL OPHTHALMIC USE.
BACKGROUND OF THE INVENTION
[0002] This invention relates to the topical ophthalmic use of brimonidine in combination with timolol when indicated for treatment of glaucoma or ocular hypertension. Such combinations or formulations are available for separate use in the ophthalmic art and have been combined in serial application during the course of treatment of glaucoma. However, there are concerns and expressed reservations in the ophthalmic community about patient compliance when the patient is required to administer separate medications to treat a single disease or condition such as glaucoma. There is, moreover, a long felt need for an effective and safe topical ophthalmic pharmaceutical composition including brimonidine and timolol which has increased stability and requires a lower effective concentration of preservative as compared to the individual agents taken alone. Finally, there is a need to increase the efficacy of many topical ophthalmic agents, without increasing the systemic concentration of such topical agents, since it is well known that many of such topically-applied ophthalmic agents cause systemic side effects, e.g. drowsiness, heart effects, etc. Unexpectedly it has been discovered that brimonidine in combination with timolol meets these criteria.
[0003] Brimonidine is disclosed in U.S. Pat. No. 3,890,319. The use of brimonidine for providing neuroprotection to the eye is disclosed in U.S. Pat. Nos. 5,856,329; 6,194,415 and 6,248,741.
[0004] Timolol, as an ophthalmic drug, is disclosed in U.S. Pat. Nos. 4,195,085 and 4,861,760.
DESCRIPTION OF THE INVENTION
[0005] Brimonidine is an alpha adrenergic agonist represented by the following formula:
[0006] The chemical name for brimonidine is 5-Bromo-6-(2-imidazolidinylideneamino)quinoxaline L-tartrate.
[0007] Brimonidine free base is the neutral form of brimonidine, i.e. 5-Bromo-6-(2-imidazolidinylideneamino)quinoxaline:
[0008] Timolol is a beta adrenergic agent represented by the following formula:
[0009] Timolol free base is the neutral form of timolol:
[0010] Brimonidine is available from Allergan, Inc., Irvine, Calif. as an ophthalmic pharmaceutical product having the name Alphagan®.
[0000] Timolol is available from various sources, including Merck Co., Rahway, N.J.
[0011] The compositions of the present invention are administered topically. The dosage is 0.001 to 1.0, e.g. mg/per eye BID; wherein the cited mass figures represent the sum of the two components, brimonidine and timolol. The compositions of the present invention can be administered as solutions in a suitable ophthalmic vehicle.
[0012] In forming compositions for topical administration, the mixtures are preferably formulated as 0.01 to 0.5 percent by weight brimonidine and 0.1 to 1.0 percent by weight timolol solution in water at a pH of 4.5 to 8.0, e.g. about 6.9. While the precise regimen is left to the discretion of the clinician, it is recommended that the solution be topically applied by placing one drop in each eye two times a day. Other ingredients which may be desirable to use in the ophthalmic preparations of the present invention include preservatives, co-solvents and viscosity building agents.
[0000] Antimicrobial Preservative:
[0013] Ophthalmic products are typically packaged in multidose form. Preservatives are thus required to prevent microbial contamination during use. Suitable preservatives include: benzalkonium chloride, thimerosal, chlorobutanol, methyl paraben, propyl paraben, phenylethyl alcohol, edetate disodium, sorbic acid, Onamer M, or other agents known to those skilled in the art. In the prior art ophthalmic products, typically such preservatives are employed at a level of from 0.004% to 0.02%. In the compositions of the present application the preservative, preferably benzalkonium chloride, may be employed at a level of from 0.001% to less than 0.01%, e.g. from 0.001% to 0.008%, preferably about 0.005% by weight. It has been found that a concentration of benzalkonium chloride of 0.005% is sufficient to preserve the compositions of the present invention from microbial attack. This concentration may be advantageously compared to the requirement of 0.01% benzalkonium chloride to preserve timolol in the individual, commercially-available ophthalmic products. Moreover, it has been found that adequate lowering of intraocular pressure has been obtained when administering the compositions of this invention twice a day as compared to the FDA-approved regimen wherein brimonidine ophthalmic solution, i.e. Alphagan® ophthalmic solution is administered three times a day and timolol ophthalmic solution, i.e. Timoptic® ophthalmic solution is administered twice a day. This results in the exposure of the patient to 67% and 50% of benzalkonium chloride, with the compositions of this invention, as compared to the administration of Alphagan® and Timoptic®, respectively. In FDA-approved adjunctive therapy, wherein Alphagan® and Timoptic® are serially administered, the patient is exposed to almost three times the concentration of benzalkonium chloride as compared to the administration of the compositions of this invention twice a day. (It is noted that it is known that benzalkonium chloride at high concentrations is cytotoxic. Therefore, minimizing the patient's exposure to benzalkonium chloride, while providing the preservative effects afforded by benzalkonium chloride, is clearly desirable.)
[0000] Co-Solvents:
[0014] The solubility of the components of the present compositions may be enhanced by a surfactant or other appropriate co-solvent in the composition. Such cosolvents include polysorbate 20, 60, and 80, Pluronic F68, F-84 and P-103, cyclodextrin, or other agents known to those skilled in the art. Typically such co-solvents are employed at a level of from 0.01% to 2% by weight.
[0000] Viscosity Agents:
[0015] Viscosity increased above that of simple aqueous solutions may be desirable to increase ocular absorption of the active compound, to decrease variability in dispensing the formulation, to decrease physical separation of components of a suspension or emulsion of the formulation and/or to otherwise improve the ophthalmic formulation. Such viscosity building agents include as examples polyvinyl alcohol, polyvinyl pyrrolidone, methyl cellulose, hydroxy propyl methylcellulose, hydroxyethyl cellulose, carboxymethyl cellulose, hydroxy propyl cellulose or other agents known to those skilled in the art. Such agents are typically employed at a level of from 0.01% to 2% by weight.
[0016] Compositions having a combination of timolol free base and brimonidine tartrate are more stable than the combination of timolol maleate and brimonidine tartrate. Compositions having a combination of timolol free base and brimonidine free base may have additional stability.
[0017] The present invention further comprises an article of manufacture comprising packaging material and a pharmaceutical agent contained within said packaging material, wherein the pharmaceutical agent is therapeutically effective for lowering intraocular pressure and wherein the packaging material comprises a label which indicates the pharmaceutical agent can be used for lowering intraocular pressure and wherein said pharmaceutical agent comprises an effective amount of
[0000] brimonidine and an effective amount of timolol.
[0018] The following example is a representative pharmaceutical composition of the invention for topical use when indicated for treating glaucoma.
EXAMPLE I
[0019] The combination of active pharmaceutical ingredients is as follows:
[0000] Brimonidine Tartrate 0.20% (w/v) and Timolol Maleate 0.68% (w/v)
[0000] (Equivalent to 0.50% (w/v) timolol)
[0020] The Brimonidine-Timolol combination formulation presented in the Table, below, is a sterile, preserved, aqueous solution. The formulation vehicle is based upon a timolol ophthalmic solution which contains an isotonic phosphate buffer system at pH 6.9. The formulation preservative is benzalalkonium chloride (BAK) at a concentration of 0.005% (w/v) (50 ppm). The formulation passes regulatory required preservative efficacy testing (PET) criteria for USP (United States Pharmacopoeia) and EP (European Pharmacopoeia-A and -B over 24 months.
TABLE Concentration, Ingredient Function % (w/v) Brimonidine Tartrate Active 0.2 Timolol Maleate, EP Active 0.68 1 Benzalkonium Chloride, NF, EP Preservative 0.005 Sodium Phosphate, monobasic Buffer 0.43 monohydrate, USP Sodium Phosphate, dibasic Buffer 2.15 heptahydrate, USP Sodium Hydroxide, NF pH adjust Adjust pH to 6.9 Hydrochloric Acid, NF pH adjust Adjust pH to 6.9 Purified Water, USP, EP Solvent q.s. ad 1 Equivalent to 0.5% (w/v) Timolol, free base
[0021] The pharmaceutical composition of Example I is used in the clinical study reported below.
EXAMPLE II
Objectives
[0022] To compare the safety and efficacy of twice-daily dosed brimonidine tartrate 0.2%/timolol 0.5% ophthalmic solution combination (henceforth referred to as Combination) with that of twice-daily dosed timolol ophthalmic solution 0.5% (henceforth referred to as Timolol) and three-times-daily dosed ALPHAGAN® (brimonidine tartrate ophthalmic solution) 0.2% (henceforth referred to as Brimonidine) administered for three months (plus 9-month masked extension) in patients with glaucoma or ocular hypertension.
[0000] Methodology:
[0000] Structure: multicenter, double-masked, randomized, parallel-group, active control
[0000] Randomization: patients were randomized to one of the 3 masked treatment groups (Combination, Brimonidine or Timolol) based on an even allocation at each site
[0000] Visit Schedule: prestudy, baseline (day 0), week 2, week 6, month 3, month 6, month 9, and month 12
[0000] Number of Patients (Planned and Analyzed):
[0023] 560 planned to enroll; 586 enrolled (Combination=193, Brimonidine=196, Timolol=197); 502 completed. Mean (range) age: 62.4 (23 to 87) years; 46.1% (270/586) males, 53.9% (316/586) females.
[0000] Diagnosis and Main Criteria for Inclusion:
[0000] Diagnosis: ocular hypertension, chronic open-angle glaucoma, chronic angle-closure glaucoma with patent iridotomy, pseudoexfoliative glaucoma or pigmentary glaucoma and requiring bilateral treatment.
[0024] Key Inclusion Criteria: ≧18 years, day 0 (post-washout) intraocular pressure (IOP) ≧22 mm Hg and ≦34 mm Hg in each eye and asymmetry of IOP ≦5 mm Hg, best-corrected Early Treatment of Diabetic Retinopathy Study (ETDRS) visual acuity equivalent to a Snellen score of 20/100 or better in each eye.
[0025] Key Exclusion Criteria: uncontrolled systemic disease, abnormally low or high blood pressure or pulse rate for age or contraindication to beta-adrenoceptor antagonist therapy, anticipated alteration of existing chronic therapy with agents which could have a substantial effect on IOP, contraindication to brimonidine therapy, allergy or sensitivity to any of the study medication ingredients, anticipated wearing of contact lenses during the study, laser surgery, intraocular filtering surgery or any other ocular surgery within the past 3 months, or required chronic use of other ocular medications during the study (intermittent use of artificial tear product was allowed).
[0000] Test Product, Dose and Mode of Administration, Batch Number:
[0026] Brimonidine tartrate 0.2%/timolol 0.5% combination ophthalmic solution one drop (˜35 μL) instilled in each eye BID in the morning and evening; and vehicle of the Combination ophthalmic solution, one drop (˜35 μL) instilled in each eye once daily (QD) in the afternoon (for masking purposes).
[0000] Duration of Treatment: 3 months (with a 9-month masked extension)
[0000] Reference Therapy, Dose and Mode of Administration, Batch Number:
[0000] Active control ALPHAGAN® (brimonidine tartrate ophthalmic solution) 0.2%, one drop (˜35 μL) instilled in each eye TID in the morning, afternoon, and evening.
[0027] Active control timolol ophthalmic solution 0.5%, one drop (˜35 μL) instilled in each eye BID in the morning and evening; and vehicle of the Combination ophthalmic solution, one drop (35 μL) instilled in each eye once daily (QD) in the afternoon (for masking purposes).
[0000] Criteria for Evaluation:
[0000] Efficacy:
[0000] IOP (hours 0, 2, 7, and 9), patient satisfaction questionnaire, patient comfort of study medication questionnaire, pharmacoeconomic evaluation by investigator
[0000] Safety:
[0000] Adverse events (AE), biomicroscopy, visual acuity (VA), visual field, opthalmoscopy, cup/disc ratio, heart rate, blood pressure, hematology, serum chemistry, urinalysis and pregnancy test.
[0000] Other:
[0000] Quantitation of plasma brimonidine and timolol concentrations (at selected sites), resource utilization (to be reported upon completion of the 1 year study).
[0000] Statistical Methods:
[0028] All data were summarized with descriptive statistics, frequency tables, and/or data listings. Safety analyses included all patients who received at least 1 dose of study medication. Analyses were performed for the primary efficacy variable IOP using the intent-to-treat (ITT) population with last observation carried forward (LOCF), and the per protocol population with observed cases.
[0029] Ordinal categorical variables were analyzed by the Wilcoxon rank-sum test. Nominal categorical variables were analyzed using Fisher's exact or Pearson's chi-square tests. Within-group changes from baseline for categorical variables were analyzed using the Wilcoxon signed-rank test.
[0000] Continuous variables (eg, IOP) were analyzed using analysis of variance (ANOVA). Within-group changes from baseline for continuous variables were analyzed using paired t-tests.
[0030] A 2-way ANOVA model with factors for treatment and investigator was used for the analysis of IOP. Comparisons were made between the Combination and each of the 2 monotherapies in a pairwise fashion using contrasts from the ANOVA model, with the same error term. A separate ANOVA model was employed at each hour/visit measurement of IOP. Each of the 2 null hypotheses (Combination versus Timolol and Combination versus Brimonidine) was tested at the 0.05 significance level. Point estimates of the mean treatment differences, as well as 2-sided 95% confidence intervals (CI) of the difference, were provided at each timepoint.
SUMMARY
Conclusions
[0000] Efficacy:
[0031] At baseline, mean values of diurnal IOP ranged from 22.2 mm Hg to 24.9 mm Hg in the Combination group, 22.5 mm Hg to 25.0 mm Hg in the Brimonidine group, and 22.3 mm Hg to 24.8 mm Hg in the Timolol group. There were no statistically significant differences between treatment groups.
[0000] Mean changes from baseline diurnal IOP at week 2, week 6 and month 3 ranged from:
[0032] −5.2 to −7.9 mm Hg in the Combination group
[0033] −3.5 to −5.7 mm Hg in the Brimonidine group
[0034] −4.5 to −6.4 mm Hg in the Timolol group
[0000] The mean decreases from baseline diurnal IOP were statistically significant within each treatment group at each follow-up timepoint (p<0.001).
[0035] The mean decrease from baseline diurnal IOP was statistically significantly greater with Combination than with Brimonidine at hours 0, 2, and 7 at all follow-up visits (p<0.001). In addition, clinically significant differences of more than 1.5 mm Hg in mean change from baseline IOP favoring Combination over Brimonidine were seen at hours 0, 2, and 7 at all follow-up visits. At hour 9, the decreases from baseline diurnal IOP were greater for the Combination group than the Brimonidine group at all follow-up visits, although the differences were not statistically significant (p≧0.104).
[0036] The mean decrease from baseline diurnal IOP was statistically significantly greater with Combination than with Timolol at hours 0, 2, 7 and 9 at all follow-up visits (p≦0.041). In addition, clinically significant differences of more than 1.5 mm Hg in mean change from baseline IOP favoring Combination over Timolol were seen at week 2 (hours 0, 2, and 7), week 6 (hours 2 and 7), and month 3 (hours 0 and 2).
[0000] Mean values of diurnal IOP at week 2, week 6 and month 3 ranged from:
[0037] 15.9 to 18.1 mm Hg in the Combination group
[0038] 17.4 to 21.5 mm Hg in the Brimonidine group
[0039] 17.5 to 18.9 mm Hg in the Timolol group
[0040] Mean values of diurnal IOP were statistically significantly less with Combination than with Brimonidine at hours 0, 2, and 7 at all follow-up visits (p<0.001) and at hour 9 at week 6 and month 3 (p≦0.011). The mean values of IOP at hour 9 at week 2 were lower for the Combination group than the Brimonidine group, although the difference was not statistically significant (p=0.205). In addition, clinically significant differences of more than 1.5 mm Hg in mean IOP favoring Combination over Brimonidine were seen at hours 0, 2, and 7 at all follow-up visits and at hour 9 at month 3.
[0041] Mean values of diurnal IOP were statistically significantly less with Combination than with Timolol at hour 0 at week 2 and month 3; and at hours 2, 7 and 9 at all follow-up visits (p≦0.050). The mean values of IOP at hour 0, week 6, were lower for the Combination group than the Timolol group, although the difference was not statistically significant (p=0.102). In addition, clinically significant differences of more than 1.5 mm Hg in mean IOP favoring Combination over Timolol were seen at week 2 (hours 0, 2, and 7), week 6 (hours 2, 7, and 9), and month 3 (hours 2 and 9).
[0042] At the month 3 or exit visit, a statistically significantly greater “yes” response to the Investigator Pharmacoeconomic Evaluation was recorded for patients receiving Combination (91.1%, 173/190) than for patients receiving Brimonidine (73.4%, 141/192, p<0.001). A “yes” response was recorded for 92.7% (179/193) of patients receiving Timolol. There were no statistically significant differences in the change from baseline in treatment comfort between Combination and each of the monotherapy groups.
[0043] Treatment satisfaction was better than baseline for a statistically significantly greater percentage of patients in the Combination group (23.4%, 36/154) than in the Brimonidine group (13.2%, 20/151, p=0.005). A total of 19.9% (30/151) of patients in the Timolol group reported better treatment satisfaction than baseline.
[0000] Safety:
[0044] Through month 3 of the study, 53.4% (103/193) of patients in the Combination group, 61.7% (121/196) of the Brimonidine group, and 50.8% (100/197) of the Timolol group experienced one or more adverse events, regardless of causality. The incidences of oral dryness, eye pruritus, foreign body sensation and conjunctival folliculosis were statistically significantly lower with the Combination than with Brimonidine (p≦0.034), while burning and stinging were statistically significantly higher with the Combination than with Brimonidine (p≦0.028). There were no statistically significant differences in adverse events between the Combination and Timolol, except for a statistically significantly higher incidence of eye discharge with the Combination (2.6%, 5/193) compared to Timolol (0%, 0/197; p=0.029). The most frequently reported adverse events (>3% in any treatment group) were as follows, tabulated by descending order in the Combination group:
Combination Brimonidine Timolol Preferred Term N = 193 N = 196 N = 197 burning sensation in eye 23 (11.9%) 11 (5.6%) 25 (12.7%) conjunctival hyperemia 16 (8.3%) 23 (11.7%) 11 (5.6%) stinging sensation eye 13 (6.7%) 4 (2.0%) 11 (5.6%) infection (body as a whole) 11 (5.7%) 6 (3.1%) 8 (4.1%) visual disturbance 6 (3.1%) 11 (5.6%) 3 (1.5%) epiphora 5 (2.6%) 8 (4.1%) 3 (1.5%) oral dryness 4 (2.1%) 19 (9.7%) 1 (0.5%) eye pruritus 3 (1.6%) 13 (6.6%) 3 (1.5%) allergic conjunctivitis 3 (1.6%) 7 (3.6%) 0 (0.0%) asthenia 3 (1.6%) 6 (3.1%) 1 (0.5%) foreign body sensation 2 (1.0%) 10 (5.1%) 5 (2.5%) conjunctival folliculosis 2 (1.0%) 9 (4.6%) 1 (0.5%) somnolence 2 (1.0%) 7 (3.6%) 0 (0.0%)
Adverse events led to the discontinuation of 3.6% (7/193) of patients in the Combination group, similar to 3.0% (6/197) of patients in the Timolol group, and statistically significantly less than 14.3% (28/196) of patients in the Brimonidine group (p<0.001). Serious adverse events were reported for 1.0% (2/193) of patients in the Combination group, 2.0% (4/196) of patients in the Brimonidine group, and 2.0% (4/197) of patients in the Timolol group. Two patients receiving Timolol had 4 serious adverse events (emphysema in one patient; nausea, sweating, and tachycardia in the other patient) which were considered possibly related to the study drug. There was 1 death in the Brimonidine group, possibly due to complications from cardiac surgery, and not related to study drug.
There were no clinically relevant differences between the Combination and either of the individual components in the mean change from baseline to month 3 for any hematology, chemistry, or urinalysis parameter. Statistically significant (p≦0.048) within-group changes from baseline were found, but were small and not clinically relevant.
Small but statistically significant (p≦0.001) mean reductions in heart rate ranging from −2.1 to −3.7 bpm were seen with the Combination, similar to Timolol. Small but statistically significant (p≦0.003) mean reductions in blood pressure at hour 2 (postdose) were seen with the Combination, similar to Brimonidine. These small changes in mean heart rate and blood pressure were associated with clinical symptoms in only a few patients.
Increases from baseline in the severity of conjunctival erythema and conjunctival follicles on biomicroscopy were statistically significantly less with the Combination than with Brimonidine (p≦0.011). The majority of patients in each treatment group showed less than a 2-line change from baseline visual acuity. There were no significant between-group differences for changes in visual fields or cup/disc ratio.
Pharmacokinetics:
Blood samples were available for 55 patients in the Combination group, 49 patients in the Brimonidine group, and 54 patients in the Timolol group. All samples were assayed for both brimonidine (lower limit of quantitation [LLOQ] 5 pg/mL) and timolol (LLOQ 5 pg/mL). Plasma brimonidine and timolol concentrations were not quantifiable in all but 1 sample on day 0, hour 0 for both Combination and the monotherapy treatment groups.
In the Combination group, mean±standard deviation (SD) plasma brimonidine concentrations 1 hour postdose at week 2 and month 3 were 49.7±36.1 and 52.8±46.7 pg/mL, respectively. In the Brimonidine group, mean±SD plasma brimonidine concentrations at week 2 and month 3 were 81.0±63.8 and 78.6±48.9 pg/mL, respectively. In the Combination group, mean±SD plasma timolol concentrations at week 2 and month 3 were 0.499±0.327 and 0.586±0.580 ng/mL, respectively. In the Timolol group, mean±SD plasma timolol concentrations at week 2 and month 3 were 0.950±0.709 and 0.873±0.516 ng/mL, respectively.
Plasma brimonidine and timolol concentrations 1 hour postdose were steady and did not increase over the 3-month study duration. Brimonidine concentrations were 39%, 34% and 39% lower in the Combination group than in the monotherapy group at week 2 (p=0.004), month 3 (p=0.013), and month 12, respectively. Timolol concentrations were 47% and 33% lower in the Combination group than in the monotherapy group at week 2 (p<0.001) and month 3 (p=0.011), respectively.
Timolol concentrations were also significantly lower in the combination treatment group than in the Timolol monotherapy treatment group (p=0.0006). Timolol concentrations were 49%, 32%, and 21% lower in the combination group than in the monotherapy group at week 2, month 3, and month 12, respectively.
The plasma brimonidine concentration in males was statistically significantly lower than in females for the Brimonidine group (37% lower at week 2 [p=0.034] and 37% lower at month 3 [p=0.017]); the difference was not statistically significant in the Combination group. The plasma timolol concentration in males was statistically significantly lower than in females for both the Combination group (not statistically significant at week 2; 52% lower at month 3 [p=0.012]) and the Timolol group (45% lower at week 2 [p=0.006] and 39% lower at month 3 [p=0.003]). Plasma brimonidine concentration in the elderly group was not significantly different from in the young group for the combined data from both the combination and Brimonidine treatment groups (p-value=0.1323). However, plasma timolol concentration in the young group was significantly lower than in the elderly group for combined data from both the combination and the Timolol treatment groups (p-value=0.0005).
CONCLUSIONS
[0045] The Combination treatment (brimonidine tartrate 0.2%/timolol 0.5%) administered BID for 3 months was superior to Timolol (timolol 0.5%) BID and Brimonidine (brimonidine tartrate 0.2%) TID in lowering the elevated IOP of patients with glaucoma or ocular hypertension. The Combination administered BID demonstrated a favorable safety profile that was comparable to Timolol BID and better than Brimonidine TID with regard to the incidence of adverse events and discontinuations due to adverse events.
EXAMPLE II
[0046] A composition is prepared as described in Example I, except 0.5% timolol free base is used instead of timolol maleate. The composition is effective as described in Example I, but is more stable.
EXAMPLE II
[0047] A composition is prepared as described in Example I, except 0.5% timolol free base is used instead of timolol maleate. The composition is effective as described in Example I, but is more stable.
EXAMPLE III
[0048] A composition is prepared as described in Example I, except 0.5% timolol free base is used instead of timolol maleate and 0.18% brimonidine free base is used instead of brimonidine tartrate.
[0049] The composition is effective as described in Example I, but is more stable.
[0050] The invention has been described herein by reference to certain preferred embodiments. However, as obvious variations thereon will become apparent to those skilled in the art, the invention is not to be considered as limited thereto.
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Disclosed are pharmaceutical compositions comprising brimondine and timolol for topical ophthalmic delivery and a method of treatment comprising administering said composition when indicated for glaucoma and associated conditions such as elevated intraocular pressure in the eyes of humans.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a heating and/or air-conditioning apparatus particularly for the cabin of a motor vehicle.
2. Discussion of the Related Art
In motor vehicle heating and/or air-conditioning units of the prior art, it is known practice to use an air blowing member, typically a blower, placed upstream of a heating system, typically made up of an evaporator/radiator, allowing the air expelled by the blower to be heated up by heat exchange. In general, a liquid such as water flows around inside the radiator under the control of a progressive valve. These members are placed in succession in a chassis inside which the air flows towards one or more ducts that convey air into the cabin.
In addition, a fresh air passage is conventionally formed on the wall of the chassis, outside of the radiator, and a hinged mixing shutter is provided to partially or fully open or close this passage so as to transmit fresh air towards the ducts, or not as the case may be.
Control of the temperature of the air conveyed to the ducts is managed by a central unit which controls the valve and the shutter operating in concert. Thus, in a first state, when only hot air is required, the valve is in a wide open operating position and the shutter is closed. All of the air therefore passes through the radiator. When warm air is required, in a variable operating state, the shutter is partially opened and the radiator valve governs the temperature of the water circuit so as to provide warm air which mixes with the fresh air. The progressive nature in raising or lowering the temperature is assisted by the valve. Finally, when only cold air is required in a second extreme state, the valve shuts off the water circuit and the fresh air passage shutter is wide open.
This solution is not satisfactory, particularly for economical reasons, because of the high cost of the progressive valve and the significant pressure drops in the liquid which are created by the valve when it is open.
SUMMARY OF THE INVENTION
The object of the invention is to allow good control over the progressive nature of the temperature for an appreciably lower cost.
To do that, provision is made for the complex valve to be replaced by a simple valve, coupled to means of mixing the air from the fresh air passage and from the radiator.
More specifically, the subject of the invention is heating and/or air-conditioning apparatus particularly for the cabin of a motor vehicle, having: a chassis within which air flows, this chassis being equipped with an air-blowing means and with a means for cooling and heating the air, which operates using a fluid flowing through it, a member for controlling the heating means, at least one air flow duct communicating with the chassis, and at least one mixing shutter with a variable degree of openness for allowing the air stream towards the duct.
In this apparatus, the member controlling the heating means is of the on/off type and the mixing shutter is arranged, in the overall direction of air flow, downstream of the heating member, particularly facing a heating surface of the heating means.
Advantageously, in an intermediate position of the air flow through the heating means being shut off, the mixing shutter governs the switching of the member controlling the heating means between the on and off modes.
According to a first particular embodiment, the fresh air passage is defined between a wall of the chassis and a side wall of the heating means. The arrangement having the following characteristics:
two operating states are considered, a first state in which the heating means (valve open) is on and the mixing shutter opens the fresh air passage to the intermediate position, and a second state in which the heating is off and the shutter pivots beyond the intermediate position to allow additional fresh air to pass through the switched-off heating means (valve closed);
when the shutter is in a first extreme position, the control member is in the on position and the shutter closes off the fresh air passage so that the air blown passes only through the heating means to form a hot air stream directed towards the duct;
between the first position and the intermediate position of the shutter in the first state, the control member remains in the on position and the shutter allows a variable fresh air stream to pass through the passage according to the orientation of the shutter, and also lets through a hot air stream from the heating means so that these streams mix as they head for the duct;
when the shutter reaches the intermediate position, the control member switches to the off position and the shutter prevents air from the heating means from flowing so that the air blown passes only through the fresh air passage; and
between the intermediate position and a second extreme position of the shutter in the second state, and in this second position, the control member remains in the off position and the shutter is directed toward the heating means so that additional fresh air passes through the heating means, now off, bound for the duct and adds to the fresh air stream coming from the passage.
According to an alternative form of the embodiment:
aside from the mixing shutter, the apparatus comprises an additional shutter also arranged downstream of the heating means, so that the two shutters are capable, in a given position, of closing off the flow of air passing through the heating means, and:
between a first position and before reaching a second position of the mixing shutter, the first state is defined by the mixing shutter switching from the fresh air passage being closed so that the blown air passes only through the heating means to form a hot air stream bound for the duct, to variable opening of the fresh air passage then in collaboration with the additional shutter so as to allow a hot air stream from the heating means to pass so that these streams mix as they head for the duct;
when the mixing shutter reaches the second position, the control member switches to the off position and the additional shutter being arranged in a first closed position, the shutters then collaborate to shut off the flow of air from the heating means so that the air blown passes only through the fresh air passage; and
between this first and a second position of the additional shutter, the mixing shutter remaining in its second position and the control member in the off position, the second state is defined by an opening of the air passage through the heating means, now off, which provides additional fresh air bound for the duct and adds to the fresh air stream coming from the fresh air passage.
According to another embodiment, a fresh air passage is provided between a wall of the chassis and a side wall of the heating means. The arrangement having the following characteristics:
the mixing shutter controls the shutting-off of the air flow through the heating means in a closed position, this flow passage being opened variably outside of this position;
the apparatus further comprises an additional shutter arranged in the chassis in such a way as to close off the fresh air passage in a closed position and to open this passage variably outside of this position;
the mixing shutter being in the closed position and the additional shutter in the open position, the control member of the heating means is in the off mode and the air blown passes only through the fresh air passage;
the mixing and additional shutters being outside of the closed positions, the control member of the heating means is in the on mode and the additional shutter allows a fresh air stream to pass through the passage and the mixing shutter allows a hot air stream from the heating means to pass so that these streams mix as they head for the duct;
the mixing shutter being outside of the closed position and the additional shutter in the closed position, the control member is in the on mode so that the blown air passes only through the heating means so as to form a hot air stream bound for the duct; and
when the shutters are in the open position, the control member is in the off mode so that additional fresh air passes through the heating means, now off, bound for the duct and adds to the fresh air stream coming from the passage.
Another subject of the invention is a vehicle equipped with heating and/or air-conditioning apparatus as described previously.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and other features, details and advantages thereof will become more clearly apparent from reading the description which follows, given by way of example with reference to the appended drawings in which:
FIGS. 1 a , 1 b and 1 c are views in cross section of a heating and/or air-conditioning apparatus according to the invention comprising a mixing shutter depicted in three operating positions;
FIGS. 2 a , 2 b and 2 c are views in cross section of a second embodiment of the present invention having an additional shutter depicted in various operating positions; and
FIGS. 3 a and 3 b are views in cross section of an alternative embodiment of FIGS. 2 a , 2 b and 2 c.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference is made first of all to FIG. 1 a to describe a heating and/or air-conditioning apparatus 1 for a motor vehicle cabin. This apparatus 1 includes an outer chassis 10 , for example made of plastic, having an upstream part 12 typically connected to a vehicle dashboard (not depicted) and a downstream part 14 communicating with a duct 16 .
An air blowing member 20 , such as a blower, together with an evaporator 22 and a radiator 24 , are mounted one beside the other in the chassis 10 , the evaporator 22 being mounted upstream of the radiator 24 and downstream of the blower 20 in the direction of flow of the air illustrated by the arrow F.
The radiator 24 has at least one downstream heating surface 25 . It operates on a fluid such as water flowing through it in such a way as to form an indirect exchanger of heat with the water. It is equipped with a control member 26 of on/off type, such as a valve so as to switch the radiator from off to on and vice versa.
A fresh air passage 27 is formed between a wall of the chassis 10 and an edge 28 of the radiator 24 and serves for the flow of air from the evaporator 22 which covers the entire cross section of the chassis 10 .
A mixing shutter 30 is arranged facing the heating surface 25 of the radiator 24 and is hinged about an axis xx′ perpendicular to the plane of section of FIG. 1 .
In all the examples mentioned hereinafter, the switch in state of the valve is controlled directly by the angular position of the mixing shutter 30 .
This shutter 30 can adopt a first extreme position illustrated in FIG. 1 a , a second intermediate position illustrated in FIG. 1 b , and a third extreme position illustrated in FIG. 1 c.
In its first extreme position, the mixing shutter 30 shuts off the fresh air passage 27 and governs the valve 26 in such a way that it is in the position of switching the radiator 24 on. Thus, a hot air stream (arrow F 1 ) only passes through the chassis 10 and the radiator 24 bound for the duct 16 . This is the position for maximum heating.
Between the first extreme position and the second intermediate position of the mixing shutter 30 , the valve 26 remains in its on position. The fresh air stream F 2 passing through the passage 27 and the hot air stream F 1 from the radiator 24 mix as they head for the duct 16 . This is the position of heating modulated with air the warmth of which varies with the angular position of the shutter 30 .
When the shutter 30 reaches the second intermediate position illustrated in FIG. 1 b , it mechanically, or electromechanically with the aid of a relay, governs the switching of the valve 26 from the position in which the radiator 24 is on to the position in which the latter is off. In this position, only the fresh air stream F 2 flows through the duct 16 , the air passing through the radiator being shut off at the shutter 30 . This is the normal fresh air position.
Finally, between the second intermediate position and the third extreme position of the shutter 30 , and in this third position illustrated in FIG. 1 c , the valve 26 remains in the off position and the shutter is inclined towards the heating surface 25 of the radiator 24 so that additional fresh air (arrow F 3 ) passes through the radiator, now off, and is added to the fresh air stream F 2 coming from the passage 27 . This is the maximum fresh air position.
In FIGS. 2 a to 2 c , the mixing shutter 30 operates in concert with an additional shutter 32 mounted to pivot about an axis yy′ situated near the wall of the chassis 10 , the additional shutter 32 being arranged facing the downstream heating surface 25 of the radiator 24 , like the mixing shutter 30 . This additional shutter 32 can adopt a first extreme position illustrated in FIGS. 2 a and 2 b , and a second extreme position illustrated in FIG. 2 c.
In FIG. 2 a , the mixing shutter 30 is in its first position in which it shuts off the fresh air passage 27 and governs the valve 26 in such a way that it is in the position that switches the radiator 24 on. Thus, a hot air stream (arrow F 1 ) only passes through the chassis 10 and the radiator 24 bound for the duct 16 . The additional shutter 32 is preferably in its first extreme position, although it may be in its second extreme position. This is the position for maximum heating.
Between the first position and the second position of the mixing shutter 30 , the valve 26 remains in its on position. The fresh air stream F 2 passing through the passage 27 and the hot air stream F 1 from the radiator 24 mix as they head for the duct 16 . The position of the additional shutter once again is of little importance here. This is the modulated heating position.
When the shutter 30 reaches the second position illustrated in FIG. 2 b it mechanically, or electromechanically with the aid of a relay, governs the switching of the valve 26 from the position in which the radiator 24 is on to the position in which the latter is off. The additional shutter 32 for its part is in its first extreme position. In this position, only the fresh air stream F 2 from the passage 27 flows through the duct 16 , the air passing through the radiator 24 being shut off at the shutters 30 and 32 . This is the normal fresh air position.
Finally, between the first extreme position and the second extreme position of the additional shutter 32 , and in this second position illustrated in FIG. 2 c and called, the valve 26 remains in the off position and the additional shutter is inclined to some extent towards the heating surface 25 of the radiator 24 so that additional fresh air illustrated by the arrow F 3 passes through the radiator, now off, and is added to the fresh air stream F 2 from the passage 27 . This is the maximum fresh air position.
An alliterative form of embodiment, not depicted, includes arranging the axis yy′ of the additional shutter 32 more or less at the end of the mixing shutter 30 , when the latter is in its second position illustrated by FIGS. 2 b or 2 c.
The alternative form of embodiment illustrated in FIGS. 3 a to 3 c also involves a mixing shutter 30 and an additional shutter 32 ′. A fresh air passage 27 ′ is arranged between the wall of the chassis 10 and an edge 28 ′ of the radiator 24 , above the radiator 24 .
In FIG. 3 a , the mixing shutter is in its first position and the additional shutter 32 ′ is in its second. With the apparatus in this state, the valve 26 is in its position for which the radiator 24 is off and only a fresh air stream (arrow F 2 ) passes through the passage 27 ′ bound for the duct 16 . This is the normal fresh air function.
When the mixing shutter leaves its first position and lies between this position and the second position (dotted lines in FIG. 3 a ), the control member 26 switches to the position of switching the radiator 24 on and a hot air stream therefore passes through the radiator and mixes with the fresh air stream F 2 passing through the passage. Orientating the mixing shutter 30 makes it possible to adjust the hot air/fresh air mix bound for the duct 16 . This is the modulated heating function.
When the mixing shutter switches to its second position illustrated in FIG. 3 b , the control member switches to its position in which the radiator 24 is off. A fresh air stream F 3 then adds to the fresh air stream F 2 from the passage 27 ′. This additional fresh air passing through the radiator 24 , now off, makes it possible to increase the rate of flow of fresh air through the duct 16 . This is the maximum fresh air function.
Finally, if the additional shutter 32 ′ switches to its first position of shutting off the passage 27 ′, which position is illustrated in FIG. 3 c , and the mixing shutter 30 fluctuates between its first and second positions, only the hot air stream F 1 from the radiator reaches the duct. This is the maximum heating function, the air flow rate of which depends on the angular position of the first shutter.
By virtue of the solutions put forward, the progressive nature in terms of temperature of the heating and/or air-conditioning apparatus is better mastered and a fresh air flow rate which is higher than in the prior art comes through the duct 16 by virtue of the maximum fresh air function.
The pressure drops in the heating fluid are minimal. There is no parasitic heating when the valve 26 is in its off position and the additional fresh air is sent to the duct 16 .
Thus, replacing an elaborate, expensive and more complicated valve with a simple economical valve of the on/off type and positioning one or more mixing shutters in suitable positions make this solution simple to implement, reliable, and less expensive than the solutions of the prior art.
While the foregoing invention has been shown and described with reference to a preferred embodiment, it will be understood by those possessing skill in the art that various changes and modifications may be made without departing from the spirit and scope of the invention. For example, it is possible, using a central unit, to manage the various modes of operation of the shutters, controlled for example by suitable software. Furthermore, the radiator could be of the electric or catalysis type. The person skilled in the art will be able to adapt any type of shutter, for example of the butterfly valve or flag valve type, or shut-off valve, to implement the invention. Thus, the axes of rotation of certain shutters may be offset so that they are placed either at their middle, or at one of their ends, depending on their position and on the angular travel they are to have.
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A heating and air-conditioning apparatus for the cabin of a motor vehicle. The apparatus includes a chassis within which air flows and equipped with an air-blowing mechanism and heating and cooling units for cooling and heating the air and a member for controlling the heating unit. At least one airflow duct communicates with the chassis, and at least one mixing shutter, with a variable degree of openness, controls the air stream towards the duct. The mixing shutter is arranged in the overall direction of the air flow downstream of the heating member and transmits additional air passing through the heating unit when the fresh air passage is wide open, and governs in an intermediate position of closure of the air flowing through the heating unit. The mixing shutter also switching a control member controlling the operation of the heating unit between an off and on position.
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BACKGROUND
[0001] The present invention relates to selecting and recording media content data, and more specifically, to individualization and encryption of on-demand media content for retail distribution.
[0002] Data terminals are employed in a variety of contexts to provide goods and services to consumers. Thus, distribution of these goods and services is managed by the data terminal communicating and exchanging information to and from a remote host computer or other communicating device.
[0003] For example, in a banking service context, automated teller machines (“ATMs”) are employed to allow bank customers to make cash withdrawals, deposits, and transfers. Furthermore, since ATMs are often deployed in convenient and open locations, ATMs provide a cost-effective, convenient, and secure method by which banks can process transactions of the bank customers. Such data terminals are configured in one of a stand-alone mode, where access to the host computer is established over the public telephone network, and in a cooperative mode, where access to the host is established over a private dedicated communication network.
[0004] Data terminals can also be employed in the media content distribution context to provide each individual customer with ready access to tens of thousands of movie titles, as well as educational programming, network programming, audio programming and the like.
SUMMARY
[0005] Implementations of the present invention provide methods and apparatus to select and record media content data for retail distribution using a data terminal.
[0006] In one implementation, a system for selecting and recording data is disclosed. The system comprises: a local storage unit for storing a subset of media content items and other content; a content selection unit to display a catalog of the media content items and other content, to allow a customer to browse, search, and select a media content item and other content from the catalog of media content items and other content, to retrieve the selected media content item and other content from the local storage unit if the selected media content item and other content is found in the subset, and otherwise to retrieve the selected media content item from a remote storage unit, the content selection unit configured to cache the retrieved media content item and other content in the local storage unit for a period of time based on the popularity of the retrieved media content item; a financial transaction unit to determine the cost of the retrieved media content item and other content and display the cost for review and payment by the customer; and a video disk authoring system configured to format, encode, encrypt, and write the media content item and other content onto an article of media when the customer makes the payment.
[0007] In another implementation, a method for selecting and recording data is disclosed. The method comprises: storing a subset of media content items and other content in a local storage unit; displaying a catalog of the media content items and other content; enabling a customer to browse, search, and select a media content item and other content from the catalog of media content items and other content; retrieving the selected media content item and other content from the local storage unit if the selected media content item and other content is found in the subset; retrieving the selected media content item from a remote storage unit if the selected media content item and other content is not included in the subset; caching the retrieved media content item and other content in the local storage unit for a period of time based on the popularity of the retrieved media content item; determining the cost of the retrieved media content item and other content; displaying the cost for review and payment by the customer; and formatting, encoding, encrypting, and writing the media content item and other content onto an article of media when the customer makes the payment.
[0008] In another implementation, a computer program, stored in a tangible storage medium, for selecting and recording data is disclosed. The program comprises executable instructions that cause a computer to: store a subset of media content items and other content in a local storage unit; display a catalog of the media content items and other content; enable a customer to browse, search, and select a media content item and other content from the catalog of media content items and other content; retrieve the selected media content item and other content from the local storage unit if the selected media content item and other content is found in the subset; retrieve the selected media content item from a remote storage unit if the selected media content item and other content is not included in the subset; cache the retrieved media content item and other content in the local storage unit for a period of time based on the popularity of the retrieved media content item; determine the cost of the retrieved media content item and other content; display the cost for review and payment by the customer; and format, encode, encrypt, and write the media content item and other content onto an article of media when the customer makes the payment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a block diagram of a media content selection and recording system including a retail distribution kiosk and a remote server in accordance with one implementation of the present invention.
[0010] FIG. 2 is a block diagram of the retail distribution kiosk including a computer system, a video disk authoring system, a network connection, and a storage area in accordance with one detailed implementation of the present invention.
[0011] FIG. 3 is a block diagram of a media content selection and recording system including the retail distribution kiosk and the remote server in accordance with another detailed implementation of the present invention.
[0012] FIGS. 4A and 4B illustrate a method for selecting and recording media content data according to one implementation of the present invention.
DESCRIPTION
[0013] Implementations of the present invention provide methods and apparatus to select and record media content data for retail distribution using a data terminal. In one implementation, a media content selection and recording system provides individualization and encryption of on-demand media content for retail distribution. In this implementation, the data terminal is configured as a retail kiosk, which provides an individual customer with ready access to a large number of movie titles in a convenient low-cost manner that fully satisfies the customer demand, while enhancing the economic incentives of content providers to create and distribute an expanding offering of movies and other video/audio content.
[0014] In one example illustrated in FIG. 1 , a media content selection and recording system 100 includes a retail distribution kiosk 102 and a remote server 104 . In the illustrated example, the retail distribution kiosk 102 is placed in a location having public access, such as a store or shopping center, by a content provider. A customer 106 uses the retail kiosk 102 to build and purchase a customized article of media (hereinafter referred to as a video disk 120 ) by selecting a movie and other items of content. The retail kiosk 102 is an automated kiosk with a computer user interface (e.g., display 110 , speakers 112 , keyboard 114 , touchpad, and the like).
[0015] In one detailed implementation illustrated in FIG. 2 , the retail kiosk 102 includes a computer system 200 , a video disk authoring system 210 , a network connection 220 , and a storage area 230 . The computer system 200 includes a processor 204 , a memory 206 , a video controller 208 , and other related elements 202 . The computer system 200 controls the operation of the kiosk 102 and its components. The video disk authoring system 210 enables the customer 212 to build and purchase a customized video disk. The network connection 220 allows the retail kiosk 102 to connect to the remote server 240 through the network 222 .
[0016] In another detailed implementation illustrated in FIG. 3 , a media content selection and recording system 300 includes a remote server 310 and a retail kiosk 320 . The retail kiosk 320 includes a financial transaction unit 322 , a content selection unit 324 , a video disk authoring system 330 , and a content database unit 326 . The retail kiosk 320 connects to the remote server 310 through a network connection. The remote server 310 includes a financial transaction processor 312 , a content delivery unit 314 , a customer database 316 , and a content database 318 .
[0017] To use the kiosk 320 to build a video disk 342 , a customer 340 initiates a transaction, such as by walking up to the kiosk 320 and pressing a key on the keyboard. The content selection unit 324 of the kiosk 320 displays a catalog of movies, organized in various ways. For example, the movies can be organized according to the title, category, or any other related terms to identify the movies. The content selection unit 324 also displays other content that can be selected, such as additional related content. Other content can include audio, text, and still images.
[0018] In one example, the additional related content includes bonus content such as director commentary, subtitles, video angles, or deleted scenes. In addition, the implementation could offer the user the ability to purchase on-line enabled services or content associated with the disk, but not necessarily included on the disk (e.g. a managed or authorized copy of disk content). The movies and other items are stored locally as data in the content database unit 326 or remotely in the content database unit 318 of the remote server 310 .
[0019] The content selection unit 324 enables the customer 340 to browse or search the catalogs of items and to select a movie and other content using the user interface. The content selection unit 324 then builds a list of items to put on the video disk 342 . The content selection unit 320 further prompts the customer 340 for selection of options based on other user selections. Examples of options include, but are not limited to, movie format, resolution, languages, second session versions. Selection of the movie format option includes selecting widescreen or fullscreen. Selection of the languages option includes selecting audio format, subtitles, and other related language options. Selection of the second session versions includes selecting from constrained image versions. The content selection unit 324 also prompts the customer 340 to accept items selected by the content selection unit 340 , such as promotional or upsell items including games, soundtracks, and other related items.
[0020] The content selection unit 324 determines which of the selected items are stored locally and which need to be retrieved from remote storage 318 . For remotely-stored items, the content selection unit 324 requests the items from the content database 318 through the content delivery unit 314 . The content selection unit 324 caches retrieved items for a period of time based on the popularity of the item. For some items, the content selection unit 324 keeps the data in the content database 326 for a period determined by an external service such the content provider who owns the kiosk 320 . Similarly, the content provider can cause the kiosk 320 to download and store items that are popular or to be promoted such as a new movie.
[0021] In one implementation, the customer 340 also provides identification information identifying the customer 340 to the content selection unit 324 . The content selection unit 324 sends the identification information to the customer database 316 of the remote server 310 through the network connection and receives a profile for the customer 340 from the content delivery unit 314 of the remote server 310 . The profile reflects characteristics supplied by the customer 340 or derived based on customer activity such as past purchases. The content selection unit 324 can use the profile to suggest or select options and promotional items.
[0022] As the customer 340 selects and confirms items to add to the video disk 342 , the financial transaction unit 322 determines the cumulative cost of the selected items. Each item has a cost, though some items may have a cost of zero or a negative cost as a promotional item. When the customer 340 is done adding and selecting items, the financial transaction unit 322 displays a payment interface showing the total cost and payment options (e.g., cash, credit or bank card, online account, etc.). The customer 340 selects a payment mode and provides the appropriate payment, for example, by inserting cash or a credit card. If the user selects a payment mode requiring external authorization (e.g., credit card), the financial transaction unit 322 uses the financial transaction processor 312 in the remote server 310 to contact the appropriate authorizing institution to confirm the purchase.
[0023] Although the above discussion describes a financial model in which the video disk is purchased, other financial models for providing the video disk can be selected including subscriptions and rentals. Thus, in one implementation, a fixed number of disks can be purchased in a time interval, or require that the disks be returned within a defined time period.
[0024] The video disk authoring system 330 includes a disk content authoring unit 332 , an encryption unit 334 , and a media writer 336 . These units 332 , 334 , 336 can be configured in hardware, software, or combination of hardware and software. Thus, in the illustrated implementation, the video disk authoring system 330 is configured to format, encode, encrypt, and write data to the video disk 342 .
[0025] For example, the disk content authoring unit 332 and the encryption unit 334 format and encrypt the selected items, or a subset of the selected items, for storage on the video disk 342 according to the selected options. The disk content authoring unit 332 adds a forensic watermark to one or more of the items (e.g., the movie), or components of the item (e.g. video, audio, or subtitles) to identify the particular copy to be placed on the video disk 342 . The disk content authoring unit 332 may also use an “anti-ripping” technology to inhibit users from making copies from the video disk 342 . An example of the anti-ripping technology includes Macrovision RipGuard. Other examples include technologies which introduce errors in video disk formats to prevent ripping software from reading the disks, or install software on the video disk to prevent ripping software from operating.
[0026] In one implementation, the encryption unit 334 of the video disk authoring system 330 uses Content Scrambling System (CSS) encryption, which uses multiple keys. These keys are basically a string of characters that are used to encode or decode the contents of the video disk read by the disk player. The implementation may also insert content certificates into the disk contents consistent with CSS disk authentication requirements. In another implementation, some or all items may already be encrypted when the items are downloaded to relieve the video disk authoring system 320 of encryption responsibility. In other implementations, the encryption unit 334 uses other encryption or digital rights management (DRM) technology, such as DivX. Depending on the specific technology used, the ordering of encryption, watermark inserted, compression, and labeling steps may be varied.
[0027] The encryption unit 334 writes the encrypted and formatted data to a video disk 342 using a media writer 336 . The video disk 342 can be provided by the customer 340 or can be obtained from a collection of blank disks stored in the kiosk 320 . The video disk 342 can be DVD recordable media such as DVD-R DVD+R, DVD+RW, or other non-standard recordable DVD disks to record data. In some implementations, the DVD recordable media includes prerecorded copy protection information, serial numbers, and/or unique numbers for security purposes. In other implementations, the DVD recordable media includes disks with secure unique serial numbers associated with prepaid financial transactions similar to prepaid phone cards. The implementation could also include support for non DVD optical disks, including any optical disk technologies which are developed to replace DVDs. The implementation could also include non optical media recordable storage including flash memory cards, magnetic storage devices, other technologies.
[0028] The video disk authoring system 330 also provides packaging for the video disk 342 , such as the disk label, a box or other container, and packaging inserts. The video disk authoring system 330 selects packaging items (e.g., a promotional coupon) and inquires the customer 340 for confirmation. The customer 340 can also select packaging options, such as artwork or other customization including inserting a name, a personalized message, an image, or other information. Other information includes barcodes, customer information, and unique identifiers. This information can be applied directly onto the disk, or onto a label which is attached to the disk. This information may be user selectable, or may be bound to the financial transaction which purchased the disk.
[0029] In one example, a customer can design and purchase a customized video disk by selecting items to place on the video disk. The customer can control what content to purchase and what extra items to receive. In addition, the content provider can identify the particular copy being generated through watermarking to track user activity. The content provider can also access a customer profile to enhance the customer experience and to provide feedback to the content provider.
[0030] FIGS. 4A and 4B illustrate a method for selecting and recording media content data according to one implementation of the present invention. To use the kiosk 320 to build a video disk 342 , a customer 340 initiates a transaction, at 400 . For example, when the customer 340 walks up to the kiosk 320 and presses a key on the keyboard, the content selection unit 324 of the kiosk 320 displays a catalog of movies, organized in various ways. The content selection unit 324 also displays other content that can be selected, such as additional related content.
[0031] The content selection unit 324 enables the customer 340 to browse or search the catalogs of items, at 402 , and to select a movie and other content using the user interface, at 404 . The content selection unit 320 further prompts the customer 340 for selection of options based on other user selections, at 406 .
[0032] In one implementation, the customer 340 may be asked to provide identification information identifying the customer 340 to the content selection unit 324 . The content selection unit 324 sends the identification information to the customer database 316 of the remote server 310 through the network connection and receives a profile for the customer 340 from the content delivery unit 314 of the remote server 310 . The profile reflects characteristics supplied by the customer 340 or derived based on customer activity such as past purchases. Thus, a determination is made, at 408 , to determine if the user profile is available. If the user profile is available, the profile is used, at 410 , to tailor the options and/or promotions specifically for the target customer 340 .
[0033] As the customer 340 selects and confirms items to add to the video disk 342 , the selected media content item and options are retrieved from storage, at 412 , and the payment for the selected media content item and options is processed, at 414 . When the customer 340 is done adding and selecting items, the financial transaction unit 322 displays a payment interface showing the total cost and payment options. The customer 340 selects a payment mode and provides the appropriate payment. A video disk including the selected media content item and options is built, at 416 , using the video disk authoring system 330 .
[0034] Various implementations of the invention are realized in electronic hardware, computer software, or combinations of these technologies. Some implementations include one or more computer programs executed by a programmable processor or computer. For example, a method for selecting and recording media content data as described above includes one or more programmable processors. Thus, the video disk authoring method can be implemented as a computer program stored on and executed by the disk authoring system. In general, each computer includes one or more processors, one or more data-storage components (e.g., volatile or non-volatile memory modules and persistent optical and magnetic storage devices, such as hard and floppy disk drives, CD-ROM drives, and magnetic tape drives), one or more input devices (e.g., mice and keyboards), and one or more output devices (e.g., display consoles and printers).
[0035] The computer programs include executable code that is usually stored in a persistent storage medium and then copied into memory at run-time. The processor executes the code by retrieving program instructions from memory in a prescribed order. When executing the program code, the computer receives data from the input and/or storage devices, performs operations on the data, and then delivers the resulting data to the output and/or storage devices.
[0036] Various illustrative implementations of the present invention have been described. However, one of ordinary skill in the art will see that additional implementations are also possible and within the scope of the present invention. For example, while the above description focuses on implementations of movie distribution using the retail kiosk, other types of content can also be purchased in a similar way, such as television programs, music, books, or software. Accordingly, the present invention is not limited to only those implementations described above.
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A system for selecting and recording data, comprising: a local storage unit for storing a subset of media content items and other content; a content selection unit to display a catalog of the media content items and other content, to allow a customer to browse, search, and select a media content item and other content from the catalog of media content items and other content, to retrieve the selected media content item and other content from the local storage unit if the selected media content item and other content is found in the subset, and otherwise to retrieve the selected media content item from a remote storage unit, the content selection unit configured to cache the retrieved media content item and other content in the local storage unit for a period of time based on the popularity of the retrieved media content item; a financial transaction unit to determine the cost of the retrieved media content item and other content and display the cost for review and payment by the customer; and an authoring system configured to format, encode, encrypt, and write the media content item and other content onto an article of media when the customer makes the payment.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a coin receiving mechanism for use with pay telephones, vending machines, coin changing machines and other coin or token activated machines, and more particularly, to a coin receiving mechanism having a foreign objects release device for releasing foreign objects jammed in the coin receiving mechanism.
2. Description of the Prior Art
A major problem associated with coin receiving mechanisms used in pay telephones, vending machines, change machines and the like is their susceptibility to being intentionally jammed by a thief intent on stealing subsequently deposited coins. The thief stuffs paper, cloth, or other foreign objects into the coin deposit chute which blocks the coin acceptor/counter device associated with the coin receiving mechanisms. After setting his trap, the thief waits until one or more paying customers have deposited coins in the coin deposit chute blocked by the foreign objects. Since the deposited coins are blocked by the foreign objects, these coins cannot be retrieved by operating the coin release lever or tapping on the coin activated machine. After the paying customer leaves, the thief returns to complete the theft by attempting to fish out the coins stuck in the coin deposit chute with a wire, comb or other instrument. In fishing out the coins, the thief often will cause further jamming and/or damage to the coin receiving mechanism and the coin acceptor/counter device. Typically, the thief will leave the foreign objects in the coin receiving mechanism, resulting in an ongoing loss of sales from the machine and requiring repair personnel to make a service call to remove the blockage. Such illegal activity not only inconveniences and upsets the customer of the coin operated machine, but also results in substantial economic loss to the owners and operators of coin operated machines by way of lost sales and higher repair costs.
Several attempts have been made to overcome the above identified problem, but they have all met with limited success. U.S. Pat. No. 4,660,706 to Wollet teaches a mechanism with a metal plate which blocks the coin deposit slot on the coin activated machine if foreign objects are stuffed between the walls of the coin chute, and thereby prevents the additional foreign objects and/or coins from being deposited. However, the Wollet device does not provide any feature which would allow the customer to clear the blockage. With the Wollet device, once the coin chute is stuffed with foreign objects, a metal plate shuts the coin deposit slot on the coin activated machine, thereby blocking further access to the coin deposit chute and rendering the coin activated machine inoperative. Although later customers are prevented from losing their coins to thieves, sales are lost until service personnel make a service call to clear the machine. U.S. Pat. No. 4,687,090 to Ramseier discloses a coin receiving mechanism having separable coin guide walls which define a coin track having sections arranged in a zigzag form. While the Ramseier device purportedly has a feature to allow unblocking of the coin chute path, one of the walls, which is set at a steep angle to the vertical, does not move and thus it cannot "kick" debris out of the coin path. Thus, the Ramseier device can require at least several operations to clear paper jams.
SUMMARY OF THE INVENTION
The invention disclosed herein solves the problems outlined above by providing a unique and novel mechanism which includes separable coin chute walls defining a coin chute path, which when separated by turning the coin return lever on the coin operated device, for example, cause objects lodged between the coin chute walls to be ejected, thereby clearing foreign objects from the coin chute path and the coin acceptor/counter device.
When the coin chute path of the instant invention is stuffed with paper or other foreign objects, thereby blocking the coin chute path through which coins normally traverse, the coin activated machine will not operate. The paying customer will invariably turn the coin return lever on the coin activated machine, thereby separating the coin chute walls and ejecting the foreign objects to clear the coin chute path. Turning the coin return lever turns a drive arm, which then rotates a cam member coupled to the two walls of the coin chute by drive arms, causing the walls to separate at their bottom portion. One of the walls swings out wider than the other, thereby flipping and ejecting any foreign objects and coins previously jammed therebetween into a waste receiver. Thereafter, when the coin release lever is released, the two walls of the coin chute spring back to their unactivated position of being parallel in a vertical plane, free from any blockage and immediately available for use. The coin release mechanism may also include a coin shutter with a coin slot passing therethrough. The coin shutter moves to block the coin accepting slot on the outside of the machine when the coin release lever is activated and/or the walls of the coin chute are spread apart because of the presence of foreign objects or tools inserted therebetween, thereby preventing further jamming of foreign articles therein and further loss of coins by a paying customer.
Ideally, the walls of the coin chute path are manufactured with several planar sections, each arranged in a zigzagged orientation in one direction with respect to each other. At least one planar section is arranged at an angle offset from the direction of the zigzagged sections. This zigzagged and turned arrangement of planar sections helps prevent a wire or other instrument from being inserted very far down into the coin path defined by the walls. The inside of the wall sections preferably have parallel grooves and ribs defined thereon in the same direction of coin travel. These grooves and ribs help prevent wet coins from sticking in the coin chute path, and also help prevent a wire or other instrument from being inserted into the mechanism and negotiated through the space between the zigzagged and angled wall sections, to the end of the sections. Groups of groove blocks are preferably located at various positions in the grooves between the ribs on the inside of the coin chute walls, which groove blocks help to catch on inserted wires or tools, thereby further frustrating attempts by the thief to push foreign objects into the coin chute path.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention as described below in greater detail with reference to the drawings.
FIG. 1 is a front view of a coin operated telephone with the location of the coin receiving mechanism having a foreign object release device outlined by dotted lines.
FIG. 2 is a front view of a coin receiving mechanism using the present invention showing the mechanism in its non-activated position, partially cut open to shown the parts thereof, in conjunction with a coin acceptor/counter device, shown in phantom lines.
FIG. 3 is a front view of the coin receiving mechanism in its activated position, partially cut open to show the parts thereof, in conjunction with a coin acceptor/counter device, shown in phantom lines.
FIG. 4 is an front view of the coin receiving mechanism in its non-activated position, with the coin shutter being shown.
FIG. 5 is a front view of the coin receiving mechanism in its activated position, with the coin shutter being shown.
FIG. 6 is top view of the coin shutter.
FIG. 7 is a partial front view, similar to FIG. 5, of a lower cost version of coin receiving mechanism.
FIG. 8 is a side elevational view of the first coin chute wall.
FIG. 9 is a bottom view of the coin chute walls generally taken through view lines 9--9 of FIG. 8.
FIG. 10 is a cross sectional view of the second coin chute wall taken through view lines 10--10 of FIG. 8.
FIG. 11 is a front view of the coin return lever mechanism, partially cut open to shown the details therein.
FIG. 12 is a side view of the coin return lever mechanism of FIG. 11, taken through view lines 11--11.
DETAILED DESCRIPTION
Referring first to FIG. 1, the front of a coin operated telephone 1 is shown. The telephone has a coin slot 2 which passes through the front panel 3 of the telephone. The coin return lever 4 is located on the front panel 3 of the telephone. The coin return door 5 is located at the bottom of the telephone front panel 3 of the telephone. The coin activated mechanism having a foreign object release device is located behind the front panel 3 in the vicinity of the dotted lines. A case 7 houses the coin activated mechanism and the electronics associated with the telephone's communication facilities. For sake of convenience, the mechanism is shown and discussed as used in a coin operated telephone, butthe mechanism is equally applicable to other coin operated machines.
Referring next to FIGS. 2 and 3, the coin receiving mechanism having a foreign object release device is generally shown by reference numeral 6 and is shown with the front panel 3 of the telephone removed. As will be subsequently discussed, it is also shown without a shutter device which will be described subsequently with reference to FIGS. 4 and 5.
The coin return lever 4, shown in dashed lines, is present on the front panel 3 of the coin operated telephone 1 and the top 7T and side walls 7R and 7L of the case 7 can be seen. The coin return lever 4 is journalled toa shaft 9. A drive arm 10 is connected either directly to the shaft 9, or indirectly through a spring, as will be described more fully below. The drive arm 10 has a contact surface 11 at one end. Positioned on the insideof front panel 3 of the telephone is a stop 12 which prevents the drive arm10 from moving beyond its unactivated position. A biasing spring 13 is connected at one end to the drive arm 10, and at the other end to a retaining post 14 fixed on the inside of the front panel 3 of the telephone. The biasing spring 13 keeps the drive arm 10 pressed against the stop 12 when the coin return lever 4 is in its unactivated position. When the coin return lever 4 is turned, the drive arm 10 moves in a path to make contact with a roller 15, rotatably mounted on a member 16, which is rotationally mounted on pivot pin 17, which in turn is mounted to a front wall 18 of a generally U-shaped frame supporting the coin receiving mechanism 6. A side wall of the frame can be seen at numeral 38, which side wall continues rearwardly as a rear wall 38 generally of similar configuration to front wall 18, except that it need not make room for coinchute 19.
The coin receiving slot 2 on the outside case 7 of the telephone 1 aligns with an entrance of coin chute 19, the coin chute providing a path for deposited coins, which path is defined by the inside surfaces of a right coin chute wall section 20 and a left coin chute wall section 21 which in their unactivated positions lie parallel to each other in a vertical position as shown in FIG. 2. Connected approximately perpendicular to the front of the right and left wall sections 20 and 21 are right and left front wall plates 22 and 23, respectively. Also connected approximately perpendicular to the rear of the right and left wall sections 20, 21 are left rear wall plate 120 and right rear wall plate 121, as shown in FIG. 8.
The right coin chute wall section 20 and left coin chute wall section 21 are pivoted together at their top portions on a pivoting shaft 24. The pivoting shaft 24 passes through and is supported by the front wall 18 andby a bracket (not shown) attached to side wall 38 of the frame supporting the mechanism 6. A bottom portion of the right front wall plate 22 is pivotally connected to member 16 via a right wall link 26 and the bottom portion of the left front wall plate 23 is pivotally connected to the cam member 16 by a left wall link 27. The left wall link 27 is pivotally connected to the left front wall plate 23 at pin 28 and to member 16 at pin 29. The right wall link 26 is pivotally connected to the right front wall plate 22 at pin 30 and to member 16 at pin 31, which is closer to pin17 than is pin 29. A debris receptacle 32 is hung by hanging pins 33 on slots 34 on the front wall 18 of the frame and rear wall 25 of the frame. It has a chute 32' which conveys debris and trapped coins to the coin return slot 5. When the coin return lever 4 is depressed, the drive arm 10moves to drive its contact surface 11 into contact with roller 15 on member16, causing member 16 to rotate in a counter-clockwise direction about pin 17, thereby opening the coin chute mechanism as shown in FIG. 3. As member16 rotates, the left wall link 27 and right wall link 26 cause the left wall section 21 and right wall section 20 to swing open at their bottoms. By virtue of the left wall link 27 being pivoted at a pin 29 further away from the pin 17 than is pin 31 of the right wall link 26, the left wall section 21 swings out wider than does the right wall section 20. The foreign objects F previously inserted into the coin chute path are then ejected into debris receiver 32 and thence to slot 5.
A coin acceptor/counter device 35 of conventional design, shown mostly in phantom lines, has tabs 36 which slide into receiving slots 37 on the front and rear walls 18, 25 of the supporting frame. The front and rear walls 18, 25 are joined to a side wall 38 of the frame. Additional tabs (not shown) may be used to hold the bottom of the coin acceptor/counter device 35 in place in the frame supporting the mechanism. The coin ancestor/counter device 35 has an opening 35' for coins exiting the coin chute 19 formed by wall sections 20 and 21. It also has a release door 39,which when relieved by pushing on release door member 40, (as shown in FIG.3) releases any coins that may have become jammed in the coin acceptor/counter device 35, moving through an opening in side wall 38. A coil spring 41 is attached at its upper end to the lower portion of member16 and at its lower end to the front wall 18 (not shown). Two tension springs (not shown) are preferably also used to further exert a counter-clockwise twisting force on wall sections 20 and 21 to urge the wall sections 21 and 20 to return to their normal unactivated position when the coin return lever 4 is released.
As shown in FIG. 3, a rocker member 42 is pivoted in its middle portion on a rocker member pivot pin 43 which is mounted on the front wall 18 of the supporting frame. At its upper end, the rocker member 42 has a forked portion which is slidingly connected to pin 30 at which the right wall link 26 pivotally connects to the bottom of the right front wall plate 22.The bottom of the rocker member has a forked portion 44. The release door member 40 of the release door 39 slides between the prongs of the forked portion 44 of the rocker member 42.
When the coin release mechanism 6 is activated, the right wall section 20 swings out at its bottom in a clockwise direction, causing the rocker member 42 to pivot about its pivot pin 43 in a counter-clockwise direction, which in turn pushes the release door member 40, causing the release door 39 to open, thereby freeing coins lodged in the coin acceptor/counter device 35. The release doors 39 of the coin acceptor/counter device 35 is conventionally spring loaded, which applies a clockwise turning force to the rocker member 42 to help return it and the entire mechanism to its unactivated position when coin lever 6 is released.
Link 26, being coupled relatively closely to pin 17 on member 16, operates with a relatively large torque, thereby making it effective for dislodgingany debris stuck in the mouth 35' of coin acceptor/counter 35.
The mechanism preferably includes a coin shutter device 46. One embodiment thereof is now disclosed with reference to FIGS. 4, 5 and 6. The coin shutter 46 is pivoted on the rocker member pivot pin 43 which is mounted on the front wall 18 of the frame. The coin shutter 46 preferably has a flat planar face 48 with a coin shutter slot 49 passing therethrough, positioned above the pivot pin 43. When the mechanism is in its unactivated position, best shown in FIG. 4, the coin shutter slot 49 aligns with the entrance of the coin chute 19 and the coin slot 2 on the outside of the telephone 1.
A shutter roller 50 is pivotally mounted at the bottom portion of the coin shutter 46. Member 16 has a lower curved lobe cam portion 51 which provides a cam surface for roller 50. When the coin receiving mechanism 6 is activated by turning the coin return lever 4 or the right wall section 20 and left wall section 21 of the coin chute are physically separated, e.g., by insertion of foreign objects or prying with tools, member 16 is rotated in a counter-clockwise direction, driving its lower curved lobe cam portion 51 into contact with the shutter roller 50, which in turn causes the coin shutter 46 to rotate in a counter-clockwise direction. As the coin shutter 46 turns on its pivot pin 43, the coin shutter slot 49 ismoved out of alignment with the coin receiving slot 2 on the outside of thetelephone 1, thereby preventing the thief from introducing any further foreign objects or tools into the coin receiving mechanism 6 or attemptingto break the machine. This also tends to prevent customers from attempting to insert coins in a debris jammed machine. A shutter return spring 52 is positioned on pivot pin 43 which biases the coin shutter 46 to return to its unactivated position.
As shown in FIG. 6, the top of the coin shutter 46 has a top portion 53 normal to flat planar face 48 of the coin shutter 46. The top portion 53 has an elongated slot 54 formed therein. The elongated slot 54 does not reach either end of the top portion. A shutter keeper post 55 is positioned on the front wall 18 and juts upward into the elongated slot 54. In the unactivated position where the coin shutter 46 aligns with the coin receiving slot 2 on the outside of the telephone 1, the shutter keeper post 55 abuts the left end of the elongate slot 54, preventing the coin shutter 46 from being moved any further to the right. When the coin chute mechanism moves to the position shown in FIGS. 3 and 5, the coin shutter 46 moves counter-clockwise direction and is stopped by the contactof the shutter keeper post 55 on the right side of the elongate slot 54. Due to the configuration of member 16 in relationship to the coin shutter 46, particularly the contour of the lower curved lobe cam portion 51, the coin shutter 46 does not return to its normal unactivated position until member 16 is at the last portion of its return motion.
Member 16 is configured such that the right and left walls section 20 and 21 of the coin chute and the release door 39 of the coin acceptor/counter device 35 operate or move in unison. If either the coin acceptor/counter device 35 or the right and left walls section 20 and 21 are jammed and cannot return to their unactivated position, then member 16 will not return to its unactivated position, thereby preventing the coin shutter slot 49 from returning to its normal position in alignment with the coin receiving slot 2 on the outside of the telephone 1. This feature saves further losses of coins by paying customers and will prevent further thefts from occurring.
An abutting member 56 is located on the left front wall plate 23 and juts outwardly to a position behind the contact surface 11 of the drive arm 10.The abutting member 56 makes it impossible to pry the right and left walls section 20 and 21 substantially apart since if an attempt is made to pry them apart, the abutting member 56 is stopped by drive arm 10. In the embodiment of FIGS. 2-6, links 26 and 27 are provided by flat elongated plates having openings at the ends thereof which rotate on pins 28, 29, 30and 31. In order to reduce the manufacturing cost of the coin receiving mechanism, elongated wire links 26' and 27' are preferably used instead ofthe elongated plates, as is shown in FIG. 7. The wire links 26' and 27' arebent at their ends either to be received in openings 28', 29' and 31' located where pins 28, 29 and 31 are shown in FIG. 2, for example, or to wrap around a pin, such as pin 30, as shown in FIG. 7.
Also, to further lower the manufacturing cost of the coin receiving mechanism, the coin shutter device is preferably rotationally mounted on pin 24 and is coupled to wall 23 so that the slot 49 therein rotates clockwise out of alignment with coin slot 2 in response to the rotation ofmember 16.
The coin chute is shown in greater detail in FIGS. 8-10. FIG. 8 is a side elevational view of wall plate 22, generally taken along line 8--8 of FIG.2, but without showing the links and other mechanics which impart motion towall 22. As can be seen from FIG. 9, the right wall section 20 and left wall section 21 lie parallel to each other and have a plurality of planar,normally vertical sections 58 offset at slight angles from each other, so that the walls have a zigzagged configuration. The space between the wall sections 20 and 21 partially define the coin chute 19 and thus the coin follows a zig zag pattern to the coin counter/acceptor 35. Indeed, the zigzag occurs in two ways, the deposited coins zigzag right and left while moving generally aftward and then change direction and move generally forwardly.
Guide walls 58 define the bottom and sides of the coin chute upon which thecoins being deposited (and following the arrows) roll. The right and left wall sections 20 and 21 of the coin chute in its unactivated (normal) position lie in vertical planes so that the coins being deposited roll on the guide walls 58 as they zig zag rearwardly down the chute 19.
In the preferred embodiment, both the right and left wall sections 20 and 21 of the coin chute have a lower section 59 turned at an angle from the sections arranged in the first mentioned zigzag. The right and left wall sections 20 and 21 preferably have grooves 60 formed thereon which define ribs 61 at least partially thereon, with the grooves and ribs located in the direction of coin travel, shown by arrows.
FIG. 10 shows the arrangement of grooves 60 and ribs 61. The ribs 61 prevent wet coins from sticking to the walls 20 and 21 of the coin chute. Groove blocks 62 are preferably located at various positions in the grooves 60 to block the spaces between the ribs. FIG. 9 is taken through agroove 60 to show more clearly groove blocks 62. When wires or other instruments are inserted into the coin chute in an attempt to force foreign objects F into the coin chute, the wire W will tend to follow a groove or grooves 60, and due to the zig zag configuration, will be caughtup on one or more groove blocks 62, preventing the foreign object F from being forced further down into the coin chute. The lower section 59 of thecoin chute also has grooves 60 defining ribs 61 thereon in the direction ofcoin travel. Groove blocks 62 are also preferably located in the grooves thereon. The combination of the zigzagged right and left wall section 20 and 21 with the lower section 59, grooves 60, ribs 61 and groove blocks 62effectively defeat the thief's attempt to force foreign objects F very far down into the coin chute path or around the turn in the coin chute into the coin acceptor/counter device 35.
Another feature of the invention is shown in FIGS. 11 and 12. The coin return lever 4 is rigidly connected to shaft 9 which is affixed to a drivearm plate 63, by a bolt, screw, or other well known attachment means. Located behind the front panel 3 of the telephone 1 is washer 64. The drive arm 10 is rotatably sandwiched between the washer 64 and a bobbin 65placed between the drive arm plate 63 and the drive arm 10 on the shaft 9. A bolt 66 or other means fixes the drive arm plate 63 to the shaft 9 so that the drive arm plate 63 does not rotate relative to the coin return lever 4. The drive arm 10 has ears 67 at its top. A torsion spring 68 is placed around the bobbin 65. The lower end of the torsion spring 69 fits into a corner edge 70 of the drive arm plate 63 and the upper end of the torsion spring 71 is retained by the ears 67. The tension on the torsion spring 68 may be adjusted by the choice of which ears 67 are used to retain the upper end 71 of the torsion spring 68.
As described, the coin return lever 4 communicates with the drive arm 10 via the torsion spring 68. Thus, the combination acts as a clutch mechanism and prevents excess force from being applied to the cam roller 15 and thereby causing damage to the coin receiving mechanism 6 in case the coin return lever 4 is violently turned in an attempt to break the mechanism. If excess force is applied to the torsion spring 68 via the coin return lever 4, the torsion spring 68 will "give", thereby preventingdamage to the coin receiving mechanism 6. FIGS. 11 and 12 show the drive arm 4 and member 16 and related parts in their activated position by phantom lines.
The drawings and foregoing description are not intended to represent the only form of the invention in regard to the details of its construction and manner of operation. In fact, it will be evident to one skilled in theart that modifications and variations may be made without departure from the spirit and scope of the invention. For example, FIG. 7 depicts a lowercost and preferred embodiment of the mechanism which impart motion to walls22 and 23. Changes in form and in proportions of parts, as well as the substance of equivalents are contemplated as circumstances may suggest or render expedient. Although specific terms have been employed, they are intended in a generic and descriptive sense only and not for the purpose of limitation, the scope of the invention being detailed in the following claims:
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The invention is a coin receiving mechanism having a foreign object release device for use with a coin receiving machine having a coin acceptor/counter device. The invention has a pair of hinged coin chute walls with planar sections arranged in a zigzag manner which define the coin path. The coin chute walls also have a section angled from the zigzagged sections. A cam member is connected by linking arms to the coin chute walls. A coin return lever on the outline of the machine is connected to a drive arm inside the machine. When turned, the coin return lever turns the cam member and causes the coin chute walls to flip open and eject any foreign objects contained therebetween. The drive arm is connected to the coin return lever through a clutch mechanism. A coin shutter with a coin slot is also operated by activating the cam member which causes the coin shutter to misalign the coin slot in the coin shutter with the coin receiving slot on the outside of the coin receiving machine, thereby preventing additional foreign objects and/or instruments from being introduced into the coin chute.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application No. 61/822,586, filed on May 13, 2013, the content of which is hereby incorporated by reference.
BACKGROUND
[0002] Saporin, a ribosome inactivating protein extracted from the seeds of Saponaria officinalis , has medicinal use, e.g., treatment of cancer.
[0003] When used as a therapeutic agent, saporin must be delivered to its target cells. The low cell permeability of this protein makes it difficult to cross cell membranes to reach an intracellular target.
[0004] Target-specific vehicles have been used to deliver therapeutics. See Place et al., Molecular Therapy-Nucleic Acids, 1, e15 (2012). Examples include polymers and inorganic nanoparticles. See Gonzales-Toro et al., Journal of American Chemical Society, 134, 6964-67 (2012). However, these vehicles are often toxic or inefficient. See Akinc et al., Molecular Therapy, 17, 872-79 (2009).
[0005] There is a need to develop an efficient and safe vehicle for delivering saporin to its intracellular target.
SUMMARY
[0006] This invention is based on the discovery that lipid-like compounds are efficient and safe vehicles for use in delivery of saporin to cells.
[0007] In one aspect, this invention features a nanocomplex containing saporin (i.e., a therapeutic protein) and a lipid-like compound. The term “saporin” herein refers to the protein itself, a saporin conjugate, and a saporin derivative.
[0008] A saporin conjugate is a compound containing a saporin molecule chemically linked to one or more other molecules. Examples include, but are not limited to, a nucleoprotein, a glycoprotein, a phosphorprotein, a hemoglobin, and a lecithoprotein. A saporin derivative is a compound formed through hydrolysis of saporin, which results in slight alteration of saporin. Examples include, but are not limited to, a metaprotein, a proteose, and a peptide.
[0009] The lipid-like compound has a hydrophilic moiety, a hydrophobic moiety, and a linker joining the hydrophilic moiety and the hydrophobic moiety.
[0010] The hydrophilic moiety, optionally positively or negatively charged, can be an aliphatic or heteroaliphatic radical containing one or more hydrophilic groups and 1-20 carbon atoms. Examples of the hydrophilic group include, but are not limited to, amino, alkylamino, dialkylamino, trialkylamino, tetraalkylammonium, hydroxyamino, hydroxyl, carboxyl, carboxylate, carbamate, carbamide, carbonate, phosphate, phosphite, sulfate, sulfite, and thiosulfate.
[0011] Examples of the hydrophilic moiety include, but are not limited to,
[0000]
[0000] in which each of R a , R a ′, R a ″, and R a ′″ independently, is a C 1 -C 20 (e.g., C 1 -C 10 and C 1 -C 6 ) monovalent aliphatic radical, a C 1 -C 20 (e.g., C 1 -C 10 and C 1 -C 6 ) monovalent heteroaliphatic radical, a monovalent aryl radical, or a monovalent heteroaryl radical; and Z is a C 1 -C 20 (e.g., C 1 -C 10 and C 1 -C 6 ) bivalent aliphatic radical, a C 1 -C 20 (e.g., C 1 -C 10 and C 1 -C 6 ) bivalent heteroaliphatic radical, a bivalent aryl radical, or a bivalent heteroaryl radical.
[0012] The hydrophobic moiety is a C 8-24 aliphatic radical or a C 8-24 heteroaliphatic radical (e.g., a C 8-24 heteroaliphatic radical containing one or more —S—S— groups, a C 12-20 aliphatic radical, a C 12-20 heteroaliphatic radical, a C 14-18 aliphatic radical, and a C 14-18 heteroaliphatic radical).
[0013] The linker can be O, S, Si, C 1 -C 6 alkylene,
[0000]
[0000] in which each of m, n, p, q, and t, independently, is 1-6; W is O, S, or NR c ; each of L 1 , L 3 , L 5 , L 7 , and L 9 , independently, is a bond, O, S, or NR d ; each of L 2 , L 4 , L 6 , L 8 , and L 10 , independently, is a bond, O, S, or NR e ; and V is OR f , SR g , or NR h R i , each of R b , R c , R d , R e , R f , R g , R h , and independently, being H, OH, a C 1 -C 10 oxyaliphatic radical, a C 1 -C 10 monovalent aliphatic radical, a C 1 -C 10 monovalent heteroaliphatic radical, a monovalent aryl radical, or a monovalent heteroaryl radical. Examples include, but are not limited to,
[0000]
[0014] The lipid-like compound described above can be a compound of formula (I): B 1 —K 1 -A-K 2 —B 2 , in which A is the hydrophilic moiety, each of B 1 and B 2 is the hydrophobic moiety, and each of K 1 and K 2 is the linker.
[0015] The term “aliphatic” herein refers to a saturated or unsaturated, linear or branched, acyclic, cyclic, or polycyclic hydrocarbon moiety. Examples include, but are not limited to, alkyl, alkylene, alkenyl, alkenylene, alkynyl, alkynylene, cycloalkyl, cycloalkylene, cycloalkenyl, cycloalkenylene, cycloalkynyl, and cycloalkynylene moieties. The term “alkyl” or “alkylene” refers to a saturated, linear or branched hydrocarbon moiety, such as methyl, methylene, ethyl, ethylene, propyl, propylene, butyl, butylenes, pentyl, pentylene, hexyl, hexylene, heptyl, heptylene, octyl, octylene, nonyl, nonylene, decyl, decylene, undecyl, undecylene, dodecyl, dodecylene, tridecyl, tridecylene, tetradecyl, tetradecylene, pentadecyl, pentadecylene, hexadecyl, hexadecylene, heptadecyl, heptadecylene, octadecyl, octadecylene, nonadecyl, nonadecylene, icosyl, icosylene, triacontyl, and triacotylene. The term “alkenyl” or “alkenylene” refers to a linear or branched hydrocarbon moiety that contains at least one double bond, such as —CH═CH—CH 3 and —CH═CH—CH 2 —. The term “alkynyl” or “alkynylene” refers to a linear or branched hydrocarbon moiety that contains at least one triple bond, such as —C≡C—CH 3 and —C≡C—CH 2 —. The term “cycloalkyl” or “cycloalkylene” refers to a saturated, cyclic hydrocarbon moiety, such as cyclohexyl and cyclohexylene. The term “cycloalkenyl” or “cycloalkenylene” refers to a non-aromatic, cyclic hydrocarbon moiety that contains at least one double bond, such as cyclohexenyl cyclohexenylene. The term “cycloalkynyl” or “cycloalkynylene” refers to a non-aromatic, cyclic hydrocarbon moiety that contains at least one triple bond, cyclooctynyl and cyclooctynylene.
[0016] The term “heteroaliphatic” herein refers to an aliphatic moiety containing at least one heteroatom selected from N, O, P, B, S, Si, Sb, Al, Sn, As, Se, and Ge.
[0017] The term “oxyaliphatic” herein refers to an —O-aliphatic. Examples of oxyaliphatic include methoxy, ethoxy, n-propoxy, isopropoxy, n-butoxy, iso-butoxy, sec-butoxy, and tert-butoxy.
[0018] The term “aryl” herein refers to a C 6 monocyclic, C 10 bicyclic, C 14 tricyclic, C 20 tetracyclic, or C 24 pentacyclic aromatic ring system. Examples of aryl groups include, but are not limited to, phenyl, phenylene, naphthyl, naphthylene, anthracenyl, anthrcenylene, pyrenyl, and pyrenylene. The term “heteroaryl” herein refers to an aromatic 5-8 membered monocyclic, 8-12 membered bicyclic, 11-14 membered tricyclic, and 15-20 membered tetracyclic ring system having one or more heteroatoms (such as O, N, S, or Se). Examples of heteroaryl groups include, but are not limited to, furyl, furylene, fluorenyl, fluorenylene, pyrrolyl, pyrrolylene, thienyl, thienylene, oxazolyl, oxazolylene, imidazolyl, imidazolylene, benzimidazolyl, benzimidazolylene, thiazolyl, thiazolylene, pyridyl, pyridylene, pyrimidinyl, pyrimidinylene, quinazolinyl, quinazolinylene, quinolinyl, quinolinylene, isoquinolyl, isoquinolylene, indolyl, and indolylene.
[0019] Unless specified otherwise, aliphatic, heteroaliphatic, oxyaliphatic, alkyl, alkylene, alkenyl, alkenylene, alkynyl, alkynylene, cycloalkyl, cycloalkylene, cycloalkenyl, cycloalkenylene, cycloalkynyl, cycloalkynylene, heterocycloalkyl, heterocycloalkylene, heterocycloalkenyl, heterocycloalkenylene, aryl, and heteroaryl mentioned herein include both substituted and unsubstituted moieties. Possible substituents on cycloalkyl, cycloalkylene, cycloalkenyl, cycloalkenylene, cycloalkynyl, cycloalkynylene, heterocycloalkyl, heterocycloalkylene, heterocycloalkenyl, heterocycloalkenylene, aryl, and heteroaryl include, but are not limited to, C 1 -C 10 alkyl, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, C 3 -C 20 cycloalkyl, C 3 -C 20 cycloalkenyl, C 3 -C 20 heterocycloalkyl, C 3 -C 20 heterocycloalkenyl, C 1 -C 10 alkoxy, aryl, aryloxy, heteroaryl, heteroaryloxy, amino, C 1 -C 10 alkylamino, C 2 -C 20 dialkylamino, arylamino, diarylamino, C 1 -C 10 alkylsulfonamino, arylsulfonamino, C 1 -C 10 alkylimino, arylimino, C 1 -C 10 alkylsulfonimino, arylsulfonimino, hydroxyl, halo, thio, C 1 -C 10 alkylthio, arylthio, C 1 -C 10 alkylsulfonyl, arylsulfonyl, acylamino, aminoacyl, aminothioacyl, amido, amidino, guanidine, ureido, thioureido, cyano, nitro, nitroso, azido, acyl, thioacyl, acyloxy, carboxyl, and carboxylic ester. On the other hand, possible substituents on aliphatic, heteroaliphatic, oxyaliphatic, alkyl, alkylene, alkenyl, alkenylene, alkynyl, and alkynylene include all of the above-recited substituents except C 1 -C 10 alkyl. Cycloalkyl, cycloalkylene, cycloalkenyl, cycloalkenylene, heterocycloalkyl, heterocycloalkylene, heterocycloalkenyl, heterocycloalkenylene, aryl, and heteroaryl can also be fused with each other.
[0020] The lipid-like compounds described above include the compounds themselves, as well as their salts and solvates, if applicable. A salt, for example, can be formed between an anion and a positively charged group (e.g., amino) on a lipid-like compound. Suitable anions include chloride, bromide, iodide, sulfate, nitrate, phosphate, citrate, methanesulfonate, trifluoroacetate, acetate, malate, tosylate, tartrate, fumurate, glutamate, glucuronate, lactate, glutarate, and maleate. Likewise, a salt can also be formed between a cation and a negatively charged group (e.g., carboxylate) on a lipid-like compound. Suitable cations include sodium ion, potassium ion, magnesium ion, calcium ion, and an ammonium cation such as tetramethylammonium ion. The lipid-like compounds also include those salts containing quaternary nitrogen atoms. A solvate refers to a complex formed between a lipid-like compound and a pharmaceutically acceptable solvent. Examples of pharmaceutically acceptable solvents include water, ethanol, isopropanol, ethyl acetate, acetic acid, and ethanolamine.
[0021] Another aspect of this invention relates a pharmaceutical composition containing the nanocomplex described above and a pharmaceutically acceptable carrier. In this composition, the nanocomplex has a particle size of 50 to 500 nm (e.g., 50 to 300 nm and 50 to 180 nm); the pharmaceutical carrier is compatible with saporin, a lipid-like compound, and a nanocomplex contained in the composition (and preferably, capable of stabilizing the nanocomplex) and not deleterious to the subject to be treated.
[0022] The term “non-covalent interaction” refers to any non-covalent binding, which includes ionic interaction, hydrogen bonding, van der Waals interaction, and hydrophobic interaction.
[0023] The details of one or more embodiments of the invention are set forth in the description below. Other features, objects, and advantages of the invention will be apparent from the description and from the claims.
DETAILED DESCRIPTION
[0024] The nanocomplex of this invention contains a lipid-like compound having a hydrophilic moiety, a hydrophobic moiety, and a linker joining the hydrophilic moiety and the hydrophobic moiety.
[0025] The hydrophilic moiety contains one or more hydrophilic functional groups, e.g., hydroxyl, carbonyl, carboxyl, amino, sulfhydryl, phosphate, amide, ester, ether, carbamate, carbonate, carbamide, and phosphodiester. These groups can form hydrogen bonds and are optionally positively or negatively charged.
[0026] Examples of the hydrophilic moiety include, but are not limited to,
[0000]
[0027] Other examples include those described in Akinc et al., Nature Biotechnology, 26, 561-69 (2008) and Mahon et al., US Patent Application Publication 2011/0293703.
[0028] The hydrophobic moiety is a saturated or unsaturated, linear or branched, acyclic or cyclic, aromatic or nonaromatic hydrocarbon moiety containing 8-24 carbon atoms. One or more of the carbon atoms can be replaced with a heteroatom, such as N, O, P, B, S, Si, Sb, Al, Sn, As, Se, and Ge. The hydrophobic moiety is optionally substituted with one or more groups described in the Summary section.
[0029] Examples include, but are not limited to,
[0000]
[0030] Turning to the linker(s), it links the hydrophilic moiety and the hydrophobic moiety. The linker can be any chemical group that is hydrophilic or hydrophobic, polar or non-polar, e.g., O, S, Si, amino, alkylene, ester, amide, carbamate, carbamide, carbonate, phosphate, phosphite, sulfate, sulfite, and thiosulfate. Examples include, but are not limited to,
[0000]
[0031] Shown below are exemplary lipid-like compounds useful for preparing the nanocomplex of this invention:
[0000]
[0032] The lipid-like compounds can be prepared by methods well known in the art. See Wang et al., ACS Synthetic Biology, 1, 403-07 (2012); Manoharan, et al., International Patent Application Publication WO 2008/042973; and Zugates et al., U.S. Pat. No. 8,071,082.
[0033] The route shown below exemplifies synthesis of certain lipid-like compounds:
[0000]
[0034] Each of L a , L a ′, L b , and L b ′ can be one of L 1 -L 10 ; each of W a and W b , independently, is W or V; and R a and R 1 -R 6 are defined above, as well as L 1 -L 10 , W, and V.
[0035] In this exemplary synthetic route, an amine compound, i.e., compound D, reacts with bromides E1 and E2 to form compound F, which is then coupled with both G1 and G2 to afford the final product, i.e., compound H. One or both of the double bonds in this compound (shown above) can be reduced to one or two single bonds to obtain different lipid-like compounds of this invention.
[0036] Other lipid-like compounds contained in the nanocomplex of this invention can be prepared using other suitable starting materials through the above-described synthetic route and others known in the art. The method set forth above can include an additional step(s) to add or remove suitable protecting groups in order to ultimately allow synthesis of the lipid-like compounds. In addition, various synthetic steps can be performed in an alternate sequence or order to give the desired material. Synthetic chemistry transformations and protecting group methodologies (protection and deprotection) useful in synthesizing applicable lipid-like compounds are known in the art, including, for example, R. Larock, Comprehensive Organic Transformations, VCH Publishers (1989); T. W. Greene and P. G. M. Wuts, Protective Groups in Organic Synthesis, 2 nd Ed., John Wiley and Sons (1991); L. Fieser and M. Fieser, Fieser and Fieser's Reagents for Organic Synthesis, John Wiley and Sons (1994); and L. Paquette, ed., Encyclopedia of Reagents for Organic Synthesis, John Wiley and Sons (1995) and subsequent editions thereof.
[0037] Certain lipid-like compounds may contain a non-aromatic double bond and one or more asymmetric centers. Thus, they can occur as racemates and racemic mixtures, single enantiomers, individual diastereomers, diastereomeric mixtures, and cis- or trans-isomeric forms. All such isomeric forms are contemplated.
[0038] As mentioned above, these lipid-like compounds are useful for delivery of saporin. They can be preliminarily screened for their efficacy in delivering saporin by an in vitro assay and then confirmed by animal experiments and clinic trials. Other methods will also be apparent to those of ordinary skill in the art.
[0039] The above-described nanocomplexes can be prepared using procedures set forth in publications such as Wang et al., ACS Synthetic Biology, 1, 403-07 (2012). Generally, they are obtained by incubating saporin and a lipid-like compound in a buffer such as a sodium acetate buffer or a phosphate buffer. Typically, the ratio of saporin to a lipid-like compound is 100:1 to 1:1 by weight (e.g., 50:1 to 5:1 and 30:1 to 20:1). Saporin, commercially available, can be extracted from the seeds of Saponaria officinalis or overexpressed in and then purified from Escherichia coli . See Stirpe et al., Biochemical Journal, 216, 617-25 (1983); Fabbrini et al., Biochemical Journal, 322, 719-27 (1997); and Fabbrini et al., the FASEB Journal, 11, 1169-76 (1997).
[0040] Still within the scope of this invention is use of one of the above-described nanocomplexes for treating diseases, such as cancer, arthritis, neurodegenerative/cognitive disorders, an infection, chronic pain, and a sleeping disorder. Thus, this invention also relates to use of such a nanocomplex for treating these diseases by administering to a patient in need of the treatment an effective amount of a nanocomplex of this invention.
[0041] Further, this invention covers a method of administering an effective amount of the nanocomplex described above to a patient in need. “An effective amount” refers to the amount of nanocomplexes that is required to confer a therapeutic effect on the treated subject. Effective doses will vary, as recognized by those skilled in the art, depending on the types of diseases treated, route of administration, excipient usage, and the possibility of co-usage with other therapeutic treatment.
[0042] The nanocomplex is useful in treating cancers. Cancers that can be treated by the method of this invention include both solid and haematological tumours of various organs. Examples of solid tumors are pancreatic cancer; bladder cancer; colorectal cancer; breast cancer, including metastatic breast cancer; prostate cancer, including androgen-dependent and androgen-independent prostate cancer; renal cancer, including metastatic renal cell carcinoma; hepatocellular cancer; lung cancer, including non-small cell lung cancer (NSCLC), bronchioloalveolar carcinoma (BAC), and adenocarcinoma of the lung; ovarian cancer, including progressive epithelial or primary peritoneal cancer; cervical cancer; gastric cancer; esophageal cancer; head and neck cancer, including squamous cell carcinoma of the head and neck; melanoma; neuroendocrine cancer, including metastatic neuroendocrine tumors; brain tumors, including glioma, anaplastic oligodendroglioma, adult glioblastoma multiforme, and adult anaplastic astrocytoma; bone cancer; and soft tissue sarcoma. Examples of hematologic malignancy are acute myeloid leukemia; chronic myelogenous leukemia (CML), including accelerated CML and CML blast phase; acute lymphoblastic leukemia; chronic lymphocytic leukemia; Hodgkin's disease; non-Hodgkin's lymphoma, including follicular lymphoma and mantle cell lymphoma; B-cell lymphoma; T-cell lymphoma; multiple myeloma; Waldenstrom's macroglobulinemia; myelodysplastic syndromes, including refractory anemia, refractory anemia with ringed siderblasts, refractory anemia with excess blasts (RAEB), and RAEB in transformation; and myeloproliferative syndromes.
[0043] To practice the method of the present invention, a composition having the above-described nanocomplexes can be administered parenterally, orally, nasally, rectally, topically, or buccally. The term “parenteral” as used herein refers to subcutaneous, intracutaneous, intravenous, intramuscular, intraarticular, intraarterial, intrasynovial, intrasternal, intrathecal, intralesional, or intracranial injection, as well as any suitable infusion technique.
[0044] A sterile injectable composition can be a solution or suspension in a non-toxic parenterally acceptable diluent or solvent, such as a solution in 1,3-butanediol. Among the acceptable vehicles and solvents that can be employed are mannitol, water, Ringer's solution, and isotonic sodium chloride solution. In addition, fixed oils are conventionally employed as a solvent or suspending medium (e.g., synthetic mono- or diglycerides). Fatty acid, such as oleic acid and its glyceride derivatives are useful in the preparation of injectables, as are natural pharmaceutically acceptable oils, such as olive oil or castor oil, especially in their polyoxyethylated versions. These oil solutions or suspensions can also contain a long chain alcohol diluent or dispersant, carboxymethyl cellulose, or similar dispersing agents. Other commonly used surfactants such as Tweens or Spans or other similar emulsifying agents or bioavailability enhancers which are commonly used in the manufacture of pharmaceutically acceptable solid, liquid, or other dosage forms can also be used for the purpose of formulation.
[0045] A composition for oral administration can be any orally acceptable dosage form including capsules, tablets, emulsions and aqueous suspensions, dispersions, and solutions. In the case of tablets, commonly used carriers include lactose and corn starch. Lubricating agents, such as magnesium stearate, are also typically added. For oral administration in a capsule form, useful diluents include lactose and dried corn starch. When aqueous suspensions or emulsions are administered orally, the active ingredient can be suspended or dissolved in an oily phase combined with emulsifying or suspending agents. If desired, certain sweetening, flavoring, or coloring agents can be added.
[0046] A nasal aerosol or inhalation composition can be prepared according to techniques well known in the art of pharmaceutical formulation. For example, such a composition can be prepared as a solution in saline, employing benzyl alcohol or other suitable preservatives, absorption promoters to enhance bioavailability, fluorocarbons, and/or other solubilizing or dispersing agents known in the art.
[0047] A composition having the nanocomplexes can also be administered in the form of suppositories for rectal administration.
[0048] The specific examples below are to be construed as merely illustrative, and not limitative of the remainder of the disclosure in any way whatsoever. Without further elaboration, it is believed that one skilled in the art can, based on the description herein, utilize the present invention to its fullest extent. All publications cited herein are hereby incorporated by reference in their entirety.
Example 1
Synthesis of Lipid-Like Compounds
[0049] Fourteen lipid-like compounds were prepared following the procedure described below.
[0050] In a 5-mL Teflon-lined glass screw-top vial, acrylate with disulfide bonds was added to amine at a molar ratio of 2.4:1. The mixture was stirred at 90° C. for two days. After cooling, the lipid-like compound thus formed was used without purification unless otherwise noted. Optionally, it was purified using flash chromatography on silica gel and characterized by proton nuclear magnetic resonance.
[0051] Following the above-described procedure, compound 80-O14B was prepared using N,N′-dimethylpropane-1,3-diamine and 2-(decyldisulfanyl)ethyl acrylate, which have the structures shown below:
[0000]
Example 2
Synthesis of Lipid-Like Compound 80-O16B
[0052] Compound 80-O16B was prepared following exactly the same procedure described in Example 1 except that 2-(dodecyldisulfanyl)ethyl acrylate (structure shown below) was used instead of 2-(decyldisulfanyl)ethyl acrylate.
[0000]
Example 3
Synthesis of Lipid-Like Compound 80-O18B
[0053] Compound 80-O18B was prepared following exactly the same procedure described in Example 1 except that 2-(tetradecyldisulfanyl)ethyl acrylate (structure shown below) was used instead of 2-(decyldisulfanyl)ethyl acrylate.
[0000]
Example 4
Synthesis of Lipid-Like Compound 87-O14B
[0054] Compound 87-O14B was prepared following exactly the same procedure described in Example 1 except that 2,2′-(3-aminopropylazanediyl)diethanol (structure shown below) was used instead of N,N′-dimethylpropane-1,3-diamine.
[0000]
Example 5
Synthesis of Lipid-Like Compound 87-O16B
[0055] Compound 87-O16B was prepared following exactly the same procedure described in Example 2 except that 2,2′-(3-aminopropylazanediyl)diethanol was used instead of N,N′-dimethylpropane-1,3-diamine.
Example 6
Synthesis of Lipid-Like Compound 87-O18B
[0056] Compound 87-O18B was prepared following exactly the same procedure described in Example 3 except that 2,2′-(3-aminopropylazanediyl)diethanol was used instead of N,N′-dimethylpropane-1,3-diamine.
Example 7
Synthesis of Lipid-Like Compound 1-O16B
[0057] Compound 1-O16B was prepared following exactly the same procedure described in Example 2 except that N 1 ,N 3 -dimethylpropane-1,3-diamine (structure shown below) was used instead of N,N′-dimethylpropane-1,3-diamine.
[0000]
Example 8
Synthesis of Lipid-Like Compound 1-O18B
[0058] Compound 1-O18B was prepared following exactly the same procedure described in Example 7 except that 2-(tetradecyldisulfanyl)ethyl acrylate was used instead of 2-(dodecyldisulfanyl)ethyl acrylate.
Examples 9-14
Synthesis of Lipid Like Compounds 80-O14, 80-O16, 80-O18, 87-O14, 87-O16, and 87-O18
[0059] Compounds 80-O14, 80-O16, 80-O18, 87-O14, 87-O16, and 87-O18 were prepared using exactly the same method described in Examples 1-6, respectively, except that tetradecyl acrylate, hexadecyl acrylate, or octadecyl acrylate was used instead of a disulfanyl acrylate.
Examples 15-18
Synthesis of Lipid-Like Compounds EC16-1, EC16-3, EC16-12, and EC16-14
[0060] In a 5-mL Teflon-lined glass screw-top vial, 1,2-epoxyoctadecane was added to amine at a molar ratio of 2.4:1. The mixture was stirred at 90° C. for two days. After cooling, the lipid-like compound thus formed was used without purification unless otherwise noted. Optionally, it was purified using flash chromatography on silica gel and characterized by proton nuclear magnetic resonance.
[0061] Following the above-described procedure, compound EC16-1 was prepared using N 1 ,N 3 -dimethylpropane-1,3-diamine; compound EC16-3 was prepared using 3-aminopropanol; compound E16-12 was prepared using N,N′-dimethylpropane-1,3-diamine; and EC16-14 was prepared using 2,2′-(3-aminopropylazanediyl)diethanol.
Examples 19-54
Preparation of Nanocomplex Compositions
[0062] The lipid-like compound prepared in one of Examples 1-18 was dissolved in sodium acetate solution (25 mM, pH=5.5) at a concentration of 1 mg/mL. Optionally, cholesterol and 1,2-dioleoyl-sn-glycero-3-phosphoethanolamine (“DOPE”) were also included. Saporin was introduced to the resulting mixture, which was incubated for 15 minutes at room temperature. The weight ratio between the lipid-like compound and saporin was 6:1, 20:1, or 40:1. The nanocomplex composition thus prepared was subjected to the in vitro assay described in Example 55 below. Compositions 1-32 were prepared following the above-described procedure. See the table below for the weight ratios between lipid-like compounds, cholesterol, DOPE, and saporin. Note that also included in this table are the weight ratios for compositions 33-35 and a comparative composition, all of which were prepared following the procedure described below.
[0063] Compositions 33 and 34 were prepared using a thin film hydration method described below. Compound 1-O16B or 1-O18B, cholesterol, and DOPE were mixed at a weight ratio of 16:4:1 in chloroform, which was then evaporated under vacuum, leaving a thin film. Re-hydrating the thin film in PBS yielded a solution of 1-O16B or 1-O18B at a concentration of 1 mg/mL. Saporin was added (1-O16B or 1-O18B:saporin=15:1 by weight). The mixture was incubated for 15 minutes at room temperature followed by addition of mPEG2000-ceramide C16/DSPE-PEG2000-Biotin (purchased from Avanti Polar Lipids, weight/weight=8:1, PEG 10% by weight of 1-O16B, this component not shown in the table above). The mixture was again incubated for 15 minutes to yield a nanocomplex composition, Composition 33 or 34. See the table below for the weight ratios between Compound 1-O16B or 1-O18B, cholesterol, DOPE, and saporin. These two compositions were subjected to the in vivo assay described in Example 55 below.
[0064] Composition 35 was prepared according to the following procedure. EC16-1 was dissolved in a phosphate buffer solution (25 mM, pH=7.4). Saporin was introduced to the resulting mixture, which was incubated for 15 minutes at room temperature. The weight ratio between EC16-1 and saporin was 20:1. A comparative composition was prepared following the same procedure described above except that RNase was used instead of saporin and the weight ratio between EC16-1 and RNase was 6:5. These two nanocomplex compositions were also subjected to the in vitro assay described in Example 55 below.
[0000]
Composition No.
Composition by weight
1
80-O14B (16 μg), cholesterol (8 μg), DOPE (1 μg), and saporin (0.8 μg)
2
80-O14 (16 μg), cholesterol (8 μg), DOPE (1 μg), and saporin (0.8 μg)
3
80-O16B (16 μg), cholesterol (8 μg), DOPE (1 μg), and saporin (0.8 μg)
4
80-O16 (16 μg), cholesterol (8 μg), DOPE (1 μg), and saporin (0.8 μg)
5
80-O18B (16 μg), cholesterol (8 μg), DOPE (1 μg), and saporin (0.8 μg)
6
80-O18 (16 μg), cholesterol (8 μg), DOPE (1 μg), and saporin (0.8 μg)
7
87-O16B (16 μg), cholesterol (8 μg), DOPE (1 μg), and saporin (0.8 μg)
8
87-O16 (16 μg), cholesterol (8 μg), DOPE (1 μg), and saporin (0.8 μg)
9
80-O14B (16 μg), cholesterol (8 μg), DOPE (1 μg), and saporin (0.4 μg)
10
80-O14 (16 μg), cholesterol (8 μg), DOPE (1 μg), and saporin (0.4 μg)
11
80-O16B (16 μg), cholesterol (8 μg), DOPE (1 μg), and saporin (0.4 μg)
12
80-O16 (16 μg), cholesterol (8 μg), DOPE (1 μg), and saporin (0.4 μg)
13
80-O18B (16 μg), cholesterol (8 μg), DOPE (1 μg), and saporin (0.4 μg)
14
80-O18 (16 μg), cholesterol (8 μg), DOPE (1 μg), and saporin (0.4 μg)
15
87-O16B (16 μg), cholesterol (8 μg), DOPE (1 μg), and saporin (0.4 μg)
16
87-O16 (16 μg), cholesterol (8 μg), DOPE (1 μg), and saporin (0.4 μg)
17
80-O14B (8 μg), cholesterol (4 μg), DOPE (1 μg), and saporin (0.4 μg)
18
80-O14 (8 μg), cholesterol (4 μg), DOPE (1 μg), and saporin (0.4 μg)
19
80-O16B (8 μg), cholesterol (4 μg), DOPE (1 μg), and saporin (0.4 μg)
20
80-O16 (8 μg), cholesterol (4 μg), DOPE (1 μg), and saporin (0.4 μg)
21
80-O18B (8 μg), cholesterol (4 μg), DOPE (1 μg), and saporin (0.4 μg)
22
80-O18 (8 μg), cholesterol (4 μg), DOPE (1 μg), and saporin (0.4 μg)
23
87-O16B (8 μg), cholesterol (4 μg), DOPE (1 μg), and saporin (0.4 μg)
24
87-O16 (8 μg), cholesterol (4 μg), DOPE (1 μg), and saporin (0.4 μg)
25
80-O14B (8 μg), cholesterol (4 μg), DOPE (1 μg), and saporin (0.2 μg)
26
80-O14 (8 μg), cholesterol (4 μg), DOPE (1 μg), and saporin (0.2 μg)
27
80-O16B (8 μg), cholesterol (4 μg), DOPE (1 μg), and saporin (0.2 μg)
28
80-O16 (8 μg), cholesterol (4 μg), DOPE (1 μg), and saporin (0.2 μg)
29
80-O18B (8 μg), cholesterol (4 μg), DOPE (1 μg), and saporin (0.2 μg)
30
80-O18 (8 μg), cholesterol (4 μg), DOPE (1 μg), and saporin (0.2 μg)
31
87-O16B (8 μg), cholesterol (4 μg), DOPE (1 μg), and saporin (0.2 μg)
32
87-O16 (8 μg), cholesterol (4 μg), DOPE (1 μg), and saporin (0.2 μg)
33
1-O16B (16 μg), cholesterol (4 μg), DOPE (1 μg), and saporin (1.07 μg)
34
1-O18B (16 μg), cholesterol (4 μg), DOPE (1 μg), and saporin (1.07 μg)
35
EC16-1 (8 μg) and saporin (0.4 μg)
Comparative
EC16-1 (8 μg) and RNase (6.7 μg)
Example 55
Evaluation of Saporin Delivery Efficiency
[0065] Compositions 1-32 were tested for delivery of saporin into cells MDA-MB-231.
Cell Culture
[0066] The two cells lines were purchased from ATCC (Manassas, Va.) and cultured in Dulbecco's Modified Eagle Medium (“DMEM”) supplemented with 10% Fetal Bovine Serum (“FBS”) and 1% penicillin/streptomycin at 37° C. in the presence of 5% CO 2 . For the protein transfection assay described below, cells were seeded in 96-well plates at a density of 10,000 cells per well a day prior to transfection.
In Vitro Protein Transfection
[0067] To evaluate saporin delivery efficiency, lipid-like compound/saporin nanocomplexes prepared in Examples 19-54 were added to MDA-MB-231 cancer cells and incubated at 37° C. for 24 hours. The saporin concentration was 0.1 ng/250 μL in PBS. The same volume of PBS without any lipid-like compound or saporin was used as a control. The cell viability was determined by the Alamar Blue assay after 24 hours of incubation. All transfection studies were performed in quadruplicate.
[0068] Unexpectedly, lipid-like compounds 80-O14B, 80-O16B, 80-O18B, and 87-O16B, 80-O16, 80-O18, and 87-O16 demonstrated high saporin delivery efficiency under all four studied conditions.
[0069] More specifically, cells treated with Compositions 9 (containing 80-O14B), 10 (containing 80-O14), 11 (containing 80-O16B), 12 (containing 80-O16), 13 (containing 80-O18B), 14 (containing 80-O18), 15 (containing 87-O16B), and 16 (containing 87-O16) showed, respectively, cell viabilities of 32%, 80%, 9%, 57%, 12%, 51%, 39%, and 72%.
[0070] Composition 35 and the comparative composition were tested for delivery of saporin into murine melanoma cell line B16F10 following the same procedure described above except that B16F10 was used instead of MDA-MB-231. Cell viability was determined by the Alamar Blue assay after 24 hours of incubation. For the cells treated with composition 35 containing saporin nanocomplexes, their viability was 25%; and for the cells treated with the comparative composition containing RNase nanocomplexes, their viability was 100%. Unexpectedly, saporin nanocomplexes demonstrated high delivery efficiency. By contrast, RNase was not delivered to B16F10 cells by RNase nanocomplexes.
In Vivo Cancer Treatment
[0071] Composition 33 (i.e., 1-O16B/saporin) and Composition 34 (i.e., 1-O18B/saporin) were tested for in vivo inhibiting tumor growth following the procedure described below. More specifically, BALB/c mice bearing 4T1-12B breast tumors were developed from a 4T1-12B cell suspension in DMEM supplemented with 10% FBS at a concentration of 10 7 cells/ml. An aliquot (100 μl) of the cell suspension was injected into the mammary fat pad of 4-6 week-old female BALB/c mice. The mice were sorted into four groups randomly (n=7 for treatment group, n=5 for control groups) seven days after the injection. The mice were injected through tail-vein every three days. For the treatment group, each mouse was injected with 5.5 mg/kg of 1-O16B or 1-O18B and 330 ng/kg of saporin. Tumor volumes were measured every three days.
[0072] PBS without 1-O16B, 1-O18B, and saporin was also injected as a control. Comparative studies were also conducted using saporin in PBS without 1-O16B and 1-O18B.
[0073] Unexpectedly, at Day 16, mice treated with Composition 31 or 32 had a tumor size of less than 100 mm 3 , much smaller than that for mice treated with PBS (i.e., 200 mm 3 ) and those treated with saporin (i.e., more than 120 mm 3 ); and at Day 22, mice treated with Composition 32 had a tumor size of 100 mm 3 , much smaller than that in mice treated with PBS or saporin (i.e., more than 250 mm 3 ).
Other Embodiments
[0074] All of the features disclosed in this specification may be combined in any combination. Each feature disclosed in this specification may be replaced by an alternative feature serving the same, equivalent, or similar purpose. Thus, unless expressly stated otherwise, each feature disclosed is only an example of a generic series of equivalent or similar features.
[0075] From the above description, one skilled in the art can easily ascertain the essential characteristics of the present 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. Thus, other embodiments are also within the scope of the following claims.
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A nanocomplex, of particle size 50 nm to 1000 nm, containing saporin and a lipid-like compound, in which saporin binds to the lipid-like compound via non-covalent interaction or covalent bonding. The lipid-like compound has a hydrophilic moiety, a hydrophobic moiety, and a linker joining the hydrophilic moiety and the hydrophobic moiety. The hydrophilic moiety is optionally charged and the hydrophobic moiety has 8 to 24 carbon atoms. Also disclosed is a pharmaceutical composition containing such a nanocomplex and a pharmaceutically acceptable carrier. The nanocomplex is useful in treating diseases, such as cancer.
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BACKGROUND OF THE INVENTION
This invention lies in the field of gravity clarifiers for separating biological solids or sludge and other flocculent solid from water, by gravity settling. More particularly, it concerns a type of gravity clarifier in which the liquid flow patterns within the clarifier are derived from the energy of the influent liquid mixture, which flows tangentially into the circular tank. It further includes the feature of an inverted conical shell through which the outflowing liquid rises through the open bottom of the conical shell, with a constantly decreasing upward velocity, thus permitting the entrained solid matter to be released, and to agglomerate, and to fall as sludge to the bottom of the tank.
In the prior art various means have been devised for settling the solids out of a liquid mixture including the use of centrifugal force as in the hydrocyclones. The high velocity liquid flow in such systems however are damaging to the character of the floc normally present in the biological material, which comes in with the influent liquid. If the floc is fragile, a much lower velocity and more streamline flow of liquid mixture is required and conditions which promote flocculation are desirable, which are provided by the system of this invention.
SUMMARY OF THE INVENTION
It is a primary object of this invention to provide a gravity clarifier which provides the circular and helical motion of the liquid in the clarifier tank by the energy of the entering liquid mixture through the influent pipe. It is a further object of this invention to provide a gravity clarifier in which the sludge is moved in toward the center of the base of the tank, due to the induced flow of liquid in the tank resulting from the tangential flow of influent. It is a further object of this invention to provide a gravity clarifier in which the upward velocity of the flow of liquid toward the outlet provides a decreasing velocity of flow to the point where the velocity is low enough so that suspended solid matter can be released and by the force of gravity carried to the bottom. It is a still further object of this invention to provide a radial flow over a weir to an outlet trough for the effluent clarified liquid.
These and other objects are realized and the limitations of the prior art are overcome in this invention by providing the clarifier with a substantially cylindrical tank and substantially flat bottom. The influent liquid comes into the tank through a tangential pipe so that there is a slowly swirling motion to the liquid in the tank. There is an inverted truncated conical shell attached to the cylindrical wall of the tank and the entering liquid flows into the space between the conical shell and the tank wall. The initial flow of liquid must be in circular downward direction with a decreasing radius of flow so that it may enter the open bottom of the conical shell and, in a helical flow, rise to the surface where it flows over a peripheral weir into an outlet trough with suitable conduit means for the effluent liquid. The sludge is removed from the center of the tank bottom either by a suitable drain conduit or by means of an axial suction pipe the open end of which is close to the bottom of the tank. Suitable pump means and, if necessary, aspirating fluid means are provided to lift the sludge.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and advantages of this invention and a better understanding of the principles and details of the invention will be evident from the following description taken in conjunction with the appended drawing in which;
FIGS. 1 and 2 illustrate elevation and plan views of a preferred embodiment of this invention.
FIG. 3 shows a detail of the sludge outlet portion.
FIGS. 4, 5 and 6 show alternate variations of the embodiment of FIGS. 1 and 2.
FIG. 7 illustrates a second means for removal of sludge from the clarifier tank.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings and in particular to FIGS. 1 and 2 there is shown in vertical cross-section and plan view one embodiment of this invention. The clarifier indicated generally by the numeral 10 comprises a cylindrical outer tank wall 12 with a substantially horizontal bottom 14. If desired the bottom 14 may be slightly sloping towards the center at an angle indicated by the numeral 40.
The sludge 22 will settle toward the bottom and can be drawn off by means of an opening 16 in the center of the bottom of the tank, and of outlet pipe 18 with suitable suction pumping means, as is well known in the art. A suitable shield 20 of conical shape may be provided. This shield is supported on a plurality of legs 17 and is provided as a vortex breaker to aid in drawing off the thicker sludge from near the bottom of the tank.
There is a downwardly depending truncated conical shell 24 which is attached at its upper larger diameter portion to the tank wall 12. This may be in conjunction with a trough 28, composed of a vertical cylindrical wall 44 and an annular bottom plate 46 attached to the outer wall 12 of the tank. As shown in FIGS. 4, 5 6, the conical shell can be attached directly to the tank wall 12.
The trough wall 44 and bottom 46 can be supported from the tank wall just above the top of the conical shell. The peripheral trough can also be mounted on the outside of the tank wall as in FIG. 5. The peripheral trough has a top edge 30, to the wall 44, which comprises a weir so that upwardly flowing liquid through the conical shell will flow over the edge 30 in accordance with arrows 36 into the trough 28, and out through the effluent conduit 32 in accordance with arrow 34.
The influent conduit 48 carries liquid in accordance with the arrow 50, which is to be clarified. As shown in the plan view of FIG. 1, this conduit 48 is attached tangentially to the tank wall and has an opening 52 through which the liquid enters in accordance with the arrow 51. While only one pipe 48 is shown, there may be a plurality of inlet pipes. The liquid flows circumferentially in accordance with the arrow 51 and partially inwardly and downwardly in accordance with arrow 53 and 54 until it is able to enter the open bottom 26 of the shell 24. After it comes into the shell the liquid flows in accordance with arrow 56 rising to flow over the weir 30 in accordance with arrow 36, and along the trough 28 in which it flows towards the outlet conduit 32 in accordance with arrows 58, 60, 34.
The inlet flow of liquid is at a relatively low velocity, which may be in the range of a few feet per second, or less, preferably of the order of one foot per second. It flows in a circular converging flow in accordance with arrows 53 and 54 so that the falling settling sludge becomes thicker as it is swept continuously toward and settles over the center of the tank. Thus the optimum point for delivery of the sludge is through a central opening 16 and pipe 18 as previously described.
As to the smaller particles, which because of their small mass are retained with the flowing liquid, the design of the expanding conical wall 24 to the rising liquid provides that the flow of liquid gradually decreases in velocity to the point where the stokes forces carrying the particles with the liquid become small enough that the gravity forces can permit the particles to drop within the rising liquid. Here they agglomerate, forming larger particles which have a better opportunity to drop through the rising liquid and thus to fall to the bottom as sludge.
In review, the construction is such that the entering liquid enters tangentially into the tank at a low enough velocity so that the structure of weak flocs is not broken up but is carried with the liquid. As the liquid slowly reduces velocity, the floc is permitted to slowly drop through the liquid producing a thicker sludge toward the bottom of the tank. The slowly rotating converging flow of the liquid sweeps this floc in toward the center and thus permits convenient withdrawal. Once the liquid enters the bottom of the central conical shell its velocity decreases as it rises, so as to permit a very quiet atmosphere in the liquid, and therefore permits the tiny particles of entrained material to slowly fall through the liquid and to be recovered. The clarified liquid rises vertically to slowly flow over the weir 30 into the outlet trough 38 and to the effluent conduit 32.
Referring now to FIGS. 4, 5 and 6, various modifications of the construction of the embodiment of FIGS. 1a and 2 are shown. In FIG. 4 the entrance conduit 48, while tangential with respect to the tank wall is indicated as downwardly depending by an angle 64, whereas in FIG. 2 it was shown as horizontal. While not shown, the angle of the inlet conduit 48 could equally well be in an upwardly direction at a corresponding angle, not shown.
Shown in FIG. 4 is an air vent 41, through the side wall 12 of the tank to vent air trapped in the angle between the walls 24 and 12. This vent connects to vent pipe 43, and to drain pipe 45 for drawing off floating material. Valve 47 can be periodically used for this purpose. This feature can be used in FIGS. 2, 4, 5, 6 and 7.
Also in FIG. 4 the conical shell 24 is shown connected directly at its top edge to the outer wall of the tank whereas in FIG. 2 it was connected to the inward bottom edge of the trough 28. A still further modification is shown in FIG. 5, where the junction of the conical shell and the tank wall by means of a horizontal annular plate 68 and short vertical cylindrical wall 65. The outflow is through the conduit 32.
In FIG. 5 the influent pipe is shown below the level of the conical shell 24. Shown in dashed lines is an alternate position for the conical shell, identified by numeral 24' which is lower in position, so that the entrance conduit 48 discharges liquid in the space between the conical wall 24' and the outer wall 12 of the tank.
The angle 42 between the wall of the shell 24 and the tank wall 12 can be varied as desired. It has been found that an angle in the range of 10° - 80° between the tank wall and the conical shell is satisfactory, however an angle in the range of 30° to 60° provides optimum action by the slowing down of the velocity of the uprising water, to release the entrained particles.
In FIG. 6 is shown another embodiment in which the outlet trough 28' with its corresponding weir is of a lesser diameter than the tank wall. It is positioned by additional supports 70 from a cover to the tank 71, or other structural means that can be supported from the tank wall 12. The construction of FIG. 6 for the outlet trough provides the inner and outer edges of the trough fro the weir flow action.
In FIG. 7 is shown a variation of the structure of FIG. 5 in which a different method of removal of sludge is shown. Here again the sludge removal is from the axial portion of the tank. A suction pipe 76 with appropriate pump 86 draws up the sludge through a conical wall, 78 the purpose of which is to provide a funnel for entering material. The flow of sludge into the pipe 76 can be aided if desired by means of air lift pumping as it is understood in the art, and indicated by introducing air 84 through pipe 82. An alternative method of sludge removal would be through mechanical pump 86. The inflow of air 84 may be through a pipe 82 into the side of the vertical pipe 76' instead of at the bottom as shown. The tank construction and outlet trough are shown corresponding to that of FIG. 5.
A slight conical shape to the bottom 14 of the tank serves to aid the removal of the sludge through a bottom opening or through the axial pipe.
It has been determined that one reason for the high degree of solids separation is the mixing of the influent with the sludge to encourage flocculation of the very fine particles.
While the invention has been described with a certain degree of particularity, it is manifest that many changes may be made in the details of construction and the arrangement of components. It is understood that the invention is not to be limited to the specific embodiments set forth herein by way of exemplifying the invention, but the invention is to be limited only by the scope of the attached claim or claims, including the full range of equivalency to which each element or step thereof is entitled.
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A gravity clarifier for separating biological sludge from the water by gravity settling, which comprises a cylindrical tank having a closed bottom with a downwardly depending truncated conical shell attached at its large end to the upper portion of the tank wall, with a peripheral trough near the top end of the tank and a weir for the overflow of effluent liquid into the trough. The influent conduit enters the tank tangentially and flows the raw mixture into the tank in the space between the outside of the inverted conical shell and the tank wall. The sludge is removed from the tank bottom near the center of the tank.
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[0001] This application is a continuation of co-pending international application designating the USA, PCT/IB99/01358, filed on Jul. 30, 1999.
FIELD OF THE INVENTION
[0002] This invention relates to non-carbon, metal-based, slow consumable anodes for use in cells for the electrowinning of aluminium by the electrolysis of alumina dissolved in a molten fluoride-containing electrolyte, and to methods for their fabrication and reconditioning, as well as to electrowinning cells containing such anodes and their use to produce aluminium.
BACKGROUND ART
[0003] The technology for the production of aluminium by the electrolysis of alumina, dissolved in molten cryolite, at temperatures around 950° C. is more than one hundred years old.
[0004] This process, conceived almost simultaneously by Hall and Héroult, has not evolved as many other electrochemical processes.
[0005] The anodes are still made of carbonaceous material and must be replaced every few weeks. During electrolysis the oxygen which should evolve on the anode surface combines with the carbon to form polluting CO 2 and small amounts of CO and fluorine-containing dangerous gases. The actual consumption of the anode is as much as 450 Kg/Ton of aluminium produced which is more than ⅓ higher than the theoretical amount of 333 Kg/Ton.
[0006] Using metal anodes in aluminium electrowinning cells would drastically improve the aluminium process by reducing pollution and the cost of aluminium production.
[0007] U.S. Pat. No. 4,614,569 (Duruz/Derivaz/Debely/Adorian) describes anodes for aluminium electrowinning coated with a protective coating of cerium oxyfluoride, formed in-situ in the cell or pre-applied, this coating being maintained by the addition of cerium to the molten cryolite electrolyte. This made it possible to have a protection of the surface only from the electrolyte attack and to a certain extent from the gaseous oxygen but not from the nascent monoatomic oxygen.
[0008] EP Patent application 0 306 100 (Nyguen/Lazouni/Doan) describes anodes composed of a chromium, nickel, cobalt and/or iron based substrate covered with an oxygen barrier layer and a ceramic coating of nickel, copper and/or manganese oxide which may be further covered with an in-situ formed protective cerium oxyfluoride layer.
[0009] Likewise, U.S. Pat. Nos. 5,069,771, 4,960,494 and 4,956,068 (all Nyguen/Lazouni/Doan) disclose aluminium production anodes with an oxidised copper-nickel surface on an alloy substrate with a protective oxygen barrier layer. However, full protection of the alloy substrate was difficult to achieve.
[0010] Metal or metal-based anodes are highly desirable in aluminium electrowinning cells instead of carbon-based anodes. As mentioned hereabove, many attempts were made to use metallic anodes for aluminium production, however they were never adopted by the aluminium industry.
OBJECTS OF THE INVENTION
[0011] An object of the present invention is to provide a non-carbon, metal-based anode for the electrowinning of aluminium so as to eliminate carbon-generated pollution and reduce the frequency of anode replacement, such an anode having an outside layer well resistant to chemical electrolyte attack whose surface is electrochemically active for the oxidation of oxygen ions contained in the electrolyte and for the formation of gaseous oxygen.
[0012] A further object of the invention is to provide a metal-based anode capable of generating during normal electrolysis at its surface an electrochemically active oxide layer which slowly and progressively dissolves into the electrolyte.
[0013] A major object of the invention is to provide an anode for the electrowinning of aluminium which has no carbon so as to eliminate carbon-generated pollution and reduce the high cell voltage.
SUMMARY OF THE INVENTION
[0014] The invention relates to a non-carbon, metal-based slow-consumable anode of a cell for the electrowinning of aluminium by the electrolysis of alumina dissolved in a molten fluoride-based electrolyte. The anode self-forms during normal electrolysis an electrochemically-active oxide-based surface layer, the rate of formation of said layer being substantially equal to its rate of dissolution at the surface layer/electrolyte interface thereby maintaining its thickness substantially constant forming a limited barrier controlling the oxidation rate.
[0015] In this context, metal-based anode means that the anode contains at least one metal as such or as an alloy, intermetallic and/or cermet.
[0016] During normal operation, the anode thus comprises a metallic (un-oxidised) anode body (or layer) on which and from which the oxide-based, surface layer is formed.
[0017] The electrochemically active oxide-based surface layer may contain an oxide as such, or in a multi-compound mixed oxide and/or in a solid solution of oxides. The oxide may be in the form of a simple, double and/or multiple oxide, and/or in the form of a stoichiometric or non-stoichiometric oxide.
[0018] The oxide-based surface layer has several functions. Besides protecting in some measure the metallic anode body against chemical attack in the cell environment and its electrochemical function for the conversion of oxygen ions to molecular oxygen, the oxide-based surface layer controls the diffusion of oxygen which oxidises the anode body to further form the surface layer.
[0019] When the oxide-based surface layer is too thin, in particular at the start-up of electrolysis, the diffusion of oxygen towards the metallic body is such as to oxidise the metallic anode body at the surface layer/anode body interface with formation of the oxide-based surface layer at a faster rate than the dissolution rate of the surface layer into the electrolyte, allowing the thickness of the oxide-based surface layer to increase. The thicker the oxide-based surface layer becomes, the more difficult it becomes for oxygen to reach the metallic anode body for its oxidation and therefore the rate of formation of the oxide-based surface layer decreases with the increasing thickness of the surface layer. Once the rate of formation of the oxide-based surface layer has met its rate of dissolution into the electrolyte an equilibrium is reached at which the thickness of the surface layer remains substantially constant and during which the metallic anode body is oxidised at a rate which substantially corresponds to the rate of dissolution of the oxide-based surface layer into the electrolyte.
[0020] In contrast to carbon anodes, in particular pre-baked carbon anodes, the consumption of the non-carbon, metal-based anodes according to the invention is at a very slow rate. Therefore, these slow consumable anodes in drained cell configurations do not need to be regularly repositioned in respect of their facing cathodes since the anode-cathode gap does not substantially change.
[0021] To practically realise the invention, the anode body can comprise an iron alloy which when oxidised will form an oxide-based surface layer containing iron oxide, such as hematite or a mixed ferrite-hematite, some of which adheres to the iron alloy, providing a good electrical conductivity and electrochemical activity, and a low dissolution rate in the electrolyte.
[0022] Optionally, the anode body may also comprise one or more additives selected from beryllium, magnesium, yttrium, titanium, zirconium, vanadium, niobium, tantalum, chromium, molybdenum, tungsten, manganese, rhodium, silver, aluminium, silicon, tin, hafnium, lithium, cerium and other Lanthanides.
[0023] Suitable kinds of anode materials which may be used for forming the oxide-based surface layer comprise high-strength low-alloy (HSLA) steels.
[0024] It has been observed that low-carbon HSLA steels such as Cor-Ten™, even at high temperature, form under oxidising conditions an iron oxide-based surface layer which is dense, electrically conductive, electrochemically active for oxygen evolution and, as opposed to oxide layers formed on standard steels or other iron alloys, is highly adherent and less exposed to delamination and limits diffusion of ionic, monoatomic and molecular oxygen.
[0025] HSLA steels are known for their strength and resistance to atmospheric corrosion especially at lower temperatures (below 0° C.) in different areas of technology such as civil engineering (bridges, dock walls, sea walls, piping), architecture (buildings, frames) and mechanical engineering (welded/bolted/riveted structures, car and railway industry, high pressure vessels). However, these HSLA steels have never been proposed for applications at high temperature, especially under oxidising or corrosive conditions, in particular in cells for the electrowinning of aluminium.
[0026] It has been found that the iron oxide-based surface layer formed on the surface of a HSLA steel under oxidising conditions limits also at elevated temperatures the diffusion of oxygen oxidising the surface of the HSLA steel. Thus, diffusion of oxygen through the surface layer decreases with an increasing thickness thereof.
[0027] If the HSLA steel is exposed to an environment promoting dissolution or delamination of the surface layer, in particular in an aluminium electrowinning cell, the rate of formation of the iron oxide-based surface layer (by oxidation of the surface of the HSLA steel) reaches the rate of dissolution or delamination of the surface layer after a transitional period during which the surface layer grows or decreases to reach an equilibrium thickness in the specific environment.
[0028] High-strength low-alloy (HSLA) steels are a group of low-carbon steels (typically up to 0.5 weight % carbon of the total) that contain small amounts of alloying elements. These steels have better mechanical properties and sometimes better corrosion resistance than carbon steels.
[0029] The surface of the high-strength low-alloy steel body may be oxidised in an electrolytic cell or in an oxidising atmosphere, in particular a relatively pure oxygen atmosphere. For instance the surface of the high-strength low-alloy steel body may be oxidised in a first electrolytic cell and then transferred to an aluminium production cell. In an electrolytic cell, oxidation would typically last 5 to 15 hours at 800 to 1000° C. Alternatively, the oxidation treatment may take place in air or in oxygen for 5 to 25 hours at 750 to 1150° C.
[0030] In order to prevent thermal shocks causing mechanical stresses, a high-strength low-alloy steel body may be tempered or annealed after pre-oxidation. Alternatively, the high-strength low-alloy steel body may be maintained at elevated temperature after pre-oxidation until immersion into the molten electrolyte of an aluminium production cell.
[0031] The high-strength low-alloy steel body may comprise 94 to 98 weight % iron and carbon, the remaining constituents being one or more further metals selected from chromium, copper, nickel, silicon, titanium, tantalum, tungsten, vanadium, zirconium, aluminium, molybdenum, manganese and niobium, and possibly small amounts of at least one additive selected from boron, sulfur, phosphorus and nitrogen.
[0032] Advantageously, the anode comprises cerium which is oxidised to ceria in the formation of the oxide-based surface layer to provide on the surface of the oxide-based surface layer a nucleating agent for in-situ formation of an electrolyte-generated protective layer. Such electrolyte-generated protective layer usually comprises cerium oxyfluoride when cerium ions are contained in the electrolyte and may be obtained by following the teachings of U.S. Pat. No. No. 4,614,569 (Duruz/Derivaz/Debely/Adorian) which describes a protective anode coating of cerium oxyfluoride, formed in-situ in the cell or pre-applied, and maintained by the addition of small amounts of cerium to the molten electrolyte.
[0033] The oxide-based surface layer may alternatively comprise ceramic oxides containing combinations of divalent nickel, cobalt, magnesium, manganese, copper and zinc with divalent/trivalent nickel, cobalt, manganese and/or iron. The ceramic oxides can be in the form of perovskites or non-stoichiometric and/or partially substituted or doped spinels, the doped spinels further comprising dopants selected from the group consisting of Ti 4+ , Zr 4+ , Sn 4+ , Fe 4+ , Hf 4+ , Mn 4+ , Fe 3+ , Ni 3+ , Co 3+ , Mn 3+ , Al 3+ , Cr 3+ , Fe 2+ , Ni 2+ , CO 2+ , Mg 2+ , Mn 2+ , Cu 2+ , Zn 2+ and Li + .
[0034] The anode can also comprise a metallic anode body or layer which progressively forms the oxide-based surface layer on an inert, inner core made of a different electronically conductive material, such as metals, alloys, intermetallics, cermets and conductive ceramics.
[0035] In particular, the inner core may comprise at least one metal selected from copper, chromium, nickel, cobalt, iron, aluminium, hafnium, molybdenum, niobium, silicon, tantalum, tungsten, vanadium, yttrium and zirconium, and combinations and compounds thereof. For instance, the core may consist of an alloy comprising 10 to 30 weight % of chromium, 55 to 90 weight % of at least one of nickel, cobalt and/or iron and up to 15 weight % of at least one of aluminium, hafnium, molybdenum, niobium, silicon, tantalum, tungsten, vanadium, yttrium and zirconium.
[0036] Resistance to oxygen may be at least partly achieved by forming an oxygen barrier layer on the surface of the inner core by surface oxidation or application of a precursor layer and heat treatment. Known barriers to oxygen are chromium oxide, niobium oxide and nickel oxide.
[0037] Advantageously, the inner core is covered with an oxygen barrier layer which is in turn covered with at least one protective layer consisting of copper, or copper and at least one of nickel and cobalt, and/or oxide(s) thereof to protect the oxygen barrier layer by inhibiting its dissolution into the electrolyte.
[0038] The invention also relates to a method of producing such anodes. The method comprises immersing an anode with an oxide-free or pre-oxidised surface into a molten fluoride-containing electrolyte and self-forming or growing an electrochemically active oxide-based surface layer as described hereabove.
[0039] An anode according to the invention can be restored when the metallic anode body or layer is worn and/or damaged. The method for restoring the anode comprises clearing and cleaning at least the worn and/or damaged parts of the anode; reconstituting the anode and optionally pre-oxidising the surface of the anode; immersing it into a molten fluoride-containing electrolyte; and self-forming or growing an electrochemically active oxide-based surface layer as described above.
[0040] A further aspect of the invention is a cell and a method for the electrowinning of aluminium comprising at least one anode which during normal electrolysis is oxidised, self-forming the electrochemically active oxide-based surface layer as described above.
[0041] Preferably, the cell comprises an aluminium-wettable cathode. Even more preferably, the cell is in a drained configuration by having a drained cathode on which aluminium is produced and from which aluminium continuously drains, as described in U.S. Pat. Nos. 5,651,874 (de Nora/Sekhar) and 5,683,559 (de Nora).
[0042] The cell may be of monopolar, multi-monopolar or bipolar configuration. A bipolar cell may comprise the anodes as described above as a terminal anode or as the anode part of a bipolar electrode.
[0043] Preferably, the cell comprises means to improve the circulation of the electrolyte between the anodes and facing cathodes and/or means to facilitate dissolution of alumina in the electrolyte. Such means can for instance be provided by the geometry of the cell as described in co-pending application PCT/IB99/00222 (de Nora/Duruz) or by periodically moving the anodes as described in co-pending application PCT/IB99/00223 (Duruz/Bello).
[0044] The cell may be operated with the electrolyte at conventional temperatures, such as 950 to 970° C., or at reduced temperatures as low as 700° C.
[0045] The invention also relates to a method of producing aluminium in a cell for the electrowinning of aluminium. The method comprises immersing a metallic anode having an oxide-free or a pre-oxidised surface into a molten fluoride-containing electrolyte, self-forming an electrochemically active oxide-based surface layer as described hereabove, and then electrolysing the dissolved alumina to produce aluminium in the same or a different fluoride-based electrolyte.
[0046] The surface of the anode may be in-situ or ex-situ pre-oxidised, for instance in air or in another oxidising atmosphere or media, or it may be oxidised in a first electrolytic cell and then transferred into an aluminium production cell.
[0047] Another aspect of the invention is an anode comprising an oxide-free or a pre-oxidised surface which when (further) oxidised during cell operation as described above gives origin to the above described self-formed, electrochemically active oxide-based surface layer.
[0048] When the anode has a pre-oxidised surface layer which is thicker than its thickness during steady operation, the rate of formation of the oxide-based surface layer is initially less than its rate of dissolution but increases to reach it. Conversely, when the anode has an oxide-free surface or a pre-oxidised surface forming an oxide-based layer which is thinner than its thickness during steady operation, the rate of formation of the oxide-based surface layer is initially greater than its rate of dissolution but decreases to reach it.
[0049] The pre-oxidised surface layer may be of such a thickness that after immersion into the electrolyte and during electrolysis the thick oxide-based surface layer prevents the penetration of nascent monoatomic oxygen beyond the oxide-based surface layer. Therefore the mechanism for forming new oxide by further oxidation of the anode is delayed until the existing pre-oxidised surface layer has been sufficiently dissolved into the electrolyte at the surface layer/electrolyte interface, no longer forming a barrier to nascent oxygen.
[0050] Anodes made according to the invention when worn can be replaced during normal use of a cell with new anodes or restored anodes.
[0051] A further aspect of the invention is a method for preparing an anode and using it for producing aluminium in a cell for the electrowinning of aluminium by the electrolysis of alumina dissolved in a molten fluoride-containing electrolyte, the method comprising preparing an anode as described above, and then utilising the anode to electrolyse dissolved alumina in a molten electrolyte contained in an aluminium electrowinning cell to produce aluminium by passing an ionic current between the anode and a facing cathode of the cell.
[0052] The anode may be pre-oxidised in-situ, or in a different electrolytic cell and then transferred to an aluminium production cell. Alternatively, the anode may be pre-oxidised in an oxygen containing atmosphere, such as air.
BRIEF DESCRIPTION OF THE DRAWINGS
[0053] Reference is made to the drawings wherein:
[0054] FIGS. 1 ( a ), 1 ( b ) and 1 ( c ) are schematic representations of the evolution in time of an anode according to the invention with a self-formed oxide-based surface layer;
[0055] FIGS. 2 ( a ) and 2 ( b ) are schematic representations of the evolution in time of an anode similar to the anode shown in FIGS. 1 ( a ), 1 ( b ) and 1 ( c ) which further comprises an inner metal core.
DETAILED DESCRIPTION
[0056] FIGS. 1 ( a ), 1 ( b ) and 1 ( c ) show an anode comprising a metallic (un-oxidised) anode body 10 which is slowly consumed as a self-formed electrochemically active oxide-based surface layer 20 progresses according to the invention when the anode is anodically polarised in an electrolytic bath 40 , such as a fluoride-based electrolyte 40 at about 950° C. containing 1 to 10% dissolved alumina in a cell for the electrowinning of aluminium. The anode for example comprises an alloy of iron with nickel, copper and/or cobalt which forms an oxide-based surface layer 20 containing ferrites.
[0057] [0057]FIG. 1( a ) shows part of a pre-oxidised anode according to the invention shortly after its immersion into the electrolyte 40 . In FIG. 1( a ) the anode is in a transitional period during which the pre-oxidised surface layer 20 ′ is grown from the metallic anode body 10 at the surface layer/anode body interface 15 at a faster rate than its dissolution 30 into the electrolyte 40 at the surface layer/electrolyte interface 25 , thereby progressively increasing its thickness. The dashed line 25 ′ shows the initial position of the surface layer/electrolyte interface 25 at or shortly after immersion of the anode into the electrolyte 40 .
[0058] FIGS. 1 ( b ) and 1 ( c ) illustrate the situation where the anode has reached its steady state of operation. The oxide-based surface layer 20 has grown from its original thickness shown in FIG. 1( a ) to its equilibrium thickness as shown in FIGS. 1 ( b ) and 1 ( c ). The rate of dissolution 30 of the surface layer 20 into the electrolyte 40 at the surface layer/electrolyte interface 25 is substantially equal to its rate of formation 35 at the surface layer/anode body interface 15 , consuming the metallic anode body 10 at an equivalent rate. Furthermore, the surface layer/electrolyte interface 25 slowly withdraws from its initial position 25 ′ while the oxide-based surface layer 20 is dissolved into the electrolyte 40 .
[0059] FIGS. 2 ( a ) and 2 ( b ) show an anode comprising an electronically conductive and oxidation resistant inner core 5 , for instance nickel-based, supporting a metallic anode layer 10 ′ having an electrochemically active oxide-based surface layer 20 as described previously.
[0060] [0060]FIG. 2( a ) illustrates the oxide-based surface layer 20 grown from the metallic anode layer 10 ′ at the surface layer/anode layer interface 15 . The formation rate 35 of the surface layer is equal to its dissolution rate 30 into the electrolyte 40 as illustrated in FIGS. 1 ( b ) and 1 ( c ).
[0061] In FIG. 2( b ), the oxide-based surface layer 20 has progressed until the metallic anode layer 10 ′ covering the inner core 5 has been nearly completely consumed. Since the inner core 5 is resistant to oxidation, further dissolution 30 of the oxide-based surface layer is not replaced by oxidation of the inner core once the metallic anode layer 10 ′ has worn away. The remaining surface layer 20 will slowly dissolve into the electrolyte 40 at the surface layer/electrolyte interface 25 and its thickness slowly decreases.
[0062] An anode having an oxidisable metallic anode layer 10 ′ covering an inner core 5 may still remain in the electrolyte 40 after its metallic anode layer 10 ′ is completely consumed, provided the inner core 5 is not fully passivated when exposed to oxygen, until the oxide-based surface layer 20 is too thin to allow the conversion of ionic oxygen to molecular oxygen. When this conversion is no longer possible the anode needs to be extracted and replaced or restored. However, the anode can be removed earlier if desired.
[0063] The invention will be further described in the following Examples.
EXAMPLE 1
[0064] Electrolysis was carried out in a laboratory scale cell equipped with an anode according to the invention.
[0065] The anode was made with a Cor-Ten™ type low-carbon high-strength (HSLA) steel doped with niobium, titanium, chromium and copper in a total amount of less than 4 weight %, which is commercially available from US-Steel. The anode was pre-oxidised in air at about 1050° C. for 15 hours to form a dense hematite-based outer layer constituting an oxide-based surface layer on an unoxidised anode body.
[0066] The anode was then tested in a fluoride-containing molten electrolyte at 850° C. containing cryolite and 15 weight % excess of AlF 3 and approximately 3 weight % alumina at a current density of about 0.7 A/cm 2 .
[0067] To maintain the concentration of dissolved alumina in the electrolyte, fresh alumina was periodically fed into the cell. The alumina feed contained sufficient iron oxide to slow down the dissolution of the hematite-based anode surface layer.
[0068] After 140 hours electrolysis was interrupted and the anode extracted. Upon cooling the anode was examined externally and in cross-section. No corrosion was observed at or near the surface of the anode.
[0069] The produced aluminium was also analysed and showed an iron contamination of about 700 ppm which is below the tolerated iron contamination in commercial aluminium production.
[0070] As variations, other HSLA steel may be used as anodes, such as a HSLA steel doped with manganese 0.4 weight %, niobium 0.02 weight %, molybdenum 0.02 weight %, copper 0.3 weight %, nickel 0.45 weight % and chromium 0.8 weight %, or a HSLA steel doped with nickel, copper and silicon in a total amount of less than 1.5 weight %.
EXAMPLE 2
[0071] A non-carbon metal-based anode according to the invention was obtained from a 15×15×80 mm sample of a nickel-iron based alloy. The sample was made of cast alloy consisting of 79 weight % nickel, 10 weight % iron and 11 weight % copper.
[0072] The sample was pre-oxidised in air at about 1100° C. for 5 hours in a furnace to form the anode with a pre-oxidised surface layer.
[0073] After pre-oxidation, the anode was immersed in molten cryolite contained in a laboratory scale cell. The molten cryolite contained approximately 6 weight % of dissolved alumina. Current was passed through the anode sample at a current density of 0.5 A/cm 2 . After 100 hours, the anode was extracted from the cell for analysis.
[0074] The anode was crack-free and its dimensions remained substantially unchanged. On the surface of the anode a well adherent oxide surface layer of a thickness of about 0.6 mm had grown providing an adequate protection.
EXAMPLE 3
[0075] This Example illustrates the wear rate of the nickel-iron containing anode of Example 2 and is based upon observations made on dissolution of nickel-based samples in a fluoride-based electrolyte.
[0076] An estimation of the wear rate is based on the following parameters and assumptions:
[0077] With a current density of 0.7 A/cm 2 and a current efficiency of 94% an aluminium electrowinning cell produces daily 53.7 kg aluminium per square meter of active cathode surface.
[0078] Assuming a contamination of the produced aluminium by 200 ppm of nickel, which corresponds to the experimentally measured quantities in typical tests, the wear rate of a nickel-iron sample corresponds to approximately 1.2 micron/day. Therefore, it will theoretically take about 80 to 85 days to wear 0.1 mm of the anode.
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A non-carbon, metal based slow-consumable anode of a cell for the electrowinning of aluminum self-forms during normal electrolysis an electrochemically-active oxide-based surface layer ( 20 ). The rate of formation ( 35 ) of the layer ( 20 ) is substantially equal to its rate of dissolution ( 30 ) at the surface layer/electrolyte interface ( 25 ) thereby maintaining its thickness substantially constant, forming a limited barrier controlling the oxidation rate ( 35 ). The anode ( 10 ) usually comprises an alloy or iron at least one of nickel, copper, cobalt or zinc which during use forms an oxide surface layer ( 20 ) mainly containing ferrite.
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