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FIELD OF THE INVENTION
[0001] The present invention generally relates to slicers, and more specifically relates to a slicer for slicing bagels into bagel chips.
SUMMARY OF THE PRESENT INVENTION
[0002] An aspect of the present invention is to provide a method of slicing a bagel comprising providing a housing having a plurality of cutting blades, moving the bagel past the cutting blades to slice the bagel into a plurality of bagel chips, and moving the cutting blades linearly and reciprocally to slice the bagel.
[0003] Another aspect of the present invention is to provide a method of slicing a bagel comprising providing a housing having a plurality of cutting blades, moving the bagel past the cutting blades to slice the bagel into a plurality of bagel chips, and wherein a distance between adjacent cutting blades is equal to or less than 0.5 inches.
[0004] Yet another aspect of the present invention is to provide a method of slicing a bagel comprising, providing a housing having a plurality of cutting blades, and moving the bagel past the cutting blades to slice the bagel into a plurality of bagel chips, with the bagel chips having a thickness equal to or less than 0.5 inches.
[0005] A further aspect of the present invention is to provide a method of slicing a whole bagel comprising providing a housing having a plurality of cutting blades and moving the whole bagel past the cutting blades to slice the bagel into a plurality of bagel chips. Only one whole bagel is sliced during moving. Multiple bagel chips are simultaneously formed during moving the whole bagel past the cutting blades.
[0006] Another aspect of the present invention is to provide a bagel slicing apparatus comprising a housing having a plurality of cutting blades comprising a first set of cutting blades and a second set of cutting blades. The first set of cutting blades move as a first unit. The second set of cutting blades move as a second unit. The first set of cutting blades moves out of phase to the second set of cutting blades. A distance between adjacent cutting blades is equal to or less than 0.5 inches.
[0007] Yet another aspect of the present invention is to provide a bagel slicing apparatus comprising a housing having a plurality of cutting blades comprising a first set of cutting blades and a second set of cutting blades. The first set of cutting blades move as a first unitary unit. The second set of cutting blades move as a second unitary unit. The first set of cutting blades moves out of phase to the second set of cutting blades. The cutting blades move linearly and reciprocally to slice the bagel.
[0008] These and other aspects, objects, and features of the present invention will be understood and appreciated by those skilled in the art upon studying the following specification, claims, and appended drawings.
BRIEF DESCRIPTION OF DRAWINGS
[0009] FIG. 1 is a front perspective view of a slicer of the present invention.
[0010] FIG. 2 is a front exploded perspective view of the slicer of the present invention.
[0011] FIG. 3 is a side view of the slicer of the present invention without a motor cover.
[0012] FIG. 4 is a rear view of the slicer of the present invention without the motor cover.
[0013] FIG. 5 is a top view of the slicer of the present invention without a cover and without a pusher handle.
[0014] FIG. 6 is a rear perspective view of the slicer of the present invention without the motor cover, the cover and the pusher handle.
[0015] FIG. 7 is a perspective view of a track of the present invention.
[0016] FIG. 8 is a top view of a cutting blade assembly of the present invention.
[0017] FIG. 9 is a cross section view of the cutting blade assembly of the present invention taken along the line IX-IX of FIG. 8 .
[0018] FIG. 10 is a cross section view of the cutting blade assembly of the present invention taken along the line X-X of FIG. 9 .
[0019] FIG. 11 is a side view of a cutting blade of the present invention.
[0020] FIGS. 12A-12C illustrates movement of the cutting blade assembly of the present invention.
[0021] FIG. 13 is a top view of the cover of the present invention.
[0022] FIG. 14 is a side view of the cover of the present invention.
[0023] FIG. 15 is a bottom view of the cover of the present invention.
[0024] FIG. 16 is a top view of the pusher handle of the present invention.
[0025] FIG. 17 is a front view of the pusher handle of the present invention.
[0026] FIG. 18 is a bottom view of the pusher handle of the present invention.
[0027] FIG. 19 is a side view of the slicer of the present invention with the pusher handle in a load position.
[0028] FIG. 20 is a top view of the slicer of the present invention with the pusher handle in the load position.
[0029] FIG. 21 is a cross section view of the slicer of the present invention taken along the line XXI-XXI of FIG. 20 .
[0030] FIG. 21A is an enlarged view of section XXIA of FIG. 21 .
[0031] FIG. 22 is a top view of the slicer of the present invention with the pusher handle in a cutting position.
[0032] FIG. 23 is a cross section view of the slicer of the present invention taken along the line XXIII-XXIII of FIG. 22 .
[0033] FIG. 24 is a side view of the slicer of the present invention without a motor cover showing an alternative of the cover to the base.
[0034] FIG. 25 is a partial perspective view of the cover and the base illustrating a stay member for maintaining the cover of FIG. 24 in an open position.
[0035] FIG. 26 is a cross section view of the slicer of the present invention illustrating a connection between the cutting blade assembly and the output assembly.
[0036] FIG. 27 is a side view of a cam of the slicer of the present invention.
[0037] FIG. 28 is a front view of the slicer of the present invention.
[0038] FIG. 29 is a top view of a modified pusher handle of the present invention.
[0039] FIG. 30 is a top view of a modified cutting blade assembly of the present invention.
[0040] FIG. 31 is a cross section view of the cutting blade assembly of the present invention taken along the line XXXI-XXXI of FIG. 30 .
[0041] FIG. 32 is a side view of a modified cutting blade of the present invention.
[0042] FIG. 33 is a side view of a second embodiment of an output assembly.
[0043] FIG. 34 is a front perspective view of a third embodiment of the slicer of the present invention.
[0044] FIG. 35 is an exploded front perspective view of the third embodiment of the slicer of the present invention.
[0045] FIG. 36 is a side view of the third embodiment of the slicer of the present invention with the pusher handle in a cutting position.
[0046] FIG. 37 is a side view of the third embodiment of the slicer of the present invention with the pusher handle in a load position.
[0047] FIG. 38 is a front view of the third embodiment of the slicer of the present invention.
[0048] FIG. 39 is a rear view of the third embodiment of the slicer of the present invention.
[0049] FIG. 40 is a top view of the third embodiment of the slicer of the present invention.
[0050] FIG. 41 is a front perspective view of the third embodiment of the slicer of the present invention with the cover in an open position.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0051] For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as orientated in FIG. 1 . However, it is to be understood that the invention may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.
[0052] The reference number 10 ( FIG. 1 ) generally designates a slicer embodying the present invention. In the illustrated example, the slicer 10 is used to slice bagels or other bread items into chips. As used herein, a bagel is a bread product having a generally ring (with a center hole) or horn (without a center hole) toroid. The slicer 10 is able to slice the bagel or other bread product into bagel chips. As used herein, a bagel chip is a bread product in the shape of a chip. As discussed in more detail below, the slicer 10 of the present invention can slice a bagel into chips having a width less than ⅛ of an inch (0.125 inches). The slicer 10 includes a cutting blade assembly 12 configured to slice the bagels, a housing 14 for the cutting blade assembly 12 and a pusher handle 16 for pushing the bagels through the cutting blade assembly 12 .
[0053] In the illustrated example, the housing 14 retains the cutting blade assembly 12 and allows the cutting blade assembly 12 to slice the bread product into a chip. The illustrated housing 14 includes a base 17 and a cover 18 . The cover 18 covers the base 17 to retain the cutting blade assembly 12 within the housing 14 . The base 17 comprises a pedestal 20 , a column 22 , a motor assembly 24 , a motor cover 26 and a platform 28 . The platform 28 is configured to receive the cutting blade assembly 12 and the cover 18 and the motor assembly 24 moves the cutting blade assembly 12 to slice the bread product.
[0054] The illustrated base 17 supports the remainder of the slicer 10 on a table or other surface. The base 17 includes a plate 30 having a skirt 32 extending downward from a front and sides of the plate 30 . As illustrated in FIG. 6 , the plate 30 has an arch-shaped slot 34 in a rear end therefore for accepting the motor assembly 24 therein. The base 17 includes a pair of bottom flanges 36 (see FIG. 4 ) having feet 38 connected thereto. The feet 38 include pads 40 on a bottom thereof for supporting the feet 38 and the base 17 on a substantially flat surface. The feet 38 can be fixed to the bottom flanges 36 (or any other portion of the base) or can be vertically adjustable relative to the bottom flanges 36 (or any other portion of the base). For example, the feet 38 can include a threaded post 42 extending from a top of the pad 40 , with the threaded post 42 being adjustably received within a threaded opening (not shown) in the bottom flanges 36 . The feet 38 can therefore be rotatable and vertically adjustable relative to the bottom flanges 36 . It is contemplated that the pads 40 could be directly connected to a bottom of the plate 30 without including any skirt 32 . The column 22 extends upward from a top surface of the plate 30 .
[0055] In the illustrated example, the column 22 connects the platform 28 to the pedestal 20 . The column 22 is C-shaped and includes an electrical receiver 44 for accepting a power cord (not shown). It is contemplated that the slicer 10 could include an on-off toggle switch and, if so, that the on-off toggle switch would be located on the column 22 . It is also contemplated that the power supply could be routed into the slicer 10 through the pedestal 20 , the platform 28 or any other portion of the housing 14 . The column 22 extends upward from the top of the plate 30 and supports the pedestal 20 . The column 22 is also configured to be connected to the motor cover 26 so as to cover the motor assembly 24 . In the illustrated example, the pedestal 20 , the column 22 and the platform 28 are integral. However, it is contemplated that the pedestal 20 , the column 22 and the platform 28 could comprise separate parts (e.g., the pedestal 20 could be a table top, the column 22 could be a wall and the platform 28 could extend from the wall in a cantilever fashion).
[0056] The illustrated platform 28 is connected to the column 22 and is configured to receive the cutting blade assembly 12 and the cover 18 . The platform 28 comprises a bottom plate 46 connected to a top of the column 22 . The platform 28 also includes a substantially rectangular side wall 48 extending upwardly from the bottom plate 46 . The bottom plate 46 includes a central opening 50 . As discussed in more detail below, the bread product falls through the central opening 50 after the bread product is sliced by the cutting blade assembly 12 . The side wall 48 includes a pair of aligned slots 54 located behind the column 22 . A pair of U-shaped handle connection members 56 extend inwardly from the slots 54 in the side wall 48 and are connected to the side wall 48 on either side of the slots 54 . Each U-shaped handle connection member 56 includes a top opening channel 58 for receiving a portion of the pusher handle 16 , as discussed in more detail below. The platform 28 includes a plurality of screw connectors 60 for connecting the cover 18 to the platform 28 . The bottom plate 46 and a rear of the side wall 48 include an L-shaped slot 52 for allowing a portion of the motor assembly 24 to engage the cutting blade assembly 12 . A motor support member 62 extends downward from a bottom of the bottom plate 46 and surrounds the L-shaped slot 52 .
[0057] In the illustrated example, the motor assembly 24 is connected to the platform 28 and causes the cutting blade assembly 12 to slice the bread product. The motor assembly 24 includes an electric motor 64 receiving power from the power cord via the electrical receiver 44 in the column 22 and a cord between the electrical receiver 44 and the electric motor 64 . A transmission housing 66 is connected to an output of the electric motor 64 . The transmission housing 66 includes gears (not shown) connected to the output of the electric motor 64 and an output shaft 68 . The transmission housing 66 is used to reposition the rotary output of the electric motor 64 . An output assembly 70 connects to the output shaft 68 . As discussed in more detail below, the output assembly 70 is configured to move the cutting blade assembly 12 . As illustrated in FIGS. 4 and 6 , the electric motor 64 extends through the arch-shaped slot 34 in the plate 30 of the platform 28 . A top of the transmission housing 66 is connected to a bottom of the motor support member 62 to retain the motor assembly 24 within the base 17 . The motor cover 26 is U-shaped and covers an area between a bottom of the bottom plate 46 of the platform 28 and a top of the plate 30 of the pedestal 20 by engaging with the column 22 . The motor cover 26 includes a bottom lip 72 forming a rear wall of the pedestal 20 . The motor assembly 24 causes the cutting blade assembly 12 to slice the bread product.
[0058] The illustrated cutting blade assembly 12 slices the bread product. The cutting blade assembly 12 includes a first slider assembly 74 and a second slider assembly 76 with the first slider assembly 74 and the second slider assembly 76 each including a plurality of cutting blades 78 . The first slider assembly 74 and the second slider assembly 76 are configured to move linearly and in a reciprocal motion to allow the cutting blades 78 to slice the bread product. The first slider assembly 74 and the second slider assembly 76 are substantially similar such that the first slider assembly 74 will be discussed below, with the understanding that the second slider assembly 76 is similarly structured.
[0059] The illustrated first slider assembly 74 of the cutting blade assembly 12 includes the plurality of cutting blades 78 extending between and connected to a closed end member 80 and an open end member 82 . As illustrated in FIG. 11 , each cutting blade 78 includes a central cutting portion 84 and a pair of enlarged ends 86 . Each enlarged end 86 of the cutting blade 78 includes a pin opening 88 adapted to receive a first connecting pin 90 or a second connecting pin 91 . The closed end member 80 includes the first connecting pin 90 and the open end member 82 includes a plurality of the second connecting pins 91 . The first connecting pin 90 and the second connecting pins 91 allow the closed end member 80 and the open end member 82 to retain the cutting blades 78 .
[0060] In the illustrated example, the closed end member 80 includes a double walled C-shaped housing 92 having an opening 94 facing towards a center of the first slider assembly 74 . A pin holding member 96 is located within the opening 94 . The pin holding member 96 includes a back wall 98 , a bottom wall 100 and a front wall 102 . A plurality of connection members 104 (e.g., screws) extend through the double walled C-shaped housing 92 and into the back wall 98 of the pin holding member 96 to connect the pin holding member 96 to the double walled C-shaped housing 92 . The front wall 102 of the pin holding member 96 includes an arcuate portion 106 having a plurality of substantially parallel slots therein. As illustrated in FIG. 10 , one of the enlarged ends 86 of each cutting blade 78 of the first slider assembly 74 extends through one of the slots in the arcuate portion 106 of the pin holding member 96 . The first connecting pin 90 abuts a rear of the arcuate portion 106 of the pin holding member 96 and extends through the pin openings 88 of the enlarged ends 86 of the cutting blades 78 . The arcuate portion 106 of the pin holding member 96 can be flexible to bias the first connecting pin 90 towards the rear of the opening 94 of the double walled C-shaped housing 92 . Furthermore, the connection members 104 can be adjustable to move the pin holding member 96 to adjust the tension of the cutting blades 78 held by the first connecting pin 90 . Therefore, the pin holding member 96 maintains the cutting blades 78 taut within the first slide assembly 74 . A pair of sliding rods 108 are fixed to the double walled C-shaped housing 92 on opposite sides of the pin holding member 96 and the cutting blades 78 . The pair of sliding rods 108 connect the closed end member 80 to the open end member 82 .
[0061] The illustrated open end member 82 of the first slider assembly 74 includes a top plate 110 , a bottom plate 112 and a C-shaped connection member 114 extending between the top plate 110 and the bottom plate 112 . The C-shaped connection member 114 has an opening 116 facing toward the closed end member 80 . The C-shaped connection member 114 includes a front wall 118 having a plurality of slots extending therethrough. The cutting blades 78 of the first slider assembly 74 extend through every other slot in the front wall 118 of the C-shaped connection member 114 . Each second connecting pin 91 abuts a rear of the front wall 118 of the C-shaped connection member 114 and extends through a second end of one of the cutting blades 78 . Every slot in the front wall 118 of the C-shaped connection member 114 not having a cutting blade 78 of the first slider assembly 74 extending therethrough includes a cutting blade 78 of the second slider assembly 76 extending therethrough (and vice versa). The sliding rods 108 are also connected to the C-shaped connection member 114 on opposite sides of the cutting blades 78 . The C-shaped connection member 114 also includes bearing tubes 120 located to a side of the sliding rods 108 . The bearing tubes 120 are configured to accept sliding rods 108 of the second slider assembly 76 therethrough.
[0062] In the illustrated example, the first slider assembly 74 and the second slider assembly 76 move linearly and in a reciprocal motion to allow the cutting blades 78 to slice the bread product. The sliding rods 108 of the first slider assembly 74 slide through the bearing tubes 120 of the open end member 82 of the second slider assembly 76 and the sliding rods 108 of the second slider assembly 76 slide through bearing tubes 120 of the open end member 82 of the first slider assembly 74 .
[0063] FIGS. 12A-12C illustrate the sliding movement of the first slider assembly 74 relative to the second slider assembly 76 . FIG. 12A illustrates the first slider assembly 74 and the second slider assembly 76 in a fully extending position. As illustrated in FIG. 12A , the closed end member 80 of the first slider assembly 74 is moved away from the open end member 82 of the second slider assembly 76 . Accordingly, the sliding rods 108 of the first slider assembly 74 and the second slider assembly 76 move the open end member 82 of the first slide assembly 74 away from the closed end member 80 of the second slider assembly 76 . FIG. 12B illustrates the first slider assembly 74 and the second slider assembly 76 as the closed end member 80 of the first slider assembly 74 is moved towards the open end member 82 of the second slider assembly 76 . Accordingly, the sliding rods 108 of the first slider assembly 74 and the second slider assembly 76 move the open end member 82 of the first slide assembly 74 towards the closed end member 80 of the second slider assembly 76 . Furthermore, the sliding rods 108 of the first slider assembly 74 will slide through the bearing tubes 120 of the second slider assembly 76 and the sliding rods 108 of the second slider assembly 76 will slide through the bearing tubes 120 of the first slider assembly 74 . Moreover, the cutting blades 78 of the first slider assembly 74 will slide through the slots extending through the front wall 118 of the C-shaped connection member 114 of the open end member 82 of the second slider assembly 76 and the cutting blades 78 of the second slider assembly 76 will slide through the slots extending through the front wall 118 of the C-shaped connection member 114 of the open end member 82 of the first slider assembly 74 . Therefore, the cutting blades 78 of the first slider assembly 74 and the cutting blades 78 of the second slider assembly 76 will reciprocate relative to each other. FIG. 12C illustrates the first slider assembly 74 and the second slider assembly 76 as the closed end member 80 of the first slider assembly 74 is adjacent the open end member 82 of the second slider assembly 76 . At the point illustrated in FIG. 12C , the closed end member 80 of the first slider assembly 74 will thereafter move away from the open end member 82 of the second slider assembly 76 and towards the position as illustrated in FIG. 12A .
[0064] In the illustrated example, the first slider assembly 74 and the second slider assembly 76 move in a linear and reciprocating fashion to slice the bread product. The first slider assembly 74 and the second slider assembly 76 could be actuated using many manners. One method of actuating the first slider assembly 74 and the second slider assembly 76 is to use motor assembly 24 and the output assembly 70 . The output assembly 70 is located between the output shaft 68 of the transmission housing 66 and the cutting blade assembly 12 .
[0065] As illustrated in FIGS. 2 , 12 A- 12 C, 21 , 21 A and 23 , the output assembly 70 includes a first gear 122 , a first pin 124 , a first connection bar 126 , a second gear 128 , a second pin 130 and a second connection bar 132 . The first gear 122 includes a bottom aperture 134 configured to accept the output shaft 68 of the transmission housing 66 therein. The output shaft 68 can include a spline 136 and the bottom aperture 134 can include a channel 138 , with the spline 136 of the output shaft 68 being inserted into the channel 138 of the bottom aperture 134 to ensure that the first gear 122 rotates with the output shaft 68 . The first pin 124 is inserted into a top aperture 140 in the first gear 122 . The top aperture 140 is off center and the first pin 124 can be fixed relative to the first gear 122 or can rotate relative to the first gear 122 . The first connection bar 126 is elongate and includes a first end opening 142 and a second end opening 144 . The first connection bar 126 is connected to the first pin 124 by inserting the first pin 124 through the first end opening 142 . As discussed in more detail below, the second end opening 144 interacts with the second slider assembly 76 to move the second slider assembly 76 . The second gear 128 includes a first hole 146 accepting the first pin 124 therein and a second hole 148 accepting the second pin 130 therein. The first hole 146 and the second hole 148 are off center and located along a diametrical line. Both the first pin 124 and the second pin 130 can be allowed to rotate freely within the second gear 128 . However, it is contemplated that both the first pin 124 and the second pin 130 are fixed in position within the second gear 128 , but the first pin 124 is allowed to freely rotate within the first gear 122 . The second connection bar 132 is elongate but shorter than the first connection bar 126 and includes a first end opening 150 and a second end opening 152 . The second connection bar 132 is connected to the second pin 130 by inserting the second pin 130 through the first end opening 150 . As discussed in more detail below, the second end opening 152 interacts with the first slider assembly 74 to move the first slider assembly 74 .
[0066] In the illustrated example, the output assembly 70 moves the cutting blade assembly 12 . As illustrated in FIG. 21A , the double walled C-shaped housing 92 of the closed end member 80 of the first slider assembly 74 includes a first double bent connection member 154 connected to a top thereof. The first double bent connection member 154 includes a first top member 156 attached to a top of the double walled C-shaped housing 92 and a first bottom member 158 including a first downwardly depending shaft 160 . The first downwardly depending shaft 160 is configured to be inserted into the second end opening 152 of the second connection bar 132 to connect the first slider assembly 74 to the output assembly 70 . Likewise, the bottom plate 112 of the open end member 82 of the second slider assembly 76 includes a second double bent connection member 162 connected to a bottom thereof. The second double bent connection member 162 includes a second top member 164 attached to a bottom of the bottom plate 112 and a second bottom member 166 including a second downwardly depending shaft 168 . The second downwardly depending shaft 168 is configured to be inserted into the second end opening 144 of the first connection bar 126 to connect the second slider assembly 76 to the output assembly 70 .
[0067] The illustrated cutting blade assembly 12 is configured to be removably inserted into the housing 14 . As illustrated in FIGS. 2 , 5 and 6 , the platform 28 of the base 17 includes a pair of slider blocks 170 on opposite sides of the central opening 50 in the bottom plate 46 of the platform 28 . Each slider block 170 (see FIG. 7 ) includes a foot 172 , a first end wedge 174 and a second end wedge 176 . The first end wedge 174 includes a pair of first sliding rod grooves 178 and the second end wedge 176 includes a pair of second sliding rod grooves 180 . The pair of first sliding rod grooves 178 are aligned with the pair of second sliding rod grooves 180 . As the cutting blade assembly 12 is inserted into the housing 14 , the sliding rods 108 of the first slider assembly 74 and the second slider assembly 76 are inserted into the first sliding rod grooves 178 and the pair of second sliding rod grooves 180 (see FIG. 5 ). It is contemplated that the pair of first sliding rod grooves 178 and the pair of second sliding rod grooves 180 of the slider blocks 170 could be concave such that the sliding rods 108 snap fit into the pair of first sliding rod grooves 178 and the pair of second sliding rod grooves 180 of the slider blocks 170 . Furthermore, the first downwardly depending shaft 160 is inserted into the second end opening 152 of the second connection bar 132 and the second downwardly depending shaft 168 is inserted into the second end opening 144 of the first connection bar 126 .
[0068] In the illustrated example, the cover 18 ( FIGS. 13-15 ) covers the cutting blade assembly 12 within the platform 28 of the housing 14 . The cover 18 includes a top panel 182 having a central opening 184 and a substantially rectangular skirt 186 extending downwardly from a periphery of the top panel 182 . The cover 18 is configured to be positioned over the platform 28 of the housing 14 , with the skirt 186 of the cover 18 enveloping the side wall 48 of the platform 28 (see FIGS. 1 , 3 and 4 ). The skirt 186 of the cover 18 includes a plurality of connector slots 188 in a side surface thereof with the connector slots 188 each having a lower mouth 190 being configured to receive the screw connectors 60 of the platform 28 . Therefore, once the cover 18 is properly positioned over the platform 28 , the screw connectors 60 can be tightened (by rotation) to maintain the cover on the platform 28 . Once the cover 18 is properly positioned on the platform 28 , the central opening 184 in the top panel 182 of the cover 18 will be generally aligned with the central opening 50 of the bottom plate 46 of the platform 28 . Accordingly, as discussed in more detail below, the bread product can be placed through the central opening 184 in the top panel 182 of the cover 18 , become sliced with the cutting blade assembly 12 and fall through the central opening 50 of the bottom plate 46 of the platform 28 . The cover 18 also includes a front guard 192 extending upwardly in front of the central opening 184 of the top panel 182 and a rear guard 194 extending upwardly behind the central opening 184 of the top panel 182 . The cover 18 also includes a comb-shaped member 199 having a plurality of slots in front of the central opening 184 extending downwardly from a bottom surface of the top panel 182 and a rear guard 201 behind the central opening 184 extending downwardly from the bottom surface of the top panel 182 . The front comb-shaped member 199 covers a top of the blades 78 and allows the blades 78 to slide though the slots thereof. The front comb-shaped member 199 and the rear guard 201 extending downwardly adjacent the central opening 184 prevents the bread product being sliced from moving too far forward or too far rearward during the slicing process. It is contemplated that the front comb-shaped member 199 can be made of any material (e.g., metal or plastic).
[0069] As illustrated in FIG. 15 , a pair of slider block closure blocks 196 are located on opposite sides on the central opening 184 on a bottom of the top panel 182 . The slider block closure blocks 196 enclose and cover the pair of first sliding rod grooves 178 and the pair of second sliding rod grooves 180 of the slider blocks 170 when the cover 18 is engaged with the platform 28 to maintain the sliding rods 108 of the first slider assembly 74 and the second slider assembly 76 within the pair of first sliding rod grooves 178 and the pair of second sliding rod grooves 180 of the slider blocks 170 . The top panel 182 of the cover 18 also includes a pair of handle slots 198 configured to accept a portion of the pusher handle 16 therethrough.
[0070] The illustrated pusher handle 16 ( FIGS. 16-18 ) is used to push the bread product through the central opening 184 in the top panel 182 of the cover 18 , through the cutting blade assembly 12 to slice the bread product and through the central opening 50 of the bottom plate 46 of the platform 28 . The pusher handle 16 includes a main plate 200 having a pair of side members 202 connected thereto. A grip 204 extends between and is connected to a first end of the side members 202 . A pair of ears 206 having outwardly extending pivot pins 208 extend downwardly from a second end of the side members 202 (see FIG. 2 ). As illustrated in FIG. 15 , the handle slots 198 of the cover 18 each include a pin niche 210 for accepting the pivot pins 208 as the ears 206 are positioned through the handle slots 198 . The cover 18 also includes a pivot pin housing 212 configured to accept the pivot pins 208 of the pusher handle 16 to connect the pusher handle 16 to the cover 18 . As the cover 18 and the pusher handle 16 are positioned over the platform 28 of the housing 14 , the pivot pins 208 of the ears 206 of the pusher handle 16 slide into the top opening channels 58 in the handle connection member 56 . Therefore, the pusher handle 16 can pivot about the pivot pins 208 between a load position as illustrated in FIGS. 19-21 and a cutting position as illustrated in FIGS. 1 and 22 and 23 .
[0071] In the illustrated example, a pusher member 214 is connected to a bottom of the main plate 200 of the pusher handle 16 for pushing the bread product through the cutting blade assembly 12 . The pusher member 214 can be removably connected to the main plate 200 by removably inserting screw members 217 (see FIG. 2 ) extending upwardly from the pusher member 214 through the main plate 200 and into a pair of nut connectors 216 . The pusher member 214 includes a plurality of pushing fins 218 extending downwardly therefrom. The pushing fins 218 have a thickness smaller than but substantially equal to a distance between adjacent cutting blades 78 in the cutting blade assembly 12 . Therefore, the pushing fins 218 can push the bread product through the cutting blade assembly 12 as the pusher handle 16 is moved to the cutting position. As illustrated in FIGS. 17 and 19 , the pusher handle 16 includes a pair of side shields 220 on either side of the pusher member 214 for enclosing an area above the cutting blades 78 while the bread product is being sliced.
[0072] The illustrated slicer 10 is used to slice a bread product. Initially, the pusher handle 16 is moved to the load position as illustrated in FIGS. 19-21 (typically using the grip 204 of the pusher handle 16 ) by pivoting the pusher handle 16 about the pivot pins 208 . As the pusher handle 16 is being raised, an area for insertion of the bread product (shown as a bagel 500 in FIGS. 19-23 ) is opened. Once the pusher handle 16 is in the load position, the bread product can be placed into the insertion area as illustrated in FIGS. 19-21 . Thereafter, the pusher handle 16 is moved towards the cutting position as illustrated in FIGS. 1 and 22 and 23 by rotating the pusher handle 16 (typically using the grip 204 ) about the pivot pins 208 in a direction opposite to the direction that the pusher handle 16 was rotated to move the pusher handle 16 to the load position (counter-clockwise as shown in FIGS. 19-23 ). In the illustrated example, the motor assembly 24 will not actuate to move the cutting blades 78 of the cutting blade assembly 12 until at least one of two switches is actuated. First, the platform 28 can include a first switch 300 (see FIG. 5 ) that is activated once the cover 18 is properly positioned onto the platform 28 . Second, the platform 28 can include a second switch 302 (see FIG. 5 ) that is activated when a projection 304 (see FIG. 2 ) on one of the ears 206 of the side members 202 of the pusher handle 16 engages with the second switch 302 . In the illustrated example, the second switch 302 is activated when the pusher handle 16 is rotated to a position where a bottom of the pushing fins 218 of the pusher member 214 is located behind and below a top of the front guard 192 of the cover 18 . Therefore, the motor assembly 24 will not actuate to move the cutting blades 78 of the cutting blade assembly 12 until the insertion area is enclosed and covered by the front guard 192 and the pushing fins 218 at a front thereof, the rear guard 194 at a rear thereof and the side shields 220 of the pusher handle 16 at sides thereof. However, it is contemplated that the slicer 10 could be activated continuously, with a button or with other switches. Nevertheless, it is contemplated that the slicer 10 would include the first switch 300 and the second switch 302 (or some other configuration wherein the cutting blades 78 would only move when the insertion area is enclosed) for safety reasons. As the pusher handle 16 is moved to the final cutting position as illustrated in FIGS. 1 and 22 and 23 , the pushing fins 218 of the pusher member 214 will push the bagel 500 through the cutting blade assembly 12 to slice the bagel 500 using the cutting blades 78 . The pushing fins 218 can extend between the cutting blades 78 to fully push the bread product through the cutting blade assembly 12 .
[0073] In the illustrated example, the motor assembly 24 is activated as the bread product is being pushed through the cutting blade assembly 12 . As the motor assembly 24 is activated, the electric motor 64 begins rotating its output shaft in the transmission housing 66 to rotate the output shaft 68 of the transmission housing 66 . As the output shaft rotates, the first gear 122 , the first pin 124 , the second gear 128 and the second pin 130 of the output assembly 70 begin to move as outlined above. As the first pin 124 revolves with the first gear 122 and the second gear 128 , the first connection bar 126 will move with the first pin 124 and move the second end opening 144 of the first connection bar 126 in a linear manner. Furthermore, as the second pin 130 revolves with the second gear 128 , the second connection bar 132 will move with the second pin 130 and move the second end opening 152 of the second connection bar 132 in a linear manner. In the illustrated example, movement of the first connection bar 126 and the second connection bar 132 are out of phase by 180° such that when the second end opening 144 of the first connection bar 126 is closest to the cutting blade assembly 12 , the second end opening 152 of the second connection bar 132 is farthest from the cutting blade assembly 12 and vice versa. Moreover, as the second end opening 144 of the first connection bar 126 and the second end opening 152 of the second connection bar 132 move, the first downwardly depending shaft 160 of the first double bent connection member 154 and the second downwardly depending shaft 168 of the second double bent connection member 162 will move to move the first slider assembly 74 and the second slider assembly 76 as discussed above to move the cutting blades 78 to slice the bread product.
[0074] The illustrated cutting blades 78 can be made of any material (e.g., metal or ceramic). For example, it is contemplated that the cutting blades 78 can be made of high carbon chrome vanadium steel. The cutting blades 78 can be made from a coil stock of material having an initial rectangular cross section. Therefore, the cutting blades 78 can be cut to size and can be cut to have cutting teeth 600 (see FIG. 11 ) on a top side of the central cutting portion 84 and a recessed portion 602 of a bottom side of the central cutting portion 84 . Forming the cutting teeth 600 and the recessed portion 602 of the central cutting portion 84 can thereby form the enlarged ends 86 of the cutting blade 78 (i.e., the enlarged ends 86 can be large because portions to the side of the ends 86 have been made smaller). Alternatively, the ends 86 can be formed larger than the rest of the cutting blade 78 in other fashions (e.g., the enlarged ends 86 can be large because they are made larger). The cutting blades 78 include enlarged ends 86 to allow for enough material surrounding the pin openings 88 to prevent fracture of the cutting blades 78 surrounding the pin openings 88 (via tension force from the first connection pin 90 (being biased by the pin holding member 96 ) and the second connection pin 91 ). Furthermore, the recessed portion 602 prevents an area of the cutting blades 78 below the cutting teeth 600 from tearing the bread product via friction as the bread product moves past the cutting blades 78 . If the cutting blades 78 have too great a height, the cutting blades will tear the bread product via friction as the bread product moves past the cutting blades 78 . It is also contemplated that that the cutting teeth 600 can be ground deeper (thereby extending the depth of the cutting teeth 600 ) instead of having the recessed portion 602 or in conjunction with the recessed portion 602 to reduce the friction of the cutting blades 78 against the bread product. However, it is contemplated that the size of the enlarged ends 86 of the cutting blades 78 are a function of the material and thickness of the cutting blades 78 . As the material of the cutting blades 78 becomes stronger and as the thickness of the cutting blades 78 becomes thicker, the size of the ends 86 of the cutting blades 78 relative to the remainder of the cutting blades 78 can decrease. However, it is contemplated that the cutting blades 78 do not want to be too thick so as to efficiently slice the bread product without tearing the bread product. In the illustrated example, the cutting blades 78 can have a thickness of about 0.0149-0.0162 inches. However, the cutting blades 78 can be thicker or thinner. Furthermore, in the illustrated example, the height of the cutting blades in the central cutting portion 84 can be about 0.25 inches. However, the height of the cutting blades in the central cutting portion 84 can be more or less than 0.25 inches. For example, an embodiment of the cutting blade 78 can have a thickness of about 0.0149-0.0162 inches, a height of the central cutting portion 84 of about 0.25 inches, a height of the enlarged ends of about 0.375 inches and a total length of about 10.8 inches. Furthermore, the distance between each cutting blade 78 can be any desired distance. For example, the cutting blades 78 can be about 0.125 inches apart (or narrower or wider). If the cutting blades 78 are about 0.125 inches apart, the resulting chip will have a thickness at its greatest extent of less than about 0.125 inches. Moreover, with the slicer 10 as described above, the slices in the bread product are made simultaneously.
[0075] FIGS. 24-32 illustrate alternative features for the slicer 10 . Any of the features shown in FIGS. 24-32 or discussed below can be used with the slicer 10 discussed above or can be used in any combination (i.e., each feature can be used with the slicer 10 one at a time or any combination of any of the features can be used with the slicer 10 ).
[0076] FIGS. 24-25 illustrate another manner of connecting the cover 18 to the platform 28 of the base 17 . As illustrated in FIG. 24 , the cover 18 can have a pair of downwardly depending ears 400 at a rear thereof, with each ear 400 being pivotally connected to the platform 28 . Therefore, the cover 18 can pivot relative to the platform 28 along line 402 . With the cover 18 being pivotally connected to the platform 28 , the connection slots 188 on either side of the cover 18 can be arcuate to allow the connection slots 188 to easily side along the screw connectors 60 . As illustrated in FIG. 25 , the platform 28 can include at least one pivoting stay member 404 for maintaining the cover 18 in a rotated position. The stay member 404 can be pivotally connected to the side wall 48 of the platform 28 . In use, after the cover 18 is pivoted to an open position, the stay member 404 can be pivoted upward to abut a block 406 connected to an inside surface of the cover 18 . The stay member 304 can include a cut out portion 408 for engagement with the block 406 . In order to close the cover 18 , the cover 18 is rotated to an further open position, the stay member 404 is rotated downward, and the cover 18 is rotated back to the closed position. It is contemplated that the platform 28 can include a pair of stay members 404 , with each stay member 404 being located at a rear side of the side walls 48 of the platform 28 .
[0077] FIG. 26 is a cross section view of the slicer 10 illustrating a connection between the cutting blade assembly 12 and the output assembly 70 . As shown in FIG. 26 , instead of a second shaft 168 for an interface between the second bottom member 166 of the second double bend connection member 162 and the first connection bar 126 of the output assembly 70 , a spherical bearing 410 is used.
[0078] FIG. 27 illustrates a cam 420 for actuating the first switch 300 as discussed above for allowing the slicer 10 to operate once the cover 18 is placed in the closed position. The cam 420 depends downwardly from a bottom surface of the top panel 182 of the cover 18 . The cam 420 includes a first plate 422 fixedly connected to the bottom surface of the top panel 182 at a top edge 421 thereof. The cam 420 also includes a second plate 424 pivotally connected to the first plate 422 at a pivot point 426 . The second plate 424 includes an arcuate slot 428 therein along with a screw member 430 extending through the arcuate slot 428 and into the first plate 422 . The screw member 430 is configured to be loosened to allow the second plate 424 to pivot relative to the first plate 422 . As the second plate 424 is pivoting relative to the first plate 422 , the screw member 430 will slide through the arcuate slot 428 . Once the second plate 424 is in a proper position, the screw member 430 is tightened to maintain the second plate 424 is position relative to the first plate 422 . The first plate 422 and the second plate 424 allow adjustment of the cam 420 relative to the first switch 300 to ensure that the cam 420 engages with the first switch 300 when the cover 18 is placed in the closed position. It is contemplated that the first plate 422 and the second plate 424 can have any periphery (e.g., a non-rectangular periphery).
[0079] FIG. 28 illustrates a stop member 440 for halting pivotal movement of the pusher handle 16 . The stop member 440 is configured to stop the pushing fins 218 of the pusher member 214 from extending between the cutting blades 78 . The stop member 440 includes a support member 442 extending upwardly from a top surface of the top panel 182 of the cover 18 . A pin assembly 444 is connected to the support member 442 and includes spring housing 446 connected to one side of the support member 442 . A pin member 448 extends through the spring housing 446 and the support member 442 . A spring in the spring housing 446 biases the pin member 448 towards the right as illustrated in FIG. 28 . A handle 450 on a left side of the spring housing 446 is connected to the pin member 448 . Pulling the handle 450 to the left as illustrated in FIG. 28 will move the pin member 448 to the left against the bias of the spring in the spring housing 446 . During use, the bread product is pushed through the cutting blade assembly 12 as described above, but the pin member 448 of the stop member 440 prevents rotation of the pusher handle 16 downward past a point wherein the pushing fins 218 of the pusher member 214 would extend between the cutting blades 78 . The bread product between the cutting blades 78 can be past the cutting blades 78 by rotating the pusher handle 16 upward and placing a further bread product in the slicer 10 . Once the bread product to be sliced is exhausted, the handle 450 of the stop member 440 is pulled to move the pin member 448 out of the path of the pusher handle 16 to allow the pusher handle 16 to fully rotate downward, thereby allowing the pushing fins 218 to extend between the cutting blades 78 to push the final bread product through the cutting blade assembly 12 .
[0080] FIG. 29 is a top view of a modified pusher handle 16 a of the present invention. In the modified pusher handle 16 a , instead of having the nut connectors 216 extending directly through the main plate 200 , the nut connectors 216 extend through a connection panel 460 connected to the main plate 200 . The connection panel 460 includes a pair of side slots 462 and a pair of inner holes 464 . The nut connectors 216 extend through the inner holes 464 , through an aperture 465 in the main plate 200 and into the pusher member 214 . Fasteners 466 extend through the side slots 462 and into openings 468 in the main plate 200 . The position of the connection panel 460 is adjustable in a lateral direction by sliding the connection panel 460 relative to the fasteners 466 (which would slide through the side slots 462 in the connection panel 460 ). The connection panel 460 and movement thereof allows for adjustment of the pusher member 214 to align with the spaces between the blades 78 to ensure that the pushing fins 218 of the pusher member 214 can properly extend between the cutting blades 78 .
[0081] FIGS. 30 and 31 illustrate a modified cutting blade assembly 12 a having a modified open end member 82 a having a bottom member 700 and a top member 702 . The modified open end member 82 a allows for easier assembly of the cutting blade assembly 12 a . With the open end member 82 described above, the cutting blades 78 must be threaded through the slots in the front wall 118 of the C-shaped connection member 114 . In the modified open end member 82 a , the connection member 114 a is L-shaped in a middle portion 704 thereof and the cutting blades 78 can be slid into the top open ended slots in the connection member 114 a from a top of the cutting blade assembly 12 a . After all of the cutting blades 78 are positioned into the top open ended slots in the connection member 114 a from a top of the cutting blade assembly 12 a , the top member 702 is positioned over the bottom member 700 and fasteners are inserted through holes 710 in ends of the top member 702 and holes 712 in top end portions 714 of the bottom member 700 .
[0082] FIG. 32 illustrates a modified cutting blade 78 a that does not include a recessed portion 602 . The cutting blades 78 a do not have a recessed portion 602 if the cutting blades 78 a are located a certain distance apart or greater. For example, it is contemplated that the cutting blades 78 a without the recessed portion 602 could be used if the cutting blades 78 a are more than 3/16″ apart. Moreover, it is contemplated that short pins could extend though each pin openings 88 in the cutting blades 78 or 78 a , with each individual short pin being associated with only one pin opening 88 instead of a long pin extending through a plurality of pin openings 88 in a plurality of cutting blades 78 or 78 (e.g., replacing a long pin extending through the pin openings 88 in a plurality of cutting blades 78 and abutting the arcuate portion 106 of the pin holding member 96 with a plurality of short pins extending through the pin openings 88 in a plurality of cutting blades 78 and abutting the arcuate portion 106 of the pin holding member 96 ).
[0083] The reference numeral 70 a ( FIG. 33 ) generally designates another embodiment of the present invention, having a second embodiment for the output assembly. Since output assembly 70 a is similar to the previously described output assembly 70 , similar parts appearing in FIGS. 1-32 and FIG. 33 , respectively, are represented by the same, corresponding reference number, except for the suffix “a” in the numerals of the latter. The second embodiment of the output assembly 70 a functions in the same manner as the previously described output assembly 70 . The second embodiment of the output assembly 70 a comprises a pair of offset discs including a bottom disc 122 a fixedly connected to the output shaft 68 a and a top disc 128 a fixedly connected to the bottom disc 122 a in an offset manner. The bottom disc 122 a and the top disc 128 a rotate about an axis co-linear with the axis of rotation of the output shaft 68 a . The first connection bar 126 a includes an opening accepting the bottom disc 122 a therein and the second connection bar 132 a includes an opening accepting the top disc 128 a therein.
[0084] The reference numeral 10 b ( FIGS. 34-41 ) generally designates another embodiment of the present invention, having a third embodiment for the slicer. Since slicer 10 b is similar to the previously described slicer 10 , similar parts appearing in FIGS. 1-32 and FIGS. 34-41 , respectively, are represented by the same, corresponding reference number, except for the suffix “b” in the numerals of the latter. The third embodiment of the slicer 10 b functions in substantially the same manner as the previously described slicer 10 . The third embodiment of the slicer 10 b can be used to slice the bread product into chips wherein the cutting blades 78 b are spaced at 0.25 inches or less. The third embodiment of the slicer 10 b includes a cover 18 b connected to a base 17 b and a pusher handle 16 b connected to the cover 18 b.
[0085] In the illustrated example, the cover 18 b covers the cutting blade assembly 12 b within the platform 28 b of the housing 14 b . The cover 18 b includes a top panel 182 b having a central opening 184 b and a substantially rectangular skirt 186 b extending downwardly from a periphery of the top panel 182 b . The cover 18 b is configured to be positioned over the platform 28 b of the housing 14 b , with the skirt 186 b of the cover 18 b enveloping the side wall 48 b of the platform 28 b (see FIGS. 34 and 36 - 40 ). The skirt 186 b of the cover 18 b includes a plurality of connector slots 188 b in a side surface thereof with the connector slots 188 b each having a lower mouth 190 b being configured to receive screw connectors 60 b of the platform 28 b . The cover 18 b can have a pair of downwardly depending ears 400 b at a rear thereof, with each ear 400 b being pivotally connected to the platform 28 b . Therefore, the cover 18 b can pivot relative to the platform 28 b . With the cover 18 b being pivotally connected to the platform 28 b , the connection slots 188 b on either side of the cover 18 b can be arcuate to allow the connection slots 188 b to easily side along the screw connectors 60 b . The platform 28 b can include at least one pivoting stay member for maintaining the cover 18 b in a rotated position as discussed above in regard to FIG. 25 . The cover 18 b and the platform 28 b can also include a cam 420 b as discussed above in regard to FIG. 27 .
[0086] The illustrated cover 18 b also includes a front guard 192 b in front of the central opening 184 b of the top panel 182 b and a rear guard 194 b behind the central opening 184 b of the top panel 182 b . The front guard 192 b includes a base portion 800 , a first angled portion 804 at an end of the base portion 800 and a second angled portion 806 at a top of the first angled portion 804 . The base portion 800 includes a connector slot 810 configured to receive a screw post 801 extending upwardly from a top of the top panel 182 b . The screw post 801 is inserted through the connector slot 810 and a nut connector 803 is connected to the screw post 801 to secure the base portion 800 of the front guard 192 b to the top panel 182 b . The base portion 800 includes a front hook 802 at a front end thereof. The front hook 802 can be grasped to slide the base portion 800 along the connector slot 810 to properly align the front guard 192 b . It is contemplated that the front hook 802 could be excluded from the front guard 192 b , that the connector slot 810 is circular and that the base portion 800 is not configured to slide on the top panel 182 b . The first angled portion 804 is located at a rear edge of the base portion 800 at a midpoint of the first angled portion 804 such that a top of the first angled portion 804 is angled rearward (see FIG. 35 ). The top of the first angled portion 804 is located at a bottom of the second angled portion 806 , with the second angled portion 806 being angled in a direction opposite to the angled direction of the first angled portion 804 . The second angled portion 806 includes a top lip 805 and a pair of handle slots 812 , which will be discussed in more detail below. The front guard 192 b also includes a front block 814 having a plurality of blade slots 816 connected to a bottom of the base portion 800 by connectors 818 . When the front guard 192 b is connected to the cover 18 b , a bottom of the first angled portion 804 and the front block 814 will be located below the top panel 182 b of the cover 18 b . The blade slots 816 are configured to accept the cutting blades 78 b therein for allowing the cutting blades 78 b to reciprocate as discussed above. The front guard 192 a covers a front of the central opening 184 b above the top panel 182 b of the cover 18 b to prevent access to the cutting blades 78 b (except for the bread product as discussed below) and to prevent the bread product from moving too far forward while being cut in the same manner as the comb-shaped member 199 as discussed above. It is contemplated that instead of the front block 814 , the front guard 192 b could include a metal comb like member (similar to the comb-shaped member 199 discussed above) depending downwardly from the first angled portion 804 and into the central opening 184 b at a front thereof.
[0087] In the illustrated rear guard 194 b protects a rear of the central opening 184 b in the top panel 182 b of the cover 18 b . The rear guard 194 b includes a base plate 820 , a rear guide plate 822 and a pair of side guide plates 824 . The base plate 820 is U-shaped and includes a pair of openings for accepting fasteners therethrough for connecting the base plate 820 to the top panel 182 b of the cover 18 b . The rear guide plate 822 and the pair of side guide plates 824 are joined to form a U-shaped structure, with the rear guide plate 822 and the pair of side guide plates 824 connected to an inside edge of the base plate 820 . The rear guard 194 b also includes a rear block 832 having a plurality of blade slots 834 connected to a bottom of the base plate 820 by connectors. When the rear guard 194 b is connected to the cover 18 b , a bottom of rear guide plate 822 , the pair of side guide plates 824 and the rear block 832 will be located below the top panel 182 b of the cover 18 b . The blade slots 834 are configured to accept the cutting blades 78 b therein for allowing the cutting blades 78 b to reciprocate as discussed above. The rear guard 194 a covers a rear and sides of the central opening 184 b above the top panel 182 b of the cover 18 b to prevent access to the cutting blades 78 b (except for the bread product as discussed below) and to prevent the bread product from moving too far rearward while being cut in the same manner as the rear guard 201 as discussed above. As illustrated in FIGS. 36-38 and 40 , the top lip 805 of the second angled portion 806 of the front guard 192 b rests on a top the pair of side guide plates 824 . It is contemplated that instead of the rear block 832 , the rear guard 194 b could include a metal comb like member (similar to the comb-shaped member 199 discussed above) depending downwardly from the rear guide plate 822 and into the central opening 184 b at a rear thereof. The front guard 192 b and the rear guard 194 b form a substantially rectangular enclosure for accepting the bread product therein. The handle 16 b is employed to push the bread product through the substantially rectangular enclosure formed by the front guard 192 b and the rear guard 194 b and through the cutting blade assembly 12 b.
[0088] In the illustrated example, the pusher handle 16 b is used to push the bread product through the central opening 184 b in the top panel 182 b of the cover 18 b and through the cutting blade assembly 12 b to slice the bread product. The pusher handle 16 b includes a main plate 200 b having a pair of side members 202 b connected thereto. A grip 204 b extends between and is connected to a first end of the side members 202 b . A pair of ears 206 b extend downwardly from a second end of the side members 202 b . As illustrated in FIG. 35 , the cover 18 b includes handle slots 198 b for accepting the ears 206 therethrough. The pusher handle 16 b can pivot about pivot pins between a load position as illustrated in FIG. 37 and a cutting position as illustrated in FIG. 36 .
[0089] The illustrated pusher handle 16 b includes a pusher block assembly 842 for pushing the bread product through the central opening 184 b in the top panel 182 b of the cover 18 b and through the cutting blade assembly 12 b to slice the bread product. The pusher block assembly 842 includes a pusher block 844 , a guide block 848 and a slider linkage 852 . The slider linkage 852 interconnects the pusher block 844 to the guide block 848 . The slider linkage 852 is also engaged with the main plate 200 b of the pusher handle 16 b to move the pusher block assembly 842 with movement of the rest of the pusher handle 16 b . The slider linkage 852 comprises a base panel 854 having a pair of openings and a pair of side panels 856 . The pair of side panels 856 extend upwardly from opposite ends of the base panel 854 and are substantially parallel. The pair of side panels 856 each include slots 858 therein. The slider linkage 852 is connected to the main plate 200 b by inserting connector pins 841 on the main plate 200 b through the openings in the base panel 854 . Nut connectors 862 are threaded onto the connector pins 841 to fixedly connect the slider linkage 852 to the main plate 200 b . As illustrated in FIGS. 38-40 , the side panels 856 of the slider linkage 852 slide through handle slots 826 in the rear guide plate 822 of the rear guard 194 b . The slider linkage 852 moves the pusher block 844 to push the bread product through the cutting blade assembly 12 b.
[0090] In the illustrated example, the pusher block 844 is connected to the guide block 848 . The guide block 848 is abuts a rear face of the rear guide plate 822 of the rear guide 194 a . The guide block 848 includes a pair of side wings 851 . Block connector pins 860 extend through the side wings 851 , through the handle slots 826 in the rear guide plate 822 of the rear guide 194 a and into the pusher block 844 . Therefore, the pusher block 844 abuts a front face of the rear guide plate 822 of the rear guide 194 a and slides with the guide block 848 . The guide block 848 also includes a pair of co-linear slide pins 850 extending outwardly from opposite sides thereof. As illustrated in FIGS. 37 and 38 , the slide pins 850 slide within the slots 858 of the pair of side panels 856 of the slider linkage 852 . Therefore, as illustrated in FIG. 36 , the slide pins 850 are located in a rear of the slots 858 of the pair of side panels 856 of the slider linkage 852 when the handle 16 b is in the cutting position. As the handle 16 b is lifted to the load position as illustrated in FIG. 37 , the slide pins 850 will slide forwardly within the slots 858 of the pair of side panels 856 of the slider linkage 852 to thereby lift the guide block 848 via the slide pins 850 and to thereby lift the pusher block 844 via the block connector pins 840 . As the handle 16 b is pushed downward back to the cutting position, the slide pins 850 is be forced rearward within the slots 858 of the pair of side panels 856 of the slider linkage 852 to thereby push the guide block 848 and the pusher block 844 downward to thereby push the bread product within the substantially rectangular enclosure formed by the front guard 192 b and the rear guard 194 b and through the cutting blade assembly 12 b . Front ends of the side panels 856 of the slider linkage 852 can also extend through the handle slots 812 as illustrated in FIG. 38 . It is contemplated that the rear face of the rear guide plate 822 of the rear guide 194 a could include at least one vertically aligned guide projection and that a front face of the guide block 848 could include at least one corresponding guide slot, with the projection fitting into the slot to assist the guide block 848 is sliding in a vertical and aligned direction along the rear face of the rear guide plate 822 of the rear guide 194 a as the handle 16 b is pulled up and pushed downward.
[0091] The illustrated slicer 10 b can include any of the features of the previously described embodiments. For example, the cover 18 b can be pivotally connected to the base 17 b as described above or can be connected to the base 17 b as described in association with FIGS. 1-23 . The slicer 10 b can also include any output assembly as described above. Moreover, the slicer 10 b can include cams 420 b identical to the cams 420 described above. The cover 18 b can also include the slider block closure blocks 196 as described above or can include slider block closure blocks 196 b as illustrated in FIGS. 35 and 41 , with the slider block closure blocks 196 b each having a pair of rod grooves 840 for engaging the sliding rods 108 b of the first slider assembly 74 b and the second slider assembly 76 b . Alternatively, the slide block closure blocks 196 b could be only connected to the housing 14 b , with a fastener going through a top of the slide block closure blocks 196 b (but not the cover 16 b ) and directly into corresponding lower slide block closure blocks and into the bottom plate 46 of the platform 28 .
[0092] The foregoing detailed description is considered that of a preferred embodiment only, and the particular shape and nature of at least some of the components in this embodiment are at least partially based on manufacturing advantages and considerations as well as on those pertaining to assembly and operation. Modifications of this embodiment may well occur to those skilled in the art and to those who make or use the invention after learning the nature of this preferred embodiment, and the invention lends itself advantageously to such modification and alternative embodiments. For example, while a particular assembly is described for moving the first slider assembly 74 and the second slider assembly 76 of the cutting blade assembly 12 , it is contemplated that any system used to move the first slider assembly 74 and the second slider assembly 76 linearly could be used (e.g., a pair of linear actuators). Moreover, it is contemplated that other manners of tensioning the cutting blades 78 within the cutting blade assembly 12 could be used. Additionally, it is contemplated that the cover 18 and pusher handle 16 could be connected in any manner (e.g., the pusher handle 16 could only be connected to the cover 18 and rotate with the cover) and that the cover 18 and pusher handle 16 could be connected to any portion of the base 17 in any manner or could be separate from the base 17 . Furthermore, it is contemplated that the slicer 10 could include a counter for counting the number revolutions of the cutting blade assembly (e.g., by counting the number of revolutions of the output shaft 68 of the motor 64 ) or for counting a number of times the unit is energized. Additionally, it is contemplated that the cutting blade assembly could only include a few cutting blades (e.g., 3 or 4 ) for cutting a loaf of bread or a bun into a plurality of slices of bread or a multi-level bun (i.e., one having a top and bottom bun along with at least one middle bun portion). Moreover, it is contemplated that the slicer 10 or 10 b could include a feature that allows the handle 16 or 16 b to be held upright (e.g., a pin that fits through the rear guard 194 b (e.g., at the rear guide plate 822 or one of the side guide plates 824 ) and into or below the pusher block 844 ). Therefore, it is to be understood that the embodiment shown in the drawings and described above is provided principally for illustrative purposes and should not be used to limit the scope of the invention. Moreover, it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.
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A bagel slicing apparatus comprising providing a housing having a plurality of cutting blades, with the cutting blades moving linearly and reciprocally to slice a bagel into a plurality of bagel chips.
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FIELD OF THE INVENTION
[0001] The present invention relates to an electric motor, comprising an electromagnetically actuated mechanical brake and to a method of operating an electric motor with an electromagnetically actuated mechanical brake.
DESCRIPTION OF THE PRIOR ART
[0002] Electric machines can be controlled by their rotational speed. Electronic means are now available with which such machines can be powered via converters by means of either alternating or direct current supplies. A known method of improving the controllability of such machines during braking, as is required in many applications of such machines, is to operate the machine as a generator and to convert the energy so produced during braking into heat by way of a load resistance. However, the provision of such an additional load resistance involves an increase in expense and complexity of construction of the machine, and furthermore the heat produced must be dissipated by means of additional extra apparatus.
[0003] It is further known that such machines, when operated predominantly as electric motors, can be provided with mechanical brakes that can be released or raised by an electromagnet arrangement. Thus, when current is supplied to the electric motor, it is also supplied to the excitation coil of an electromagnetically actuated mechanical brake, and when no current is supplied to the motor, the brake operates to immobilize the motor.
[0004] The object of the present invention is to provide an electric motor and a method of operating an electric motor wherein the braking process is substantially simplified with respect to the prior art.
SUMMARY OF THE INVENTION
[0005] According to a first aspect of the present invention there is provided a method of operating a converter-controlled electric motor with an electromagnetically actuated brake comprising an excitation coil wherein the method comprises the step of supplying electrical energy to the excitation coil of the brake during braking in a generational mode of the motor for at least one of storage temporarily as magnetic energy and conversion to thermal energy.
[0006] According to a second aspect of the present invention there is provided an electric motor comprising an electromagnetically actuated mechanical brake; an excitation coil forming part of the brake; a converter; and a brake control means connected to the electric motor and the excitation coil in such a way that during braking of the electric motor in a generational mode of operation electrical energy produced by the motor is supplied to the excitation coil for at least one of temporary storage and conversion into heat.
[0007] By virtue of the invention, the electrical energy produced while the equipment is operating in a generational mode during braking is converted into heat in an excitation coil of the electromagnetically releasable mechanical brake. Conventionally, during mechanical braking the excitation coil is not supplied with any energy. However, the invention makes it possible to operate without a braking resistance and furthermore to exploit the inductivity function of the coil that is, its particular dynamic action, which the coil exhibits in contrast to an additional ohmic resistance such as is customarily employed.
[0008] Preferably, when the brake is applied strongly during operation in a generational mode, a current is supplied to the excitation coil that is considerably larger than that used to release the brake or keep it raised in an off position. That is, advantage is taken of electrical properties of the coil that in normal operation, for the usual release of the brake, are not exploited. However, the excitation coil can be supplied for a certain period with a much larger current than is supplied during normal operation to release the brake or to keep it in an off position.
[0009] Preferably, the thermal load on the excitation coil is ascertained and the current supplied to the coil is kept below a predetermined value beyond which the thermal load would exceed a predetermined temperature. It can thereby be ensured that no damage is caused by overheating. Preferably when there is a risk of thermal overloading, the current is limited to the maintenance level for the excitation coil, i.e. the amount of current that flows through the electric motor during maintained operation of the electric motor and is tailored to the excitation coil.
[0010] In a preferred embodiment of the invention the thermal load is ascertained by measuring the temperature of the excitation coil. With this kind of load measurement particularly accurate results can be expected. In an alternative embodiment of the invention, which can also be employed as an adjunct to the first embodiment, the current and/or voltage supplied to the excitation coil are/is monitored and these values, in combination with parameters specific to the excitation coil, in particular the thermal time constant of the excitation coil, are processed in such a way that not only is the momentary thermal load known but also, at any time, it can be estimated how long the excitation coil can continue to be operated with the present braking performance before the excitation current must be reduced. By this means the braking behavior can be optimized.
[0011] Preferably in addition to the thermal load on the excitation coil, the ambient temperature is also measured. As a result, the excitation coil is still more reliably protected from overloading. The same applies to a measurement of the temperature at the electric motor by means of a corresponding temperature sensor, which is usually present in any case. Once the brake has been mounted on the electric motor, along with its excitation coil, and heat flow is occurring, the temperature of the electric motor also provides a measure of the amount of heat that can still be conducted to the excitation coil.
[0012] The various aspects of the present invention will now be described by way of example with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] [0013]FIG. 1 is a block diagram showing a method of operating an electrical motor according to the present invention;
[0014] [0014]FIG. 2 is a circuit block diagram of a control unit shown in FIG. 1;
[0015] [0015]FIG. 3 is a circuit block diagram of a triggering unit;
[0016] [0016]FIG. 4 shows in more detail part of the circuit block diagram shown in FIG. 3,
[0017] [0017]FIG. 5 is a circuit block diagram of a second embodiment of triggering unit;
[0018] [0018]FIG. 6 is a circuit block diagram of a third embodiment of triggering unit; and
[0019] [0019]FIGS. 7 and 8 are diagrams showing two methods respectively of deriving the thermal load on an excitation coil.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] In the following description, the same reference numerals are used for identical components or parts with identical functions.
[0021] In the block diagram of FIG. 1, the reference numeral 1 identifies an alternating-current mains supply, which is applied to a rectifier 2 . A rectified output voltage of the latter is applied to a direct-current intermediate circuit 3 . To the output terminals of the DC intermediate circuit 3 are attached input connectors of a brake control unit 4 , in parallel with input connectors of a converter 5 .
[0022] Output terminals of the brake control unit 4 are connected to an excitation coil 62 of an electromagnetically actuated mechanical brake, which when supplied with current allows a motor 61 to run freely, and when the current is cut off brakes said motor.
[0023] The motor 61 is driven in a manner known per se by the converter 5 .
[0024] The electric motor 61 is preferably combined with the rectifier 2 , the brake control unit 4 , the excitation coil 62 and the converter 5 to form a unitary device 8 , preferably in a common housing.
[0025] The brake control unit 4 comprises, as shown in FIG. 2, in a first embodiment of the invention an electronic one-way valve 41 , which can be turned on and off by way of a triggering unit 42 . This one-way valve 41 is connected in series with the excitation coil 42 across the output terminals of the DC intermediate circuit 3 . The terminals of the excitation coil 62 are connected by way of a recovery diode 7 disposed such that its polarity is reversed with respect to the one-way valve.
[0026] In FIG. 2 the current flowing through the excitation coil 62 is designated I B and the voltage across the terminals of the excitation coil 62 is designated U B . The mode of operation of the arrangement is as follows.
[0027] The direct current required to raise the electromagnetically actuated mechanical brake has the value I 1 . When this current is flowing, a voltage U 1 exists across the excitation coil 62 .
[0028] When the current I 1 is turned on, a period of time t 1 elapses before the brake has been completely raised. Once it is in the raised position, the direct current needed to keep it in that position is I 2 , which in general is smaller than or equal to I 1 . In this state, the voltage drop across the excitation coil 62 has the value U 2 .
[0029] From the circuit shown in FIG. 2 it can be seen that the electronic one-way valve 41 can be switched on and off by the triggering unit 42 in such a way that the entire output voltage U Z of the DC intermediate circuit 3 can be applied to the excitation coil 62 . The modes of operation thus made possible are as follows.
[0030] Operating Condition A: the motor 61 is not supplied with any current from the converter 5 . The excitation coil 62 is also without current. In this operating condition the motor is firmly braked.
[0031] Operating Condition B: at the beginning of motor operation, i.e. when the converter 5 begins to supply current to the motor 61 , the brake control unit 4 supplies a direct current I B =I 1 to the excitation coil 62 for a time period t 1 , in order to raise the brake.
[0032] Operating Condition C: while the motor 61 is running in an unbraked state, the brake control unit 4 sends through the excitation coil 62 a direct current I B =I 2 that is required to maintain the electromagnetically actuated mechanical brake in the raised position; this maintenance current I 2 can be smaller than the current I 1 . When the maintenance current I 2 s equal to the current I 1 needed to raise the brake, the previously described operating condition B is eliminated.
[0033] Operating Condition D: when the running motor 61 is to be braked, i.e. switched to operate in a generational mode, the brake control unit 4 sends the direct current I B =I 2 , which is needed to keep the electromagnetically actuated mechanical brake in the raised position, through the excitation coil 62 as long as the power fed back from the converter 5 into the DC intermediate circuit 3 is not larger than the power needed to keep the electromagnetically actuated mechanical brake raised.
[0034] Operating Condition E: if the power fed back from the converter 5 into the DC intermediate circuit 3 exceeds the power needed to keep the electromagnetically actuated mechanical brake raised, because the braking or generator performance has increased, the brake control unit 4 conducts the entire power returned by the electric motor 61 into the excitation coil 62 . This current is considerably larger than the above-mentioned values I 1 and I 2 .
[0035] Operating condition F: if the thermal load associated with the supplied current exceeds a maximum permissible value for the excitation coil 62 , the brake control unit 4 reduces the current I B supplied to the excitation coil 62 to the level required to keep the electromagnetically actuated mechanical brake raised, namely the direct current I B =I 2 .
[0036] In the following a preferred embodiment, a circuit for a brake control unit 4 is described with reference to FIGS. 3 and 4.
[0037] As shown in FIG. 3, the trigger unit 42 comprises a signal generator 421 , the output of which is connected to an input of a pulse-width modulator (PWM) 422 . The output of the PWM 422 is supplied to the input of an override unit 423 , the output of which is supplied to a control input of the electronic one-way valve 41 , which can thereby be turned on and off. The entire arrangement is powered by way of the output terminals of the DC intermediate circuit 3 .
[0038] Triggering by way of the override unit 423 is achieved as follows. In all operating conditions except Condition E described above, the override unit 423 supplies the output signal of the PWM 422 to the electronic on/off one-way valve 41 . The ratio of the durations of “on” and “off”, i.e. the duty factor λ of the PWM 422 , in this case directly determines the mean direct current U B supplied to the excitation coil 62 . It follows that U B =λ·U Z , where U Z is the output-terminal voltage of the DC intermediate circuit 3 . The signal generator 421 generates the standard value for the voltage U B .
[0039] In operating Condition E, when the power sent back from the converter 5 during braking into the DC intermediate circuit 3 exceeds the power needed to keep the electromagnetically actuated mechanical brake raised, the intermediate-circuit voltage U Z begins to rise above the level of the rectified mains voltage. During this process, if U Z exceeds a limiting value U 3 , the on/off one-way valve 41 is switched into a conducting state by the override unit 423 , regardless of the standard voltage provided to the pulse-width modulator 422 .
[0040] The limiting value U 3 is set such that on one hand it is appreciably above the rectified mains voltage and on the other hand appreciably below the highest voltage load that can be sustained by the rectifier 2 , the DC intermediate circuit 3 , the brake control unit 4 , the rectifier 5 , the motor 61 and the excitation coil 62 .
[0041] While the system is in the Operating Condition E, if a signal Θ B generated by a temperature sensor to represent the thermal stress on the excitation coil 62 , such as is explained in greater detail below, exceeds the highest value that can be sustained by said coil, namely Θ B max, a transition to the operating condition F occurs. In this case the override unit 423 again sends the output signal of the PWM 422 to the electronic on/off one-way valve 41 such that current supplied to the excitation coil 62 becomes I B =I 2 ; that is, the current is reduced to the level that the excitation coil 62 can withstand during long-term operation of the electric motor 61 .
[0042] The above situation is represented in FIG. 4 in the form of a control circuit. Here the override unit 423 comprises a first comparator, which sends out a positive digital output signal when the voltage U Z at the output terminals of the DC intermediate circuit 3 exceeds a predetermined voltage U 3 . This limiting value U 3 has already been defined above.
[0043] A second comparator is provided that compares an actual temperature value Θ B with a maximum permissible temperature value Θ B max and sends out a positive digital output signal when the actual value exceeds the maximum value.
[0044] The value of the output signal of the first comparator is sent to a non-inverting input of an AND gate, whereas the value of the output signal of the second comparator is sent to an inverting input of the same AND gate. The output of the AND gate is sent to an input of an OR gate, the other input of which is connected to the output of the PWM 422 . The output of the OR gate is sent to the control input of the electronic on/off one-way valve 41 . As those skilled in the art will see, this circuitry carries out the procedure described above with reference to FIG. 3.
[0045] In the embodiment shown in FIG. 5, the voltage associated with the current I B through the excitation coil 62 is again supplied from the signal generator 421 to the PWM 422 . This voltage U B , associated with the current I B , has the value zero when the system is in Operating Condition A, the value U 1 , associated with current I 1 , when in Operating Condition B, and the value U 2 , associated with current I 2 , while in Operating Conditions C, D, E and F.
[0046] It is also possible to operate using the embodiment as shown in FIG. 6, in which the current is regulated by reference to a standard current. Here the signal generator 421 comprises a profile generator 4211 , the output signal of which is sent to a comparator, the output of which is sent to the input of a regulator unit 4212 in the signal generator 421 . The comparator receives from the excitation coil 62 a signal proportional to the current I B , so that the output signal of the comparator corresponds to the difference or deviation between the output value or set point derived from the profile generator 4211 and the current-proportional value or actual value derived from the current sensor.
[0047] In all the embodiments described herein, it is advantageous for the thermal state of or the thermal stress on the excitation coil 62 to be monitored. For this purpose, as indicated in FIG. 7, a signal Θ B can be obtained from an actual value p B of the energy dissipated in the excitation coil 62 on the basis of a thermal time constant τ B of the excitation coil 62 , with addition of a value Θ UB max, which corresponds to the maximal ambient temperature of the excitation coil 62 . This value Θ B is then, as shown in FIG. 4, further processed in order to protect the excitation coil 62 from overheating.
[0048] The actual momentary amount of energy dissipated in the excitation coil 62 , the quantity p B , is derived from the current measured through or the voltage measured across the excitation coil 62 and its ohmic resistance, or from the control signal of an electronic on/off one-way valve 41 , the (measured) value of the voltage across the output terminals of the DC intermediate circuit 3 and the measured value of the current through the excitation coil 62 or its ohmic resistance. Alternatively it is derived from the measured value of the voltage across the excitation coil 62 and the measured value of the current through the excitation coil 62 . The resulting value of Θ B , as shown in FIG. 7, is then used at a later stage in the circuitry as shown in FIG. 4.
[0049] The arrangement shown in FIG. 8 differs from that shown in FIG. 7 in that the derivation is based not on a fixed predetermined maximum ambient temperature Θ UB max for the excitation coil 62 , but rather on a temperature Θ M that corresponds to the temperature measured at the motor 6 . This in turn is a representation of the temperature at the electromagnetically actuated mechanical brake or the excitation coil 62 , because the brake is attached to the motor 61 by way of a thermally conducting contact area. This motor temperature Θ M allows the excitation coil 62 to be still better utilized, because during ordinary operation the ambient temperature Θ UB of the excitation coil 62 is below the value Θ UB max which is assumed above to be the maximum. The factor K Θ , by which the motor temperature Θ M is modified, as shown in FIG. 8, is so dimensioned that the quantity K Θ ·Θ M corresponds approximately to the actual ambient temperature Θ UB of the excitation coil 62 .
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Conventionally converter-controlled electric motors are allowed to operate in generational mode during braking and to convert the electrical energy so produced into heat. Such motors may also comprise electromagnetically actuated mechanical brakes. In the present invention it is proposed to supply the electrical energy produced by the motor when in a generational mode to an excitation coil of the brake and there store it temporarily as magnetic energy or convert it into heat.
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FIELD OF THE INVENTION
[0001] The present invention relates to a recording apparatus, and more particularly, to a recording apparatus that records by operating a recording head having a plurality of nozzles.
BACKGROUND OF THE INVENTION
[0002] So-called on-demand-type ink jet recording methods have developed rapidly in recent years, among which the so-called bubble jet method, in which ink is heated to boiling by a heater and the force created by the bursting of the bubbles is used to eject ink onto a recording medium, has gained particular favor due to its several advantages, mainly the simplicity of the recording head structure and the density with which a multiplicity of nozzles can be packed onto the recording head. Thus, for example, in a bubble jet recording apparatus, in order to increase the number of nozzles of the recording head it is enough simply to increase the number of nozzles of the recording head.
[0003] However, driving a multiplicity of nozzles simultaneously requires instantaneous delivery of large amounts of power, which leads to the occurrence of power voltage drops. Accordingly, steady driving of the nozzles requires an extremely large current.
[0004] Moreover, bubble jet recording requires heating the ink to the point of boiling using extremely short pulse power of a few milliseconds in duration, so a large current flows when the nozzles are driven, causing a voltage drop. As a result, when driving a multiplicity of nozzles simultaneously the drive energy for driving the recording head is apt to be inadequate, causing the nozzle drive to become unstable, in other words degrading the recording image.
[0005] In order to avoid this problem, the conventional solution is to divide the nozzles of the recording head into a plurality of blocks, turn the blocks into drive control units and drive the blocks separately.
[0006] However, if the total number of nozzles is very large then the number of nozzles included in one block increases, with the result that the same voltage drop problem arises as when the nozzles are driven individually.
[0007] By the same token, reducing the number of nozzles included within a block and increasing the number of blocks in order to reduce the number of nozzles driven simultaneously within the same block results in an increase in the time required to drive the blocks by an amount equivalent to the number of additional blocks, thus necessarily reducing the drive frequency.
[0008] One common and widely known method for solving the voltage drop problem is called “remote sensing”. The remote sensing method involves detecting the voltage at the circuit portion of the end that consumes power and feeding the detected voltage back to the power source constant voltage circuit so as to maintain the voltage at the power-consuming end portion.
[0009] However, the remote sensing method requires a high-speed feedback circuit in order to feed back such an extremely short pulse current. Moreover, where the wiring is long a phase lag arises, making it impossible to operate the high-speed feedback circuit with stability, causing the circuit operation to become unstable and creating oscillation.
[0010] A previous application by the applicant, Japanese Laid-Open Patent Application No. 10-181017, discloses a method of counting the number of nozzles to be driven simultaneously and determining the length of the drive voltage pulse according to the count. This method involves predicting the voltage drop to be incurred based on the number of nozzles to be driven simultaneously and correcting the drive pulse length by an amount equivalent to the predicted voltage drop so as to deliver a predetermined amount of power, making it possible to drive the recording head with stability and without excess voltage.
[0011] However, the method described above also suffers from a disadvantage, in that unevenness in the wiring resistances of the drive circuit of the recording head and of the heat-emitting element make it difficult to perfectly correct the drive pulse length.
[0012] Moreover, in the event that a large capacity condenser is provided on the power supply wiring, the voltage drop cannot be completely corrected because the voltage drop is affected not only by the instantaneous current consumption but also by the immediately preceding power consumption.
[0013] Thus, as described above, a variety of factors contributed to fluctuations in the power supply voltage, and ordinarily even with a voltage drop, in order to ensure that the power required to drive the nozzles the pulse length must of necessity be set rather larger than would ordinarily be the case. As a result, an excessive load is applied to the heat-emitting element and the heat-emitting element is therefore heated excessively, thus shortening the working life of the heat-emitting element and degrading the quality of the recording image as overheating reduces the ejection capacity of the nozzles.
SUMMARY OF THE INVENTION
[0014] Accordingly, the present invention has been proposed to solve the above-described problems of the conventional art, and has as its object to provide a recording apparatus capable of providing superior image recording free from the influence of voltage drops and the like.
[0015] According to one aspect of present invention, the above-described objects are achieved by a recording apparatus that uses information transmitted from an external device to scan a carriage mounting a recording head across a recording medium, the recording apparatus comprising:
[0016] recording data generating means for converting information transmitted from an external device into recording data appropriate to a configuration of the recording head;
[0017] a drive element for driving heat-emitting elements of the recording head selectively, in order to record based on the recording data converted by the recording data generating means;
[0018] a first power supply means for supplying drive power to the drive element; and
[0019] a second power supply means for supplying drive power to the heat-emitting elements.
[0020] According to another aspect of present invention, the above-described objects are achieved by the recording apparatus as described above, wherein the first and second power supply means are independent power supply sources.
[0021] According to another aspect of present invention, the above-described objects are achieved by the recording apparatus as described above, wherein:
[0022] the drive element is either an emitter follower-type drive transistor or a source follower-type drive transistor; and
[0023] the first power supply means supplies power to drive either the base or the gate of the drive transistor.
[0024] According to another aspect of present invention, the above-described objects are achieved by the recording apparatus as described above, wherein:
[0025] the drive element is a p-channel MOS transistor; and
[0026] the power that drives the drive element and the power supplied to the heating element are both negative power sources.
[0027] Other objects, features and advantages of the present invention will become more apparent from the following description taken in conjunction with the accompanying drawings, in which like reference characters designate the same or similar parts throughout the figures thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
[0029] [0029]FIG. 1 is a perspective external view of a recording apparatus that is one embodiment of the present invention;
[0030] [0030]FIG. 2 is a block diagram of a printer control mechanism;
[0031] [0031]FIG. 3 is a diagram of an ink jet cartridge for the printer of FIG. 1;
[0032] [0032]FIG. 4 is a circuit diagram for illustrating the circuit configuration of the recording apparatus of FIG. 1;
[0033] [0033]FIG. 5 is a diagram showing a detailed view of a drive circuit and a drive transistor of the circuit shown in FIG. 4;
[0034] [0034]FIG. 6 is a diagram illustrating a modification of one embodiment of the present invention that eliminates the effects of a voltage drop across the ground wiring;
[0035] [0035]FIG. 7 is a diagram illustrating a configuration in which power lines to the heat-emitting element and the drive circuit are separated at the circuit but joined at a remote location; and
[0036] [0036]FIG. 8 is a diagram of a drive circuit and drive transistor of a second embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0037] Preferred embodiments of the present invention will now be described in detail in accordance with the accompanying drawings.
[0038] It should be noted that, in the following embodiments, the description assumes a printer that is a recording apparatus employing an ink jet recording method.
[0039] It should further be noted that, in the present specification, the term “recording” (hereinafter sometimes used interchangeably with the term “print”) is used not only in the case of print, graphics and other meaningful information. Rather, the term is used in its broadest sense to include also images, patterns and the like on a recording medium, whether meaningful or not, whether directly readable by the human eye or not, and also specifically includes the processing of such medium as well.
[0040] Additionally, the term “recording medium” herein means not only the paper used in any typical recording apparatus but any material capable of retaining ink, including (but not limited to) cloth and other fabrics, plastic and film, metallic plates, glass, ceramics, wood, leather, and so forth.
[0041] Moreover, the term “ink” (hereinafter sometimes used interchangeably with the term “fluid”), like the term “recording” (or “print”), is also meant to be interpreted in the broadest sense to mean a fluid that forms an image, pattern or the like when applied to the surface of the recording medium as well as the fluid supplied in the processing of the recording medium or the processing of the ink.
[0042] [0042]FIG. 1 is a perspective external view of a recording apparatus that is one embodiment of the present invention, in this case an ink jet printer IJRA.
[0043] As shown in FIG. 1, a head carriage (HC) engages a spiral groove 5004 of a lead screw 5005 that is rotated via a drive force transmission gear assembly 5009 - 5011 linked to the forward and reverse rotation of a drive motor 5013 . The head carriage HC has a pin (not shown in the diagram), and moves back and forth in directions indicated by arrows a and b while supported by a guide rail 5003 . The head carriage HC mounts an ink jet cartridge (IJC) that forms a single integrated unit with a recording head (IJH) and ink tank (IT).
[0044] Reference numeral 5002 denotes a paper retention plate, and presses the recording paper against a platen as the carriage HC moves in the a-b direction. Reference numerals 5007 and 5008 denote photo couplers, which check the area for the presence of a carriage lever 5006 and thus act as a position detector. The photo couplers 5007 , 5008 , upon sensing that presence of the lever 5006 , reverse the direction of rotation of the motor 5013 .
[0045] Reference numeral 5016 is a member that supports a cap member 5022 that caps a front surface of the recording head IJH. Reference numeral 5015 is a suction unit that that exerts suction on an inner surface of the cap, suctionally returning the recording head via an opening 5023 in the cap. Reference numeral 5017 is a cleaning blade and 5019 is a member that allows the cleaning blade 5017 to move back and forth, supported by a main support plate 5018 . Those of ordinary skill in the art can appreciate that the cleaning blade 5017 may be any cleaning blade commonly used and widely known, and adapted to the present embodiment.
[0046] Additionally, reference numeral 5021 denotes a lever that commences suction for the suctional return, which moves with a cam 5020 that engages the carriage and is controlled by a commonly known drive mechanism such as a clutch switch and the like for controlling the drive force from the drive motor.
[0047] This capping, cleaning and suctional return are enabled by a construction in which the desired operation can be carried out at positions which correspond to these processes as appropriate, by the operation of the lead screw 5005 when the carriage has come to the home position. Provided these processes are carried out in any well-known sequence, any or all of these may be adapted to the present embodiment.
[0048] Next, a description will be given of a control configuration for executing recording control of the apparatus described above.
[0049] [0049]FIG. 2 is a block diagram of a control circuit for an ink jet recording apparatus.
[0050] As shown in the diagram, reference numeral 1700 denotes an interface that inputs a recording signal, 1701 denotes an MPU, 1702 denotes a ROM containing a program that the MPU 1701 executes and 1703 is a DRAM that stores a wide variety of data, including the above-described recording signals and recording data supplied to the head. Reference numeral 1704 denotes a gate array that controls the supply of recording data to the recording head IJH, and controls the transfer of data among the interface 1700 , the MPU 1701 and the RAM 1703 . Reference numeral 1710 is a carrier motor for transporting the recording head IJH. Reference numeral 1709 is a transport motor for transporting the recording paper. Reference numeral 1705 is a head driver for driving the recording head, and 1706 and 1707 are motor drivers for driving the transport motor 1709 and the carrier motor 1710 , respectively.
[0051] When a recording signal is entered into the interface 1700 , the recording signal is converted to print recording data between the gate array 1704 and the MPU 1701 . Then, when the motor drivers 1706 , 1707 are driven, the recording head is driven in accordance with the recording data sent from the head driver 1705 and recording performed.
[0052] It should be noted that, although in the above-described embodiment the control program executed by the MPU 1701 is stored in the ROM 1702 , it is also possible to further add an erasable/writable recording medium such as an EEPROM and the like and to alter the control program from a host computer connected to the ink jet printer IJRA.
[0053] Those of ordinary skill in the art can appreciate that, as described above, the ink tank IT and the recording head IJH may be formed into a single unit as an interchangeable ink jet cartridge IJC. Of course, the ink tank IT and the recording head IJH may be detachable from each other, so that the ink tank IT can be replaced when the ink is depleted.
[0054] [0054]FIG. 3 is an external perspective diagram of an ink jet cartridge IJC for the printer of FIG. 1, in which the ink tank can be detached from the head.
[0055] As shown in FIG. 3, the ink jet cartridge IJC is constructed so that the ink tank IT and the recording head IJH are separable along the borderline K. The ink jet cartridge IJC is equipped with an electrode (not shown in the diagram) that receives electrical signals supplied from the head carriage HC when the ink jet cartridge IJC is loaded into the carriage. As described above, the electrical signals so supplied drive the ink jet recording head IJH, expelling the ink.
[0056] It should be noted that, in FIG. 3, reference numeral 500 denotes a row of ink jet ejection ports. Additionally, the ink tank IT is provided with an ink absorber made of fibrous or porous material to hold the ink.
[0057] A description will now be given of a first embodiment of the present invention, with reference to the accompanying drawings.
[0058] [0058]FIG. 4 is a circuit diagram for illustrating the circuit configuration of the recording apparatus of FIG. 1.
[0059] The circuit diagram of FIG. 4 represents the drive circuit of the present invention adapted to a drive circuit for a heat-emitting element disclosed in the applicant's previous application, Japanese Laid-Open Patent Application No. 10-44411. Those of ordinary skill in the art can appreciate that the applications of the present invention are not limited to such an adaptation, and it goes without saying that the present invention can be adapted to any other ink jet recording head having an equivalent logic circuit. In the diagram, the heat-emitting element (resistor) drive voltage is supplied from the V H .
[0060] A detailed description will now be given of the drive voltage and the heat-emitting element, with reference to FIG. 5.
[0061] [0061]FIG. 5 is a diagram showing a detailed view of a drive circuit and a drive transistor of the circuit shown in FIG. 4.
[0062] As shown in the diagram, V H is a supply voltage that supplies a drive voltage to the heat-emitting element, and is typically set at approximately 10-40 volts. V DR denotes a supply voltage that drives the drive circuit, and is approximately the same as the heat-emitting element power. The circuit is configured so that the power lines for the heat-emitting element and the drive circuit are separate.
[0063] In the circuit described above, when the drive transistor is switched to the ON state (that is, the base voltage is HIGH), the base (B) current and the collector (C) current are both applied to the heat-emitting element. In other words, the voltage applied to the heat-emitting element is determined by the voltage that turns the drive transistor base (B) ON/OFF, so although the effect of the voltage (V H ) supplied from the collector side is eliminated the circuit still does not avoid the effect of the voltage drop over the wiring on the ground (G) side. In other words, when the heat-emitting element is driven and a large current flows, the electric potential at the ground rises and, as a result, the voltage applied between the terminals of the heat-emitting element drops. By contrast, by sufficiently reducing the impedance in the ground wiring it is possible to prevent a voltage drop.
[0064] Conventionally it has been necessary to reduce the impedance in the wiring at both sides of the heat-emitting element, but by the application of the present invention it is sufficient to reduce the impedance at one end only (the ground side), thus simplifying design.
[0065] Additionally, the effect of the voltage drop over the ground (G) wiring can be eliminated by modifying the embodiment. FIG. 6 shows one such embodiment.
[0066] [0066]FIG. 6 is a diagram illustrating a modification of one embodiment of the present invention that eliminates the effects of a voltage drop across the ground wiring.
[0067] Although in the embodiment shown in FIG. 6, on the power supply side, the heat-emitting element power ground V H G and logic as well as the drive ground V DR , V DD G are each provided separately, nevertheless both the drive circuit ground and the heat-emitting element drive power ground are jointly connected on the ink jet head side. The drive circuit power consumption is small, so it is possible to ignore the ground wiring voltage drop, the power is sufficiently stable, and providing an adequate electrostatic condenser on the power outlet terminal smoothes the drive circuit high side voltage and is constant with respect to the ground electric potential at the head unit. Accordingly, the base electric potential of the drive transistor of the drive circuit is virtually constant with respect to the earth ground voltage, and the voltage across the terminals of the heat-emitting element is virtually constant.
[0068] It should be noted that providing a bypass condenser can at a location near the ink jet head of the power source of the drive circuit and the logic circuit is also effective.
[0069] [0069]FIG. 7 is a diagram illustrating a configuration in which power lines to the heat-emitting element and the drive circuit are separated at the circuit but joined at a remote location.
[0070] As shown in FIG. 7, when a bypass condenser of sufficient electrostatic capacity is provided at a location near the ink jet head of the power source of the drive circuit and the logic circuit, and the wiring for the output unit (heat-emitting element) and for the drive circuit are separated as the heat-emitting element drive voltage (V H ) and the drive circuit drive voltage (V DR ), a remote power supply source may be common and still function effectively.
[0071] By using an emitter follower-type circuit or a source follower-type circuit, the voltage applied to the heat-emitting element is controlled by the voltage applied to the base or gate of the transistor virtually unaffected by the voltage over the power lines applied to the collector or drain of the transistor. Accordingly, by making the power for the drive circuit that drives the base or gate separate from the power line that supplies power to the heat-emitting element, the voltage applied to the heat-emitting element by the supply of power from the base remains virtually unchanged and can thus be stabilized even when the electric current flowing to the heat-emitting element increases sharply and a voltage drop over the power line occurs. Accordingly, the heat-emitting element can be driven at a constant power, without a sharp decrease in current.
[0072] Additionally, excess voltage when the voltage drop is small is absorbed by the drive transistor, without being applied to the heat-emitting element. As a result, the drive transistor, though larger than the conventional ink jet recording head, overall consumes less power. The reduction in power consumption arises because the current is practically proportional to the voltage in the conventional ink jet recording head circuit, and so power consumption is practically proportional to the square of the voltage. By contrast, in the application of the present embodiment according to the present invention, the power consumption is no more than proportional to the voltage. As a result, excess heating of the recording head where the recording density is low (such low-density areas accounting for the majority of the typical recording image)can be prevented and the speed of the recording can be increased.
[0073] A description will now be given of a second embodiment of the present invention, with reference to the accompanying drawings.
[0074] [0074]FIG. 8 is a diagram of a drive circuit and drive transistor of a second embodiment of the present invention.
[0075] As shown in FIG. 8, the drive element is a p-channel MOS transistor, and power supplied to the heat-emitting element V H and the drive circuit drive power V DR are both negative power sources. Additionally, the positive side of the power for the drive circuit and the positive side of the power for the logic circuit are the same. In such a circuit as well, the voltage applied to the negative side of the heat-emitting element is the source voltage of the drive transistor and is controlled by the gate voltage, so the effects of fluctuations in the V H side voltage are virtually eliminated.
[0076] Accordingly, by providing a drive circuit power source that is independent of the power line that supplies power to the heat-emitting element, the voltage that is applied to the heat-emitting element remains virtually unchanged and can thus be stabilized even when the electric current flowing to the heat-emitting element increases sharply and a voltage drop over the power line occurs. Accordingly, the heat-emitting element can be driven at a constant power, without a sharp decrease in current.
[0077] Those of ordinary skill in the art can appreciate that although the embodiments described above assume that the fluid ejected from the recording head is ink, and that the fluid contained in the ink tank is ink, the present invention is not limited to a case in which the fluid is ink. Thus, for example, a processing fluid ejected onto the recording medium in order to enhance the adhesive or waterproof qualities of the recording image or to improve the quality of the image may be contained in the ink tank.
[0078] Those of ordinary skill in the art can appreciate that the present invention can be adapted to a system composed of a plurality of devices. These devices may include a host computer, an interface device, a reader, a printer, and so forth. Or alternatively, the present invention may be adapted to an apparatus composed of a single device.
[0079] As described above, the present invention makes it possible to supply a constant voltage to the heat-emitting element without regard to the number of heat-emitting elements to be driven simultaneously, and without being affected by any voltage drop across the power lines.
[0080] Additionally, the present invention makes it possible to in order to prevent excess voltage supply and to drive the heat-emitting element with the minimum required voltage and pulse length. As a result, the heat-emitting element suffers no burns, and a stable, superior recording image can be obtained.
[0081] Additionally, the heat-emitting element does not get overheated and deterioration due to that cause can be prevented, thereby making it possible to improve and extend the working life of the heat-emitting element.
[0082] As many apparently widely different embodiments of the present invention can be made without departing from the spirit and scope thereof, it is to be understood that the invention is not limited to the specific preferred embodiments described above thereof except as defined in the claims.
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A recording apparatus has a recording head has a data generating unit that converts information transmitted from an external device into recording data that matches the configuration of the recording head for recording by the recording head. The recording apparatus has a first power supply circuit for supplying drive power to a drive element that drive by the nozzles of the recording head and a second power supply circuit that drives the heating elements that control recording by the nozzles. As a result, the recording apparatus can provide stable recording, unaffected by any voltage drop in the circuitry that drives the recording head.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
BACKGROUND OF THE INVENTION
[0003] The embodiments of the present invention relate generally to measurement while drilling data transmission technologies. More specifically, the embodiments relate to methods and apparatus for generating pressure pulse signals in a circulating drilling fluid. Still more specifically, the embodiments relate to methods and apparatus for using an electroactive fluid to create pressure pulse signals.
[0004] Modern petroleum drilling and production operations demand a great quantity of information relating to parameters and conditions downhole. Such information typically includes characteristics of the earthen formations traversed by the wellbore, data relating to the size and configuration of the wellbore itself, and information as to tool orientation, location, and operating parameters. Techniques used to measure conditions in the wellbore, including the movement and location of the drilling assembly, during drilling operations are commonly known as measurement-while-drilling (MWD) or logging-while-drilling (LWD).
[0005] These techniques often involve the use of a telemetry system that employs one or more sensors or transducers at the lower end of the drill string that collect data from the drill string or wellbore. These sensors relay the gathered information to an encoder that coverts the data to digital signals, which can be transmitted to receiving equipment at the surface. A commonly employed technique to relay signals from downhole to the surface is transmission of pressure pulses through the column of drilling mud that fills the borehole. These pulses are then received and decoded by a pressure transducer and computer at the surface.
[0006] In typical prior art mud pressure pulse systems, the pressure pulses in the drilling mud are created by means of a valve and control mechanism, generally termed a pulser or mud pulser. Mud pressure pulses are generated by opening and closing a valve, normally near the bottom of the drill string, so as to momentarily restrict or increase the mud flow. Early MWD tools used a “negative” pressure pulse that was created in the fluid by temporarily opening a valve in the drill collar allowing direct communication between the high pressure fluid inside the drill string and the fluid at lower pressure returning to the surface via the wellbore annulus. Negative pressure pulse techniques proved less than ideal because a failure in the valve could result in an uncontrolled release of drill string fluid into the annulus.
[0007] Alternatively, and often more preferably, a “positive” pressure pulse was created by temporarily restricting the flow of drilling fluid by partially blocking the fluid path in the drill string. Devices used to create these positive pressure pulses include poppets, sirens, and rotary pulsers.
[0008] Poppet-type pulsers operate like unidirectional check valves by permitting the flow of fluid in only one direction. The poppet employs an axially moveable plug to open and close a fluid pathway that, when closed, causes a pressure rise in the drilling fluid.
[0009] Sirens typically feature a stationary stator and a coaxially mounted, motor driven rotor. The stator and the rotor have a plurality of radially extending lobes such that when the lobes of the stator and the rotor are aligned, a fluid port is formed for the passage of fluid. As the rotor rotates, the flow of fluid is interrupted and pressure pulses are generated.
[0010] A rotary pulser is similar to a siren but rather than being driven to produce a relatively continuous series of signals like a siren, the actuation of a rotary pulser is controlled to produce a desired sequence of pulses in the drilling fluid. Thus, instead of the constant rotation of a siren, a rotary pulser is intermittently rotated a small amount to open and close fluid pathways.
[0011] Because all of these pulser designs operate by restricting the flow of drilling fluid through relatively small passageways, erosion and wear caused by the abrasive-laden drilling fluid is a serious concern. Drilling fluid normally contains some concentration of solid particles, which, at the pressure and flow rates typically encountered, tend erode the pulser components. Such erosion can lead to relatively short useful lives for many pulser components. Thus, there remains a need in the art for a pulser design exhibiting improved wear characteristics.
[0012] Disclosed in U.S. Pat. No. 2,661,596, the entire disclosure of which is hereby incorporated by reference, are electroactive fluids whose viscosity, or resistance to flow, is modifiable by subjecting the fluid to a magnetic or electric field. Electroactive fluids that are responsive to an electrical field are known as electrorheological (ER) fluids, while those responsive to magnetic fields are known as magnetorheological (MR) fluids. Of these two, MR fluids have proved easier to work with because they are less susceptible to performance-degrading contamination, and are easily controllable using magnetic fields easily created with either permanent magnets or electromagnets.
[0013] MR fluids can be formed by combining a low viscosity fluid, such as a type of oil, with magnetizable particles to form a viscous slurry. U.S. Pat. No. 2,661,596 used particles of iron on the order of 0.1 to 5 microns, with the particles comprising 20% or more by volume of the MR fluid. More recent work in MR fluids can be found, for instance, in U.S. Pat. No. 6,280,658, the entire disclosure of which is hereby incorporated herein by reference.
[0014] When a magnetic field passes through an MR fluid, the magnetizable particles align with the field, limiting movement of the fluid due to the arrangement of the magnetizable particles. As the field increases, the MR fluid becomes increasingly solid, but when the field is removed, the fluid reassumes its liquid state again. MR fluids have been used in such areas as dampers, locks, brakes, and abrasive finishing and polishing. MR fluids can be commercially obtained from the Lord Corporation of Cary, N.C.
[0015] The embodiments of the present invention are directed to methods and apparatus for generating a pressure pulse in drilling fluid using a pulser, controlled by an electroactive fluid, that seeks to overcome the limitations of the prior art.
SUMMARY OF THE PREFERRED EMBODIMENTS
[0016] The preferred embodiments provide a mud pulser controlled by a field applied to an electroactive fluid. The electroactive fluid is employed to act as a rapid-response brake to interrupt the rotation of the rotor of a mud motor or mud siren, thus creating pressure pulses in the circulating fluid. In certain embodiments, the electroactive fluid is used as a direct brake, acting on a shaft rotating in a volume of electroactive fluid where the shaft is coupled to the rotor. The application of a field to the electroactive fluid impedes the rotation of the shaft, thus slowing the rotor and creating a pressure pulse in the circulating fluid. In another embodiment, a Moineau pump circulating electroactive fluid is coupled to the rotor. The application of a field to the electroactive fluid slows the rotation of the pump, thus slowing the rotor and creating a pressure pulse in the circulating fluid.
[0017] In one embodiment, the pressure pulser comprises a first body rotated by flowing fluid and a second body rotatably coupled to the first body and at least partially disposed within an electroactive fluid. The pulser is actuated by applying a field to the electroactive fluid. The field causes the physical properties of the electroactive fluid to change, which affects the rotation of the second body.
[0018] In certain embodiments, the first body is a mud motor. The second body may be a shaft rotating in the electroactive fluid or a pump rotor circulating the electroactive fluid through a flowline having an electroactive fluid valve. Alternate embodiments may also comprise a mud siren where the rotation of the siren rotor is controlled by an electroactive fluid.
[0019] In an alternative embodiment, a method for generating a pressure pulse includes disposing a first body in a flowing fluid so as to rotate the first body, coupling the first body to a second body disposed in an electroactive fluid, and applying a field to the electroactive fluid. A magnetic field may be applied by applying a current to an electromagnetic coil or removing a shunt from a permanent magnet.
[0020] Thus, the present invention comprises a combination of features and advantages that enable it to provide for a mud pulser actuated by the intermittent application of a field to an electroactive fluid. These and various other characteristics and advantages of the preferred embodiments will be readily apparent to those skilled in the art upon reading the following detailed description and by referring to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] For a more detailed understanding of the preferred embodiments, reference is made to the accompanying Figures, wherein:
[0022] FIG. 1 is a schematic view of one embodiment of an electroactive fluid controlled pulser;
[0023] FIG. 2 is a schematic view of a second embodiment of an electroactive fluid controlled pulser;
[0024] FIG. 3 is a schematic view of one embodiment of an electroactive fluid controlled mud siren; and
[0025] FIGS. 4A-4C are schematic views of alternative embodiments of permanent magnet circuits.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] In the description that follows, like parts are marked throughout the specification and drawings with the same reference numerals, respectively. The drawing figures are not necessarily to scale. Certain features of the invention may be shown exaggerated in scale or in somewhat schematic form and some details of conventional elements may not be shown in the interest of clarity and conciseness. The present invention is susceptible to embodiments of different forms. There are shown in the drawings, and herein will be described in detail, specific embodiments of the present invention with the understanding that the present disclosure is to be considered an exemplification of the principles of the invention, and is not intended to limit the invention to that illustrated and described herein. It is to be fully recognized that the different teachings of the embodiments discussed below may be employed separately or in any suitable combination to produce the desired results.
[0027] In particular, various embodiments of the present invention provide a number of different methods and apparatus for using an electroactive fluid to generate a pressure pulse in fluid. The concepts of the invention are discussed in the context of a mud pulser, but the use of the concepts of the present invention is not limited to this particular application and may be applied in other, downhole rotating mechanisms. The concepts disclosed herein may find application in other downhole tool applications, as well as other hydraulically actuated components, both within oilfield technology and other technologies to which the concepts of the current invention may be applied.
[0028] As used herein, an electroactive fluid is a fluid, gel, or other material having physical properties that change in response to a magnetic or electric field. Although the present invention is discussed relative to an MR fluid, an electrorheological (ER) or other electroactive fluid may be used without departing from the scope of this disclosure. It is understood that physical properties of an electroactive fluid can be changed by applying a magnetic field to an MR fluid or by applying an electrical field to an ER fluid.
[0029] A Moineau pump is a positive displacement or progressive cavity pump that includes a helical rigid rotor which rotates inside an elastic helical stator. The geometry and dimensions of these components are designed so that a double string of sealed chambers (or cavities) are formed when the rotor turns relative to the stator. These volumes within these chambers effectively move from one end of the pump to the other as the rotor rotates. A Moineau pump can be used as a pump by rotating the rotor or can be used as a motor by forcing fluid through the chambers, with the rotating rotor acting as an output shaft. Moineau pumps are commonly known in drilling applications as mud motors.
[0030] Referring now to FIG. 1 , a pulser 10 is shown including a motor section 12 and a brake section 14 . In the preferred embodiments motor section 12 and brake section 14 are a component of a drill string or integrated into a drilling tool or sub. The motor section 12 includes a mud motor 16 rotated by flowing drilling fluid, represented by arrows 18 . Mud motor 16 is preferably a Moineau pump having a rubberized stator 20 and a metallic rotor 22 that rotates in response to pressurized fluid being applied to the pump. Brake section 14 includes a housing 24 containing a shaft 26 in a cavity 28 filled with an MR fluid 30 . The MR fluid 30 is isolated from the drilling fluid 18 , which flows through bypass ports 32 to motor section 12 . Shaft 26 of brake section 14 includes an electromagnet coil 34 wound around the shaft that, when energized, creates a magnetic field in the MR fluid 30 .
[0031] The application of a magnetic field to the MR fluid 30 cause the characteristics of the fluid to change from a liquid to a near solid. The coil can be powered with batteries, a generator that extracts its power from the flow, such as a turbine, or a generator that produces its own power from stored chemical energy, such as a fuel cell. This phase-shift of MR fluid 30 , from viscous liquid to near-solid, increases the friction on the rotating shaft 26 , which reduces the rotational speed of the shaft 26 and the coupled mud motor 16 . The reduction in rotational speed of the mud motor 16 reduces the flow of drilling fluid 18 through the motor, causing a pressure increase in the drilling fluid that can be detected at the surface by conventional pressure pulse sensing and recording equipment.
[0032] Referring now to FIG. 2 , a pulser 36 is shown including an alternative braking section 38 coupled with motor section 12 . Braking section 38 includes a second Moineau pump 40 that is rotated by rotor 22 . Pump 40 circulates an MR fluid 42 through flowline 44 that includes an MR valve 46 . The MR fluid 42 is isolated from the drilling fluid 18 , which flows through bypass ports 48 to motor section 12 . MR valve 46 applies a magnetic field to the MR fluid 42 in flowline 44 , which changes the characteristics of the fluid from a liquid to a near solid. The change of the viscosity of fluid 42 causes pump 40 to slow or stop rotating, which in turn slows motor 16 , causing a pressure increase in the drilling fluid 18 .
[0033] MR valve 46 operates by applying a magnetic field to a small area of flowline 44 . The MR fluid 42 within this portion of the flowline changes from a liquid to a near solid and effectively blocks flow through the flowline 44 . The magnetic field of MR valve 46 can be created by an electromagnet or a permanent magnet and many different MR valve designs are known in the art. A number of MR valve designs are disclosed in U.S. Patent Application No. ______ (2001-IP-004288), titled “Valve and Position Control using Magnetorheological Fluids,” which is hereby incorporated by reference for all purposes.
[0034] Referring now to FIG. 3 , one embodiment of a continuous wave telemetry system using a mud siren 50 controlled by an electroactive fluid is shown. Mud siren 50 includes a slotted rotor 52 and stator 54 , which restrict the mud flow in such a way as to generate a modulating positive pressure wave that travels to the surface. Rotor 52 is mounted on a shaft 60 , which rotates in a housing 58 containing an electroactive fluid 56 . Thus, the electroactive fluid 56 can be used as the method through which the rotation of the rotor 52 is modulated. Activating an electric field across housing 58 solidifies the fluid 56 and causes rotor 52 to slow, which changes the frequency and/or phase of the rotor and creates a corresponding change in the continuous pressure wave. In certain embodiments, rotor 52 self-rotates, powered by flowing mud, while in other embodiments, it is driven by an electric or hydraulic drive motor 59 . If rotor 52 is self-rotating, then fluid 56 acts as a brake. If rotor 52 is driven by drive motor 59 , then fluid 56 acts as a clutch between the drive motor and the rotor.
[0035] As an alternative to electromagnet coil 34 , the magnetic field needed to activate MR fluid 30 may also be created by a permanent magnet. While the electromagnetic coil 34 creates a magnetic field when a current is applied, a permanent magnet creates a permanent magnetic field and a magnetic circuit is used to control the application of the field to the MR fluid. Power is required only to operate the magnetic circuit switching mechanism and not to apply the magnetic field to the fluid. Thus, although potentially of greater mechanical complexity, employing a permanent magnet may potentially reduce the power required to create pressure pulses.
[0036] Referring now to FIG. 4A , one embodiment of a magnetic circuit 62 is shown. Circuit 62 includes MR fluid path 64 , permanent magnet 66 , moveable ferromagnetic bar 68 , and flux path 70 . Permanent magnet 66 creates a magnetic field that is transferred through flux path 70 to fluid path 64 . To provide for an intermittent magnetic field, ferromagnetic bar 68 is placed across the flux path 70 , effectively shifting the magnetic field from the fluid path 64 to the bar 68 . Removing bar 68 allows the magnetic field to be applied to fluid path 64 . Moveable ferromagnetic bar 68 may preferably be a rotating or oscillating disk having ferromagnetic portions.
[0037] FIG. 4B shows an alternative permanent magnet circuit 72 including MR fluid path 74 , permanent magnet 76 , moveable member 78 , and flux path 80 . Permanent magnet 76 creates a magnetic field that is transferred through flux path 80 to fluid path 74 . To provide for an intermittent magnetic field, member 78 is used to complete flux path 70 , effectively completing the circuit to allow the magnetic field from magnet 76 to reach fluid path 74 . Removing member 78 breaks the circuit and prevents the magnetic field from being applied to fluid path 74 . Moveable member 78 may preferably be a rotating or oscillating disk having field transferring portions.
[0038] In an alternative embodiment as shown in FIG. 4C , a negative fluid pulser may be utilized including circuit 82 . Circuit 82 includes MR fluid path 84 , permanent magnet 86 , electromagnet 88 , and flux path 90 . The permanent magnet 86 generates a constant magnetic field that solidifies the MR fluid in fluid path 84 when the power to the electromagnet 86 is off. Once power is applied to the electromagnet 86 , the field generated by the electromagnet 86 cancels the field generated by the permanent magnet 84 and the MR fluid in fluid path 84 liquefies.
[0039] While MWD telemetry is sometime thought of as producing a single pulse, it actually produces two pulses. A first pulse propagates directly from the pulse generator up the mud column to the surface. Another pulse propagates downward and then reflects off of the bit. These two pulses can cause confusion at the surface. Because the use of an electroactive fluid provides excellent response times for a pulse generator, a feedback control could be included so that the two pulses constructively interfered with each other. For example, if the frequency of the generator is such that the travel time for the downward pulse corresponds to one wavelength of the frequency, then, upon reflection, that pulse will constructively interfere with the upward pulse and the combined pulse will have a larger amplitude. The combination of a feedback controller and an electroactive fluid could ensure that the two pulses constructively interfere during changes in the drilling environment.
[0040] The embodiments set forth herein are merely illustrative and do not limit the scope of the invention or the details therein. It will be appreciated that many other modifications and improvements to the disclosure herein may be made without departing from the scope of the invention or the inventive concepts herein disclosed. Because many varying and different embodiments may be made within the scope of the present inventive concept, including equivalent structures or materials hereafter thought of, and because many modifications may be made in the embodiments herein detailed in accordance with the descriptive requirements of the law, it is to be understood that the details herein are to be interpreted as illustrative and not in a limiting sense.
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A mud pulser controlled by a field applied to an electroactive fluid. The electroactive fluid is employed to act as a rapid-response brake to slow or interrupt the rotation of a mud motor or mud siren, thus creating pressure pulses in a circulating fluid. In certain embodiments, the electroactive fluid is used as a direct brake acting on a shaft rotating in a volume of electroactive fluid where the shaft is coupled to the mud motor or siren. The application of a field to the electroactive fluid impedes the rotation of the shaft, thus slowing the mud motor and creating a pressure pulse in the circulating fluid. In another embodiment, a Moineau pump circulating an electroactive fluid is coupled to the mud motor. The application of a field to the electroactive fluid slows the rotation of the pump, thus slowing the mud motor and creating a pressure pulse in the circulating fluid.
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FIELD OF THE INVENTION
This invention generally relates to methods for forming copper filled semiconductor features and more particularly to a method for producing a copper filled semiconductor feature by adding metal dopants including preferential segregation at copper grain boundaries to produce a copper filled semiconductor feature having low resistivity, increased stress and electromigration resistance, and thereby having an increased resistance to copper hillock formation in subsequent thermal processes to improve device reliability.
BACKGROUND OF THE INVENTION
Sub-micron multi-level metallization is one of the key technologies for ultra large scale integration (ULSI). The multilevel interconnects that lie at the heart of this technology require planarization of interconnect features formed in high aspect ratio openings, including contacts, vias, metal interconnect lines and other features. Reliable formation of these interconnect features is very important to the success of ULSI and to the continued effort to increase circuit density and quality on individual substrates and die.
Copper and copper alloys have become the metal of choice for filling sub-micron, high aspect ratio interconnect features on semiconductor substrates. Copper and its alloys have lower resistivity compared to other metals such as, for example, aluminum. These characteristics are critical for achieving higher current densities with increased device speed. Copper, however, has exhibited certain processing problems that must be overcome to achieve a mature copper metal interconnect semiconductor processing technology. For example, copper filled features have been found to have a tendency to form sharp protrusions, otherwise known as hillocks into overlying material layers, for example a nitride layer formed to contact the copper and while subjected to thermal processing temperatures. The cause of the formation of copper hillocks has been thought to be related to thermal mismatch stresses as well as low electromigration resistance and the low strength and ductility of copper which may contribute to the formation of hillocks in a subsequent plasma enhanced and thermal processes.
Other problems associated with copper filled semiconductor features include the fact that copper, for example, electro-chemically deposited copper tends to form relatively large grains in subsequent thermal processes which increases the roughness of surface morphology thereby compromising adhesion of overlying layers. In addition, the tendency of copper to form copper oxides at exposed surfaces at room temperature in the presence of oxygen containing atmospheres presents processing constraints to prevent formation of copper oxides at the surface and penetrating into the copper bulk via grain boundary diffusion. The formation of copper oxides at the copper surface within grain boundaries degrades the overall resistivity of the copper feature and contributes to other reliability problems including reducing adhesion of overlying material layers in contact with the copper feature.
One exemplary process for forming a series of interconnected multiple layers, for example, is a damascene process. Although there are several different manufacturing methods for manufacturing damascene structures, all such methods employ at least two photolithographic masking and etching steps, typically including a reactive ion etch (RIE). In the typical multilayer semiconductor manufacturing process, for example, a series insulating layers are deposited to include a series of interconnecting metallization structures such as vias and trench lines to electrically interconnect different device levels (e.g., vias) and to interconnect various areas within a device level (e.g., trench lines). In most devices, pluralities of vias are separated from one another along a process wafer and selectively interconnect conductive regions between layers of a multi-layer device. Trench lines typically serve to selectively interconnect conductive regions within a layer of a multilayer device. Vias and trench lines formed together, for example a trench line overlying one or more vias is referred to as a dual damascene.
For example, in a typical dual damascene process, an opening is formed by at least two conventional reactive ion etching (RIE) process to first form a via opening in one or more dielectric insulating layers followed by a similar process to form a trench line opening overlying and encompassing one or more via openings to form a dual damascene opening. Prior to filling the dual damascene opening with a metal, for example copper, a barrier layer is deposited to cover the sidewalls and bottom portion of the feature opening to prevent copper diffusion into the dielectric insulating layer and to improve the adhesion of an overlying copper layer filling the feature opening. For example, an electrochemical deposition (ECD) method also known as electroplating is used to deposit copper since it is a preferable method to achieve superior step coverage in sub-micron feature openings. The method generally includes depositing a metal seed layer, for example copper, over the barrier layer and then electroplating copper over the seed layer to fill a feature opening to form a dual damascene structure. A seed layer is required to carry electrical current for electroplating, the seed layer preferably being continuous over the wafer surface to provide for uniform electro-deposition of copper. The deposited copper layer is then planarized, for example by chemical mechanical polishing (CMP), to define a conductive interconnect feature. Since copper is easily oxidized when exposed to moisture or oxygen containing ambient, typically a protective layer is formed soon after the CMP process defining the copper filled feature.
To overcome the several processing challenges associated with copper technology, prior art processes have proposed depositing a copper alloy seed layer including various metal additives to form a copper alloy over the barrier layer to improve adhesion and electromigration resistance of the copper filled feature. For example, U.S. Pat. No. 6,181,012 proposes forming a copper alloy seed layer prior to forming an overlying copper layer to improve adhesion and electromigration resistance of the overlying copper layer. U.S. Pat. Nos. 5,243,222 and 5,130,274 teach the formation of copper alloys for diffusion barriers. However, none of these processes teach methods of copper feature formation that adequately address problems related to the bulk properties of the copper filled feature including the formation of copper hillocks penetrating into material layers overlying the copper feature. In addition, the prior art processes do not address bulk properties of the copper feature including bulk electromigration, grain boundary oxidation, and adhesion of material layers formed overlying the copper feature. Moreover, prior art processes significantly increase the resistivity of the copper feature making such processes unacceptable for 0.13 micron technologies and below.
These and other shortcomings demonstrate a need in the semiconductor device processing art to develop a method for forming copper filled features with more robust bulk properties including among other properties, resistance to bulk copper electromigration and stress migration, improved adhesion of material layers to the copper feature, and resistance to grain boundary oxidation.
It is therefore an object of the invention to provide a method for forming copper filled features with more robust bulk properties including among other properties, resistance to bulk copper electromigration and stress migration, improved adhesion of material layers to the copper feature, and resistance to grain boundary oxidation while overcoming other shortcomings and deficiencies of the prior art.
SUMMARY OF THE INVENTION
To achieve the foregoing and other objects, and in accordance with the purposes of the present invention, as embodied and broadly described herein, the present invention provides a copper filled semiconductor feature and method of forming the same having improved bulk properties.
In a first embodiment, the method includes providing a semiconductor process wafer having a process surface including an opening for forming a semiconductor feature; depositing at least one metal dopant containing layer over the opening to form a thermally diffusive relationship to a subsequently deposited copper layer; depositing said copper layer to substantially fill the opening; and, thermally treating the semiconductor process wafer for a time period sufficient to distribute at least a portion of the metal dopants to collect along at least a portion of the periphery of said copper layer including a portion of said copper layer grain boundaries.
These and other embodiments, aspects and features of the invention will be better understood from a detailed description of the preferred embodiments of the invention which are further described below in conjunction with the accompanying Figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A–1G are cross-sectional side views of a portion of a semiconductor device at stages of manufacture according to embodiments of the present invention.
FIG. 2A is a graphical representation of resistivity data including copper features formed according to embodiments of the present invention.
FIG. 2B is a graphical representation of stress failure data including copper features formed according to embodiments of the present invention.
FIG. 3 is a process flow diagram including several embodiments of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Although the method of the present invention is explained with reference to a dual damascene structure including copper filled vias and trench lines it will be understood that the method of the present invention is applicable to any copper filled feature formed in a dielectric insulating layer including, for example, bonding pads or single damascene structures where metal dopants are advantageously segregated at the periphery and grain boundaries of the copper feature to form more robust copper features while maintaining a low copper feature resistivity. For example, the method of the present invention advantageously suppresses bulk electromigration and bulk stress migration thereby suppressing copper hillock formation while improving copper feature surface morphology thereby improving adhesion of material layers to the copper bulk. In addition, a grain boundary oxidation resistance is advantageously realized. Unless otherwise indicated the term ‘copper’ refers to copper and its alloys.
In a first embodiment, at least one metal doping layer is deposited over a feature opening lined with a barrier layer to contact an adjacently deposited metal seed layer. Preferably, the metal seed layer is formed to allow thermal diffusion of the metal dopants into the bulk of the copper filled feature. In one embodiment, the at least one metal doping layer is optionally deposited prior to, or following deposition of a metal seed layer. Preferably, the metal seed layer is substantially pure copper. In another embodiment, the at least one metal doping layer is sandwiched between two metal seed layers. In another embodiment, the at least one metal doping layer is optionally deposited following deposition of a copper layer to fill the feature but prior to a chemical mechanical polishing (CMP) step to planarize the copper filled feature. Following deposition of copper to fill the feature and deposition of the at least one metal doping layer, a thermal annealing treatment is carried out to distribute at least a portion of the metal dopants in the metal doping layer to the copper feature periphery and to segregate at least a portion of the metal dopants to at least a portion of the copper layer grain boundaries.
In an exemplary implementation of an embodiment of the present invention, representative cross sectional side views of a dual damascene or portion thereof at stages in manufacture are shown in FIGS. 1A–1G . Referring to FIG. 1A is shown a typical dual damascene structure having a trench line portion 12 B, formed overlying a via portion 12 A. The via portion 12 A is typically formed first by a photolithographic and reactive ion etching (RIE) step through insulating dielectric layers 16 A and 16 B, also referred to as inter-metal dielectric (IMD) layers, formed of, for example, fluorinated silicate glass (FSG) or carbon doped silicon oxide (C-oxide). Etching stop layers 14 A and 14 B, for example formed of silicon nitride (e.g., SiN, Si 3 N 4 ), respectively separate underlying conductive area 11 and IMD layer 16 A and separate IMD layers 16 A and 16 B. A bottom anti-reflectance coating (BARC) layer 18 , also functioning as an etching mask, for example formed of silicon oxynitride (e.g., SiON) is formed over IMD layer 16 B. The via portion 12 A and trench line portion 12 B are formed by a conventional photolithographic and RIE etching process to first form via portion 12 A followed by a similar process to form trench portion 12 B overlying and encompassing via portion 12 A. It will be appreciated that the trench line portion may be formed overlying one or more vias to form a dual damascene structure.
Referring to FIG. 1B a barrier layer 20 , for example, including at least one layer of a refractory metal and refractory metal nitride is deposited to line the feature opening to prevent copper diffusion into the IMD layers 16 A and 16 B. For example, the barrier layer 20 may include a layer of tantalum (Ta), tantalum nitride (TaN), titanium (Ti), titanium nitride (TiN) or silicided titanium nitride (TiSiN). The barrier layer may be a multiple layer structure, for example including a bi-layer of Ta/TaN, Ti/TiN, and Ti/TiSiN. The barrier layer is formed by PVD and or CVD methods, including silicidation and nitridation processes known in the art. Preferably, the barrier layer 20 is formed having a thickness of about 50 Angstroms to about 150 Angstroms.
Referring to FIG. 1C , showing an expanded portion of the dual damascene, for clarity, following formation of the barrier layer 20 , in one embodiment, a metal doping layer 30 A is blanket deposited over the barrier layer 20 . In one embodiment, the metal doping layer is preferably deposited as an ultra thin layer having a dopant concentration of about 0.005 weight % to about 0.1 weight % with respect to the metal doping layer 30 A plus a subsequently deposited metal seed layer 32 A, for example, substantially pure copper. By ‘substantially pure’ is meant including trace impurities, for example less than about 0.001 weight percent. By ‘ultra thin layer’ is meant a thickness in the range of about 10 Angstroms to about 300 Angstroms. It will be appreciated that the thickness of the desired metal doping layer will vary depending on the doping level of the metal doping layer and the thickness of the copper seed layer. Preferably, the metal doping layer is formed such that a metal dopant concentration is about 0.005 weight % to about 0.1 weight % with respect to the total atomic weight of a metal doping layer, e.g., 30 A plus adjacently deposited copper seed layers, e.g., 32 A. For example the metal doping layer may include copper plus an appropriate level of metal dopants to make up the preferred weight percentages of the metal dopants. It has been found by experimentation that the preferred ranges enable the preferred metal dopants to diffuse to the copper feature interfaces (periphery) including copper feature grain boundaries in a subsequent thermal annealing step while maintaining a low electrical resistivity of the copper feature comparable with a substantially pure copper feature. Preferably, the metal doping layer includes one or more of the metal dopants Zr, Mg, Sn, Ag, Ti, Al, Pd, In, Au, Ca, Zn, and Cr.
These metal dopants are preferred for their ability to diffuse through copper bulk in a copper filled feature and segregate at the copper feature interfaces and grain boundaries according to a subsequent thermal annealing treatment in one embodiment of the present invention.
In another embodiment, the metal doping layer is formed substantially of metal dopants where the thickness of the metal doping layer and a seed layer are such that the metal doping layer is about 0.001 weight % to about 0.2 weight % with respect to a total weight (atomic) of the metal doping layer plus adjacently deposited seed layers. In this case, depending on the thickness of the seed layer, which may range from about 500 Angstroms to about 1200 Angstroms, and the type of metal dopant, the metal doping layer may be deposited, for example, having a thickness ranging from about 10 Angstroms to about 50 Angstroms. The metal doping layer is preferably deposited by a conventional PVD or CVD process. For example in a PVD sputter process for example, a collimated sputter process or ionized metal plasma process including one or several targets comprising one or several preferred metal dopants including copper, may be simultaneously sputtered to form a composite metal doping layer. More preferably, an atomic layer CVD (ALCVD) process is used to form the metal doping layer, for example, having a thickness of less than about 50 Angstroms thick to form a substantially conformal layer. The superior conformality of metal layers deposited by the ALCVD process contributes to optimal distribution of the metal dopants in a subsequent thermal annealing process.
In one embodiment, still referring to FIG. 1C , a metal seed layer 32 A, preferably copper, is blanket deposited over the metal doping layer 30 A by a PVD and/or CVD process as is known in the art to form a continuous layer over the wafer process surface to form an electro-chemical deposition surface. Referring to FIG. 1D , in another embodiment, a first seed layer 32 B is first deposited over the barrier layer 20 followed by deposition of a metal doping layer 30 B, followed by another deposition of a seed layer 32 C over the metal doping layer. In this embodiment, the metal doping layer includes a concentration of metal dopants of about 0.005 weight % to about 0.1 weight % with respect to the total weight (atomic) of the metal doping layer 30 B plus the two adjacent seed layers 32 B and 32 C. For example, if the the seed layers are substantially pure copper, then the preferred weight percents are about with respect to a total copper weight (atomic) . Referring to FIG. 1E , in another embodiment, a seed layer 32 D if first deposited over the barrier layer 20 , followed by deposition of a metal doping layer 30 D over the seed layer 32 D. In this embodiment, the metal doping layer 30 D preferably includes copper to improve adhesion of a subsequently deposited copper filling layer, for example by electro-chemical deposition (ECD)
Referring to FIG. 1F , showing again a larger portion of the dual damascene, following deposition of the metal doping layers and seed layers (not shown in FIG. 1F ), for example as shown in the embodiment in FIG. 1C , a copper filling layer 34 is deposited to fill the dual damascene semiconductor feature including the via portion and trench portion. The copper layer 34 may be deposited in several ways including physical vapor deposition (PVD) and chemical vapor deposition (CVD) methods but is preferably deposited according to electrochemical deposition (ECD) methods. ECD or electroplating is a preferable method to achieve superior step coverage of sub-micron etched features, for example having about a 0.13 micron line width or less. The method generally includes known electroplating methods including reverse pulse plating copper over a seed layer or metal doping layer, for example a doping layer including copper, to fill the feature opening.
Still referring to FIG. 1F , following deposition of the copper layer 34 , in one embodiment, a metal doping layer 30 E is optionally deposited overlying the electroplated copper layer 34 as the only metal dopant layer deposited or in addition to the metal doping layers included in the embodiments as shown in FIGS. 1C , 1 D, and 1 E.
Referring to FIG. 1G , showing again an expanded portion of the dual damascene structure, following copper layer 34 deposition and/or metal doping layer 30 E deposition, the process wafer is subjected to a thermal annealing treatment according to an aspect of the invention. Note that the metal doping layer and copper seed layers are not shown in FIG. 1G . According to the thermal treatment, the process wafer is subjected to temperatures preferably less than about 350° C., for example from about 200° C. to about 350° C., to thermally activate diffusion of the metal dopants included in the one or more metal doping layers to diffuse to the copper feature interfaces, e.g., sidewalls 36 A, and bottom portion of the feature, e.g., 36 B to segregate on the feature side of the barrier layer, to include segregating at the copper layer 34 grain boundaries e.g., 36 C. Preferably, the annealing treatment is carried out in a substantially oxidant free atmosphere, for example having a partial pressure of oxidants less than about 10 −3 Torr. The temperature of annealing is important since higher temperature annealing treatments will tend to form copper hillocks prior to adequate distribution of the metal dopants. It will be appreciated that the depicted grains are representative of grains formed in the copper layer 34 . It will further be appreciated that metal dopants may be present at the sidewalls the feature prior to the thermal annealing treatment, for example where a metal doping layer is deposited over the barrier layer 20 . It will be appreciated that a portion of the metal dopants diffuse both through the bulk of the copper and a portion along the grain boundaries. It will also be appreciated that the appropriate thermal treatment time will vary depending on the annealing temperature and the size of the copper feature including grain size. For example, an appropriate time for annealing the copper features may range from about 30 minutes to about 60 minutes.
The several advantages of the present invention include suppression of grain growth in the copper resulting in smoother copper film morphology, thereby improving adhesion characteristics of the copper feature including to overlying material layers. The suppressed growth of grains is believed to be due to metal dopant segregation at the grain boundaries. Another advantage of the present invention according to preferred metal dopant concentrations is maintaining a copper resistivity within about 10% percent of a substantially pure copper layer.
For example, referring to FIG. 2A is shown a graph showing the percent change in resistivity on the vertical axis of copper features relative to a substantially pure copper feature. The horizontal axis is representative of a decreasing weight percent metal dopant magnesium weight percent with respect to metal dopant layers prepared according to preferred embodiments including an annealing step to distribute the metal dopants into the bulk of the copper feature including the periphery and grain boundaries following copper filling deposition. The enclosed areas for samples A through E represent a range of measured resistivity values and Mg weight percentages for the particular sample. In contrast, Sample A includes a Cu(Mg) alloyed seed layer, for example a metal solid solution having about 0.5 weight % Mg, formed prior to deposition of the copper filling and prepared without an annealing process to distribute the Mg into the copper bulk (filling). Samples B through E are prepared according to preferred embodiments including a copper seed layer together with a metal doping formed to have weight percentages of Mg within preferred ranges. For example, about 0.001 weight % Mg for sample E, 0.01 weight % Mg for sample D, 0.05 weight % Mg for sample C, and about 0.1 weight % Mg for sample B.
It is seen in Samples B thru E that following the dopant diffusing annealing treatment according to the present invention, a feature resistivity according to preferred embodiments can be achieved that is within about 10% of a substantially pure copper feature (i.e., 0%). As a result, preparing copper features including a metal doping layer according to preferred embodiments allows design constraints for copper features, for example having a line width of about 0.13 microns or less, to be satisfactorily met. For example, it has been found that copper features having a resistivity greater than about 10 percent of the value of a substantially pure copper feature do not satisfactorily meet design constraints for 0.13 micron technologies and below.
Yet another advantage of the present invention is the increased strength of the copper features, thus increasing a resistance to electromigration and copper hillock formation due to electrical and thermally induced stresses. Referring to FIG. 2B is shown a graph of data obtained according to a stress test showing the failure probability according to a conventional Weibull analysis on the vertical axis versus a stressing time on the horizontal axis according to a conventional stress test. Data from area A 2 represents a failure probability according to a control sample including copper features prepared according to the prior art whereas area B 2 includes copper features prepared with a metal doping layer followed by an annealing process to distribute the metal dopants according to preferred embodiments of the present invention. It is seen that the stress time to failure for about 50 percent of samples prepared according to an embodiment of the present invention is greater by about an order of magnitude compared to samples prepared according to prior art processes.
Yet an additional advantage of the present invention is increased resistance to oxidation of the copper, particularly where oxidants penetrate into the copper bulk grain boundaries. Such oxidation processes degrade electrical performance and are essentially unable to be removed once formed. For example, if an oxidizing atmosphere is present, for example following a CMP process exposing the copper feature, an oxide layer of material including copper alloy oxides e.g., (Cu x M y O z ) where M is a metal dopant and x,y, and z, are variable stoichiometric proportions, are formed at the grain copper feature grain boundaries. As a result, formation of high resistivity copper oxides is avoided. As such, copper processing constraints, also known as process windows, may be relaxed, for example, by eliminating the need for, or increasing a process window for adding a protective layer over the exposed copper feature following a CMP process. For example, although not shown, following formation of the copper layer 34 and optional formation of the metal doping layer followed by an annealing process according to preferred embodiments, the excess copper of copper layer 34 above the feature level is removed according to a single or multi-step CMP process as is known in the art including removing the barrier layer 20 overlying the feature level.
Referring to FIG. 3 is a process flow diagram including several embodiments of the present invention. In process 301 , a semiconductor feature opening is provided lined with a barrier layer. In process 303 , at least one metal doping layer and at least one seed layer are deposited according to preferred embodiments. In process 305 , the bulk of the copper feature is deposited to fill the feature. In process 307 , an optional metal doping layer is deposited over the copper filling layer. In process 309 , a thermal annealing process according to preferred embodiments is carried out to distribute the metal dopants. In process 311 , a CMP process is carried out to complete formation of the copper filled feature.
The preferred embodiments, aspects, and features of the invention having been described, it will be apparent to those skilled in the art that numerous variations, modifications, and substitutions may be made without departing from the spirit of the invention as disclosed and further claimed below.
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A copper filled semiconductor feature and method of forming the same having improved bulk properties the method including providing a semiconductor process wafer having a process surface including an opening for forming a semiconductor feature; depositing at least one metal dopant containing layer over the opening to form a thermally diffusive relationship to a subsequently deposited copper layer; depositing said copper layer to substantially fill the opening; and, thermally treating the semiconductor process wafer for a time period sufficient to distribute at least a portion of the metal dopants to collect along at least a portion of the periphery of said copper layer including a portion of said copper layer grain boundaries.
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CROSS REFERENCE TO RELATED APPLICATION
This application is a 35 U.S.C. 371 National Phase Entry Application from PCT/JP2013/054615, filed Feb. 22, 2013, which claims the benefit of Japanese Patent Application No. 2012-037565 filed Feb. 23, 2012, the disclosures of which are incorporated herein in their entirety by reference.
TECHNICAL FIELD
The present invention relates to quinolyl pyrrolo pyrimidyl condensed-ring compounds having an inhibitory action against Epidermal Growth Factor Receptor (EGFR), and pharmaceutical compositions containing those as an active ingredient.
BACKGROUND ART
EGFR is a receptor type tyrosine kinase, exerts its physiological function in normal tissue when being bound to Epidermal Growth Factor (EGF) which is a ligand, and contributes to growth, apoptosis inhibition, etc., in epithelial tissues (Non-Patent Literature (NPL) 1).
In addition, EGFR is one of the oncogenes, and amplification of the EGFR gene and high expression or mutation of its protein are seen in various cancer types such as head and neck cancer, breast cancer, colorectal cancer, esophagus cancer, pancreatic cancer, lung cancer, ovarian cancer, renal cancer, bladder cancer, skin cancer, and brain tumor (Non-Patent Literature (NPL) 2). In Japan and western countries, approximately 170 to 375 in every 100,000 people perish due to cancer every year, and cancer ranks high as a cause of death (Non-Patent Literature (NPL) 3). Above all, the death toll due to lung cancer reaches approximately 1,400,000 per year worldwide, and since non-small cell lung cancer accounts for equal to or more than 80% of lung cancers, there has been a desire for development of effective therapy for that (Non-Patent Literature (NPL) 4).
In recent years, responsible genes for these cancers are being identified, and a mutation in the EGFR gene is also one of them and results in an active mutated EGFR protein. An active mutated EGFR protein is, for example, a deletion of amino acid at positions 746-750 (EGFR (d746-750)), a mutation of amino acid at position 858 from leucine to arginine (EGFR (L858R)), or the like. Such mutations are reported, for example, in 20-40% of non-small cell lung cancer cases in Japan, and in 10-15% of non-small cell lung cancer cases in western countries. Since non-small cell lung cancer having these mutations is highly susceptible against gefitinib (product name: Iressa®) and erlotinib (product name: Tarceva®) which are chemical agents (EGFR inhibitors) that inhibit the kinase activity of EGFR, these chemical agents are used as therapeutic agents in Japan and western countries. However, the cancer acquires resistance against gefitinib and erlotinib after 6 to 12 months from the beginning of use and therapeutic effect becomes weak. Therefore, this acquired resistance has been a serious problem for treating non-small cell lung cancer having a highly-susceptible mutated EGFR. It has been revealed that approximately 50% of the acquired resistance is due to emergence of a resistant mutated EGFR protein (EGFR (d746-750/T790M) or EGFR (T790M/L858R)) having a second mutation in the EGFR gene resulting in amino acid at position 790 to change from threonine to methionine. It has been an important task to develop a therapeutic agent that is effective against non-small cell lung cancer having this drug resistant mutated EGFR (Non-Patent Literature (NPL) 5).
On the other hand, skin abnormality and alimentary canal disorder are reported as common side effects of the EGFR inhibitors of gefitinib and erlotinib, which are clinically used as therapeutic agents at present, and of EGFR inhibitors such as BIBW2992 etc., which are under clinical trial. It is widely thought that these side effects are caused by the EGFR inhibitors inhibiting the activity of not only a mutated EGFR expressed in non-small cell lung cancer, but also the activity of the wild-type EGFR (EGFR (WT)) expressed in the skin or alimentary canal (Non-Patent Literature (NPL) 1). From a standpoint of side effect reduction, it is considered to be preferable to have a weak inhibitory activity against EGFR (WT) in normal tissues.
Thus, there is expectation of possibly suppressing growth of non-small cell lung cancer cells having a drug resistant mutated EGFR through administration of a chemical agent having weaker inhibitory activity against the wild-type EGFR when compared to inhibitory activity against the drug resistant mutated EGFR whose amino acid at position 790 has mutated to methionine, at an administration dose where the side effect to the skin or alimentary canal does not appear strongly. This is predicted to contribute to treating the cancer, and prolonging life and improving QOL of patients. In addition, if the chemical agent has weak inhibitory activity against the wild-type EGFR but has strong in inhibitory activity not only against drug resistant mutated EGFR but also against highly-susceptible mutated EGFRs such as the EGFR (d746-750) and the EGFR (L858R) etc., which are highly susceptible against gefitinib and erlotinib; there is expectation of possibly suppressing growth of non-small cell lung cancer cells expressing a highly-susceptible mutated EGFR or a drug resistant mutated EGFR at an administration dose where the side effect to the skin or alimentary canal does not appear strongly, or expectation of possibly reducing the frequency of drug resistant mutated EGFR that emerges, as acquired resistance, from non-small cell lung cancer cells expressing a highly-susceptible mutated EGFR. This is predicted to contribute to treating the cancer, and prolonging life and improving QOL of patients. Furthermore, since expressions of highly-susceptible mutated EGFR and drug resistant mutated EGFR can be used in the actual scene of therapy as indices for stratification to enable selection of patients, they contribute greatly from an ethical viewpoint.
As a compound having a structure analogous to a compound according to present invention, N-(3-(4-amino-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-5-yl)phenyl)benzamide derivative is known (Patent Literature (PTL) 1). Although Patent Literature 1 describes using the amide compound for treating diseases characterized by B-RAF kinase, the Literature does not disclose specific tests and results therefrom corroborating a kinase inhibiting activity, and such activity is not confirmed.
CITATION LIST
Patent Literature
PTL 1: International Publication No. WO2006/102079 pamphlet
Non-Patent Literature
NPL 1: Nature Rev. Cancer, vol. 6, pp 803-811 (2006)
NPL 2: J. Clin. Oncol., vol. 19, 32s-40s (2001)
NPL 3: Ministry of Internal Affairs and Communications Statistics Bureau homepage/statistical data/world statistics “World Statistics 2011” Chapter 14 People's Life and Social Security, 14-1 Death Rates by Causes Death
NPL 4: Lung Cancer, vol. 69, pp 1-12 (2010)
NPL 5: Nature Rev. Cancer, vol. 10, pp 760-774 (2010)
SUMMARY OF INVENTION
Technical Problem
As described above, EGFR inhibitors, although expected to be effective in cancer therapy, are currently not clinically effective enough.
Therefore, an object of the present invention is to provide a new compound that strongly inhibits EGFR, or a salt thereof. A further object of the present invention is to provide: a new compound that inhibits EGFR (d746-750), EGFR (L858R), EGFR (d746-750/T790M), and EGFR (T790M/L858R), but does not inhibit EGFR (WT); or a salt thereof.
Solution to Problem
The present inventors have conducted thorough research in order to achieve the above described object. As a result, they have found that a group of quinolyl pyrrolo pyrimidyl condensed-ring compounds of the present invention have excellent inhibitory activity against EGFR and have cancer-cell-growth inhibitory action, and are useful as medication for treating cancer, and thereby they have achieved the present invention.
Thus, the present invention provides the following items.
Item 1. A compound represented by the following Formula (I) or a salt thereof.
(In the formula, m is 1 or 2;
n is 1 or 2;
R 1 is a hydrogen atom or a C 1 -C 4 alkyl group; and
R 2 , R 3 , and R 4 are the same or different, and are each a hydrogen atom, a halogen atom, a C 1 -C 4 alkyl group, or a group represented by Formula (a):
—CH 2 —N(R 5 )(R 6 ) (a)
(in the formula, R 5 and R 6 are the same or different and each represents a hydrogen atom or a C 1 -C 4 alkyl group, or R 5 and R 6 may form a heterocycloalkyl group having a 4 to 6 membered-ring, together with the nitrogen atom bound thereto)).
Item 2. The compound or a salt thereof according to item 1, wherein
m is 1 or 2;
n is 1 or 2;
R 1 is a hydrogen atom or a C 1 -C 4 alkyl group; and
R 2 , R 3 , and R 4 are the same or different, and are each a hydrogen atom, a halogen atom, a C 1 -C 4 alkyl group, or a group represented by Formula (a):
—CH 2 —N(R 5 )(R 6 ) (a)
(in the formula, R 5 and R 6 are the same or different and each represents a C 1 -C 4 alkyl group).
Item 3. The compound or a salt thereof according to item 1 or 2, wherein
m is 1 or 2;
n is 1 or 2;
R 1 is a hydrogen atom or methyl group; and
R 2 , R 3 , and R 4 are the same or different, and are each a hydrogen atom, a chlorine atom, or a dimethylamino methyl group.
Item 4. The compound or a salt thereof according to any one of items 1 to 3, wherein m and n are (m,n)=(1,1), (1,2), or (2,1).
Item 5. The compound or a salt thereof according to any one of items 1 to 4, wherein the compound is selected from the following group of compounds.
(R)-N-(4-amino-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-8-yl)acrylamide (S)-N-(4-amino-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-8-yl)acrylamide N-(4-amino-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-8-yl)-N-methylacrylamide (E)-N-(4-amino-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-8-yl)-4-(dimethylamino)-2-butenamide (S,E)-N-(4-amino-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-8-yl)-3-chloroacrylamide (S,Z)—N-(4-amino-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-8-yl)-3-chloroacrylamide (S)-N-(4-amino-5-(quinolin-3-yl)-7,8,9,10-tetrahydro-6H-pyrimido[5′,4′:4,5]pyrrolo[1,2-a]azepin-8-yl)acrylamide (S)-N-(4-amino-5-(quinolin-3-yl)-7,8,9,10-tetrahydro-6H-pyrimido[5′,4′:4,5]pyrrolo[1,2-a]azepin-9-yl)acrylamide (R)-N-(4-amino-5-(quinolin-3-yl)-7,8,9,10-tetrahydro-6H-pyrimido[5′,4′:4,5]pyrrolo[1,2-a]azepin-9-yl)acrylamide
Item 6. An EGFR inhibitor comprising the compound or a salt thereof according to any one of items 1 to 5 as an active ingredient.
Item 7. A pharmaceutical composition comprising the compound or a salt thereof according to any one of items 1 to 5.
Item 8. An antitumor agent comprising the compound or a salt thereof according to any one of items 1 to 5 as an active ingredient.
Item 9. A method for treating or preventing cancer, the method comprising a step of administering, to a mammal, the compound or a salt thereof according to any one of items 1 to 5 at a dose effective for treating or preventing cancer.
Item 10. Use of the compound or a salt thereof according to any one of items 1 to 5 in the manufacture of an antitumor agent.
Item 11. The compound or a salt thereof according to any one of items 1 to 5 for use in the treatment or prevention of cancer.
The present invention also provides a method for producing synthetic intermediates of the compound of the present invention specified in the following items.
Item 12. A method for producing a compound represented by formula (VIII), or a salt thereof, the method comprising the steps of:
[I] causing an organoborane reagent to act on a compound represented by formula (VII), or a salt thereof
(in the formula, P 1 is a protecting group of a hydroxy group, n is 1 or 2, and m 1 is 0 or 1); and
[II] causing intramolecular cyclization to occur in a reaction product of the step [I] with usage of a palladium(0) catalyst and in the presence of an alkali metal hydroxide.
(In the formula, m is 1 or 2, and P 1 and n are as described above).
Item 13. A method for producing a compound represented by formula (XX) or a salt thereof,
(in the formula, R 1 is a hydrogen atom or a C 1 -C 4 alkyl group, P 2 is a protecting group of an amino group, m is 1 or 2, and n is 1 or 2)
the method comprising the steps of:
[I] causing an organoborane reagent to act on a compound represented by formula (XIX), or a salt thereof
(in the formula, R 1 , P 2 , and n are as described above, and m 1 is 0 or 1); and
[II] causing intramolecular cyclization to occur in a reaction product of the step [I] with usage of a palladium(0) catalyst and in the presence of an alkali metal hydroxide.
Advantageous Effects of Invention
According to the present invention, a new compound represented by Formula (I) described above or a salt thereof useful as an EGFR inhibitor is provided.
It is clear that the compound of the present invention or a salt thereof has excellent EGFR inhibition activity and a growth suppression effect against cancer cell lines. In addition, the compound or a salt thereof has an advantage of having small side effects since having excellent selectivity against EGFRs. Therefore, the compound or a salt thereof of the present invention is useful as an agent for treating and/or preventing cancer.
DESCRIPTION OF EMBODIMENTS
The compound of Formula (I) according to the present invention is a quinolyl pyrrolo pyrimidyl condensed-ring compound that has a quinoline structure and an α,β-unsaturated amide structure, and is thus a novel compound nowhere disclosed in any of the above-mentioned prior art documents, etc.
Specifically, the compound specifically disclosed in PTL 1 is an N-(3-(4-amino-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-5-yl)phenyl)benzamide derivative. The compound of the present invention is different from the compound disclosed in PTL 1 in that the compound of the present invention has a quinoline structure and an α,β-unsaturated amide structure.
In the present specification, the term “C 1 -C 4 alkyl” refers to a straight or branched alkyl group having 1 to 4 carbon atoms. Specific examples thereof include methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, sec-butyl, tert-butyl, and the like.
In this specification, examples of the “halogen” include chlorine, bromine, fluorine, and iodine.
In this specification, the term “4 to 6 membered heterocycloalkyl” refers to a 4 to 6 membered cycloalkyl group having 1 to 2 nitrogen atoms in the ring. Specific examples thereof include azetidinyl, pyrrolidinyl, piperidyl, imidazolidinyl, and the like.
m and n in Formula (I) are preferably (m,n)=(1,1), (1,2), or (2,1).
R 1 in Formula (I) is preferably hydrogen or methyl.
R 2 , R 3 , and R 4 in Formula (I) may be the same or different, and each preferably represents hydrogen, halogen, C 1 -C 4 alkyl, or a group represented by the above Formula (a). When at least one of R 2 , R 3 , and R 4 in Formula (I) is a group represented by Formula (a), each of R 5 and R 6 is preferably C 1 -C 4 alkyl, and both of R 5 and R 6 are more preferably methyl.
R 2 in Formula (I) is more preferably hydrogen.
R 3 in Formula (I) is more preferably hydrogen, chlorine, or dimethylaminomethyl.
R 4 in Formula (I) is more preferably hydrogen or chlorine.
In the present invention, the compound of Formula (I) wherein m is 1 or 2; n is 1 or 2; R 1 is hydrogen or methyl; R 2 , R 3 , and R 4 are the same or different and represent hydrogen, chlorine, or dimethylaminomethyl, or a salt thereof, is preferable.
When m is 1 and n is 1, the compound of Formula (I) wherein R 1 is hydrogen or methyl; R 2 is hydrogen; one of R 3 and R 4 is hydrogen, chlorine, or dimethylaminomethyl, and the other is hydrogen; or a salt thereof, is preferable.
When m=1 and n=2 or m=2 and n=1, the compound of Formula (I) wherein all of R 1 , R 2 , R 3 , and R 4 are hydrogen or a salt thereof is preferable.
Specific examples of preferable compounds of the present invention include the following:
(R)-N-(4-amino-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-8-yl)acrylamide; (S)-N-(4-amino-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-8-yl)acrylamide; N-(4-amino-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-8-yl)-N-methylacrylamide; (E)-N-(4-amino-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-8-yl)-4-(dimethylamino)-2-butenamide; (S,E)-N-(4-amino-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-8-yl)-3-chloroacrylamide; (S,Z)—N-(4-amino-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-8-yl)-3-chloroacrylamide; (S)-N-(4-amino-5-(quinolin-3-yl)-7,8,9,10-tetrahydro-6H-pyrimido[5′,4′:4,5]pyrrolo[1,2-a]azepin-8-yl)acrylamide; (S)-N-(4-amino-5-(quinolin-3-yl)-7,8,9,10-tetrahydro-6H-pyrimido[5′,4′:4,5]pyrrolo[1,2-a]azepin-9-yl)acrylamide; and (R)-N-(4-amino-5-(quinolin-3-yl)-7,8,9,10-tetrahydro-6H-pyrimido[5′,4′:4,5]pyrrolo[1,2-a]azepin-9-yl)acrylamide.
Compounds that have potent enzyme inhibitory activity against EGFR (T790M/L858R) are preferable, and compounds with an enzyme inhibitory activity of 2 nM or less are more preferable. Compounds that have potent enzyme inhibitory activity against EGFR (d746-750/T790M) are preferable, and compounds with an enzyme inhibitory activity of 2 nM or less are more preferable.
Next, the method for producing the compound according to the present invention will be explained:
Compound (I) of the present invention can be produced, for example, by the following production methods or the methods described in Examples. However, the method for producing Compound (I) of the present invention is not limited to these reaction examples.
Production Method 1
(wherein P 1 is a protecting group of a hydroxy group, L 1 and L 2 are leaving groups, m 1 is 0 to 1; and R 2 , R 3 , R 4 , m, and n are as defined above).
(Step a)
In this step, the compounds of Formulas (II) and (III) are used in the presence of a base to produce the compound of Formula (IV).
Examples of the leaving group represented by L 1 in the compound of Formula (II) include a bromine or iodine atom. The compound of Formula (II) may be a commercially available product, or can be produced by a known method. Examples of the protecting group of a hydroxy group represented by P 1 in Formula (III) include tert-butyldimethylsilyl, tert-butyldiphenylsilyl, triethylsilyl, and the like. Examples of leaving groups represented by L 2 include bromine, iodine, methanesulfonic acid ester, p-toluenesulfonic acid ester, and the like. The compound of Formula (III) may be a commercially available product, or can be produced according to a known method. The compound of Formula (III) can be used in an amount of 1 to 10 moles, and preferably 1 to 5 moles, per mole of the compound of Formula (II).
Examples of usable bases include inorganic bases such as sodium hydrogen carbonate, sodium carbonate, potassium carbonate, cesium carbonate, cesium hydroxide, sodium hydride, and potassium hydride; and organic amines such as trimethylamine, triethylamine, tripropylamine, diisopropylethylamine, methylmorpholine, pyridine, 4-(N,N-dimethylamino)pyridine, lutidine, and collidine. Such a base can be used in an amount of 1 to 100 moles, and preferably 1 to 10 moles, per mole of the compound of Formula (II).
Examples of usable solvents include N,N-dimethylformamide, N,N-dimethylacetamide, dimethyl sulfoxide, tetrahydrofuran, 1,4-dioxane, N-methylpyrrolidin-2-one, acetonitrile, and the like. Such solvents can be used singly, or as a mixture. The reaction time is 0.1 to 100 hours, and preferably 0.5 to 24 hours. The reaction temperature is 0° C. to the boiling temperature of the solvent, and preferably 0 to 100° C.
The thus-obtained compound of Formula (IV) can be subjected to the subsequent step after or without isolation or purification by known separation and purification means, such as concentration, vacuum concentration, crystallization, solvent extraction, reprecipitation, and chromatography.
(Step b)
In this step, the compound of Formula (IV) is reacted with ammonia or a salt thereof to produce the compound of Formula (V).
The amount of ammonia or a salt thereof used in this step is typically an equimolar to excessive molar amount per mole of the compound of Formula (IV).
Any reaction solvent that does not adversely affect the reaction can be used. Examples of usable reaction solvents include water, methanol, ethanol, isopropanol, tert-butyl alcohol, tetrahydrofuran, 1,2-dimethoxyethane, 1,4-dioxane, N,N-dimethylformamide, N-methylpyrrolidin-2-one, dimethyl sulfoxide, and mixed solvents thereof.
The reaction temperature is typically 0 to 200° C., and preferably room temperature to 150° C. The reaction time is typically 5 minutes to 7 days, and preferably 30 minutes to 24 hours.
The thus-obtained compound of Formula (V) can be subjected to the subsequent step after or without isolation and purification by known separation and purification means, such as concentration, vacuum concentration, crystallization, solvent extraction, reprecipitation, and chromatography.
(Step c)
In this step, the compound of Formula (V) is subjected to a coupling reaction with 3-quinolineboronic acid or 3-quinolineboronic acid ester to produce the compound of Formula (VI).
This step can be performed according to a generally known method (for example, Chemical Reviews, Vol. 95, p. 2457, 1995). For example, this step can be performed in the presence of a transition metal catalyst and a base in a solvent that does not adversely affect the reaction.
The amount of 3-quinolineboronic acid or 3-quinolineboronic acid ester used may be 1 to 10 moles, and preferably 1 to 3 moles, per mole of the compound of Formula (V).
Examples of transition metal catalysts include palladium catalysts (e.g., palladium acetate, palladium chloride, tetrakistriphenylphosphine palladium, 1,1′-bis(diphenylphosphino)ferrocene-palladium (II)dichloride, and tris(dibenzylideneacetone)dipalladium(0)), nickel catalysts (e.g., nickel chloride), and the like. If necessary, a ligand (e.g., triphenylphosphine, tri-tert-butylphosphine, or 2-dicyclohexylphosphino-2′,4′,6′-triisopropylbiphenyl) can be added, and a metal oxide (such as copper oxide or silver oxide) can be used as a cocatalyst. The amount of the transition metal catalyst used may vary depending on the type of catalyst. The transition metal catalyst is typically used in an amount of 0.0001 to 1 mole, and preferably 0.01 to 0.5 moles, per mole of the compound of Formula (V). The amount of the ligand used is typically 0.0001 to 4 moles, and preferably 0.01 to 2 moles, per mole of the compound of Formula (V). The amount of the cocatalyst used is typically 0.0001 to 4 moles, and preferably 0.01 to 2 moles, per mole of the compound of Formula (V).
Examples of usable bases include organic amines (e.g., trimethylamine, triethylamine, diisopropylethylamine, N-methylmorpholine, 1,8-diazabicyclo[5,4,0]undec-7-ene, pyridine, and N,N-dimethylaniline), alkali metal salts (e.g., sodium hydrogen carbonate, potassium hydrogen carbonate, sodium carbonate, potassium carbonate, cesium carbonate, sodium phosphate, potassium phosphate, sodium hydroxide, and potassium hydroxide), metal hydrides (e.g., potassium hydride and sodium hydride), alkali metal alkoxides (e.g., sodium methoxide, sodium ethoxide, sodium tert-butoxide, and potassium tert-butoxide), alkali metal disilazides (e.g., lithium disilazide, sodium disilazide, and potassium disilazide), and the like. Among them, alkali metal salts such as sodium carbonate, potassium carbonate, cesium carbonate, sodium phosphate, and potassium phosphate; alkali metal alkoxides such as sodium tert-butoxide and potassium tert-butoxide; and organic amines such as triethylamine and diisopropylethylamine are preferable. The amount of the base used is typically 0.1 to 10 moles, and preferably 1 to 5 moles, per mole of the compound of Formula (V).
Any solvent that does not adversely affect the reaction can be used. Examples of usable solvents include hydrocarbons (e.g., benzene, toluene, and xylene), halogenated hydrocarbons (e.g., chloroform and 1,2-dichloroethane), nitriles (e.g., acetonitrile), ethers (e.g., 1,2-dimethoxyethane, tetrahydrofuran, and 1,4-dioxane), alcohols (e.g., methanol and ethanol), aprotic polar solvents (e.g., N,N-dimethylformamide, dimethyl sulfoxide, and hexamethyl phosphoryl amide), water, and mixed solvents thereof. The reaction time is 0.1 to 100 hours, and preferably 0.5 to 24 hours. The reaction temperature is 0° C. to the boiling temperature of the solvent, and preferably 20 to 150° C.
The thus-obtained compound of Formula (VI) can be subjected to the subsequent step after or without isolation and purification by known separation and purification means, such as concentration, vacuum concentration, crystallization, solvent extraction, reprecipitation, and chromatography.
(Step d)
In this step, Compound (VI) is brominated with N-bromosuccinimide to produce Compound (VII).
The halogenation can be performed by the method disclosed in WO 2006/102079, or by a method similar thereto.
The amount of N-bromosuccinimide used in this step is 0.5 to 2.0 moles, and preferably 0.9 to 1.2 moles, per mole of the compound of Formula (VI).
Any reaction solvent that does not adversely affect the reaction can be used. For example, tetrahydrofuran, 1,4-dioxane, N,N-dimethylformamide, N-methylpyrrolidin-2-one, or a mixed solvent thereof can be preferably used.
The reaction temperature is typically −20 to 50° C., and preferably 0° C. to room temperature. The reaction time is typically 1 minute to 2 days, and preferably 5 minutes to 12 hours.
The thus-obtained compound of Formula (VII) can be subjected to the subsequent step after or without isolation or purification by known separation and purification means, such as concentration, vacuum concentration, crystallization, solvent extraction, reprecipitation, and chromatography.
(Step e)
In this step, an organic borane reagent is allowed to act on the compound of Formula (VII) to prepare an alkyl borane intermediate in the system, and the intermediate is converted to a compound of Formula (VIII) in the presence of a transition metal catalyst and a base.
This step can be performed according to a generally known method (for example, WO 2006/102079).
Examples of organic borane reagents include 9-BBN(9-borabicyclo[3.3.1]-nonane), 9-BBN(9-borabicyclo[3.3.1]-nonane)dimer, disiamylborane(bis(1,2-dimethylpropyl)borane), thexylborane(1,1,2-trimethylpropyl)borane), and the like. The organic borane reagent is preferably 9-BBN(9-borabicyclo[3.3.1]-nonane) or 9-BBN(9-borabicyclo[3.3.1]-nonane)dimer, and particularly preferably 9-BBN(9-borabicyclo[3.3.1]-nonane). The amount of the organic borane reagent used is not particularly limited insofar as an alkyl borane intermediate can be produced. The organic borane reagent can be used in an amount of 1 to 20 moles per mole of the compound of Formula (VII); the amount of the organic borane reagent is preferably 6 to 10 moles from the viewpoint of facilitating the progress of the reaction.
As a transition metal catalyst, for example, a bivalent palladium catalyst (e.g., palladium acetate, palladium chloride, and 1,1′-bis(diphenylphosphino)ferrocene-palladium (II)dichloride) can be used. If necessary, a ligand (e.g., triphenylphosphine and tri-tert-butylphosphine) can be used. The amount of the transition metal catalyst used may vary depending on the type of catalyst. The transition metal catalyst is typically used in an amount of 0.0001 to 1 mole, and preferably 0.01 to 0.5 moles, per mole of the compound of Formula (VII). The ligand is typically used in an amount of 0.0001 to 4 moles, and preferably 0.01 to 2 moles, per mole of the compound of Formula (VII).
Alternatively, for example, a zerovalent palladium catalyst can be used. Examples of zerovalent palladium catalysts include tetrakistriphenylphosphine palladium (0), tris(dibenzylideneacetone)dipalladium (0), palladium carbon (0), and the like. Tetrakistriphenylphosphine palladium (0) or tris(dibenzylideneacetone)dipalladium (0) is preferable, and tetrakistriphenylphosphine palladium (0) is particularly preferable. The amount of the zerovalent palladium catalyst used is not particularly limited insofar as the intramolecular cyclization reaction can proceed, and may vary depending on the type of catalyst. The zerovalent palladium catalyst can be used in an amount of 0.0001 to 1 mole, and preferably 0.01 to 0.5 moles, per mole of the compound of Formula (VII).
If necessary, a ligand may be added with a zerovalent palladium catalyst. Examples of such ligands include triphenylphosphine, 1,1′-bis(diphenylphosphino)ferrocene, tri-tert-butylphosphine, tricyclohexylphosphine, 2-dicyclohexylphosphino-2′,6′-dimethoxybiphenyl, 2-dicyclohexylphosphino-2′,4′,6′-triisopropylbiphenyl, 2-(di-tert-butylphosphino)biphenyl, 2-dicyclohexylphosphino-2′-(N,N-dimethylamino)biphenyl, 4,5′-bis(diphenylphosphino)-9,9′-dimethylxanthene, and the like. When tris(dibenzylideneacetone)dipalladium (0) is used as a zerovalent palladium catalyst, triphenylphosphine can be added as a ligand. The amount of the ligand used is not particularly limited insofar as the intramolecular cyclization reaction can proceed. The ligand can be used in an amount of 0.0001 to 4 moles, and preferably 0.01 to 2 moles, per mole of the compound of Formula (VII).
Examples of bases include inorganic bases such as sodium hydrogen carbonate, sodium carbonate, potassium carbonate, cesium carbonate, and alkali metal hydroxides. Alkali metal hydroxides are preferable. Examples of alkali metal hydroxides include lithium hydroxide, sodium hydroxide, potassium hydroxide, and cesium hydroxide. Lithium hydroxide, sodium hydroxide, potassium hydroxide, or cesium hydroxide is preferably used. Lithium hydroxide or sodium hydroxide is particularly preferable. The amount of the base used is not particularly limited insofar as the reaction proceeds. The base can be used in an amount of 1 to 100 moles, and preferably 2 to 20 moles, per mole of the compound of Formula (VII). Alkali metal hydroxide can be used in the form of an aqueous alkali metal hydroxide solution.
As the combination of an organic borane reagent, an alkali metal hydroxide, and a zerovalent palladium catalyst, a combination of a preferable organic borane reagent, a preferable alkali metal hydroxide, and a preferable zerovalent palladium catalyst is preferable. A combination of a particularly preferable organic borane reagent, a particularly preferable alkali metal hydroxide, and a particularly preferable zerovalent palladium catalyst is particularly preferable.
Any solvent that does not adversely affect the reaction can be used. Examples thereof include hydrocarbons (e.g., benzene, toluene, and xylene), ethers (e.g., 1,2-dimethoxyethane, tetrahydrofuran, and 1,4-dioxane), aprotic polar solvents (e.g., N,N-dimethylformamide, dimethyl sulfoxide, and hexamethyl phosphoryl amide), water, and mixtures thereof. 1,2-Dimethoxyethane or tetrahydrofuran is preferably used. Tetrahydrofuran is particularly preferable from the viewpoint of stability of the organic borane reagent and the generated alkylborane intermediate. The amount of the solvent used is not particularly limited insofar as the reaction proceeds. The solvent can be used in an amount that is 1 to 300 times, and preferably 10 to 96 times, the weight of the compound of Formula (VII).
The reaction time is not particularly limited insofar as the compound of Formula (VIII) can be obtained. The reaction time may be 0.1 to 100 hours, and preferably 0.5 to 24 hours.
The reaction temperature is not particularly limited insofar as the compound of Formula (VIII) can ultimately be obtained. The reaction temperature may be −20° C. to the boiling temperature of the solvent, and preferably 0 to 150° C. In the intramolecular cyclization reaction of the alkylborane intermediate using a zerovalent palladium catalyst and an alkali metal hydroxide aqueous solution, a low reaction temperature tends to cause side reactions, which results in a low yield. Therefore, the temperature is preferably 61° C. or higher.
The thus-obtained compound of Formula (VIII) can be subjected to the subsequent step after or without isolation and purification by known separation and purification means, such as concentration, vacuum concentration, crystallization, solvent extraction, reprecipitation, and chromatography.
In this step, generation of an alkylborane intermediate in the system can be confirmed. For example, LCMS spectra can be used as the confirmation method.
(Step f)
In this step, the protected hydroxy group of the compound of Formula (VIII) is deprotected to produce the compound of Formula (IX).
The deprotection can be performed by a known method, such as the method described in Protective Groups in Organic Synthesis, T. W. Greene, John Wiley & Sons (1981); or a method similar thereto.
When tert-butyldimethylsilyl is used as a protecting group, tetrabutyl ammonium fluoride is used as a deprotection reagent. The amount of the reagent used is preferably 1 to 10 moles per mole of the compound (VIII).
Any solvent that does not adversely affect the reaction can be used. Examples of usable solvents include ethers (e.g., 1,2-dimethoxyethane and tetrahydrofuran), aprotic polar solvents (e.g., N,N-dimethylformamide, dimethyl sulfoxide, and hexamethyl phosphoryl amide), and mixed solvents thereof. The reaction time is 0.1 to 100 hours, and preferably 0.5 to 24 hours. The reaction temperature is 0 to 80° C., and preferably 0 to 50° C.
The thus-obtained compound of Formula (IX) can be subjected to the subsequent step after or without isolation and purification by known separation and purification means, such as concentration, vacuum concentration, crystallization, solvent extraction, reprecipitation, and chromatography.
(Step g)
In this step, methanesulfonyl chloride is allowed to act on the compound of Formula (IX) to produce the compound of Formula (X).
The amount of methanesulfonyl chloride used may be 1 to 5 moles, and more preferably 1 to 2 moles, per mole of the compound of Formula (IX).
Examples of usable bases include organic amines such as trimethylamine, triethylamine, tripropylamine, diisopropylethylamine, N-methylmorpholine, pyridine, 4-(N,N-dimethylamino)pyridine, lutidine, and collidine. Such a base can be used in an amount of 1 to 10 moles, and preferably 1 to 5 moles, per mole of the compound of Formula (IX).
Any solvent that does not adversely affect the reaction can be used. Examples of usable solvents include hydrocarbons (e.g., benzene, toluene, and xylene), halogenated hydrocarbons (e.g., chloroform and 1,2-dichloroethane), nitriles (e.g., acetonitrile), ethers (e.g., 1,2-dimethoxyethane, tetrahydrofuran, and 1,4-dioxane), alcohols (e.g., methanol and ethanol), aprotic polar solvents (e.g., N,N-dimethylformamide, dimethyl sulfoxide, and hexamethylphosphoramide), and mixed solvents thereof. The reaction time is 0.1 to 24 hours, and preferably 0.1 to 12 hours. The reaction temperature is −20° C. to the boiling temperature of the solvent, and preferably 0° C. to room temperature.
The thus-obtained compound of Formula (X) can be subjected to the subsequent step after or without isolation or purification by known separation and purification means, such as concentration, vacuum concentration, crystallization, solvent extraction, reprecipitation, and chromatography.
(Step h)
In this step, sodium azide is allowed to act on the compound of Formula (X) to produce the compound of Formula (XI).
The sodium azide can be used in an amount of 1 to 10 moles, and preferably 1 to 5 moles, per mole of the compound of Formula (X).
Any solvent that does not adversely affect the reaction can be used. Examples of usable solvents include N,N-dimethylformamide, dimethyl sulfoxide, hexamethyl phosphoryl amide, and mixed solvents thereof. The reaction time is 0.1 to 24 hours, and preferably 0.5 to 12 hours. The reaction temperature is room temperature to the boiling temperature of the solvent, and preferably 50 to 100° C.
The thus-obtained compound of Formula (XI) can be subjected to the subsequent step after or without isolation or purification by known separation and purification means, such as concentration, vacuum concentration, crystallization, solvent extraction, reprecipitation, and chromatography.
(Step i)
In this step, the compound of Formula (XI) is reacted in the presence of triphenylphosphine in an aqueous solvent to produce the compound of Formula (XII).
The triphenylphosphine may be a commonly used reagent or a solid-supported reagent. The amount of triphenylphosphine used may be 1 to 10 moles, and preferably 1 to 5 moles, per mole of the compound of Formula (XI).
Any solvent that does not adversely affect the reaction can be used. Examples of usable solvents include tetrahydrofuran/water, 1,4-dioxane/water, and the like. The reaction time is 0.1 to 24 hours, and preferably 0.5 to 12 hours. The reaction temperature is room temperature to the boiling temperature of the solvent, and preferably 50° C. to the boiling temperature of the solvent.
The thus-obtained compound of Formula (XII) can be subjected to the subsequent step after or without isolation or purification by known separation and purification means, such as concentration, vacuum concentration, crystallization, solvent extraction, reprecipitation, and chromatography.
(Step j)
In this step, the compound of Formula (XII) is amidated with an α,β-unsaturated carboxylic acid or an α,β-unsaturated acid chloride or bromide to produce the compound of Formula (I-a) according to the present invention.
When a carboxylic acid is used as an amidation reagent, the carboxylic acid can be used in an amount of 0.5 to 10 moles, preferably 1 to 3 moles, per mole of the compound of Formula (XII), in the presence of a suitable condensing agent. The carboxylic acid may be a commercially available product, or can be produced according to a known method.
Any reaction solvent that does not adversely affect the reaction can be used. Examples of usable solvents include toluene, benzene, methylene chloride, chloroform, tetrahydrofuran, 1,4-dioxane, N,N-dimethylformamide, dimethylacetamide, N-methylpyrrolidin-2-one, dimethyl sulfoxide, and mixed solvents thereof. The reaction temperature is typically −78 to 200° C., and preferably 0 to 50° C. The reaction time is typically 5 minutes to 3 days, and preferably 5 minutes to 10 hours.
Examples of condensation agents include diphenylphosphoryl azide, N,N′-dicyclohexylcarbodiimide, benzotriazol-1-yloxy-trisdimethylaminophosphonium salts, 4-(4,6-dimethoxy-1,3,5-triazin-2-yl)-4-methylmorpholinium chloride, 1-ethyl-3-(3-dimethylaminopropyl)carbodiimide, a combination of 1-ethyl-3-(3-dimethylaminopropyl)carbodiimide and 1-hydroxybenzotriazole, 2-chloro-1,3-dimethylimidazolinium chloride, 0-(7-azabenzotriazo-1-yl)-N,N,N′,N′-tetramethylhexauronium hexafluorophosphate, and the like.
If necessary, a base can be optionally added for the reaction. Examples of usable bases include organic bases such as triethylamine, diisopropylethylamine, pyridine, lutidine, collidine, 4-(N,N-dimethylamino)pyridine, potassium tert-butyrate, sodium tert-butyrate, sodium methoxide, sodium ethoxide, lithium hexamethyldisilazide, sodium hexamethyldisilazide, potassium hexamethyldisilazide, and butyl lithium; and inorganic bases such as sodium hydrogen carbonate, sodium carbonate, potassium carbonate, cesium carbonate, sodium hydroxide, and sodium hydride. Such a base can be added in an amount of 1 to 100 moles, and preferably 1 to 10 moles, per mole of the compound of Formula (XII).
When an acid chloride or acid bromide is used as an amidation reagent, the acid halide is used in an amount of 0.5 to 5 moles, and preferably 0.9 to 1.1 moles, per mole of the compound of Formula (XII). The acid halide may be a commercially available product, or can be produced according to a known method.
Any reaction solvent that does not adversely affect the reaction can be used. Examples thereof include toluene, benzene, methylene chloride, chloroform, tetrahydrofuran, 1,4-dioxane, N,N-dimethylformamide, dimethylacetamide, N-methylpyrrolidin-2-one, acetonitrile, water, and mixed solvents thereof. The reaction temperature is typically −78 to 200° C., preferably 0 to 50° C. The reaction time is typically 5 minutes to 3 days, and preferably 5 minutes to 10 hours.
If necessary, a base can be added for the reaction. Examples of usable bases include organic bases such as triethylamine, diisopropylethylamine, pyridine, lutidine, collidine, 4-(N,N-dimethylamino)pyridine, potassium tert-butyrate, sodium tert-butyrate, sodium methoxide, sodium ethoxide, lithium hexamethyldisilazide, sodium hexamethyldisilazide, potassium hexamethyldisilazide, and butyl lithium; and inorganic bases such as sodium hydrogen carbonate, sodium carbonate, potassium carbonate, cesium carbonate, sodium hydroxide, and sodium hydride. Such a base can be added in an amount of 1 to 100 moles, and preferably 1 to 20 moles, per mole of the compound of Formula (XII).
The thus-obtained compound of Formula (I-a) can be isolated and purified by known separation and purification means, such as concentration, vacuum concentration, crystallization, solvent extraction, reprecipitation, and chromatography.
[Chem. 7]
Production Method 2
(wherein R 1 , R 2 , R 3 , R 4 , m, and n are as defined above).
(Step k)
In this step, an alkylamine is allowed to react on the compound of Formula (X) to produce the compound of Formula (XIV).
The amount of the alkylamine used is 2 moles to an excess molar amount per mole of the compound of Formula (X).
Any solvent that does not adversely affect the reaction can be used. Examples thereof include hydrocarbons (e.g., benzene, toluene, and xylene), halogenated hydrocarbons (e.g., chloroform and 1,2-dichloroethane), nitriles (e.g., acetonitrile), ethers (e.g., 1,2-dimethoxyethane, tetrahydrofuran, and 1,4-dioxane), aprotic polar solvents (e.g., N,N-dimethylformamide, dimethyl sulfoxide, and hexamethyl phosphoryl amide), and mixed solvents thereof. The reaction time is 0.1 to 100 hours, and preferably 1 to 24 hours. The reaction temperature is room temperature to the boiling temperature of the solvent, and preferably 50° C. to the boiling temperature of the solvent.
The thus-obtained compound of Formula (XIV) can be subjected to the subsequent step after or without isolation or purification by known separation and purification means, such as concentration, vacuum concentration, crystallization, solvent extraction, reprecipitation, and chromatography.
(Step l)
This step can be performed in the same manner as in step j.
Production Method 3
(wherein P 2 is a protecting group of an amino group, L 1 is a leaving group, m1 is 0 or 1; and R 1 , R 2 , R 3 , R 4 , m, and n are as defined above.)
(Step m)
In this step, the compounds of Formulas (II) and (XV) are subjected to a Mitsunobu reaction to produce the compound of Formula (XVI).
In the compound of Formula (II), the leaving group represented by L 1 may be, for example, a bromine or iodine atom. The compound of Formula (II) may be a commercially available product, or can be produced according to a known method. In Formula (XV), the protecting group of an amino group represented by P 2 may be, for example, tert-butoxycarbonyl or benzoyl. The compound of Formula (XV) may be a commercially available product, or can be produced according to a known method. The compound of Formula (XV) can be used in an amount of 1 to 10 moles, and preferably 1 to 5 moles, per mole of the compound of Formula (II).
The Mitsunobu reaction can be performed by a generally known method (for example, Synthesis, p. 1, 1981), or a method similar thereto.
Examples of azodicarboxylic acid esters include diethyl azodicarboxylate and diisopropyl azodicarboxylate. Such an azodicarboxylic acid ester can be used in an amount of 1 to 10 moles, and preferably 1 to 5 moles, per mole of the compound of Formula (II).
As the phosphine compound, triphenylphosphine, tributylphosphine, or the like can be used. The phosphine compound can be used in an amount of 1 to 10 moles, and preferably 1 to 5 moles, per mole of the compound of Formula (II).
As a solvent, tetrahydrofuran, 1,2-dimethoxyethane, 1,4-dioxane, toluene, N,N-dimethylformamide, N,N-dimethylacetamide, dimethyl sulfoxide, N-methylpyrrolidin-2-one, or the like can be used singly, or as a mixture thereof. The reaction time is 0.1 to 100 hours, and preferably 0.1 to 24 hours. The reaction temperature is 0° C. to the boiling temperature of the solvent, and preferably 0 to 100° C.
The thus-obtained compound of Formula (XVI) can be subjected to the subsequent step after or without isolation or purification by known separation and purification means, such as concentration, vacuum concentration, crystallization, solvent extraction, reprecipitation, and chromatography.
(Step n)
In this step, the compound of Formula (XVI) is reacted with ammonia or a salt thereof to produce the compound of Formula (XVII).
This step can be performed in the same manner as in step b.
The thus-obtained compound of Formula (XVII) can be subjected to the subsequent step after or without isolation or purification by known separation and purification means, such as concentration, vacuum concentration, crystallization, solvent extraction, reprecipitation, and chromatography.
(Step o)
In this step, the compound of Formula (XVII) is subjected to a coupling reaction with 3-quinolineboronic acid or a 3-quinolineboronic acid ester to produce the compound of Formula (XVIII).
This step can be performed in the same manner as in step c.
The thus-obtained compound of Formula (XVIII) can be subjected to the subsequent step after or without isolation or purification by known separation and purification means, such as concentration, vacuum concentration, crystallization, solvent extraction, reprecipitation, and chromatography.
(Step p)
In this step, Compound (XVIII) is brominated with N-bromosuccinimide to produce the compound of Formula (XIX).
This step can be performed in the same manner as in step d. The thus-obtained compound of Formula (XIX) can be subjected to the subsequent step after or without isolation or purification by known separation and purification means, such as concentration, vacuum concentration, crystallization, solvent extraction, reprecipitation, and chromatography.
(Step q)
In this step, after an organic borane reagent is allowed to act on the compound of Formula (XIX) and an alkylborane intermediate is produced in the system, the compound of Formula (XX) is produced in the presence of a transition metal catalyst and a base.
This step can be performed according to a generally known method (for example, WO2006/102079).
Examples of organic borane reagents include 9-BBN(9-borabicyclo[3.3.1]-nonane), 9-BBN (9-borabicyclo[3.3.1]-nonane)dimer, disiamylborane(bis(1,2-dimethylpropyl)borane), thexylborane((1,1,2-trimethylpropyl)borane), and the like. 9-BBN(9-borabicyclo[3.3.1]-nonane) or 9-BBN (9-borabicyclo[3.3.1]-nonane)dimer are preferably used. 9-BBN(9-borabicyclo[3.3.1]-nonane) is particularly preferable. The amount of the organic borane reagent used is not particularly limited, insofar as an alkylborane intermediate is produced. The organic borane reagent can be used in an amount of 1 to 20 moles per mole of the compound of Formula (XIX). In view of facilitating the progress of the reaction, the amount of the organic borane reagent is preferably 6 to 10 moles per mole of the compound of Formula (XIX).
Examples of transition metal catalysts include bivalent palladium catalysts (e.g., palladium acetate, palladium chloride, and 1,1′-bis(diphenylphosphino)ferrocene-palladium (II)dichloride). If necessary, a ligand (e.g., triphenylphosphine and tri-tert-butylphosphine) can be added. The amount of the transition metal catalyst used may vary depending on the type of catalyst. The transition metal catalyst is typically used in an amount of 0.0001 to 1 mole, and preferably 0.01 to 0.5 moles, per mole of the compound of Formula (XIX). The amount of the ligand used is typically 0.0001 to 4 moles, and preferably 0.01 to 2 moles, per mole of the compound of Formula (XIX).
As a transition metal catalyst, for example, a zerovalent palladium catalyst can also be used. Examples of usable zerovalent palladium catalysts include tetrakistriphenylphosphine palladium (0), tris(dibenzylideneacetone)dipalladium (0), and palladium carbon (0). Tetrakistriphenylphosphine palladium (0) or tris(dibenzylideneacetone)dipalladium (0) is preferably used. Tetrakistriphenylphosphine palladium (0) is particularly preferable. The amount of the zerovalent palladium catalyst used is not particularly limited insofar as the intramolecular cyclization reaction can proceed. The amount of the zerovalent palladium catalyst used may vary depending on the type of catalyst. The zerovalent palladium catalyst can be used in an amount of 0.0001 to 1 mole, and preferably 0.01 to 0.5 moles, per mole of the compound of Formula (XIX).
If necessary, a ligand can be further added with a zerovalent palladium catalyst. Examples of such ligands include triphenylphosphine, 1,1′-bis(diphenylphosphino)ferrocene, tri-tert-butylphosphine, tricyclohexylphosphine, 2-dicyclohexylphosphino-2′,6′-dimethoxybiphenyl, 2-dicyclohexylphosphino-2′,4′,6′-triisopropylbiphenyl, 2-(di-tert-butylphosphino)biphenyl, 2-dicyclohexylphosphino-2′-(N,N-dimethylamino)biphenyl, 4,5′-bis(diphenylphosphino)-9,9′-dimethylxanthene, and the like. When tris(dibenzylideneacetone)dipalladium (0) is used as a zerovalent palladium catalyst, triphenylphosphine can be added as a ligand. The amount of the ligand used is not particularly limited insofar as the intramolecular cyclization reaction can proceed. The ligand can be used in an amount of 0.0001 to 4 moles, and preferably 0.01 to 2 moles, per mole of the compound of Formula (XIX).
Examples of bases include inorganic bases such as sodium hydrogen carbonate, sodium carbonate, potassium carbonate, cesium carbonate, and alkali metal hydroxides. Alkali metal hydroxides are preferable. Examples of alkali metal hydroxides include lithium hydroxide, sodium hydroxide, potassium hydroxide, cesium hydroxide, and the like. Lithium hydroxide, sodium hydroxide, potassium hydroxide, or cesium hydroxide is preferably used. Lithium hydroxide or sodium hydroxide is particularly preferable. The amount of the base used is not particularly limited insofar as the reaction proceeds. The base can be used in an amount of 1 to 100 moles, and preferably 2 to 20 moles, per mole of the compound of Formula (XIX). The alkali metal hydroxide can be used in the form of an aqueous alkali metal hydroxide solution.
As the combination of an organic borane reagent, an alkali metal hydroxide, and a zerovalent palladium catalyst, a combination of a preferable organic borane reagent, a preferable alkali metal hydroxide, and a preferable zerovalent palladium catalyst is preferable. A combination of a particularly preferable organic borane reagent, a particularly preferable alkali metal hydroxide, and a particularly preferable zerovalent palladium catalyst is particularly preferable.
Any solvent that does not adversely affect the reaction can be used. Examples thereof include hydrocarbons (e.g., benzene, toluene, and xylene), ethers (e.g., 1,2-dimethoxyethane, tetrahydrofuran, and 1,4-dioxane), aprotic polar solvents (e.g., N,N-dimethylformamide, dimethyl sulfoxide, and hexamethyl phosphoryl amide), water, and mixtures thereof. 1,2-dimethoxyethane or tetrahydrofuran is preferably used. Tetrahydrofuran is particularly preferable from the viewpoint of stability of the organic borane reagent and the generated alkylborane intermediate. The amount of the solvent used is not particularly limited insofar as the reaction proceeds. The solvent can be used in an amount that is 1 to 300 times, and preferably 10 to 96 times, the weight of the compound of Formula (XIX).
The reaction time is not particularly limited insofar as the compound of Formula (XX) can be obtained. The reaction time may be 0.1 to 100 hours, and preferably 0.5 to 24 hours.
The reaction temperature is not particularly limited insofar as the compound of Formula (XX) can finally be obtained. The reaction temperature may be −20° C. to the boiling temperature of the solvent, and preferably 0 to 150° C. In the intramolecular cyclization reaction of the alkylborane intermediate using a zerovalent palladium catalyst and an alkali metal hydroxide aqueous solution, a low reaction temperature tends to cause side reactions, which results in a low yield. Therefore, the temperature is preferably 61° C. or higher.
The thus-obtained compound of Formula (XX) can be subjected to the subsequent step after or without isolation and purification by known separation and purification means, such as concentration, vacuum concentration, crystallization, solvent extraction, reprecipitation, and chromatography.
In this step, generation of an alkylborane intermediate in the system may be confirmed. For example, LCMS spectra can be used as the confirmation method.
(Step r)
In this step, the protected amino group of the compound of Formula (XX) is deprotected to produce the compound of Formula (XXI).
The deprotection can be performed by a known method, such as the method described in Protective Groups in Organic Synthesis, T. W. Greene, John Wiley & Sons (1981); or a method similar thereto.
When tert-butoxycarbonyl is used as a protecting group, hydrochloric acid, sulfuric acid, methanesulfonic acid, trifluoroacetic acid, or the like can be used as a deprotection reagent. The reagent is preferably used in an amount of 1 to 100 moles per mole of Compound (XX).
Any solvent that does not adversely affect the reaction can be used. Examples of usable solvents include water, methanol, ethanol, methylene chloride, chloroform, and mixed solvents thereof. The reaction time is 0.1 to 100 hours, and preferably 0.5 to 24 hours. The reaction temperature is 0° C. to the boiling point of the solvent.
The thus-obtained compound of Formula (XXI) can be subjected to the subsequent step after or without isolation and purification by known separation and purification means, such as concentration, vacuum concentration, crystallization, solvent extraction, reprecipitation, and chromatography.
(Step s)
This step can be performed in the same manner as in step j.
In the above production methods 1 to 3, for functional groups having an active proton, such as amino, imino, hydroxy, carboxy, carbonyl, and amide groups, and indole, protected reagents can be used or a protecting group is introduced into such a functional group according to a usual method, and then the protecting group can be removed in an appropriate step in each production method.
The “protecting group of an amino group or protecting group of an imino group” is not particularly limited, insofar as it has a protecting function. Examples of such protecting groups include aralkyl groups such as benzyl, p-methoxybenzyl, 3,4-dimethoxybenzyl, o-nitrobenzyl, p-nitrobenzyl, benzhydryl, trityl, and cumyl; lower alkanoyl groups such as formyl, acetyl, propionyl, butyryl, pivaloyl, trifluoroacetyl, and trichloroacetyl; benzoyl; arylalkanoyl groups such as phenylacetyl and phenoxyacetyl; lower alkoxycarbonyl groups such as methoxycarbonyl, ethoxycarbonyl, propyloxycarbonyl, and tert-butoxycarbonyl; aralkyloxycarbonyl groups such as p-nitrobenzyloxycarbonyl and phenethyloxycarbonyl; lower alkylsilyl groups such as trimethylsilyl and tert-butyldimethylsilyl; tetrahydropyranyl; trimethylsilylethoxymethyl; lower alkylsulfonyl groups such as methylsulfonyl, ethylsulfonyl, and tert-butylsulfonyl; lower alkylsulfinyl groups such as tert-butylsulfinyl; arylsulfonyl groups such as benzenesulfonyl and toluenesulfonyl; and imido groups such as phthalimido. In particular, trifluoroacetyl, acetyl, tert-butoxycarbonyl, benzyloxycarbonyl, trimethylsilylethoxymethyl, cumyl, and the like are preferable.
The “protecting group of a hydroxy group” is not particularly limited insofar as it has a protecting function. Examples of such protecting groups include lower alkyl groups such as methyl, ethyl, propyl, isopropyl, and tert-butyl; lower alkylsilyl groups such as trimethylsilyl and tert-butyldimethylsilyl; lower alkoxymethyl groups such as methoxymethyl and 2-methoxyethoxymethyl; tetrahydropyranyl; trimethylsilylethoxymethyl; aralkyl groups such as benzyl, p-methoxybenzyl, 2,3-dimethoxybenzyl, o-nitrobenzyl, p-nitrobenzyl, and trityl; and acyl groups such as formyl, acetyl, and trifluoroacetyl. In particular, methyl, methoxymethyl, tetrahydropyranyl, trimethylsilylethoxymethyl, tert-butyldimethylsilyl, and acetyl are preferable.
The “protecting group of a carboxy group” is not particularly limited insofar as it has a protecting function. Examples of such protecting groups include lower alkyl groups such as methyl, ethyl, propyl, isopropyl, and tert-butyl; halo-lower-alkyl groups such as 2,2,2-trichloroethyl; lower alkenyl groups such as allyl; trimethylsilylethoxymethyl; and aralkyl groups such as benzyl, p-methoxybenzyl, p-nitrobenzyl, benzhydryl, and trityl. In particular, methyl, ethyl, tert-butyl, allyl, benzyl, p-methoxybenzyl, trimethylsilylethoxymethyl, and the like are preferable.
The “protecting group of a carbonyl group” is not particularly limited insofar as it has a protecting function. Examples of such protecting groups include ethylene ketal, trimethylene ketal, dimethyl ketal, and like ketals and acetals.
The method for removing such a protecting group may vary depending on the type of protecting group, stability of the desired compound (I), etc. For example, the following methods can be used: solvolysis using an acid or a base according to the method disclosed in a publication (Protective Groups in Organic Synthesis, third edition, T. W. Green, John Wiley & Sons (1999)) or a method similar thereto, i.e., a method comprising reacting with 0.01 moles or a large excess of an acid, preferably trifluoroacetic acid, formic acid, or hydrochloric acid, or an equimolar to large excessive molar amount of a base, preferably potassium hydroxide or calcium hydroxide; chemical reduction using a metal hydride complex, etc.; or catalytic reduction using a palladium-carbon catalyst, Raney nickel catalyst, etc.
The compound of the present invention can be isolated and purified by usual isolation and purification means. Examples of such means include solvent extraction, recrystallization, preparative reversed-phase high-performance liquid chromatography, column chromatography, preparative thin-layer chromatography, and the like.
When the compound of the present invention has isomers such as optical isomers, stereoisomers, regioisomers, and rotational isomers, any of the isomers and mixtures thereof is included within the scope of the compound of the present invention. For example, when the compound has optical isomers, the optical isomer separated from a racemic mixture is also included within the scope of the compound of the present invention. Each of such isomers can be obtained as a single compound by known synthesis and separation means (e.g., concentration, solvent extraction, column chromatography, recrystallization, etc.).
In the present invention, the carbon atom bound to a substituent represented by —NR 1 —(C═O)—CR 2 ═C(R 3 )R 4 in Formula (I) is an asymmetric carbon; therefore, the compound includes isomers. As stated above, unless otherwise specified, the compound of the present invention includes all of the enantiomers and mixtures thereof. The compound of the present invention may be a mixture of R and S enantiomers. Such a mixture may be a mixture comprising 90% or more, 95% or more, or 99% or more of R enantiomer; or a mixture comprising 90% or more, 95% or more, or 99% or more of S enantiomer.
Methods for chiral resolution include, for example: diastereomer method of causing a chiral resolving agent to act on the compound of the present invention to form a salt, and resolving one of the enantiomers using a solubility difference etc., of the obtained salt; preferential crystallization method of adding one of the enantiomers to a supersaturated solution of a racemate as a seed for crystallization; and column chromatography such as HPLC using a chiral column. A chiral resolving agent that can be used in the diastereomer method can be appropriately selected from, for example, acid resolving agents such as tartaric acid, malic acid, lactic acid, mandelic acid, 10-camphorsulfonic acid, and derivatives thereof; and basic resolving agents such as brucine, strychnine, quinine, and like alkaloid compounds, amino acid derivatives, cinchonidine, and α-methylbenzylamine. In addition, one of the enantiomers of the compound of the present invention alone can be obtained not only by obtaining the compound of the present invention as a mixture of each of the enantiomers and then conducting the above described methods of chiral resolution, but also by obtaining, through chiral resolution by the above described methods etc., and using one enantiomer of the compound of the present invention as a synthetic raw material. Furthermore, methods for obtaining one of the enantiomers of the compound of the present invention or its raw material compound include a method of preferentially obtaining one of the enantiomers by adjusting reaction conditions for a catalyst or the like in a reaction step of generating asymmetric carbon.
The compound or a salt thereof of the present invention may be in the form of crystals. Single crystals and polymorphic mixtures are included within the scope of the compound or a salt thereof of the present invention. Such crystals can be produced by crystallization according to a crystallization method known per se in the art. The compound or a salt thereof of the present invention may be a solvate (e.g., a hydrate) or a non-solvate. Any of such forms are included within the scope of the compound or a salt thereof of the present invention. Compounds labeled with an isotope (e.g., 3H, 14C, 35S, and 125I) are also included within the scope of the compound or a salt thereof of the present invention.
The salt of the compound of the present invention or of the intermediate thereof refers to a common salt used in the field of organic chemistry. Examples of such salts include base addition salts to carboxy when the compound has carboxy, and acid addition salts to an amino or basic heterocyclic group when the compound has an amino or basic heterocyclic group.
Examples of base addition salts include alkali metal salts such as sodium salts and potassium salts; alkaline earth metal salts such as calcium salts and magnesium salts; ammonium salts; and organic amine salts such as trimethylamine salts, triethylamine salts, dicyclohexylamine salts, ethanolamine salts, diethanolamine salts, triethanolamine salts, procaine salts, and N,N′-dibenzylethylenediamine salts.
Examples of acid addition salts include inorganic acid salts such as hydrochlorides, sulfates, nitrates, phosphates, and perchlorates; organic acid salts such as acetates, formates, maleates, fumarates, tartrates, citrates, ascorbates, and trifluoroacetates; and sulfonates such as methanesulfonates, isethionates, benzenesulfonates, and p-toluenesulfonates.
The compound or a salt thereof of the present invention has excellent EGFR inhibitory activity and is useful as an antitumor agent. Further, the compound or a salt thereof of the present invention has excellent selectivity toward EGFR, and advantageously fewer side effects caused by other kinases. Although the target cancer is not particularly limited, examples thereof are head and neck cancer, esophagus cancer, gastric cancer, colon cancer, rectum cancer, liver cancer, gallbladder cancer, cholangiocarcinoma, biliary tract cancer, pancreatic cancer, lung cancer, breast cancer, ovarian cancer, cervical cancer, endometrial cancer, renal cancer, bladder cancer, prostate cancer, testicular tumor, osteosarcoma, soft-tissue sarcoma, blood cancer, multiple myeloma, skin cancer, brain tumor, and mesothelioma. Preferably, the target cancer is head and neck cancer, gastric cancer, colon cancer, rectum cancer, liver cancer, pancreatic cancer, lung cancer, breast cancer, ovarian cancer, renal cancer, or prostate cancer. Lung cancer is particularly preferable.
When the compound or a salt thereof of the present invention is used as a pharmaceutical preparation, a pharmaceutical carrier can be added, if required, thereby forming a suitable dosage form according to prevention and treatment purposes. Examples of the dosage form include oral preparations, injections, suppositories, ointments, patches, and the like. Of these, oral preparations are preferable. Such dosage forms can be formed by methods conventionally known to persons skilled in the art.
As the pharmaceutical carrier, various conventional organic or inorganic carrier materials used as preparation materials may be blended as an excipient, binder, disintegrant, lubricant, or colorant in solid preparations; or as a solvent, solubilizing agent, suspending agent, isotonizing agent, buffer, or soothing agent in liquid preparations. Moreover, pharmaceutical preparation additives, such as antiseptics, antioxidants, colorants, sweeteners, and stabilizers, may also be used, if required.
Oral solid preparations are prepared as follows. After an excipient is added optionally with a binder, disintegrant, lubricant, colorant, taste-masking or flavoring agent, etc., to the compound of the present invention, the resulting mixture is formulated into tablets, coated tablets, granules, powders, capsules, or the like by ordinary methods.
Examples of excipients include lactose, sucrose, D -mannitol, glucose, starch, calcium carbonate, kaolin, microcrystalline cellulose, and silicic acid anhydride. Examples of binders include water, ethanol, 1-propanol, 2-propanol, simple syrup, liquid glucose, liquid α-starch, liquid gelatin, D -mannitol, carboxymethyl cellulose, hydroxypropyl cellulose, hydroxypropyl starch, methyl cellulose, ethyl cellulose, shellac, calcium phosphate, polyvinylpyrrolidone, and the like. Examples of disintegrators include dry starch, sodium alginate, powdered agar, sodium hydrogen carbonate, calcium carbonate, sodium lauryl sulfate, stearic acid monoglyceride, lactose, and the like. Examples of lubricants include purified talc, stearic acid salt sodium, magnesium stearate, borax, polyethylene glycol, and the like. Examples of colorants include titanium oxide, iron oxide, and the like. Examples of taste-masking or flavoring agents include sucrose, bitter orange peel, citric acid, tartaric acid, and the like.
When a liquid preparation for oral administration is prepared, a taste-masking agent, a buffer, a stabilizer, a flavoring agent, and the like may be added to the compound of the present invention; and the resulting mixture may be formulated into an oral liquid preparation, syrup, elixir, etc., according to an ordinary method.
In this case, the same taste-masking or flavoring agent as those mentioned above may be used. An example of the buffer is sodium citrate, and examples of the stabilizer include tragacanth, gum arabic, and gelatin. As necessary, these preparations for oral administration may be coated according to methods known in the art with an enteric coating or other coating for the purpose of, for example, persistence of effects. Examples of such coating agents include hydroxypropyl methylcellulose, ethyl cellulose, hydroxymethyl cellulose, hydroxypropyl cellulose, polyoxyethylene glycol, and Tween 80®.
When an injection agent is prepared, a pH regulator, a buffer, a stabilizer, an isotonizing agent, a local anesthetic, and the like, may be added to the compound of the present invention; and the mixture may be formulated into a subcutaneous, intramuscular, or intravenous injection according to an ordinary method.
Examples of the pH adjuster and the buffer used herein include sodium citrate, sodium acetate, and sodium phosphate. Examples of the stabilizer include sodium pyrosulfite, EDTA, thioglycolic acid, and thiolactic acid. Examples of the local anesthetic include procaine hydrochloride and lidocaine hydrochloride. Examples of the tonicity agent include sodium chloride, dextrose, D -mannitol, and glycerol.
When a suppository is prepared, pharmaceutically acceptable carriers known in the art, such as polyethylene glycol, lanolin, cacao butter, and fatty acid triglyceride; and as necessary, surfactants such as Tween 80 ®, may be added to the compound of the present invention, and the resulting mixture may be formulated into a suppository according to an ordinary method.
When an ointment is prepared, a commonly used base, stabilizer, wetting agent, preservative, and the like, may be blended into the compound of the present invention, as necessary; and the obtained mixture may be mixed and formulated into an ointment according to an ordinary method.
Examples of the base include liquid paraffin, white petrolatum, white beeswax, octyl dodecyl alcohol, and paraffin.
Examples of the preservative include methyl paraoxybenzoate, ethyl paraoxybenzoate, and propyl paraoxybenzoate.
When a patch is prepared, the above-described ointment, cream, gel, paste, or the like, may be applied to an ordinary substrate according to an ordinary method.
As the substrate, woven fabrics or non-woven fabrics comprising cotton, staple fibers, or chemical fibers; and films or foam sheets of soft vinyl chloride, polyethylene, polyurethane, etc., are suitable.
The amount of the compound of the present invention to be incorporated in each of such dosage unit forms depends on the condition of the patient to whom the compound is administered, the dosage form thereof, etc. In general, in the case of an oral agent, the amount of the compound is 0.05 to 1000 mg per dosage unit form. In the case of an injection, the amount of the compound is 0.01 to 500 mg per dosage unit form; and in the case of a suppository, the amount of the compound is 1 to 1000 mg per dosage unit form.
The daily dose of the medicine in such a dosage form depends on the condition, body weight, age, gender, etc., of the patient, and cannot be generalized. For example, the daily dose for an adult (body weight: 50 kg) may be generally 0.05 to 5,000 mg, and preferably 0.1 to 1,000 mg; and is preferably administered in one dose, or in two to three divided doses, per day.
Examples of mammals to which the compound of the present invention is administered include humans, monkeys, mice, rats, rabbits, dogs, cats, cows, horses, pigs, and sheep.
EXAMPLES
The present invention is explained in detail below with reference to Examples; however, the scope of the present invention is not limited to these Examples.
In the Examples, commercially available reagents were used, unless otherwise specified. Purif-Pack® SI, produced by Moritex Corp. (produced by Shoko Scientific Co., Ltd.); KP-Sil® Silica prepacked column, produced by Biotage; or HP-Sil® Silica prepacked column, produced by Biotage was used as the silica gel column chromatography. Purif-Pack® NH, produced by Moritex Corp (produced by Shoko Scientific Co., Ltd.); or KP-NH® prepacked column, produced by Biotage was used as the basic silica gel column chromatography. Kieselgel TM 60F 254, Art. 5744 produced by Merck, or NH 2 Silica Gel 60F254 Plate, produced by Wako, was used as the preparative thin-layer chromatography. NMR spectrum was measured by using AL400 (400 MHz; produced by JEOL), Mercury 400 (400 MHz; produced by Agilent Technologies, Inc.) spectrometer, or Inova 400 (400 MHz; produced by Agilent Technologies, Inc.) model spectrometer equipped with an OMNMR probe (produced by Protasis). When its deuterated solvent contains tetramethylsilane, the tetramethylsilane was used as the internal reference; and when tetramethylsilane is not contained, an NMR solvent was used as the reference. All of the delta values are shown by ppm. The microwave reaction was performed using Discover S-class, produced by CEM Corporation.
The LCMS spectrum was measured using an Acquity SQD (quadrupole), produced by Waters Corporation, under the following conditions.
Column: YMC-Triart C18, 2.0×50 mm, 1.9 μm (produced by YMC)
MS detection: ESI positive
UV detection: 254 and 210 nm
Column flow rate: 0.5 mL/min
Mobile phase: Water/acetonitrile (0.1% formic acid)
Injection volume: 1 μL
TABLE 1
Gradient
Time (min)
Water
Acetonitrile
0
95
5
0.1
95
5
2.1
5
95
3.0
STOP.
Reversed-phase HPLC purification was performed using a preparative separation system available from Waters Corporation.
Column: Connected YMC-Actus Triart C18, 20×50 mm, 5 μm (produced by YMC) and YMC-Actus Triart C18, 20×10 mm, 5 μm (produced by YMC).
UV detection: 254 nm
MS detection: ESI positive
Column flow rate: 25 mL/min
Mobile phase: Water/acetonitrile (0.1% formic acid)
Injection volume: 0.1 to 0.5 mL
Each symbol stands for the following.
s: Singlet
d: Doublet
t: Triplet
dd: Double Doublet
m: Multiplet
brs: Broad Singlet
DMSO-d 6 : Deuterated dimethyl sulfoxide
CDCl 3 : Deuterated chloroform
CD 3 OD: Deuterated methanol
THF: Tetrahydrofuran
DMF: N,N-dimethylformamide
DME: 1,2-Dimethoxyethane
HATU: O-(7-azabenzotriazol-1-yl)-N,N,N′,N′-tetramethyluronium hexafluorophosphate
Example 1
(R)-N-(4-amino-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-8-yl)acrylamide (Compound I-1) and (S)-N-(4-amino-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-8-yl)acrylamide (Compound I-2)
Step 1
Synthesis of 4-chloro-5-iodo-7H-pyrrolo[2,3-d]pyrimidine
N-Iodosuccinimide (11.6 g) was added to a solution of 4-chloro-7H-pyrrolo[2,3-d]pyrimidine (7.52 g) in DMF (49 ml) at room temperature. The mixture was stirred at the same temperature for 1 hour, and water (150 ml) was added to the reaction mixture. The resulting precipitate was collected by filtration, washed with water, and dried to obtain the title compound as a light-yellow solid (13.57 g).
ESI-MS m/z 280, 282 (MH + ).
Step 2
Synthesis of 1-bromo-2-(tert-butyldimethylsilyloxy)-3-butene
Imidazole (2.25 g) and tert-butyldimethylsilylchloride (4.75 g) were added to a solution of 1-bromo-3-buten-2-ol (4.5 g) in DMF (30 ml) at room temperature. The mixture was stirred at the same temperature for 16 hours, and water was added thereto, followed by extraction with hexane. The organic layer was washed with water, and dried over anhydrous sodium sulfate. The solvent was distilled off under reduced pressure to obtain the title compound as a light-yellow, oily substance (7.0 g).
Step 3
Synthesis of 7-(2-(tert-butyldimethylsilyloxy)-3-butenyl)-4-chloro-5-iodo-7H-pyrrolo[2,3-d]pyrimidine
Potassium carbonate (2.2 g) was added to a solution of 4-chloro-5-iodo-7H-pyrrolo[2,3-d]pyrimidine (3.7 g) obtained in Step 1 and 1-bromo-2-(tert-butyldimethylsilyloxy)-3-butene (3.5 g) obtained in Step 2 in DMF (26 ml) at room temperature, and the mixture was stirred at 80° C. for 5 hours. After cooling the reaction mixture, water and ethyl acetate were added thereto, and the generated insoluble matter was filtered off. The organic layer was separated, washed with water and a saturated sodium chloride solution, and dried over anhydrous sodium sulfate. The solvent was then distilled off under reduced pressure. The resulting residue was purified by silica gel column chromatography (developing solvent: hexane/ethyl acetate) to obtain the title compound as a light-yellow solid (2.25 g).
ESI-MS m/z 464, 466 (MH + ).
Step 4
Synthesis of 7-(2-(tert-butyldimethylsilyloxy)-3-butenyl)-5-iodo-7H-pyrrolo[2,3-d]pyrimidin-4-amine
25% aqueous ammonia (9 ml) was added to a solution of 7-(2-(tert-butyldimethylsilyloxy)-3-butenyl)-4-chloro-5-iodo-7H-pyrrolo[2,3-d]pyrimidine (1.12 g) obtained in Step 3 in THF (7 ml). The mixture was stirred at 120° C. for 5 hours using a microwave reactor. The reaction mixture was cooled, and then diluted with water. The resulting precipitate was collected by filtration, washed with water, and then dried to obtain the title compound as a white solid (1.06 g).
ESI-MS m/z 445 (MH + ).
Step 5
Synthesis of 7-(2-(tert-butyldimethylsilyloxy)-3-butenyl)-5-(quinolin-3-yl)-7H-pyrrolo[2,3-d]pyrimidin-4-amine
A mixture of 7-(2-(tert-butyldimethylsilyloxy)-3-butenyl)-5-iodo-7H-pyrrolo[2,3-d]pyrimidin-4-amine (3.62 g) obtained in Step 4,3-quinolineboronic acid (1.47 g), sodium carbonate (1.72 g), 2-dicyclohexylphosphino-2′,4′,6′-triisopropylbiphenyl (154 mg), tris(dibenzylideneacetone)dipalladium (0) (148 mg), DME (40 ml), and water (16 ml) was stirred under a nitrogen atmosphere at 100° C. for 3 hours. After cooling, the reaction mixture was poured into water, followed by extraction with ethyl acetate. The organic layer was dried over anhydrous sodium sulfate, and the solvent was then distilled off under reduced pressure. The resulting residue was purified by silica gel column chromatography (developing solvent: hexane/ethyl acetate) to obtain the title compound as a light-yellow solid (2.13 g). ESI-MS m/z 446 (MH + ).
Step 6
Synthesis of 6-bromo-7-(2-(tert-butyldimethylsilyloxy)-3-butenyl)-5-(quinolin-3-yl)-7H-pyrrolo[2,3-d]pyrimidin-4-amine
N-Bromosuccinimide (894 mg) was added to a solution of 7-(2-(tert-butyldimethylsilyloxy)-3-butenyl)-5-(quinolin-3-yl)-7H-pyrrolo[2,3-d]pyrimidin-4-amine (2.13 g) obtained in Step 5 in DMF (25 ml) at room temperature. After stirring at the same temperature for 30 minutes, the mixture was poured into a saturated aqueous sodium bicarbonate solution, followed by extraction with ethyl acetate. The organic layer was washed with water and a saturated sodium chloride solution, and dried over anhydrous sodium sulfate. The solvent was then distilled off under reduced pressure. The resulting residue was purified by silica gel column chromatography (developing solvent: hexane/ethyl acetate) to obtain the title compound as a yellow solid (2.26 g).
ESI-MS m/z 524, 526 (MH + ).
Step 7
Synthesis of 8-(tert-butyldimethylsilyloxy)-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-4-amine
A solution of 0.5 M 9-borabicyclo[3.3.1]nonane in THF (50 ml) was added to a solution of 6-bromo-7-(2-(tert-butyldimethylsilyloxy)-3-butenyl)-5-(quinolin-3-yl)-7H-pyrrolo[2,3-d]pyrimidin-4-amine (2.26 g) obtained in Step 6 in THF (30 ml) under ice-cooling. The mixture was stirred at room temperature for 4 hours. After slowly adding a 3 N aqueous sodium hydroxide solution (19.5 ml) to the reaction mixture at room temperature, a [1,1′-bis(diphenylphosphino)ferrocene]dichloropalladium (II) complex with dichloromethane (676 mg) was added to the reaction mixture. The mixture was stirred under a nitrogen atmosphere at 70° C. for 4 hours. After cooling, the reaction mixture was poured into water, followed by extraction with ethyl acetate. The organic layer was dried over anhydrous sodium sulfate, and the solvent was distilled off under reduced pressure. The resulting residue was purified by silica gel column chromatography (developing solvent: hexane/ethyl acetate) to obtain the title compound as a yellow, oily substance (778 mg).
ESI-MS m/z 446 (MH + ).
Step 8
Synthesis of 4-amino-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-8-ol
A solution of 1 M tetrabutylammonium fluoride in THF (2.09 ml) was added to a solution of 8-(tert-butyldimethylsilyloxy)-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-4-amine (778 mg) obtained in Step 7 in THF (20 ml) at room temperature. The mixture was stirred at the same temperature for 1 hour, and the solvent was distilled off under reduced pressure. The resulting residue was treated with a saturated aqueous ammonium chloride solution, followed by extraction with ethyl acetate. The organic layer was dried over anhydrous sodium sulfate, and the solvent was then distilled off under reduced pressure. The resulting residue was purified by silica gel column chromatography (developing solvent: chloroform/methanol) to obtain the title compound as a light-yellow solid (580 mg).
ESI-MS m/z 332 (MH + ).
Step 9
Synthesis of 4-amino-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-8-yl methanesulfonate
Triethylamine (0.157 ml) and methanesulfonyl chloride (0.074 ml) were added to a solution of 4-amino-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-8-ol (288 mg) obtained in Step 8 in THF (5 ml) under ice-cooling. After stirring at the same temperature for 15 minutes, the mixture was poured into a saturated aqueous sodium bicarbonate solution, followed by extraction with ethyl acetate. The organic layer was dried over anhydrous sodium sulfate. The solvent was distilled off under reduced pressure to obtain the title compound as a light-brown solid (615 mg).
ESI-MS m/z 410 (MH + ).
Step 10
Synthesis of 8-azido-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-4-amine
Sodium azide (361 mg) was added to a solution of 4-amino-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-8-yl methanesulfonate (758 mg) obtained in Step 9 in DMF (9 ml) at room temperature, and the mixture was stirred at 80° C. for 4 hours. After cooling, the reaction mixture was poured into water, followed by extraction with ethyl acetate. The organic layer was washed with water and a saturated sodium chloride solution, and dried over anhydrous sodium sulfate. The solvent was distilled off under reduced pressure to obtain the title compound as a yellow solid (508 mg).
ESI-MS m/z 357 (MH + ).
Step 11
Synthesis of 5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizine-4,8-diamine
Polymer-supported triphenylphosphine (˜3.0 mmol/g, 1.42 g) was added to a solution of 8-azido-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-4-amine (508 mg) obtained in Step 10 in THF (10 ml) and water (1 ml) at room temperature. The reaction mixture was heated under reflux for 1 hour. After cooling, the reaction mixture was filtered through Celite, washed with ethanol, and the solvent was distilled off under reduced pressure. The resulting residue was purified by silica gel column chromatography (developing solvent: chloroform/methanol) to obtain the title compound as a yellow solid (342 mg). ESI-MS m/z 331 (MH + ).
Step 12
Synthesis of N-(4-amino-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-8-yl)acrylamide
N,N-diisopropylethylamine (0.033 ml) and acryloyl chloride (0.0154 ml) were added to a solution of 5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizine-4,8-diamine (68 mg) obtained in Step 11 in chloroform (2.5 ml) under ice-cooling. After stirring at the same temperature for 15 minutes, the mixture was poured into a saturated aqueous sodium bicarbonate solution, followed by extraction with chloroform. The organic layer was dried over anhydrous sodium sulfate, and the solvent was then distilled off under reduced pressure. The resulting residue was purified by silica gel column chromatography (developing solvent: chloroform/methanol) to obtain the title compound as a yellow solid (35.4 mg).
1 H-NMR (CDCl 3 ) δ: 2.14 (2H, d, J=5.6 Hz), 3.04 (2H, t, J=6.2 Hz), 4.17 (1H, dd, J=12.7, 5.8 Hz), 4.46 (1H, dd, J=12.7, 4.5 Hz), 4.70-4.80 (1H, m), 4.89 (2H, brs), 5.71 (1H, d, J=10.2 Hz), 6.21 (1H, dd, J=16.8, 10.2 Hz), 6.39 (1H, d, J=16.8 Hz), 6.50 (1H, d, J=7.0 Hz), 7.62 (1H, t, J=7.4 Hz), 7.77 (1H, t, J=7.4 Hz), 7.87 (1H, d, J=8.0 Hz), 8.15 (1H, d, J=8.0 Hz), 8.25 (1H, s), 8.32 (1H, s), 9.00 (1H, s). ESI-MS m/z 385 (MH + ).
Step 13
Separation of N-(4-amino-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-8-yl)acrylamide enantiomer A and N-(4-amino-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-8-yl)acrylamide enantiomer B
N-(4-amino-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-8-yl)acrylamide (197 mg) obtained in Step 12 was subjected to optical resolution using a column for optical resolution (CHIRALPAK AD-H 20 mm×250 mm, manufactured by Daicel Chemical Industries, Ltd.), mobile phase: hexane/ethanol/triethylamine, 50:50:0.1, flow rate: 10 ml/min) to obtain 72.4 mg of enantiomer A (retention time: 15.4 min, (R)-N-(4-amino-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-8-yl)acrylamide (Compound I-1)) and 78.3 mg of enantiomer B (retention time: 32.5 min, (S)-N-(4-amino-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-8-yl)acrylamide (Compound I-2)) as a light-yellow solid.
Enantiomer A
ESI-MS m/z 385 (MH + ).
Enantiomer B
ESI-MS m/z 385 (MH + ).
When the (R)-N-(4-amino-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-8-yl)acrylamide obtained in the same method as Example 2 described later was subjected to a column treatment under the same conditions as described above, its retention time was the same as that of enantiomer A. It was confirmed that the enantiomer A was an R isomer, i.e., Compound I-1; and that the enantiomer B was an S isomer, i.e., Compound I-2.
Example 2
(R)-N-(4-amino-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-8-yl)acrylamide (Compound I-1)
Step 1
Synthesis of (S)-2-(tert-butyldimethylsilyloxy)-3-butenyl 4-methylbenzenesulfonate
In accordance with Step 2 of Example 1, except that (S)-3-butene-1,2-diol-1-(p-toluenesulfonate) was used in place of 1-bromo-3-buten-2-ol, the title compound was obtained as a colorless, oily substance (2.74 g).
Step 2
Synthesis of (R)-N-(4-amino-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-8-yl)acrylamide
In accordance with Steps 1 to 12 of Example 1, except that (S)-2-(tert-butyldimethylsilyloxy)-3-butenyl 4-methylbenzenesulfonate obtained in Step 1 was used in place of 1-bromo-2-(tert-butyldimethylsilyloxy)-3-buten, the title compound was obtained as a yellow solid (13.9 mg).
Example 3
N-(4-amino-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-8-yl)-N-methylacrylamide (Compound I-3)
Step 1
Synthesis of N 8 -methyl-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizine-4,8-diamine
4-Amino-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-8-yl methanesulfonate (30 mg) obtained in Step 9 of Example 1 was dissolved in a solution of methylamine in 40% methanol (1 ml). The solution was stirred at 60° C. for 1 hour and at 80° C. for 22 hours. After cooling, the reaction mixture was concentrated under reduced pressure. The resulting residue was purified by silica gel column chromatography (developing solvent: ethyl acetate/methanol) to obtain the title compound as a light-yellow, oily substance (8.1 mg).
ESI-MS m/z 345 (MH + ).
Step 2
Synthesis of N-(4-amino-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-8-yl)-N-methylacrylamide
In accordance with Step 12 of Example 1, except that N 8 -methyl-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizine-4,8-diamine obtained in Step 1 was used in place of 5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizine-4,8-diamine used in Step 12 of Example 1, the title compound was obtained as a light-yellow solid (6.2 mg).
1 H-NMR (CDCl 3 ) δ: 1.90-2.15 (2H, m), 3.00-3.15 (2H, m), 3.06 (3H, s), 3.90-4.03 (1H, m), 4.56-4.64 (1H, m), 5.06 (2H, brs), 5.15-5.30 (1H, m), 5.77 (1H, d, J=10.2 Hz), 6.38 (1H, d, J=16.6 Hz), 6.54-6.70 (1H, m), 7.63 (1H, t, J=7.3 Hz), 7.78 (1H, t, J=7.3 Hz), 7.88 (1H, d, J=8.0 Hz), 8.16 (1H, s), 8.17 (1H, d, J=8.0 Hz), 8.31 (1H, s), 9.01 (1H, s).
ESI-MS m/z 399 (MH + ).
Example 4
(E)-N-(4-amino-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-8-yl)-4-(dimethylamino)-2-butenamide (Compound I-4)
HATU (10.3 mg) and 5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizine-4,8-diamine (8.8 mg) obtained in Step 11 of Example 1 were added to a solution of trans-4-dimethylaminocrotonic acid hydrochloride (4.5 mg) in DMF (0.5 ml) at room temperature. After being stirred for 1 hour at the same temperature, the mixture was poured into a saturated aqueous sodium bicarbonate solution, followed by extraction with ethyl acetate. The organic layer was dried over anhydrous sodium sulfate, and the solvent was then distilled off under reduced pressure. The resulting residue was purified by preparative thin-layer chromatography (produced by Wako, NH 2 silica-gel 60 F254 plate, developing solvent: chloroform/methanol) to obtain the title compound as a light-yellow solid (6.4 mg).
1 H-NMR (CDCl 2 ) δ: 2.05-2.20 (2H, m), 2.27 (6H, s), 2.49-2.65 (4H, m), 4.10-4.20 (1H, m), 4.46-5.02 (1H, m), 4.68-4.77 (1H, m), 4.91 (2H, brs), 6.06 (1H, d, J=15.4 Hz), 6.39 (1H, d, J=7.0 Hz), 6.85-6.95 (1H, m), 7.62 (1H, t, J=7.4 Hz), 7.77 (1H, t, J=7.4 Hz), 7.87 (1H, d, J=8.0 Hz), 8.15 (1H, d, J=8.0 Hz), 8.17 (1H, s), 8.25 (1H, s), 9.00 (1H, s). ESI-MS m/z 442 (MH + ).
Example 5
(S,E)-N-(4-amino-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-8-yl)-3-chloroacrylamide (Compound I-5)
Trans-3-chloroacrylic acid (399.5 mg) was added to a suspension of 5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizine-4,8-diamine (498.0 mg) obtained in Step 11 of Example 1 in DMF (8 ml) at room temperature. After dissolving, 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide hydrochloride (350.1 mg) was added thereto under ice-cooling, and the mixture was stirred for 1 hour at the same temperature. The reaction mixture was poured into a saturated aqueous sodium bicarbonate solution, followed by extraction with ethyl acetate. The organic layer was dried over anhydrous sodium sulfate, and the solvent was then distilled off under reduced pressure. The resulting residue was purified by silica gel column chromatography (developing solvent: ethyl acetate/methanol) to obtain the title compound as a light-yellow solid (261.2 mg).
1 H-NMR (DMSO-d 6 ) δ: 1.84-2.07 (2H, m), 2.92-3.08 (2H, m), 3.88-4.02 (1H, m), 4.27-4.43 (2H, m), 6.07 (2H, brs), 6.48 (1H, d, J=13.4 Hz), 7.31 (1H, d, J=13.2 Hz), 7.63 (1H, t, J=7.4 Hz), 7.75 (1H, t, J=7.6 Hz), 8.03 (1H, d, J=10.7 Hz), 8.05 (1H, d, J=10.7 Hz), 8.13 (1H, s), 8.29 (1H, d, J=2.0 Hz), 8.53 (1H, d, J=6.6 Hz), 8.92 (1H, d, J=2.2 Hz).
ESI-MS m/z 419, 421 (MH + ).
Example 6
(S,Z)—N-(4-amino-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-8-yl)-3-chloroacrylamide (Compound I-6)
In accordance with Example 5, except that cis-3-chloroacrylic acid was used in place of trans-3-chloroacrylic acid used in Example 5, the title compound was obtained as a light-yellow solid (93 mg).
1 H-NMR (DMSO-d 6 ) δ: 1.82-1.96 (1H, m), 1.96-2.07 (1H, m), 2.92-3.08 (2H, m), 3.85-3.97 (1H, m), 4.27-4.41 (2H, m), 6.05 (2H, brs), 6.39 (1H, d, J=8.0 Hz), 6.77 (1H, d, J=8.0 Hz), 7.63 (1H, t, J=7.4 Hz), 7.75 (1H, t, J=7.4 Hz), 8.02 (1H, d, J=11.4 Hz), 8.04 (1H, d, J=11.4 Hz), 8.13 (1H, s), 8.29 (1H, d, J=2.0 Hz), 8.50 (1H, d, J=6.3 Hz), 8.92 (1H, d, J=2.0 Hz).
ESI-MS m/z 419, 421 (MH + ).
Example 7
(S)-N-(4-amino-5-(quinolin-3-yl)-7,8,9,10-tetrahydro-6H-pyrimido[5′,4′:4,5]pyrrolo[1,2-a]azepin-8-yl)acrylamide (Compound I-7)
Step 1
Synthesis of (R)-tert-butyl (1-hydroxy-5-(methylthio)pentan-3-yl)carbamate
N-methylmorpholine (3.63 ml) and ethyl chloroformate (3.01 ml) were added to a solution of (R)-3-((tert-butoxycarbonyl)amino)-5-(methylthio)pentanoic acid (7.92 g) in THF (79.2 ml) at −10° C. After stirring at −10° C. for 15 minutes, the generated insoluble matter was filtered off. An aqueous solution of sodium borohydride (1.55 g) (15 ml) was added to the filtrate at −10° C., and the mixture was stirred at −10° C. for 1 hour. A saturated aqueous ammonium chloride solution was added thereto, and the mixture was stirred at room temperature for 30 minutes. Ethyl acetate was added thereto to separate the organic layer. The organic layer was washed with a 0.5 N aqueous potassium hydrogensulfate solution, water, a 0.5 N aqueous sodium hydroxide solution and a saturated sodium chloride solution, and dried over anhydrous sodium sulfate. The solvent was then distilled off under reduced pressure. The resulting residue was purified by silica gel column chromatography (developing solvent: chloroform/ethyl acetate) to obtain the title compound as a light-yellow, oily substance (7.18 g).
Step 2
Synthesis of tert-butyl ((3R)-1-hydroxy-5-(methylsulfinyl)pentan-3-yl)carbamate
A suspension of sodium periodate (7.0 g) in water (32 ml) was added to a solution of (R)-tert-butyl (1-hydroxy-5-(methylthio)pentan-3-yl)carbamate (8.16 g) obtained in Step 1 in methanol (98 ml) at a temperature 10° C. or lower, and the mixture was stirred at room temperature for 2 hours. The generated insoluble matter was filtered off, and the filtrate was distilled off under reduced pressure. The resulting residue was dissolved in a saturated sodium chloride solution, followed by extraction with chloroform for 3 times. The organic layer was dried over anhydrous sodium sulfate, and the solvent was distilled off under reduced pressure to obtain the title compound as a light-yellow solid (9.38 g).
Step 3
Synthesis of (R)-tert-butyl (5-hydroxypent-1-en-3-yl)carbamate
Sodium acetate (13.45 g) was added to a solution of tert-butyl ((3R)-1-hydroxy-5-(methylsulfinyl)pentan-3-yl)carbamate (9.38 g) obtained in Step 2 in 1,2-dichlorobenzene (140 ml) at room temperature. The mixture was stirred at an internal temperature of 166° C. for 18 hours. After cooling the reaction mixture, the insoluble matter was filtered off, and 1,2-dichlorobenzene was distilled off under reduced pressure. The resulting residue was dissolved in ethyl acetate, washed with a saturated aqueous sodium chloride solution, water, and a saturated sodium chloride solution; and dried over anhydrous sodium sulfate. The solvent was then distilled off under reduced pressure. The resulting residue was purified by silica gel column chromatography (developing solvent: hexane/ethyl acetate) to obtain the title compound 2.50 g as a light-yellow, oily substance.
Step 4
Synthesis of (R)-tert-butyl (5-(4-chloro-5-iodo-7H-pyrrolo[2,3-d]pyrimidin-7-yl)pent-1-en-3-yl)carbamate
Triphenylphosphine (3.25 g) was added to and dissolved in a solution of (R)-tert-butyl (5-hydroxypent-1-en-3-yl)carbamate (2.5 g) obtained in Step 3 and 4-chloro-5-iodo-7H-pyrrolo[2,3-d]pyrimidine (2.31 g) obtained in Step 1 of Example 1 in DME (23 ml) under ice-cooling. Thereafter, diisopropyl azodicarboxylate (2.44 ml) was gradually added thereto. The reaction mixture was stirred under ice-cooling for 30 minutes and at room temperature for 1 hour, and the solvent was then distilled off under reduced pressure. The resulting residue was dissolved in ethyl acetate, washed with water, and dried over anhydrous sodium sulfate. The solvent was then distilled off under reduced pressure. The resulting residue was purified by silica gel column chromatography (developing solvent: hexane/ethyl acetate) to obtain the title compound as a light-yellow solid (3.49 g).
ESI-MS m/z 463, 465 (MH + ).
Step 5
Synthesis of (R)-tert-butyl (5-(4-amino-5-iodo-7H-pyrrolo[2,3-d]pyrimidin-7-yl)pent-1-en-3-yl)carbamate
28% aqueous ammonia (17.5 ml) was added to a solution of (R)-tert-butyl (5-(4-chloro-5-iodo-7H-pyrrolo[2,3-d]pyrimidine-7-yl)pent-1-en-3-yl)carbamate (3.49 g) obtained in Step 4 in DME (17.5 ml), and the mixture was stirred in an autoclave at an internal temperature of 105° C. for 8 hours. After cooling the reaction mixture, water (70 ml) was added thereto, and the mixture was stirred at room temperature for 4 hours. The resulting precipitate was collected by filtration, washed with water, and dried to obtain the title compound as a light-yellow solid (3.20 g).
ESI-MS m/z 444 (MH + ).
Step 6
Synthesis of (R)-tert-butyl (5-(4-amino-5-(quinolin-3-yl)-7H-pyrrolo[2,3-d]pyrimidin-7-yl)pent-1-en-3-yl)carbamate
A mixture of (R)-tert-butyl (5-(4-amino-5-iodo-7H-pyrrolo[2,3-d]pyrimidin-7-yl)pent-1-en-3-yl)carbamate (3.2 g) obtained in Step 5,3-quinolineboronic acid (1.37 g), sodium carbonate (843 mg), tetrakis(triphenylphosphine)palladium (250 mg), DME (32 ml) and water (32 ml) was stirred under a nitrogen atmosphere at 100° C. for 6 hours. After cooling the reaction mixture, a saturated aqueous sodium bicarbonate solution and ethyl acetate were added thereto. The resulting mixture was stirred at room temperature for 30 minutes. After filtering off the insoluble matter, the organic layer was separated and dried over anhydrous sodium sulfate. The solvent was then distilled off under reduced pressure. The resulting residue was purified by silica gel column chromatography (developing solvent: hexane/ethyl acetate, ethyl acetate/methanol) to obtain the title compound as a light-orange solid (3.21 g).
ESI-MS m/z 445 (MH + ).
Step 7
Synthesis of (R)-tert-butyl (5-(4-amino-6-bromo-5-(quinolin-3-yl)-7H-pyrrolo[2,3-d]pyrimidin-7-yl)pent-1-en-3-yl)carbamate
A solution of N-bromosuccinimide (1.35 g) in THF (23 ml) was added to a solution of (R)-tert-butyl (5-(4-amino-5-(quinolin-3-yl)-7H-pyrrolo[2,3-d]pyrimidin-7-yl)pent-1-en-3-yl)carbamate (3.21 g) obtained in Step 6 in THF (26 ml) under ice-cooling over 30 minutes. The mixture was stirred under ice-cooling for 30 minutes. After adding a 5% aqueous sodium thiosulfate solution, the mixture was poured into a saturated aqueous sodium bicarbonate solution, followed by extraction with ethyl acetate. The organic layer was washed with a saturated sodium chloride solution and dried over anhydrous sodium sulfate. The solvent was then distilled off under reduced pressure. The resulting residue was purified by silica gel column chromatography (developing solvent: hexane/ethyl acetate, ethyl acetate/methanol) to obtain the title compound as a light-brown solid (3.15 g).
ESI-MS m/z 523, 525 (MH + ).
Step 8
Synthesis of (S)-tert-butyl (4-amino-5-(quinolin-3-yl)-7,8,9,10-tetrahydro-6H-pyrimido[5′,4′:4,5]pyrrolo[1,2-a]azepin-8-yl)carbamate
(R)-tert-Butyl (5-(4-amino-6-bromo-5-(quinolin-3-yl)-7H-pyrrolo[2,3-d]pyrimidin-7-yl)pent-1-en-3-yl)carbamate (994 mg) obtained in Step 7 was added to a solution of 9-borabicyclo[3.3.1]nonane in 0.5 M THF (22.8 ml) at room temperature. The mixture was stirred at the same temperature for 1 hour, and a 4 N aqueous sodium hydroxide solution (5.7 ml) was carefully added thereto. After nitrogen purging, the mixture was heated to have an internal temperature of 55° C. Tetrakis(triphenylphosphine)palladium (275 mg) was added thereto, and the mixture was stirred at an internal temperature of 66° C. for 15 hours. After cooling the reaction mixture, the organic layer was separated, and toluene (7.7 ml) and a 20% aqueous ammonium chloride solution (5 ml) were added thereto. The organic layer was separated, washed with a 20% saline solution, and SH silica gel (produced by Fuji Silysia, 1 g) was added thereto. The mixture was stirred at an internal temperature 68° C. for 1 hour, and SH silica gel (produced by Fuji Silysia, 1 g) was added thereto. The mixture was stirred at an internal temperature of 68° C. for 1 hour. After cooling, the silica gel was filtered off, and the solvent was distilled off under reduced pressure. The resulting residue was purified by silica gel column chromatography (developing solvent: ethyl acetate/methanol) to obtain the title compound as a yellow solid (439 mg).
ESI-MS m/z 445 (MH + ).
Step 9
Synthesis of (S)-5-(quinolin-3-yl)-7,8,9,10-tetrahydro-6H-pyrimido[5′,4′:4,5]pyrrolo[1,2-a]azepin-4,8-diamine
5 N Hydrochloric acid (1 ml) was added to a solution of (S)-tert-butyl (4-amino-5-(quinolin-3-yl)-7,8,9,10-tetrahydro-6H-pyrimido[5′,4′:4,5]pyrrolo[1,2-a]azepin-8-yl)carbamate (436 mg) obtained in Step 8 in ethanol (4 ml) at room temperature. The mixture was stirred at 60° C. for 3 hours. After cooling, the reaction mixture was basified with a 5 N aqueous sodium hydroxide solution, followed by extraction with chloroform. The organic layer was dried over anhydrous sodium sulfate, and the solvent was distilled off under reduced pressure. The resulting residue was purified by silica gel column chromatography (developing solvent: chloroform/methanol) to obtain the title compound as a light-yellow solid (320 mg).
ESI-MS m/z 345 (MH + ).
Step 10
Synthesis of (S)-N-(4-amino-5-(quinolin-3-yl)-7,8,9,10-tetrahydro-6H-pyrimido[5′,4′:4,5]pyrrolo[1,2-a]azepin-8-yl)acrylamide
N,N-Diisopropylethylamine (0.192 ml) and a solution of acryloyl chloride (83.3 mg) in acetonitrile (0.83 ml) were added to an acetonitrile (1.6 ml)-water (1.6 ml) solution of the (S)-5-(quinolin-3-yl)-7,8,9,10-tetrahydro-6H-pyrimido[5′,4′:4,5]pyrrolo[1,2-a]azepin-4,8-diamine (317 mg) obtained in Step 9 under ice-cooling. After being stirred at the same temperature for 15 minutes, the mixture was poured into a saturated aqueous sodium bicarbonate solution, followed by extraction with chloroform. The organic layer was dried over anhydrous sodium sulfate, and the solvent was then distilled off under reduced pressure. The resulting residue was purified by silica gel column chromatography (developing solvent: ethyl acetate/methanol) to obtain the title compound as a light-yellow solid (226 mg).
1 H-NMR (DMSO-d 6 ) δ: 1.37-1.56 (2H, m), 1.98-2.20 (2H, m), 2.75-2.83 (1H, m), 2.88-2.97 (1H, m), 3.96-4.18 (2H, m), 4.78-4.90 (1H, m), 5.58 (1H, dd, J=10.0, 2.2 Hz), 5.93 (2H, brs), 6.19 (1H, dd, J=17.1, 2.2 Hz), 6.21 (1H, dd, J=17.1, 10.0 Hz), 7.64 (1H, t, J=7.4 Hz), 7.77 (1H, t, J=7.4 Hz), 8.01-8.09 (2H, m), 8.14 (1H, s), 8.17 (1H, d, J=7.6 Hz), 8.27 (1H, d, J=2.0 Hz), 8.85 (1H, d, J=2.0 Hz).
ESI-MS m/z 399 (MH + ).
Example 8
(S)-N-(4-amino-5-(quinolin-3-yl)-7,8,9,10-tetrahydro-6H-pyrimido[5′,4′:4,5]pyrrolo[1,2-a]azepin-9-yl)acrylamide
Step 1
Synthesis of (S)-tert-butyl (1-hydroxypent-4-en-2-yl)carbamate
N-methylmorpholine (15.25 ml) and ethyl chloroformate (12.60 ml) were added to a solution of (S)-2-((tert-butoxycarbonyl)amino)pent-4-enoic acid (25.0 g) in THF (250 ml) at −15° C. After stirring the mixture at −15° C. for 15 minutes, the generated insoluble matter was filtered off. A solution of sodium borohydride (3.23 g) in water (32 ml) was added to the filtrate at −15° C., and the mixture was stirred at −15° C. for 1 hour. A saturated aqueous ammonium chloride solution was added thereto, and the mixture was stirred at room temperature for 30 minutes. Ethyl acetate was added thereto to separate the organic layer. The organic layer was washed with a 0.5 N aqueous potassium hydrogensulfate solution, water, a 0.5 N aqueous sodium hydroxide solution, and a saturated sodium chloride solution; and dried over anhydrous sodium sulfate. The solvent was then distilled off under reduced pressure. The resulting residue was purified by silica gel column chromatography (developing solvent: hexane/ethyl acetate) to obtain the title compound as a light-yellow, oily substance (11.93 g).
Step 2
Synthesis of (S)-N-(4-amino-5-(quinolin-3-yl)-7,8,9,10-tetrahydro-6H-pyrimido[5′,4′:4,5]pyrrolo[1,2-a]azepin-9-yl)acrylamide
In accordance with Steps 4 to 10 of Example 7, except that (S)-tert-butyl (1-hydroxypent-4-en-2-yl)carbamate obtained in Step 1 was used in place of (R)-tert-butyl (5-hydroxypent-1-en-3-yl)carbamate obtained in Step 4 of Example 7, the title compound was obtained as a milky-white solid (400.0 mg).
1 H-NMR (DMSO-d 6 ) δ: 1.57-1.65 (1H, m), 1.78-1.86 (1H, m), 1.93-2.05 (2H, m), 2.77-2.89 (2H, m), 3.98-4.04 (1H, m), 4.21-4.26 (1H, m), 4.63 (1H, d, J=13.7 Hz), 5.60 (1H, dd, J=10.0, 2.4 Hz), 5.93 (1H, brs), 6.12 (1H, dd, J=17.1, 2.4 Hz), 6.25 (1H, dd, J=17.1, 10.0 Hz), 7.63-7.67 (1H, m), 7.77-7.81 (1H, m), 8.07 (1H, t, J=8.8 Hz), 8.12 (1H, s), 8.15 (1H, d, J=7.6 Hz), 8.28 (1H, d, J=2.2 Hz), 8.87 (1H, d, J=2.2 Hz).
ESI-MS m/z 399 (MH + ).
Example 9
(R)-N-(4-amino-5-(quinolin-3-yl)-7,8,9,10-tetrahydro-6H-pyrimido[5′,4′:4,5]pyrrolo[1,2-a]azepin-9-yl)acrylamide (Compound I-9)
Step 1
Synthesis of (R)-tert-butyl (1-hydroxypent-4-en-2-yl)carbamate
In accordance with Step 1 of Example 8, except that (R)-2-((tert-butoxycarbonyl)amino)pent-4-enoic acid was used in place of (S)-2-((tert-butoxycarbonyl)amino)pent-4-enoic acid used in Step 1 of Example 8, the title compound was obtained as a light-yellow, oily substance.
Step 2
Synthesis of (R)-N-(4-amino-5-(quinolin-3-yl)-7,8,9,10-tetrahydro-6H-pyrimido[5′,4′:4,5]pyrrolo[1,2-a]azepin-9-yl)acrylamide
In accordance with Steps 4 to 10 of Example 7, except that (R)-tert-butyl (1-hydroxypent-4-en-2-yl)carbamate obtained in Step 1 was used in place of (R)-tert-butyl (5-hydroxypent-1-en-3-yl)carbamate used in Step 4 of Example 7, the title compound was obtained as a milky-white solid (115.5 mg).
1 H-NMR (DMSO-d 6 ) δ: 1.57-1.65 (1H, m), 1.78-1.86 (1H, m), 1.93-2.05 (2H, m), 2.77-2.89 (2H, m), 3.98-4.04 (1H, m), 4.21-4.26 (1H, m), 4.63 (1H, d, J=13.7 Hz), 5.60 (1H, dd, J=10.0, 2.4 Hz), 5.93 (1H, brs), 6.12 (1H, dd, J=17.1, 2.4 Hz), 6.25 (1H, dd, J=17.1, 10.0 Hz), 7.63-7.67 (1H, m), 7.77-7.81 (1H, m), 8.07 (1H, t, J=8.8 Hz), 8.12 (1H, s), 8.15 (1H, d, J=7.6 Hz), 8.28 (1H, d, J=2.2 Hz), 8.87 (1H, d, J=2.2 Hz).
ESI-MS m/z 399 (MH + ).
Comparative Example 1
Synthesis of N-(3-(4-amino-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-5-yl)phenyl)benzamide
Synthesis was performed according to the method disclosed in WO2006/102079.
ESI-MS m/z 384 (MH + ).
The methods for synthesizing the production intermediates of the compounds of the present invention are explained below. The methods are not limited thereto.
Reference Example 1
(S)-tert-Butyl (1-(4-amino-6-bromo-5-(quinolin-3-yl)-7H-pyrrolo[2,3-d]pyrimidin-7-yl)but-3-en-2-yl)carbamate
Step 1
Synthesis of (S)-tert-butyl (1-(4-chloro-5-iodo-7H-pyrrolo[2,3-d]pyrimidin-7-yl)but-3-en-2-yl)carbamate
Diisopropyl azodicarboxylate (2.44 ml) was slowly added to a solution of triphenylphosphine (13.1 g) in tetrahydrofuran (70 ml) under ice-cooling. The reaction mixture was stirred under ice-cooling for 1 hour, and then a solution of (S)-tert-butyl (1-hydroxybut-3-en-2-yl)carbamate (7.0 g) synthesized according to the method disclosed in Non-patent Literature Org. Lett., 2005, vol. 7, No. 5, pp. 847-849 and 4-chloro-5-iodo-7H-pyrrolo[2,3-d]pyrimidine (6.97 g) in tetrahydrofuran (35 ml) was slowly added thereto. After the reaction mixture was stirred at room temperature for 2 hours, the solvent was distilled off under reduced pressure. The resulting residue was purified by silica gel column chromatography (developing solvent: hexane/ethyl acetate) to obtain the title compound (20.84 g) as a light-yellow, oily substance.
ESI-MS m/z 448,450 (MH + ).
Step 2
Synthesis of (S)-tert-butyl (1-(4-amino-5-iodo-7H-pyrrolo[2,3-d]pyrimidin-7-yl)but-3-en-2-yl)carbamate
An 8 N ammonia methanol solution (89.4 ml) was added to the (S)-tert-butyl (1-(4-chloro-5-iodo-7H-pyrrolo[2,3-d]pyrimidin-7-yl)but-3-en-2-yl)carbamate (20.84 g) obtained in Step 1, and the mixture was stirred in an autoclave at 120° C. for 6 hours. The reaction mixture was cooled with ice, and the solvent was distilled off under reduced pressure. After the resulting residue was diluted with a small amount of methanol, the resulting precipitate was collected by filtration, washed with cold methanol (11 ml), and then dried under reduced pressure to obtain the title compound (8.28 g) as a milky-white solid.
ESI-MS m/z 430 (MH + ).
Step 3
Synthesis of (S)-tert-butyl (1-(4-amino-5-(quinolin-3-yl)-7H-pyrrolo[2,3-d]pyrimidin-7-yl)but-3-en-2-yl)carbamate
A mixture of (S)-tert-butyl (1-(4-amino-5-iodo-7H-pyrrolo[2,3-d]pyrimidin-7-yl)but-3-en-2-yl)carbamate (8.26 g) obtained in Step 2,3-quinolineboronic acid (4.99 g), cesium carbonate (12.54 g), 1,1′-bis(diphenylphosphino)ferrocene-palladium(II)dichloride (785.6 mg), DME (66 ml), and water (33 ml) was stirred under a nitrogen atmosphere at 100° C. for 2 hours. After cooling the reaction mixture, water and ethyl acetate were added thereto to separate the organic layer. The aqueous layer was then extracted with ethyl acetate twice. The resulting organic layer was dried over anhydrous magnesium sulfate, and the solvent was distilled off under reduced pressure. The resulting residue was purified by silica gel column chromatography (developing solvent: hexane/ethyl acetate, ethyl acetate/methanol) to obtain the title compound (8.0 g) as a light-orange solid.
ESI-MS m/z 431 (MH + ).
Step 4
Synthesis of (S)-tert-butyl (1-(4-amino-6-bromo-5-(quinolin-3-yl)-7H-pyrrolo[2,3-d]pyrimidin-7-yl)but-3-en-2-yl)carbamate
N-Bromosuccinimide (3.63 g) was added to a solution of (S)-tert-butyl (1-(4-amino-5-(quinolin-3-yl)-7H-pyrrolo[2,3-d]pyrimidin-7-yl)but-3-en-2-yl)carbamate (7.98 g) obtained in Step 3 in DMF (64 ml) at −15° C., and the mixture was stirred at −15° C. for 1 hour. A 10% aqueous sodium thiosulfate solution and ethyl acetate were added to the reaction mixture, and stirred at room temperature for 10 minutes. The organic layer was separated, and the aqueous layer was extracted with ethyl acetate twice. The resulting organic layer was washed with a saturated sodium chloride solution twice, and dried over anhydrous magnesium sulfate. The solvent was distilled off under reduced pressure. The resulting residue was purified by silica gel column chromatography (developing solvent: ethyl acetate/methanol) to obtain the title compound (6.30 g) as a light-brown solid.
1 H-NMR (CDCl 3 ) δ: 1.26 (9H, s), 4.35-4.39 (1H, m), 4.50-4.56 (1H, m), 4.72 (1H, brs), 4.92 (1H, brs), 5.26 (2H, d, J=10.5 Hz), 5.33-5.39 (1H, m), 5.92 (1H, ddd, J=17.2, 10.6, 5.4 Hz), 7.63-7.67 (1H, m), 7.79-7.83 (1H, m), 7.90-7.92 (1H, m), 8.19 (1H, d, J=8.3 Hz), 8.27 (1H, d, J=1.7 Hz), 8.35 (1H, s), 9.07 (1H, d, J=2.2 Hz).
ESI-MS m/z 509,511 (MH + ).
Reference Example 2
(R)-tert-Butyl (1-(4-amino-6-bromo-5-(quinolin-3-yl)-7H-pyrrolo[2,3-d]pyrimidin-7-yl)but-3-en-2-yl)carbamate
Step 1
Synthesis of (R)-tert-butyl (1-(4-chloro-5-iodo-7H-pyrrolo[2,3-d]pyrimidin-7-yl)but-3-en-2-yl)carbamate
In accordance with Step 1 in Reference Example 1, except that (R)-tert-butyl (1-hydroxybut-3-en-2-yl)carbamate (8.74 g) was used in place of the (S)-tert-butyl (1-hydroxybut-3-en-2-yl)carbamate obtained in Step 1 in Reference Example 1, the title compound (11.05 g) was obtained as a white solid.
ESI-MS m/z 448,450 (MH + ).
Step 2
Synthesis of (R)-tert-butyl (1-(4-amino-6-bromo-5-(quinolin-3-yl)-7H-pyrrolo[2,3-d]pyrimidin-7-yl)but-3-en-2-yl)carbamate
In accordance with Steps 2 to 4 in Reference Example 1, except that the (R)-tert-butyl (1-(4-chloro-5-iodo-7H-pyrrolo[2,3-d]pyrimidin-7-yl)but-3-en-2-yl)carbamate (7.88 g) obtained in Step 1 was used in place of the (S)-tert-butyl (1-(4-chloro-5-iodo-7H-pyrrolo[2,3-d]pyrimidin-7-yl)but-3-en-2-yl)carbamate obtained in Step 2 in Reference Example 1, the title compound (6.80 g) was obtained as a yellow solid.
1 H-NMR (CDCl 3 ) δ: 1.26 (9H, s), 4.35-4.39 (1H, m), 4.50-4.56 (1H, m), 4.72 (1H, brs), 4.92 (1H, brs), 5.26 (2H, d, J=10.5 Hz), 5.33-5.39 (1H, m), 5.92 (1H, ddd, J=17.2, 10.6, 5.4 Hz), 7.63-7.67 (1H, m), 7.79-7.83 (1H, m), 7.90-7.92 (1H, m), 8.19 (1H, d, J=8.3 Hz), 8.27 (1H, d, J=1.7 Hz), 8.35 (1H, s), 9.07 (1H, d, J=2.2 Hz).
ESI-MS m/z 509,511 (MH + ).
Reference Example 3
(S)-tert-Butyl (1-(4-amino-6-bromo-5-(quinolin-3-yl)-7H-pyrrolo[2,3-d]pyrimidin-7-yl)penta-4-en-2-yl)carbamate
Step 1
Synthesis of (S)-tert-butyl (1-(4-chloro-5-iodo-7H-pyrrolo[2,3-d]pyrimidin-7-yl)penta-4-en-2-yl)carbamate
In accordance with Step 1 in Reference Example 1, except that (S)-tert-butyl (1-hydroxypenta-4-en-2-yl)carbamate (11.93 g) was used in place of the (S)-tert-butyl (1-hydroxybut-3-en-2-yl)carbamate obtained in Step 1 in Reference Example 1, the title compound (4.96 g) was obtained as a yellow-brown, oily substance.
1 H-NMR (CDCl 3 ) δ: 1.35 (9H, s), 2.18-2.35 (2H, m), 3.97-4.05 (1H, m), 4.27-4.33 (1H, m), 4.40-4.45 (1H, m), 4.63-4.65 (1H, m), 5.14-5.19 (2H, m), 5.76-5.86 (1H, m), 7.42 (1H, brs), 8.62 (1H, s).
ESI-MS m/z 462, 464 (MH + ).
Step 2
Synthesis of (S)-tert-butyl (1-(4-amino-6-bromo-5-(quinolin-3-yl)-7H-pyrrolo[2,3-d]pyrimidin-7-yl)penta-4-en-2-yl)carbamate
In accordance with Steps 2 to 4 in Reference Example 1, except that the (S)-tert-butyl (1-(4-chloro-5-iodo-7H-pyrrolo[2,3-d]pyrimidin-7-yl)penta-4-en-2-yl)carbamate (4.90 g) obtained in Step 1 was used in place of the (S)-tert-butyl (1-(4-chloro-5-iodo-7H-pyrrolo[2,3-d]pyrimidin-7-yl)but-3-en-2-yl)carbamate obtained in Step 2 in Reference Example 1, the title compound (3.67 g) was obtained as a light-yellow solid.
1 H-NMR (CDCl 3 ) δ: 1.23 (9H, s), 2.39-2.42 (2H, m), 4.19-4.27 (1H, m), 4.29-4.34 (1H, m), 4.43-4.50 (1H, m), 4.92 (2H, brs), 5.04 (1H, d, J=8.5 Hz), 5.18-5.24 (2H, m), 5.86-5.96 (1H, m), 7.63-7.67 (1H, m), 7.79-7.83 (1H, m), 7.90-7.92 (1H, m), 8.19 (1H, d, J=8.5 Hz), 8.27 (1H, d, J=1.5 Hz), 8.34 (1H, s), 9.07 (1H, d, J=2.0 Hz). ESI-MS m/z 523,525 (MH + ).
Reference Example 4
(R)-tert-Butyl (1-(4-amino-6-bromo-5-(quinolin-3-yl)-7H-pyrrolo[2,3-d]pyrimidin-7-yl)penta-4-en-2-yl)carbamate
Step 1
Synthesis of (R)-tert-butyl (1-(4-chloro-5-iodo-7H-pyrrolo[2,3-d]pyrimidin-7-yl)penta-4-en-2-yl)carbamate
In accordance with Step 1 in Reference Example 1, except that (R)-tert-butyl (1-hydroxypenta-4-en-2-yl)carbamate (856.4 mg) was used in place of (S)-tert-butyl (1-hydroxybut-3-en-2-yl)carbamate in Step 1 in Reference Example 1, the title compound (1.54 g) was obtained as a milky-white solid.
1 H-NMR (CDCl 3 ) δ: 1.35 (9H, s), 2.18-2.35 (2H, m), 3.97-4.05 (1H, m), 4.27-4.33 (1H, m), 4.40-4.45 (1H, m), 4.63-4.65 (1H, m), 5.14-5.19 (2H, m), 5.76-5.86 (1H, m), 7.42 (1H, brs), 8.62 (1H, s).
ESI-MS m/z 462, 464 (MH + ).
Step 2
Synthesis of (R)-tert-butyl (1-(4-amino-6-bromo-5-(quinolin-3-yl)-7H-pyrrolo[2,3-d]pyrimidin-7-yl)penta-4-en-2-yl)carbamate
In accordance with Steps 2 to 4 in Reference Example 1, except that the (R)-tert-butyl (1-(4-chloro-5-iodo-7H-pyrrolo[2,3-d]pyrimidin-7-yl)penta-4-en-2-yl)carbamate (974.9 mg) obtained in Step 1 was used in place of the (S)-tert-butyl (1-(4-chloro-5-iodo-7H-pyrrolo[2,3-d]pyrimidin-7-yl)but-3-en-2-yl)carbamate obtained in Step 2 in Reference Example 1, the title compound (1.02 g) was obtained as a light-brown solid.
1 H-NMR (CDCl 3 ) δ: 1.23 (9H, s), 2.39-2.42 (2H, m), 4.19-4.27 (1H, m), 4.29-4.34 (1H, m), 4.43-4.50 (1H, m), 4.92 (2H, brs), 5.04 (1H, d, J=8.5 Hz), 5.18-5.24 (2H, m), 5.86-5.96 (1H, m), 7.63-7.67 (1H, m), 7.79-7.83 (1H, m), 7.90-7.92 (1H, m), 8.19 (1H, d, J=8.5 Hz), 8.27 (1H, d, J=1.5 Hz), 8.34 (1H, s), 9.07 (1H, d, J=2.0 Hz).
ESI-MS m/z 523,525 (MH + ).
Reference Example 5
(R)-tert-Butyl (5-(4-amino-6-bromo-5-(quinolin-3-yl)-7H-pyrrolo[2,3-d]pyrimidin-7-yl)penta-1-en-3-yl)carbamate
Step 1
Synthesis of (R)-tert-Butyl (5-(4-chloro-5-iodo-7H-pyrrolo[2,3-d]pyrimidin-7-yl)penta-1-en-3-yl)carbamate
In accordance with Step 1 in Reference Example 1, except that (S)-tert-butyl (5-hydroxypenta-1-en-3-yl)carbamate (2.5 g) was used in place of the (S)-tert-butyl (1-hydroxybut-3-en-2-yl)carbamate obtained in Step 1 in Reference Example 1, the title compound (3.49 g) was obtained as a light-yellow solid.
ESI-MS m/z 463,465 (MH + ).
Step 2
Synthesis of (R)-tert-Butyl (5-(4-amino-6-bromo-5-(quinolin-3-yl)-7H-pyrrolo[2,3-d]pyrimidin-7-yl)penta-1-en-3-yl)carbamate
In accordance with Steps 2 to 4 in Reference Example 1, except that the (R)-tert-butyl (5-(4-chloro-5-iodo-7H-pyrrolo[2,3-d]pyrimidin-7-yl)penta-1-en-3-yl)carbamate (3.21 g) obtained in Step 1 was used in place of the (S)-tert-butyl (1-(4-chloro-5-iodo-7H-pyrrolo[2,3-d]pyrimidin-7-yl)but-3-en-2-yl)carbamate obtained in Step 2 in Reference Example 1, the title compound (3.15 g) was obtained as a light-brown solid.
1 H-NMR (CDCl 3 ) δ: 1.46 (9H, s), 2.02-2.21 (2H, m), 4.26-4.53 (3H, m), 4.90 (2H, brs), 5.07 (1H, d, J=12.4 Hz), 5.15 (1H, d, J=17.2 Hz), 5.15-5.23 (1H, m), 5.78 (1H, ddd, J=17.2, 12.4, 5.2 Hz), 7.61-7.67 (1H, m), 7.78-7.83 (1H, m), 7.88-7.93 (1H, m), 8.17-8.21 (1H, m), 8.26 (1H, d, J=2.2 Hz), 8.35 (1H, s), 9.06 (1H, d, J=2.2 Hz).
ESI-MS m/z 523, 525 (MH + ).
Reference Example 6
(R)-6-Bromo-7-(2-((tert-butyldimethylsilyl)oxy)but-3-en-1-yl)-5-(quinolin-3-yl)-7H-pyrrolo[2,3-d]pyrimidin-4-amine
Step 1
Synthesis of 4-chloro-5-iodo-7-((2-(trimethylsilyl)ethoxy)methyl)-7H-pyrrolo[2,3-d]pyrimidine
A solution of 4-chloro-5-iodo-7H-pyrrolo[2,3-d]pyrimidine (20.0 g) in DMF (50 ml) was slowly added to a solution of sodium hydride (3.4 g) in DMF (190 ml) under ice cooling. Thereafter, 2-(trimethylsilyl)ethoxymethyl chloride (13.3 ml) was added thereto, and stirred at the same temperature for 2 hours. 2-(Trimethylsilyl)ethoxymethyl chloride (1.3 ml) was additionally added to the reaction mixture, and stirred at room temperature for 1 hour. The reaction mixture was poured into water (600 ml), and stirred at room temperature for 15 minutes. The resulting precipitate was collected by filtration and washed with water and diisopropyl ether, followed by dissolution with ethyl acetate again. Insoluble matter was then filtered off by filtration. The solvent of the filtrate was distilled off under reduced pressure. Heptane was added to the resulting residue to collect the precipitate by filtration. The precipitate was washed with heptane, and dried under reduced pressure to obtain the title compound (21.2 g) as a white solid.
ESI-MS m/z 409,411 (MH + ).
Step 2
Synthesis of 5-iodo-7-((2-(trimethylsilyl)ethoxy)methyl)-7H-pyrrolo[2,3-d]pyrimidin-4-amine
An 8 N ammonia methanol solution (120 ml) was added to the 4-chloro-5-iodo-7-((2-(trimethylsilyl)ethoxy)methyl)-7H-pyrrolo[2,3-d]pyrimidine (20.0 g) obtained in Step 1, and the mixture was stirred in a microwave reactor at 120° C. for 1 hour. After being cooled, the reaction mixture was diluted with methanol (65 ml) and water (185 ml). The resulting precipitate was collected by filtration, washed with water, and dried under reduced pressure to obtain the title compound (15.2 g) as a white solid.
ESI-MS m/z 391 (MH + ).
Step 3
Synthesis of 5-(quinolin-3-yl)-7-((2-(trimethylsilyl)ethoxy)methyl)-7H-pyrrolo[2,3-d]pyrimidin-4-amine
A 2 M sodium carbonate aqueous solution (38 ml) was added to a solution of 5-iodo-7-((2-(trimethylsilyl)ethoxy)methyl)-7H-pyrrolo[2,3-d]pyrimidin-4-amine (15.0 g) obtained in Step 2,3-quinolineboronic acid (8.6 g), and tetrakis triphenyl phosphine palladium(0) (2.2 g) in DME (270 ml), and stirred under a nitrogen atmosphere at 90° C. for 6 hours. After the reaction mixture was cooled, water (300 ml) was added thereto. The resulting precipitate was collected by filtration, then washed with water and diisopropyl ether, and dried under reduced pressure. The resulting residue was purified by silica gel column chromatography (developing solvent: methanol/chloroform) to obtain the title compound (10.17 g) as a light-yellow solid.
ESI-MS m/z 392 (MH + ).
Step 4
Synthesis of 5-(quinolin-3-yl)-7H-pyrrolo[2,3-d]pyrimidin-4-amine hydrochloride
Concentrated hydrochloric acid (20 ml) was added at 90° C. to a solution of 5-(quinolin-3-yl)-7-((2-(trimethylsilyl)ethoxy)methyl)-7H-pyrrolo[2,3-d]pyrimidin-4-amine (10.0 g) obtained in Step 3 in ethanol (200 ml), and the mixture was stirred at the same temperature for 25 minutes. Subsequently, concentrated hydrochloric acid (30 ml) was added thereto, and the mixture was stirred at the same temperature for 75 minutes. After the reaction mixture was cooled, ethanol (100 ml) was added thereto, and stirred at 95° C. for 90 minutes. Subsequently, ethanol (100 ml) and concentrated hydrochloric acid (25 ml) were added, and the mixture was stirred at the same temperature for 4 days. After the reaction mixture was cooled, ethyl acetate was added thereto. The resulting precipitate was then collected by filtration, washed with ethyl acetate, and dried under reduced pressure to obtain the title compound (4.4 g) as a yellow solid.
ESI-MS m/z 335 (MH + ).
Step 5
Synthesis of (R)-7-(2-((tert-butyldimethylsilyl)oxy)but-3-en-1-yl)-5-(quinolin-3-yl)-7H-pyrrolo[2,3-d]pyrimidin-4-amine
Potassium carbonate (4.0 g) and (R)-2-((tert-butyldimethylsilyl)oxy)but-3-en-1-yl 4-methylbenzenesulfonate (1.43 g) were added to a solution of 5-(quinolin-3-yl)-7H-pyrrolo[2,3-d]pyrimidin-4-amine hydrochloride (1.22 g) obtained in Step 4 in DMF (12.2 ml) at room temperature, and the mixture was stirred at 90° C. for 20 hours. After the reaction mixture was cooled, water (49 ml) was added thereto, and the resulting mixture was stirred at room temperature for 3 hours. The resulting precipitate was collected by filtration, washed with water, and dried under reduced pressure. The resulting residue was purified by silica gel column chromatography (developing solvent: methanol/ethyl acetate) to obtain the title compound (1.31 g) as a light-yellow solid.
1 H-NMR (CDCl 3 ) δ: −0.32 (3H, s), −0.11 (3H, s), 0.80 (9H, s), 4.06 (1H, dd, J=13.9, 8.5 Hz), 4.46 (1H, dd, J=13.9, 3.2 Hz), 4.59-4.64 (1H, m), 5.06 (2H, brs), 5.22 (1H, d, J=10.5 Hz), 5.40 (1H, d, J=16.8 Hz), 5.89-5.97 (1H, m), 7.21 (1H, s), 7.61-7.65 (1H, m), 7.74-7.78 (1H, m), 7.89 (1H, d, J=8.1 Hz), 8.17 (1H, d, J=8.3 Hz), 8.23 (1H, d, J=2.2 Hz), 8.40 (1H, s), 9.10 (1H, d, J=2.0 Hz).
ESI-MS m/z 446 (MH + ).
Step 6
Synthesis of (R)-6-bromo-7-(2-((tert-butyldimethylsilyl)oxy)but-3-en-1-yl)-5-(quinolin-3-yl)-7H-pyrrolo[2,3-d]pyrimidin-4-amine
In accordance with Step 4 in Reference Example 1, except that the (R)-7-(2-((tert-butyldimethylsilyl)oxy)but-3-en-1-yl)-5-(quinolin-3-yl)-7H-pyrrolo[2,3-d]pyrimidin-4-amine (1.30 g) obtained in Step 5 was used in place of (S)-tert-butyl (1-(4-amino-5-(quinolin-3-yl)-7H-pyrrolo[2,3-d]pyrimidin-7-yl)but-3-en-2-yl)carbamate in Step 4 in Reference Example 1, the title compound (1.44 g) was obtained as a yellow solid.
1 H-NMR (CDCl 3 ) δ: −0.34 (3H, s), −0.12 (3H, s), 0.75 (9H, s), 4.33-4.40 (2H, m), 4.74-4.79 (1H, dm), 4.91 (2H, brs), 5.21-5.24 (1H, m), 5.36-5.41 (1H, m), 5.92-6.01 (1H, m), 7.63-7.67 (1H, m), 7.79-7.83 (1H, m), 7.92 (1H, d, J=7.8 Hz), 8.20 (1H, d, J=8.5 Hz), 8.24 (1H, d, J=2.2 Hz), 8.37 (1H, s), 9.06 (1H, d, J=2.2 Hz).
ESI-MS m/z 524, 526 (MH+).
Example 10
(S)-tert-Butyl (4-amino-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-8-yl)carbamate
A solution of 0.5 M 9-borabicyclo[3.3.1]nonane in tetrahydrofuran (141.3 ml) was added to a solution of (S)-tert-butyl (1-(4-amino-6-bromo-5-(quinolin-3-yl)-7H-pyrrolo[2,3-d]pyrimidin-7-yl)but-3-en-2-yl)carbamate (6.0 g) obtained in Reference Example 1 in tetrahydrofuran (42 ml) under a nitrogen atmosphere at room temperature, and stirred at room temperature for 2 hours. A 2 N sodium hydroxide aqueous solution (84.8 ml) was slowly added to the reaction mixture at room temperature, and degassed under reduced pressure. Under a nitrogen atmosphere, (tetrakistriphenylphosphine)palladium(0) (1.70 g) was added thereto, and the mixture was stirred at 66° C. for 12 hours. After the reaction mixture was cooled, the organic layer was separated and washed with a 20% ammonium chloride aqueous solution (60 ml). SH silica gel (6.0 g) was then added to the organic layer, and the result was stirred at 50° C. under a nitrogen atmosphere for 14 hours, and then filtered. SH silica gel (produced by Fuji Silysia Chemical Ltd.) (6.0 g) was added to the filtrate again, and the result was stirred under a nitrogen atmosphere at 50° C. for 14 hours, and then filtered. The solvent was distilled off from the filtrate under reduced pressure. The resulting residue was purified by silica gel column chromatography (developing solvent: ethyl acetate/methanol) to obtain the title compound (4.46 g) (yield: 88%) as a light-yellow solid.
1 H-NMR (CDCl 3 ) δ: 1.48 (9H, s), 1.91-2.00 (1H, m), 2.12-2.19 (1H, m), 2.98-3.11 (2H, m), 4.00 (1H, dd, J=12.7, 7.1 Hz), 4.32 (1H, brs), 4.55 (1H, dd, J=12.7, 4.6 Hz), 4.81-4.83 (1H, m), 4.90 (2H, brs), 7.61-7.65 (1H, m), 7.75-7.80 (1H, m), 7.88 (1H, d, J=8.0 Hz), 8.16-8.18 (2H, m), 8.33 (1H, s), 9.02 (1H, d, J=2.2 Hz). ESI-MS m/z 431 (MH + ).
Example 11
9-Borabicyclo[3.3.1]nonane dimer (0.431 g) was added to a solution of (S)-tert-butyl (1-(4-amino-6-bromo-5-(quinolin-3-yl)-7H-pyrrolo[2,3-d]pyrimidin-7-yl)but-3-en-2-yl)carbamate (0.3 g) obtained in Reference Example 1 in tetrahydrofuran (4.5 ml) under a nitrogen atmosphere at room temperature, and the mixture was stirred at room temperature for 2 hours. A 4 N sodium hydroxide aqueous solution (2.12 ml) was slowly added to the reaction mixture at room temperature, and degassed under reduced pressure. Under a nitrogen atmosphere, (tetrakistriphenylphosphine)palladium(0) (0.136 g) was added to the resulting mixture, and stirred at 64° C. for 12 hours. After the reaction mixture was cooled, and diluted with ethyl acetate, a saturated ammonium chloride aqueous solution was added thereto. After the insoluble matter resulting in this stage was removed by filtration, the organic layer was separated. The resulting organic layer was dried over anhydrous sodium sulfate, then filtered, and concentrated under reduced pressure to obtain a crude product. The crude product was purified by silica gel column chromatography (developing solvent: ethyl acetate/methanol) to obtain (S)-tert-butyl (4-amino-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-8-yl)carbamate (203 mg) (yield: 80%) as a light-yellow solid.
Example 12
9-Borabicyclo[3.3.1]nonane dimer (431 mg) was added to a solution of (S)-tert-butyl (1-(4-amino-6-bromo-5-(quinolin-3-yl)-7H-pyrrolo[2,3-d]pyrimidin-7-yl)but-3-en-2-yl)carbamate (300 mg) obtained in Reference Example 1 in 1,2-dimethoxyethane (4.5 ml) under a nitrogen atmosphere at room temperature, and the mixture was stirred at 48° C. for 40 minutes. After the mixture was allowed to cool to room temperature, a 4 N sodium hydroxide aqueous solution (2.1 ml) was slowly added to the reaction mixture at room temperature, and degassed under reduced pressure. Under a nitrogen atmosphere, (tetrakistriphenylphosphine)palladium(0) (136 mg) was added thereto, and stirred at 79° C. for 5 hours. After the reaction mixture was cooled, and diluted with ethyl acetate, a saturated ammonium chloride aqueous solution was added. The insoluble matter resulting in this stage was removed by filtration, and the organic layer was separated. The resulting organic layer was dried over anhydrous sodium sulfate and filtered, and then concentrated under reduced pressure to obtain a crude product. The crude product was purified by silica gel column chromatography (developing solvent: ethyl acetate/methanol) to obtain (S)-tert-butyl (4-amino-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-8-yl)carbamate (0.190 g) (yield: 75%) as a light-yellow solid.
Example 13
In accordance with Example 10, except that a 4 N lithium hydroxide aqueous solution (1.8 ml) was used in place of the sodium hydroxide aqueous solution used in Example 10, (S)-tert-butyl (4-amino-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-8-yl)carbamate (224 mg) (yield: 88%) was obtained as a light-yellow solid.
Example 14
In accordance with Example 10, except that a 4 N potassium hydroxide aqueous solution (1.8 ml) was used in place of the sodium hydroxide aqueous solution used in Example 10, (S)-tert-butyl (4-amino-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-8-yl)carbamate (198 mg) (yield: 78%) was obtained as a light-yellow solid.
Example 15
In accordance with Example 10, except that a 4 N cesium hydroxide aqueous solution (1.8 ml) was used in place of the sodium hydroxide aqueous solution used in Example 10, (S)-tert-butyl (4-amino-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-8-yl)carbamate (202 mg) (yield: 80%) was obtained as a light-yellow solid.
Example 16
In accordance with Example 10, except that tris(dibenzylideneacetone)dipalladium(0) (34 mg) and triphenylphosphine (39 mg) were used in place of the (tetrakistriphenylphosphine)palladium(0) used in Example 10, (S)-tert-butyl (4-amino-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-8-yl)carbamate (194 mg) (yield: 76%) was obtained as a light-yellow solid.
Example 17
(R)-tert-butyl (4-amino-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-8-yl)carbamate
In accordance with Example 10, except that the (R)-tert-butyl (1-(4-amino-6-bromo-5-(quinolin-3-yl)-7H-pyrrolo[2,3-d]pyrimidin-7-yl)but-3-en-2-yl)carbamate (6.70 g) obtained in Reference Example 2 was used in place of the (S)-tert-butyl (1-(4-amino-6-bromo-5-(quinolin-3-yl)-7H-pyrrolo[2,3-d]pyrimidin-7-yl)but-3-en-2-yl)carbamate obtained in Example 10, (R)-tert-butyl (4-amino-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-8-yl)carbamate (4.76 g) (yield: 84%) was obtained as a light-yellow solid.
1 H-NMR (CDCl 3 ) δ: 1.48 (9H, s), 1.91-2.00 (1H, m), 2.12-2.19 (1H, m), 2.98-3.11 (2H, m), 4.00 (1H, dd, J=12.7, 7.1 Hz), 4.32 (1H, brs), 4.55 (1H, dd, J=12.7, 4.6 Hz), 4.81-4.83 (1H, m), 4.90 (2H, brs), 7.61-7.65 (1H, m), 7.75-7.80 (1H, m), 7.88 (1H, d, J=8.0 Hz), 8.16-8.18 (2H, m), 8.33 (1H, s), 9.02 (1H, d, J=2.2 Hz). ESI-MS m/z 431 (MH + ).
Example 18
(S)-tert-Butyl (4-amino-5-(quinolin-3-yl)-7,8,9,10-tetrahydro-6H-pyrimido[5′,4′:4,5]pyrrolo[1,2-a]azepin-9-yl)carbamate
In accordance with Example 10, except that the (S)-tert-butyl (1-(4-amino-6-bromo-5-(quinolin-3-yl)-7H-pyrrolo[2,3-d]pyrimidin-7-yl)penta-4-en-2-yl)carbamate (2.0 g) obtained in Reference Example 8 was used in place of the (S)-tert-butyl (1-(4-amino-6-bromo-5-(quinolin-3-yl)-7H-pyrrolo[2,3-d]pyrimidin-7-yl)but-3-en-2-yl)carbamate obtained in Example 10, the title compound (1.56 g) (yield: 92%) was obtained as a light-yellow solid.
1 H-NMR (CDCl 3 ) δ: 1.43 (9H, s), 1.77-1.89 (2H, m), 1.95-2.14 (2H, m), 2.71-2.84 (1H, m), 2.86-3.00 (1H, m), 4.00-4.15 (1H, m), 4.24-4.40 (1H, m), 4.40-4.50 (1H, m), 4.84 (3H, brs), 7.62-7.66 (1H, m), 7.77-7.81 (1H, m), 7.89-7.91 (1H, m), 8.18-8.20 (2H, m), 8.33 (1H, s), 8.98 (1H, d, J=1.5 Hz).
ESI-MS m/z 445 (MH + ).
Example 19
(R)-tert-Butyl (4-amino-5-(quinolin-3-yl)-7,8,9,10-tetrahydro-6H-pyrimido[5′,4′:4,5]pyrrolo[1,2-a]azepin-9-yl)carbamate
In accordance with Example 10, except that the (R)-tert-butyl (1-(4-amino-6-bromo-5-(quinolin-3-yl)-7H-pyrrolo[2,3-d]pyrimidin-7-yl)penta-4-en-2-yl)carbamate (690 mg) obtained in Reference Example 9 was used in place of the (S)-tert-butyl (1-(4-amino-6-bromo-5-(quinolin-3-yl)-7H-pyrrolo[2,3-d]pyrimidin-7-yl)but-3-en-2-yl)carbamate obtained in Example 10, the title compound (429 mg) (yield: 73%) was obtained as a yellow solid.
1 H-NMR (CDCl 3 ) δ: 1.43 (9H, s), 1.77-1.89 (2H, m), 1.95-2.14 (2H, m), 2.71-2.84 (1H, m), 2.86-3.00 (1H, m), 4.00-4.15 (1H, m), 4.24-4.40 (1H, m), 4.40-4.50 (1H, m), 4.84 (3H, brs), 7.62-7.66 (1H, m), 7.77-7.81 (1H, m), 7.89-7.91 (1H, m), 8.18-8.20 (2H, m), 8.33 (1H, s), 8.98 (1H, d, J=1.5 Hz).
ESI-MS m/z 445 (MH + ).
Example 20
(S)-tert-Butyl (4-amino-5-(quinolin-3-yl)-7,8,9,10-tetrahydro-6H-pyrimido[5′,4′:4,5]pyrrolo[1,2-a]azepin-8-yl)carbamate
In accordance with Example 10, except that the (R)-tert-butyl (5-(4-amino-6-bromo-5-(quinolin-3-yl)-7H-pyrrolo[2,3-d]pyrimidin-7-yl)penta-1-en-3-yl)carbamate (994 mg) obtained in Reference Example 10 was used in place of the (S)-tert-butyl (1-(4-amino-6-bromo-5-(quinolin-3-yl)-7H-pyrrolo[2,3-d]pyrimidin-7-yl)but-3-en-2-yl)carbamate obtained in Example 10, the title compound (439 mg) (yield: 52%) was obtained as a yellow solid.
1 H-NMR (CDCl 3 ) δ: 1.46 (9H, s), 2.18-2.28 (1H, m), 2.32-2.42 (1H, m), 2.65-2.77 (1H, m), 2.99-3.08 (1H, m), 3.80-3.97 (2H, m), 4.53-4.62 (1H, m), 4.80 (2H, brs), 4.97-5.11 (1H, m), 7.61-7.66 (1H, m), 7.76-7.81 (1H, m), 7.88 (1H, d, J=8.0 Hz), 8.15-8.20 (2H, m), 8.33 (1H, s), 8.97 (1H, d, J=2.2 Hz).
ESI-MS m/z 445 (MH + ).
Example 21
(R)-8-((tert-Butyldimethylsilyl)oxy)-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-4-amine
In accordance with Example 10, except that the (R)-6-bromo-7-(2-((tert-butyldimethylsilyl)oxy)but-3-en-1-yl)-5-(quinolin-3-yl)-7H-pyrrolo[2,3-d]pyrimidin-4-amine (1.0 g) obtained in Reference Example 11 was used in place of the (S)-tert-butyl (1-(4-amino-6-bromo-5-(quinolin-3-yl)-7H-pyrrolo[2,3-d]pyrimidin-7-yl)but-3-en-2-yl)carbamate obtained in Example 10, (R)-8-((tert-butyldimethylsilyl)oxy)-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-4-amine (546 mg) (yield: 64%) was obtained.
1 H-NMR (CDCl 3 ) δ: 0.14 (3H, s), 0.15 (3H, s), 0.91 (9H, s), 1.97-2.02 (2H, m), 2.85-2.92 (2H, m), 3.14-3.22 (1H, m), 4.11-4.18 (1H, m), 4.28-4.33 (1H, m), 4.41-4.46 (1H, m), 4.95 (2H, brs), 7.61-7.65 (1H, m), 7.75-7.79 (1H, m), 7.88-7.90 (1H, m), 8.16-8.18 (2H, m), 8.35 (1H, s), 9.04 (1H, d, J=2.0 Hz).
ESI-MS m/z 446 (MH + ).
Reference Example 7
In accordance with Example 10, except that 1,1′-bis(diphenylphosphino)ferrocenepalladium(II)dichloride (32 mg) was used in place of the (tetrakistriphenylphosphine)palladium(0) used in Example 10, (S)-tert-butyl (4-amino-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-8-yl)carbamate (21 mg) (yield: 25%) was obtained as a light-yellow solid.
Reference Example 8
In accordance with Example 10, except that cesium carbonate (2.3 g) and water (1.8 ml) were used in place of the sodium hydroxide aqueous solution obtained in Example 10, (S)-tert-butyl (4-amino-5-(quinolin-3-yl)-6,7,8,9-tetrahydropyrimido[5,4-b]indolizin-8-yl)carbamate (88 mg) (yield: 35%) was obtained as a light-yellow solid.
Test Examples
The compounds of the present invention were tested by the following methods.
Test Example 1
Measurement of Inhibitory Activity for Various EGFR Kinases (In Vitro)
1) Measurement of EGFR (T790M/L858R) Kinase Inhibitory Activity
The inhibitory activities of the compounds I-1, I-2, I-3, I-4, I-5, I-6, I-7, I-8, and I-9 for EGFR (T790M/L858R) kinase were measured.
The materials were as follows. The substrate peptide was a biotinylated peptide (biotin-EEPLYWSFPAKKK) synthesized by reference to the amino acid sequence of FL-Peptide 22 (a reagent for LabChip® Series; Caliper Life Sciences, Inc.). The EGFR (T790M/L858R) was a purified recombinant human EGFR (T790M/L858R) protein purchased from Carna Biosciences, Inc.
The measurement method was as follows. The compounds I-1, I-2, I-3, I-4, I-5, I-6, I-7, I-8, and I-9 were each dissolved in dimethylsulfoxide (DMSO), and then each serially diluted with DMSO. Next, the EGFR (T790M/L858R) protein, substrate peptide (final concentration: 250 nM), magnesium chloride (final concentration: 10 mM), manganese chloride (final concentration: 10 mM), ATP (final concentration: 1 μM), and the diluted DMSO solution of each compound (final concentration of DMSO: 2.5%) were added to a kinase reaction buffer (Carna Biosciences, Inc.), and the mixture was incubated at 25° C. for 120 minutes for kinase reaction. EDTA was added thereto to a final concentration of 24 mM to thereby terminate the reaction. Then, a detection solution containing europium (Eu)-labeled anti-phosphorylated tyrosine antibody PT66 (PerkinElmer) and SureLight APC-SA (PerkinElmer) was added, and the resulting mixture was allowed to stand at room temperature for 2 hours or more. Finally, the intensity of fluorescence under the excitation light with a wavelength of 337 nm was measured by a PHERAstar FS (BMG LABTECH) at two wavelengths of 620 nm and 665 nm. The level of phosphorylation of each test sample was calculated from the fluorescence intensity ratio of the two wavelengths in DMSO control and in the test sample, and the compound concentration at which phosphorylation was inhibited by 50% was determined as the IC 50 value (nM) of each compound.
2) Measurement of EGFR (d746-750/T790M) Kinase Inhibitory Activity
The inhibitory activities of the compounds I-1, I-2, I-3, I-4, I-5, I-6, I-7, I-8, and I-9 for EGFR (d746-750/T790M) kinase were measured.
The materials were as follows. The EGFR (d746-750/T790M) was a purified recombinant human EGFR (d746-750/T790M) protein purchased from Carna Biosciences, Inc. The final concentration of ATP was 1.5 μM. As for other conditions, the same materials and methods as those used in the measurement of EGFR (T790M/L858R) kinase inhibitory activity were used to determine the IC 50 value (nM) of each compound.
3) Measurement of EGFR (L858R) Kinase Inhibitory Activity
The inhibitory activities of the compounds I-1, I-2, I-3, I-4, I-5, I-6, I-7, I-8, and I-9 for EGFR (L858R) kinase were measured.
The materials were as follows. The EGFR (L858R) was a purified recombinant human EGFR (L858R) protein purchased from Carna Biosciences, Inc. The final concentration of ATP was 4 μM. As for other conditions, the same materials and methods as those used in the measurement of EGFR (T790M/L858R) kinase inhibitory activity were used to determine the IC 50 value (nM) of each compound.
4) Measurement of EGFR (d746-750) Kinase Inhibitory Activity
The inhibitory activities of the compounds I-1, I-2, I-3, I-4, I-5, I-6, I-7, I-8, and I-9 for EGFR (d746-750) kinase activity were measured.
The materials were as follows. The EGFR (d746-750) was a purified recombinant human EGFR (d746-750) protein purchased from Carna Biosciences, Inc. The final concentration of ATP was 5 μM. The incubation time for the kinase reaction was 90 minutes. As for other conditions, the same materials and methods as those used in the measurement of EGFR (T790M/L858R) kinase inhibitory activity were used to determine the IC 50 value (nM) of each compound.
5) EGFR (WT)
The inhibitory activities of the compounds I-1, I-2, I-3, I-4, I-5, I-6, I-7, I-8, and I-9 on EGFR (WT) kinase were measured.
The materials were as follows. As the EGFR (WT), the cytoplasmic domain of human EGFR (WT) in which a FLAG tag was fused to the N-terminus was expressed in a baculovirus expression system using insect Sf9 cells, and purified with anti-FLAG antibody agarose (Sigma-Aldrich). The final concentration of the substrate peptide was 500 nM, and the final concentration of ATP was 4.7 μM. As for other conditions, the same materials and methods as those used in the measurement of EGFR (T790M/L858R) kinase inhibitory activity were used to determine the IC 50 value (nM) of each compound.
Table 1 shows the results.
It was confirmed that the compounds I-1, I-2, I-3, I-4, I-5, I-6, I-7, I-8, and I-9 showed potent inhibitory activities not only for EGFR (L858R) and EGFR (d746-750), but also for EGFR (T790M/L858R) and EGFR (d746-750/T790M). It was also confirmed that their inhibitory activities for EGFR (WT) were lower than those for the above mutant EGFR proteins.
In contrast, it was confirmed that N-(3-(4-amino-6,7,8,9-tetrahydropyrimide[5,4-b]indolizin-5-yl)phenyl)benzamide (PTL 1), which was a compound having a structure similar to that of the compound of the present invention, had almost no inhibitory activity for these EGFR kinases.
TABLE 1
Type of EGFR
EGFR
EGFR
EGFR
(T790M/
(d746-750/
EGFR
(d746-
EGFR
L858R)
T790M)
(L858R)
750)
(WT)
Compound
I-1
5.3
2.8
14
13
170
I-2
0.3
0.2
0.4
0.4
4.3
I-3
1.3
0.6
1.3
1
18
I-4
6.7
4.1
12
10
120
I-5
0.4
0.3
0.7
0.5
5.9
I-6
1.2
1.2
2.9
3.6
41
I-7
1.4
0.5
2.9
1.8
33
I-8
18
13
41
20
490
I-9
160
82
350
270
3600
Comp. Ex. 1
>5000
>5000
>5000
1500
>5000
Test Example 2
Measurement of Growth Inhibitory Activity for Wild Type and Mutant EGFR-Expressing Cell Lines (In Vitro)
1) A lung adenocarcinoma cell line NCI-H1975 expressing EGFR (T790M/L858R), 2) a lung adenocarcinoma cell line HCC827 expressing EGFR (d746-750), and 3) a human epidermoid carcinoma cell line A431 expressing EGFR (WT) were each suspended in the medium recommended by ATCC. The cell suspension was seeded in each well of a 384-well flat microplate or 96-well flat plate, and cultured in an incubator containing 5% carbon dioxide gas at 37° C. for one day. The compound of the present invention and the reference compound were dissolved in DMSO, and then the DMSO solution of each test compound was diluted with DMSO to a concentration 200 times higher than the final concentration. The diluted DMSO solution of the test compound was diluted with the medium used to suspend each cell line, and the diluted solution was added to each well of the cell culture plate so that the final concentration of DMSO was 0.5%. Then, the cells were cultured in an incubator containing 5% carbon dioxide gas at 37° C. for three days. The number of cells was measured at the time of initiation and termination of the culture by using a CellTiter-Glo Assay (produced by Promega) according to a protocol recommended by Promega. The cell growth inhibition rate was calculated by the following formula, and the concentration of the test compound at which the cell growth was inhibited by 50% (GI 50 (nM)) was determined.
Growth inhibition rate (%)=( C−T )/( C−C 0)×100
T: Luminescence intensity of well to which test compound was added
C: Luminescence intensity of well to which test compound was not added
C0: Luminescence intensity of well measured before addition of test compound
Table 2 shows the results.
It was confirmed that the compounds I-2 and I-3 showed potent growth-inhibitory activities not only for the EGFR (d746-750)-expressing cells, but also for the EGFR (T790M/L858R)-expressing cells. It was also confirmed that the compounds I-2 and I-3 showed weaker growth-inhibitory activities for the EGFR (WT)-expressing cells than for the above cells expressing mutant EGFRs.
TABLE 2
Test Example 2
1)
2)
3)
Type of EGFR
EGFR
EGFR
EGFR
(T790M/L858R)
(d746-750)
(WT)
Cell name
NCI-H1975
HCC827
A431
Compound
I-2
27
5
590
I-3
86
10
1800
|
The present invention provides a new compound that has an inhibitory action against EGFR and that has cell growth inhibitory effects. The present invention further provides a pharmaceutical preparation useful for preventing and/or treating cancer, based on the EGFR inhibitory effect of the compound. A compound represented by the following Formula (I)
or a salt thereof.
| 2
|
BACKGROUND
The present invention relates to a weft band with a carrier or looper for looper looms.
Normally loopers are undetachably or permanently connected with the particular end of the weft band by soldering or the like. Practice has shown that in operation such weft bands frequently break in the immediate vicinity of their connection area with the looper, because on the one hand the weft band ends passing into and out of the shed with the looper are subject to elevated vibratory stresses, and on the other hand have at this particular point undergone a material structural change caused by the heat action during soldering, by means of which a weakened or breakage zone has formed.
SUMMARY
The problem of the present invention is therefore to provide a weft band with looper wherein the above-indicated weakened or breakage zone can be bridged.
According to the invention, this problem is solved by providing the weft band with at least one material recess means in the zone in the vicinity of the connecting area of the weft band with the looper.
It will be appreciated that such a material recess means can be obtained in various ways. This material recess can advantageously be a groove extending at right angles to the longitudinal direction of the band on the top thereof. In addition, the material recess means can define an approximately teardrop-shaped opening or a slot or a constriction. Also, the material recess means can define a plurality of spaced holes arranged in the longitudinal direction of the band whose diameter appropriately decreases in sequence away from the connecting area of the band.
As a result of the above improvements, there is provided a means to remove the load from the breaking zone which has hitherto existed and in such an effective manner that no further breaking can occur because of vibratory stressing since it is substantially displaced into the zone of the material recess means. In this connection, it has surprisingly been found that no breaks occur in the breakage zone with the material recess means provided in the weft band. This result is obviously due to the higher band elasticity in this zone obtained because of the appropriate type of material recesses provided in this zone.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects of the present invention will be apparent from the following description and claims, and are illustrated in the accompanying drawings which by way of illustration show preferred embodiments of the present invention and the principles thereof, and what are now considered to be the best modes contemplated for applying these principles. Other embodiments of the invention embodying the same or equivalent principles may be used, and structural changes may be made as desired by those skilled in the art without departing from the present invention and the scope of the appended claims. In the drawings:
FIG. 1a shows a side view of a cut-away portion of a weft band with a looper;
FIG. 1b shows a plan view of a further embodiment of the weft band with looper in which the weft band has a teardrop-shaped opening therein;
FIG. 1c shows a plan view of a further embodiment of the weft band with looper in which the weft band has a plurality of spaced holes therein;
FIG. 1d shows a plan view of a further embodiment of the weft band with looper in which the weft band has a slot therein; and
FIG. 1e shows a plan view of a further embodiment of the weft band with looper in which the weft band has two concave indentations.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The drawings illustrate the looper attachment end of a weft band 2 of a looper loom, with which band is undetachably or permanently connected a looper 3, in the present case by solder joint 4. In the same way, the looper can also be detachably connected with the weft band, whereby an assembly plate is then soldered to the latter so that relative to the risk of breakage on the band substantially the same problems occur. A weft band with a detachably connected looper forms the object of a parallel application of the same applicant.
As indicated hereinbefore, with weft bands with loopers of the type indicated hereinbefore there is an increased danger of band breakage in the immediate proximity of the connecting area between band and looper, whereby in the drawings this area terminates at soldered joint 4. The area with increased breakage risk is designated in the drawings by dash line 5.
As can be seen in the drawings, the weft band 2 is provided with at least a material recess means in an area which is close to the connecting area 4 or the breakage or weakened area 5, whereby as indicated hereinbefore this material recess means effectively prevents the band breakages which have hitherto occurred. The area or zone designated by the material recess means can be called the elasticity zone or vibration zone, and the recess means can be one or more grooves, holes, indentations, and the like.
In the embodiment according to FIG. 1a, the material recess means is a groove 6 running at right angles to the longitudinal direction of the band 2 on the top thereof in the said vibration zone, whereby the transition edges of the said groove are preferably chamfered or curved.
In the embodiment according to FIG. 1b, an approximately teardrop-shaped opening 7 is defined in the said vibration zone whose widened portion is located closer to the connecting area 4.
In a further embodiment according to FIG. 1c, three holes 8, 9, 10 spacedly arranged along the centerline and in the longitudinal direction of band 2 are provided in the vibration zone, whereby the diameters of the said holes decrease sequentially away from the connecting area 4.
FIG. 1d illustrates an embodiment wherein only a single slot 11 is provided in the oscillation zone of the weft band.
FIG. 1e shows a further embodiment wherein the edges of the weft band 2 provided with concave indentations or cut-away portions 12 in the area of the said vibration zone, in such a way that at this point a constriction is formed on the band.
It has been shown that the above improvements provided by the invention can be realized in simple manner and can also be applied subsequently to existing weft bands.
While there has been described and illustrated the preferred embodiments of the invention, it is to be understood that these are capable of variation and modification, that the material recess means may have a variety of shapes and forms, and that the invention is not to be limited to the precise details set forth but is to include such modifications and alterations as fall within the scope of the appended claims.
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A weft band with carrier for looper looms in which the weft band has a material recess or recesses in the area of the connection of the weft band to the looper.
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FIELD OF THE INVENTION
The present invention relates generally to retractable scalpels and similar devices which have a tool/blade movable between an exposed operative position and a covered nonoperative position. In one embodiment, the invention relates to a protective retractable scalpel in which the blade is extended against the force of a spring to expose a cutting surface, and upon completion of the activity, the cutting surface of the blade is quickly and automatically retracted into a sheath.
BACKGROUND OF THE INVENTION
Scalpels are a class of knives used in the surgical environment for incising, stabbing, shaving, and curetting of human and animal tissue. Conventional scalpels used for this purpose have a stationary blade. The blade is always exposed thereby creating a hazard of inadvertent puncture to an operating team member and to any other person who may come in contact with an instrument. The primary hazard of puncture is the possible transmission of an infectious agent, such as the AIDS virus. It has long been a desire of the medical profession to provide a protective scalpel which completely and absolutely encircles and protects the blade during non-use.
In some emergency situations, a surgeon must work quickly and hand instruments back and forth to assistants. It is dangerous sometimes because the sharp scalpels can accidentally cut or jab the personnel's hands during the operation. Certain fatal infections can be transferred to individuals through small cuts.
Presently existing protective scalpels have removable guards to prevent contact with the blade during non-use. However, with the rapidity in which surgery is conducted, this imposes a degree of inconvenience which would be burdensome. Other conventional protective scalpels include examples in which a blade sheath pivots or extends and retracts upon a given force applied to a handle of the scalpel. These scalpels do not provide absolute security of the blade such as the present invention where the blade is completely encased in a sheath.
Prior art tool retraction/latch mechanisms have the disadvantage of exposed screws, springs, fasteners, gears, links, and the like which, upon certain conditions, could loosen and fall into a wound or cavity.
Another disadvantage of many protective scalpels is the encroachment of a portion of the scalpel blade. This interfaces with normal use of the scalpel, as entire length of the blade is typically used.
Examples of known prior art are:
U.S. Pat. No. 3,657,812 which discloses a retractable tool holder;
S. Pat. No. 5,071,426 which discloses a surgical scalpel with a retractable blade guard;
U.S. Pat. No. 5,116,351 which discloses a safety scalpel having a blade protecting sheath;
U.S. Pat. No. 5,139,507 which discloses a surgical scalpel with a retractable blade guard; and
U.S. Pat. No. 5,141,517 which discloses a retractable instrument automatically actuating the instrument to extend forward from a protective sheath.
The present invention solves many of the problems associated with prior art scalpels and latch mechanisms.
SUMMARY OF THE INVENTION
The present invention provides a tool holder in which a tool retracts into a chassis of the tool holder when not in use such that the tool is shielded.
In one embodiment, it is specifically intended that this tool be a scalpel which functions much like a typical retractable ball point pen with its simple actuation and detent type of release.
One advantage of one embodiment of the present invention is to provide a scalpel having a retractable blade which is relatively inexpensive to produce.
One advantage of the present invention is to provide a scalpel that is free of encumbrance long the entire length of the blade in its extended operative position.
In one embodiment of the present invention, there is provided a scalpel, in either an extended or a retracted position, which has no element or part, such as a pin, screw, fastener, link, or spring, that could become dislodged and be lost in a patient's tissues or body cavity.
In one embodiment of the present invention, the retractable scalpel comprises a tubular sheath member and a tubular blade support member which are secured together by a locking collar.
In one embodiment, the blade support member is slidably mounted and partially disposed in the sheath member. A cutting blade, connectible to one end of the blade support member, is shielded in the sheath member when the scalpel is not in use. The blade is extended from the sheath member and exposed when the scalpel is in its operative position.
Still in one embodiment, when the scalpel is in its operative position, the blade support member is forced forward against the strain of a spring and is locked by a latch mechanism. The blade support member is automatically released by deactuating the latch mechanism when the scalpel is not in use. Accordingly, when the blade support member is forced forward, the cutting blade extends from the sheath member. When the blade support member is released backward, the cutting blade retracts into the sheath member.
Further in one embodiment, a first spring is disposed between a back end of the blade support member and proximate the back end of the sheath member. The spring is compressed in the operative position.
In one embodiment, the blade support member comprises a pair of transversely elongated and longitudinally extended slots wherein one of the slots is disposed at a top side and another slot is disposed at a bottom side of the blade support member. When the scalpel is made into its operating position, the latch mechanism is longitudinally slid along the slots, and is received in an enlarged slot portion disposed proximate a back end of the top side slot.
Still in this embodiment, the latch mechanism includes an upper section, an enlarged section integrated with the upper section, and a lower section. A second spring is compressed under the upper section when the scalpel is not in use. The enlarged section is received into the enlarged slot portion by sliding and pushing the blade support member toward a front end of the blade support member. Upon the receipt of the latch mechanism enlarged section into the enlarged slot portion, the first spring is compressed and the already compressed second spring extends so as to force the enlarged section into the enlarged slot portion so as to lock the blade support member in place.
Still in this embodiment, the latch mechanism is deactuated by transversely compressing the second spring to separate the enlarged section from the enlarged slot portion. The first spring extends backward so as to retract the blade into the sheath member wherein the scalpel is not in use. The latch mechanism serves an additional function in that it prevents the scalpel from rolling more than 180° on a surface.
Furthermore, in one embodiment, a limiting pin and a stop pin are disposed on each side of the latch mechanism which are used to limit the blade extending movement of the blade support member and to stop the blade retracting movement of the blade support member, respectively.
In one embodiment, the blade is removably and securely attached into the blade support member by a blade receiving portion and a fitting member.
In one embodiment, the scalpel is made of stainless steel or any disposable plastic material.
Yet in one embodiment, a plurality of holes are disposed on top and bottom sides of the sheath member so that it reduces the weight of the scalpel, as well as easily washes away blood products from the blade during non-use.
Further in one embodiment, the front end of the sheath member is beveled.
Yet in one embodiment, an external surface of the sheath member is knurled so that the operator can easily control the scalpel during the operation.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawing in which like reference numerals and letters generally indicate corresponding parts throughout the several views,
FIG. 1 is a perspective view of an embodiment of a retractable scalpel in accordance with the principles of the present invention when the scalpel is in an inoperative retracted position.
FIG. 2 is a perspective view of the scalpel shown in FIG. 1 when the scalpel is in an operative extended position.
FIG. 3 is a longitudinal cross-sectional view of the scalpel shown in FIG. 1 when the scalpel is in an inoperative position.
FIG. 4 is a longitudinal cross-sectional view of the scalpel shown in FIG. 1 when the scalpel is in an operative position.
FIG. 5 is an exploded assembly view of the scalpel shown in FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the Figures, there is shown an embodiment of a retractable scalpel, designated 40, generally in accordance with the principles of the present invention.
The scalpel 40 broadly comprises a tubular barrel or sheath member 42 and a blade support assembly 44 including an inner tubular blade support member 45 which is received telescopically within the sheath member 42. A surgical blade 46, which is mounted on a front end 48 of the blade support assembly 44, is shielded in the sheath member 42. A plurality of holes 50 are disposed on a top side and a bottom side (not shown) of the sheath member 42. The surgical blade 46 is in communication with outside through the holes 50. Accordingly, the holes reduce the weight of the scalpel 40 as well as facillitatively washing away blood products from the blade 46.
The blade support member 45 includes a pair of longitudinally extended, diametrically opposed slots 52,53 wherein the slot 52 is disposed at a top side of the blade support member 45 and the slot 53 is disposed at a bottom side (shown in FIGS. 3, 4) of the blade support member 45. An enlarged slot portion 54 is disposed proximate a back end 56 of the top side slot 52, a portion of the slot 52, shown as a slot portion 52a in FIGS. 3 and 4, extending beyond the enlarged slot portion 54. The slot 53 also extends beyond the enlarged slot portion 54. The enlarged slot portion 54 is able to receive a larger diameter member than the other portion of the top side slot 52. Further, upon receipt of the larger diameter member, which has the diameter larger than the top side slot 52 but smaller than the enlarged slot portion 54, into the enlarged slot portion 54, the member is longitudinally locked relative to the sheath member 42 and the blade support member 45.
A spring 58, which is received between a diameter reducing end cap 60 (see FIG. 3) of the blade support member 45 and a limiting pin 61 at the back end 62 of the sheath member 42, is visible from outside through the slots 52, 53. The spring 58 is compressed or released between the limiting pin 61 and the end cap 60 when the blade support assembly 44 is slidably moved relative to the sheath member 42.
A latch mechanism 64 is disposed proximate the back end 62 of the sheath member 42. The latch mechanism 64 includes a push button section 66, a spring 76 and a bottom section 65 which comprises a bottom pin section 67, a flange section 69 and a hollow section 71. The push button section 66 transversely projects from the top side slot 52 and a top opening 68 of the sheath member 42, while the bottom pin section 67 projects from the bottom side slot 53 and a bottom opening 70 in the sheath member 42 which is diametrically opposite to the top opening 68 (shown in FIG. 3). The openings 68,70 are in transverse alignment with the slots 52,53 wherein the diameter of the top opening 68 is larger than the top side slot 52 and the diameter of the bottom opening 70 is smaller than the slots 52,53.
A locking collar 72 receives the latch mechanism 64, and locks the latch mechanism 64, the sheath member 42 and the blade support assembly 44 together. The structure of the locking collar 72 will be discussed later.
Now referring to FIG. 2, the blade 46 is shown extending from the sheath member 42 in the operative position. The blade support assembly 44 is pushed toward a front end 74 of the sheath member 42 and the spring 58 is compressed accordingly. The front end 74 of the sheath member 42 is beveled. Thus, the whole portion of the blade 46 which contacts a cutting piece (not shown) is wholly exposed so that the surgeon can have a larger view of the cutting piece.
FIGS. 3 and 4 show longitudinal cross-sectional views of FIGS. 1 and 2 respectively, wherein the blade 46 is shielded under the sheath member 42 in FIG. 3 when the scalpel is in the retracted, inoperative position, while the blade 46 is projected from the sheath member 42 in FIG. 4 when the scalpel 40 is in the extended, operative position.
In FIG. 3, the spring 76 is compressedly disposed under the push button section 66 and received in the hollow section 71 of the latch mechanism 46. An enlarged section 78 of the push button section 66, has a larger diameter than the top side slot 52 but smaller than the diameter of the enlarged slot portion 54. Thus, the enlarged section 78 is disposed underneath the top side slot 52 as well as the top opening 68 of the sheath member 42. Accordingly, the spring 76 is kept compressed between the push button section 66 and the bottom section 65 when the scalpel 40 is not in use. As mentioned above, the push button section 66 projects through the top side slot 52 and the top opening 68 of the sheath member 42, while the bottom pin section 67 projects from the bottom side slot 53 and the bottom opening 70 of the sheath member 42.
Now referring to FIG. 4, there is shown a cross-sectional view of the scalpel 40 having the blade extended from the sheath member 42. The blade support assembly 44 is slidably moved toward the front end 74 of the sheath member 42 during which the enlarged section 78 is able to align with the enlarged slot portion 54. When the enlarged section 78 aligns with the enlarged slot portion 54, the enlarged section 78 is automatically received into the enlarged slot portion 54 of the blade support member 45 as well as the top opening 68 as a result of the spring 76 extending. Thereupon, the latch mechanism 64 stops the longitudinal movement between the sheath member 42 and the blade support assembly 44.
The latch mechanism 64 is disposed between the limiting pin 61 and a stop pin 80. The stop pin 80 is aligned with the slots 52,53. The stop pin 80 engages a front end 49 of the slots 52, 53. Thus, the stop pin 80 reduces the possibility of damages of the latch mechanism 64. Upon pushing the push button section 66, the enlarged section 78 is accordingly pushed away from the enlarged slot portion 54 so as to allow the longitudinal movement between the sheath member 42 and the blade support assembly 44. Therefore, the blade support assembly 44 is automatically released backward so as to retract the blade into the sheath member 42.
Now referring to FIG. 5, an exploded view of scalpel 40 is shown. The locking collar 72 includes a L-shape slot 82 on a top side of the locking collar 72, and an opening 84 (shown in FIGS. 3, 4) on a bottom side of the locking collar 72. The push button section 66 is received in a slot terminal point 86 which is disposed at one end of the L-shape slot 82. The bottom pin section 67 projects outside through the bottom opening 84. The diameter of the opening 84 is smaller than that of the slot terminal point 86 so that the opening 84 receives a smaller size of the bottom pin section 67, while the slot terminal point 86 receives a larger size of the push button section 66. Consequently, the L-shape slot 82 secures the sheath member 42, the blade support assembly 44 and the latch mechanism 64 together. Further, the slot terminal point 86 is smaller than the diameter of the enlarged section 78 of the latch mechanism 64. Thus, the locking collar 72 retains the latch mechanism 64 in place on the scalpel 40.
Now referring to the blade 46 and its mounting mechanism. A blade receiving portion 88, having a needle-like head 89, includes a longitudinal projection 90 which is received into a corresponding slot 92 on the blade 46. A through hole 94 which is disposed on the blade receiving portion 88 aligns with a corresponding through hole 96 on a fitting portion 98 and further aligns with a corresponding through hole 100 on the blade support member 45. A pin 102, having a length the same as the diameter of the blade support member 45, passes through the through holes 94,96 and 100 so as to secure the blade 46 onto the blade support member 45. The blade receiving portion 88 can be replaced by removing the pin 102. A back portion 104 of the blade receiving portion 88 is received in a bore 106 of the fitting portion 98. The blade receiving portion 88 and the fitting portion 98 are standard and universal which are able to receive most regular scalpel blades. It will be appreciated that various blade mounting detach mechanisms might be used.
The limiting pin 61, having a length the same as the diameter of the sheath member 42, passes through a pair of transversely opposite openings 108 in the sheath member 42 and extends into the slot portion 52a and the slot 53. The stop pin 80, having a length the same as the diameter of the sheath member 42, passes through a top opening 110 and a transversely opposite bottom opening 112 in the sheath member 42. The stop pin 80 has a top portion larger than a bottom portion which are respectively received in the larger top opening 110 and the smaller bottom opening 112.
The scalpel 40 is made of stainless steal in the preferred embodiment. Alternatively, the scalpel 40 can be made of any kind of metal or plastic materials.
Further, an external surface 114 of the sheath member 42 is knurled so that the surgeon can easily grab or control the scalpel 40 during the operation.
When the scalpel 40 is in use, the blade support assembly 44 is pushed forward. The blade 46 is exposed outside of the sheath member 42 accordingly. The scalpel 40 is locked into an operative position when the enlarged section 78 engages with the enlarged slot portion 54.
When the scalpel 40 is not in use, the push button section 66 is pushed transversely. The blade support assembly 44 is automatically retracted and the blade 46 is accordingly shielded in the sheath member 42.
In assembling the scalpel 40, the longitudinal projection of the blade receiving portion 88 is received in the slot 92 of the blade 46. The blade receiving portion 88 is placed into the bore 106 of the fitting portion 98. The spring 58 is inserted and disposed at the end cap 60. The blade 46, the blade receiving portion 88 and the fitting portion 98 are inserted into the front end 48 of the blade support member 45. The through holes 94, 96 and 100 are aligned to each other and receive the pin 102 therebetween. Thus, the blade assembly 44 is formed.
The blade support assembly 44 is then slidably inserted into the sheath member 42 until the slots 52, 53 align with the openings 68, 70, respectively. The pins 61, 80 are inserted into the openings 108 and 110,112, respectively. The bottom section 65, the spring 76 and the push button section 66 are inserted in the slots 52,53 and the enlarged slot portion 54 from the top opening 68 to the bottom opening 70. The bottom pin section 67 is received in the bottom opening 70 while the flange section 69 stops the further insertion of the bottom pin section 67. The spring 76 is positioned in the hollow section 71 between the bottom pin section 67 and the push button section 66. At this moment, the enlarged section 78 is disposed outside of the top side slot 52. The blade support assembly 44 is pushed to allow the enlarged section 78 aligning with the enlarged slot portion 54 so that the enlarged section 78 is able to move underneath the top side slot 52. The bottom pin section 67 is pushed into the bottom side slot 53 to allow the locking collar 72 to slide over the latch mechanism 64. The locking collar 72 is slid over the back end of 62 the sheath member 42. The locking collar 72 is moved along the L-shaped slot 82 to the position where a clockwise rotation of the locking collar 72 is allowed. Then the locking collar 72 is rotated in a clockwise manner to allow the latch mechanism 64 slide into the slot terminal point 86. The push button section 66 is received in the slot terminal point 86, while the bottom pin section 67 projects through the bottom side slot 53, the bottom opening 70 of the sheath member 42 and the bottom opening 84 of the locking collar 72. Upon this step, the scalpel 40 is assembled.
The scalpel 40 can be disassembled following the reverse procedures of assembling the scalpel 40.
The blade 46 can be replaced by any type of standard scalpel blade. In replacing the blade 46, the blade 46 is simply removed from the longitudinal projection 90 of the blade receiving portion 88.
It is to be understood, however, that even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size and arrangement of parts within the principles of the invention 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 retractable "ball-pen" like tool/scalpel, provided with a latch mechanism, is automatically retracted when not in use by pushing the latch mechanism and is extended when in use by pushing a tool/blade support member of the tool/scalpel. An enlarged section of the latch mechanism is matched and engaged with an enlarged slot portion of the tool/blade support member when the tool/blade support member is pushed to an operative position wherein a tool/blade is exposed from a sheath member. The enlarged section of the latch mechanism is pushed transversely and disengaged with the enlarged slot portion of the tool/blade support member, the tool/blade support member is forced back to an inoperative position wherein the tool/scalpel is retracted into the sheath member.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation-in-part of my earlier filed application Ser. No. 10/963,188, filed Oct. 12, 2004, entitled “Cooling Assembly”, presently pending.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates in general to low powered air conditioning systems, and in particular, to a low power air conditioning system capable of running on direct current which is also capable of generating potable drinking water from humidity in the air. The system can be used in such irregularly powered locations as those that are affected by natural disaster or power blackouts and, in addition to cooling, produce potable drinking water.
[0004] 2. Description of the Prior Art
[0005] Heat in tropical and semi-tropical regions is usually accompanied by extremes of high humidity, especially at low altitude where the geographic features include bayous, marshlands, swamps, shallow lakes, heavy vegetations, and forests. This is also true in the case of tropical islands, such as the islands of the Caribbean Sea; arid land and deserts which are adjacent oceans shorelines or seashores; such as the regions East of the red Sea and West of the Gulf on the Arabian Peninsula. Generally, natural freshwater resources are scarce or limited in very hot and humid arid areas by or near shorelines due to low precipitation and rainfall and high salinity of underground water. There are also portions of the United States which have sufficient humidity to make the removal of drinking water from the atmosphere a feasible quest.
[0006] Shortage in supply of potable water and freshwater is increasing at a vast rate as deserts expand and overtake fertile land and as many of the existing water resources are being depleted. Global weather patterns in recent years have, in some cases, resulted in a drop in the rate of rainfall in many populated areas. In addition, large cities are expanding at a fast pace, swallowing neighboring villages and small towns, leading to drastic change in the lifestyle of inhabitants. The shift from rural to urban lifestyle has, in many cases, forced people to live in crowded housing and congested apartments with no or little opportunities to fresh air, thus suffering from stuffiness, heat and humidity, and being more exposed to an increasing shortage of freshwater supply.
[0007] Historically, power outages can have devastating effects on residential populations such as apartment dwellings that require electricity to power, among other things, air conditioning units that primarily run on AC. Blackouts are especially dangerous in high temperature environments where extended exposure to the heat for long periods of time may result in adverse health conditions. Children and elderly are especially vulnerable to extreme heat conditions, wherein heat related sickness such as heat strokes can cause serious health detriment or even death. Therefore a problem exists with current air conditioning technology, which is primarily based on powering units by AC, as users of these units are susceptible to power outages. There are numerous reasons for power failures, such as defects in a power station, damage to a power line or other part of the distribution system, a short circuit, or the overloading of electricity mains. Overloading of electricity mains is common during the hottest months of the year in highly populated areas, largely due to the fact that there is such a large demand for power in order to run the enormous amount of air conditioning units located in the region.
[0008] In addition to the problem of power outages and the need to supply air conditioning in hot environments, the problem of supplying drinking water often goes hand in hand, particularly in the area of natural disaster. In the event of serious natural disasters, access to freshwater needed for drinking purposes can be limited or even completely eliminated for long periods of time. This can have a devastating effect on residential communities located within the region of the disaster, whereby purifying and providing potable water may pose serious health threats. In some cases, disaster relief agencies aid residents by distributing bottled water to disaster areas. However, this activity is not always efficient in getting the drinking water to those who need it the most. In addition, this process is not energy efficient due to transport and labor needed to execute properly.
[0009] Water condensation from humid hot air takes place as part of any air conditioning or air drying cycle. Usually the condensate from such devices drips out and is customarily disposed of as useless wastewater. It would be preferable to be able to reclaim such condensate for use as drinking water, or for other household purposes. Some technologies exist for this or similar purposes. For example, air-drying equipment is presently used in such applications as for dehumidify air in basements. Dehumidifiers are also used in cold regions as well as hot humid regions in spaces used for storage of clothes and household furniture that can be affected by humidity and subsequent mold buildup. Air-drying equipment is also used in drying of manufacturing environment wherein wet raw material and stock material saturated with moisture for ease of production; such as the case in paper and wood fabrication. Often relatively dry air is required for maintenance of the quality of some products that may be affected by increase in humidity over a set level even for a short period.
[0010] The quantity of wastewater produced by dehumidifiers depends on the humidity of the ambient air and could reach large quantities in regions of extremely high humidity and high temperature wherein water is usually scarce. In case of traditional air conditioning equipment used for air-cooling and ventilation, the amount of water condensate depends on the capacity of equipment, the temperature setting inside and the temperature and relative humidity outside the building and accordingly the rate of condensation changes with the daily and seasonal variation of the local weather.
[0011] The use of such air conditioning or dehumidification product as potable water offers a number of potential advantages. Perhaps one of the greatest is the fact that the effort to condense air humidity to obtain a specific quantity of water is much less than the effort to be expended in obtaining the same quantity of freshwater by desalination of seawater or underground brackish water. Water quality in areas for which freshwater can be transported from natural or man-made resources is often lower than the standards for drinking water quality due to exposure to contamination during handling, transport and storage in water tanks on top of buildings, thus forcing the residents to use bottled water. The transportation of loads of freshwater is costly and exposes the water to contamination en route and during handling and storage. Also, reliance on bottled water is expensive for the average consumer.
[0012] Prior art encompasses inventions that utilize chemical adsorbents to dry atmospheric air or moisture-laden gases. The moisture from these type units is extracted as water for use whether as drinking water or fresh water after appropriate treatment. The adsorbent is regenerated and recycled for reuse. The use of adsorbents may be necessary in cases wherein insignificant amount of moisture is present in the atmosphere, but in the case of hot and humid environments the use of chemicals seems to be a nuisance and would require additional steps for extraction of water and regeneration of the chemicals. It would therefore be preferable to provide a system which does not require the use of adsorbents, desiccants and hygroscopic materials.
[0013] Heat pipes are also used in some applications to cool a condensing surface to dew point to precipitate the water vapor from the atmosphere and thereby control the indoor environment. However, the present invention is not based on this type of technology and does not contemplate the use of heat pipes to achieve its objectives.
[0014] Other applications in the prior art have relied upon heat convection in large structures in extraction of freshwater from the atmosphere and cooling or dehumidification of local open space. However, these type systems also do not relate to the present invention since they are generally not capable of performing economically within compact structures.
[0015] Domestic central air conditioning units used to cool homes or any other buildings operate in combination with air directing units that produce a quantity of waste condensate. However, to the best of Applicant's knowledge, none of the prior art-references disclose modifications of those units that enhance cooling while increasing of freshwater output of the units by condensation of outdoor atmospheric humidity. Rather, the condensate and drainage that come from such units has generally been limited to watering of flower beds, lawns and similar limited applications.
[0016] In view of the foregoing, a need exists in residential areas, particularly in humid regions, for a means for supplying a freshwater potable water supply as well as for means to cool and dry indoor atmospheres to levels which are promote a healthy and relatively comfortable existence in the dwellings of people with limited resources.
[0017] A need also exists for such a means which is preferably operable on direct current, so that the system can be powered by solar panels or batteries in areas where no electrical grid is present, or in the case of emergency conditions.
SUMMARY OF THE INVENTION
[0018] The present invention seeks to provide an alternative evaporative air conditioning unit that is capable of producing potable drinking while cooling an enclosure. The system is able to effectively function on direct current, making it ideal for use in areas effected by natural disaster, power outage, or simply rural locations without access to electricity.
[0019] In the method and system of the invention, an air conditioning system is provided that includes both evaporative air conditioning and mechanical air conditioning functioning components and which produces a water discharge, the mechanical air conditioning component of the system being operable entirely off direct current supplied from a direct current energy source. The air conditioning unit is operated to cool an enclosure. A portion of the water discharge is drawn off and purified before being discharged as potable drinking water.
[0020] The mechanical air conditioning component of the system includes a compressor for pumping a compressible refrigerant in a closed loop while the evaporative air conditioning component of the system includes a vortex cooling chamber. The preferred evaporative air conditioning component of the system includes a liquid sump and wherein a liquid conduit is run from the liquid sump to a water cooler. A motive means, such as a positive displacement pump is connected to the liquid conduit, wherein the pump propels the liquid from the liquid sump to the water cooler. At least one filter element is located in series with the liquid conduit, whereby the filter unit purifies the liquid before reaching the water cooler. Preferably, the water in the water cooler is maintained at a desired level, and wherein the level of water in the water cooler is automatically adjusted by means of a float and an associated valve between the pump and the water cooler.
[0021] In one version, the air conditioning system of the present invention is comprised of a shell and tube heat exchanger wherein ambient air is forced through both sides and discharged approximately together into the interior of the structure that is to be cooled. The shell side of the heat exchanger is preferably wet with a shower or weep of liquid such as water, and the air flow is turbulent through the shell side. The stream of flowing air is directed from the shell side to an outlet. The air flowing through the tube side is cooled by contact with the walls of the tubes, and is discharged to an outlet. For convenience, the air streams from the two sides can be combined into one combined stream before being discharged into the interior of the structure, or they may be is charged separately into the structure.
[0022] In a particularly preferred embodiment, the air conditioning system of the present invention comprises a direct/indirect evaporative cooler with refrigerated chilled sump water. The cooler is preferably designed as a stacked arrangement. A refrigeration compressor and storage batteries occupy a top section of the design and rest on a top shelf. The top shelf forms the top wall of an exhaust air plenum. A forced-air evaporative cooling chamber, located below the exhaust air plenum, occupies the middle section of the design. A cold water sump and an intake air plenum occupy the bottom floor of the cooling chamber. The bottom floor of the cooling chamber also comprises the top wall of an intake plenum which houses an intake fan. The intake fan draws air upwardly through a plurality of riser tubes which connect the intake plenum with the exhaust plenum and which pass through the cooling chamber.
[0023] Water in the cold water sump is refrigerated by the refrigeration compressor located in the top section of the design. Cold water from the cold water sump is introduced into the evaporative cooling chamber through a distribution header. The cold water saturates an evaporative media which surrounds or otherwise contacts the riser tubes in the cooling chamber. Air is introduced into the cooling chamber by means of oppositely arranged fans mounted on sidewalls of the cooling chamber which create a turbulent air flow in the cooling chamber and which enhance the evaporative cooling process. Cooled air from the cooling chamber can be discharged through a suitable duct to the interior of the structure to be cooled.
[0024] Air is also being drawn into the intake plenum by the intake fan, which air flow is forced upwardly through the riser tubes in the cooling chamber. The riser tubes pass through the cold water sump and also contact the evaporative media in the cooling chamber, whereby the outside of the tubes are cooled. The air within the tubes is cooled by conduction through the tubes. This relatively drier air can be directed through a suitable duct to the interior of the structure to be cooled and can be combined with the more moist, cooled air from the cooling chamber, if desired.
[0025] In this version of the invention, air is being cooled using two simultaneous processes. Air is cooled by direct contact with water in the evaporative cooling chamber, raising the absolute humidity of the air cooled in this manner. Additional air is also being cooled by conductive heat transfer within the riser tubes. If desired, the two air flows can be combined into a discharge duct so that the discharged air consists of a mixture of relatively humid air from the evaporative process and air with near ambient humidity. The cold water sump at the bottom of the cooling chamber serves as a cooling mass, as well as a water storage sump. The water in the sump is refrigerated to near freezing by means of a low temperature compressor similar to that used on an ice machine. The compressor can be AC or DC operated, but is preferably DC operated. The electric fans used in the intake plenum and on the cooling chamber are preferably DC fans which can be driven by solar cells or storage batteries.
[0026] The present invention therefore has as a primary aim to provide purified, potable drinking water while operating as an air conditioning unit. The excess discharge water that is generated during the air conditioning process is filtered and can be channeled through a fluid conduit directly into a water cooler, if desired. In one version of the device, the air conditioning system of the invention has been used to produce up to about a gallon and a half of purified, potable drinking water every day in addition to providing indoor cooling for an inhabited structure. The system requires low power input to operate, and is capable of functioning on direct current, allowing the system to be ideal for locations experiencing irregular power distribution or blackouts. The direct current power source may be a battery, or in the preferred embodiment of the present invention, a solar panel which may be used to charge a storage battery.
[0027] Additional objects, features and advantages will be apparent in the written description which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1 is a perspective view of one embodiment of the device of the invention which features combined direct/indirect evaporative cooling with refrigerated chilled sump water.
[0029] FIG. 2 is a partially schematic view of the cooling chamber of the device of FIG. 1 showing the evaporative cooling pads hanging therein.
[0030] FIG. 3 is a perspective view of the device of FIG. 1 with the rear wall removed for ease of illustration of the internal components of the device.
[0031] FIG. 4 is an isolated view of the cooling chamber and refrigeration manifold used in the device of FIGS. 2 and 3 .
[0032] FIG. 5 is a perspective view of the device of FIG. 1 with the rear wall removed for ease of illustration.
[0033] FIG. 6 is a view of the top wall of the cooling chamber which also serves as a tube sheet for the riser tubes.
[0034] FIG. 7 is a side view of the cooling chamber showing the location of the water distribution array.
[0035] FIG. 8 is an isolated view of the cooling chamber of the device of FIG. 1
[0036] FIG. 9 is an isolated view of the air intake plenum and air intake fan.
[0037] FIG. 10 is an isolated view of the refrigeration manifold used in the cold water sump of the device of FIG. 1 .
[0038] FIG. 11 is a cross sectional view taken along lines 11 A- 11 A in FIG. 10 .
[0039] FIG. 12 is an end view of the manifold of FIG. 10 showing the cross-over piping arrangement used to produce the interlayered flow pattern.
[0040] FIG. 13 is a simplified schematic view of the air conditioning system of the invention being used to provide potable water to a self-filling water cooler.
[0041] FIG. 14 is an isolated view of the water cooler bottle which receives water from the air conditioning system of the invention.
[0042] FIG. 15 is a side view of the water cooler of FIG. 14 , showing the filter units located on the back side thereof.
DETAILED DESCRIPTION OF THE INVENTION
[0043] Referring now to FIGS. 1-16 , there is shown an air conditioning system of the invention which can be adapted for use in high temperature, low humidity environments, but which is preferably used in a higher humidity environment, including tropical or semi-tropical environments.
[0044] With reference to FIG. 1 , there is shown an air conditioner 201 which is a combined direct/indirect evaporative cooler with refrigerated chilled sump water. The variable humidity device 201 shown in FIG. 1 is preferably designed as a stacked arrangement having a top section 203 , a middle section 205 and a bottom section 207 . A refrigeration compressor 209 , an associated condenser unit 210 , and a storage battery 211 ( FIG. 3 ) occupy the top section 203 of the design and rest on a top shelf 213 . The top shelf 213 forms the top wall of an exhaust air plenum 215 having an opposing wall 216 . A forced-air evaporative cooling chamber ( 217 in FIG. 3 ) is located below the exhaust air plenum and occupies the middle section of the design. The cooling chamber comprises a shell plenum for the air conditioner and comprises about 65% of the total height of the unit in the particular embodiment illustrated in the drawings. A cold water sump 219 (indicated by dotted lines in FIG. 3 ) is located in the bottom of the cooling chamber. The bottom floor 223 of the cooling chamber 217 also comprises the top wall of an intake plenum 221 housing an intake fan 225 . The intake fan 225 draws air upwardly through a plurality of riser tubes 227 which connect the intake plenum 221 with the exhaust plenum 215 and which pass through the cooling chamber 217 .
[0045] As shown in FIG. 5 , the bottom floor 223 of the cooling chamber has a plurality of openings 224 (detail shown in FIG. 6 ) which form a lower tube sheet for the riser tubes 227 . Similarly, the opposing wall 216 has aligned openings ( 214 in FIG. 4 ) which form an upper tube sheet. In the embodiment of the invention illustrated in FIGS. 1-9 , there are approximately 49 copper tubes of approximate ¼-⅜ inch diameter arranged vertically within the cooling chamber 217 between the tube sheets. The sizing and arrangement of the tube bundle creates a back pressure effect during operation which acts as a self-regulating thermostat.
[0046] The operation of the variable humidity embodiment of the invention will now be briefly described. Cold water from the cold water sump 219 ( FIG. 3 ) is introduced into the evaporative cooling chamber through a distribution header 229 . The distribution header in FIG. 3 is a series of PVC pipes which have downwardly directed perforations. The cold water which is sprayed downwardly from the distribution header saturates an evaporative media which surrounds or otherwise contacts the riser tubes 227 in the cooling chamber 217 . The evaporative media is illustrated by the downwardly hanging pads 218 in FIG. 2 . The evaporative media is removed for ease of illustration in FIGS. 3 and 5 but can comprise any of the media materials known in the relevant arts, e.g., tubular foam blankets or loose reticulated foam sheets. Preferably, the evaporative media is supplied as generally rectangular pads which are suspended from a rack (see FIG. 2 ) on the roof of the cooing chamber so that the pads are spaced between and separate the various vertical riser tubes 227 .
[0047] Air is introduced into the cooling chamber by means of oppositely arranged fans 231 , 233 ( FIG. 3 ). The fans 231 , 233 are mounted on louvers ( 235 , 237 in FIG. 3 ) which can be manually adjusted to direct incoming and exhaust air from the cooling chamber 217 in a circular, vortex type flow path which creates a turbulent air flow in the cooling chamber 217 and which enhances the evaporative cooling process. The vortex effect created by the side louvers 235 , 237 causes air moving through the cooling chamber 217 to have an increased residence time within the cooling chamber. This increases the cooling effect and also prevents water droplets from being blown directly out of the shell plenum. Cooled air from the cooling chamber can be discharged through a suitable grate (such as grate 239 in FIG. 5 ) to the interior of the structure to be cooled or can be routed through suitable ducts to the desired regions of the interior of the structure being cooled.
[0048] Air is also being drawn into the intake plenum 221 by the intake fan 225 , which air flow is forced upwardly through the riser tubes 227 located in the cooling chamber. The riser tubes pass though the cold water sump and also contact the evaporative media in the cooling chamber, so that the outside of the tubes are cooled. The air within the tubes 227 is cooled by conduction through the tubes. This relatively drier air can be directed through a suitable duct to the interior of the structure to be cooled and can be combined with the cooled air from the cooling chamber, if desired.
[0049] In this embodiment of the invention, air is being cooled using two simultaneous processes. Air is cooled by direct contact with water in the evaporative cooling chamber 217 , raising the absolute humidity of the air cooled in this manner. Additional air is also being cooled by conductive heat transfer within the riser tubes 227 . The absolute humidity of this additional air is either unchanged or only slightly changed, or decreases slightly, due to condensation on the inside of the riser tubes. If desired, the two air flows can be combined into a single discharge duct as described with respect to the first embodiment of the invention, so that the discharged air consists of a mixture of relatively humid air from the evaporative process and air with near ambient humidity.
[0050] The cold water sump (illustrated generally at 219 in FIG. 3 ) at the bottom of the cooling chamber serves as a cooling mass, as well as a sump. The water in the sump is refrigerated to near freezing by means of a commercially available, low temperature compressor similar to that used on an ice machine and which can be AC or DC operated, but is preferably operable on 12 Volt DC power. In the embodiment of the invention illustrated in FIG. 5 , the compressor 209 is battery operated. However, an associated inverter 243 (in FIG. 5 ), which in this case is located within the exhaust plenum area 215 allows the unit to be operated off AC current to, for example, charge the batteries, during non-peak hours of operation. Locating the inverter within the chilled exhaust plenum compartment prolongs its life since the operating temperature is reduced. The electric fans used in the intake plenum and on the cooling chamber are also preferably 12 Volt DC fans which can be driven by solar cells or storage batteries.
[0051] FIGS. 10-13 illustrate another feature of the system in which a particularly preferred refrigeration manifold 245 ( FIG. 10 ) is cooled by the compressor 209 and associated condenser 210 using traditional mechanical refrigeration techniques. While a number of different traditional manifold or coil arrangements could be utilized with the compressor 209 to cool the water in the sump 219 , the preferred manifold 245 is especially efficient for the intended application. As best seen in the isolated view of FIG. 10 , the manifold 245 is a “double shock” manifold having a front layer 247 and a rear layer 249 . The front and rear layers or coils are spaced apart by means of a plurality of cylindrical spacers 251 . The cylindrical spacers 251 are less wide than the total width of the manifold, leaving a distance “d” between adjacent spacers. The cylindrical spacers are also hollow and open at both ends, allowing water in the sump 219 to flow around and through the spacers. As shown in FIG. 10 , the manifold 245 is arranged in a generally horizontal plane when in place in the sump region of the cooling chamber.
[0052] Refrigerant is supplied to and returned from the manifold layers by a pair of “splits”, shown generally at 253 and 255 in FIG. 12 . As shown in FIG. 12 , the top layer of coils is made up of loops 252 , 254 , 256 , 258 , 260 , 262 , 264 , and 266 . (The loops are shown as broken-away halves for ease of illustration.) The rear layer of coils is made up of loops 268 , 270 , 272 , 274 , 276 , 278 , 280 and 282 . The loop halves 252 - 266 form a continuous coil on the front of the manifold. The loop halves 268 - 282 similarly from a continuous loop on the rear of the manifold. The points at which the front and rear loops exit or terminate (generally 266 , 268 in FIG. 12 ) are connected by cross-over pipes 284 , 286 . The cross-over pipes 284 , 286 intersect the first loop halves ( 252 , 282 , in FIG. 12 ) to form the “splits 253 , 255 . The cross-over piping arrangement and the splits 253 and 255 result in a type of “interlayered flow” through the manifold. For example, refrigerant passing through the split 253 flows through branch 253 B ( FIG. 12 ) to the front layer 247 and through branch 253 A to the rear layer 249 . Refrigerant returning from the front and rear layers 247 , 249 meets at the split 255 . The double shock manifold with its split flow operation nearly doubles the cooling capacity of the compressor 209 .
[0053] In less arid climates it will generally be possible to extract humidity from the previously described system and use such water as a potable water supply. As briefly mentioned above, the water within sump region 219 of the cooling chamber of the device is typically at least about 10 to 15 degrees Fahrenheit cooler than the surrounding environment. This provides the opportunity to provide some cooling to objects placed in heat exchange relationship with this water. For example, small objects can be cooled without the expenditure of significant additional amounts of energy. Suitable containers can be placed directly in the water on the shell side, or a cabinet accessible from the outside can be built into the shell side, or a stream of water circulated through, for example, cooling coils external to the shell side, or the like.
[0054] The chilled water within the sump region 219 also provides the opportunity to provide a source of potable drinking water from the air conditioning system. The hybrid cooler which has been described can be operated in a humid environment to provide fairly large amount of excess water during operation. As illustrated in simplified fashion in FIG. 14 , the excess water generated during the air conditioning process routed by means of a suitable conduit 512 and positive displacement pump 514 to a water cooler 410 . For purposes of the present invention, the water cooler is preferably a “self-filling water cooler” which comes supplied with its own filtration units located on a rear wall thereof. It is important to note that the removal of the excess water will not hinder the operation of the air conditioning unit in any way, as there will remain ample condensation to recirculate back through the system in order to continue the cooling aspect of the air conditioning system.
[0055] FIGS. 13-15 illustrate one form of the water generating system of the invention in which a self-filling water cooler 410 is utilized. This type water cooler is known generally in the industry and is described, for example, in issued U.S. Pat. No. 4,881,661, issued Nov. 21, 1989. The following description is intended to be merely explanatory of the general workings of such devices. Referring to FIG. 14 , the bottled water cooler 41 . 0 comprises a lower frame member 411 which serves as a storage container for various well known appurtenances of a conventional cooler, such as connectors, conduits chilling mechanism (not shown) which are connected in series between the water bottle 412 positioned on top of the stand 411 to the spigot means 413 and 414 . In that particular embodiment, such coolers are provided with two spigots generally to give a source of chilled water and hot water. In the latter instance, a heating apparatus would be included within the stand 411 connected in the conduit of the water bottle 412 . Such bottled water coolers including many variations are old and well known in the art.
[0056] Referring now to FIGS. 15 and 16 , the device includes the five gallon plastic bottle 412 which in turn is further defined as comprising the conventionally operated float valve means 415 which is attached inside of the water bottle 412 . The float valve 415 is attached thereto via a bulk head tubing fitting 416 which protrudes through the side wall of the five gallon water bottle 412 . The tubing fitting or adapter 416 provides for connecting the float mechanism to a purified water supply via the conduit means 417 .
[0057] The five gallon water bottle 412 also has an additional tubing bulkhead fitting 420 protruding through the rear wall portion of the five gallon bottle 412 to allow connection to the air vent filter means 421 . The latter mechanism allows the displacement of trapped air inside of the bottle 412 as the bottle fills and empties. As the bottle 412 is filled with water, air trapped in the bottle will be discharged through the filter. Conversely, as water is emptied from the bottle, suction produced on the bottle will be alleviated by air passing through the filter member 421 which in turn flows through the conduit member 422 connecting the member 421 to the bulk head fitting 420 . In such manner, air entering the bottle 412 is purified.
[0058] The five gallon bottle 412 is sealed to the base 423 of the water cooler 410 by a conventional rubber boot/gasket means 424 . An inner container or sump is positioned immediately below the base 423 . In a conventional bottle water cooler, as water is drawn from either of the spigots 413 or 414 , water exits from the container 412 into the upper tank (not shown) of the cooler; however, the tank does not flow due to the vacuum created within the water bottle 412 even though the tank is opened to the atmosphere. However, in the present system, it is necessary that the water bottle 412 be sealed to the tank. The flexible rubber boot or gasket 424 ( FIG. 15 ) accomplishes this purpose by sealing the neck 425 of the five gallon water bottle 412 to the upper tank (not shown) of the water cooler 410 . This is accomplished by providing the member 424 with the elongated flexible constricted portion 426 which is adapted to fit over the neck portion 425 of bottle 412 . The bottom portion 428 fits over the top portion of the tank, thus sealing the tank to the container 412 .
[0059] FIG. 16 of the drawings illustrates the filter unit of the water cooler which features a small reverse osmosis purification system 430 . The system 430 is further defined as comprising the series of conventional water filtering members 431 , 432 , and 433 which function in combination with the reverse osmosis filter 434 . In such a system, water from, such a conventional tap water source 435 is fed in series through the filter members 431 and 432 via the connecting conduit 436 and 437 to the reverse osmosis unit 434 which in turn is connected via the conduit 438 to the filter member 433 from which a source of high purified water exits and flows through the conduit 417 into the water bottle 412 by virtue of the float means 415 , which operates in a conventional fashion by virtue of the leverage action of the buoyant float member 439 operably connected to the main frame portion of the float member 415 by virtue of the elongated connecting means 440 which is hinged to provide articulate motion relative to the main from body of the float mechanism 415 and is operably connected to a plunger mechanism (not shown) positioned therein which includes a conventional valve stem or piston member that is cause to reciprocate against a seated opening therein so as to seal said opening when the buoyant member 413 is in an upraised position. Conversely, when the member 439 is allowed to deflect downward, water enters the container 412 by virtue of the float valve opening 441 .
[0060] When the float valve means 415 is sealed, pressure increases in the conduit 417 , which pressure level is reflected in the flow control member 442 shown in FIG. 16 of the drawings which in turn causes flow from the water source 435 to be interrupted through the first filter member 431 . The over flow line 443 is provided for catching any moisture that may flow through the sub-micron filter member 421 .
[0061] While one particular filter system has been illustrated in the drawings, it will be understood that a variety of filter systems could also be utilized with the air conditioning system of the invention in order to supply potable drinking water from the air conditioning condensate.
[0062] An invention has been provided with several advantages. The system of the present invention is ideal for use in areas affected by natural disaster, or areas that have limited or no access to purified water. Health risks related to the consumption of unsuitable water is eliminated due to the purification elements involved with the present invention. Furthermore, this method provides an economic and environmentally sound alternative to bottled drinking water. In addition, the present invention requires low power input to operate, and is capable of functioning on direct current, such as battery power, or in the preferred embodiment of the present invention, on solar power. This allows the system to be ideal for locations experiencing irregular power distribution or blackouts. The cooling system of the invention is relatively inexpensive to manufacture. The system achieves as much as a 30 degree or more temperature “split” between incoming and discharged air temperatures. The system can be operated on DC power which can be obtained from solar panels or from wind mills. The inverter lets the unit be plugged into AC power during non-peak times to recharge the DC battery power source. The typical unit can be operated on less than 20 amps of AC power under even peak conditions. The vortex nature of the wet chamber necessarily picks up pollutants in the air such as pollen, dust and the like. The pollutants drop down into the sump area of the device and can be discharged, making the unit act as an air purifier in addition to an air conditioner. The humidity of the system can be adjusted in several different ways, depending upon the intended end application of the unit.
[0063] Those skilled in the relevant arts will understand that various changes and modifications may be made in the preferred embodiments of the invention described above. While the present invention has been described with reference to specific embodiments wherein the shell side of a heat exchanger is the wet side and the tube side is the dry side, those skilled in the art will readily appreciate from a consideration of these teachings that other arrangements are possible, including, for example, the use of a wet tube side and a dry shell side, or the like. Also, those skilled in the art will be taught by the teachings herein that other forms of heat exchangers other than shell and tube can be employed, if desired.
[0064] What have been described are preferred embodiments in which modifications and changes may be made without departing from the spirit and scope of the accompanying claims. Many modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described.
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A system and method are shown which utilize a hybrid mechanical and evaporative air conditioning system to produce potable drinking while cooling an enclosure. The system operates on direct current, making it suitable for use in areas effected by natural disaster, power outage, or simply rural locations without access to electricity. The conditioning system includes both evaporative air conditioning and mechanical air conditioning functioning components to produce a water discharge. The system is operated to cool an enclosure. A portion of the water discharge is then drawn off and purified for use as drinking water.
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BACKGROUND OF THE INVENTION
This invention relates to systems for maintaining a cargo in a refrigerated condition over an extended duration by means of a finite amount of solid carbon dioxide which is not replenished during such duration.
It has long been the practice to refrigerate items in an insulated enclosure by placing solid carbon dioxide either directly into the storage area of the enclosure or into a separate compartment adjacent to the storage area. Such systems are shown, for example, in the following publications:
U.S. Pat. No. 2,508,385
U.S. Pat. No. 3,206,946
U.S. Pat. No. 3,561,226
U.S. Pat. No. 4,498,306
U.S. Pat. No. 4,502,293
U.S. Pat. No. 4,593,536
U.S. Pat. No. 4,704,876
U.S. Pat. No. 4,761,969
U.S. Pat. No. 4,766,732
U.S. Pat. No. 4,825,666
U.S. Pat. No. 4,891,954
U.S. Pat. No. 5,168,717
American Frozen Food Institute, "Cryogenic Railcar Project, Executive Summary Report," March 1985.
The foregoing systems have been especially applicable for shipment of refrigerated items by railcar where a finite amount of solid carbon dioxide is placed in a bunker at the top of the railcar prior to shipment and gradually receives heat through the bunker floor from the cargo, and through the railcar roof from the surrounding environment, which converts the solid carbon dioxide to a gas by the process of sublimation. The gas is vented from the bunker into the cargo area where it circulates to cool the cargo and then is exhausted to the atmosphere. In such systems, as exemplified by the above-listed U.S. Pat. Nos. 4,502,293, 4,593,536, 4,704,876, and 4,761,969, it has been a common practice to insulate the floor of the carbon dioxide-containing bunker to limit the heat transfer directly from the cargo to the carbon dioxide to avoid overcooling of the cargo. This, together with the heavy steel construction of the railcar which functions advantageously as a heat sink, has had the effect of extending the period during which the cargo can be maintained in a refrigerated condition without replenishing the carbon dioxide to durations of as much as 12 to 15 days, with carbon dioxide sublimation occurring over a substantially shorter period (until exhaustion of the solid carbon dioxide) followed by gradual warming of the cargo. A railcar modified and used commercially in 1991 by the present inventor, for example, was capable of maintaining adequate refrigeration of a cargo over a 12-day duration employing a carbon dioxide bunker floor which, although insulated, provided a heat transfer rate greater than 0.08 BTU per hour per square foot per degree Fahrenheit of temperature difference between the top and bottom of the bunker floor. This caused exhaustion of the solid carbon dioxide after seven to nine days, depending on the ambient temperature, followed by gradual warming of the cargo.
What has not previously been accomplished nor considered feasible is the attainment of significantly longer refrigeration durations utilizing a finite, nonreplenished amount of solid carbon dioxide, and not necessitating the heavy steel heat sink characteristics of a railcar to achieve such durations. Nevertheless there is a great need for such a low-maintenance refrigeration system for longer-duration shipments, particularly transoceanic shipments.
SUMMARY OF THE INVENTION
The present invention provides a system for maintaining a cargo in a refrigerated condition over extended durations, preferably 30 days or more, utilizing a finite amount of solid carbon dioxide initially placed in a carbon dioxide-enclosing portion of an insulated enclosure separated from a cargo-enclosing portion by an insulated barrier so that sublimation occurs over a duration of at least 15 days. Although it is within the scope of the invention to employ it in railcars, the invention is even more advantageously employed in stackable cargo-carrying containers of much lighter construction than railcars and having significantly less heat sink capacity. Such exceptionally lengthy refrigeration durations are unique for a system of this type, requiring no external power or replenishment of the carbon dioxide during shipment, and are sufficient to accommodate not only normal transoceanic transport times but also loading and unloading delays likely to occur at the origin and destination points, respectively.
The present invention recognizes that achieving such lengthy refrigeration durations in nonreplenished carbon dioxide systems requires a more highly-insulated barrier, separating the carbon dioxide-enclosing portion of the enclosure from the cargo-enclosing portion, than has been considered appropriate in the past, while nevertheless limiting the insulation of the barrier so that it is not excessive. In accordance with the present invention, the insulation of the barrier should be such as to provide a rate of heat transfer across the barrier greater than the rate at which heat is transferred from the cargo to the carbon dioxide gas vented into the cargo-containing portion of the enclosure after initial placement of the solid carbon dioxide has been completed, but no greater than 0.08 BTU per hour per square foot per degree Fahrenheit of temperature difference between the opposite sides of the barrier. Rates of heat transfer below this range, due to excessive insulation, are likely to provide insufficient cooling of the cargo by the carbon dioxide, while rates of heat transfer above this range, due to insufficient insulation, are likely to refrigerate the cargo for too short a duration due to an excessive rate of sublimation of the carbon dioxide.
The present invention also recognizes that finite, nonreplenished carbon dioxide refrigeration systems are capable of obtaining such lengthy refrigeration durations especially if employed in vertically-stackable cargo-carrying containers, as opposed to nonstackable transporting enclosures such as railcars. Normally, a large proportion of the refrigeration capacity of the solid carbon dioxide in a railcar is wastefully expended by the absorption of heat from the environment into the carbon dioxide enclosure through the roof of the railcar. However if stackable containers are used, such wasteful absorption of heat through the roofs is greatly reduced by thermal shielding of the roofs due to stacking. Even in the topmost container having an exposed roof, the wasteful heat absorption is nevertheless at least partially offset by lesser heat absorption through the floor of the container due to the shielding provided by another refrigerated container immediately below it. Similarly, such stackable containers can further limit heat absorption from the environment through their sides and ends by their ability to be arranged in very close side-by-side proximity to one another, thereby further maximizing the durations of refrigeration which are obtainable.
The foregoing and other objectives, features, and advantages of the invention will be more readily understood upon consideration of the following detailed description of the invention, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of an exemplary embodiment of a stackable cargo-carrying container constructed in accordance with the present invention.
FIG. 2 is an enlarged end view of the container of FIG. 1, showing the entry doors for loading the container.
FIG. 3 is an enlarged opposite end view of the container of FIG. 1, showing a carbon dioxide charging and venting assembly.
FIG. 4 is an enlarged detail view of the charging and venting assembly shown in FIG. 3.
FIG. 5 is an enlarged cross-sectional view taken along line 5--5 of FIG. 1.
FIG. 6 is an enlarged partial sectional view taken along line 6--6 of FIG. 1.
FIG. 7 is an enlarged partial sectional view taken along line 7--7 of FIG. 3.
FIG. 8 is a partial perspective view of multiple containers of the type shown in FIG. 1 being loaded onto the deck of a ship.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
An exemplary embodiment of a container suitable for use in the present invention, indicated generally as 10, comprises an elongate, generally rectangular enclosure having a top 12, bottom 14, sides 16, permanently closed end 18 and openable end 20 having doors 22. Posts such as 24 are spaced longitudinally along the container to provide not only vertical support for the top 12 but support for enabling multiple containers 10 to be stacked atop one another as depicted in FIG. 8. When stacked vertically, or in side-by-side or end-to-end relationship, conventional locking members 26 can be used to fasten the respective containers to one another for stability. Although the size of the container may be variable, the exemplary container 10 is of a standard 40-foot length with an exterior height of 91/2 feet and an exterior width of 8 feet.
With reference to FIGS. 5, 6 and 7, the container 10 comprises a thermally insulated enclosure having a cargo-enclosing portion 28, constituting the majority of the volume of the enclosure, and a carbon dioxide-enclosing bunker portion 30 constituting a minority of the volume of the enclosure. The portions 28 and 30 are separated by a horizontal insulated barrier 32 consisting of multiple bunker floor panels 32a (FIG. 6) supported by metal angle channels 34 extending longitudinally along the interior of the container sides. Preferably, the interior vertical height of the bunker portion 30 is about 13 inches. Each panel 32a has apertures 36, 38 formed therein for venting carbon dioxide gas from the bunker portion 30 into the cargo-enclosing portion 28, both rapidly during the initial injection of carbon dioxide into the bunker portion 30 as described hereafter, and then gradually thereafter during the storage period as the solid carbon dioxide in the bunker portion 30 sublimates. As the carbon dioxide gas is vented from the bunker portion 30 into the cargo-enclosing portion 28 through the venting apertures 36, 38, the gas flows down the interior sides of the container through a series of vertical channels 40 (FIG. 6) approximately 1/2 inch in depth, and beneath the cargo through longitudinally-extending channels 42 formed between dividers 44 approximately 1 inch in height. The channels 42 and dividers 44 are preferably part of a commercially available standard refrigeration floor such as that manufactured by Alumax Extrusions, Inc. of Yankton, S.D. After flowing around the sides and bottom of the cargo, and thus cooling the cargo, the carbon dioxide gas is exhausted at the end 18 of the container by passing behind a baffle 46 (FIG. 7) and thence to the exterior of the container through an exhaust vent 48 formed in a carbon dioxide charging and venting assembly 50 mounted in the end 18.
As shown in FIGS. 3 and 4, the charging and venting assembly 50 also includes temperature gauges such as 52 for monitoring the interior temperature of the container 10, and a carbon dioxide injection fitting 54 communicating between a pair of ball valves 56a and 56b with a copper loading pipe 58 approximately 11/2 inches in diameter. A portion of the pipe 58 extending longitudinally centrally along the interior surface of the roof 12 of the container 10 contains spaced perforations 60 (FIG. 7) for injecting carbon dioxide into the bunker portion 30. After a cargo has been loaded into the container 10, and the doors 22 closed, a source of liquid carbon dioxide under pressure is connected to the fitting 54 with the upper valve 56a open and the lower valve 56b closed. Thereafter, as the carbon dioxide flows through the pipe 58 and through the perforations 60 into the bunker portion 30, approximately half of it flashes to gas which is vented through the apertures 36, 38, channels 40 and channels 42 around the cargo and out the exhaust vent 48, while the remainder of the carbon dioxide is deposited as solid carbon dioxide particles onto the upper surfaces of the barrier panels 32a. Preferably, dams 36a and 38a are provided around the respective apertures 36, 38 to prevent the solid carbon dioxide particles from clogging the apertures and hindering proper venting, as disclosed in Thomsen U.S. Pat. No. 4,891,954, which is incorporated herein by reference. The maintenance of adequate venting is extremely important, especially during the initial carbon dioxide injection procedure, to prevent excessive pressure within the bunker portion 30. Such excessive pressure can fracture the bunker floor panel 32a and alter the critical heat transfer characteristics of the container between the portion 28 and the portion 30, thereby preventing the maintenance of proper refrigeration. In addition, even with the clogging prevention afforded by the dams 36a and 38a, to ensure the absence of panel fracture during the initial carbon dioxide injection procedure the rate of carbon dioxide injection should be no greater than 0.42 pounds of liquid carbon dioxide per minute per square inch of combined vent apertures 36, 38 for panels 32a constructed as described hereafter.
Although the thermal insulation provided in the top, bottom, sides and ends of the container 10 may vary, such insulation preferably comprises polyurethane foam 62 having a thickness of 6 inches on the top, bottom and ends of the container 10, with similar insulation 5 inches in thickness along the sides. The foam 62 is preferably of a closed-cell type resistant to water absorption and having a density of approximately two pounds per cubic foot. The foam may be applied by spraying or pouring. Alternatively, a polystyrene closed-cell foam could be used. The interior sides of the foam insulation are preferably finished with fiberglass reinforced plastic sheets 64.
The structure of the bunker panels 32a is a critical factor in determining whether refrigeration of the cargo can be maintained over extended storage durations using a finite initial injection of solid carbon dioxide which is not replenished during the storage duration. In accordance with the present invention, the thermal insulation of the panels 32a and combined area of the apertures 36, 38 should be such as to provide a rate of heat transfer across the barrier 32 greater than the rate at which heat is transferred from the cargo to the carbon dioxide gas vented into the cargo-containing portion of the container after completion of initial injection of the carbon dioxide into the bunker portion 30, but at a rate no greater than 0.08 BTU per hour per square foot of area of the barrier per degree Fahrenheit of temperature difference between the two sides of the barrier 32. Rates of heat transfer below this range, due to excessive insulation, are likely to provide insufficient cooling of the cargo by the carbon dioxide, while rates of heat transfer above this range, due to insufficient insulation, are likely to refrigerate the cargo for too short a duration due to an excessive rate of sublimation of the solid carbon dioxide. Rates of heat transfer within this range will enable sublimation of the solid carbon dioxide to continue over a duration of at least 15 days before the solid carbon dioxide is exhausted, enabling refrigeration durations of up to 30 days or more.
When major areas of the container's exterior, particularly the sides and/or bottom, are not abutting other similar containers but rather are exposed to the environment, it is further preferable that the heat transfer through the insulated barrier 32 from the cargo-enclosing portion 28 to the bunker portion 30 be at an average time rate over the duration of storage which is less than the average time rate over the same duration at which heat is transferred from outside of the container into the cargo-enclosing portion 28.
In order to achieve the foregoing objectives in the exemplary container 10 each of the panels 32a of the barrier 32 is preferably constructed of closed-cell polyurethane foam 66 (sprayed or poured) having a density of two pounds per cubic foot and a thickness of 2 inches, sandwiched between a pair of fiberglass-reinforced plastic sheets 68, each sheet having a thickness of 3/16 inch. Each sheet is preferably finished on both sides with white gelcoat, except for the upper surface of the panels 32a which are finished with plain resin. Each panel 32a, of which there are a total of ten, is 48×84 inches and has four venting apertures 36 which are 3×6 inches and four venting apertures 38 which are 3×10 inches.
In use, the container 10 may, for example, be loaded with 42,000-43,000 pounds of frozen french fries, or with any other frozen food, the doors 22 closed, and 22,000 pounds of liquid carbon dioxide initially injected into the bunker portion 30 through the pipe 58 at a rate preferably not exceeding about 800 pounds of liquid per minute to avoid fracture of the panels 32a. During initial injection, approximately half of the carbon dioxide flashes to gas which is exhausted through the venting apertures 36, 38 into the cargo-enclosing portion 28 from which it flows around and under the cargo to the exterior of the container through the exhaust vent 48. After initial carbon dioxide injection has been completed, the upper valve 56a is closed and the container 10 may be transported for durations of 30 days or more without further attention while maintaining the cargo in an adequately-refrigerated condition even if all outer surfaces of the container are exposed to ambient temperature. Alternatively, if multiple such containers are stacked atop one another and alongside one another in close proximity as shown in FIG. 8, significantly longer durations of refrigeration are obtainable from the same initial amount of carbon dioxide in each container.
The terms and expressions which have been employed in the foregoing specification are used therein as terms of description and not of limitation, and there is no intention, in the use of such terms and expressions, of excluding equivalents of the features shown and described or portions thereof, it being recognized that the scope of the invention is defined and limited only by the claims which follow.
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A system for maintaining a cargo in a refrigerated condition over an extended duration employs an insulated enclosure having both a cargo-enclosing portion and a carbon dioxide-enclosing portion separated by an insulated barrier. A finite amount of solid carbon dioxide is placed in the carbon dioxide-enclosing portion at the beginning of the duration. By properly insulating the barrier to provide a rate of heat transfer within a predetermined range, the cargo is maintained in a refrigerated condition without replenishing the solid carbondioxide for uniquely lengthy durations. Such durations are especially maximized by employing such enclosures in the form of cargo-carrying containers of generally rectangular shape stackable vertically atop one another and/or in close side-by-side relation to one another.
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BACKGROUND TO THE INVENTION
1. Field of the Invention
This invention relates to user equipment for communication systems and in particular, but not exclusively for high speed downlink packet access (HSDPA) for WCDMA communication systems.
2. Description of the Related Art
As is known in the field a further development of the wideband code division multiple access (WCDMA)/universal mobile telecommunications system (UMTS) communication system defined by the 3GPP organization, is the definition of the system known as high speed downlink packet access (HSDPA). HSDPA operates as a time shared communications channel which provides the potential for high peak data rates as well as the possibility for having a high spectral efficiency.
Current 3GPP HSDPA standards (e.g. 3GPP TS 25.858) define a HS-DSCH channel (high speed downlink shared channel), which is a downlink transport channel shared by several user equipment units. The HS-DSCH is associated with one downlink DPCH (downlink dedicated physical channel) or F-DPCH (option in 3GPP Rel6) per active user, and one or several shared control channels (HS-SCCH). The HS-DSCH can be transmitted over the entire cell or over only part of the cell using for example beam-forming antennas.
HSDPA improves system capacity and increases user data rates in the downlink, in other words for transmission of data from a radio base station (RBS) which in a UMTS system is also known as a node B server (and in the GSM by the term base transceiver station BTS) to the user equipment.
This improved performance is based on three aspects. The first aspect is the use of adaptive modulation and coding.
In HSDPA, the link adaptation entity in the radio base station (Node-B server) tries to adapt to the current channel conditions of a certain user equipment (or user terminal) by selecting the highest possible modulation and coding scheme keeping the frame error probability below a certain threshold. For that purpose, the user equipment periodically sends channel quality feedback reports to the respective serving RBS, which indicate the recommended transmission format for the next transmission time interval (TTI), including the recommended transport block size, the recommended number of codes and the supported modulation scheme as well as a possible power offset. The reported channel quality indicator (CQI) value is determined on the basis of measurements of a common pilot channel. In a typical implementation it is a pointer to an index in one of the tables specified in the document “3GPP TS 25.214—Physical Layer Procedures (FDD)” that define the possible transmission format combinations (as mentioned above) for different categories of user equipment (UE).
The second aspect is the provision of fast retransmissions with soft combining and incremental redundancy, so that should link errors occur the user equipment rapidly requests retransmission of the data packets. Whereas the standard WCDMA network specifies that the requests are processed by the radio network controller (RNC), in HSDPA the request is processed by the RBS. Furthermore the use of incremental redundancy, allows the selection of correctly transmitted bits from the original transmission and retransmission in order to minimize the need for further repeat requests when multiple errors occur in transmitted signals.
The third aspect of HSDPA is fast scheduling in the RBS. This is where data to be transmitted to the user equipment is buffered within the RBS prior to transmission and the RBS using a selection criteria selects some of the packets to be transmitted based on information about the channel quality, user equipment capability, the quality of service class and power/code availability. A commonly used scheduler is the so-called proportional fair (P-FR) scheduler.
Although HSDPA is an efficient method for delivering relatively large amounts of data in relatively small time periods (the TTI for a HSDPA system is 2 ms).
This performance however can only be used when the user equipment is operating within the dedicated channel state (CELL_DCH state), in other words after a physical layer connection between UE and the RBS has been established and the layer connection has dedicated channels allocated to it.
The transition of the UE to the dedicated channel state (CELL_DCH state) and establishing a HSDPA connection may take up to a second, Thus specifically where the amount of data required to be transmitted is relatively small the state transition to the CELL_DCH state can take longer that the actual data transmission.
Moreover, when the UE is in the process of changing state to the CELL_DCH state, the required state change has to be addressed to the UE by the forward access channel (FACH) which is significantly slower and less robust than the later HSDPA transmission channels.
Before and during the transition to the CELL_DCH state, the CELL_FACH state requires that both the downlink dedicated control channel (DCCH) and the downlink dedicated traffic channel (DTCH) are mapped onto the forward access channel (FACH). This requirement increases the radio resource control (RRC) signalling (caused by the extra DCCH information) and data (caused by the extra DTCH information) transmission delay. The minimum time duration of the FACH transmission (which is carried over the secondary common control physical channel (S-CCPCH)) is approximately 10 milliseconds.
During the radio resource control (RRC) connection establishment phase the common control channel (CCCH) transmission is mapped onto the forward access channel (FACH). FIG. 1 shows the procedure for transition of the UE to the dedicated channel state (CELL_DCH) as described in 3GPP technical report TR 25.931. In step 107 of FIG. 1 , the RRC connection setup message which is typically carried over the common control channel (CCCH) is carried on the forward access channel (FACH) which in turn is mapped on the secondary common control physical channel (S-CCPCH).
It is also known to deliver data to a UE not in the dedicated channel (CELL_DCH) state by using the forward access channel (FACH) to deliver small amounts of data or control information to the UE. However this approach suffers from the inherent problems associated with the FACH, a low data rate and slow retransmission.
The capacity on the forward access channel (FACH) carried on the S-CCPCH is relatively low, typically between 32 to 64 kbps, which limits the use of the forward access channel to small packets.
Typically it is therefore only possible to transmit one or two common control channel (CCCH) radio link control protocol data units (RLC PDU) in a single TTI (a typical CCCH RLC PDU packet is 152 bits). Signalling radio bearers (SRB) mapped onto the dedicated control channel (DCCH) and utilising unacknowledged mode radio link control (UM RLC) packets produce RLC PDUs which are either 136 or 120 bits long. SRBs using acknowledged mode radio link control (AM RLC) produce RLC PDUs which are 128 bits long. In both the unacknowledged and acknowledged modes using the common control channel (CCCH) one or two protocol data units can be transmitted per TTI.
A typical dedicated traffic channel (DTCH) RLC PDU size is 320 bits. As the typical TTI for FACH is 10 ms a single DTCH RLC PDU (or packet) transmitted per TTI uses up all of a 32 kbps data rate capacity of the FACH alone.
The reliability of the forward access channel (FACH) is also limited since retransmissions take a considerable amount of time as retransmissions are carried out on the RLC based on the RLC status indicators transmitted on the random access channel in the uplink. In addition a message transmitted on CCCH does not have any retransmission on the RLC layer and in the case of signalling error the RRC layer needs to initiate retransmission of the RRC message if the appropriate response message is not received within a certain time. This time is typically very long (in the order of seconds), due to transmission delays in the FACH (DL) and RACH (UL) channels.
The typical 3G UE power consumption in the dedicated channel state (CELL_DCH) is approximately 250 mA, in the transitional forward access channel state (FACH) is approximately 120 mA, and in the paging channel state (CELL/URA_PCH) or in the idle state is typically <5 mA. The use of the FACH channel to transmit data can result in a higher power consumption as the forward access channel (FACH) reception requires more time to receive all of the (slow speed) data.
Therefore, in summary, the requirement to use the forward access channel (FACH) over the secondary common control physical channel (S-CCPCH) for transmission (either as an transitional state or as the operating state for passing data) are those of low data rates, slow retransmission rates, and also a relatively high UE power consumption.
SUMMARY OF THE INVENTION
It is an aim of the invention, and embodiments thereof, to provide an improvement to mobile access systems which at least partially addresses the problem disclosed above.
There is provided according to the invention a user equipment for communicating data in a communications system comprising a set of user equipment; at least one user equipment comprising: a transceiver arranged to receive a first data packet over a communications data channel and an associated second data packet over a communications control channel, wherein the second data packet comprises a first identifier arranged to identify a subset of the set of user equipment and the first data packet comprises a second identifier arranged to identify at least one of the subset of user equipment; and a processor arranged to determine from the second data packet first identifier if the said user equipment is one of the said subset of user equipment and from the second identifier if the said user equipment is said the at least one of the subset of user equipment; wherein the processor is further arranged to decode the first data packet if the processor determines the said user equipment is one of the said subset of user equipment and is the said at least one of the subset of user equipment.
The transceiver may further be arranged to receive in a further data packet a first identifier value arranged to identify the subset of user equipment as not being in a dedicated channel state.
The transceiver may further be arranged to receive in the further data packet a second identifier value to identify each of the user equipment within the same subset.
The transceiver is preferably arranged to transmit from the user equipment a feedback message.
The communications data channel is preferably a high-speed downlink shared channel (HS-DSCH).
The communications data channel may comprise at least one of: a dedicated traffic channel (DTCH); a dedicated control channel (DCCH) and a common control channel (CCCH).
The communications control channel is preferably a high speed shared control channel (HS-SCCH).
The first data packet preferably comprises radio resource communication data.
The second identifier is preferably located in a medium access control (MAC) header of the first data packet.
The first identifier is preferably located in the CRC of the second data packet.
The second identifier is preferably in a RRC level message on top of the MAC layer.
The first identifier value is preferably equal to the second identifier value.
The second data packet preferably comprises the first identifier, and the first identifier is preferably located in the CRC of the second data packet header.
The user equipment as described above may be incorporated within a communications system further comprising a communications node, the communications node may be arranged to transmit the first and second data packets over the communication data and control channels respectively to the set of user equipment, wherein the communications node is preferably further arranged to receive the feedback message.
The communications node is preferably further arranged to modify at least one transmission parameter for subsequent transmission of the first or second data packets.
The communications system may further be arranged to retransmit the first and second packets in dependence of the feedback message.
The communications node may be a radio base station.
According to a second aspect of the present invention there is provided a method for communicating a first data packet over a communications data channel to at least one user equipment; comprising the steps of: transmitting a second data packet over a communications control channel, the second data packet comprising a first identifier arranged to identify a subset of a set of user equipment; transmitting the first data packet over the communications data channel, the first data packet comprising a second identifier arranged to identify at least one of the subset of user equipment; receiving the first and second data packets at the at least one of the plurality of user equipment; determining from the second data packet first identifier if the said user equipment is one of the said subset of user equipment and from the second identifier if the said user equipment is the said at least one of the subset of user equipment; and decoding the first data packet if the said user equipment is one of the said subset of user equipment and the said user equipment is the said at least one of the subset of user equipment.
The method preferably further comprises the step of supplying each of the user equipment with a first identifier value arranged to identify the subset of user equipment as not being in a dedicated channel state.
The method may further comprise the step of supplying each of the user equipment with a first identifier value a second identifier value to identify each of the user equipment within the subset.
The method may further comprise the step of transmitting from the user equipment a feedback message.
The method may further comprise the step of receiving at a communications node the feedback message at a communications node.
The method may further comprise the step of modifying at least one transmission parameter of the communications node for subsequent transmission of the first or second data packets.
The method may further comprise the step of retransmitting the first and second packets from the communications node in dependence of the feedback message.
The communications data channel is preferably a high-speed downlink shared channel (HS-DSCH).
The communications data channel preferably comprises at least one of: a dedicated traffic channel (DTCH); a dedicated control channel (DCCH); and a common control channel (CCCH).
The communications control channel is preferably a high speed shared control channel (HS-SCCH).
The first data packet may comprise radio resource communication data.
According to a third aspect of the present invention there is provided a computer program when loaded into a computer arranged to carry out the method of communicating a first data packet over a communications data channel to at least one user equipment; comprising the steps of: receiving a first and second data packets at the at least one of the set of user equipment; the second data packet having been transmitted over a communications control channel, the second data packet comprising a first identifier arranged to identify a subset of a set of user equipment and the first data packet comprising a second identifier arranged to identify at least one of the said subset of user equipment; determining from the second data packet first identifier if the said user equipment is one of the said subset of user equipment and from the second identifier if the said user equipment is the said at least one of the subset of user equipment; and decoding the first data packet if the said user equipment is one of the said subset of user equipment and the said user equipment is the said at least one of the subset of user equipment.
According to a fourth aspect of the present invention there is provided a user equipment comprising a transceiver arranged to receive and decode data from a channel within a shared communications channel with a capacity greater than 64 kbps, wherein the channel is a free channel.
The free channel is preferably an unreserved or undedicated channel.
The user equipment is preferably arranged to receive and decode the data when the user equipment operates in at least one of: a idle state; a forward access state and a paging state.
The channel is preferably a high speed downlink shared communications channel within a high speed downlink packet access system.
According to a fifth aspect of the present invention there is provided a user equipment comprising a transceiver arranged to receive and decode radio resource connection data from a single unreserved channel within a shared communications channel.
According to a sixth aspect of the present invention there is provided a communications node comprising a transceiver arranged to transmit radio resource connection data into a single unreserved channel within a shared communications channel.
According to a seventh aspect of the present invention there is provided a user equipment for communicating data in a communications system comprising a set of user equipment; comprising: a transceiver arranged to receive a first data packet over a communications data channel and an associated second data packet over a communications control channel, wherein the second data packet comprises a first identifier arranged to identify a subset of the set of user equipment and either of the first data packet or the second data packet comprise a second identifier arranged to identify at least one of the subset of user equipment; and a processor arranged to determine from the second data packet first identifier if the said user equipment is one of the said subset of user equipment and from the second identifier if the said user equipment is said the at least one of the subset of user equipment, wherein the processor is further arranged to decode the first data packet if the processor determines the said user equipment is one of the said subset of user equipment and is the said at least one of the subset of user equipment.
BRIEF DESCRIPTION OF THE FIGURES
The invention is described by way of example only with reference to the accompanying figures in which
FIG. 1 shows a flow diagram showing the steps performed as a UE establishes a RRC connection and moves to a dedicated channel (CELL_DCH) state;
FIG. 2 shows a schematic view of a communications system within which embodiments of the present invention can be implemented; and
FIG. 3 shows a flow diagram showing the steps performed in a first embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention is described herein by way of example with reference to a number of embodiments. The invention is described in the context of a cellular communications system and specifically to a HSDPA WCDMA/UMTS communications system. It is however understood that the invention may equally be capable of being implemented in any communications system which implements scheduling of data packets especially those which need to address the problem of latency and spectral efficiency in transmission of data packets.
FIG. 2 shows a schematic view of a communications system within which the embodiments of the present invention can be implemented. The system comprises at least one user equipment (UE) 1 . User equipment 1 can be for example a mobile telephone, but could also be for example a communication capable laptop, personal digital assistant, or any other suitable device.
User equipment 1 communicates wirelessly by radio with a series of radio base stations (RBS) 3 . The radio base stations are also known in the UMTS standard as Node-B. In the following description the terms Node-B and radio base station (RBS) are to be used interchangeably.
Each user equipment 1 is arranged to be able to communicate to more than one RBS 3 and similarly each RBS 3 is arranged to be capable of communicating to more than one UE 1 . The RBS 3 further communicates with a radio network controller (RNC) 5 (which is also known in the GSM standard as a Base station controller (BSC)). The RNC 5 can further communicate to a core network (CN) 7 . The CN 7 can further communicate with other networks, for example further public land mobile networks (PLMNs) or to the network of computers known as the ‘Internet’.
To clarify some of the terms used in the embodiments of the invention described below we describe with the assistance of FIG. 1 a flowchart for a radio resource controller (RRC) connection establishment as would be carried out by a UE 1 in the network as defined by 3GPP TR 25.931.
In step 101 , the UE 1 initiates set up of a radio resource controller connection by sending a radio resource controller (RRC) connection request message on the common control channel (CCCH) to the serving RNC 5 via the selected cell that is the cell of the RBS 3 . The connection request contains the parameters of the initial user equipment (UE) 1 identity value, and the cause for establishment of the connection.
In the step 102 , the serving radio network controller (RNC) 5 establishes the Radio Resource Control (RRC) connection to the UE 1 and decides to use a dedicated channel for this particular RRC connection, and allocates a UTRAN (UMTS terrestrial radio access network) RNTI (radio network temporary identifier) and radio resources L 1 , L 2 for the radio resource controller connection. When a dedicated channel is to be set up, a node B application protocol (NBAP) message, a “radio link set up request” message, is sent to the RBS 3 . The parameters contain within the radio link set up request include the cell identification value, the transport format set, the transport format combination set, the frequency, the uplink scrambling codes to be used (for frequency division duplex (FDD) communication only), the time slots to be used (for time division duplex (TDD) communication only), the user code (for TDD only) and power control information.
In step 103 , the RBS 3 allocates the resources, starts reception of the uplink physical channels, and responds with a NBAP message, a “radio link setup response” message. The radio link set up response message contains parameters defining signalling link termination, transport layer addressing information (such as the ATM adaptation layout type 2 (AAL2) address, AAL2 binding identity) for the lub data transport bearer.
In step 104 , the serving radio network controller initiates the set up of lub data transport bearer using the access link control application part protocol (ALCAP). This request contains the AAL2 binding identity to bind the lub data transport bearer to the dedicated channel. The request for setup of lub data transport bearer is acknowledged by the RBS 3 .
In steps 105 and 106 , the RBS 3 and the serving RNC 5 establish synchronism for the lub and lur data transport bearers by means of exchange of the appropriate dedicated channel frame protocol frames, e.g. the “downlink synchronisation” and “uplink synchronisation” messages. Following synchronisation, the RBS 3 starts the downlink transmission to the UE 1 .
In step 107 , a message is sent from the serving RNC 5 to the UE 1 , the message being a radio resource controller (RRC) connection set up message sent on the common control channel (CCCH). The RRC connection set up messages contains the parameters of the initial UE identity value, the U-RNTI, (valid inside UTRAN in CELL_FACH state and in CELL/URA_PCH), the C-RNTI (valid inside cell in CELL_FACH state), the capability update requirement, the transport format set, the transport format combination set, the frequency, the downlink frequency scrambling code (FDD only), the time slots (TDD only), the user code (TDD only), power control information and other data as defined in 3GPP standard TS25.331 section 10.2.40 in particular in order to configure the signalling connection on HSDPA.
In step 108 , the RBS 3 achieves uplink synchronisation and notifies the serving RNC 5 with a NBAP message, a “radio link restore indication”.
In step 109 , a RRC connection set up complete message is sent on the dedicated control channel (DCH) from the UE 1 to the serving RNC 5 via the serving RBS 3 . This RRC connection set up complete message contains the parameters of integrity information, ciphering information, and UE radio access capability.
As has been described above, these steps are required in order to carry out a high speed downlink packet access communication.
Thus in HSDPA operation in CELL_DCH state each UE is assigned a unique H-RNTI that is used to identify the intended receiver of each transmitted packet already in the physical layer.
In the embodiments of the invention as described in detail below the HSDPA usage in other than CELL_DCH state uses a common physical layer identifier (i.e. a group UE ID value) which is known to a UE 1 without the need to uniquely assign a ID to each UE. The intended UE receiver is then identified then by the MAC header in case of DTCH or DCCH transmission or from UE ID included in RRC message in case of CCCH message (RRC connection setup, Cell update confirm) just as is done by the FACH in the prior art.
In embodiments of the present invention a UE in either the dedicated or non dedicated channel state can detect whether the transmission was for it or not, but in CELL_DCH the UE knows this from the physical layer without needing to receive and decode the data packet first.
In FIG. 3 a flow chart showing the steps carried out in a first embodiment of the invention are described.
In step 201 a UE 1 receives a group identification value (a group UE ID value) from a system information broadcast that is typically used for HS-SCCH detection before the RRC connection has been established or when C-RNTI is not valid after cell reselection, i.e. to receive the RRC connection setup message or the cell update confirm (when only U-RNTI is valid).
The UE 1 also receives an individual identification value (an individual UE ID value) identifying a single UE 1 . This ID value can be assigned, during a RRC connection (C-RNTI), at step 107 , so that UE having RRC connection and valid C-RNTI can detect if the transmission is intended to it directly from HS-SCCH at physical layer. In some embodiments of the invention these ID values can be updated by dedicated RRC signalling.
In step 203 the received identification values are stored in the UE 1 .
In step 205 the UE receives a high speed downlink packet access (HSDPA) data frame sent using the high speed downlink shared channel (HS-DSCH) with a MAC header value indicating a unique UE ID value. The associated high speed shared control channel (HS-SCCH) data for the same frame comprises information identifying a group UE ID value. The HS-SCCH data also specifies the transport format and the rate of the associated high speed physical downlink shared channel—the physical channel the HS-DSCH data is transmitted over. As the U-RNTI or C-RNTI values are used in the MAC header the UE can detect if the data transmission was for it or not, even if the group ID is used, for example in case of a CCCH transmission the UE 1 can identify if the transmission was for the UE in the RRC layer.
In step 207 the UE 1 checks to see if for the ID sent over the high speed shared control channel (HS-SCCH) matches the group ID of the UE or, if one was assigned, the dedicated ID of the UE. The group UE ID or dedicated ID value is transmitted in a known manner, i.e. the value within the HS-SCCH is transmitted in the same way as would be carried out for any UE in the dedicated channel state which has a specific UE ID assigned to it during the RRC setup as described above.
The specific UE to which the data is addressed, rather than the group of UEs identified by the group UE ID value is determined by a unique identifier in the medium access control (MAC) protocol header associated with the HS-DSCH.
Thus in embodiments of the invention small amounts of high speed data can be received by a UE not in the dedicated channel without the requirement of passing through the forward access channel state.
In some embodiments of the invention the group ID value is known in advance, based on predefined rules, to all UE not in the dedicated channel state (CELL_DCH)—i.e. all UE 1 not currently carrying out data communication with the network.
In some embodiments of the invention the group ID value is transmitted to all UE not in the dedicated channel state (CELL_DCH)—i.e. all UE 1 not currently carrying out data communication with the network.
In further embodiments of the invention any UE 1 establishing the RRC connection as described earlier can use the UE ID value transmitted to it in the system information broadcast (SIB). The SIB is information broadcast across the cell and can be received by any UE within the cell without the RBS 3 knowing which UE 1 have received the SIB. The SIB transmissions do not require an acknowledgement transmission and therefore can be advantageous carriers of the group UE ID value. In further embodiments the RNC 5 allocates the group UE ID values which are passed to the RBS 3 to be transmitted to the UE 1 .
In some embodiments the group UE ID value is known by RBS 3 as a result of a network configuration or reconfiguration process.
In some embodiments of the invention the unique ID is transmitted to the UE 1 by being masked directly to a CRC in the HS-SCCH. Masking a unique ID to a CRC on HS-SCCH means that the CRC, a kind of a checksum to enable the receiver to determine if a packet is correctly received, is modified by the ID value in such a way that only a receiver knowing the ID can determine the correct CRC value and therefore is able to detect whether the HS-SCCH was received correctly. The advantage with masking an ID to a CRC on the HS-SCCH is that no additional bits are inserted onto the HS-SCCH due to the inclusion of the UE unique ID, but the unique UE ID information is present in the HS-SCCH message. In other embodiments the ID value is inserted on the MAC header/RRC layer where there is a specific bit field for the UE ID value reserved. The embodiments using the MAC header are not required to carry out a masking or modification of the signal other than the insertion of the value in the bit field.
As the UE 1 must first detect the ID (i.e. determine if the UE-specific CRC indicates a correct reception) on the HS-SCCH before it tries to decode the HS-DSCH to see if the unique ID in either the MAC header or the RRC message matches the UE unique ID value. Therefore the MAC/RRC level ID must be the unique UE ID if the HS-SCCH ID is the group UE ID and if the HS-SCCH ID is the unique UE ID then the MAC/RRC UE ID can be considered to be equal in value.
In some embodiments of the invention UE 1 in the UTRAN registration area paging channel state (CELL/URA_PCH) or in the idle state would not listen to the high speed downlink packet access information continuously, but is arranged to receive both HS-DSCH and HS-SCCH packets only at predetermined times.
In a further embodiment the UE 1 is arranged to listen for the HS-SCCH at predetermined times and then only if it receives a data packet with the predetermined group UE ID listen for the data on the HS-DSCH. This embodiment is similar to the conventional HSDPA reception mode whereby the UE detects a HS-SCCH packet addressed to it before arranging itself to receive an associated UE addressed HS-DSCH packet with the difference that the UE is only listening to the HS-SCCH at predetermined times and not therefore allowing the UE to switch off the radio receiver during the non-reception periods thus saving battery power.
In other embodiments of the invention, the UE listens when triggered by an event. For example the random access channel (RACH) can be used due to UE activity or in response to a paging message. In such embodiments the UE is able to conserve power, in other words to “sleep” and save battery power if no activity is expected.
In such an embodiment an UE 1 in idle mode would start high speed data packet access reception after sending the radio resource controller connection request on the random access channel (RACH). An UE 1 in CELL/URA_PCH state would start HSDPA reception after sending the cell update message. The sleep mode is simpler to organise with the use of the HS-DSCH since the TTI is short (2 milliseconds compared to the forward access channel with a 10 millisecond TTI).
The user equipment 1 in the transitional CELL_FACH state can be arranged in some embodiments to receive HSDPA data continuously if the network is able to transmit data or signalling to the user equipment on either the dedicated traffic channel (DTCH) or the dedicated control channel (DCCH). UE 1 in the CELL_FACH state can also be arranged to receive the data occasionally where discontinuous reception periods (DRX) are indicated for the HSDPA data transmission.
In the above embodiments of the invention, compared against conventional HSDPA from UE in CELL_DCH states, does not have the provision to send from the UE 1 to the RBS 3 a specific channel quality indicator (CQI) report (this is typically transmitted on the high speed dedicated control channel—the uplink feedback channel of the HSDPA, for the user equipment in the dedicated channel mode in order to assist the selection of MCS (modulation and coding scheme) selection for the high speed physical downlink shared channel (HS-PDSCH) and the power setting of the high speed shared control channel (HS-SCCH). The selection of the MCS values is arranged so that for a good quality channel the MCS values can be chosen to use higher order modulation and less coding and thus increase the data throughput and in bad quality channels the MCS values can be chosen to use a simple modulation and more error correction coding to reduce errors at the cost of smaller data transmission capacity.
Furthermore the above embodiments have no acknowledgment feedback (ACK/NACK) for the high speed acknowledgement request (HARQ—the high speed downlink shared channel reception acknowledgement). Thus for the above embodiments there is no signal to indicate whether a retransmission is requested as the ACK/NACK signals are typically transmitted on the uplink on a high speed dedicated control channel (the uplink feedback channel of the HSDPA) for the user equipment in the dedicated channel state.
In a further embodiment of the invention, the RBS 3 selects the high speed-shared control channel power and the MCS values for the HS-DSCH accordingly in order that it is able to be received at the cell edge. In further embodiments of the invention mechanisms are provided for estimating the required HS-SCCH power requirements and suitable MCS values for the HS-DSCH are required and these values selected for the HS-SCCH and HS-DSCH data streams.
In some embodiments of the present invention an uplink feedback channel, such as an L 1 channel, can be set up and used to transfer CQI and acknowledgement channel data.
In other embodiments of the invention the RNC can determine the modulation and coding scheme (MCS) to be used based on measurement of the channel. In other embodiments of the invention the RNC 5 may send information to the Node-B on selecting a suitable MCS.
In other embodiments the same transmission values are transmitted more than once in order to produce the required time diversity in the system and also to produce a required HARQ gain.
In the above embodiments the transmission system is provided with a degree of system control—all of the UE 1 in the cell are able to receive the data.
In a further embodiment of the invention, the RBS 3 , although not having a user equipment specific CQI report, receives from the UE 1 a predefined uplink scrambling code containing transmission feedback after receiving the high downlink shared channel transmission intended for it. The transmission feedback signal in these embodiments enables a HARQ method as known in the art to be used. This is shown in FIG. 3 in step 209 .
In further embodiments of the invention, a CQI report is transmitted from the UE with transmission feedback in order to be able to calculate subsequent high speed shared control channel (HS-SCCH) power settings and high speed downlink shared channel (HS-DSCH) MCS selection.
Embodiments of this invention as described above can be implemented by requiring any UE with the group UE ID to acknowledge the receipt of the packet and to transmit CQI report as if the data was intended for it. An alternative embodiment requires that any UE identifying the UE's individual UE ID in the medium access controller protocol data unit and/or the radio resource controller message after first detecting the group UE ID in the HS-SCCH before transmitting any acknowledgment to the network.
In some embodiments of the invention the controlling radio network controller (RNC) could use single ATM adaptation layout type 2 (AAL2) connection over the lub interface for common control channel (CCCH) and for all downlink control channel (DCCH) and dedicated traffic channel (DTCH) allocated for the UE in the forward access channel transitional state. Thus MAC-c multiplexing can in some embodiments be used instead of forward access channel transmission state.
In further embodiments of the invention, where it is required to meet different priority and quality of service (QoS) requirements separate AAL2 connections are allocated for the CCCH, DCCH and DTCH. For example transmission of the common control channel (CCCH) and dedicated control channel (DCCH) could have in some embodiments a higher priority and reliability factor than the dedicated traffic channel (DTCH).
Although the embodiments described above refer to the use of the HSDPA channels to transmit moderate amounts of data to the UE this transmission of data also applies to the transmission of data in the RRC connection step 107 from the RNC 5 to the UE 1 via the RBS 3 as shown in FIG. 1 . As described above by using a channel faster than the FACH the speed of receiving the CCCH data packets can be increased and therefore the time required to setup the UE in CELL_DCH mode decreased. A specific UE ID for the CELL_DCH state is assigned to the UE at this stage.
The embodiments as described above provide a more robust and faster way to deliver user data and RRC signalling messages to a UE than using a conventional delivery method (FACH) as used in the prior art. Also by using these embodiments, UE 1 not in the dedicated channel mode of operation have a faster state transition to the dedicated channel mode of operation from the idle or paging modes as they only require to receive a moderate amount of data which can be served with HSDPA techniques without requiring the user equipment to exchange data via the FACH state.
Although the above embodiments only have partial HSDPA support (for example in some embodiments there is no uplink feedback from the user equipment and therefore no knowledge of CQI or no possibility to receive ACK/NACK messages in the RBS 3 ), the gain in terms of decreased delays would be inevitable due to the much shorter TTI of the HSDPA over the FACH. Furthermore, as described in some embodiments there is a possibility of using blind retransmissions to achieve a gain from HARQ combining.
Although the system requires approximately 5 times more power to deliver the same data in 2 ms than in 10 ms and thus there is no power saving in this and, there is a benefit in that it is not necessary to allocate a specific power share for HSDPA transmission for users not in the dedicated channel state (CELL_DCH) as all of the UE time-share the same power resource. In the prior art examples FACH power was needed to be statically allocated for FACH used whether the channel was actually utilised or not.
Furthermore, as the present invention uses the existing layer-1 of the HSDPA network specification the implementation of the invention is relatively simple.
As also described above the power consumption of the UE in the CELL_FACH state is an issue in always on applications for example in push mail which send periodic keep alive messages. In these situations, even if the amount of data is very low the user equipment is kept on the forward access channel until the inactivity timer expires. Typically the inactivity timer is about 2 seconds. Using discontinuous reception (DRX) as described above the power consumption could be considerably reduced. This would enable a major improvement in the UE stand by time for always on applications.
The applicant hereby discloses in isolation each individual feature described herein and any combination of two or more such features, to the extent that such features or combinations are capable of being carried out based on the present specification as a whole in the light of the common general knowledge of a person skilled in the art, irrespective of whether such features or combinations of features solve any problems disclosed herein, and without limitation to the scope of the claims. The applicant indicates that aspects of the present invention may consist of any such individual feature or combination of features. In view of the foregoing description it will be evident to a person skilled in the art that various modifications may be made within the scope of the invention.
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The invention describes user equipment for communicating data in a communications system comprising a set of user equipment; comprising a transceiver arranged to receive a first data packet over a communications data channel and an associated second data packet over a communications control channel. The second data packet comprises a first identifier arranged to identify a subset of the set of user equipment and the first data packet comprises a second identifier arranged to identify at least one of the subset of user equipment. The user equipment further comprising a processor arranged to determine from the second data packet first identifier if the said user equipment is one of the said subset of user equipment and from the second identifier if the said user equipment is said the at least one of the subset of user equipment. Wherein the processor is further arranged to decode the first data packet if the processor determines the said user equipment is one of the said subset of user equipment and is the said at least one of the subset of user equipment.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a method for selecting modulation and coding schemes for a communication system, and more particularly, to a method for selecting modulation and coding schemes for a multi-antenna system.
[0003] 2. Description of the Related Art
[0004] In Wi-Fi wireless local area networks, such as those following the IEEE 802.11in standard, a receiver is required to suggest a transmitter the modulation and coding scheme (MCS) based on transmission environment, and the MCS adopted by the transmitter is adjusted with the variation of the transmission environment so as to maintain the highest transmission throughput.
[0005] Automatic rate fallback (ARF) algorithm is a popular MCS selection technique. It establishes a priority order for every MCS for the applied communication system, and calculates the packet error rate (PER) for a fixed amount of time in the receiver. If, within a fixed amount of time, the PER in the receiver exceeds an upper threshold, an MCS with lower data rate is adopted according to the priority order. If, in the fixed amount of time, the PER in the receiver drops below a lower threshold, another MCS with higher data rate is adopted according to the priority order. Since the ARF algorithm needs to calculate the PER within a fixed amount of time for every MCS adjustment, a lot amount of time is spent on lesser MCSs, which affects the throughput of the communication system. In addition, for a multi-antenna system, the real data rates provided by every MCS depend on the signal to noise ratio (SNR) of each antenna, and therefore the priority order cannot be established based on data rates for single-antenna systems. An ill-established priority order can cause the communication system to be unable to select the optimum MCS.
[0006] Another MCS selection method is based on the transmission environment, that is, adjusting the MCS for the transmitter based on the SNR. FIG. 1 shows experiment results of the optimum MCSs for different SNRs in a wireless communication system complying with IEEE 802.11in standard. As shown in FIG. 1 , the system structure is a double antenna system, wherein a double transmission antenna and a double receiving antenna are included. There are 16 MCSs available, wherein number 0 to number 7 are single spatial stream MCSs, and number 8 to number 15 are double spatial stream MCSs. The receiver stores the experiment results shown in FIG. 1 in a table and adjusts the MCS adopted by the transmitter according to the stored experiment results. One drawback of this method is that the accuracy of the estimated SNR affects the performance of the communication system. In addition, this table requires an excessively large storage space of the receiver such that the hardware cost increases significantly. Furthermore, if a triple antenna system or a system structure with more antennas is used, the required storage space would increase exponentially such that the hardware limitations could be prohibitive.
[0007] Therefore, there is a need to design a method for selecting MCS for multi-antenna systems that is fast and easy to implement.
SUMMARY OF THE INVENTION
[0008] The method for selecting modulation and coding schemes of the present invention transmits signal based on MCSs of single spatial stream signals and increments the dimension of the single spatial stream signals until an optimum MCS is found.
[0009] The method for selecting modulation and coding schemes according to one embodiment of the present invention comprises the steps of: setting the dimension of transmission spatial stream signals of a multi-antenna system to 1 and transmitting signals based on different MCSs to determine an initial MCS; repeating incrementing the dimension of the transmission spatial stream signals by 1 and transmitting signals based on different MCSs to update the MCS of the multi-antenna system until the updated MCS is equal to the MCS before update or the dimension of the transmission spatial stream signals reaches a threshold; selecting the MCS before update as the MCS of the multi-antenna system if the updated MCS is equal to the MCS before update; and selecting the updated MCS as the MCS of the multi-antenna system if the dimension of the transmission spatial stream signals reaches a threshold.
[0010] The method for selecting modulation and coding schemes according to another embodiment of the present invention comprises the steps of: setting the dimension of transmission spatial stream signals of a multi-antenna system to 1 and transmitting signals based on different MCSs to determine an initial MCS; repeating incrementing the dimension of the transmission spatial stream signals by 1 and transmitting signals based on different MCSs to update the MCS of the multi-antenna system until the data rate of the multi-antenna system is smaller than that of the multi-antenna system before update or the dimension of the transmission spatial stream signals reaches a threshold; selecting the MCS before update as the MCS of the multi-antenna system if the data rate of the multi-antenna system is smaller than that of the multi-antenna system before update; and selecting the updated MCS as the MCS of the multi-antenna system if the data rate of the multi-antenna system is greater than that of the multi-antenna system before update and the dimension of the transmission spatial stream signals reaches a threshold.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The objectives and advantages of the present invention will become apparent upon reading the following description and upon referring to the accompanying drawings of which:
[0012] FIG. 1 shows experiment results of the optimum MCSs for different SNRs;
[0013] FIG. 2 shows the flow chart of a method for selecting MCSs for multi-antenna systems according to an embodiment of the present invention;
[0014] FIG. 3 shows a double antenna system;
[0015] FIG. 4 shows the corresponding data rates of a plurality of MCSs according to an embodiment of the present invention; and
[0016] FIG. 5 shows the available MCSs under selection according to an embodiment of the present invention
DETAILED DESCRIPTION OF THE INVENTION
[0017] FIG. 2 shows the flow chart of a method for selecting MCSs for multi-antenna systems according to an embodiment of the present invention. In step 201 , the dimension of the transmission spatial stream signals of a multi-antenna system is set to 1, and step 202 is executed. In step 202 , signals of different MCSs are transmitted by the multi-antenna system, and step 203 is executed. In step 203 , an optimum MCS is determined from the applied MCSs in step 201 according to the quality of the transmitted signals at the receiver, and step 204 is executed. In the present embodiment, the optimum MCS is the MCS with the highest data rate. In step 204 , the dimension of the transmission spatial stream signals is incremented by 1, and step 205 is executed. In step 205 , signals of different MCSs are transmitted by the multi-antenna system according to the updated spatial stream signals, and step 206 is executed. In step 206 , an optimum MCS is determined from the applied MCSs in step 205 and the previous determined MCS according to the quality of the transmitted signals at the receiver, and step 207 is executed. In step 207 , whether the updated optimum MCS is the previous determined MCS is checked. If the result is positive, step 208 is executed; otherwise, step 209 is executed. In step 208 , the previous determined MCS is set as the MCS of the multi-antenna system, and the selecting method is finished. In step 209 , whether the dimension of the transmission spatial stream signals reaches a threshold, e.g. the maximum dimension the multi-antenna system can provide, is checked. If the result is positive, step 204 is executed; otherwise, step 210 is executed. In step 210 , the updated MCS is set as the MCS of the multi-antenna system, and the selecting method is finished.
[0018] In another embodiment of the present invention, in step 206 , the optimum MCS is determined only from the applied MCSs in step 205 , and therefore the updated optimum MCS is not the same as the previous determined MCS. Therefore, the check condition in step 207 can be revised to determine whether the data rate of the multi-antenna system is lower than that of the multi-antenna system before update. If the result is positive, step 208 is executed; otherwise, step 209 is executed.
[0019] In one embodiment of the present invention, in step 202 , signals are transmitted by the multi-antenna system with all MCSs of single spatial stream signals. In another embodiment of the present invention, in step 205 , signals are transmitted by the multi-antenna system according to all MCSs of the updated spatial stream signals. In yet another embodiment of the present invention, in step 205 , signals are transmitted by the multi-antenna system according to a part of MCSs of the updated spatial stream signals. For example, if the data rate of the determined MCS in steps 203 or 206 is R, in step 205 , under the updated spatial stream signals, the MCSs of the transmitted signals can be selected such that the data rates of the transmitted signal are between R and a x R, wherein a is a positive integer. For another example, if the determined MCS in steps 203 or 206 is MCS k , in step 205 , under the updated spatial stream signals, the MCSs of the transmitted signals can be derived from the previous MCS k according to experiment data.
[0020] FIG. 3 shows a double antenna system 300 , comprising a transmitting end 310 and a receiving end 320 . The double antenna system 300 uses the method shown in FIG. 2 to select the applied MCS. The double antenna system 300 is implemented based on the IEEE 802.11in wireless communication network standard, and comprises MCS 0 to MCS 15 , a total of 16 MCSs, wherein MCS 0 to MCS 7 are single spatial stream MCSs, and MCS 8 to MCS 15 are double spatial stream MCSs. FIG. 1 shows the experiment results of the double antenna system 300 of the optimum MCSs for different SNRs. FIG. 4 shows the data rates for every MCS of the double antenna system 300 .
[0021] Following step 201 , the dimension of the transmission spatial stream signals of the double antenna system 300 is set to 1. Following step 202 , signals of different MCSs are transmitted by the double antenna system 300 . In one embodiment of the present invention, signals are transmitted by the double antenna system 300 with all MCSs of single spatial stream signals, i.e., MCS 0 to MCS 7 . Following step 203 , the double antenna system 300 compares MCS 0 to MCS 7 according to the quality of the transmitted signals at the receiver and determined MCS 5 as the optimum MCS, wherein the data rate of MCS 5 is 52 Mbps as shown in FIG. 4 . Following step 204 , the dimension of the transmission spatial stream signals of the double antenna system 300 is incremented by 1 to be 2. Following step 205 , signals of different MCSs are transmitted by the double antenna system 300 according to the updated spatial stream signals, i.e., double spatial stream signals. In one embodiment of the present invention, signals are transmitted by the double antenna system 300 according to all MCSs of the updated spatial stream signals, i.e., MCS 8 to MCS 15 . In yet another embodiment of the present invention, the MCSs of the transmitted signals are selected from the double spatial MCSs such that the data rates of the transmitted signal are between R and a×R, wherein if a is 3, the selected MCSs are MCS 11 , MCS 12 , MCS 13 , MCS 14 and MCS 15 . In yet another embodiment of the present invention, MCS 11 , MCS 12 , MCS 13 and MCS 14 are the derived MCSs from MCS 5 according to the experiment results shown in FIG. 1 and are thus selected as the MCSs of the transmitted signals. Following step 206 , from the applied MCSs in step 205 (MCS 8 to MCS 15 , MCS 11 to MCS 15 or MCS 8 to MCS 14 ) and the previous determined MCS 5 , MCS 5 is determined as the optimum MCS according to the quality of the transmitted signals at the receiver. Following step 207 , since the updated optimum MCS is the previous determined MCS, step 208 is executed, MCS 5 is set as the MCS of the double antenna system 300 , and the selecting method is finished.
[0022] FIG. 5 shows MCS data for the double antenna system 300 including MCS values selected in step 203 from MCS 0 to MCS 7 , and the available MCSs under selection in step 205 . The first row shows all the double spatial MCSs; the second row shows the MCSs for which the data rates of the transmitted signal are between R and a×R, and a is 3; the third row shows the MCSs derived from MCS 0 to MCS 7 according to the experiment results shown in FIG. 1 .
[0023] In conclusion, the method for selecting modulation and coding schemes for a multi-antenna system disclosed by the present invention quickly an optimum MCS according to a simple determining procedure, and is not affected by poorly established priority order or inaccurate estimated SNR and can be easily implemented.
[0024] The above-described embodiments of the present invention are intended to be illustrative only. Those skilled in the art may devise numerous alternative embodiments without departing from the scope of the following claims.
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A method for selecting modulation and coding scheme (MCS) for multi-antenna systems comprises the steps of: a multi-antenna system transmits signals according to MCSs of single spatial stream and determines an MCS accordingly. Subsequently, the multi-antenna system increases the number of the spatial streams applied, transmits signals according to the corresponding MCSs and determines an MCS accordingly until an optimum MCS is found.
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RELATED APPLICATIONS
This application is a Continuation of U.S. patent application Ser. No. 11/196,634 filed Aug. 2, 2005, now U.S. Pat. No. 7,534,402, which is a Divisional of U.S. patent application Ser. No. 10/007,412 filed Dec. 5, 2001, now U.S. Pat. No. 6,960,235. This application claims priority to these prior applications and incorporates them by reference.
The United States Government has rights in this invention pursuant to Contract No. DE-AC52-07NA27344 between the United States Department of Energy and the Lawrence Livermore National Security, LLC for the operation of Lawrence Livermore National Laboratory.
BACKGROUND OF THE INVENTION
Porous membrane reactors typically utilize a bulk porous media which is affixed to the end of stainless steel tubing through which the chemical species is delivered. For the application of steam reforming hydrogen containing fuels, a catalyst is introduced to the porous membrane and the entire fixture is heated as gas is delivered to the membrane. While steam reforming of methanol has been reported at 350° C., typical operating temperatures are high, e.g., 500° C. to 700° C. due to the inability of the reactor to adequately exchange heat with the outside environment.
German patent application, DE 1998-19825102 discloses a method to produce catalytic microreactors that includes “placing a catalyst in the reaction spaces.” The microreactors can be used for steam reforming or partial oxidation of hydrocarbons to produce hydrogen gas for fuel cells.
Srinivasan et al disclose in the American Institute of Chemical Engineers (AIChE) journal (1997), 43(11), 3059-3069, a silicon-based microfabrication of a chemical reactor (microreactor) having submillimeter flow channels with integrated heaters, and flow and temperature sensors. The article discusses the potential applications of this reactor and the feasibility of a variety of operating conditions.
SUMMARY OF THE INVENTION
A method for forming a chemical microreactor according to one embodiment includes forming at least one capillary microchannel in a silicon substrate having at least one inlet and at least one outlet, integrating at least one heater into the chemical microreactor, interfacing the capillary microchannel with a liquid chemical reservoir at the inlet of the capillary microchannel, and interfacing the capillary microchannel with a porous membrane at the outlet of the capillary microchannel, such that gas flow moves in a horizontal direction from the inlet through the microchannel and moves in a vertical direction from the microchannel through the outlet, wherein the porous membrane has at least one catalyst material imbedded therein.
A method for forming a chemical microreactor includes forming at least one capillary microchannel in a substrate having at least one inlet and at least one outlet, integrating at least one heater into the chemical microreactor, interfacing the capillary microchannel with a liquid chemical reservoir at the inlet of the capillary microchannel, and interfacing the capillary microchannel with a porous membrane near the outlet of the capillary microchannel, the porous membrane being positioned beyond the outlet of the capillary microchannel, wherein the porous membrane has at least one catalyst material imbedded therein.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A shows an embodiment of a microreactor.
FIG. 1B shows a top view of the porous membrane structure portion of an embodiment of a microchannel.
FIG. 2A shows a cross-sectional view of an embodiment of a microreactor with multiple microchannels.
FIG. 2B shows a cross-sectional view of the microchannel and resistive heater portion of an embodiment of a microreactor.
FIG. 3 shows a cross-sectional view of the microchannel and resistive heater portion of an embodiment of a microreactor with multiple microchannels.
FIG. 4A shows a cross-sectional view of the microchannel and resistive heater portion of an embodiment of a microreactor.
FIG. 4B shows a cross-sectional view of the microchannel and resistive heater portion of an embodiment of a microreactor with multiple microchannels.
FIG. 5 shows a cross-sectional view of an embodiment of a microreactor integrated with a microcumbuster.
DETAILED DESCRIPTION
Referring to FIG. 1A , a chemical microreactor 2 comprises: a bottom substrate 4 a comprising silicon, glass or ceramic, a top substrate 4 b comprising silicon, glass or ceramic, at least one capillary microchannel 6 having at least one inlet 8 for fuel and water and at least one outlet 10 for gases, a liquid reservoir (not shown) containing a fuel source, at least one porous membrane 12 , and at least one integrated heater 14 for heating the microchannel. Referring to FIG. 1B , a porous membrane support structure 13 comprising silicon, glass or ceramic containing a plurality of porous membranes 12 is an effective alternate embodiment to porous membrane 12 of FIG. 1A . Microreactor 2 can further comprise a catalytic combustion microfluidic heat source (not shown) to heat the gases flowing through the microchannel and porous membrane(s).
Chemical microreactor 2 provides a means to generate hydrogen fuel from liquid sources such as ammonia, methanol, and butane through steam reforming processes when mixed with the appropriate amount of water. In an alternate embodiment to that shown in FIG. 1A , capillary microchannel inlet 8 mixes and delivers a fuel-water mixture from the liquid reservoir (not shown) through microchannel 6 and porous membrane 12 . Porous membrane 12 can alternately be replaced with a porous membrane support structure containing a plurality of porous membranes.
Referring to FIG. 2A , the fuel-water mixture can first be heated by resistive heaters in a “gassifier region” 15 , i.e., the region where the fuel inlet connects to the microchannel, forming a fuel-steam gas. The fuel-steam gas then flows through microchannel 6 . The microchannel can be packed with a catalyst material such as, platinum, platinum-ruthenium, nickel, palladium, copper, copper oxide, ceria, zinc oxide, alumina, combinations thereof and alloys thereof. Resistive heaters 14 can be positioned along the microchannel. Heating microchannel 6 to a temperature between about 250° C. and about 650° C. by resistive heaters facilitates the occurrence of catalytic steam reforming reactions. The desired temperature depends upon the source of fuel. For example, about 250° C. is an effective temperature if methanol is used, whereas ammonia requires a temperature closer to about 650° C. Microchannel 6 is formed in a configuration that allows adequate volume and surface area for the fuel-steam gas to react as it flows through microchannel 6 and porous membrane 12 . Electrical connection pads 16 provide current to resistive heaters 14 . Although not shown, electrical pads 16 are connected to a power source. FIG. 2B is a cross-sectional illustration of the embodiment depicted in FIG. 2A .
Two distinct embodiment styles are effective. The first embodiment employs a packed catalyst capillary microchannel and at least one porous membrane. In this embodiment, the primary purpose of the porous membrane is to prevent large particles or molecules flowing through the microchannel to pass through the membrane. The porous membrane may or may not contain catalyst materials.
The second embodiment style employs a porous membrane with a large surface area or a porous membrane support structure containing a plurality of porous membranes having a large surface area in the aggregate, i.e., greater than about 1 m 2 /cm 3 . Surface areas on the order of about 1 m 2 /cm 3 to about 100 m 2 /cm 3 are effective. In this embodiment, a catalyst material is imbedded within the porous membrane(s) and the primary purpose of the porous membrane(s) is to facilitate the occurrence of catalytic steam reforming reactions. Packed catalyst capillary microchannels may or may not be used with this embodiment style. This embodiment style can reduce the size and length requirements of microchannel 6 . For example, referring to FIGS. 1A and 1B , positioning porous membrane support structure 13 which contains a plurality of porous membranes 12 at outlet 10 of microchannel 6 provides a high surface area catalytic reaction. Minimizing the size of the microchannel region in this manner makes it easier to heat and maintain microchannel 6 at the high temperatures required for the steam reforming reactions to occur, i.e., about 250° C. to about 650° C. Additionally, the porous membrane support structure 13 provides a flow interface with outlet 10 and provides some restriction to gas flow resulting in a slight increase in the back-pressure of the microchannel region.
Hydrogen gas is generated by heating microchannel 6 and porous membrane 12 to an appropriate temperature, i.e., about 250° C. to about 650° C. The fuel-steam source is reformed into gaseous byproducts, i.e., hydrogen and subsequent byproducts, such as carbon monoxide and carbon dioxide, as the molecules diffuse through the membrane and flow into a fuel cell or other power source. Hydrogen is the component of the liquid fuel source that is converted into energy by a fuel cell. If chemical microreactor 2 is used in concert with a fuel cell, the gaseous molecules, after passing through the membrane structure, flow through at least one other microchannel, i.e., a gas flow channel. The gas flow channel is located at the exit side of catalytic membrane 12 and is connected to the anode manifold of a fuel cell. Additional embodiments can include the integration of a porous getter structure or permaselective membrane material at the exit side of porous membrane 12 to adsorb the product gases allowing only the hydrogen to diffuse through to the fuel cell. It is beneficial to adsorb product gases if the presence of the additional byproducts will degrade the components of the fuel cell. Any fuel cell that uses hydrogen as a fuel source can be effectively used with this invention. For example, effective fuel cells include the micro-electro mechanical system based (MEMS-based) fuel cells discussed in U.S. patent application Ser. No. 09/241,159 by Alan Jankowski and Jeffrey Morse which is hereby incorporated by reference.
A chemical microreactor can be constructed by using micromachining of silicon, glass, or ceramic materials, and wafer bonding. This method of construction involves first forming the microchannel by etching a pattern in the bottom surface of a substrate. For example, the pattern may be serpentine or straight. The depth of the microchannel is approximately 20 O Am, and penetrates only a fraction of the way through the total depth of the substrate, which can range in thickness from about 400 m to about 600 μm. Referring to FIGS. 2A (top view) and 2 B (cross-sectional view), resistive heaters 14 are formed on the top surface of substrate 4 b and positioned above microchannel 6 in a mariner which optimizes the heat transfer from the heaters to the microchannels. The resistive heaters can also be formed on the top surface of substrate 4 a , so that they are positioned adjacent to the surface of the microchannel. Thus, the power input required to heat the fuel-water to product gases and complete the catalytic reaction as the gases flow through the channel is minimized.
Further embodiments facilitate a process referred to as counter-flow heat exchange. Such embodiments position the microchannels in configurations that permit the heat that is lost from the product gases flowing through one microchannel to be transferred to gas flow streams in adjacent microchannels. Such embodiments can include counterflow heat exchangers (not shown). The counterflow heat exchangers can be located in the following three areas and serve three different functions. First, counterflow heat exchangers can be located in the gassifier region to initially heat the fuel water mixture. A second set of counterflow heat exchangers can be located in the area between the gassifier region and the packed catalyst microchannel to add extra heat to the gas as it flows into the capillary microchannel. Finally, more counterflow heat exchangers can be located at the outlet of the porous membrane to recuperate any extra heat given off by the byproduct flow stream. The hot gas outlet of catalytic microreactors integrated with a fuel cell connect directly to the fuel cell anode manifold, and incorporate a counterflow heat exchanger at the fuel cell anode exhaust. That counterflow heat exchanger transfers extra heat from the anode exhaust from the fuel cell back through the gassifier region and inlet flow stream to the catalytic microreactor.
The inlet port(s) 8 and porous membrane structure 13 are formed by patterning and etching into the top surface of the substrate 4 a . Referring to FIG. 3 , an inlet port 8 is approximately 1 mm in diameter and opens up to the entrance of microchannel 6 . Separate inlets for fuel and water may be formed, or a single inlet for premixed fuel-water mixtures (as shown in FIG. 3 ) may suffice. An array of vias 17 with diameters ranging from 0.1-5.0 μm can be patterned and etched into a porous membrane support structure 13 . The pores are straight, and go through to the end of microchannel 6 (for example, about 100 μm to about 200 μm deep). Silicon can be etched using conventional plasma etch (Bosch process) techniques, laser etching, or photoinduced electrochemical etching. Each etching technique will create an array of very straight, deep, narrow pores which extend to the microchannel, which is formed from the bottom side.
Another approach to forming a porous silicon membrane is to use an electrochemical etch technique whereby hydrofluoric acid is used to etch pores in the silicon. The electrochemical etch creates a random porous layer in the silicon. The pore sizes, for example, have diameters of about 0.1 μm to about 1.0 Am, and thicknesses on the order of about 60 μm to about 200 μm.
A porous membrane support structure can be positioned at the outlet of the microchannel using a combination of thin film deposition, thick film formation, and electrochemistry techniques. Referring to FIG. 4A , the membrane structure 13 may be a porous thick film structure comprising anodic alumina, xerogel, or glass and is formed over an opening creating vias 17 which are etched down to the microchannel 6 at the outlet end. FIG. 4B shows a multiple channel embodiment. In one example, a thick film membrane comprising xerogels is formed by depositing a solgel coating of glass on the top surface of the substrate, and drying it in such a way as to create random porosity through the film. For instance, a 30 minute bake at 120° C. to remove any remaining solvents is followed by a high temperature bake at 600-800° C. Others methods known to those familiar with the art will also apply. The diameter of these pores may range in size from about 0.1 μm to about 1.0 μm, and the film can be up to about 100 um thick.
In a second example, the membrane 13 is formed by bonding a porous alumina film about 50 μm thick to the top surface of the substrate 4 a over an opening leading to the microchannel 6 . The porous alumina is formed by anodization of aluminum which creates arrays of narrow pores ranging in diameter from about 0.02 μm to about 0.2 gm.
The porous thick film membrane structure has two primary purposes. First, it provides mechanical strength in the case where a pressure differential exists between the inlet 8 to microchannel and the outlet 10 from the microchannel. Second, it provides a natural flow control of the gaseous reaction byproducts flowing through the porous membrane 12 . The membrane structure can be controlled for the specific requirements of the power source it is feeding. For example, the fuel, when fully processed, in a 6 microliters/minute flow of a methanol:water (50:50) fuel mixture can provide approximately 500 milliwatts of electrical power from a fuel cell at 50 percent efficiency if the microchannels and microfluidic system are designed to provide minimal pressure drops the 6 microliters/minute flow rate.
Once the microchannels, porous membrane structures, resistive heaters, and counterflow heat exchangers are formed, the catalytic microreactor is completed by integrating the catalyst materials into the microchannel and porous membrane, then bonding a first substrate 4 a made of glass, silicon, or ceramic to a second substrate 4 b made of glass, silicon, or ceramic.
The catalyst used may be platinum, platinum-ruthenium, nickel, palladium, copper, copper oxide, ceria, zinc oxide, alumina, combinations thereof, alloys thereof or other materials commonly used in steam reforming processes. Various coating methods are used to position the catalyst materials. For example, the catalyst materials can be imbedded within the membrane and the microchannel by thin film deposition techniques or they can be imbedded within the microchannel and porous membrane structure by ion exchange or solgel doping methods. These coating methods can be tailored to provide porous, high surface area coatings, thereby enhancing the reaction kinetics.
Other effective processes use small pellets or particles of a supported catalyst material, such as Copper/Zinc Oxide/Alumina, for example, which are larger in diameter than the pore sizes of the porous membrane. This kind of catalyst material is commercially available, and is typically formed by imbedding the copper/zinc oxide materials in to a porous alumina support particle. Once formed, the catalyst particles can be colloidally suspended in a liquid solution. The colloidal solution can then be injected through the microchannel. The porous membrane traps the catalyst particles inside the microchannel. After some time, the microchannel becomes filled with catalyst particles. This process creates a packed catalyst microchannel that is porous enough for gases to readily flow through and at the same time be exposed to a high surface area of catalyst materials. This process can be used in combination with the catalyst coating methods described above, or by itself.
The membrane area and microchannel areas are made large enough to allow sufficient fuel flow for the power source requirements. In some cases, if resistive heaters require too much input electrical power to heat the microchannels and porous membrane, exothermic combustion reactions may be initiated. These exothermic combustion reactions may be self-sustaining and thus, do not require additional power.
Referring to FIG. 5 , these self-sustaining exothermic combustion reactions can be accomplished by forming a microcombustor 20 . Microcombuster 20 comprises a small microchannel 22 with a catalyst wire or electrode 23 (typically is a catalyst bed heater), which is separate from the capillary microchannel 6 and porous membrane 12 , and at least one electrical contact pad 30 connected to a power source (not shown). This microcombustor has a first inlet 24 for a fuel such as butane or methanol, which is heated with a small resistive heater to form a gas, and a second inlet 26 for air or other oxygen-containing gaseous mixture. The fuel and air are mixed and flow over the catalyst wire or electrode, which is heated by running a current through it similar to a resistor. The fuel/air mixture then ignites a combustion reaction which generates heat, carbon dioxide and water. The heat is transferred to the capillary microchannel and porous membrane and the carbon dioxide and water flow to an outlet (not shown). Once ignited, the reaction is sustained as long as fuel and air flow through inlets 24 and 26 without further current flowing through the catalyst wire 23 or filament. The heat generated from the combustion reaction can be efficiently transferred to the chemical microreactor and, if present, an integrated fuel cell, using the counterflow heat exchange process described above. The outlet gas stream from the microchannel combustor will be hot, and this heat can be readily transferred through high surface area microchannels to adjacent cold gases flowing in opposite directions. The microchannel combustor can be formed using the same approaches described above for the chemical microreactor. In certain fuel cell embodiments, heat may be coupled between the steam reforming packed catalyst microchannel and porous membrane and the fuel cell, thereby reducing the power requirement to heat the fuel cell and make a very efficient power source. The membrane material and porosity, catalyst deposition, and integrated heater layout can be optimized to match a specific fuel, such as methanol, or specific groups of fuels, such as ammonia, methanol and butane.
Several microreactors can be integrated to allow processing of a variety of liquid fuel components. Integrated microreactors which incorporate both fuel cells and fuel reforming may be fabricated in parallel in order to make them suitable for higher power applications ranging from about 10 Watts to about 50 Watts.
While particular operational sequences, materials, temperatures, parameters, and particular embodiments have been described and or illustrated, such are not intended to be limiting. Modifications and changes may become apparent to those skilled in the art, and it is intended that the invention be limited only by the scope of the appended claims.
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A method for forming a chemical microreactor includes forming at least one capillary microchannel in a substrate having at least one inlet and at least one outlet, integrating at least one heater into the chemical microreactor, interfacing the capillary microchannel with a liquid chemical reservoir at the inlet of the capillary microchannel, and interfacing the capillary microchannel with a porous membrane near the outlet of the capillary microchannel, the porous membrane being positioned beyond the outlet of the capillary microchannel, wherein the porous membrane has at least one catalyst material imbedded therein.
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PRIORITY TO RELATED APPLICATION(S)
This application claims the benefit of European Patent Application No. 06125645.9, filed Dec. 7, 2006, which is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
Vasopressin is a 9 amino acid peptide mainly produced by the paraventricular nucleus of the hypothalamus. Three vasopressin receptors, all belonging to the class I G-protein coupled receptors, are known. The V1a receptor is expressed in the brain, liver, vascular smooth muscle, lung, uterus and testis, the V1b or V3 receptor is expressed in the brain and pituitary gland, the V2 receptor is expressed in the kidney where it regulates water excretion and mediates the antidiuretic effects of vasopressin.
In the periphery vasopressin acts as a neurohormone and stimulates vasoconstriction, glycogenolysis and antidiuresis. In the brain vasopressin acts as a neuromodulator and is elevated in the amygdala during stress (Ebner, K., C. T. Wotjak, et al. (2002), “Forced swimming triggers vasopressin release within the amygdala to modulate stress-coping strategies in rats.” Eur J Neurosci 15(2): 384-8). The V1a receptor is extensively expressed in the brain and particularly in limbic areas like the amygdala, lateral spectrum and hippocampus which are playing an important role in the regulation of anxiety. Indeed V1a knock-out mouse show a reduction in anxious behavior in the plus-maze, open field and light-dark box (Bielsky, I. F., S. B. Hu, et al. (2003). “Profound Impairment in Social Recognition and Reduction in Anxiety-Like Behavior in Vasopressin V1a Receptor Knockout Mice.” Neuropsychopharmacology ). The downregulation of the V1a receptor using antisense oligonucleotide injection in the septum also causes a reduction in anxious behavior (Landgraf, R., R. Gerstberger, et al. (1995), “V1 vasopressin receptor antisense oligodeoxynucleotide into septum reduces vasopressin binding, social discrimination abilities, and anxiety-related behavior in rats.” Regul Pept 59(2): 229-39).
The V1a receptor is also mediating the cardiovascular effects of vasopressin in the brain by centrally regulating blood pressure and heart rate in the solitary tract nucleus (Michelini, L. C. and M. Morris (1999). “Endogenous vasopressin modulates the cardiovascular responses to exercise.” Ann N Y Acad Sci 897: 198-211). In the periphery it induces the contraction of vascular smooth muscles and chronic inhibition of the V1a receptor improves hemodynamic parameters in myocardial infarcted rats (Van Kerckhoven, R., I. Lankhuizen, et al. (2002). “Chronic vasopressin V(1A) but not V(2) receptor antagonism prevents heart failure in chronically infarcted rats.” Eur J Pharmacol 449(1-2): 135-41).
SUMMARY OF THE INVENTION
The present invention provides novel indol-2-yl-carbonyl-spiro-piperidine derivatives as V1a receptor antagonists, their manufacture, pharmaceutical compositions containing them and their use for the treatment of anxiety and depressive disorders and other diseases.
In particular, the present invention provides compounds of formula (I)
wherein
X is O or CH 2 ; R 1 is hydrogen,
C 1-6 -alkyl, optionally substituted by CN or OH, or —(C 1-6 -alkylene)—C(O)—NR a R b ;
R 2 is hydrogen,
C 1-6 -alkyl, C 1-6 -alkoxy, —(C 1-6 -alkylene)—NR c R d , —(C 1-6 -alkylene)—C(O)R f , benzyl, optionally substituted by one or more halo, halo-C 1-6 -alkyl, C 1-6 -alkyl, C 1-6 -alkoxy, halo-C 1-6 -alkoxy, nitro, or cyano, or phenyl, optionally substituted by one or more halo, halo-C 1-6 -alkyl, C 1-6 -alkyl, C 1-6 -alkoxy, halo-C 1-6 -alkoxy, nitro, or cyano;
R 3 is hydrogen,
halo, or C 1-6 -alkyl;
R 4 is hydrogen,
halo, C 1-6 -alkyl, halo-C 1-6 -alkyl, C 1-6 -alkoxy, halo-C 1-6 -alkoxy, or —O—C 2-10 -alkenyl;
R 5 is hydrogen,
halo, C 1-6 -alkyl, or C 1-6 -alkoxy;
or R 4 and R 5 are bound together to form a ring with the benzo moiety, wherein
—R 4 —R 5 — is —O—(CH 2 ) n —O— wherein n is 1 or 2;
R 6 is hydrogen,
C 1-6 -alkyl, optionally substituted by CN or OH, —(C 1-6 -alkylene)—NR g R h , —(C 1-6 -alkylene)—C(O)—NR i R j , —O-benzyl, optionally substituted by one or more halo, halo-C 1-6 -alkyl, C 1-6 -alkyl, C 1-6 -alkoxy, halo-C 1-6 -alkoxy, nitro, or cyano, nitro, halo, cyano, C 1-6 -alkoxy, halo-C 1-6 -alkoxy, halo-C 1-6 -alkyl, —(C 1-6 -lkylene)—C(O)R f , phenyl, optionally substituted by one or more halo, halo-C 1-6 -alkyl, C 1-6 -alkyl, C 1-6 -alkoxy, halo-C 1-6 -alkoxy, nitro, or cyano, —(C 1-3 -alkylene)—R m ,
wherein R m is phenyl, a 5- to 6-membered heteroaryl, 4- to 6-membered heterocycloalkyl or 3 to 6-membered cycloalkyl, each optionally substituted by one or more halo, halo-C 1-6 -alkyl, C 1-6 -alkyl, C 1-6 -alkoxy, halo-C 1-6 -alkoxy, nitro, or cyano;
or R 5 and R 6 are bound together to form a ring with the benzo moiety, wherein
—R 5 —R 6 — is —O—(CH 2 ) n —C(O)—, —C(O)—(CH 2 ) n —O—, or —O—(CH 2 ) n —O— wherein n is 1 or 2;
R 7 is hydrogen or C 1-6 -alkyl; R 8 , R 9 , R 10 , and R 11 are each independently hydrogen, halo, C 1-6 -alkyl, halo-C 1-6 -alkyl, C 1-6 -alkoxy or halo-C 1-6 alkoxy; R a , R b , R i and R j are each independently
hydrogen, C 1-6 -alkyl, —(C 1-6 -alkylene)—NR k R l ;
wherein R k and R l are each independently hydrogen or C 1-6 -alkyl,
or R a and R b , or R i and R j together with the nitrogen to which they are bound form a five or six membered heterocycle comprising one or two heteroatoms selected from the group of nitrogen, oxygen and sulfur;
R c , R d , R g and R h are each independently
hydrogen, C 1-6 -alkyl, —C(O)R e , or —S(O) 2 R e ,
wherein R e is selected from
hydrogen, C 1-6 -alkyl, and phenyl, optionally substituted by one or more halo, halo-C 1-6 -alkyl, C 1-6 -alkyl, C 1-6 -alkoxy, halo-C 1-6 -alkoxy, nitro, or cyano, or
R c and R d , or R g and R h together with the nitrogen to which they are bound form a five or six membered heterocycle comprising one or two heteroatoms selected from the group of nitrogen, oxygen and sulfur, or R c and R d , or R g and R h together with the nitrogen to which they are bound form isoindole-1,3-dione;
R f is selected from
hydrogen, C 1-6 -alkyl, C 1-6 -alkoxy; and phenyl, optionally substituted by one or more halo, halo-C 1-6 -alkyl, C 1-6 -alkyl, C 1-6 -alkoxy, halo-C 1-6 -alkoxy, nitro, or cyano;
or a pharmaceutically acceptable salt thereof.
The compounds of formula (I) can be manufactured by the methods given below, by the methods given in the examples or by analogous methods. Appropriate reaction conditions for the individual reaction steps are known to a person skilled in the art. Starting materials are either commercially available or can be prepared by methods analogous to the methods given below, by methods described in references cited in the text or in the examples, or by methods known in the art.
The compounds of formula (I) possess pharmaceutical activity, in particular they are modulators of V1a receptor activity. More particular, the compounds are antagonists of the V1a receptor.
The present invention provides compounds which act as V1a receptor modulators, and in particular as V1a receptor antagonists. Such antagonists are useful as therapeutics in the conditions of dysmenorrhea, hypertension, chronic heart failure, inappropriate secretion of vasopressin, liver cirrhosis, nephrotic syndrome, obsessive compulsive disorder, anxiety and depressive disorders. The preferred indications with regard to the present invention are the treatment of anxiety and depressive disorders.
DETAILED DESCRIPTION OF THE INVENTION
The following definitions of the general terms used in the present description apply irrespective of whether the terms in question appear alone or in combination. It must be noted that, as used in the specification and the appended claims, the singular forms “a”, “an,” and “the” include plural forms unless the context clearly dictates otherwise.
In the present description, the term “alkyl,” alone or in combination with other groups, refers to a branched or straight-chain monovalent saturated hydrocarbon radical. The term “C 1-6 -alkyl” denotes a saturated straight- or branched-chain hydrocarbon group containing from 1 to 6 carbon atoms, for example, methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, tert-butyl, the isomeric pentyls and the like. A preferred sub-group of C 1-6 -alkyl is C 1-4 -alkyl, i.e. with 1-4 carbon atoms.
In the present invention, the term “alkylene” refers to a linear or branched saturated divalent hydrocarbon radical. In particular, “C 1-6 -alkylene” means a linear saturated divalent hydrocarbon radical of one to six carbon atoms or a branched saturated divalent hydrocarbon radical of three to six carbon atoms, e.g. methylene, ethylene, 2,2-dimethylethylene, n-propylene, 2-methylpropylene, and the like.
In the present description, the terms “alkoxy” and “C 1-6 -alkoxy” refer to the group R′—O—, wherein R′ is C 1-6 -alkyl as defined above. Examples of alkoxy groups are methoxy, ethoxy, n-propoxy, isopropoxy, n-butoxy, tert-butoxy, sec-butoxy and the like. A preferred sub-group of C 1-6 -alkoxy, and still more preferred alkoxy groups are methoxy and/or ethoxy.
In the present description, the terms “thioalkyl” and “C 1-6 -thioalkyl” refer to the group R′—S—, wherein R′ is C 1-6 -alkyl as defined above.
The terms “C 1-6 -hydroxyalkyl” and “C 1-6 -alkyl substituted by OH” denote a C 1-6 -alkyl group as defined above wherein at least one of the hydrogen atoms of the alkyl group is replaced by a hydroxyl group.
The terms “C 1-6 -cyanoalkyl” and “C 1-6 -alkyl substituted by CN” denote a C 1-6 -alkyl group as defined above wherein at least one of the hydrogen atoms of the alkyl group is replaced by a CN group.
The terms “halo” or “halogen” refer to fluorine (F), chlorine (Cl), bromine (Br) and iodine (I) with fluorine, chlorine and bromine being preferred.
The term “halo-C 1-6 -alkyl” denotes a C 1-6 -alkyl group as defined above wherein at least one of the hydrogen atoms of the alkyl group is replaced by a halogen atom, preferably fluoro or chloro, most preferably fluoro. Examples of halo-C 1-6 -alkyl include but are not limited to methyl, ethyl, propyl, isopropyl, isobutyl, sec-butyl, tert-butyl, pentyl or n-hexyl substituted by one or more Cl, F, Br or I atom(s) as well as those groups specifically illustrated by the examples herein below. Among the preferred halo-C 1-6 -alkyl groups are difluoro- or trifluoro-methyl or -ethyl.
The term “halo-C 1-6 -alkoxy” denotes a C 1-6 -alkoxy group as defined above wherein at least one of the hydrogen atoms of the alkyl group is replaced by a halogen atom, preferably fluoro or chloro, most preferably fluoro. Among the preferred halogenated alkoxy groups are difluoro- or trifluoro-methoxy or -ethoxy.
The term “C 2-12 -alkenyl”, alone or in combination, denotes a straight-chain or branched hydrocarbon residue of 2 to 12 carbon atoms comprising at least one double bond. A preferred sub-group of C 2-12 -alkenyl is C 2-6 -alkyenyl. Examples of the preferred alkenyl groups are ethenyl, propen-1-yl, propen-2-yl (allyl), buten-1-yl, buten-2-yl, buten-3-yl, penten-1-yl, penten-2-yl, penten-3-yl, penten-4-yl, hexen-1-yl, hexen-2-yl, hexen-3-yl, hexen-4-yl and hexen-5-yl, as well as those specifically illustrated by the examples herein below.
The term “5 or 6 membered heteroaryl” means an aromatic ring of 5 or 6 ring atoms as ring members containing one, two, or three ring heteroatoms selected from N, O, or S, the rest being carbon atoms, 5 or 6 membered heteroaryl can optionally be substituted with one, two, three or four substituents, wherein each substituent may independently be selected from the group consisting of hydroxy, C 1-6 -alkyl, C 1-6 -alkoxy, C 1-6 -thioalkyl, halo, cyano, nitro, halo-C 1-6 -alkyl, C 1-6 -hydroxyalkyl, C 1-6 -alkoxycarbonyl, amino, C 1-6 -alkylamino, di(C 1-6 )alkylamino, aminocarbonyl, or carbonylamino, unless otherwise specifically indicated. Preferred substituents are halo, halo-C 1-6 -alkyl, C 1-6 -alkyl, C 1-6 -alkoxy, halo-C 1-6 -alkoxy, nitro, or cyano. Examples of heteroaryl moieties include, but are not limited to, optionally substituted imidazolyl, optionally substituted oxazolyl, optionally substituted thiazolyl, optionally substituted pyrazinyl, optionally substituted pyrrolyl, optionally substituted pyrazinyl, optionally substituted pyridinyl, optionally substituted pyrimidinyl, optionally substituted furanyl, and those which are specifically exemplified herein.
The term “heterocycloalkyl” means a monovalent saturated moiety, consisting of one ring of 3 to 7, preferably from 4 to 6 atoms as ring members, including one, two, or three heteroatoms chosen from nitrogen, oxygen or sulfur, the rest being carbon atoms. 3 to 7 membered heterocycloalkyl can optionally be substituted with one, two, three or four substituents, wherein each substituent is independently hydroxy, C 1-6 -alkyl, C 1-6 -alkoxy, C 1-6 -thioalkyl, halo, cyano, nitro, halo-C 1-6 -alkyl, C 1-6 -hydroxyalkyl, C 1-6 -alkoxycarbonyl, amino, C 1-6 -alkylamino, di(C 1-6 )alkylamino, aminocarbonyl, or carbonylamino, unless otherwise specifically indicated.
Preferred substituents are halo, halo-C 1-6 -alkyl, C 1-6 -alkyl, C 1-6 -alkoxy, halo-C 1-6 -alkoxy, nitro, or cyano. Examples of heterocyclic moieties include, but are not limited to, optionally substituted tetrahydro-furanyl, optionally substituted piperidinyl, optionally substituted pyrrolidinyl, optionally substituted morpholinyl, optionally substituted piperazinyl, and the like or those which are specifically exemplified herein.
The term “heterocycle” in the definition “R a and R b , R c and R d , R g and R h , R i and R j , together with the nitrogen to which they are bound form a five- or six-membered heterocycle comprising one or two heteroatoms selected from the group of nitrogen, oxygen and sulfur” means either heterocycloalkyl or heteroaryl in the above-given sense, which may optionally be substituted as described above. Preferably, the “heterocycle” may optionally be substituted with one, two or three substituents selected from halo, halo-C 1-6 -alkyl, C 1-6 -alkyl, C 1-6 -alkoxy, halo-C 1-6 -alkoxy, nitro, or cyano. Preferred heterocycles are piperazine, N-methylpiperazine, morpholin, piperidine and pyrrolidine.
The term “one or more” substituents preferably means one, two or three substituents per ring.
The term “3- to 6-membered cycloalkyl” denotes a saturated or partially saturated ring containing from 3 to 6 carbon atoms, for example cyclopropyl, cyclopentyl, cyclopentenyl, cyclohexyl, or cyclohexenyl.
“Pharmaceutically acceptable,” such as pharmaceutically acceptable carrier, excipient, etc., means pharmacologically acceptable and substantially non-toxic to the subject to which the particular compound is administered.
The term “pharmaceutically acceptable acid addition salt” embraces salts with inorganic and organic acids, such as hydrochloric acid, nitric acid, sulfuric acid, phosphoric acid, citric acid, formic acid, fumaric acid, maleic acid, acetic acid, succinic acid, tartaric acid, methane-sulfonic acid, p-toluenesulfonic acid and the like.
“Therapeutically effective amount” means an amount that is effective to prevent, alleviate or ameliorate symptoms of disease or prolong the survival of the subject being treated.
In detail, the present invention relates to compounds of the general formula (I)
wherein
X is O or CH 2 ; R 1 is hydrogen,
C 1-6 -alkyl, optionally substituted by CN or OH, or —(C 1-6 -alkylene)—C(O)—NR a R b ;
R 2 is hydrogen,
C 1-6 -alkyl, C 1-6 -alkoxy, —(C 1-6 -alkylene)—NR c R d , —(C 1-6 -alkylene)—C(O)R f , benzyl, optionally substituted by one or more halo, halo-C 1-6 -alkyl, C 1-6 -alkyl, C 1-6 -alkoxy, halo-C 1-6 -alkoxy, nitro, or cyano, or phenyl, optionally substituted by one or more halo, halo-C 1-6 -alkyl, C 1-6 -alkyl, C 1-6 -alkoxy, halo-C 1-6 -alkoxy, nitro, or cyano;
R 3 is hydrogen,
halo, or C 1-6 -alkyl;
R 4 is hydrogen,
halo, C 1-6 -alkyl, halo-C 1-6 -alkyl, C 1-6 -alkoxy, halo-C 1-6 -alkoxy, or —O—C 2-10 -alkenyl;
R 5 is hydrogen,
halo, C 1-6 -alkyl, or C 1-6 -alkoxy;
or R 4 and R 5 are bound together to form a ring with the benzo moiety, wherein
—R 4 —R 5 — is —O—(CH 2 ) n —O— wherein n is 1 or 2;
R 6 is hydrogen,
C 1-6 -alkyl, optionally substituted by CN or OH, —(C 1-6 -alkylene)—NR g R h , —(C 1-6 -alkylene)—C(O)—NR i R j , —O-benzyl, optionally substituted by one or more halo, halo-C 1-6 -alkyl, C 1-6 -alkyl, C 1-6 -alkoxy, halo-C 1-6 -alkoxy, nitro, or cyano, nitro, halo, cyano, C 1-6 -alkoxy, halo-C 1-6 -alkoxy, halo-C 1-6 -alkyl, —(C 1-6 -alkylene)—C(O)R f , phenyl, optionally substituted by one or more halo, halo-C 1-6 -alkyl, C 1-6 -alkyl, C 1-6 -alkoxy, halo-C 1-6 -alkoxy, nitro, or cyano, —(C 1-3 -alkylene)—R m ,
wherein R m is phenyl, a 5- to 6-membered heteroaryl, 4- to 6-membered heterocycloalkyl or 3 to 6-membered cycloalkyl, each optionally substituted by one or more halo, halo-C 1-6 -alkyl, C 1-6 -alkyl, C 1-6 -alkoxy, halo-C 1-6 -alkoxy, nitro, or cyano;
or R 5 and R 6 are bound together to form a ring with the benzo moiety, wherein
—R 5 —R 6 — is —O—(CH 2 ) n —C(O)—, —C(O)—(CH 2 ) n —O—, or —O—(CH 2 ) n —O— wherein n is 1 or 2;
R 7 is hydrogen or C 1-6 -alkyl; R 8 , R 9 , R 10 , and R 11 are each independently hydrogen, halo, C 1-6 -alkyl, halo-C 1-6 -alkyl, C 1-6 -alkoxy or halo-C 1-6 alkoxy; R a , R b , R i and R j are each independently
hydrogen, C 1-6 -alkyl, —(C 1-6 -alkylene)—NR k R l ;
wherein R k and R l are each independently hydrogen or C 1-6 -alkyl,
or R a and R b , or R i and R j together with the nitrogen to which they are bound form a five or six membered heterocycle comprising one or two heteroatoms selected from the group of nitrogen, oxygen and sulfur;
R c , R d , R g and R h are each independently
hydrogen, C 1-6 -alkyl, —C(O)R e , or —S(O) 2 R e ,
wherein R e is selected from
hydrogen, C 1-6 -alkyl, and phenyl, optionally substituted by one or more halo, halo-C 1-6 -alkyl, C 1-6 -alkyl, C 1-6 -alkoxy, halo-C 1-6 -alkoxy, nitro, or cyano, or
R c and R d , or R g and R h together with the nitrogen to which they are bound form a five or six membered heterocycle comprising one or two heteroatoms selected from the group of nitrogen, oxygen or sulfur, or R c and R d , or R g and R h together with the nitrogen to which they are bound form isoindole-1,3-dione;
R f is selected from
hydrogen, C 1-6 -alkyl, C 1-6 -alkoxy; and phenyl, optionally substituted by one or more halo, halo-C 1-6 -alkyl, C 1-6 -alkyl, C 1-6 -alkoxy, halo-C 1-6 -alkoxy, nitro, or cyano;
or a pharmaceutically acceptable salt thereof.
In certain embodiments of the invention, R a and R b , R c and R d , R i and R j , or R g and R h together with the nitrogen to which they are bound may form piperazine, 4-(C 1-6 -alkyl)-piperazine, 4-methylpiperazine, morpholine, piperidine or pyrrolidine.
In certain embodiments of the invention, wherein R m is a 5- to 6-membered heteroaryl, the preferred heteroaryl is selected from the group consisting of pyridine, pyrimidine, pyrazine, pyridazine, imidazole, pyrazole, oxazole, and isoxazole.
In embodiments of the invention, wherein R m is a 4- to 6-membered heterocycloalkyl, the preferred heterocycloalkyl is selected from the group consisting of pyrrolidine, oxethane, tetrahydropyrane, piperidine, morpholine, and piperazine.
In certain embodiments of the invention, R 1 is hydrogen or C 1-6 -alkyl, optionally substituted by CN or OH.
In certain embodiments of the invention,
R 2 is hydrogen,
C 1-6 -alkyl, C 1-6 -alkoxy, —(C 1-6 -alkylene)—NR c R d , wherein R c and R d are each independently
hydrogen, —C(O)R e , or —S(O) 2 R e ,
wherein R e is selected from
hydrogen, C 1-6 -alkyl, and phenyl, optionally substituted by one or more halo, halo-C 1-6 -alkyl, C 1-6 -alkyl, C 1-6 -alkoxy, halo-C 1-6 -alkoxy, nitro, or cyano, or
R c and R d together with the nitrogen to which they are bound form isoindole-1,3-dione;
—(C 1-6 -alkylene)—C(O)R f , wherein R f is selected from
hydrogen, C 1-6 -alkyl, C 1-6 -alkoxy, and phenyl, optionally substituted by one or more halo, halo-C 1-6 -alkyl, C 1-6 -alkyl, C 1-6 -alkoxy, halo-C 1-6 -alkoxy, nitro, or cyano;
benzyl, optionally substituted by halo, halo-C 1-6 -alkyl, C 1-6 -alkyl, C 1-6 -alkoxy, halo-C 1-6 -alkoxy, nitro, or cyano, or phenyl, optionally substituted by halo, halo-C 1-6 -alkyl, C 1-6 -alkyl, C 1-6 -alkoxy, halo-C 1-6 -alkoxy, nitro, or cyano.
In certain embodiments of the invention, R 2 is hydrogen or C 1-6 -alkyl.
In certain embodiments of the invention, R 3 is hydrogen.
In certain embodiments of the invention, R 4 is hydrogen, halo, C 1-6 -alkyl, or C 1-6 -alkoxy.
In certain embodiments of the invention,
R 6 is hydrogen,
C 1-6 -alkyl, optionally substituted by CN or OH, —(C 1-6 -alkylene)—NR g R h ,
wherein R g and R h are each independently selected from hydrogen, and C 1-6 -alkyl; or wherein R g and R h together with the nitrogen to which they are bound form a five or six membered heterocycle comprising one or two heteroatoms selected from the group of nitrogen, oxygen and sulfur,
—(C 1-6 -alkylene)—C(O)—NR i R j ,
wherein R i and R j are each independently
hydrogen, C 1-6 -alkyl, —(C 1-6 -alkylene)—NR k R l ,
wherein R k and R l are each independently hydrogen or C 1-6 -alkyl,
or R i and R j together with the nitrogen to which they are bound form a five or six membered heterocycle comprising one or two heteroatoms selected from the group of nitrogen, oxygen and sulfur,
—O-benzyl, optionally substituted by one or more halo, halo-C 1-6 -alkyl, C 1-6 -alkyl, C 1-6 -alkoxy, halo-C 1-6 -alkoxy, nitro, or cyano, nitro, halo, cyano, C 1-6 -alkoxy, halo-C 1-6 -alkoxy, halo-C 1-6 -alkyl, —(C 1-6 -alkylene)—C(O)R f ,
R f is selected from
hydrogen, C 1-6 -alkyl, C 1-6 -alkoxy, or phenyl, optionally substituted by one or more halo, halo-C 1-6 -alkyl, C 1-6 -alkyl, C 1-6 -alkoxy, halo-C 1-6 -alkoxy, nitro, or cyano,
phenyl, optionally substituted by one or more halo, halo-C 1-6 -alkyl, C 1-6 -alkyl, C 1-6 -alkoxy, halo-C 1-6 -alkoxy, nitro, or cyano, —(C 1-3 -alkylene)—R m ,
wherein R m is phenyl, a 5- to 6-membered heteroaryl, 4- to 6-membered heterocycloalkyl or 3 to 6-membered cycloalkyl, each optionally substituted by one or more halo, halo-C 1-6 -alkyl, C 1-6 -alkyl, C 1-6 -alkoxy, halo-C 1-6 -alkoxy, nitro, or cyano.
In certain embodiments of the invention,
R 6 is hydrogen,
C 1-6 -alkyl, optionally substituted by CN or OH, —(C 1-6 -alkylene)—NR g R h ,
wherein R g and R h are each independently selected from hydrogen, and C 1-6 -alkyl; or wherein R g and R h together with the nitrogen to which they are bound form a five or six membered heterocycle comprising one or two heteroatoms selected from the group of nitrogen, oxygen and sulfur,
—(C 1-6 -alkylene)—C(O)—NR i R j ,
wherein R i and R j are each independently
hydrogen, C 1-6 -alkyl, —(C 1-6 -alkylene)—NR k R l ,
wherein R k and R l are each independently hydrogen or C 1-6 -alkyl,
or R i and R j together with the nitrogen to which they are bound form a five or six membered heterocycle comprising one or two heteroatoms selected from the group of nitrogen and oxygen.
In certain embodiments of the invention, R 6 is hydrogen or C 1-6 -alkyl.
In certain embodiments of the invention, R 7 is hydrogen.
In certain embodiments, all R 8 to R 11 are hydrogen.
In certain embodiments, R 8 to R 11 are independently hydrogen or halo.
In certain embodiments, R 9 is fluoro, and R 8 , R 10 and R 11 are hydrogen.
In certain embodiments, R 8 , R 9 and R 11 are hydrogen and R 10 is bromo.
In certain embodiments, R 8 to R 11 are independently hydrogen or methyl.
In certain embodiments, R 8 to R 10 are hydrogen and R 11 is methyl.
In certain embodiments of the invention, X is O, i.e. compounds of formula (Ia)
wherein R 1 to R 11 are as defined herein above.
In certain embodiments of the invention, X is CH 2 , i.e. compounds of formula (Ib)
wherein R 1 to R 11 are as defined herein above.
In certain embodiments of the invention, R 1 to R 6 are not all hydrogen.
In certain embodiments of the invention, R 1 to R 11 are not all hydrogen.
The invention further encompasses an embodiment with the compound of formula (I), wherein
X is O or CH 2 ; R 1 is hydrogen;
C 1-6 -alkyl, optionally substituted by CN or OH; —(C 1-6 -alkylene)—C(O)—NR a R b ,
wherein R a and R b are each independently hydrogen or C 1-6 -alkyl,
R 2 is hydrogen,
C 1-6 -alkyl, C 1-6 -alkoxy, —(C 1-6 -alkylene)—NR c R d , wherein R c and R d are each independently
hydrogen, —C(O)R e , or —S(O) 2 R e ,
wherein R e is selected from
hydrogen, C 1-6 -alkyl, and phenyl, optionally substituted by one or more halo, halo-C 1-6 -alkyl, C 1-6 -alkyl, C 1-6 -alkoxy, halo-C 1-6 -alkoxy, nitro, or cyano, or
R c and R d together with the nitrogen to which they are bound form isoindole-1,3-dione;
—(C 1-6 -alkylene)—C(O)R f , wherein R f is selected from
hydrogen, C 1-6 -alkyl, C 1-6 -alkoxy, and phenyl, optionally substituted by one or more halo, halo-C 1-6 -alkyl, C 1-6 -alkyl, C 1-6 -alkoxy, halo-C 1-6 -alkoxy, nitro, or cyano,
benzyl, optionally substituted by halo, halo-C 1-6 -alkyl, C 1-6 -alkyl, C 1-6 -alkoxy, halo-C 1-6 -alkoxy, nitro, or cyano or phenyl, optionally substituted by halo, halo-C 1-6 -alkyl, C 1-6 -alkyl, C 1-6 -alkoxy, halo-C 1-6 -alkoxy, nitro, or cyano;
R 3 is hydrogen,
halo, or C 1-6 -alkyl;
R 4 is hydrogen,
halo, C 1-6 -alkyl, halo-C 1-6 -alkyl, C 1-6 -alkoxy, halo-C 1-6 -alkoxy, or —O—C 2-10 -alkenyl;
R 5 is hydrogen,
halo, C 1-6 -alkyl, or C 1-6 -alkoxy;
or R 4 and R 5 are bound together to form a ring with the benzo moiety, wherein
—R 4 —R 5 — is —O—(CH 2 ) n —O— wherein n is 1 or 2;
R 6 is hydrogen,
C 1-6 -alkyl, optionally substituted by CN or OH, —(C 1-6 -alkylene)—NR g R h ,
wherein R g and R h are each independently selected from hydrogen, and C 1-6 -alkyl, or wherein R g and R h together with the nitrogen to which they are bound form a five or six membered heterocycle comprising one or two heteroatoms selected from the group of nitrogen, oxygen and sulfur,
—(C 1-6 -alkylene)—C(O)—NR i R j ,
wherein R i and R j are each independently
hydrogen, C 1-6 -alkyl, —(C 1-6 -alkylene)—NR k R l ,
wherein R k and R l are each independently hydrogen or C 1-6 -alkyl;
or R i and R j together with the nitrogen to which they are bound form a five or six membered heterocycle comprising one or two heteroatoms selected from the group of nitrogen, oxygen and sulfur,
—O-benzyl, optionally substituted by one or more halo, halo-C 1-6 -alkyl, C 1-6 -alkyl, C 1-6 -alkoxy, halo-C 1-6 -alkoxy, nitro, or cyano, nitro, halo, cyano, C 1-6 -alkoxy, halo-C 1-6 -alkoxy, halo-C 1-6 -alkyl, —(C 1-6 -alkylene)—C(O)R f ; wherein
R f is selected from
hydrogen, C 1-6 -alkyl, C 1-6 -alkoxy, and phenyl, optionally substituted by one or more halo, halo-C 1-6 -alkyl, C 1-6 -alkyl, C 1-6 -alkoxy, halo-C 1-6 -alkoxy, nitro, or cyano,
phenyl, optionally substituted by one or more halo, halo-C 1-6 -alkyl, C 1-6 -alkyl, C 1-6 -alkoxy, halo-C 1-6 -alkoxy, nitro, or cyano, —(C 1-3 -alkylene)—R m , wherein R m is phenyl, a 5- to 6-membered heteroaryl, 4- to 6-membered heterocycloalkyl or 3 to 6-membered cycloalkyl, each optionally substituted by one or more halo, halo-C 1-6 -alkyl, C 1-6 -alkyl, C 1-6 -alkoxy, halo-C 1-6 -alkoxy, nitro, or cyano;
or R 5 and R 6 are bound together to form a ring with the benzo moiety, wherein
—R 5 —R 6 — is —O—(CH 2 ) n —C(O)—, —C(O)—(CH 2 ) n —O—, or —O—(CH 2 ) n —O— wherein n is 1 or 2;
R 7 is hydrogen or C 1-6 -alkyl; R 8 , R 9 , R 10 , and R 11 are each independently hydrogen, halo, C 1-6 -alkyl or halo-C 1-6 -alkyl.
The invention further encompasses an embodiment with the compound of formula (I), wherein
X is O or CH 2 ; R 1 is hydrogen, or C 1-6 -alkyl, optionally substituted by CN or OH; R 2 is hydrogen or C 1-6 -alkyl; R 3 is hydrogen; R 4 is hydrogen,
halo, C 1-6 -alkyl, or C 1-6 -alkoxy;
R 5 is hydrogen or halo; or R 4 and R 5 are bound together to form a ring with the benzo moiety, wherein
—R 4 —R 5 — is —O—(CH 2 ) n —O— wherein n is 1 or 2,
R 6 is hydrogen or C 1-6 -alkyl, optionally substituted by CN or OH; R 7 is hydrogen or C 1-6 -alkyl; R 8 , R 9 , R 10 , and R 11 are each independently hydrogen or halo.
The invention further encompasses an embodiment with the compound of formula (Ia), wherein
X is O; R 1 is hydrogen, or C 1-6 -alkyl, optionally substituted by CN or OH; R 2 is hydrogen or C 1-6 -alkyl; R 3 is hydrogen; R 4 is hydrogen, halo, or C 1-6 -alkyl; R 5 is hydrogen or halo; R 6 is hydrogen or C 1-6 -alkyl, optionally substituted by CN or OH; R 7 is hydrogen; R 8 , R 9 , R 10 , and R 11 are each independently hydrogen.
The invention further encompasses an embodiment with the compound of formula (Ib), wherein
X is CH 2 ; R 1 is hydrogen, or C 1-6 -alkyl, optionally substituted by CN or OH; R 2 is hydrogen or C 1-6 -alkyl; R 3 is hydrogen; R 4 is hydrogen, halo, or C 1-6 -alkoxy; R 5 is hydrogen; or R 4 and R 5 are bound together to form a ring with the benzo moiety, wherein
—R 4 —R 5 — is —O—(CH 2 ) n —O— wherein n is 1 or 2,
R 6 is hydrogen; R 7 is hydrogen; R 8 , R 9 , R 10 , and R 11 are each independently hydrogen or halo.
Preferred compounds of the invention are those shown in the examples.
More preferred compounds of formula Ia:
1′-[(5-chloro-1-methyl-1H-indol-2-yl)carbonyl]spiro[3,1-benzoxazine-4,4′-piperidin]-2(1H)-one, {2-[(2-oxo-1,2-dihydro-1′H-spiro[3,1-benzoxazine-4,4′-piperidin]-1′-yl)carbonyl]-1H-indol-1-yl}acetonitrile, and {5-chloro-2-[(2-oxo-1,2-dihydro-1′H-spiro[3,1-benzoxazine-4,4′-piperidin]-1′-yl)carbonyl]-1H-indol-1-yl}acetonitrile.
More preferred compound of formula Ib:
{2-[(6′-bromo-2′-oxo-2′,3′-dihydro-1H,1′H-spiro[piperidine-4,4′-quinolin]-1-yl)carbonyl]-5-chloro-1H-indol-1-yl}acetonitrile.
The invention also encompasses the compounds of formula (I) for a use in the prevention or treatment of dysmenorrhea, hypertension, chronic heart failure, inappropriate secretion of vasopressin, liver cirrhosis, nephrotic syndrome, obsessive compulsive disorder, anxiety and depressive disorders.
The invention also encompasses a pharmaceutical composition comprising a compound of formula (I) which pharmaceutical composition is useful against dysmenorrhea, hypertension, chronic heart failure, inappropriate secretion of vasopressin, liver cirrhosis, nephrotic syndrome, obsessive compulsive disorder, anxiety and depressive disorders. The pharmaceutical composition may further comprise at least one pharmaceutically acceptable excipient.
The invention further encompasses the use of a compound of formula (I) for the preparation of a medicament which is useful against dysmenorrhea, hypertension, chronic heart failure, inappropriate secretion of vasopressin, liver cirrhosis, nephrotic syndrome, obsessive compulsive disorder, anxiety and depressive disorders.
In a certain embodiment, the compound of the invention can be manufactured according to a process comprising reacting a compound of formula (II):
with an amine of formula I
wherein R 1 to R 11 and X are as defined above.
In a certain embodiment, the compound of the invention can be manufactured according to a process comprising reacting a compound of formula (I-1):
with an electophlie of formula R 1 -hal, to give a compound of general formula (I) as defined herein above.
The synthesis of compounds of general formula (I) will be described in more detail below and in the examples. The compounds of formula I may be prepared in accordance with the process variants as described above and with the following schemes A-C. The starting materials described in the Example section are either commercially available or are otherwise known or derived from the chemical literature, for instance as cited below, or may be prepared as described in the Examples section.
where in A is:
wherein X is O or CH 3
Compounds of formula (I) can be prepared via an amide coupling between an indole 2-carboxylic acid (II) and a compound of formula (A-H), wherein A is defined as hereinabove. The usual reagents and protocols known in the art can be used to effect the amide coupling. Indole 2-carboxylic acids (II) are either commercially available or readily prepared using procedures described hereinafter. The compounds of formula (A-H) are either commercially available or prepared using methods known in the art starting from commercially available materials. General scheme A is hereinafter further illustrated with general procedure I.
Compounds of formula (I-2) (compounds of formula (I) wherein R 1 is different from H), can be prepared by alkylation of the indole derivative of formula (I-1), with an electrophile of formula R 1 -hal (commercially available, wherein hal is halo, preferably Cl or Br) using standard procedures. Derivatives (I-1) are prepared using the amide coupling as described in the general scheme A.
General Scheme C: Preparation of Acids II
Substituted indole 2-carboxylic acids can be prepared according to the general scheme C. Indoles V are obtained by a Fischer indole synthesis from an aryl hydrazine III and a α-ketoester IV. Saponification gives an acid of formula II-a. Alternatively, Boc protection of the indole nitrogen gives VI. Selective bromination of the methyl group in the 7-position of the indole using NBS affords VII. Subsequent nucleophilic substitution of 7-bromomethyl indole intermediate VII with NaCN or a secondary amine yields intermediates VIII and IX, respectively. After N-deprotection and saponification of the ester moiety, the corresponding carboxylics acids II-b and II-c are obtained.
Abbreviations used:
NBS=N-Bromosuccinimide Boc=tert-buthoxycarbonyl EDC=N-(3-dimethylaminopropyl)-N′-ethyl-carbodiimide hydrochloride HOBt=1-hydroxybenzotriazole DMF=N,N-dimethylformamide DMSO=dimethylsulfoxide DMAP=4-dimethylaminopyridine TFA=trifluoroacetic acid
V1a Activity
Material & Method
The human V1a receptor was cloned by RT-PCR from total human liver RNA. The coding sequence was subcloned in an expression vector after sequencing to confirm the identity of the amplified sequence. To demonstrate the affinity of the compounds from the present invention to the human V1a receptor binding studies were performed. Cell membranes were prepared from HEK293 cells transiently transfected with the expression vector and grown in 20 liter fermenters with the following protocol.
50 g of cells were resuspended in 30 ml freshly prepared ice cold Lysis buffer (50 mM HEPES, 1 mM EDTA, 10 mM MgCl2 adjusted to pH=7.4+complete cocktail of protease inhibitor (Roche Diagnostics)). Homogenized with Polytron for 1 min and sonicated on ice for 2×2 minutes at 80%, intensity (Vibracell sonicator). The preparation was centrifuged 20 min at 500 g at 4° C., the pellet was discarded and the supernatant centrifuged 1 hour at 43,000 g at 4° C. (19,000 rpm). The pellet was resuspended in 12.5 ml Lysis buffer+12.5 ml Sucrose 20% and homogenized using a Polytron for 1-2 min. The protein concentration was determined by the Bradford method and aliquots were stored at −80° C. until use. For binding studies 60 mg Yttrium silicate SPA beads (Amersham) were mixed with an aliquot of membrane in binding buffer (50 mM Tris, 120 mM NaCl, 5 mM KCl, 2 mM CaCl2, 10 mM MgCl2) for 15 minutes with mixing. 50 ul of bead/membrane mixture was then added to each well of a 96 well plate, followed by 50 ul of 4 nM 3H-Vasopressin (American Radiolabeled Chemicals). For total binding measurement 100 ul of binding buffer were added to the respective wells, for non-specific binding 100 ul of 8.4 mM cold vasopressin and for compound testing 100 ul of a serial dilution of each compound in 2% DMSO. The plate was incubated 1 h at room temperature, centrifuged 1 min at 1000 g and counted on a Packard Top-Count. Non-specific binding counts were subtracted from each well and data was normalized to the maximum specific binding set at 100%. To calculate an IC 50 the curve was fitted using a non-linear regression model (XLfit) and the Ki was calculated using the Cheng-Prussoff equation.
Ex.
pKi(hV1a)
7
7.325
14
7.525
15
7.22
16
7.975
The present invention also provides pharmaceutical compositions containing compounds of formula I and/or their pharmaceutically acceptable acid addition salts. Such compositions can be in the form of tablets, coated tablets, dragées, hard and soft gelatin capsules, solutions, emulsions or suspensions. The pharmaceutical compositions also can be in the form of suppositories or injectable solutions.
The pharmaceutical compositions of the invention, in addition to one or more compounds of the invention, contain a pharmaceutically acceptable carrier. Suitable pharmaceutically acceptable carriers include pharmaceutically inert, inorganic or organic carriers. Lactose, corn starch or derivatives thereof, talc, stearic acid or its salts etc can be used as such excipients, e.g. for tablets, dragées and hard gelatine capsules.
Suitable excipients for soft gelatine capsules are e.g. vegetable oils, waxes, fats, semi-solid and liquid polyols etc. Suitable excipients for the manufacture of solutions and syrups are e.g. water, polyols, saccharose, invert sugar, glucose etc. Suitable excipients for injection solutions are e.g. water, alcohols, polyols, glycerol, vegetable oils, etc. Suitable excipients for suppositories are e.g. natural or hardened oils, waxes, fats, semi-liquid or liquid polyols etc.
Moreover, the pharmaceutical compositions can contain preservatives, solubilizers, stabilizers, wetting agents, emulsifiers, sweeteners, colorants, flavorants, salts for varying the osmotic pressure, buffers, masking agents or antioxidants. They can also contain still other therapeutically valuable substances.
The dosage at which compounds of the invention can be administered can vary within wide limits and will, of course, be fitted to the individual requirements in each particular case. In general, in the case of oral administration a daily dosage of about 10 to 1000 mg per person of a compound of general formula (I) should be appropriate, although the above upper limit can also be exceeded when necessary.
The following Examples illustrate the present invention without limiting it. All temperatures are given in degrees Celsius.
EXAMPLE A
Tablets of the following composition can be manufactured in the usual manner:
mg/tablet
Active substance
5
Lactose
45
Corn starch
15
Microcrystalline cellulose
34
Magnesium stearate
1
Tablet weight
100
EXAMPLE B
Capsules of the following composition can be manufactured:
mg/capsule
Active substance
10
Lactose
155
Corn starch
30
Talc
5
Capsule fill weight
200
The active substance, lactose and corn starch can be firstly mixed in a mixer and then in a comminuting machine. The mixture can be returned to the mixer, the talc can be added thereto and mixed thoroughly. The mixture the can be filled by machine into hard gelatine capsules.
EXAMPLE C
Suppositories of the following composition can be manufactured:
mg/supp.
Active substance
15
Suppository mass
1285
Total
1300
The suppository mass can be melted in a glass or steel vessel, mixed thoroughly and cooled to 45° C. Thereupon, the finely powdered active substance can be added thereto and stirred until it has dispersed completely. The mixture can be poured into suppository moulds of suitable size, left to cool; the suppositories then can be removed from the moulds and packed individually in wax paper or metal foil.
In the following, the synthesis of compounds of formula (I) is further exemplified:
The compounds of formula I may be prepared in accordance with the process variants as described above. The starting materials described in the Example section are either commercially available or are otherwise known or derived from the chemical literature, for instance as cited below, or may be prepared as described in the Examples section.
EXAMPLES
General Procedure I—Amide Coupling
To a 0.1 M stirred solution of an indole-2-carboxylic acid derivative of type (II) in CH 2 Cl 2 are added EDC (1.3 eq), HOBt (1.3 eq), Et 3 N (1.3 eq) and the amine derivative (A-H, as defined above, 1 eq). The mixture is stirred overnight at room temperature and then poured onto water and extracted with CH 2 Cl 2 . The combined organic phases are dried over Na 2 SO 4 and concentrated in vacuo. Flash chromatography or preparative HPLC affords a compound of formula (I).
General Procedure II—Alkylation
To a 0.1 M stirred solution of a derivative of general formula (I-1) in DMF is added NaH (60% in oil, 2.1 eq). After stirring the mixture at room temperature for 30 min. the electrophilic reactant R 1 -hal (1.1 eq.) is added. The mixture is stirred an additional 14 hours at 60° C. and then poured onto water and extracted with ethyl acetate. The combined organic phases are dried over Na 2 SO 4 and concentrated in vacuo. Purification by preparative HPLC affords the corresponding derivatives of general formula (I-2).
Example 1
6′-Bromo-1-[(5-methoxy-3-methyl-1H-indol-2-yl)carbonyl]-1′H-spiro[piperidine-4,4′-quinolin]-2′(3′H)-one
Amide coupling according to general procedure I:
Amine: 6′-Bromo-1′H-spiro[piperidine-4,4′-quinolin]-2′(3′H)-one (prepared herein), Acid: 5-Methoxy-3-methyl-1H-indole-2-carboxylic acid,
ES-MS m/e (%): 482.4 (M+H + ).
6′-Bromo-1′H-spiro[piperidine-4,4′-quinolin]-2′(3′H)-one (Scheme 1)
1′-(tert-Butyloxycarbonyl)spiro(indene-1,4′-piperidine) 3:
To a solution of indene 1 (34.6 g, 298 mmol) in dry THF (40 mL) maintained under a nitrogen blanket was added lithium bis(trimethylsilyl) amide (596 mL of a 1.0 M solution in THF; 596 mmol) over 30 min. The mixture was stirred in the cold for 30 min and then transferred by a canula to a solution of N, N-bis (2-chloroethyl)-tert-butyl carbamate 2 (68 g, 281 mmol) in dry THF (40 mL), and stirred in an ice bath. The mixture was stirred for 2 hours in the cold and for 30 min at ambient temperature under nitrogen and then evaporated in vacuo to a foam. Methylene chloride was added and the resulting reaction mixture was chromatographed on silica (1:20 ethyl acetate-hexane). The product fractions were evaporated to dryness in vacuo to give (49 g, 57%) of 1′-(tert-butyloxycarbonyl)spiro(indene-1,4′-piperidine) 3 as a white solid. mp 128° C. IR (KBr) 3435, 2964, 2856, 1679, 1427, 1165 cm-1; 1H NMR (CDCl3, 400 MHz) δ 1.26 (br d, J=13.4 Hz, 2H), 1.43 (s, 9H), 1.93 (dt, J=12.9, 4.5 Hz, 2H), 3.04 (dt, J=13.0, 2.7 Hz, 2H), 4.11 (br d, J=13.5 Hz, 2H), 6.71 (d, J=5.7 Hz, 1H), 6.77 (d, J=5.7 Hz, 1H), 7.11-7.19 (m, 2H), 7.23-7.26 (m, 2H); 13C NMR (CDCl3, 100 MHz) δ 28.47, 33.39, 42.48, 52.03, 79.56, 121.45, 121.65, 125,30, 126.98, 130.25, 140.32, 142.73, 151.65, 155.01; GC MS (EI) m/z 285.
1′-(tert-Butyloxycarbonyl)spiro(indan-1-ol,4′-piperidine) 5:
To a stirring solution of 3 (20 g, 70.2 mmol) in dry methylene chloride (450 mL) was passed gaseous HBr for 12 hours. The reaction mixture was carefully neutralized with saturated sodium bicarbonate solution (150 ml). The aqueous part was separated out and the organic part back extracted with saturated sodium bicarbonate (2×50 mL). To the aqueous extract and the combined washings was added 14.7 g of solid sodium bicarbonate, 400 mL of methylene chloride followed by 15.4 g (70.2 mmol) of di-tert-butyl pyrocarbonate. The reaction mixture was stirred at ambient temperature for 3 hours. The organic layer was separated out and the aqueous part was washed successively with methylene chloride (3×50 mL), dried and concentrated in vacuo to provide a foaming liquid which was chromatographed on silica (3:7 ethyl acetate-hexane followed by 1:1 ethyl acetate-hexane) to provide 1′-(tert-butyloxycarbonyl)spiro(indan-1-ol, 4′-piperidine) 5 (21 g, 99%) as a viscous liquid. IR (film) 3401, 2925, 2347, 1691, 1669, 1425, 1365, 1166 cm-1; 1H NMR (CDCl3, 400 MHz) δ 1.37 (dd, J=13.4, 2.0 Hz, 1H), 1.49 (s, 9H), 1.62 (dd, J=13.2, 1.9 Hz, 1H), 1.73 (dt, J=13.0, 4.4 Hz, 1H), 1.87-1.96 (m, 2H), 2.49 (dd, J=13.4, 7.1 Hz, 1H), 2.62 (br s, 1H), 2.92 (tt, J=11.7, 2.9 Hz, 2H), 4.09 (d, J=11 Hz, 2H), 5.25 (t, J=12.2 Hz, 1H), 7.18 (d, J=7.4 Hz, 1H), 7.25-7.33 (m, 2H), 7.41 (d, J=7.09 Hz, 1H); 13C NMR (CDCl3, 100 MHz) δ 28.39, 37.04, 38.04, 41.21, 41.37, 44.70, 44.94, 73.98, 79.52, 122.59, 124.43, 127.48, 128.64, 143.96, 150.10, 154.90; MS (EI) m/z 303.
1′-(tert-Butyloxycarbonyl)-spiro-(indan-1-one, 4′-piperidine) 6:
A stirring solution of 5 (20 g, 66 mmol) in ethyl acetate (300 mL) was treated with o-iodoxybenzoic acid (IBX) (37 g, 132 mmol) and was heated at 80° C. for 12 hours. The reaction mixture was brought to room temperature and then filtered under pump. The residue was thoroughly washed with ethylacetate (3×100 mL). The filtrate with the combined washings were concentrated under vacuo to provide a solid residue which was chromatographed over silica (1:10 ethyl acetate-hexane followed by 1:3 ethyl acetate-hexane) to provide 1′-(tert-butyloxycarbonyl)spiro(indan1-one,4′-piperidine) 6 (19.5 g, 98%) as a white solid, mp 121° C. IR (KBr) 3388, 2980, 2917, 2847, 1704, 1688, 1603, 1418, 1364, 1278, 1160 cm-1; 1H NMR (CDCl3, 400 MHz) δ 1.46 (s, 9H), 1.49 (m, 2H), 1.95 (dt, J=13.2, 4.6 Hz, 2H), 2.60 (s, 2H), 2.83 (dt, J=13.3, 2.5 Hz, 2H), 4.19 (td, J=13.7, 4.3 Hz, 2H), 7.38 (dt, J=7.1, 0.8 Hz, 1H), 7.46 (d, J=7.8 Hz, 1H), 7.61 (td, J=7.7, 1.2 Hz, 1H), 7.70 (dt, J=7.4, 0.9 Hz, 1H). 13C NMR (CDCl3, 100 MHz) δ 28.38, 37.52, 41.47, 41.58, 46.84, 79.73, 123.62, 123.87, 128.03, 135.09, 135.61, 154.75, 162.02; GC-MS (EI) m/z 301.
1′-(tert-Butyloxycarbonyl)spiro(tetrahydro quinol-2-one)-4′-piperidine 10 and 1′-(tert-butyloxycarbonyl)spiro(tetrahydro isoquinol-1-one)-4′-piperidine 9:
To a cooled solution of 6 (10 g, 33 mmol) in dry benzene (40 mL), concentrated sulphuric acid was added with stirring. The reaction mixture was thereafter maintained at 40° C. under stirring followed by dropwise addition of a freshly prepared solution of hydrazoic acid (2.84 g, 66 mmol) in benzene [A paste is prepared from 4.26 g of sodium azide, 4.26 mL of water and 56.8 mL of benzene is added. The mixture is cooled to 0° C. and 1.18 mL of concentrated sulfuric acid is added dropwise with control of temperature from 0-5° C. The organic layer (a solution of hydrazoic acid in benzene) is separated, dried over sodium sulphate and used for the reaction. When the effervescence had ceased, the benzene layer was carefully decanted off and the residue washed with benzene (2×10 mL). Traces of benzene were removed under vacuo and the residue dissolved in 70 mL of water followed by neutralization with liquor ammonia (10 mL). The reaction mixture was then treated with 7 g of solid sodium bicarbonate, di-tert-butyl pyrocarbonate (7.2 g) in 250 mL of methylene chloride and stirred for 2 hours ambient temperature. The organic layer was separated out and the aqueous part was washed with methylene chloride (2×50 mL). The combined organic extract and washings were washed with brine, dried (anhydrous Na2SO4), concentrated under vacuo to provide a foamy material which was chromatographed over silica (1:3 ethyl acetate-hexane followed by 1:1 ethyl acetate hexane) to provide 1′-(tert-butyloxycarbonyl)spiro(tetrahydro quinol-2-one)-4′-piperidine 10 (6.7 g, 64%) as a creamish white solid, mp 198° C. C. IR (KBr) 3205, 3080, 2978, 1681, 1591, 1487, 1432, 1381, 1252, 1174 cm-1; 1H NMR (CDCl3, 400 MHz) δ 1.46 (s, 9H), 1.67 (d, J=12.2 Hz, 2H), 1.88 (br t, J=10.1 Hz, 2H), 2.70 (s, 2H), 3.08 (t, J=12.2 Hz, 2H), 4.00 (br d, J=9.2 Hz, 2H), 6.83 (dd, J=7.8, 1.1 Hz, 1H), 7.06 (dt, J=7.6, 1.2 Hz, 1H), 7.20 (dt, J=7.6, 1.2 Hz, 1H), 7.29 (dd, J=7.3, 0.9 Hz, 1H), 8.75 (br s, 1H); 13C NMR (CDCl3, 100 MHz) δ 28.39, 33.69, 35.32, 37.75, 39.31, 79.73, 116.38, 123.82, 124.00, 127.89, 131.25, 136.24, 154.76, 170.67; GC-MS (EI) m/z 316.
1′-(tert-Butyloxycarbonyl)spiro(tetrahydro isoquinol-1-one)-4′-piperidine 9:
This was compound was eluted with 1:1 ethyl acetate-hexane, (3.8 g, 36%) mp 182° C.; IR (KBr) 3337, 3232, 2867, 1692, 1679, 1635, 1603, 1415, 1165 cm-1; 1H NMR (400 MHz, CDCl3) δ 1.47 (s, 9H), 1.78 (m, 2H), 1.94 (br s, 2H), 2.99 (t, J=12.9 Hz, 2H), 3.57 (br d, J=1.7 Hz, 2H), 4.01 (br d, J=15.6 Hz, 2H), 6.24 (br s, 1H), 7.38 (m, 2H), 7.53 (m, 1H), 8.10 (dd, J=7.9, 1.6 Hz, 1H); 13C NMR (CDCl3, 100 MHz) δ 28.35, 29.59, 32.59, 35.63, 44.79, 79.73, 122.99, 127.04, 127.83, 128.46, 132.83, 146.36, 154.74; GC-MS (EI) m/z: (M-100).
6-Bromo-1′-(tert-butoxycarbonyl) spiro (tetrahydro quinol-2-one)-4′-piperidine 11:
A solution of 10 (10 g, 31.6 mmol) in dry acetonitrile (250 mL) was cooled to −10° C., and N-bromosuccinimide (5.62 g, 31.6 mmol) was added portion wise with stirring. The reaction mixture was stirred for 1 h at −10 C, 2 h at 0° C. and finally at ambient temperature for 24 h. The solvent was removed and the residue dissolved in methylene chloride (500 ml), organic extract washed with brine-water (1:1) (3×50 mL), dried (anhydrous Na2SO4), concentrated in vacuo to provide a creamish white solid which was chromatographed over silica (1:3 ethyl acetate-hexane followed by 1:1 ethyl-acetate hexane) to give 6-bromo-1′-(tert-butyloxycarbonyl) spiro (tetrahydro quinol-2-one)-4′-piperidine 11 (11.8 g, 94%) as a white solid of mp 226° C. IR (KBr) 3178, 3083, 2923, 1686, 1586, 1491, 1432, 1380, 1255, 1171 cm-1; 1H NMR (CDCl3, 400 MHz) δ 1.46 (s, 9H), 1.65 (m, 2H), 1.85 (br t, 2H), 2.69 (br s, 2H), 3.05 (br t, 2H), 4.02 (br s, 2H), 6.72 (d, J=8.4 Hz, 1H), 7.32 (dd, J=8.4, 2.0 Hz, 1H), 7.41 (d, J=2.0 Hz, 1H), 8.75 (s, 1H); 13C NMR (100 MHz, CDCl3) δ 28.38, 33.56, 35.58, 37.31, 79.88, 116.46, 117.93, 127.31, 130.76, 133.33, 135.39, 154.62, 170.58; GC-MS (EI) m/z (M-100) 294.
6′-Bromo-1′H-spiro[piperidine-4,4′-quinolin]-2′(3′H)-one 12:
To a stirring solution of 11 (10 g, 25.3 mmol) in 750 mL of methanol, dry HCl was passed for 10 hrs and the stirring was continued for overnight. The reaction mixture was neutralized with liquor ammonia (75 mL) under ice-cold condition. Methanol and excess ammonia were removed under vacuo and the residue dissolved in methylene chloride (500 mL) followed by the addition of 25 mL of liquor ammonia to dissolve the remaining solid. The organic layer was separated out and the aqueous part washed extracted with methylene chloride (3×150 mL), dried (anhydrous Na2SO4), concentrated under vacuo to provide 6-bromo-spiro (tetrahydro quilon-2-one)-4′-piperidine 12 as a creamish white solid (7.0 g, 94%) of mp 218° C. IR (KBr) 3434, 3318, 3180, 2823, 1668, 1600, 1483, 1389 cm-1; 1H NMR (d6-DMSO, 400 MHz) δ 1.45 (d, J=12.7 Hz, 2H), 1.71 (dt, J=12.3, 4.8 Hz, 2H); 2.57 (br s, 2H), 2.68-2.78 (m, 4H), 6.83 (d, J=8.4 Hz, 1H), 7.33 (dd, J=8.4, 1.9 Hz, 1H), 7.41 (br d, J=1.9 Hz, 1H), 10.3 (br s, 1H); 1H NMR (D 2 O exchange, d6-DMSO, 400 MHz) δ 1.43 (d, J=12.9 Hz, 2H), 1.71 (dt, J=12.2, 4.8 Hz, 2H), 2.55 (br s, 2H), 2.65-2.76 (m, 4H), 6.82 (d, J=8.4 Hz, 1H), 7.29 (dd, J=8.4, 1.9 Hz, 1H), 7.39 (br d, J=1.9 Hz, 1H); 13C NMR (100 MHz, d6-DMSO) δ 34.14, 35.58, 37.34, 41.06, 114.28, 117.57, 126.75, 129.89, 134.74, 136.56, 168.73; GC-MS (EI) m/z 294.
Example 2
6′-Bromo-1-(5H-[1,3]dioxolo[4,5-f]indol-6-ylcarbonyl)-1′H-spiro[piperidine-4,4′-quinolin]-2′(3′H)-one
Amide coupling according to general procedure I:
Amine: 6′-Bromo-1′H-spiro[piperidine-4,4′-quinolin]-2′(3′H)-one (prepared herein above), Acid: 5H-[1,3]Dioxolo[4,5-f]indole-6-carboxylic acid,
ES-MS m/e (%): 482.3 (M+H 1 ).
Example 3
6′-Bromo-1-[(5-methoxy-1H-indol-2-yl)carbonyl]-1′H-spiro[piperidine-4,4′-quinolin]-2′(3′H)-one
Amide coupling according to general procedure I:
Amine: 6′-Bromo-1′H-spiro[piperidine-4,4′-quinolin]-2′(3′H)-one (prepared herein above), Acid: 5-Methoxy-1H-indole-2-carboxylic acid,
ES-MS m/e (%): 468.4 (M+H 1 ).
Example 4
6′-Bromo-1-[(5-fluoro-1H-indol-2-yl)carbonyl]-1′H-spiro[piperidine-4,4′-quinolin]-2′(3′H)-one
Amide coupling according to general procedure I:
Amine: 6′-Bromo-1′H-spiro[piperidine-4,4′-quinolin]-2′(3′H)-one (prepared herein above), Acid: 5-Fluoro-1H-indole-2-carboxylic acid,
ES-MS m/e (%): 456.4 (M+H + ).
Example 5
6′-Bromo-1-[(5-chloro-1-methyl-1H-indol-2-yl)carbonyl]-1′H-spiro[piperidine-4,4′-quinolin]-2′(3′H)-one
Amide coupling according to general procedure I:
Amine: 6′-Bromo-1′H-spiro[piperidine-4,4′-quinolin]-2′(3′H)-one (prepared herein above), Acid: 5-Chloro-1-methyl-1H-indole-2-carboxylic acid,
ES-MS m/e (%): 488.3 (M+H + ).
Example 6
{2-[(6′-Bromo-2′-oxo-2′,3′-dihydro-1H,1′H-spiro[piperidine-4,4′-quinolin]-1-yl)carbonyl]-1H-indol-1-yl}acetonitrile
Amide coupling according to general procedure I:
Amine: 6′-Bromo-1′H-spiro[piperidine-4,4′-quinolin]-2′(3′H)-one (prepared herein above), Acid: 1-Cyanomethyl-1H-indole-2-carboxylic acid (prepared herein below),
ES-MS m/e (%): 477.4 (M+H 1 ).
Cyanomethyl-1H-indole-2-carboxylic acid
To a solution of 1.0 eq. of 1-cyanomethyl-1H-indole-2-carboxylic acid ethyl ester in a mixture of THF/H 2 O ((9/1) was added LiOH.H 2 O (1.0 eq.) and the reaction mixture stirred 6 h at RT, acidified to pH 2 and then partially concentrated until precipitation of the crude product which was filtered off and washed with Et 2 O and then dried to give the desired product as a light yellow solid (70%).
ES-MS m/e (%): 199.0 (M−H + ).
Example 7
{2-[(6′-Bromo-2′-oxo-2′,3′-dihydro-1H,1′H-spiro[piperidine-4,4′-quinolin]-1-yl)carbonyl]-5-chloro-1H-indol-1-yl}acetonitrile
Amide coupling according to general procedure I:
Amine: 6′-Bromo-1′H-spiro[piperidine-4,4′-quinolin]-2′(3′H)-one (prepared herein above), Acid: 5-Chloro-1-cyanomethyl-1H-indole-2-carboxylic acid (prepared herein below),
ES-MS m/e (%): 511.0 (M+H + ).
5-Chloro-1-cyanomethyl-1H-indole-2-carboxylic acid
To a solution of 1.0 eq. of 5-chloro-1-cyanomethyl-1H-indole-2-carboxylic acid ethyl ester (CAS 126718-08-9; prepared according to Indian Journal of Chemistry, Section B: Organic Chemistry Including Medicinal Chemistry (1989), 28B(12), 1065-8) in a mixture of THF/H 2 O ((9/1) was added LiOH.H 2 O (1.0 eq.) and the reaction mixture stirred 6 h at RT, acidified to pH 2 and then partially concentrated until precipitation of the crude product which was filtered off and washed with Et 2 O and then dried to give the desired product as a light yellow solid (84%).
Example 8
1-[(5-Chloro-1H-indol-2-yl)carbonyl]-1′H-spiro[piperidine-4,4′-quinolin]-2′(3′H)-one
Amide coupling according to general procedure I:
Amine: 1′H-Spiro[piperidine-4,4′-quinolin]-2′(3′H)-one hydrochloride (prepared herein above), Acid: 5-Chloro-1H-indole-2-carboxylic acid,
ES-MS m/e (%): 394.4 (M+H 1 ).
Example 9
6′-Bromo-1-[(5-chloro-1H-indol-2-yl)carbonyl]-1′H-spiro[piperidine-4,4′-quinolin]-2′(3′H)-one
Amide coupling according to general procedure I:
Amine: 6′-Bromo-1′H-spiro[piperidine-4,4′-quinolin]-2′(3′H)-one (prepared herein above), Acid: 5-Chloro-1H-indole-2-carboxylic acid,
ES-MS m/e (%): 470.3 (M−H + ).
Example 10
1′-[(3-Methyl-1H-indol-2-yl)carbonyl]spiro[3,1-benzoxazine-4,4′-piperidin]-2(1H)-one
Amide coupling according to general procedure I:
Amine: Spiro[3,1-benzoxazine-4,4′-piperidin]-2(1H)-one (CAS 84060-09-3; described in Chemical & Pharmaceutical Bulletin (1985), 33(3), 1129-39.), Acid: 3-Methyl-1H-indole-2-carboxylic acid,
ES-MS m/e (%): 374.4 (M−H 1 ).
Example 11
1′-[(7-Methyl-1H-indol-2-yl)carbonyl]spiro[3,1-benzoxazine-4,4′-piperidin]-2(1H)-one
Amide coupling according to general procedure I:
Amine: Spiro[3,1-benzoxazine-4,4′-piperidin]-2(1H)-one (CAS 84060-09-3; described in Chemical & Pharmaceutical Bulletin (1985), 33(3), 1129-39.), Acid: 7-Methyl-1H-indole-2-carboxylic acid,
ES-MS m/e (%): 376.4 (M+H + ).
Example 12
1′-[(6-Chloro-1H-indol-2-yl)carbonyl]spiro[3,1-benzoxazine-4,4′-piperidin]-2(1H)-one
Amide coupling according to general procedure I:
Amine: Spiro[3,1-benzoxazine-4,4′-piperidin]-2(1H)-one (CAS 84060-09-3; described in Chemical & Pharmaceutical Bulletin (1985), 33(3), 1129-39.), Acid: 6-Chloro-1H-indole-2-carboxylic acid,
ES-MS m/e (%): 396.4 (M+H + ).
Example 13
1′-[(5-Methyl-1H-indol-2-yl)carbonyl]spiro[3,1-benzoxazine-4,4′-piperidin]-2(1H)-one
Amide coupling according to general procedure I:
Amine: Spiro[3,1-benzoxazine-4,4′-piperidin]-2(1H)-one (CAS 84060-09-3; described in Chemical & Pharmaceutical Bulletin (1985), 33(3), 1129-39.), Acid: 5-Methyl-1H-indole-2-carboxylic acid,
ES-MS m/e (%): 376.4 (M+H + ).
Example 14
1′-[(5-Chloro-1-methyl-1H-indol-2-yl)carbonyl]spiro[3,1-benzoxazine-4,4′-piperidin]-2(1H)-one
Amide coupling according to general procedure I:
Amine: Spiro[3,1-benzoxazine-4,4′-piperidin]-2(1H)-one (CAS 84060-09-3; described in Chemical & Pharmaceutical Bulletin (1985), 33(3), 1129-39.), Acid: 5-Chloro-1-methyl-1H-indole-2-carboxylic acid,
ES-MS m/e (%): 410.4 (M+H + ).
Example 15
{2-[(2-Oxo-1,2-dihydro-1′H-spiro[3,1-benzoxazine-4,4′-piperidin]-1′-yl)carbonyl]-1H-indol-1-yl}acetonitrile
Amide coupling according to general procedure I:
Amine: Spiro[3,1-benzoxazine-4,4′-piperidin]-2(1H)-one (CAS 84060-09-3; described in Chemical & Pharmaceutical Bulletin (1985), 33(3), 1129-39.), Acid: 1-Cyanomethyl-1H-indole-2-carboxylic acid (prepared herein above),
ES-MS m/e (%): 401.4 (M+H + ).
Example 16
{5-Chloro-2-[(2-oxo-1,2-dihydro-1′H-spiro[3,1-benzoxazine-4,4′-piperidin]-1′-yl)carbonyl]-1H-indol-1-yl}acetonitrile
Amide coupling according to general procedure I:
Amine: Spiro[3,1-benzoxazine-4,4′-piperidin]-2(1H)-one (CAS 84060-09-3; described in Chemical & Pharmaceutical Bulletin (1985), 33(3), 1129-39.), Acid: 5-Chloro-1-cyanomethyl-1H-indole-2-carboxylic acid (prepared herein above),
ES-MS m/e (%): 435.4 (M+H + ).
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Present invention is concerned with novel indol-2-yl-carbonyl-spiro-piperidine derivatives as V1a receptor antagonists, their manufacture, pharmaceutical compositions containing them. The active compounds of the present invention are useful in the treatment of anxiety and depressive disorders and other diseases. The compounds of present invention have the general formula (I)
wherein R 1 to R 11 and X are as defined in the description.
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RELATED APPLICATION
This application is related to copending U.S. application Ser. No. 09/325,690, entitled “COMMON MANAGEMENT INFORMATION BASE (MIB).”
TECHNICAL FIELD OF THE INVENTION
This invention relates generally to telecommunications systems, and more particularly to a method and system for managing multiple management protocols in a network element.
BACKGROUND OF THE INVENTION
Telecommunications systems include customer premise equipment (CPE), local loops connecting each customer premise to a central office (CO) or other node, nodes providing switching and signaling for the system, and internode trunks connecting the various nodes. The customer premise equipment (CPE) includes telephones, modems for communicating data over phone lines, computer and other devices that can directly communicate video, audio, and other data over a datalink. The network nodes include traditional circuit-switch nodes, which have transmission pass dedicated to specific users for the duration of a call and employ continuous, fixed-bandwidth transmission as well as packet-switch nodes that allow dynamic bandwidth, dependent on the application. The transmission media between the nodes may be wireline, wireless, or a combination of these or other transmission medias.
In a telecommunication system, the nodes are managed by standardized management protocols such as Transaction Language One (TL-1), simple network management protocol (SNMP), Common Management Information Service Element (CMISE), and the like. Generally speaking, each of these management protocols includes a protocol agent and object model. The agent is responsible for parsing the external management commands and maintaining communication sessions with external management stations or users. The object model is a management information base (MIB). The MIB is a data structure built for a specific management protocol to exchange the management information between a node and external management stations.
Multiple protocol nodes that handle disparate types of traffic are typically required to support multiple management protocols such as TL-1, SNMP, and/or CMISE. Provision of multiple databases to support the different protocols requires large amounts of resources to implement the databases and maintain data integrity across the databases. One attempt to use a single database for multiple protocols configured the database in accordance with one protocol and used a protocol adapter for a second protocol. The protocol adapter translates protocol messages from the second protocol to the first protocol and responses back to the second protocol. Due to the incompatibility between management protocols, however, the adapter is a complex component that is expensive to implement. In addition, the adapter is inefficient due to the protocol translations, which slow down response time. Other attempts to support multiple management protocols with a single database provided only limited functionality for one of the protocols while creating special commands for the other. This solution is expensive to implement and provides only a partial solution.
SUMMARY OF THE INVENTION
The present invention provides a method and system for managing multiple management protocols in a network element that substantially eliminates or reduces problems associated with previous methods and systems. In particular, the common MIB provides a layer of abstraction to isolate internal data representations from data representations made externally to a network element. This allows a network element to have a single, consistent internal representation of data, and at the same time, support multiple different external interfaces for management.
In accordance with one embodiment of the present invention, a network element comprises a first subsystem operable to receive management transactions in a first management protocol and to map the transactions to a common management protocol. A second subsystem is operable to receive management transactions in a second management protocol and to map the transactions to the common management protocol. A common management information base (MIB) includes a dataset and a common interface to the dataset. The common interface is operable to access the dataset to process transactions received from the first and second subsystems in the common management protocol.
Technical advantages of the present invention include providing a protocol independent MIB for managing multi-protocol network elements within a telecommunications network. In particular, the common MIB provides a layer of abstraction to isolate data representations internal to the network element from data representations made externally to the network element. This allows the network element to have a single, consistent internal representation of data and at the same time support multiple different external interfaces for management. As a result, data integrity and consistency is guaranteed as only a single database is maintained.
To support multiple external data representations, the network element performs transformations to convert the data between the internal representation and the required external representation format. Thus, adaptation functions between management protocols is eliminated and each management protocol is capable to support complete management of the network element. Moreover, the modular design of the common MIB allows for time and cost efficient testing, integration and packaging of the system.
Other technical advantages of the present invention will be readily apparent to one skilled in the art from the following figures, description, and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention and its advantages, reference is now made to the following description taken in conjunction with the accompanying drawings, wherein like reference numerals represent like parts, in which:
FIG. 1 is a block diagram illustrating a common management information base (MIB) in accordance with one embodiment of the present invention;
FIG. 2 is a block diagram illustrating relationships between interface, base and managed entities (ME) classes in the common MIB of FIG. 1 in accordance with one embodiment of the present invention;
FIG. 3 is a block diagram illustrating the ME command object of FIG. 1 in accordance with one embodiment of the present invention; and
FIG. 4 is a flow diagram illustrating a method for performing a management transaction with the common MIB of FIG. 1 in accordance with one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates management components of a multi-protocol network element (NE) 10 in accordance with one embodiment of the present invention. In this embodiment, the NE 10 includes Internet Protocol (IP), Asynchronous Transfer Mode (ATM), and Synchronous Optical Network (SONET) layers and functionality and can communicate over local area networks (LANs) as well as transmission line trunks. IP and other suitable traffic from the LAN is converted to ATM traffic for transmission by the SONET layer which forms the physical interface for the transmission line trunks.
The NE 10 supports Common Management Information Service Element (CMISE), simple network management protocol (SNMP), and Transaction Language One (TL-1) management protocols. A CMISE management station 14 , SNMP management station 16 , and TL-1 management station 18 are coupled to the NE 10 by a local area network (LAN), wide area network (WAN), or other communication link 20 . Accordingly, the management stations 14 , 16 , and 18 may be local or remote from the NE 10 .
Referring to FIG. 1, the NE 10 includes a plurality of protocol-specific subsystems 30 , a common management information base (MIB) 32 , and a set of low level software drivers 34 . Each subsystem 30 includes a protocol-specific agent 40 and a data model 42 . The protocol-specific agent 40 parses external management commands and maintains communication sessions with external management stations or users. The data model 42 maps protocol-specific management transactions received from a management station to a common management protocol for processing by the common MIB 32 . Accordingly, all protocol-specific processing is local to the subsystems 30 , allowing the common MIB 32 to be protocol independent.
For the embodiment of FIG. 1, the subsystems 30 include a CMISE subsystem 50 for supporting the CMISE management station 14 , a SNMP subsystem 52 for supporting the SNMP management station 16 , and a TL-1 subsystem 54 for supporting the TL-1 management station 18 . The CMISE protocol is an OSI defined management service containing an interface with a user, specifying the service provided, and a protocol, specifying the protocol data unit format and the associated procedures. In the CMISE subsystem 50 , the data model 42 is a Guideline for Definition of Managed Object (GDMO) which is an OSI specification for defining a management information structure used in the CMISE environment. SNMP is an IETF defined network management protocol including definitions of a database and associated concepts. In the SNMP subsystem 52 , the data model 42 is an entity-relationship model in accordance with SNMP standards. TL-1 is an ASCII or man-machine management protocol defined by Bellcore and typically used to manage broadband and access equipment in North America. In the TL-1 subsystem 54 , the data model 42 includes a data dictionary for access identifiers (AIDs) and commands in accordance with TL-1 standards. In this way, the data models 42 only occupy a small amount of memory resources in the network element 10 and keep protocol-specific processing local to each subsystem 50 , 52 , or 54 .
The common MIB 32 includes an application interface (API) 60 , a transaction queue 62 , a set of response queues 64 , and a database 66 . The API 60 provides generic management functionality to the CMISE, SNMP, and TL-1 subsystems 50 , 52 , and 54 . As described in more detail below, the common MIB 32 provides an efficient and flexible component to allow a telecommunications device to be controlled and monitored by external interfaces using specific management protocols.
The API 60 includes an interface object 70 for each subsystem 30 registered with the API 60 , one or more command objects 72 for each registered subsystem 30 , and a set of managed entity (ME) classes 74 to which protocol-specific transactions are mapped by the subsystems 30 . As described in more detail below, by applying object-oriented modeling techniques, the information of the hardware and/or software resource is encapsulated into the class definition, which then provides service interfaces to other software components.
The interface objects 70 are each accessed by a corresponding subsystem 30 to communicate with the API 60 . The interface object 70 for a subsystem 30 is created by the API 60 upon registration by the subsystem 30 . At that time, the subsystem 30 requests a number of command objects 72 that can be simultaneously used by the subsystem 30 , which are generated and allocated by the API 60 .
The command objects 72 each encapsulate a base class 76 for the ME classes 74 . The ME classes 74 each include specific functionality for an ME type. The base class 76 includes function calls, methods, parameters, behaviors, and other attributes shared by all or at least some of the ME classes 74 . Accordingly, each command object 72 includes base functionality that is used by the ME classes 74 to access the database 66 or perform functions within the common MIB 32 , such as communicating with the low level software driver 34 in order to determine or change the state of hardware in the NE 10 . As described in more detail below, portions of the base class 76 may be overloaded by specific ME classes 74 when forming an ME command object 78 . The ME command object 78 forms an interface for accessing ME attributes and functions in the database 66 and the low level software driver 34 . In this way, each ME class 74 may select functionality from the base class 76 to be used in accessing the corresponding ME.
The transaction queue 62 stores ME command objects 78 generated by the API 60 in conjunction with the subsystems 30 for processing by the common MIB 32 . In one embodiment, the transaction queue 32 is a first-in-first-out (FIFO) buffer that serializes processing in the common MIB 32 to prevent multiple operations from being performed at the same time, and thus prevent corruption of data, data contention, and race conditions within the common MIB 32 .
In the database 66 , attributes for each of the ME types are stored in ME data structures 80 . Preferably, the data structures are non-volatile structures to ensure data integrity. In one embodiment, the database 66 is a relational database and the ME data structures 80 are relational database tables. It will be understood that the ME attributes may be otherwise suitably stored without departing from the scope of the present invention.
The response queues 64 store responses to transactions processed by the common MIB 32 . In one embodiment, the response queues 64 include a discrete queue for each subsystem 30 . In this embodiment, each subsystem 30 reads responses in its corresponding queue 64 and extracts data for generating a protocol-specific response for transmission to the management station originating the transaction. It will be understood that responses to transactions may be otherwise made available by the common MIB 32 to the subsystems 30 .
FIG. 2 illustrates details of the object interfaces 70 , command objects 72 , and ME class objects 74 in accordance with one embodiment of the present invention. In this embodiment, the objects 70 , 72 , and 74 are each fully instantiated objects encapsulating both data and behavior and inheriting data and behavior from parent classes.
Referring to FIG. 2, the interface object 70 includes client callback, client quality of service (QoS), client command objects, and client interface parameters. The interface object 70 calls an associated command object 72 in the API 60 .
The command objects 72 include command methods, command correlation, command errors, and command parameters. The command object 72 further inherits attributes of the base class 76 . As previously described, the base class 76 includes common ME attributes and common ME methods.
The ME class objects 74 each include functionality associated with a particular ME type. Such functionality includes ME attributes, methods, parameters, and behavior for the ME type. Attributes of an ME class 74 are inherited by the command objects 72 through the base class 76 to generate the ME command object 78 . As previously described, the ME command object 78 provides an interface for accessing data and functionality in the common MIB 32 .
FIG. 3 illustrates details of an ME command object 78 in accordance with one embodiment of the present invention. In this embodiment, the ME command object 78 is self contained. Any system resources obtained, such as memory or buffers are “owned” by the object 78 and released when the object 78 is destructed. It will be understood that the ME command object 78 may be otherwise suitably implemented for accessing data and attributes and common MIB 32 .
Referring to FIG. 3, the ME command object 78 includes a public data section 100 and a private data section 102 . The public data section 100 of the ME command object 78 is accessible by the client subsystem 30 . The public data section 100 includes method functions that hide the structure, data manipulation, and allocation details from the client subsystem 30 . In addition, the methods in the public data section 100 respond to affects of the methods chosen and perform any command integrity checks required.
In one embodiment, the methods may include inline functions, particularly those used for setting and retrieving small (typically integer) attribute values. Attribute methods, for example, will be available to populate get/set/create commands, and to retrieve values resulting from the same. Constructor, invoker, and releasor methods will be used to create, execute, and destroy ME command objects 78 . Behavior methods are used by common MIB 32 to execute the commands.
The private data section 102 of the ME command object 78 includes data to complete the command. The response data for successful or error return will also be contained in the private data section 102 . In one embodiment, any miscellaneous system resources dynamically allocated for the command are retained in the private data section 102 . This type of allocation is preferably minimized.
FIG. 4 is a flow diagram illustrating a method for performing a management transaction in accordance with one embodiment of the present invention. In this embodiment, the transaction may be received from any one of the plurality of management stations in a management protocol supported by the NE 10 .
Referring to FIG. 4, the method begins at step 110 in which subsystem 30 receives a transaction in a specific management protocol. Next, at step 112 , the subsystem 30 maps the protocol specific transaction to a protocol independent ME class 74 which will be used by the common MIB 32 to perform the transaction. Mapping may include any suitable type of transaction, conversion, or associations. Accordingly, protocol specific processing is retained at the subsystem level.
At step 114 , the subsystem 30 opens a communications session with the API 60 . As previously described, the session may be opened by calling an interface object 70 in the API 60 corresponding to the subsystem 30 . Proceeding to step 116 , the subsystem 30 requests a command object 72 from the API 60 . The subsystem 30 may use any number of command object 72 at a time up to the number allocated to the subsystem 30 in the API 60 .
At step 118 , the subsystem 30 identifies the protocol independent ME class 74 to which the protocol specific transaction was mapped. Next, at step 120 , the API 60 generates and returns an ME command object 70 to the subsystem 30 . As previously described, the ME command object 78 includes attributes of the base class 76 and the ME class 74 . Portions of the ME class 74 may overload portions of the base class 76 to provide specific functionality in place of base functionality. At step 122 , the subsystem 30 populates the ME command object 78 based on the transaction by calling command functions stored in the ME command object 78 .
Proceeding to step 124 , the populated ME command object 78 is transferred to the transaction queue 62 in common MIB 32 for processing. The transaction queue 32 serializes processing in common MIB 32 to prevent data contention between co-pending ME command objects 78 . At step 126 , the ME command object 78 is removed from the transaction queue 62 and executed by the common MIB 32 . During execution, the ME command object 78 accesses the corresponding ME table 80 and/or performs functions in accordance with functions, behaviors, and parameters in the ME command object 78 which are based on the transaction.
Next, at step 128 , the common MIB 32 generates a response in accordance with the function calls in the ME command object 78 . At step 130 , the response is transferred to the response queue 64 for the subsystem 30 that generated the ME command object 78 . Next, at step 132 , the subsystem 30 extracts data from the response and generates a protocol specific response for transfer back to the requesting management station. At step 134 , the subsystem 30 releases the command object 72 back to the API 60 . In this way, the common MIB 32 provides a layer of abstraction to isolate data representations internal to the network element 10 from data representations made externally to the network element 10 . Data integrity and consistency is guaranteed as only a single database is maintained.
Although the present invention has been described with several embodiments, various changes and modifications may be suggested to one skilled in the art. 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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In accordance with one embodiment of the present invention, a network element comprises a first subsystem operable to receive management transactions in a first management protocol and to map the transactions to a common management protocol. A second subsystem is operable to receive management transactions in a second management protocol and to map the transactions to the common management protocol. A common management information base (MIB) includes a dataset and a common interface to the dataset. The common interface is operable to access the dataset to process transactions received from the first and second subsystems in the common management protocol.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 09/249,388, filed on Feb. 12, 1999, which is a divisional of prior application Ser. No. 08/940,307, filed on Sep. 30, 1997, both of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. The Field of the Invention
[0003] The present invention relates generally to a method for making an improved isolation trench for a semiconductor memory device. More particularly, the present invention relates to a method for fabricating a low leakage trench for a Dynamic Random Access Memory (DRAM) cell wherein trench sidewall leakage currents from the bitline contact to the storage node and from the storage node to the substrate are minimized by an isolation oxide film that is disposed within the trench.
[0004] 2. The Relevant Technology
[0005] In the microelectronics industry, a substrate refers to one or more semiconductor layers or structures which includes active or operable portions of semiconductor devices. In the context of this document, the term “semiconductive substrate” is defined to mean any construction comprising semiconductive material, including but not limited to bulk semiconductive material such as a semiconductive wafer, either alone or in assemblies comprising other materials thereon, and semiconductive material layers, either alone or in assemblies comprising other materials. The term substrate refers to any supporting structure including but not limited to the semiconductive substrates described above.
[0006] In a capacitor used in VLSI technology, it is desirable to minimize storage cell leakage in order to reduce refresh frequency requirements and to improve storage reliability. It is also desirable to increase storage cell capacity without increasing lateral geometries and without subjecting vertical storage cells to physical destruction during fabrication.
[0007] Both stack and trench DRAM cells suffer from sidewall leakage and from node-to-substrate leakage from the bitline contact. Stack DRAM cells suffer from two additional disadvantages that can result in device destruction and shorting. The first additional disadvantage is that the raised topography of the stack subjects it to the risk of being damaged in subsequent processing such as chemical-mechanical planarization (CMP), that exposes the stack. Subsequent processing, such as rapid thermal processing (RTP), can cause unwanted diffusion of dopants. The second additional disadvantage is that the configuration of the stacked capacitor requires a high aspect ratio of contacts used in connecting the stack capacitor, such as the bit line contact corridor. As one example, metal reflow into a high aspect-ratio contact requires a high amount of heat and pressure. There is also the chance of shorting out the bitline contact into the cell plate in the bitline contact corridor because both the cell plate and the bitline contact corridor are in the same horizonal plane and must intersect without making contact.
[0008] Processing of stack DRAMs requires a large amount of thermal energy. The DRAM structure is limited in its ability to withstand the thermal energy without diffusing doped elements to an extent that is destructive. This thermal energy limit is referred to as the thermal budget and must be taken into account in DRAM fabrication. Utilizing more than the entire thermal budget translates into dopant diffusion that may exceed structure design and cause device underperformance or failure. Dealing with the thermal budget adds another dimension to processing that correspondingly decreases the processing degrees of freedom.
[0009] Given the forgoing, there is a need in the art for a robust DRAM device that has a low profile above a semiconductor substrate and a highcharge storage capacity. There is also a need in the art for a DRAM device with decreased lateral geometries, and minimized charge leakage. There is also a need in the art for a method of fabricating a robust DRAM that fabricates the DRAM with only a fraction of the thermal budget presently required for similar capacity DRAMs and that allows for optional further processing such as metallization with the unused portion of the thermal budget.
BRIEF SUMMARY OF THE INVENTION
[0010] The present invention comprises a method of forming a self-aligned recessed container capacitor. The capacitor is self-aligning in its critical container cell dimensions. The capacitor also presents a low profile for a robust device such that it is less susceptible to physical damage. The capacitor of the present invention is preferably a DRAM device that avoids cell plate-bit line contact shorting by placing the cell plate and bit line contact in different horizontal planes. The capacitor of the present invention provides for a large vertical storage node-semiconductor substrate interface that cannot be achieved with horizontal interfaces without significantly increasing the lateral geometries and thus increasing the overall lateral size of the device.
[0011] The method of the present invention comprises etching a trench into a semiconductor substrate and depositing an isolation oxide film into the trench. Gate stacks are formed upon and around the trench. The isolation oxide film within the trench is patterned and etched with the aid of the gate stacks which act as self-aligning etch stops for the purpose of forming a container cell. During the etch of the container cell, critical dimensions are maintained in that the width of the container cell will not exceed the spacing between gate stacks.
[0012] The semiconductor substrate has a trench and an active area therein, and the semiconductor substrate defines a plane. An isolation film is disposed within the trench and a container cell disposed within the isolation film. The container cell has an edge that exposes an edge of the semiconductor substrate in an exposure that is substantially orthogonal to the plane of the semiconductor substrate. The etch of the container cell therefore exposes a portion of the semiconductor substrate at a vertically oriented edge thereof below and adjacent to one of the gate stacks. Storage node formation is then preferably done by chemical vapor deposition (CVD) of polysilicon. A cell dielectric is then deposited and a cell plate is deposited upon the cell dielectric, preferably by CVD.
[0013] These and other objects and features of the present invention will become more fully apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] To further clarify the above and other advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered 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:
[0015] [0015]FIG. 1 depicts a nitride/oxide double layer on a semiconductor substrate.
[0016] [0016]FIG. 2 depicts an isolation trench that has been etched in the semiconductor substrate of FIG. 1.
[0017] [0017]FIGS. 3 and 4 depict an isolation oxide film that has filled the trench of FIG. 2 and has been chemical-mechanically planarized down to the nitride layer, respectively.
[0018] [0018]FIG. 5 depicts the results of a nitride strip on the structure surface of FIG. 4.
[0019] [0019]FIG. 6 depicts gate stack construction on the structure of FIG. 5.
[0020] [0020]FIG. 7 depicts the results of an anisotropic etch into the structure of FIG. 6 that creates the container cell of the present invention.
[0021] [0021]FIG. 8 depicts a completed self-aligned recessed container cell capacitor within the container cell of FIG. 7.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] The present invention comprises a process of forming a container cell in a semiconductor substrate. FIG. 1 illustrates the beginning of the fabrication of the container cell. First an oxide layer 14 is formed upon a semiconductor substrate 12 of the device 10 . Oxide layer 14 if present, is preferably SiO 2 and is preferably grown thermally. Oxide layer 14 is formed in order to protect semiconductor substrate 12 from contamination. A nitride layer 16 , preferably composed of Si 3 N 4 , is formed upon oxide layer 14 , thereby forming a nitride/oxide double layer 16 , 14 upon semiconductor substrate 12 . In order to assure minimized charge leakage by isolating the container cell within an isolating amorphous film, an isolation trench 18 is formed as illustrated in FIG. 2. Isolation trench 18 is patterned and etched through nitride/oxide double layer 16 , 14 and into semiconductor substrate 12 . Patterning and etching may include spinning on a photoresist, masking, exposing and patterning the photoresist to create a photoresist mask, and anisotropically etching through the photoresist mask.
[0023] [0023]FIG. 3 illustrates the next process step in which a conformal isolation film 20 , preferably deposited as a tetra ethy ortho silicate (TEOS) or a boro phospho silicate glass (BPSG) process, is deposited upon nitride/oxide double layer 16 , 14 and within isolation trench 18 . Conformal isolation film 20 is preferably formed of an insulating material such as silicon dioxide, phosphosilicate glass (PSG), BPSG, thallium oxide, polyimide, etc. Most preferably, conformal isolation film 20 is formed of silicon dioxide that is deposited with a TEOS process. FIG. 4 illustrates the removal of excess isolation film 20 from above nitride/oxide double layer 16 , 14 . The excess of isolation film 20 is preferably removed by a planarizing technique such as mechanical planarization or abrasion of device 10 . An example thereof is chemical-mechanical planarization (CMP) using nitride layer 16 as a CMP stop.
[0024] After conducting the CMP, conformal isolation film 20 remains only in isolation trench 18 , such that conformal isolation film 20 fills isolation trench 18 to a level that is flush with the upper surface of nitride layer 16 . A hot phosphoric acid bath or equivalent is preferably used to remove nitride layer 16 as illustrated in FIG. 5. Because of a high amount of exposure of the original deposited oxide, oxide layer 14 can be significantly damaged at this point in the process and it can be removed by an aqueous HF bath in the concentration range from 2:1 to 300:1. Alternatively, oxide layer 14 and the portion of conformal isolation film that extends above substrate 12 may be removed by a technique such as densification followed by CMP or an equivalent.
[0025] With oxide layer 14 and nitride layer 16 removed there remains an intermediate structure that is ready for construction of gate stacks. The gate stacks will assist, upon construction completion, as self-aligning etch stops for the container cell. Gate stacks are formed by various known technologies depending upon the desired device performance requirements. FIG. 6 illustrates only generally the formation of gate stacks wherein a gate oxide 22 has been grown on substrate 12 . In the present invention, a first gate stack 24 is formed upon a gate oxide 22 immediately adjacent to the edge of isolation trench 18 . Concurrently, a second gate stack 26 is formed upon the upper surface of conformal isolation film 20 within isolation trench 18 . First and second gate stacks 24 , 26 may be formed simultaneously by forming preferred layers and removing all material therebetween. Removing all material between gate stacks 24 , 26 may be done by patterning a mask and etching to isolate gate stacks 24 , 26 .
[0026] Preferably, first and second gate stacks 24 , 26 have etch stop qualities relative to conformal isolation film 20 . Most preferably, a nitride or Si 3 N 4 spacer is formed upon gate stacks 24 , 26 as an insulator and as the preferred etch stop.
[0027] Finally, in forming the container cell of the present invention, FIG. 7 illustrates an anisotropic etch that is performed in which the container cell 28 is etched into conformal isolation film 20 as performed through a masking 38 . The etch may be preferably a reactive ion etch (RIE).
[0028] Semiconductor substrate 12 thus includes trench 18 and active area 22 therein, and semiconductor substrate 12 defines a plane. Isolation film 20 is disposed within the trench 18 and container cell 28 is disposed within isolation film 20 . Container cell 28 has an edge that exposes a surface of the semiconductor substrate in an exposure that is substantially orthogonal to the plane of the semiconductor substrate 12 along the line A-A. The etch of container cell 28 therefore exposes a portion of semiconductor substrate 12 at a vertically oriented edge thereof below and adjacent to one of the gate stacks.
[0029] Storage node formation is then preferably done by CVD of polysilicon. A cell dielectric is then deposited and a cell plate is deposited upon the cell dielectric, preferably by CVD.
[0030] As set forth above, gate stacks 24 , 26 act as etch stops. If first gate stack 24 is slightly misaligned, a portion 29 of semiconductor substrate 12 will be etched away in addition to conformal isolation film 20 that is exposed adjacent to first and second gate stacks 24 , 26 . Although misalignment is not desirable, the present invention achieves an etch of conformal isolation film 20 that exposes at least some portion of semiconductor substrate 12 at a vertically oriented face on one side of etched container cell 28 . This partial exposure of semiconductor substrate 12 creates two advantages. The first advantage is that the partial exposure of semiconductor substrate 12 allows for a vertical contact interface with container cell 28 and semiconductor substrate 12 as illustrated along the dashed line A. The etch-stop function of first and second gate stacks 24 , 26 assures that this partial exposure will be achieved with the container cell. This vertical contact interface with the semiconductor substrate allows for greater contact area without increasing lateral geometries as would be required in a stack DRAM where the storage node-substrate contact interface is horizontal and usually limited to the footprint size of the storage node on the substrate. The second advantage is that the remainder of container cell 28 is electrically isolated in conformal isolation film 20 and charge leakage is thereby minimized.
[0031] Following the container cell etch, the storage node 30 is deposited as illustrated in FIG. 8. Preferably in-situ-doped CVD polycrystalline silicon is deposited within container cell 28 as the storage node. Electrical conduction or insulation between storage node 30 and the exposed portion of semiconductor substrate 12 , illustrated along dashed line A can be controlled by relative doping of the two 12 , 30 and by controlling the overall depth of container cell 28 . The deeper that container cell 28 penetrates into semiconductor substrate 12 , the more that the vertically oriented contact area is exposed between storage node 30 and semiconductor substrate 12 along dashed line A.
[0032] The capacitor cell is completed by depositing a cell dielectric 32 upon storage node 30 followed by deposition of a cell plate 34 . Cell plate 34 is preferably an in-situ-doped CVD polysilicon, however doping can be achieved by other methods such as directional implantation or vaporization and annealing.
[0033] The structure of the present invention is illustrated as a DRAM cell by way of non-limiting example in FIG. 8. Semiconductor substrate 12 has isolation trench 18 and an active area 36 that is preferably N+ doped. Between isolation trench 18 and active area 36 , semiconductor substrate 12 supports first gate stack 24 . Within isolation trench 18 there is disposed conformal isolation film 20 . Conformal isolation film 20 is preferably a heavy TEOS that planarizes easily after deposition. Within conformal isolation film 20 there is disposed container cell 28 that vertically exposes a portion of semiconductor substrate 12 at least tangentially to container cell 28 along dashed line A. Vertical exposure A is below and adjacent to a side edge of first gate stack 24 . Second gate stack 26 is disposed upon conformal isolation film 20 adjacent to an edge of container cell 28 .
[0034] Within container cell 28 there is conformably disposed storage node 30 that contacts conformal isolation film 20 having a cylinder-like shape. Below a side of first gate stack 24 , storage node 30 forms a vertical interface with semiconductor substrate 12 along dashed line A. Cell dielectric 32 is substantially conformably disposed on storage node 30 . Cell plate 34 is substantially conformably disposed upon first gate stack 24 , cell dielectric 32 , and second gate stack 26 .
[0035] It is thus achieved that minimal leakage occurs from storage node 30 . This minimal leakage occurs where the entire storage node is isolated. Most of the isolation is due to conformal isolation film 20 that forms container cell 28 for storage node 30 . A portion of storage node 30 is not isolated by conformal isolation film 20 , along dashed line A. This portion is where storage node 30 vertically interfaces with semiconductor substrate 12 . However this vertical interfacing achieves isolation due to the low conductivity in semiconductor substrate 12 . A suitable charge can be stored due to the size of storage node 30 . The breakdown voltage of the exposed portion of semiconductor substrate 12 is low between storage node 30 and bit line contact 38 due to the large vertical contact interface along dashed line A. Critical dimensions are maintained for the container cell due to the etch-stop quality of materials that are formed as spacers over first and second gate stacks 24 , 26 .
[0036] The present 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 by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.
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Methods for fabricating low leakage trenches for Dynamic Random Access Memory (DRAM) cells and the devices formed thereby are disclosed. In one embodiment of the present invention, the method includes etching a container cell in an isolation film that is disposed within a trench. The container cell forms a vertical interface with the semiconductor substrate on one side through the isolation film. Formation of the container cell is self-aligning wherein previously-formed gate stacks act as etch stops for the container cell etch. In this way the container cell size is dependent for proper etch alignment only upon proper previous alignment and spacing of the gate stacks. The method of forming the container cell within an isolation film that is within a trench in the semiconductor substrate prevents cell-bit line shorting where the cell and the bit line are not horizontally adjacent to each other.
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FIELD OF THE INVENTION
[0001] The present invention relates to the field of field effect transistors (FETs); more specifically, it relates to high-mobility p-channel field effect transistors (PFETs) and methods of fabricating high-mobility PFETs.
BACKGROUND OF THE INVENTION
[0002] Complimentary metal-oxide-silicon (CMOS) technology is used in many integrated circuits. CMOS technology utilizes n-channel metal-oxide-silicon field effect transistors (n-MOSFETs) often shortened to NFETs and p-channel metal-oxide-silicon field effect transistors (p-MOSFETs) often shortened to PFETs. Conventional NFETs and PFETs are well known in the art and comprise a source region and a drain region on opposite sides of a channel region formed in single-crystal silicon with a gate electrode formed on top of a gate dielectric layer which is itself formed on top of the channel region.
[0003] When NFETs and PFETs are used in high performance circuits, the PFETs need to be larger than the NFETs to overcome the difference in carrier mobility between NFETs and PFETs so as not to let the PFETs limit overall circuit switching speed. The hole mobility in PFETs is about 25% that of the electron mobility of NFETs. Larger PFETs require more silicon area and more power in a time when modern integrated circuits need to be smaller and consume less power in very many applications.
[0004] Therefore there is a need for both an improved PFET with high switching speed at reduced silicon area and power consumption compared to conventional PFETs and an NFET that may be fabricated simultaneously with the improved PFET.
SUMMARY OF THE INVENTION
[0005] The present provides both an improved PFET with high switching speed at reduced silicon area and power consumption compared to conventional PFETs by inducing stress in the PFET channel as well as an NFET that may be fabricated simultaneously with the improved PFET.
[0006] A first aspect of the present invention is a field effect transistor, comprising: a gate electrode formed on a top surface of a gate dielectric layer, the gate dielectric layer on a top surface of a single-crystal silicon channel region, the single-crystal silicon channel region on a top surface of a Ge comprising layer, the Ge comprising layer on a top surface of a single-crystal silicon substrate, the Ge comprising layer between a first dielectric layer and a second dielectric layer on the top surface of the single-crystal silicon substrate.
[0007] A second aspect of the present invention is a method of fabricating a field effect transistor comprising: (a) providing a single-crystal silicon substrate having a single-crystal Ge comprising layer formed on a top surface of the single-crystal silicon substrate and a single-crystal silicon layer formed on a top surface of the single-crystal Ge comprising layer; (b) forming a gate dielectric layer on a top surface of the single-crystal silicon layer; (c) forming a gate electrode on a top surface of the dielectric layer; (d) removing the single-crystal silicon layer to form a single crystal-silicon island and removing a less than whole portion of the single-crystal Ge comprising layer to form an island of single-crystal silicon under the gate electrode where the single-crystal silicon layer and the single-crystal Ge comprising layer are not protected by the gate electrode; (e) oxidizing an entire remaining portion of the single-crystal Ge comprising layer not protected by the gate electrode, and a less than whole portion of the single-crystal Ge comprising layer under the gate electrode to form a single-crystal Ge comprising island under the single-crystal silicon island and having a first dielectric layer on a first side and a second dielectric layer on second and opposite side of the single-crystal Ge comprising island, the first dielectric layer and the second dielectric layer each extending under the gate electrode; and (f) forming a polysilicon source region over the first dielectric layer and forming a polysilicon drain region over the second dielectric layer, the polysilicon source region and the polysilicon drain region abutting opposite sides of the single-crystal silicon channel island.
BRIEF DESCRIPTION OF DRAWINGS
[0008] The features of the invention are set forth in the appended claims. The invention itself, however, will be best understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein:
[0009] FIG. 1 is a cross-sectional view of a PFET 100 according to the present invention;
[0010] FIGS. 2A through 2P are cross-sectional views illustrating fabrication of PFET 100 of FIG. 1 ;
[0011] FIGS. 3A through 3D are cross-sectional views illustrating fabrication of an NFET 300 of FIG. 4 that may be fabricated alone or simultaneously with PFET 100 of FIG. 1 ; and
[0012] FIG. 4 is a cross-sectional view of NFET 300 that may be fabricated alone or simultaneously with the PFET 100 of FIG. 1 according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0013] FIG. 1 is a cross-sectional view of a PFET 100 according to the present invention. FIG. 1 is a cross-section along the channel length direction of PFET 100 . In FIG. 1 , PFET 100 includes a gate 105 ; an N-doped single-crystal silicon region 110 under gate 105 , a P-doped polysilicon source region 120 A abutting shallow trench isolation (STI) 115 (that bounds PFET 100 but is technically not part of PFET 100 ); a single-crystal silicon source region 125 A extending into single-crystal silicon region 110 (bounded by the dashed lines) and extending under gate 105 ; a P-doped polysilicon drain region 120 B abutting STI 115 ; and a P-doped single-crystal silicon drain region 125 B abutting polysilicon drain region 120 B and extending into single-crystal silicon region 110 (bounded by the dashed lines) and extending under gate 105 . PFET 100 further includes a buried dielectric layer 130 A under polysilicon source region 120 A and single-crystal silicon source region 125 A and extending from STI 115 to under gate 105 ; and a buried dielectric layer 130 B under drain region 120 B and single-crystal silicon drain region 125 B and extending from STI 115 to under gate 105 . PFET 100 still further includes a single-crystal Ge comprising layer 135 under single-crystal silicon region 110 and extending between buried dielectric layers 130 A and 130 B; an N-well 145 under buried dielectric layers 130 A and 130 B and Ge comprising layer 135 ; and a retrograde N-type ion-implant peak 140 in a single-crystal silicon N-well 145 (in a silicon substrate 150 ) under buried dielectric layers 130 A and 130 B and Ge comprising layer 135 and bounded by STI 115 .
[0014] It should be understood that polysilicon source region 120 A and single-crystal silicon source region 125 A are physically and electrically in contact and structurally and electrically comprise the source of PFET 100 . Likewise, it should be understood that polysilicon drain region 120 B and single-crystal silicon drain region 125 B are physically and electrically in contact and structurally and electrically comprise the drain of PFET 100 .
[0015] Gate 105 includes a gate dielectric layer 155 on a top surface 160 of single-crystal silicon region 110 and a P-doped or undoped polysilicon gate electrode 165 on a top surface 170 of gate dielectric layer 155 and a capping layer 175 on a top surface 180 of gate electrode 165 . Optional sidewall insulation layers 185 A and 185 B are formed on opposing sidewalls 190 A and 190 B respectively of gate electrode 165 and dielectric spacers 195 A and 195 B are formed on outer surfaces 200 A and 200 B respectively of corresponding sidewall insulation layers 185 A and 185 B. Gate dielectric layer 155 is illustrated in FIG. 1 extending under spacers 195 A and 195 B. Alternatively, gate dielectric layer may extend partially or not at all under spacers 195 A and 195 B.
[0016] A channel region 205 is defined in single-crystal silicon region 110 . Channel region 205 may include a portion of adjacent to top surface 160 of substrate 150 between single-crystal silicon source region 125 A and single-crystal silicon drain region 125 B or channel region 205 may include all of single-crystal silicon region 110 between single-crystal silicon source region 125 A and single-crystal silicon drain region 1250 B. Single-crystal silicon region 110 extends under spacers 195 A and 195 B as illustrated in FIG. 1 or may extend under and past spacers 195 A and 195 B toward STI 115 .
[0017] Buried dielectric layer 130 A includes a first region 210 A and a second region 215 A. Second region 215 A is thicker than first region 210 A. First region 210 A extends under polysilicon source region 120 A from STI 115 to meet second region 215 A under spacer 195 A. Second region 215 A extends from first region 210 A from under spacer 195 A to Ge comprising layer 135 under gate 105 .
[0018] Buried dielectric layer 130 B includes a first region 210 BA and a second region 215 B. Second region 215 B is thicker than first region 210 B. First region 210 B extends under polysilicon drain region 120 B from STI 115 to meet second region 215 A under spacer 195 B. Second region 215 B extends from first region 210 B from under spacer 195 A to Ge comprising layer 135 under gate 105 .
[0019] A top surface 220 A of second region 215 A slopes upward (toward surface 160 of substrate 150 ) from Ge comprising layer 135 to meet polysilicon source region 120 A under spacer 195 A. A bottom surface 225 A of second region 215 A slopes downward (away from surface 160 of substrate 150 ) from Ge comprising layer 135 to meet first region 210 A under spacer 195 A. A top surface 220 B of second region 215 B slopes upward from Ge comprising layer 135 to meet polysilicon drain region 120 B under spacer 195 B. A bottom surface 225 B of second region 215 B slopes downward from Ge comprising layer 135 to meet first region 210 B under spacer 195 B.
[0020] The upward slope of top surface 220 A of second region 215 A of buried dielectric layer 130 A and of top surface 220 B of second region 215 B of buried dielectric layer 130 B which is in the order of 50 % percent from flat (relative to top surface 160 of substrate 150 ) imparts a stress of about 50 mega-pascals to about 1000 mega-pascals to the crystal lattice of single-crystal silicon region 110 and channel region 205 . Stress on silicon the silicon lattice of PFETs has been shown to increase the hole mobility and thus the drain current of the PFET which can be advantageously used to reduce the silicon area of a PFET required for a given PFET drain current rating.
[0021] FIGS. 2A through 2P are cross-sectional views illustrating fabrication of PFET 100 of FIG. 1 . In FIG. 2A , single-crystal silicon substrate 150 has a Ge comprising layer 135 formed on a top surface 230 of a single-crystal silicon substrate 150 and a single-crystal silicon layer 240 formed on a top surface 235 of Ge comprising layer 135 . Single-crystal silicon substrates are also called mono-crystalline silicon substrates or bulk silicon substrates. In a first example, Ge comprising layer 135 comprises Si (1-X) Ge x where X equals about 0.15 to about 0.5. In a second example, Ge comprising layer 135 comprises Si (1-X-Y) Ge X C Y where X equals about 0.15 to about 0.5 and Y equals about 0 to about 0.1. A single-crystal SiGe layer may be epitaxially formed by low pressure chemical vapor deposition (LPCVD) using SiH 4 and GeH 4 . A single-crystal SiGeC layer may be epitaxially formed by LPCVD using a combination of SiH 4 , GeH 4 and CH 3 SiH 3 or C 2 H 6 . In one example Ge comprising layer 135 is about 10 nm to about 100 nm thick. A single-crystal silicon layer may be epitaxially formed by LPCVD using SiH 4 and/or H 2 . In one example single-crystal silicon layer 240 is about 5 nm to about 50 nm thick.
[0022] In FIG. 2B , STI 115 is formed. STI 115 extends from a top surface 245 of single-crystal silicon layer 240 through single-crystal silicon layer 240 , through single-crystal Ge comprising layer 135 into substrate 150 . STI 115 may be formed by reactive ion etching (RIE) trenches through single-crystal Ge comprising layer 135 into substrate 150 , depositing an insulator such as SiO 2 or tetraethoxysilane (TEOS) oxide to fill the resultant trench and chemical-mechanical polishing (CMP) down to top surface 245 of single-crystal silicon layer 240 to remove excess insulator.
[0023] In FIG. 2C , N-well 145 is formed in substrate 150 by ion implantation of an N-dopant such as arsenic or phosphorus. While N-well 145 is illustrated as extending below STI 145 , N-well 145 may be about even with or shallower than the STI.
[0024] In FIG. 2D , a retrograde ion implantation is performed using an N-dopant such as arsenic. A retrograde ion implant is defined as an ion implant having a peak concentration below a surface of the material into which the ion implantation is performed. Peak 140 of the retrograde ion implant is located a distance D below top surface 235 of Ge comprising layer 240 .
[0025] In FIG. 2E , gate dielectric layer 155 is formed on top surface 245 of single-crystal silicon layer 240 . In one example, gate dielectric layer 155 comprises deposited or thermal SiO 2 , but may be any gate dielectric known in the art. An N-doped or undoped polysilicon layer 250 is formed on top surface 170 of gate dielectric layer 155 . Polysilicon may be formed by CVD using SiH 4 (and optionally AsH 4 or PH 4 if the gate is to be doped at this point in the fabrication). Capping layer 175 is formed on a top surface 255 of polysilicon layer 250 . In one example, capping layer 175 comprises a TEOS oxide layer over a thermal SiO 2 layer.
[0026] In FIG. 2F , a photolithography process is performed and capping layer 175 is patterned and used as a hard mask to etch away undesired portions of polysilicon layer 250 (see FIG. 2E ) to form gate electrode 165 under remaining capping layer 175 .
[0027] In FIG. 2G an optional sidewall isolation layer 185 is formed on sidewalls 190 of gate electrode 165 . Then an optional P-dopant extension ion implant using, for example, boron and/or an optional N-dopant halo ion implant using, for example, arsenic is performed to form extension/halo regions 260 in single-crystal silicon layer 240 . Extension and halo implants may be performed at an angle of other than 90° relative to top surface 245 of single-crystal silicon layer 240 . The halo and extension implants are performed such that, while they extend under gate electrode 165 , they will not extend as far as thick regions 215 A and 215 B of respective buried dielectric layers 130 A and 130 B extend under the gate electrode (see FIG. 1 ). The halo and extension implants are shallow implants and do not extend below Ge comprising layer 135 .
[0028] Alternatively, the extension and/or halo ion implants may be performed after formation of gate electrode 165 but before formation of sidewall isolation layer 185 .
[0029] In FIG. 2H , spacers 195 are formed on outer surfaces 200 of sidewall insulation layer 185 . Spacers 195 may comprise Si 3 N 4 , SiO 2 , or combinations thereof. For example, spacers 195 may comprise a multiple overlaid spacers, each spacer formed from either SiO 2 and Si 3 N 4 . Further, one or both of the halo and extension ion implants discussed supra, may be alternatively, performed after formation of spacers 195 . Spacers are formed by depositing a conformal layer of material and then performing an RIE process. Gate dielectric layer 155 , not protected by gate electrode 165 and spacers 195 may also be removed by the RIE process or another process.
[0030] In FIG. 21 , portions of single-crystal silicon layer 240 not protected by gate electrode 165 and spacers 195 are removed. Also Ge comprising layer 135 is etched to recess the Ge comprising layer in regions where single-crystal silicon layer 240 were removed, so that Ge comprising layer 135 is thinner in these regions than under gate electrode 165 and spacers 195 . In one example, Ge comprising layer 135 is thinned to half its original thickness where not protected by gate electrode 165 and spacers 195 . In a second example, Ge comprising layer 135 is thinned to between about 5 nm to about 50 nm where not protected by gate electrode 165 and spacers 195 . The etching of single-crystal silicon layer 240 and Ge comprising layer 135 may be accomplished using an RIE process that selectively etches Si, SiGe and SiGeC relative to the material of capping layer 175 , spacers 195 , and STI 115 . In the example that capping layer 175 spacers 195 and STI 115 are forms of silicon oxide, a suitable RIE process would utilize a mixture of CF 4 and O 2 .
[0031] In FIG. 2J , Ge comprising layer 135 is oxidized to form buried dielectric layer 130 which comprises oxides of Si and Ge. In one example, an oxidation at about 600° C. or less using a mixture of H 2 O vapor and O 2 is performed. Under these conditions, single-crystal SiGe and single-crystal SiGeC oxidize about 40 times faster than single-crystal silicon. During oxidation, the volume of the oxidized SiGe or SiGeC about doubles with about 40% of the volume being below the original surface and about 60% of the volume being above the original surface. Also, Ge comprising layer 135 oxidizes horizontally under spacers 195 and gate electrode 165 a distance equal to the thickness of oxidized SiGe or SiGeC formed where Ge comprising layer 135 was not protected by gate electrode 165 and spacers 195 . It should also be remembered that Ge comprising layer 135 was thicker under spacers 195 and gate electrode 165 than where the Ge comprising layer was exposed. Therefore, buried dielectric layer 130 includes a thick region 215 under spacers 195 and extending partially under gate electrode 165 and a thin region 210 where buried dielectric layer 130 is not under spacers 195 and gate electrode 165 . In one example thin region 210 of buried dielectric layer 130 is about 10 nm to about 100 nm thick, thick region 215 of buried dielectric layer 130 is about 10 nm to about 200 nm thick and extends under spacers 195 about 10 nm to about 200 nm.
[0032] After the oxidation, the only remaining Ge comprising layer 135 is an island under gate electrode 165 . Also a thin layer of SiO 2 265 is formed on exposed edges of single-crystal silicon layer 240 . A effect of the oxidation process is that regions of single-crystal silicon layer 240 between thick region 215 of buried dielectric layer 130 and gate dielectric layer 155 under spacers 195 are strained, that is, the crystal lattice is distorted from normal.
[0033] In FIG. 2K , thin layer of SiO 2 265 (see FIG. 2J ) is removed to expose edges 270 of single-crystal silicon region 240 .
[0034] In FIG. 2L , epitaxial silicon regions 275 are grown on edges 270 (see FIG. 2K ) of single-crystal silicon region 240 . As described supra, epitaxial Si may be grown by LPCVD using SiH 4 .
[0035] In FIG. 2M , a polysilicon layer 280 is formed of sufficient thickness to cover capping layer 175 and spacers 195 . As described supra, polysilicon layer 280 may be doped P-type or undoped. Epitaxial regions 275 on single-crystal silicon layer 240 (see FIG. 2L ) may increase in size slightly and single-crystal silicon region 110 results (see also FIG. 1 ).
[0036] In FIG. 2N , a CMP process is performed so that a top surface 285 of polysilicon layer 280 is coplanar with a top surface 290 of capping layer 175 .
[0037] In FIG. 20 , a RIE etch back process is performed, so that polysilicon layer 280 (see FIG. 2N ) is removed from spacers 195 , exposed ends of gate dielectric layer 155 and atop surface 295 of STI 115 . Polysilicon layer 280 remains in the space defined by single-crystal silicon region 110 , buried dielectric layer 130 and STI 115 .
[0038] In FIG. 2P , an optional P-type (for example boron) ion implantation is performed to form P-doped polysilicon source/drains 120 in remaining polysilicon layer 280 (see FIG. 280 ). The P-type ion implant may also be used to dope gate electrode 165 . If polysilicon layer 280 was P-doped as deposited, this P-type ion implantation may be eliminated or not depending upon whether it is desired to P-type ion implant gate electrode 165 .
[0039] Returning to FIG. 1 , the structure of PFET 100 improves several operational parameters of the PFET. First, the relatively shallow single-crystal silicon region 110 under gate electrode 165 , particularly near sidewalls 190 A and 190 B of the gate electrode, result in improved short channel characteristics such as decreased sub-threshold voltage swing (S SWING ), decreased drain induced barrier loading, and more precise threshold voltage (V T )control. Second, the relatively deep polysilicon source and drain regions 120 A and 120 B result in lower source/drain resistance. Third, buried dielectric layers 130 A and 130 B lower source/drain capacitance (compared to a conventional bulk silicon PFET). Fourth, Ge comprising layer 135 between second region 215 A of buried dielectric layer 130 A and second region 215 B of buried dielectric layer 130 B (because of the high Ge doping levels) allows control of V T by voltage biasing N-well 145 . These improved operating parameters have been experimentally shown to result in a significantly faster PFET (when compared to a conventional bulk silicon PFET of about the same channel width and channel length as a PFET of the present invention) and results in up to about a 42% increase in drain region current at saturation (I DSAT ) on short channel length devices. Fabrication of a PFET according to the present invention is essentially complete.
[0040] FIGS. 3A through 3D are cross-sectional views illustrating fabrication of an NFET 300 (see FIG. 4 ) that may be fabricated alone or simultaneously with PFET 100 (see FIG. 1 ). by several changes to the PFET process described supra. Before describing these changes, it should be understood, that it is well known in the art, that when both PFETs and NFETs are being fabricated on the same substrate, that the PFETs are protected from ion implantation during ion implants required only for the NFETs and that NFETs are protected from ion implantation during ion implants required only for the PFETs. Often this protection is provided by a photo resist layer. Thus, it should be understood in the description that follows, that such steps have taken place relative to the PFET and that such steps would also have taken place relative to an NFET is the previous description of formation of a PFET if PFETs and NFETs are being simultaneously fabricated according to the present invention.
[0041] Fabrication of NFET 300 (see FIG. 4 ) alone or simultaneously with PFET 100 (see FIG. 1 ) is similar to the fabrication of PFET 100 (see FIG. 1 ) illustrated in FIGS. 2A through 2M and described supra, with the differences described immediately infra
[0042] In FIG. 2C , N-well 145 is replaced by a P-Well formed by ion implantation of a P-dopant such as boron. In FIG. 2D , the N-doped retrograde ion implantation is replaced with a P-dopant retrograde ion implantation using a P-dopant species such as boron. In FIG. 2G , the P-dopant extension ion implantation is replaced with an N-dopant extension ion implantation using an N-dopant species such as arsenic and the optional N-dopant halo ion implantation is replaced with a P-dopant ion extension ion implantation using a P-dopant species such as boron.
[0043] Between the processes illustrated in FIGS. 21 and 2 J, the processes illustrated in FIGS. 3A and 3B are performed. In FIG. 3A , a directional RIE is performed to remove thin region 210 of buried dielectric layer 130 not protected by spacer 195 , capping layer 175 and gate electrode 165 . Also capping layer 175 may be alternatively formed from Si 3 N 4 or layers of Si 3 N 4 and SiO 2 . In FIG. 3B , a isotropic silicon etch is performed to remove exposed portions of silicon substrate and undercut thick regions 215 of dielectric layer 130 . STI 115 is not undercut. Removing silicon from under undercut thick regions 215 of dielectric layer 130 removes most or all of the stress previously induced into single-crystal silicon region 110 and channel region 205 (see FIG. 4 ).
[0044] For an NFET, FIG. 2L is replaced with FIG. 3C and FIG. 20 is replaced with FIG. 3D . In FIG. 3C , epitaxial silicon regions 275 are grown on edges 270 (see FIG. 2K ) of single-crystal silicon region 240 and an epitaxial layer 285 is grown on exposed surface of silicon substrate 215 . As described supra, epitaxial Si may be grown by LPCVD using SiH 4 . In FIG. 3D , a RIE etch back process is performed, so that polysilicon layer 280 (see FIG. 2N ) is removed from spacers 195 , exposed ends of gate dielectric layer 155 and a top surface 295 of STI 115 . A polysilicon layer 290 remains in the space defined by single-crystal silicon region 110 , thick region 215 of buried dielectric layer 130 , epitaxial layer 285 and STI 115 .
[0045] In FIG. 2P , the optional P-type ion implantation is replaced with an optional N-type ion implantation (for example using arsenic) to form N-doped source/drains 120 . Fabrication of an NFET according to the present invention is essentially complete.
[0046] FIG. 4 is a cross-sectional view of NFET 300 that may be fabricated alone or simultaneously with PFET 300 of FIG. 1 , according to the present invention. FIG. 4 is similar to FIG. 1 , except for several differences. First, single crystal region 110 is P-doped, instead of N-doped, source and drain regions 120 A and 120 B are N-doped instead of P-doped, single crystal regions 125 A and be are N-doped instead of P-doped, N-well 145 is replaced with a P-well 145 . Second, structurally, only thick regions 215 A and 215 B of respective dielectric layers 130 A and 130 B, epitaxial layers 285 A and 285 B intervene between respective polysilicon source/drain regions 120 A and 120 B and silicon substrate 150 rather than respective thin regions 210 A and 210 B (see FIG. 1 ) of dielectric layers 130 A and 130 B, and epitaxial layers 285 A and 285 B extend under respective thick regions 215 A and 215 B of dielectric layers 130 A and 130 B. Source/drain dopant species from source 120 A and drain 120 B may or may not extend into respective epitaxial layers 285 A and 285 B.
[0047] Thus the present invention provides both an improved PFET with high switching speed at reduced silicon area and power consumption compared to conventional PFETs and an NFET that may be fabricated simultaneously with the improved PFET.
[0048] The description of the embodiments of the present invention is given above for the understanding of the present invention. It will be understood that the invention is not limited to the particular embodiments described herein, but is capable of various modifications, rearrangements and substitutions as will now become apparent to those skilled in the art without departing from the scope of the invention. Therefore, it is intended that the following claims cover all such modifications and changes as fall within the true spirit and scope of the invention.
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A field effect transistor and method of fabricating the field effect transistor. The field effect transistor, including: a gate electrode formed on a top surface of a gate dielectric layer, the gate dielectric layer on a top surface of a single-crystal silicon channel region, the single-crystal silicon channel region on a top surface of a Ge including layer, the Ge including layer on a top surface of a single-crystal silicon substrate, the Ge including layer between a first dielectric layer and a second dielectric layer on the top surface of the single-crystal silicon substrate.
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FIELD OF THE INVENTION
[0001] The invention relates to a method and conveying device for mounting and removing a continuous conveyor belt for a printing press.
BACKGROUND OF THE INVENTION
[0002] Conveyor belts of printing presses (also known as webs), for conveying stock through the printing press, include a continuous belt, which is stretched around a frame and which is driven by high-speed rollers. With the operation of a printing press, a change of the web is required from time to time, whereby the mounted web is removed and another web is mounted in its place. The changing of the web is particularly impeded by the fact that the web is a continuous closed loop that cannot be separated. As such there are considerable possibilities that the web will come into damaging contact with various elements of the printing press located in proximity to the web and its path within the printing press.
[0003] To date, a maintenance technician trained on the specialized printing press had to be called to the premises of the printing press in order to have the web changed. The changing of the web, even for a dedicated maintenance technician, is difficult and takes a considerable amount of time. This creates high maintenance costs for the printing press and long, costly down times of the printing press.
SUMMARY OF THE INVENTION
[0004] In view of the above, this invention is directed to mounting and removing a continuous conveyor belt for a printing press. A sub-carrier is attached to each front side of a frame which is approximately the same width as the conveyor belt, and has surface shape that is somewhat similar to the track of the conveyor belt on the frame in the areas of the frame; and the continuous conveyor belt or is mounted or removed from the frame via the sub-carriers.
[0005] The purpose of the invention is to mount a continuous conveyor belt or web on a frame or to remove it from the frame in a cost-effective, quick and simple manner. The invention makes it possible for a single operator of a machine to simply and quickly change the continuous conveyor belt or web. In order to reduce the force required to change the web, the frame with the web is folded down prior to the change of the web.
[0006] The invention, and its objects and advantages, will become more apparent in the detailed description of the preferred embodiment presented below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] In the detailed description of the preferred embodiment of the invention presented below, reference is made to the accompanying drawing, in which the single FIGURE shows a perspective view of a frame of a printing press including a conveying device, for mounting and removing a continuous conveyor belt, according to this invention.
DETAILED DESCRIPTION OF THE INVENTION
[0008] The invention is described with reference to the attached FIGURE, which shows a perspective view of a frame 2 of a printing press. The frame 2 contains a plurality of rollers 7 , and first corner rollers 5 and second corner rollers 6 (as shown only on the front side of the frame 2 ). A continuous conveyor belt (or web) 1 is stretched around a frame 2 , around the rollers 7 , and around the first corner rollers 5 and the second corner rollers 6 . The web 1 is a continuous belt, for example made of a transparent plastic material, and is driven at high speed by the rollers 7 , or by at least one of the corner rollers 5 , 6 .
[0009] The web 1 is subject to high wear and tear and is required to be changed from time to time. Just pulling the mounted web 1 off of the frame 2 is arduous, at least for a single operator of the printing press, due to the dimensions of the arrangement according to the FIGURE. Furthermore, there is the danger that when the web 1 is put on or simply pulled off the frame 2 , it may be damaged by the frame, or may damage the frame or elements of the printing press around the frame.
[0010] With respect to the invention, the operator of the printing press opens the housing of the printing press (not shown) in which the frame 2 is located according to the FIGURE, and then simply attaches self-locking sub-carriers 3 to each front side of the frame 2 . The sub-carriers 3 have an external form that corresponds approximately to the track of the web 1 on the frame 2 in the end areas of the frame 2 , as can be seen in the FIGURE, and are of a length substantially equal to the width of the web. In this connection, the term “external form” indicates the outerlying surfaces 12 of the attached sub-carriers 3 as viewed from the frame 2 .
[0011] The ends of the frame 2 each have a first corner roller 5 and a second corner roller 6 , which are offset at various heights and which are arranged so that they are offset from each other in the longitudinal direction to the frame 2 . Consequently, the track of the web 1 in the end areas of the frame 2 shows a curvature, whereby the cross-section of the end areas of the frame 2 is approximately triangular when the missing triangular side is formed beginning with the vertical line at the first corner roller 5 and finishing with the web 1 on the under side of the frame 2 .
[0012] The sub-carriers 3 have an external shell with an approximately triangular cross-section, which has been configured with respect to the end areas of the frame 2 accordingly. The sub-carriers 3 have thin walls that are manufactured, for example, from aluminum. They are hollow and, when viewed from frame 2 with the fixed position of the sub-carriers 3 according to the FIGURE, may have innerlying stabilizing components 8 in the form of somewhat thin ribs that extend vertically within the sub-carriers 3 and which are solidly connected with the sub-carriers. The outerlying surfaces 12 of the sub-carriers 3 have a very small friction coefficient, so that the force required for sliding the web 1 on or pulling the web off the frame 2 is very small. The outerlying surfaces 12 are, for example, polished for this purpose.
[0013] On one side, the sub-carrier 3 shows a sidewall 10 , which closes the sub-carrier on such side and stabilizes the sub-carrier. But there is no wall on the opposite side of the sub-carrier 3 . This serves to enable the sub-carrier to be attached to the frame 2 . For simple and quick attachment, a pin 11 protrudes from the frame 2 substantially perpendicular to the frame, and is adapted to engage the sub-carrier 3 and establishes a connection therewith. The outerlying surfaces 12 form almost homogenous planes with the surfaces of the web 1 adjacent to the first corner rollers 5 and the second corner rollers 6 , and after the attachment of the sub-carrier 3 , the outerlying surfaces 12 almost seamlessly blend in with the surfaces of the web 1 .
[0014] The operator can therefore simply pull the web 1 over the outlying surfaces 12 of the sub-carrier 3 , whereby the web 1 with low frictional resistance slides over the outlying surfaces 12 , and remove the web 1 without it being damaged by the frame 2 . To this end, the operator needs only to pull on the web 1 a few times from one of the front sides of the frame 2 end area with sub-carrier 3 to the other front side of the frame end area with the other sub-carrier to pull the web 1 at the corresponding front side, piece by piece, via the corresponding sub-carriers. The mounting of the web 1 onto the frame 2 is carried out in a similar manner.
[0015] To change the web 1 , after the opening of the housing (not shown) of the printing press on the opened long side, the frame 2 can preferably be folded downward. On the opposite frame side, a pivot is located around which the frame 2 is folded. The frame 2 is folded downward to a limit stop (not shown) by the operator, which considerably facilitates the removal or the attachment of the web 1 . Following the changing of the web 1 , i.e., the removal of the web 1 and the mounting of another web, the self-locking sub-carriers 3 are removed by simply lifting them off of the frame 2 . The printing press is operational once the printing press housing is closed. The pulling off or lifting up of the frame 2 from the printing press to change the web 1 , and the required state-of-the-art devices are economized in this manner.
[0016] The invention has been described in detail with particular reference to a certain preferred embodiment thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention.
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A method and conveying device for mounting and removing a conveyor belt or web, particularly for a printing press. A shell-shaped sub-carrier is attached to each front side of a frame of a printing press, and the conveyor belt or web is mounted or removed from this frame via the sub-carriers. The invention makes it possible for a single operator of a machine to simply and quickly change the conveyor belt or web.
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INTRODUCTION
Methods of thin layer preparation for radionuclide sources have been a subject of many publications and review articles (Van der Eijk, W., Oldenhof, W. and Zehner, W. <<Preparation of thin sources, a review>> Nud. Instr. and Meth. 112 (1973) 343; Lowenthal, G. C. and Wyllie, H. A. “Special methods of source preparation”. Nucl. Instr. and Meth. 112 (1973) 353). Amongst the applied techniques are: electrolytic or electrophoretic deposition, evaporation, sputtering or sublimation under vacuum, direct spraying or painting, precipitation and self transfer or drying of a liquid drop directly deposited on a substrate. Only the last method can be used for quantitative source preparation. All other methods require an independent determination of the deposition yield and hence, cannot be regarded as absolute source preparation methods.
Standardization of the activity concentration of radionuclide solutions by some important methods requires the preparation of solid samples with known amounts of the radioactive substance on a suitable substrate. The deposits should also be stable, well defined and rigidly bonded to the substrate. A uniform distribution of the source material over a large area on the supporting substrate minimizes self-absorption.
In most cases, drying of a liquid drop of a radioactive solution results in an agglomeration of crystals, the final size of which depends mainly on the time available for the crystals to grow The usual practice, as described by Van der Eijk and Zehner, in “Preparation of thin sources for absolute beta-counting” Radiochimica Acta 24, 205 (1977), was to dry the sources in a fume hood by the air draft.
The results were often unsatisfactory since large crystals were formed mainly at the boundary of the drop and at dust particle inclusions. In some cases the liquid withdrew to a much smaller area than the initial drop size, resulting in a very inhomogeneous distribution of the deposit.
The uniformity of the deposit was improved by stirring the drop with a dry nitrogen jet (Wyllie, H. A., Johnson, E. P. and Lowenthal, G. C. <<A procedure for stirring aliquots of radioactive solutions when making thin 4π counting sources>>. Int. J. Appl. Radiat. Isot. Vol 21,497 (1970)). However, due to the long drying time of typically 10 to 20 minutes, crystals could still grow to large sizes.
OBJECT OF THE INVENTION
The object of the present invention is to provide a method and a device to prepare a thin and uniform deposit on a solid substrate by accelerated drying of a droplet of a solution containing dissolved crystalline material so as to obtain a solid residue as thin and uniform as possible, firmly bonded to the substrate without loss of dissolved matter.
GENERAL DESCRIPTION OF THE INVENTION
In order to overcome the above mentioned problem, the present invention provides a method of thin layer preparation for a radionuclide source comprising the following steps:
deposition of a drop of a radionuclide dissolved in a solvent onto a on a substrate,
placing said drop in a confined space with a reduced pressure,
directing at least one flow of a hot gas onto the drop,
rotating the source relative to the hot gas jet creating turbulences inside the drop,
evaporating the solvent and obtaining a thin layer of dry radionuclide.
The method allows to prepare a thin and uniform deposit of a radionulcide or any other crystalline product on a solid substrate by accelerated drying of a drop of a solution containing dissolved radionulcide or crystalline material so as to obtain a solid residue as thin and uniform as possible, firmly bonded to the substrate without loss of dissolved matter.
According to a preferred embodiment the flow of a hot gas is lowered as the solvent is evaporated. It is also recommended to lower the temperature of the hot gas flow is lowered as the solvent is evaporated. Preferably, the temperature of the hot gas is varied from about 200° C. to about 50° C. For example, the temperature of the hot gas may be lowered to about 50° C. as soon as about 70 to 90% of the solvent is evaporated. In general, the temperature of the gas flow is not critical.
In a preferred embodiment, at least four flows of hot gas are directed onto said drop and the hot gas flows are spaced symmetrically around said drop. At the beginning of the drying process, the gas flow can be moved from a stand-by position outside said drop towards just inside said drop boundary. The gas flow hit said drop preferably at four diametrically opposite positions so as to keep said drop safely confined.
In order to accelerate the method further, the gas flow is regulated in such a way that a depression is created in the drop and that said the depression does not reach the support substrate.
According to another aspect of the invention an Apparatus for thin layer preparation for a radionuclide source is proposed. The apparatus comprises:
block means with a moving mechanism,
heatable gas injector means movably fixed to said block means,
turntable means mounted on a shaft of a motor, said turntable means comprising a space for removably fixing a support means for said radionuclide source;
bell jar means connected to a vacuum pump for applying a reduced pressure to said bell jar means, said bell jar means covering said turntable means and said gas injector means.
said block means is supported by supporting means comprising power and gas supply means for said gas injector means;
said block means is mounted above said turntable in such a way that said gas injector means are directed towards said support means for said radionuclide source.
The motor may be e.g. a geared asynchronous motor using frequency control to vary rotation speed from 5 to 150 rpm.
According to another aspect of the invention, the gas injector means comprise four gas injectors placed symmetrically with an inclination in a distance above said turntable. Said distance between the gas injector means and the turntable as well as the inclination of the gas injectors are adjustable.
DETAILED DESCRIPTION OF THE INVENTION
The present invention will be more apparent from the following description of not limiting embodiments with reference to the attached drawings, wherein
FIG. 1 shows a schematic drawing of the device according to a preferred embodiment of the invention,
FIG. 2 shows the cross section of the hot gas injectors,
FIG. 3 represents microphotographs documenting crystal size and distribution of two TINO 3 deposits: (a) and (b) dried according to the described prior art method, (c) and (d) drying accelerated by the new drying device,
FIG. 4 represents contour maps of the shape and activity distribution of 237 Np sources obtained from scanning of autoradiographs. The sources were prepared by: (a) drying according to the described prior art method, (b) drying accelerated by the new drying device and (c) sublimation of 237 NpF 4 under vacuum.
Quantitative sources are prepared by drying a drop of known mass of the radioactive solution on various supporting substrates. First, a seeding agent of diluted colloidal silica (LUDOX form E.I. DuPont de Nemours & Co (Inc.) Chemicals and Pigments Dept Wilmington, Del. USA) is deposited on the substrate. In case of a hydrophobic surface, like chromium-plated glass, a wetting agent is used to extend the drop size. Finally, a liquid drop of the radionuclide solution is dispensed from a polyethylene pycnometer onto the substrate. Drop masses ranging from 10 to 50 mg can be determined with an accuracy of approximately 5 μg by weighing the pycnometer before and after drop dispense.
The drying apparatus 10 as represented on FIG. 1 comprises a block 12 with a moving mechanism and four movable gas injectors 14 (two of which are shown). The block 12 is mounted above a turntable 16 on a supporting tube 18 which is also the power and gas supply duct of the gas injectors 14 . The turntable 16 is covered by a bell jar (not shown) and attached to a vacuum pump (not shown).
The turntable 16 is directly mounted on the shaft 20 of a geared asynchronous motor 22 using frequency;control to vary the rotation speed from 5 to 150 rpm.
The source substrate 24 with the deposited drop 26 of radionuclide dissolved in a solvent (mainly water), carried on a circular transport tray, is centered on the turntable 16 over the shaft 20 . The top of the turntable is then covered by the bell jar (not shown) and pumping is started to reach a pre-set pressure of about 10 kPa. In the meantime, rotation is started at a low speed to prevent a possible asymmetric liquid drop to sling off from the center. Finally, the gas injectors 14 are moved from a stand-by position outside the drop 26 towards just inside the drop boundary and start to stir the liquid. The gas jets hit the drop 26 at four diametrically opposite positions and keep the liquid safely confined in the center. The depression in the drop surface should not reach the supporting substrate; otherwise additional three-phase boundaries would be created inside the drop, which disturbs the uniform drying.
As the drop reduces in size, the rotation speed is increased for better stirring of the liquid and the temperature of the gas jets is reduced to avoid overheating of the drop. Mixing of the now already concentrated liquid layer is continuing. By adapting the impact positions of the gas jets to the shape of the liquid layer one can keep the liquid evenly spread. Fast rotation of the turntable and movements of the jets are continued until a uniform dry deposit is obtained.
To confine drops 26 of various sizes at the center of the spinning substrate 24 the four gas injectors 14 placed concentric above the turntable 16 are engaged. They are mounted diametrically opposed to each other and can be moved simultaneously. The gas jets emitted by the gas injectors 14 cause turbulence within the drop 26 and stir the remaining liquid during drying.
Only two of the four gas injectors 14 are shown. All four gas injectors 14 are mounted symmetrically into a supporting block 12 that conducts the drying gas and contains the supply cables for the heating power. The distance between the gas injectors 14 and the turntable 16 and the inclination of the gas injectors 14 are adjustable. The inclination and the distance of the gas injectors 14 with respect to the source plane, and hence their impact positions on the drop 26 , can be remotely controlled during the drying process. The operator is able to observe the drying process through the transparent bell jar. He can adapt the position of the gas injectors 14 to meet the drop size and vary the nitrogen flow rate and temperature externally.
Placing a bell jar over the turntable 16 creates a closed and dust-free environ- ment around the drop source 26 . Pumping is needed to remove the water vapor from the closed recipient and allows to control the pressure between 5 kPa and 101.3 kPa, which additionally accelerates the evaporation.
All gases introduced into the bell jar are filtered to ensure that no dust particles contaminate the source.
The immediate removal of the saturated vapor from the drop 26 surface by the jet blows and subsequent extraction by the vacuum pump reduces the drop drying time to a few minutes. Due to the drastically reduced crystal growing time, the resulting deposit consists of a large number of small crystals that are uniformly distributed over the initial area of the drop size. Such deposits are comparable to layers formed by vacuum sublimation, one of the best but non-quantitative deposit-preparation methods (FIG. 3 ). The turbulence and stirring prevents the accumulation of large crystals at the three-phase boundary between the drop 26 and the substrate 24 around the drying source, which guarantees a clean environment excluding dust particles to merge with the source material during the drying process.
Intense evaporation begins when the temperature and the flows of the gas jet are set high. In this phase, mainly water evaporates and only a film of the concentrated acid solution and remains on the substrate. At this point, the heat input to the gas jets can be reduced to limit the temperature rise of the deposit and substrate and to reduce the build-up of material stresses in the deposit. These stresses may tear a thin foil substrate or reduce adherence between the deposit and the substrate.
The maximum temperature of the gas flow depends mainly on the substrate 24 . The temperatures must be regulated in such a way that the substrate is not damaged. In case the substrate is made of plastic material the temperatures must be lower than for substrates made of glass.
The gas injectors 14 are shown in more detail in FIG. 2 . The gas injector 14 comprises a gas duct 28 having an inlet 30 and an outlet or nozzle 32 . A hinge 34 to mount the gas injectors 14 into the supporting block 12 is fitted on the Lipper end 3 , 6 of the gas duct 28 . Inside the gas duct 28 is placed a heating element 38 consisting of a helix of resistive wire on a glass tube core 40 placed close to the nozzle 32 of the injector 14 . Two thin-walled tubes thermally insulate the gas duct 28 .
The gas jets formed by the narrow nozzle 32 of the gas injectors 14 at an elevated temperature are impacting directly onto the rotating liquid drop 26 deposited on a substrate 24 . A sensor to monitor the temperature of the gas flow is attached to the nozzle 32
To increase the temperature of the gas jets emitted by the gas injectors 14 up to 200° C., electric heating elements 38 made of helical resistance wire 40 are placed close to the nozzle 30 of the injectors 14 .
To reduce a temperature drop at the relatively low gas-flow rate of about 300 cm 3 min −1 , thermal insulation of the gas duct 28 was necessary. A prompt response of the gas jet temperature to changes of the heating power input was obtained by minimizing all masses in contact with the heated gas. The nozzle 32 shape was optimized to form gentle impacts of the gas jets on the drop surface.
By using multiple gas jets at an elevated temperature and rotating the source at the same time the evaporation of the solvent was accelerated substantially and turbulences were caused within the drop. This turbulence prevented the formation of a few large crystals at the three-phase boundary between the drop and the substrate. As a result of the steady remixing, a large number of small crystals, uniformly distributed over the original drop size, were formed.
The homogeneous distribution of the source material was confirmed by qualitative and quantitative methods. The quality of the layers, concerning the crystal size and distribution, was:documented by microphotographs of TINO3 deposits taken with a stereo microscope (FIG. 3 ). Concentration at the boarder of the deposit and few crystals of up to 80 μm were found in normally dried deposits FIGS. 3 a and 3 b ). A much better distribution and crystals smaller than 10 μm were found when the accelerated drying technique according to the invention was used (FIGS. 3 c and 3 ).
The uniformity of the activity distribution of different 237 Np sources was documented by autoradiography using 3H-sensitive films at a distance of 0.3 mm from the source. The films were exposed for various times to trace also low-activity spots on the sources and to stay within the linear range of the emulsions. A subsequent scanning of the autoradiographs and plotting of the contour maps revealed the shape and distribution of the deposits quantitatively (FIG. 4 ).
A sensitive quality indicator of the crystal size was found in the low-energy tailing seen in the peak shape of a particle spectra of 237 Np sources also used for the autoradiographs of FIG. 4. A figure of merit was obtained from the peak-fitting parameters of a spectrum deconvolution as described by Babeliowsky T. and Bortels G., 1993. ALFA: <<A program for accurate analysis of complex alpha-particle spectra on a PC>>; Appl. Radiat. Isot. 44, 1349) using a Gaussian peak shape combined with two exponential tails as a model. Energy absorption and straggling of the alpha particles in the source material does not affect the Gaussian peak width , σ, but it increases the value of both exponential tails, τ 1 , and τ 2 drastically. In table 1, the shape parameters are given in channels;: each channel corresponds to 0.6 keV. All shape parameters of the two 237 Np drop sources, also used for the autoradiographs of FIG. 4, were compared with those of a 237 NpF 4 source produced by vacuum sublimation, one of the best available, however, non-quantitative source preparation methods (see Table 1). The improvement of the deposit quality is clearly seen in both tail parameters. The FWHM is less sensitive to the source thickness and uniformity since it is a convolution of the individual peak-shape parameters.
TABLE 1
Peak shape parameters
Gauss
Tail weight
Source
Source type
shape σ
Short tail τ 1
Long tail τ 2
ratio η
FWHM
activity Bq
Normal
4.3
51
300
0.13
33.3
318
drying
Accelerated
4.56
15.5
93
0.23
15.1
1463
drying
Vacuum
4.23
5.32
25.4
0.06
9.28
444
sublimation
The results obtained with the new accelerated drying technique are very encouraging. Sources could be dried in less than 3 minutes, which is shorter than the drop weighing and deposition time. The quality and production speed of quantitative source preparation were significantly improved. Of importance is also the closed volume. It is recommended to place the dried sources immediately into a desiccator to avoid the absorption of water and to prevent recrystallisation, which increases self-absorption, in particular when the deposits are hygroscopic.
Reference List
10
Drying apparatus
12
Supporting block
14
Gas injectors
16
turntable
18
Supporting tube
20
Shaft
22
motor
24
Substrate
26
Drop
28
Gas duct
30
Inlet
32
outlet or nozzle
34
Hinge
36
Upper end
38
Heating element
40
Heating wire
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Method of thin layer preparation for a radionuclide source comprising the following steps:
deposition of a drop of a radionuclide dissolved in a solvent onto a on a support substrate,
placing said support substrate with said drop in a confined space with a reduced pressure,
directing at least one flow of a hot gas onto the drop,
rotating the source relative to the hot gas jet creating turbulences inside the drop,
evaporating the solvent and obtaining a thin layer of dry radionuclide.
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TECHNICAL FIELD
[0001] The present disclosure generally relates to integrated circuits. More specifically, the present disclosure relates to packaging integrated circuits.
BACKGROUND
[0002] Electronic devices are continually shrinking in size to improve portability of the electronic devices. For example, cellular telephones have recently decreased in size to fit in shirt pockets, and are continuing to decrease in size. As the devices shrink, the components inside the device, including the integrated circuits, also shrink. In integrated circuits, a significant amount of the overall thickness is the die rather than circuitry on the die. One method of decreasing the integrated circuit thickness uses thinner dies for the integrated circuits.
[0003] Thin dies are fragile and difficult to handle during manufacturing processes. For example, when heating a thin die during reflow, unbalanced stresses in the die cause the die to warp. Warpage results in poor contact between interconnects (e.g., non-wets) leading to yield and reliability problems at die thicknesses less than 100 micrometers. A conventional die attach process having wafer warpage is illustrated in FIGS. 1A-1B .
[0004] FIG. 1A is a cross-sectional view illustrating a conventional packaged integrated circuit before heating. A die 120 with interconnects 122 is coupled to a substrate 102 having interconnects 110 . The interconnects 122 are attached to the interconnects 110 through a flux material 112 . The die 120 and the substrate 102 are heated to reflow the interconnects 122 and the interconnects 110 and bond the interconnects 122 with the interconnects 110 .
[0005] FIG. 1B is a cross-sectional view illustrating a conventional packaged integrated circuit after heating. During heating, the die 120 may warp due to unbalanced stresses. Warpage at edges of the die 120 is larger than the center of the die 120 . As a result, connections 130 are created between the interconnects 122 and the interconnects 110 in the center of the die 120 . However, non-wets 132 occur between the interconnects 122 and the interconnects 110 at the edges of the die 120 .
[0006] The non-wets 132 reduce yield and reliability of integrated circuits manufactured that include the die 120 . Thus, there is a need for an improved method of attaching thin dies during manufacturing of integrated circuits.
BRIEF SUMMARY
[0007] According to one aspect of the disclosure, a method of packaging includes depositing a sacrificial material on a die. The method also includes attaching a first group of interconnects of the die to a second group of interconnects of a substrate after depositing the sacrificial material on the die. The method further includes heating the die to a first temperature after depositing the sacrificial material. The first temperature causing the first group of interconnects of the die to connect to the second group of interconnects of the substrate. The method also includes heating the die to a second temperature after heating the die to the first temperature. The second temperature causes the sacrificial material to sublime.
[0008] According to another aspect of the disclosure, a method of packaging includes the step of depositing a sacrificial material on a die. The method also includes the step of attaching a first group of interconnects of the die to a second group of interconnects of a substrate after depositing the sacrificial material on the die. The method further includes the step of heating the die to a first temperature after depositing the sacrificial material. The first temperature causing the first group of interconnects on the die to connect to the second group of interconnects on the substrate. The method also includes the step of heating the die to a second temperature after heating the die to the first temperature. The second temperature causing the sacrificial material to sublimate.
[0009] According to a further aspect of the disclosure, an apparatus includes a substrate having a first group of interconnects. The apparatus also includes a die having a second group of interconnects attached to the first group of interconnects. The apparatus further includes a sacrificial layer on a side of the die opposite the second group of interconnects. The sacrificial layer has a sublimation temperature above the liquidus temperature of the second group of interconnects.
[0010] According to another aspect of the disclosure, an apparatus includes a substrate having a first group of interconnects. The apparatus also includes a die having a second group of interconnects attached to the first group of interconnects. The apparatus further includes means for reducing warpage on a side of the die opposite the second group of interconnects. The warpage reducing means has a sublimation temperature above the liquidus temperature of the second group of interconnects.
[0011] The foregoing has outlined rather broadly the features and technical advantages of the present disclosure in order that the detailed description that follows may be better understood. Additional features and advantages will be described hereinafter which form the subject of the claims of the disclosure. It should be appreciated by those skilled in the art that the conception and specific embodiments disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present disclosure. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the technology of the disclosure as set forth in the appended claims. The novel features which are believed to be characteristic of the disclosure, 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 disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] For a more complete understanding of the present disclosure, reference is now made to the following description taken in conjunction with the accompanying drawings.
[0013] FIG. 1A is a cross-sectional view illustrating a conventional packaged integrated circuit before heating for die attach.
[0014] FIG. 1B is a cross-sectional view illustrating a conventional packaged integrated circuit after heating for die attach.
[0015] FIG. 2 is a flow chart illustrating an exemplary process flow for die attach with thin dies according to one embodiment.
[0016] FIG. 3A is a cross-sectional view illustrating an exemplary die after deposition of a sacrificial material according to one embodiment.
[0017] FIG. 3B is a cross-sectional view illustrating an exemplary die after heating to a first temperature according to one embodiment.
[0018] FIG. 3C is a cross-sectional view illustrating an exemplary die after heating to a second temperature according to one embodiment.
[0019] FIG. 3D is a cross-sectional view illustrating an exemplary die after removal of the sacrificial material according to one embodiment.
[0020] FIG. 4A is a graph illustrating a temperature applied during die attach according to one embodiment.
[0021] FIG. 4B is a graph illustrating a thickness of a sacrificial material during die attach according to one embodiment.
[0022] FIG. 5 is a flow chart illustrating an exemplary process flow for die attach with stacked thin dies according to one embodiment.
[0023] FIG. 6 is a block diagram showing an exemplary wireless communication system in which an embodiment of the disclosure may be advantageously employed.
[0024] FIG. 7 is a block diagram illustrating a design workstation used for circuit, layout, and logic design of a semiconductor component according to one embodiment.
DETAILED DESCRIPTION
[0025] Depositing a sacrificial material during packaging of an integrated circuit (IC) with a thin die temporarily increases the thickness of the thin die to provide additional support for the die. For example, during solder reflow high temperatures applied to a die may cause warpage of a die having a thickness below 100 micrometers. A sacrificial material may be deposited on the thin die before stacking on a substrate and before application of high temperatures in order to inhibit warpage of the die during reflow. The sacrificial material may be used in packaging techniques such as face-to-face die bonding or other technologies in which contacts of the die are facing the substrate or printed circuit board.
[0026] FIG. 2 is a flow chart illustrating an exemplary process flow for die attach with thin dies according to one embodiment. An exemplary process for die attach begins at block 210 with depositing sacrificial material. FIG. 3A is a cross-sectional view illustrating an exemplary packaged integrated circuit after deposition of a sacrificial material according to one embodiment. A sacrificial material 330 is deposited on a die 320 . The die 320 may be, for example, silicon, glass, or sapphire. The sacrificial material 330 may be, for example, polyethylene carbonate (PEC) or polypropylene carbonate (PPC). According to one embodiment, the sacrificial material 330 is spun on to the die 320 at a thickness of between 10 and 100 micrometers. In another embodiment, the sacrificial material 330 may be deposited by chemical vapor deposition (CVD). The die 320 having interconnects 322 is placed on a substrate 302 having interconnects 304 . According to one embodiment, the interconnects 322 are microbumps for flip chip packaging. According to another embodiment, through silicon stacking with or without through vias may be used for stacking. A flux material 306 between the interconnects 304 and the interconnects 322 holds the die 320 in place before heating. According to one embodiment, the flux material may be rosin-based.
[0027] In one embodiment, the sacrificial material 330 has a sublimation temperature above the liquidus temperature of the interconnects 304 and the interconnects 322 . For example, the liquidus temperature of eutectic SnPb is approximately 183 degrees Celsius and the liquidus temperature of SAC 305 is approximately 221 degrees Celsius.
[0028] The die attach process continues to block 220 and heats the die 320 to a first temperature. FIG. 3B is a cross-sectional view illustrating an exemplary die after heating to a first temperature according to one embodiment. The first temperature may be selected to significantly bond the interconnects 322 with the interconnects 304 . During bonding of the interconnects 322 , the flux material 306 activates and cleans oxide from the solder surface. At the first temperature, thickness of the sacrificial material 330 is substantially constant and provides support for the die 320 to inhibit warpage.
[0029] After heating the die to the first temperature at block 220 , the die is heated to a second temperature at block 230 . FIG. 3C is a cross-sectional view illustrating an exemplary die after heating to a second temperature according to one embodiment. At the second temperature, the sacrificial material 330 sublimes resulting in removal of substantially all the sacrificial material 330 . According to one embodiment, the second temperature is applied for approximately 45-90 seconds to cause sublimation of the sacrificial material 330 . According to another embodiment, the sacrificial material 330 may be partially etched or ground away and a heating process applied to remove remaining residue of the sacrificial material 330 .
[0030] FIG. 3D is a cross-sectional view illustrating an exemplary packaged integrated circuit after removal of the sacrificial material according to one embodiment. Removal of substantially all of the sacrificial material 330 on the die 320 facilitates good adhesion to subsequent backside die attach material or overmold materials during packaging. Sacrificial material 330 remaining on the die 320 may inhibit bonding of additional materials to the die 320 .
[0031] According to one embodiment, a heating process for die attach of the die 320 to the substrate 302 is described with respect to FIGS. 4A-4B . FIG. 4A is a graph illustrating a temperature applied during die attach according to one embodiment. A line 400 represents the temperature applied to a die during a die attach process. FIG. 4B is a graph illustrating a thickness of a sacrificial material during die attach according to one embodiment. A line 420 represents thickness of a sacrificial material on a die during a die attach process.
[0032] At block 220 , the die is heated to the first temperature, T 1 , at a first time, t 1 , as illustrated by point 402 on the line 400 . A thickness of the sacrificial material at the first time, t 1 , is illustrated as point 422 on the line 420 . At the first temperature, T 1 , interconnects of the die bond to interconnects of the substrate. The first temperature, T 1 , may be, for example, a liquidus temperature of the interconnects. At the first temperature, the thickness of the sacrificial material is substantially constant as indicated by the point 422 on the line 420 .
[0033] At block 230 , the die is heated to a peak temperature of the process, a second temperature, T 2 , at a second time, t 2 , as illustrated by point 404 on the line 400 . A thickness of the sacrificial material at the second time, t 2 , is illustrated as point 424 on the line 420 . At the second temperature, T 2 , the sacrificial material thins until substantially no sacrificial material remains on the die. The second temperature, T 2 , may be, for example, a decomposition temperature of the sacrificial material.
[0034] Although the line 400 is shown as one set of temperature, the line 400 may take on different profiles. For example, the line 400 may be a continuous ramp without local maximums. In one embodiment, a continuous ramp may be used in tape automated bonding (TAB) to sublimate the sacrificial material 330 .
[0035] A sacrificial material applied to a thin die during die attach provides additional support for the thin die and inhibits warpage of the thin die. After die attach using the sacrificial material, the thin die may be incorporated into an integrated circuit. The sacrificial material may be selected such that the sacrificial material remains substantially the same thickness at temperatures used for bonding of the interconnects, such as solder liquidus temperatures and sublimates at peak temperatures of the die attach process.
[0036] A die attach process using the sacrificial material may apply a first temperature for reflow during which the sacrificial material remains substantially the same thickness. The die attach process may apply a second temperature during which the sacrificial material decomposes resulting in removal of substantially all of the sacrificial material. The sacrificial material allows manufacturing using thin dies, such as those below 100 micrometers in thickness, and production of thin electronic devices.
[0037] The die attach process and sacrificial material may also be applied during stacking of dies as illustrated in the flow chart of FIG. 5 , which continues from the flow shown in FIG. 2 . According to one embodiment, at block 540 a second tier die may be attached to a first tier die with a flux material through a interconnects on the first tier die and the second tier die. At block 550 , a second sacrificial material is deposited on the second tier die to inhibit warpage of the second tier die. At block 560 , the second tier die is heated to a third temperature causing the interconnects on the second tier die to connect to the interconnects of the first tier die. At block 570 , the second tier die is then heated to a fourth temperature causing the sacrificial material to sublimate. According to one embodiment, the third and fourth temperature are equal to the first and second temperature, respectively.
[0038] FIG. 6 shows an exemplary wireless communication system 600 in which an embodiment of the disclosure may be advantageously employed. For purposes of illustration, FIG. 6 shows three remote units 620 , 630 , and 650 and two base stations 640 . It will be recognized that wireless communication systems may have many more remote units and base stations. Remote units 620 , 630 , and 650 include improved packaged ICs 625 A, 625 C, and 625 B, respectively, which are embodiments as discussed above. FIG. 6 shows forward link signals 680 from the base stations 640 and the remote units 620 , 630 , and 650 and reverse link signals 690 from the remote units 620 , 630 , and 650 to base stations 640 .
[0039] In FIG. 6 , the remote unit 620 is shown as a mobile telephone, the remote unit 630 is shown as a portable computer, and the remote unit 650 is shown as a computer in a wireless local loop system. For example, the remote units may be cell phones, hand-held personal communication systems (PCS) units, portable data units such as personal data assistants, fixed location data units such as meter reading equipment, set top boxes, music players, video players, entertainment units, navigation devices, or computers. Although FIG. 6 illustrates remote units according to the teachings of the disclosure, the disclosure is not limited to these exemplary illustrated units. The disclosure may be suitably employed in any device which includes packaged ICs.
[0040] FIG. 7 is a block diagram illustrating a design workstation used for circuit, layout, and logic design of a die or a circuit implemented on a die as disclosed below. A design workstation 700 includes a hard disk 701 containing operating system software, support files, and design software such as Cadence or OrCAD. The design workstation 700 also includes a display to facilitate design of a circuit 710 or a semiconductor component 712 such as a wafer or die. A storage medium 704 is provided for tangibly storing the circuit design 710 or the semiconductor component 712 . The circuit design 710 or the semiconductor component 712 may be stored on the storage medium 704 in a file format such as GDSII or GERBER. The storage medium 704 may be a CD-ROM, DVD, hard disk, flash memory, or other appropriate device. Furthermore, the design workstation 700 includes a drive apparatus 703 for accepting input from or writing output to the storage medium 704 .
[0041] Data recorded on the storage medium 704 may specify logic circuit configurations, pattern data for photolithography masks, or mask pattern data for serial write tools such as electron beam lithography. The data may further include logic verification data such as timing diagrams or net circuits associated with logic simulations. Providing data on the storage medium 704 facilitates the design of the circuit design 710 or the semiconductor component 712 by decreasing the number of processes for designing semiconductor wafers.
[0042] The methodologies described herein may be implemented by various components depending upon the application. For example, these methodologies may be implemented in hardware, firmware, software, or any combination thereof. For a hardware implementation, the processing units may be implemented within one or more application specific integrated circuits (ASICs), digital signal processors (DSPs), digital signal processing devices (DSPDs), programmable logic devices (PLDs), field programmable gate arrays (FPGAs), processors, controllers, micro-controllers, microprocessors, electronic devices, other electronic units designed to perform the functions described herein, or a combination thereof.
[0043] For a firmware and/or software implementation, the methodologies may be implemented with modules (e.g., procedures, functions, and so on) that perform the functions described herein. Any machine-readable medium tangibly embodying instructions may be used in implementing the methodologies described herein. For example, software codes may be stored in a memory and executed by a processor unit. Memory may be implemented within the processor unit or external to the processor unit. As used herein the term “memory” refers to any type of long term, short term, volatile, nonvolatile, or other memory and is not to be limited to any particular type of memory or number of memories, or type of media upon which memory is stored.
[0044] If implemented in firmware and/or software, the functions may be stored as one or more instructions or code on a computer-readable medium. Examples include computer-readable media encoded with a data structure and computer-readable media encoded with a computer program. Computer-readable media includes physical computer storage media. A storage medium may be any available medium that can be accessed by a computer. By way of example, and not limitation, such computer-readable media can comprise RAM, ROM, EEPROM, CD-ROM or other optical disk storage, magnetic disk storage or other magnetic storage devices, or any other medium that can be used to store desired program code in the form of instructions or data structures and that can be accessed by a computer; disk and disc, as used herein, includes compact disc (CD), laser disc, optical disc, digital versatile disc (DVD), floppy disk and blu-ray disc where disks usually reproduce data magnetically, while discs reproduce data optically with lasers. Combinations of the above should also be included within the scope of computer-readable media.
[0045] In addition to storage on computer readable medium, instructions and/or data may be provided as signals on transmission media included in a communication apparatus. For example, a communication apparatus may include a transceiver having signals indicative of instructions and data. The instructions and data are configured to cause one or more processors to implement the functions outlined in the claims.
[0046] Although the present disclosure 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 technology of the disclosure 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, 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 disclosure. 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 sacrificial material applied to a thin die prior to die attach provides stability to the thin die and inhibits warpage of the thin die as heat is applied to the die and substrate during die attach. The sacrificial material may be a material that sublimates at a temperature near the reflow temperature of interconnects on the thin die. A die attach process deposits the sacrificial material on the die, attaches the die to a substrate, and applies a first temperature to reflow the interconnects. At the first temperature, the sacrificial material maintains substantially the same thickness. A second temperature is applied to sublimate the sacrificial material leaving a clean surface for the later packaging processes. Examples of the sacrificial material include polypropylene carbonate and polyethylene carbonate.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. patent application Ser. No. 15/590,797, filed May 9, 2017, pending, which is a divisional of U.S. patent application Ser. No. 15/216,884, filed Jul. 22, 2016, now U.S. Pat. No. 9,676,764, issued Jun. 13, 2017, which is a divisional of U.S. patent application Ser. No. 14/383,083, filed Sep. 4, 2014, now U.S. Pat. No. 9,453,012, issued Sep. 27, 2016, which is a national phase entry under 35 U.S.C. § 371 of International Patent Application PCT/EP2013/054449, filed Mar. 5, 2013, designating the United States of America and published in English as International Patent Publication WO 2013/131931 Al on Sep. 12, 2013, which claims the benefit under Article 8 of the Patent Cooperation Treaty to European Patent Application Serial No. 12183784.3, filed Sep. 10, 2012, and to European Patent Application Serial No. 12158253.0, filed Mar. 6, 2012, the disclosure of each of which is hereby incorporated herein in its entirety by this reference.
TECHNICAL FIELD
[0002] The invention is in the field of medicinal treatment of carcinoma, in particular, by using a compound with a core structure of aminomethylene pyrazolone.
BACKGROUND
[0003] Carcinomas, which are cancers that originate from epithelial tissues, comprise the most dangerous types of cancers. Gastric, bladder and esophageal cancer are examples of carcinomas of epithelial origin. Glandular tissue often is of epithelial origin, so that breast cancer, prostate cancer and pancreas cancer also belong to the group of cancers from epithelial origin.
[0004] If a carcinoma is diagnosed early and still localized, the disease is curable by surgery, radiation therapy with or without (neo)adjuvant and chances of survival are high (>90%). However, in early stages, cancers can grow slowly and can remain locally confined for many years without causing overt symptoms. Notorious in this respect is prostate cancer. Therefore, such types of cancer often remain undiagnosed until cancerous cells have already spread beyond the prostate into the surrounding tissues (local spread) or eventually migrate (metastasize) through the blood stream or lymphatic spread into other areas of the body.
[0005] Progressive growth of epithelial cancer and invasive metastasis involves a multistep process. Tumors can generally not grow beyond a certain size, due to a lack of oxygen and other essential nutrients. However, tumors induce blood vessel growth by secreting various growth factors that induce capillary growth into the tumor to supply nutrients, allowing for tumor expansion. This physiological process is called angiogenesis. Angiogenesis is a normal and vital process in growth and development, such as in wound healing, but also a fundamental step in the transition of tumors from small harmless clusters of cells to a malignant tumor. Angiogenesis is also required for the spread, or metastasis, of a tumor. Single cancer cells can break away from an established solid tumor, enter the blood vessel, and be carried to a distant site, where they can implant and begin the growth of a secondary tumor. Such spread to other tissues (metastasis) involves invasion of other parts of the body by mesenchymal cells. Cancer cell invasion and spread is determined by epithelial-mesenchymal-transition (EMT). The spread to other tissues is preceded by transition of the epithelial cells to mesenchymal cells, indicated as epithelial-mesenchymal transition (EMT). Thereby the incipient cancer cells acquire mesenchymal, fibroblast-like properties and show reduced intercellular adhesion and increased motility, endowing the incipient cancer cells with invasive and metastatic properties. The reversed process in which mesenchymal-to-epithelial transition (MET), creates new secondary tumors at the other sites. Many patients die when diagnosed with an aggressive form of cancer in which the cancerous cells have spread, or metastasized.
[0006] It is important to improve the efficacy of medicinal treatment by providing compounds that can interfere with the metastasis of cells, more in particular, compounds that can reverse EMT or interfere with the process of EMT.
[0007] Some treatment options of carcinomas are available, but are of limited success and provide no permanent cure. For prostate or breast cancer endocrine therapy, also called hormone deprivation therapy, has long been considered as the main suppression therapy to control neoplasms. The goal is to limit the body's production of the hormones. However, current endocrine therapy does not cure prostate or breast cancer. Moreover, it has become clear that expansive growth of cancer cells that become unresponsive (resistant) to the current available endocrine therapies is inevitable. In addition, it was found that in the majority of advanced cancers the hormone receptor mediated signaling pathway is still active, even at extremely low hormone levels. At this stage, the cancer can no longer be treated with available therapy and often results in progression to a lethal disease.
[0008] New chemotherapeutic drugs demonstrating improved response rates and prolonged survival are being developed. One of the examples is docetaxel (Taxotere). Unfortunately, chemotherapy reaches all parts of the body, not just only the cancer cells. It has been established that these therapies have serious side effects. Patients will undergo low blood cell counts, nausea, vomiting, abdominal pain, diarrhea, hair loss, impotence, incontinence and other unwanted symptoms. Hence, the side effects significantly hamper the quality of life of the patients. Many scientists are convinced that this treatment will offer little room for future improvements and has come close to the end of its product life cycle. Docetaxel is the current standard of care for patients that are unresponsive to the currently available endocrine therapies. In view of limited curative potential of docetaxel, and also in view of better understanding of the underlying etiology of the disease and improved early diagnosis, there is an urgent need for novel treatment strategies to prevent the progression, treat the tumor and avoid metastasis of this disease. In the present invention new compounds and a new use of such compounds for use in these novel treatment strategies are found within a chemical group with a core structure of 4-(aminomethylene)-2-(2-benzothiazolyl)-2,4-dihydro-3H-pyrazol-3-one or 4-(aminomethylene)-2-(1H-benzimidazol-2-yl)-2,4-dihydro-3H-pyrazol-3-one. In Wu et al. ( J. Med. Chem ., vol. 55-2597-2605; 2012) a compound 2-(2-benzothiazolyl)-4-[1-[[(3,4-dichlorphenyl)methyl]amino]ethylidene]-2,4-dihydro-5-(trifluoromethyl)-3H-pyrazol-3-one is drawn in a table, whereby some weak activity in one of the used biochemical assays for inhibition of 5-lipoxygenase is displayed. The activity is not confirmed in a second assay, so a speculative link to any therapeutic activity cannot be justified from this information. In published texts on suggested inhibitors of O-linked and N-linked glycan glycosylation two structures of compounds within this chemical group, namely 2-(2-benzothiazolyl)-4-[1-[(2-ethoxyphenyl)amino]ethylidene]-2,4-dihydro-5-phenyl-3H-pyrazol-3-one and 2-(2-benzothiazolyl)-2,4-dihydro-4-[[[(4-methoxyphenyl])methyl]amino]methylene]-5-phenyl-3H-pyrazol-3-one are drawn without indicating a method of synthesis. In this context the possibility is discussed of therapeutic activity of such inhibitors, but such a target is not plausibly validated as model for any treatment target. Compounds with the mentioned core structures seem also to have been passed in screening tests with targets for anti-infective effects (U.S. 2003/0229065), for: “Life span prolongation” (WO 2009/086303, U.S. 2009/163545), for herbicide and fungicide activity (EP0274642), for muscular dystrophy (WO 2007/091106) and for anti-inflammatory effects by phosphodiesterase inhibition (PDE4) (WO 2008/045664). In WO 2005/094805 the compound 2-(2-benzothiazolyl)-4-[(dimethylamino)methylene]-2,4-dihydro-5-methyl-3H-pyrazol-3-one is used as synthesis intermediate. In compounds in Reis et al. ( Eur. J. Med. Chem . vol. 46, pp. 1448-1452, 2011) the aminomethylene pyrazolone structure may be recognized in a fixed structure of pyrazoloquinolinones. None of these disclosures reach out to the present invention.
BRIEF SUMMARY
[0009] The present invention provides for compounds having the structure according to formula I:
[0000]
[0010] wherein:
X is NH or S; R 1 is H or (1C-4C)alkyl; R 2 is (1C-4C)alkyl, phenyl or a monocyclic aromatic ring having one or more N—, O— or S— atoms in the ring, which alkyl, phenyl or aromatic ring is optionally substituted with one or more groups selected from (1C-4C)alkyl, (1C-4C)alkyloxy, halo(1C-4C)alkyl, halo(1C-4C)alkyloxy, phenyloxy, phenylthio, halogen, or nitro; R 3 and R 4 are each independently H, (1C-6C)alkyl, (2C-6C) alkenyl, (2C-6C)alkynyl, cyano, (3C-6C)cycloalkyl, phenyl, a monocyclic aromatic ring having one or more N—, O— or S— atoms in the ring, a monocyclic non-aromatic ring having one or more N—, O— or S— atoms in the ring, each optionally substituted with hydroxyl, (1C-4C)alkoxy, phenyl, cycloalkyl, piperidyl, piperazinyl, furyl, thienyl, pirazinyl, pyrrolyl, 2H-pyrrolyl, pyrazolyl, isoxazolyl, isothiazolyl, pyrrolidonyl, pyrrolinyl, imidazolinyl, imidazolyl, a monocyclic aromatic ring having one or more N—, O— or S— atoms in the ring, whereby each of these optional substituents is optionally further substituted with (1C-4C)alkyl, (1C-4C)alkyloxy, halo(1C-4C)alkyl, halo(1C-4C)alkyloxy, halogen, nitro or (1C-2C)dioxol forming a ring; or R 3 and R 4 form together pyrrolyl, imidazolyl, pyrazolyl, pyrrolidinyl, pyrrolinylimidazolidinyl, imidazolinyl, piperidyl, piperazinylmorpholinyl, each optionally substituted with (1C-6C)alkyl, phenyl(1C-4C)alkyl, phenylketo(1C-4C)alkyl; R 5 is H or CF 3 ; R 6 is H, (1C-4C)alkyl, (1C-4C)alkyloxy, halo(1C-4C)alkyl, halo(1C-4C)alkyloxy, nitro or halogen; and pharmaceutically acceptable addition salts thereof.
[0019] Such compounds may advantageously be used for therapy, i.e., the prevention or treatment of a disease. More in particular, they may be used in the prevention or treatment of a carcinoma. Even more in particular, the compounds according to the invention may be used in the treatment or prevention of metastasis of a carcinoma.
[0020] The term “carcinoma” is used herein to indicate a cancer of epithelial origin, more in particular, a disease selected from the group consisting of gastric cancer, bladder cancer, esophageal cancer, breast cancer, prostate cancer or pancreas cancer. In particular, the use for the treatment or prevention of metastasis of prostate cancer is preferred.
[0021] In a more specific embodiment, the invention is directed to a compound having the structure and meanings of symbols according to formula I and wherein R 3 and R 4 are independently hydrogen, methyl, ethyl, or propyl or a group as represented in the following list of structures:
[0000]
[0022] Or R 3 ad R 4 form together an optionally substituted ring as represented in the following structures:
[0000]
[0023] Other embodiments of the invention are compounds according to the above defined embodiments, but therein:
R 1 is H or (1C-4C)alkyl; R 2 is (1C-4C)alkyl, phenyl or a monocyclic aromatic ring having one or more N—, O— or S— atoms in the ring, which alkyl, phenyl or aromatic ring is optionally substituted with one or more groups selected from (1C-4C)alkyl, OCF 3 or halogen; and R 5 and R 6 are hydrogen; or pharmaceutically acceptable addition salts thereof.
[0027] Preferred embodiments of the invention are as those defined above but wherein the meaning of X is S.
[0028] Other preferred embodiments are those as defined above, wherein R 1 is H or (1C-4C)alkyl and wherein R 2 is (1C-4C)alkyl or phenyl.
[0029] Other preferred embodiments are the embodiments as defined above wherein R 3 and R 4 are both methyl or wherein R 3 is hydrogen and R 4 is as defined in the respective embodiments above.
[0030] More specific embodiments are those as defined above, but wherein R 6 is (1C-4C)alkyl, (1C-4C)alkyloxy, halo(1C-4C)alkyl, halo(1C-4C)alkyloxy, nitro or halogen.
[0031] Another preferred embodiment of the invention is a compound according to formula II:
[0000]
[0032] or a pharmaceutically acceptable addition salt thereof.
[0033] In another embodiment of the invention, the compound having the structure according to formula I, wherein:
X is NH or S; R 1 is H or (1C-4C)alkyl; R 2 is —Z or —Y—Z, wherein Y is —CH 2 — or —CH 2 —CH 2 —, and Z is phenyl or a monocyclic aromatic ring having one or more N—, O— or S— atoms in the ring, optionally substituted with one or more groups selected from (1C-4C)alkyl, (1C-4C)alkyloxy, halo(1C-4C)alkyl, halo(1C-4C)alkyloxy, phenyloxy, phenylthio, halogen, or nitro from (1C-4C)alkyl, (1C-4C)alkyloxy, halo(1C-4C)alkyl, halo(1C-4C)alkyloxy, phenyloxy, phenylthio, halogen, or nitro or Z is thien-2-yl, optionally substituted at position 3, 4 or 5 with halogen or Z is N-methylpyrol-3-yl or benzo[b]thien-2-yl or 2-naphthalenyl; R 3 and R 4 are each independently H, (1C-6C)alkyl, (2C-6C) alkenyl, (2C-6C)alkynyl, cyano, (3C-6C)cycloalkyl, phenyl, a monocyclic aromatic ring having one or more N—, O— or S— atoms in the ring, a monocyclic non-aromatic ring having one or more N—, O— or S— atoms in the ring, each optionally substituted with hydroxyl, (1C-4C)alkoxy, phenyl, cycloalkyl, piperidyl, piperazinyl, furyl, thienyl, pirazinyl, pyrrolyl, 2H-pyrrolyl, pyrazolyl, isoxazolyl, isothiazolyl, pyrrolidonyl, pyrrolinyl, imidazolinyl, imidazolyl, a monocyclic aromatic ring having one or more N—, O— or S— atoms in the ring, whereby each of these optional substituents is optionally further substituted with (1C-4C)alkyl, (1C-4C)alkyloxy, halo(1C-4C)alkyl, halo(1C-4C)alkyloxy, halogen, nitro or (1C-2C)dioxol forming a ring; or R 3 and R 4 form together pyrrolyl, imidazolyl, pyrazolyl, pyrrolidinyl, pyrrolinylimidazolidinyl, imidazolinyl, piperidyl, piperazinylmorpholinyl, each optionally substituted with (1C-6C)alkyl, phenyl(1C-4C)alkyl, phenylketo(1C-4C)alkyl; R 5 is H or CF 3 ; R 6 is H, (1C-4C)alkyl, (1C-4C)alkyloxy, halo(1C-4C)alkyl, halo(1C-4C)alkyloxy, nitro or halogen; or pharmaceutically acceptable addition salts thereof.
[0044] In a preferred embodiment, the compound having the structure according to formula I, whereby X is S; R 1 is H; R 2 is Z and Z is phenyl, optionally substituted at meta or para position, or at both positions, with one or two substituents selected from the list consisting of —NO 2 , halogen, CF 3 , (1C-4C)alkyl and methoxy; or Z is thien-2-yl, optionally substituted at position 3, 4 or 5 with halogen; or Z is N-methylpyrol-3-yl or benzo[b]thien-2-yl or 2-naphthalenyl; R 3 , R 4 are H, H or H, CH 3 or CH 3 , H 3 ; R 5 is H; and R 6 is H, halogen or methoxy.
[0045] In another embodiment, the compound is defined as in the previous paragraph, but R 2 is phenyl, optionally substituted at meta or para position, or at both positions, with one or two substituents selected from the list consisting of halogen, CF 3 , (1C-4C)alkyl and methoxy or R 2 is thien-2-yl, optionally substituted at position 3, 4 or 5 with halogen or R 2 is N-methylpyrol-3-yl or benzo[b]thien-2-yl or 2-naphthalenyl.
[0046] In another embodiment of the invention, the compound having the structure according to formula III:
[0000]
[0047] wherein:
X is NH or S; R 1 is H or (1C-4C)alkyl; R 2 is —Z or —Y—Z, wherein Y is —CH 2 — or —CH 2 —CH 2 —, and Z is phenyl or a monocyclic aromatic ring having one or more N—, O— or S— atoms in the ring, optionally substituted with one or more groups selected from (1C-4C)alkyl, (1C-4C)alkyloxy, halo(1C-4C)alkyl, halo(1C-4C)alkyloxy, phenyloxy, phenylthio, halogen, or nitro from (1C-4C)alkyl, (1C-4C)alkyloxy, halo(1C-4C)alkyl, halo(1C-4C)alkyloxy, phenyloxy, phenylthio, halogen, or nitro; or Z is thien-2-yl, optionally substituted at position 3, 4 or 5 with halogen; or Z is N-methylpyrol-3-yl or benzo[b]thien-2-yl or 2-naphthalenyl; R 3 and R 4 are each independently H, (1C-6C)alkyl, (2C-6C) alkenyl, (2C-6C)alkynyl, cyano, (3C-6C)cycloalkyl, phenyl, a monocyclic aromatic ring having one or more N—, O— or S— atoms in the ring, a monocyclic non-aromatic ring having one or more N—, O— or S— atoms in the ring, each optionally substituted with hydroxyl, (1C-4C)alkoxy, phenyl, cycloalkyl, piperidyl, piperazinyl, furyl, thienyl, pirazinyl, pyrrolyl, 2H-pyrrolyl, pyrazolyl, isoxazolyl, isothiazolyl, pyrrolidonyl, pyrrolinyl, imidazolinyl, imidazolyl, a monocyclic aromatic ring having one or more N—, O— or S— atoms in the ring, whereby each of these optional substituents is optionally further substituted with (1C-4C)alkyl, (1C-4C)alkyloxy, halo(1C-4C)alkyl, halo(1C-4C)alkyloxy, halogen, nitro or (1C-2C)dioxol forming a ring; or R 3 and R 4 form together pyrrolyl, imidazolyl, pyrazolyl, pyrrolidinyl, pyrrolinylimidazolidinyl, imidazolinyl, piperidyl, piperazinylmorpholinyl, each optionally substituted with (1C-6C)alkyl, phenyl(1C-4C)alkyl, phenylketo(1C-4C)alkyl; R 5 is H, Cl, F, Br, Me, NO 2 , t-butyl, OCF 3 , OCH 3 , CF 3 ; R 6 is H, (1C-4C)alkyl, (1C-4C)alkyloxy, halo(1C-4C)alkyl, halo(1C-4C)alkyloxy, nitro or halogen; R 7 is H, F, Cl, Br, Me, NO 2 , t-butyl, OCF 3 , OCH 3 , CF 3 , or pharmaceutically acceptable addition salts thereof.
[0059] In a more specific embodiment, the compound having the structure according the formula III, whereby X is S; R 1 is H; R 2 is Z and Z is phenyl, optionally substituted at meta or para position, or at both positions, with one or two substituents selected from the list consisting of —NO 2 , halogen, CF 3 , (1C-4C)alkyl and methoxy; or Z is thien-2-yl, optionally substituted at position 3, 4 or 5 with halogen; or Z is N-methylpyrol-3-yl or benzo[b]thien-2-yl or 2-naphthalenyl; R 3 , R 4 are H, H or H, CH 3 or CH 3 , CH 3 ; R 5 is H; and R 6 is H, halogen or methoxy; R 7 is H or Cl.
[0060] In all of the above described embodiments, excepting in those whereby R 6 is H, the compound has preferably R 6 being methoxy.
[0061] Another, more specified embodiment of the invention is a compound according to Formula III, wherein:
X is S; R 1 is H, CH 3 ;
[0064] R 2 is CF 3 , CH 3 , phenylethyl,
[0000]
[0000] wherein R a is H, F, Cl, Br, I, NO 2 , methyl, ethyl, isopropyl, t-butyl, methoxy or CF 3 and R b is H, Cl or CH 3 ;
[0065] R 3 , R 4 is H, H or H, CH 3 , or CH 3 , CH 3 or one of R 3 or R 4 is —CN or p-methoxyphenylmethyl or R 3 and R 4 together represent a ring
[0000]
[0000] on the nitrogen of Formula III to represent a piperidyl or R 3 and R 4 together represent a ring
[0000]
[0000] on the nitrogen of Formula III to pyrrolidinyl, or R 3 is methyl and R 4 is dichlorbenzyl
[0000]
R 5 is H, Cl, F, Br, Me, NO 2 , t-butyl, OCF 3 , OCH 3 , CF 3 ,
R 6 is H, F, Cl, Br, NO 2 , CH 3 , t-butyl, OCH 3 , OCF 3 , CF 3 ;
R 7 is H, F, Cl, Br, Me, NO 2 , t-butyl, OCF 3 , OCH 3 , CF 3 .
[0069] A more preferred embodiment is a compound according to formula III, wherein:
X is S; R 1 is H, CH 3 ; R 2 is CF 3 , CH 3 , phenylethyl,
[0000]
[0000] wherein R a is H, F, Cl, Br, I, NO 2 , methyl, ethyl, isopropyl, t-butyl, methoxy or CF 3 and R b is H, Cl or CH 3 ;
R 3 , R 4 is H, H or H, CH 3 , or CH 3 , CH 3 or one of R 3 or R 4 is —CN or p-methoxyphenylmethyl or R 3 and R 4 together represent a ring
[0000]
[0000] on the nitrogen of Formula III to represent a piperidyl or R 3 and R 4 together represent a ring
[0000]
[0000] on the nitrogen of Formula III to pyrrolidinyl, or R 3 is methyl and R 4 is dichlorbenzyl
[0000]
R 5 is H, Cl;
R 6 is H, F, Cl, NO 2 , CH 3 , t-butyl, OCH 3 or OCF 3 ;
R 7 is H, Cl.
[0077] Another more preferred embodiment is a compound according to formula III, wherein:
X is S; R 1 is H; R 2 is CF 3 , CH 3 , phenylethyl,
[0000]
[0000] wherein R a is H, F, Cl, Br, I, NO 2 , methyl, ethyl, isopropyl, t-butyl, methoxy or CF 3 and R b is H, Cl or CH 3 ;
R 3 , R 4 is H, H or H, CH 3 , or together represent a ring
[0000]
[0000] on the nitrogen of Formula III to represent piperidyl, or R 3 is methyl and R 4 is dichlorbenzyl
[0000]
R 5 is H;
R 6 is H, Cl, NO 2 , CH 3 , OCH 3 , OCF 3 ;
R 7 is H.
[0085] Another more specified preferred embodiment is a compound according to formula III, wherein:
X is S; R 1 is H; R 2 is CF 3 , CH 3 ,
[0000]
[0000] wherein R a is H, F, Cl, Br, I, methyl, ethyl, isopropyl, t-butyl or CF 3 and R b is H, Cl or CH 3 ;
R 3 , R 4 is H, H or H, CH 3 , or together represent a ring
[0000]
[0000] on the nitrogen of Formula III to represent piperidyl, or R 3 is methyl and R 4 is dichlorbenzyl
[0000]
R 5 is H;
R 6 is H, Cl, NO 2 , CH 3 , OCH 3 , OCF 3 ;
R 7 is H.
[0093] In all embodiments the compounds defined comprise also their pharmaceutically acceptable addition salts.
[0094] A further embodiment of the present invention is a compound according to formula III and defined as in the embodiments with formula III above but wherein R 3 or R 4 is not p-methoxyphenylmethyl.
[0095] A compound according to the invention is also a compound for use in a treatment of carcinoma, according to formula I, wherein:
X is NH or S; R 1 is H or (1C-4C)alkyl; R 2 is —Z or —Y—Z, wherein Y is —CH 2 — or —CH 2 —CH 2 —, and Z is phenyl or a monocyclic aromatic ring having one or more N—, O— or S— atoms in the ring, optionally substituted with one or more groups selected from (1C-4C)alkyl, (1C-4C)alkyloxy, halo(1C-4C)alkyl, halo(1C-4C)alkyloxy, phenyloxy, phenylthio, halogen, or nitro from (1C-4C)alkyl, (1C-4C)alkyloxy, halo(1C-4C)alkyl, halo(1C-4C)alkyloxy, phenyloxy, phenylthio, halogen, or nitro or Z is thien-2-yl, optionally substituted at position 3, 4 or 5 with halogen or Z is N-methylpyrol-3-yl or benzo[b]thien-2-yl or 2-naphthalenyl; R 3 and R 4 are each independently H, (1C-6C)alkyl, (2C-6C) alkenyl, (2C-6C)alkynyl, cyano, (3C-6C)cycloalkyl, a monocyclic aromatic ring having one or more N—, O— or S— atoms in the ring, a monocyclic non-aromatic ring having one or more N—, O— or S— atoms in the ring, each optionally substituted with hydroxyl, (1C-4C)alkoxy, cycloalkyl, piperidyl, piperazinyl, furyl, thienyl, pirazinyl, pyrrolyl, 2H-pyrrolyl, pyrazolyl, isoxazolyl, isothiazolyl, pyrrolidonyl, pyrrolinyl, imidazolinyl, imidazolyl, a monocyclic aromatic ring having one or more N—, O— or S— atoms in the ring, whereby each of these optional substituents is optionally further substituted with (1C-4C)alkyl, (1C-4C)alkyloxy, halo(1C-4C)alkyl, halo(1C-4C)alkyloxy, halogen, nitro or (1C-2C)dioxol forming a ring; or R 3 and R 4 form together pyrrolyl, imidazolyl, pyrazolyl, pyrrolidinyl, pyrrolinylimidazolidinyl, imidazolinyl, piperidyl, piperazinylmorpholinyl, each optionally substituted with (1C-6C)alkyl, phenyl(1C-4C)alkyl, phenylketo(1C-4C)alkyl; R 5 is H or CF 3 ; R 6 is H, (1C-4C)alkyl, (1C-4C)alkyloxy, halo(1C-4C)alkyl, halo(1C-4C)alkyloxy, nitro or halogen; or pharmaceutically acceptable addition salts thereof.
[0106] Another embodiment of the invention is a compound according to formula I, wherein:
X is NH or S; R 1 is H or (1C-4C)alkyl; R 2 is a monocyclic aromatic ring having one or more N—, O— or S— atoms in the ring, which aromatic ring is optionally substituted with one or more groups selected from (1C-4C)alkyl, (1C-4C)alkyloxy, halo(1C-4C)alkyl, halo(1C-4C)alkyloxy, phenyloxy, phenylthio, halogen, or nitro; R 3 and R 4 are each independently H, (1C-6C)alkyl, (2C-6C) alkenyl, (2C-6C)alkynyl, cyano, (3C-6C)cycloalkyl, a monocyclic non-aromatic ring having one or more N—, O— or S— atoms in the ring, each optionally substituted with hydroxyl, (1C-4C)alkoxy, cycloalkyl, piperidyl, piperazinyl, furyl, thienyl, pyrrolyl, 2H-pyrrolyl, pyrazolyl, isoxazolyl, isothiazolyl, pyrrolidonyl, pyrrolinyl, imidazolinyl, imidazolyl, whereby each of these optional substituents is optionally further substituted with (1C-4C)alkyl, (1C-4C)alkyloxy, halo(1C-4C)alkyl, halo(1C-4C)alkyloxy, halogen, nitro or (1C-2C)dioxol forming a ring; or R 3 and R 4 form together pyrrolyl, imidazolyl, pyrazolyl, pyrrolidinyl, pyrrolinylimidazolidinyl, imidazolinyl, piperidyl, piperazinylmorpholinyl, each optionally substituted with (1C-6C)alkyl, phenyl(1C-4C)alkyl, phenylketo(1C-4C)alkyl; R 5 is H or CF 3 ; R 6 is H, (1C-4C)alkyl, (1C-4C)alkyloxy, halo(1C-4C)alkyl, halo(1C-4C)alkyloxy, nitro or halogen; and pharmaceutically acceptable addition salts thereof.
[0115] A more specific embodiment of the invention is a compound according to formula III, wherein:
X is S; R 1 is H, CH 3 ; R 2 is phenylethyl,
[0000]
[0000] wherein R a is F, Cl, Br, I, NO 2 , methyl, ethyl, isopropyl, t-butyl, methoxy or CF 3 and R b is H, Cl or CH 3 ;
R 3 , R 4 is H, H or H, CH 3 , or CH 3 , CH 3 or one of R 3 or R 4 is —CN or p-methoxyphenylmethyl or R 3 and R 4 together represent a ring
[0000]
[0000] on the nitrogen of Formula III to represent a piperidyl or R 3 and R 4 together represent a ring
[0000]
[0000] on the nitrogen of Formula III to pyrrolidinyl, or R 3 is methyl and R 4 is dichlorbenzyl
[0000]
R 5 is H, Cl, F, Br, Me, NO 2 , t-butyl, OCF 3 , OCH 3 , CF 3 ; preferred is R 5 is H, Cl;
R 6 is H, F, Cl, Br, NO 2 , CH 3 , t-butyl, OCH 3 , OCF 3 , CF 3 ;
R 7 is H, F, Cl, Br, Me, NO 2 , t-butyl, OCF 3 , OCH 3 , CF 3 ; preferred is R 7 is H or Cl.
[0123] Most preferred is a compound according to formula III, wherein:
X is S; R 1 is H; R 2 is
[0000]
[0000] wherein R a is F, Cl, Br, I, methyl, ethyl, isopropyl, t-butyl or CF 3 and R b is H, Cl or CH 3 ;
R 3 , R 4 is H, H or H, CH 3 , or together represent a ring
[0000]
[0000] on the nitrogen of Formula III to represent piperidyl, or R 3 is methyl and R 4 is dichlorbenzyl
[0000]
R 5 is H;
R 6 is H, Cl, NO 2 , CH 3 , OCH 3 , OCF 3 ;
R 7 is H.
[0131] When embodiments are defined as characteristics of a compound this invention also provides for the use of the compounds in therapy, more specifically carcinoma, as are gastric cancer, bladder cancer, esophageal cancer, breast cancer, prostate cancer or pancreas cancer and, in particular, for patients wherein metastasis of the carcinoma, in particular, prostate cancer, is diagnosed.
DETAILED DESCRIPTION
[0132] The terms used in the description have the following meaning:
[0133] The prefix (1C-4C) refers to the number of 1-4 carbon atoms in the alkyl, alkenyl or alkynyl group. The definition includes amongst others a methyl, ethyl, propyl, isopropyl, butyl, tertiary butyl, vinyl, ethynyl, cyclopropyl and propynyl.
[0134] Halo or halogen means fluorine, chlorine, bromine, iodine.
[0135] Haloalkyl, haloalkenyl or haloalkynyl means respectively an alkyl, alkenyl and alkynyl substituted with one or more halogens.
[0136] A pharmaceutically acceptable addition salt is known in the art of pharmaceutics, such as a chloride, maleate, lactate, etc.
[0137] It should be realized that the compounds according to the invention exist in tautomeric isomers when R 3 and/or R 4 are hydrogen. As shown in the formulas A, B and C below the double bond system over the aminomethylenepyrazolone [A] can shift to the iminomethylpyrazolone system in [B] so that the delocalized representation as in formula [C] would be an equivalent manner to represent the compounds according to the invention. Anyway, these tautomeric isomers are comprised into the definition of the compounds according to the invention as defined with the support of the formulas.
[0000]
[0138] Furthermore, the double bond at the methylene, or methylidene if R 1 has an alkyl meaning, and the imino bond can be in Z or E configuration. The compound according to the invention is not specified regarding this isomerism. Only the outcome of the syntheses of specified compounds has determined and thereby implicitly defines such characteristic of particular compounds.
[0139] A compound according to the invention may be prepared, for example, by starting with preparation a 2,4-dihydropyrazol-3-one scaffold, which is synthesized through a condensation-cyclization reaction of suitable hydrazines and acetoacetate esters in either ethanol or ethanol/acetic acid mixtures at reflux temperatures where X=S and in methanol containing a catalytic amount of concentrated HCl where X=N. The cyclization product is usually collected by filtration, rinsing of the filter cake with ethanol and in vacuo drying.
[0140] In the second reaction step, the thus obtained 1,2-dihydropyrazol-3-one is subjected to an aminomethylenation reaction in THF at room temperature. The precipitated product may be purified by filtration, rinsing of the filter cake with a suitable solvent and in vacuo drying.
[0141] In the third and final step, the aminomethylidenepyrazol-3-one is treated with a suitable primary amine in methanol or ethanol at room temperature or at any temperature leading up to reflux temperature of the reaction solvent. The product may be purified by filtration and rinsing with methanol or ethanol and in vacuo drying.
[0142] A pharmaceutically acceptable addition salt of a compound may be prepared according to conventional methods. Salts are usually obtained by combining the free base with inorganic or organic acids such as hydrochloric, fumaric, maleic, citric or succinic acid.
[0143] The therapeutic or preventive effect of a compound according to the invention can be obtained by administration of the compound to a patient (human or animal, male or female) in need of treatment by administering the compound either topically, locally or systemically. Any enteral or parenteral route, such as transdermal, transmucosal, oral, rectal, intravenous, intramuscular or subcutaneous, can be selected as most suitable under the circumstances of the condition of the patient and the location of cancer cells. The administration will be greatly aided by the manufacture of pharmaceutical compositions comprising a compound according to the invention. A pharmaceutical formulation of a compound according to the invention can be prepared according to methods known in the art, varying from conventional pills, tablets and solutions to more sophisticated formulations for depot formulations or formulations adapted for particular routes of administration. Resorption of the compound according to the invention by the patient can be facilitated or delayed by pharmaceutical additives.
[0144] In therapeutic use it is possible to select particular regimes of administration for continuous or multiple dosing per day, or for detailed treatment regimes for a certain period of time, for example, a week, a month or other continuous or intermittent periods. In the field of cancer therapy it is often needed or beneficial to use more than one method to combat the disease. A compound according to the invention is suitable for combination treatment with other treatments.
[0145] Dose selection depends on routes of administration and type and condition of the treated patient. The effective dose per administration or per day will usually be in the range of 0.001-1000 mg per patient, or, expressed in amount per kg patient, in particular, in consideration of small weight patients (for example, children or animals) between 0.0001-100 mg/kg. The preferred range is 0.01-5 mg/kg or 1-350 mg for an average human patient.
[0146] Without wanting to be bound by theory in the use of the invention, it was found that an important contribution to the therapeutic mechanism of compounds of the invention can reside in interference with the process of invasion into healthy tissue, as, for example, the interaction between prostate cancer cells and the bone micro-environment.
[0147] For determining the effectiveness of the compounds according to the invention, a model assay based on the migration of cells in a migration chamber was employed. This model is accepted in the art as providing representative data on the ability of cells to metastasize.
[0148] It was found that a preferred compound according to the invention inhibits tumor cell invasion more than 25%. Particularly preferred compound also showed dose-dependent anti-invasion activity of over 40%. The compounds according to the invention are thus capable of interfering with the acquisition of an invasive phenotype in human prostate cancer by inhibiting the EMT process. The more potent compounds for this effect are most preferred in view of the reduced dosage needed for use in therapy.
[0000]
Results % inhibition of invasion
in invasion assays
If more values are given these are
Compound
results of repeated assays
52 49 45
35
93 45
91
91
89%
89 82 78
88
87 76
86
76%
75%
73
70
67
57%
57
56
[0149] Further embodiments are compounds shown in the following table:
[0000]
[0150] Treatment of mice with 4-[1-aminomethylidene]-2-benzothiazol-2-yl-5-phenyl-2,4-dihydro-pyrazol-3-one decreased the number of bone lesions and metastatic tumor burden. Cancer cells and tumor burden were monitored by whole body bioluminescence imaging. The data show that a compound according to the invention affects the formation of de novo skeletal metastases by PC-3M-Pro4luc+cells in vivo. Such in vivo testing may lead to further selection, preference, deselection or disfavor of individual compounds for further programs for development of a compound for use in a prescription medicine. A particular compound of interest for such advanced testing is, 4-(aminomethylene)-2-(2-benzothiazolyl)-2,4-dihydro-5-(3-chlorophenyl)-3H-pyrazol-3-one.
EXAMPLES
Example 1
Preparation of 4-[1-Aminomethylidene]-2-benzothiazol-2-yl-5-(2-methoxyphenyl)-2,4-dihydropyrazol-3-one
[0151] A solution of 1.00 g (4.45 mmol) of ethyl (2-methoxybenzoyl)acetate and 743 mg (4.45 mmol) of 2-hydrazinobenzothiazole in 15 ml of ethanol, containing a few drops of AcOH, was refluxed overnight under a nitrogen atmosphere. After evaporating the reaction solvent and replacing it with diethyl ether containing a small amount of acetone, the precipitate was filtered, washed with diethyl ether and dried to give 1.33 g (4.11 mmol, 92%) of 2-benzothiazol-2-yl-5-(2-methoxyphenyl)-1,2-dihydropyrazol-3-one. 1H-NMR (DMSO-d6): δ 12.40 (bs, 1H), 8.05 (d, 1H), 7.90 (d, 1H), 7.80 (s, 1H), 7.50 (m, 2H), 7.40 (t, 1H), 7.20 (d, 1H), 7.10 (m, 1H), 6.05 (s, 1H), 3.90 (s, 3H).
[0152] To a solution of 722 mg (2.23 mmol) of 2-benzothiazol-2-yl-5-(2-methoxyphenyl)-1,2-dihydropyrazol-3-one in 15 ml of THF was added N,N-dimethylformamide dimethylacetal (326 μl, 2.46 mmol). The reaction was stirred overnight at room temperature under a nitrogen atmosphere, after which, the reaction mixture was diluted with a small amount of diethyl ether. The solids were filtered off, washed with diethyl ether and dried to give 824 mg (2.18 mmol, 98%) of 2-benzothiazol-2-yl-4-[1-dimethylaminomethylidene]-5-(2-methoxy-phenyl)-2,4-dihydropyrazol-3-one. 1H-NMR (DMSO-d6): δ 8.00 (d, 1H), 7.75 (d, 1H), 7.50 (t, 1H), 7.40 (m, 2H), 7.30 (m, 2H), 7.20 (d, 1H), 7.10 (t, 1H), 3.80 (s, 3H), 3.70 (s, 3H), 3.35 (s, 3H).
[0153] A suspension of 625 mg (1.65 mmol) of 2-benzothiazol-2-yl-4-[1-dimethylaminomethylidene]-5-(2-methoxy-phenyl)-2,4-dihydropyrazol-3-one in 10 ml ethanol and 10 ml of a 25% ammonia solution was heated to 60° C. under a nitrogen atmosphere overnight. After cooling to room temperature, the reaction mixture was diluted with a little water, the solids were filtered, washed with ethanol and dried to give 481 mg (1.37 mmol, 83%) of 4-[1-aminomethylidene]-2-benzothiazol-2-yl-5-(2-methoxyphenyl)-2,4-dihydropyrazol-3-one. 1H-NMR (DMSO-d6): δ 9.40 (bs, 2H), 8.00 (d, 1H), 7.80 (d, 1H), 7.70 (s, 1H), 7.45 (m, 3H), 7.30 (t, 1H), 7.20 (d, 1H), 7.10 (t, 1H), 3.80 (s, 3H).
Example 2
Preparation of 4-[1-Aminomethylidene]-2-benzothiazol-2-yl-5-phenyl-2,4-dihydro-pyrazol-3-one
[0154] A solution of 1.75 g (9.08 mmol) of ethyl benzoylacetate and 1.50 g (9.08 mmol) of 2-hydrazinobenzothiazole in 30 ml of ethanol was refluxed for 4 hours under a nitrogen atmosphere. After cooling to room temperature, the precipitate was filtered, washed with cold ethanol, diethylether and dried to give 1.66 g (5.66 mmol, 62%) of 2-benzothiazol-2-yl-5-phenyl-1,2-dihydropyrazol-3-one as a white solid. 1 H-NMR (DMSO-d6): δ 12.90 (bs, 1H), 8.05 (d, 1H), 7.90 (m, 3H), 7.50 (m, 4H), 7.30 (t, 1H), 6.10 (s, 1H).
[0155] To a solution of 190 mg (0.648 mmol) of 2-benzothiazol-2-yl-5-phenyl-1,2-dihydropyrazol-3-one in 10 ml of THF was added N,N-dimethylformamide dimethylacetal (90 μl, 0.680 mmol). The reaction was stirred for 3 hours at room temperature under a nitrogen atmosphere, the solids were filtered off, washed with acetone and dried to give 125 mg (0.359 mmol, 55%) of 2-benzothiazol-2-yl-4-[1-dimethylaminomethylidene]-5-phenyl-2,4-dihydropyrazol-3-one as a yellow solid. 1 H-NMR (DMSO-d6): δ 8.00 (d, 1H), 7.80 (d, 1H), 7.70 (s, 1H), 7.65 (m, 2H), 7.55 (m, 3H), 7.40 (t, 1H), 7.30 (t, 1H), 3.75 (s, 3H), 3.40 (s, 3H).
[0156] A suspension of 100 mg (0.287 mmol) of 2-benzothiazol-2-yl-4-[1-dimethylaminomethylidene]-5-phenyl-2,4-dihydropyrazol-3-one in 5 ml of a 25% ammonia solution was heated to 120° C. in a pressure vessel overnight. After cooling to room temperature, the solids were filtered, washed with water and dried to give 48 mg (0.150 mmol, 52%) of 4-[1-aminomethylidene]-2-benzothiazol-2-yl-5-phenyl-2,4-dihydro-pyrazol-3-one as a yellow solid. 1 H-NMR (DMSO-d6): δ 9.05 (bs, 2H), 8.00 (m, 2H), 7.85 (d, 1H), 7.75 (m, 2H), 7.55 (m, 3H), 7.45 (t, 1H), 7.30 (t, 1H).
Example 3
Preparation of 4-[1-Aminomethylidene]-2-(1H-benzoimidazol-2-yl)-5-phenyl-2,4-dihydropyrazol-3-one
[0157] A solution of 500 mg (3.37 mmol) of 2-hydrazino-1H-benzimidazole and 713 mg (3.70 mmol) of ethyl benzoylacetate of in 15 ml of methanol containing a catalytic amount of concentrated HCl. The reaction mixture was stirred at 65° C. under a nitrogen atmosphere overnight. After cooling to room temperature, the precipitate was filtered and dried to give 966 mg (3.09 mmol, 92%) of 2-(1H-benzoimidazol-2-yl)-5-phenyl-1,2-dihydropyrazol-3-one as the hydrochloride salt. 1H-NMR (DMSO-d6): δ 7.95 (m, 2H), 7.65 (m, 2H), 7.45 (m, 3H), 7.20 (m 2H), 6.10 (s, 1H).
[0158] To a suspension of 100 mg (0.36 mmol) of 2-(1H-benzoimidazol-2-yl)-5-phenyl-1,2-dihydropyrazol-3-one hydrochloride salt in 5 ml of dioxane was added N,N-dimethylformamide dimethylacetal (52 μl, 0.39 mmol). The reaction was stirred for 2 hours at room temperature under a nitrogen atmosphere, after which, the reaction mixture was cooled on an ice bath and diluted with a small amount of diethyl ether. The solids were filtered off, washed with diethyl ether and dried to give 99 mg (0.30 mmol, 83%) of 2-(1H-benzoimidazol-2-yl)-4-[1-dimethylaminomethylidene]-5-phenyl-2,4-dihydropyrazol-3-one as a yellow solid. 1H-NMR (DMSO-d6): δ 13.40 (bs, 1H), 8.55 (bs, 2H), 7.70 (s, 1H), 7.65 (m, 2H), 7.55 (m, 3H), 7.20 (m, 2H), 3.70 (s, 3H), 3.40 (s, 3H).
[0159] A suspension of 50 mg (0.15 mmol) of 2-(1H-benzoimidazol-2-yl)-4-[1-dimethylaminomethylidene]-5-phenyl-2,4-dihydropyrazol-3-one in 3 ml of a 25% ammonia solution was heated to 65° C. under a nitrogen atmosphere for 3 hours. After cooling to room temperature, the solids were filtered and dried to give 32 mg (0.11 mmol, 70%) of 4-[1-aminomethylidene]-2-(1H-benzoimidazol-2-yl)-5-phenyl-2,4-dihydropyrazol-3-one as a yellow solid. 1H-NMR (DMSO-d6): δ 12.20 (bs, 1H), 9.40 (bs, 2H), 8.05 (m, 1H), 7.70 (m, 2H), 7.50 (m, 5H), 7.10 (m, 2H).
Example 4
Preparation of 4-[1-Aminomethylidene]-2-(4-chlorobenzothiazol-2-yl)-5-phenyl-2,4-dihydropyrazol-3-one
[0160] 4-Chlorobenzothiazol-2-ylamine (5.04 g, 27.29 mmol) was suspended in 35 ml of ethylene glycol at room temperature under a nitrogen atmosphere. Hydrazine hydrate (3.98 ml, 81.87 mmol) was added followed by concentrated hydrochloric acid (2.24 ml, 27.29 mmol) and the resulting reaction mixture was heated on an oil bath to 150° C. After 1.5 hours, a precipitate was formed and heating was continued for an additional 1.5 hours, after which time, the mixture was cooled, water was added and the resulting solids were filtered, washed with water and dried to give 5.33 g (26.69 mmol, 98%) of (4-chlorobenzothiazol-2-yl)-hydrazine. 1 H-NMR (DMSO-d6): δ 9.40 (bs, 1H), 7.62 (d, 1H), 7.25 (d, 1H), 6.95 (t, 1H), 5.15 (bs, 2H).
[0161] A solution of 1.09 g (5.46 mmol) of (4-chlorobenzothiazol-2-yl)-hydrazine and 1.15 g (6.01 mmol) of ethyl benzoylacetate in 30 ml of ethanol was refluxed for 2 days under a nitrogen atmosphere. The reaction mixture was cooled and the precipitate was collected by filtration, washed with a little EtOH and dried to give 1.56 g (4.76 mmol, 87%) of 2-(4-chlorobenzothiazol-2-yl)-5-phenyl-1,2-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 12.80 (bs, 1H), 8.05 (d, 1H), 7.85 (m, 2H), 7.60-7.40 (m, 4H), 7.35 (t, 1H), 6.15 (s, 1H).
[0162] To a solution of 657 mg (2.00 mmol) of 2-(4-chlorobenzothiazol-2-yl)-5-phenyl-1,2-dihydro-pyrazol-3-one in 20 ml of THF was added N,N-dimethylformamide dimethylacetal (293 μl, 2.26 mmol). The reaction was stirred overnight at room temperature under a nitrogen atmosphere, after which, the solids were filtered off, washed with diethyl ether and dried to give 681 mg (1.78 mmol, 89%) of 2-(4-chlorobenzothiazol-2-yl)-4-[1-dimethylaminomethylidene]-5-phenyl-2,4-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 7.95 (d, 1H), 7.60 (m, 3H), 7.55 (m, 4H), 7.25 (t, 1H), 3.75 (s, 3H), 3.40 (s, 3H).
[0163] A suspension of 545 mg (1.42 mmol) of 2-(4-chlorobenzothiazol-2-yl)-4-[1-dimethylaminomethylidene]-5-phenyl-2,4-dihydro-pyrazol-3-one in 10 ml 7N ammonia solution in MeOH was heated to 100° C. in a pressure vessel for 18 hours. After cooling to room temperature, the solids were filtered, washed with a little EtOH and dried to give 460 mg (1.37 mmol, 91%) of 4-[1-aminomethylidene]-2-(4-chlorobenzothiazol-2-yl)-5-phenyl-2,4-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 9.45 (bs, 2H), 8.00 (m, 2H), 7.75 (m, 2H), 7.50 (m, 4H), 7.35 (t, 1H).
Example 5
Preparation of 4-[1-Aminomethylidene]-2-(5-chlorobenzothiazol-2-yl)-5-phenyl-2,4-dihydropyrazol-3-one
[0164] 5-Chlorobenzothiazole-2-thiol (5.21 g, 25.83 mmol) was dissolved in 50 ml DMF at room temperature under a nitrogen atmosphere. To the reaction mixture were added 4.28 g (31.00 mmol) of potassium carbonate and 1.93 ml (31.00 mmol) of methyl iodide and stirring was continued overnight, after which time, TLC (silica, 25% EtOAc in PE 40/60) indicated complete consumption of the starting material. Water was added to the reaction mixture and the resulting solids were filtered off, washed with water and dried to give 5.35 g (24.80 mmol, 96%) of 5-chloro-2-methylsulfanylbenzothiazole. 1 H-NMR (DMSO-d6): δ 8.05 (d, 1H), 7.90 (s, 1H), 7.40 (d, 1H), 2.75 (s, 3H).
[0165] A mixture of 5-chloro-2-methylsulfanylbenzothiazole (5.03 g, 23.32 mmol) and hydrazine hydrate (11.33 ml, 233.17 mmol) in 5 ml of EtOH was heated under a nitrogen atmosphere to 100° C. After 3 hours, a heavy precipitation was present in the reaction mixture, after which time, the suspension was cooled, water was added and the resulting solids were collected, washed with water and dried to give 4.43 g (22.83 mmol, 95%) of (5-chlorobenzothiazol-2-yl)-hydrazine. 1 H-NMR (DMSO-d6): δ 9.10 (bs, 1H), 7.65 (d, 1H), 7.30 (s, 1H), 6.95 (d, 1H), 5.10 (bs, 2H).
[0166] A solution of 935 g (4.68 mmol) of (5-chlorobenzothiazol-2-yl)-hydrazine and 990 mg (5.15 mmol) of ethyl benzoylacetate in 30 ml of ethanol was refluxed overnight under a nitrogen atmosphere. The reaction mixture was cooled and the precipitate was collected by filtration, washed with a little EtOH and dried to give 970 mg (2.96 mmol, 63%) of 245-chlorobenzothiazol-2-yl)-5-phenyl-1,2-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 13.00 (bs, 1H), 8.05 (d, 1H), 7.90 (m, 3H), 7.50 (m, 3H), 7.40 (t, 1H), 6.10 (s, 1H).
[0167] To a solution of 800 mg (2.44 mmol) of 2-(5-chlorobenzothiazol-2-yl)-5-phenyl-1,2-dihydro-pyrazol-3-one in 20 ml of THF was added N,N-dimethylformamide dimethylacetal (357 μl, 2.68 mmol). The reaction was stirred overnight at room temperature under a nitrogen atmosphere, after which, ether was added and the solids were filtered off, washed with diethyl ether and dried to give 790 mg (2.06 mmol, 85%) of 245-chlorobenzothiazol-2-yl)-4-[1-dimethylaminomethylidene]-5-phenyl-2,4-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 8.05 (d, 1H), 7.85 (s, 1H), 7.70 (s, 1H), 7.60-7.40 (m, 5H), 7.35 (d, 1H), 3.75 (s, 3H), 3.40 (s, 3H).
[0168] A suspension of 650 mg (1.70 mmol) of 2-(5-chlorobenzothiazol-2-yl)-4-[1-dimethylaminomethylidene]-5-phenyl-2,4-dihydropyrazol-3-one in 10 ml 7N ammonia solution in MeOH was heated to 100° C. in a pressure vessel for 24 hours. After cooling to room temperature, the solids were filtered, washed with a little EtOH and dried to give 439 mg (1.38 mmol, 82%) of 4-[1-aminomethylidene]-2-(5-chlorobenzothiazol-2-yl)-5-phenyl-2,4-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 9.50 (bs, 2H), 8.05 (m, 2H), 7.90 (s, 1H), 7.75 (m, 2H), 7.50 (m, 3H), 7.40 (t, 1H).
Example 6
Preparation of 4-[1-Aminomethylidene]-2-(6-chlorobenzothiazol-2-yl)-5-phenyl-2,4-dihydropyrazol-3-one
[0169] 6-Chlorobenzothiazol-2-ylamine (5.44 g, 27.84 mmol) was suspended in 35 ml of ethylene glycol at room temperature under a nitrogen atmosphere. Hydrazine hydrate (4.06 ml, 83.52 mmol) was added followed by concentrated hydrochloric acid (2.28 ml, 27.84 mmol) and the resulting reaction mixture was heated on an oil bath to 150° C. After 3 hours the mixture was cooled, poured onto water and the resulting solids were filtered, washed with water and dried to give 4.98 g (24.94 mmol, 90%) of (6-chlorobenzothiazol-2-yl)-hydrazine. 1 H-NMR (DMSO-d6): δ 9.15 (bs, 1H), 7.70 (s, 1H), 7.25 (d, 1H), 7.15 (d, 1H), 5.05 (bs, 2H).
[0170] A solution of 1.06 g (5.28 mmol) of (6-chlorobenzothiazol-2-yl)-hydrazine and 1.01 g (5.82 mmol) of ethyl benzoylacetate in 25 ml of ethanol was refluxed for 5 hours under a nitrogen atmosphere. The reaction mixture was filtered while warm, washed with EtOH and dried to give 580 mg (4.76 mmol, 34%) of 2-(6-chlorobenzothiazol-2-yl)-5-phenyl-1,2-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 13.00 (bs, 1H), 8.20 (s, 1H), 7.90 (m, 3H), 7.50 (m, 4H), 6.10 (s, 1H).
[0171] To a solution of 580 mg (1.77 mmol) of 2-(6-chlorobenzothiazol-2-yl)-5-phenyl-1,2-dihydropyrazol-3-one in 20 ml of THF was added N,N-dimethylformamide dimethylacetal (282 μl, 2.12 mmol). The reaction was stirred for 3 hours at room temperature under a nitrogen atmosphere, after which, the solids were filtered off, washed with diethyl ether and dried to give 628 mg (1.78 mmol, 93%) of 2-(6-chlorobenzothiazol-2-yl)-4-[1-dimethylaminomethylidene]-5-phenyl-2,4-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 8.15 (s, 1H), 7.80 (d, 1H), 7.70 (s, 1H), 7.60 (m, 2H), 7.50 (m, 3H), 7.45 (d, 1H), 3.70 (s, 3H), 3.40 (s, 3H).
[0172] A suspension of 420 mg (1.10 mmol) of 2-(6-chlorobenzothiazol-2-yl)-4-[1-dimethylaminomethylidene]-5-phenyl-2,4-dihydro-pyrazol-3-one in 10 ml 7N ammonia solution in MeOH was heated to 100° C. in a pressure vessel for 24 hours. After cooling to room temperature, the solids were filtered, washed with a little EtOH and dried to give 275 mg (0.775 mmol, 70%) of 4-[1-aminomethylidene]-2-(6-chlorobenzothiazol-2-yl)-5-phenyl-2,4-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 9.50 (2bs, 2H), 8.20 (s, 1H), 8.00 (bs, 1H), 7.80 (d, 1H), 7.70 (m, 2H), 7.50 (m, 4H).
Example 7
Preparation of 4-[1-Aminomethylidene]-2-(6-methoxybenzothiazol-2-yl)-5-(3-trifluoromethylphenyl)-2,4-dihydropyrazol-3-one
[0173] 6-Methoxybenzothiazol-2-ylamine (7.20 g, 40.00 mmol) was suspended in 40 ml of ethylene glycol at room temperature under a nitrogen atmosphere. Hydrazine hydrate (5.80 ml, 120.00 mmol) was added followed by concentrated hydrochloric acid (3.28 ml, 40.00 mmol) and the resulting reaction mixture was heated on an oil bath to 150° C. After 2.5 hours the mixture was cooled water was added and the resulting solids were filtered, washed with water and dried to give 7.09 g (36.31 mmol, 91%) of (6-methoxybenzothiazol-2-yl)-hydrazine. 1 H-NMR (DMSO-d6): δ 8.75 (s, 1H), 7.30 (s, 1H), 7.20 (d, 1H), 6.80 (d, 1H), 4.90 (bs, 2H), 3.70 (s, 3H).
[0174] A solution of 789 mg (4.04 mmol) of (6-methoxybenzothiazol-2-yl)-hydrazine and 9.95 mg (4.04 mmol) of methyl (3-trifluorobenzoyl)acetate in 30 ml of ethanol was refluxed for 5 hours under a nitrogen atmosphere, cooled, the solids were filtered, washed with EtOH and dried to give 1.06 g (2.71 mmol, 67%) of 2-(6-methoxybenzothiazol-2-yl)-5-(3-trifluoromethylphenyl)-1,2-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 12.80 (bs, 1H), 8.20 (m, 2H), 7.80 (m, 2H), 7.70 (t, 1H), 7.60 (s, 1H), 7.10 (d, 1H), 6.20 (s, 1H), 3.80 (s, 3H).
[0175] To a solution of 458 mg (1.17 mmol) of 2-(6-methoxybenzothiazol-2-yl)-5-(3-trifluoromethylphenyl)-1,2-dihydro-pyrazol-3-one in 20 ml of THF was added N,N-dimethylformamide dimethylacetal (171 μl, 1.29 mmol). The reaction was stirred for 2 hours at room temperature under a nitrogen atmosphere. Diethyl ether was added to induce precipitation. After an additional hour of stirring, the reaction volume was concentrated to ca 10% of the original volume, diethyl ether was added and the solids were filtered off, washed with diethyl ether and dried to give 450 mg (1.00 mmol, 86%) of 2-(6-methoxybenzothiazol-2-yl)-4-[1-dimethylaminomethylidene]-5-(3-trifluoromethylphenyl)-2,4-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 8.00-7.80 (m, 3H), 7.80-7.70 (m, 3H), 7.55 (s, 1H), 7.05 (d, 1H), 3.80 (s, 3H), 3.70 (s, 3H), 3.40 (s, 3H).
[0176] A suspension of 355 mg (0.725 mmol) of 2-(6-methoxybenzothiazol-2-yl)-4-[1-dimethylaminomethylidene]-5-(3-trifluoromethylphenyl)-2,4-dihydropyrazol-3-one in 10 ml 7N ammonia solution in MeOH was heated to 100° C. in a pressure vessel overnight. After cooling to room temperature, the solids were filtered, washed with a little EtOH and dried to give 280 mg (0.669 mmol, 92%) of 4-[1-aminomethylidene]-2-(6-methoxybenzothiazol-2-yl)-5-(3-trifluoromethylphenyl)-2,4-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 9.50 (2bs, 2H), 8.10 (m, 3H), 7.85 (d, 1H), 7.75 (m, 2H), 7.60 (s, 1H), 7.05 (d, 1H), 3.80 (s, 3H).
Example 8
Preparation of 4-[1-Aminomethylidene]-2-benzothiazol-2-yl-5-(3-trifluoromethylphenyl)-2,4-dihydro-pyrazol-3-one
[0177] A solution of 1.80 g (7.31 mmol) of benzothiazol-2-yl-hydrazine and 1.21 g (7.31 mmol) of 3-(3-trifluoromethylphenyl)-3-oxo-propionic acid methyl ester in 50 ml of ethanol was refluxed for 5 hours under a nitrogen atmosphere, cooled, the solids were filtered, washed with EtOH and dried to give 2.12 g (5.87 mmol, 80%) of 2-benzothiazol-2-yl-5-(3-trifluoromethylphenyl)-1,2-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 13.00 (bs, 1H), 8.20 (m, 2H), 8.05 (d, 1H), 7.90 (d, 1H), 7.80 (s, 1H), 7.70 (m, 1H), 7.50 (t, 1H), 7.40 (t, 1H), 6.25 (s, 1H).
[0178] To a solution of 414 mg (1.15 mmol) of 2-benzothiazol-2-yl-5-(3-trifluoromethylphenyl)-1,2-dihydro-pyrazol-3-one in 10 ml of THF was added N,N-dimethylformamide dimethylacetal (160 1 11, 1.20 mmol). The reaction was stirred for 3 hours at room temperature under a nitrogen atmosphere. A small amount of diethyl ether was added and the solids were filtered off, washed with diethyl ether and dried to give 398 mg (0.956 mmol, 83%) of 2-benzothiazol-2-yl-4-[1-dimethylaminomethylidene]-5-(3-trifluoromethylphenyl)-2,4-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 8.00-7.70 (m, 7H), 7.50 (t, 1H), 7.45 (t, 1H), 3.70 (s, 3H), 3.40 (s, 3H).
[0179] A suspension of 239 mg (0.574 mmol) of 2-benzothiazol-2-yl-4-[1-dimethylaminomethylidene]-5-(3-trifluoromethylphenyl)-2,4-dihydropyrazol-3-one in 10 ml 7N ammonia solution in MeOH was heated to 100° C. in a pressure vessel overnight. After cooling to room temperature, the solids were filtered, washed with a little EtOH and dried to give 163 mg (0.420 mmol, 73%) of 4-[1-aminomethylidene]-2-benzothiazol-2-yl-5-(3-trifluoromethylphenyl)-2,4-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 9.60 (bs, 2H), 8.10 (m, 4H), 7.90 (m, 2H), 7.80 (m, 1H), 7.45 (t, 1H), 7.30 (t, 1H).
Example 9
Preparation of 4-[1-Aminomethylidene]-2-benzothiazol-2-yl-5-(3-chlorophenyl)-2,4-dihydro-pyrazol-3-one
[0180] A solution of 1.00 g (4.20 mmol) of benzothiazol-2-yl-hydrazine and 730 mg (4.20 mmol) of 3-(3-chlorophenyl)-3-oxopropionic acid ethyl ester in 20 ml of ethanol was refluxed overnight under a nitrogen atmosphere, cooled, the solids were filtered, washed with EtOH and dried to give 1.25 g (3.81 mmol, 91%) of 2-benzothiazol-2-yl-5-(3-chlorophenyl)-1,2-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 13.00 (bs, 1H), 8.10 (d, 1H), 8.00-7.80 (m, 3H), 7.50 (m, 3H), 7.40 (t, 1H), 6.20 (s, 1H).
[0181] To a solution of 647 mg (1.97 mmol) of 2-benzothiazol-2-yl-5-(3-chlorophenyl)-1,2-dihydro-pyrazol-3-one in 15 ml of THF was added N,N-dimethylformamide dimethylacetal (288 μl, 2.17 mmol). The reaction was stirred for 2 days at room temperature under a nitrogen atmosphere. The solids were filtered off, washed with diethyl ether and dried to give 706 mg (1.84 mmol, 94%) of 2-benzothiazol-2-yl-5-(3-chlorophenyl)-4-[1-dimethylaminomethylidene]-2,4-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 8.00 (d, 1H), 7.80 (d, 1H), 7.70 (2s, 2H), 7.60 (m, 3H), 7.40 (t, 1H), 7.30 (t, 1H), 3.70 (s, 3H), 3.40 (s, 3H).
[0182] A suspension of 424 mg (1.11 mmol) of 2-benzothiazol-2-yl-5-(3-chlorophenyl)-4-[1-dimethylaminomethylidene]-2,4-dihydropyrazol-3-one in 5 ml EtOH and 20 ml of 25% aqueous ammonia solution was heated to 60° C. overnight. After cooling to room temperature, the solids were filtered, washed with a little EtOH and dried to give 386 mg (1.09 mmol, 98%) of 4-[1-aminomethylidene]-2-benzothiazol-2-yl-5-(3-chlorophenyl)-2,4-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 9.60 (bs, 2H), 8.10 (s, 1H), 8.00 (d, 1H), 7.90 (s, 1H), 7.85 (d, 1H),7.65 (m, 2H), 7.45 (m, 2H), 7.30 (t, 1H).
Example 10
Preparation of 4-[1-Aminomethylidene]-2-benzothiazol-2-yl-5-(3-methylphenyl)-2,4-dihydropyrazol-3-one
[0183] A solution of 801 mg (4.85 mmol) of benzothiazol-2-yl-hydrazine and 1.00 g (4.20 mmol) of 3-(3-methylphenyl)-3-oxopropionic acid ethyl ester in 25 ml of ethanol was refluxed for 22 hours under a nitrogen atmosphere, cooled, the solids were filtered, washed with a little cold EtOH and dried to give 1.41 g (4.59 mmol, 95%) of 2-benzothiazol-2-yl-5-(3-methylphenyl)-1,2-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 12.90 (bs, 1H), 8.10 (d, 1H), 7.90 (d, 1H), 7.75 (s, 1H), 7.70 (d, 1H), 7.50 (t, 1H), 7.40-7.20 (m, 4H), 6.10 (s, 1H), 2.40 (s, 3H).
[0184] To a solution of 525 mg (1.71 mmol) of 2-benzothiazol-2-yl-5-(3-methylphenyl)-1,2-dihydropyrazol-3-one in 10 ml of THF was added N,N-dimethylformamide dimethylacetal (238 μl, 1.79 mmol). The reaction was stirred for 4 hours at room temperature under a nitrogen atmosphere. The solids were filtered off, washed with diethyl ether and dried to give 565 mg (1.56 mmol, 91%) of 2-benzothiazol-2-yl-5-(3-methylphenyl)-4-[1-dimethylaminomethylidene]-2,4-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 8.00 (d, 1H), 7.80 (d, 1H), 7.70 (s, 1H), 7.50-7.20 (m, 6H), 3.70 (s, 3H), 3.40 (s, 3H), 2.40 (s, 3H).
[0185] A suspension of 350 mg (0.966 mmol) of 2-benzothiazol-2-yl-5-(3-methylphenyl)-4-[1-dimethylaminomethylidene]-2,4-dihydropyrazol-3-one in 10 ml 7N ammonia solution in MeOH was heated to 100° C. in a pressure vessel overnight. After cooling to room temperature, the solids were filtered, washed with a little EtOH and dried to give 300 mg (0.897 mmol, 93%) of 4-[1-aminomethylidene]-2-benzothiazol-2-yl-5-(3-methylphenyl)-2,4-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 9.45 (bs, 2H), 8.00 (m, 2H), 7.80 (d, 1H), 7.60 (s, 1H), 7.55 (d, 1H), 7.45-7.30 (m, 4H), 2.40 (s, 3H).
Example 11
Preparation of 4-[1-Aminomethylidene]-2-benzothiazol-2-yl-5-(3-methoxyphenyl)-2,4-dihydro-pyrazol-3-one
[0186] A solution of 1.23 g (7.44 mmol) of benzothiazol-2-yl-hydrazine and 1.65 g (7.44 mmol) of 3-(3-methoxyphenyl)-3-oxopropionic acid ethyl ester in 40 ml of ethanol was refluxed for 5 hours under a nitrogen atmosphere, cooled, the solids were filtered, washed with EtOH and dried to give 1.68 g (5.20 mmol, 70%) of 2-benzothiazol-2-yl-5-(3-methoxyphenyl)-1,2-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 13.00 (bs, 1H), 8.10 (d, 1H), 7.90 (d, 1H), 7.55-7.30 (m, 5H), 7.05 (m, 1H), 6.10 (s, 1H), 3.85 (s, 3H).
[0187] To a solution of 504 mg (1.56 mmol) of 2-benzothiazol-2-yl-5-(3-methoxyphenyl)-1,2-dihydro-pyrazol-3-one in 10 ml of THF was added N,N-dimethylformamide dimethylacetal (217 μl, 1.64 mmol). The reaction was stirred overnight at room temperature under a nitrogen atmosphere. The solids were filtered off, washed with acetone and dried to give 549 mg (1.45 mmol, 93%) of 2-benzothiazol-2-yl-5-(3-methoxyphenyl)-4-[1-dimethylaminomethylidene]-2,4-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 8.00 (d, 1H), 7.80 (d, 1H), 7.70 (s, 1H), 7.45 (m, 2H), 7.30 (t, 1H), 7.15 (m, 2H), 7.10 (d, 1H), 3.80 (s, 3H), 3.70 (s, 3H), 3.40 (s, 3H).
[0188] A suspension of 266 mg (0.703 mmol) of 2-benzothiazol-2-yl-5-(3-methoxyphenyl)-4-[1-dimethylaminomethylidene]-2,4-dihydropyrazol-3-one in 10 ml 7N ammonia solution in MeOH was heated to 100° C. in a pressure vessel overnight. After cooling to room temperature, the solids were filtered, washed with a little EtOH and dried to give 168 mg (0.479 mmol, 68%) of 4-[1-aminomethylidene]-2-benzothiazol-2-yl-5-(3-methoxyphenyl)-2,4-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 9.40 (bs, 2H), 8.00 (m, 2H), 7.85 (d, 1H), 7.45 (m, 2H), 7.40-7.20 (m, 3H), 7.10 (d, 1H), 3.80 (s, 3H).
Example 12
Preparation of 4-[1-Aminomethylidene]-2-benzothiazol-2-yl-5-(3-bromo-4-methylphenyl)-2,4-dihydro-pyrazol-3-one
[0189] To a suspension of 376 mg NaH (9.39 mmol, 60% dispersion in mineral oil) in 30 ml of dry THF under a nitrogen atmosphere was slowly added diethyl carbonate (1.14 ml, 9.39 mmol) and 3-bromo-4-methylacetophenone (1.00 g, 4.69 mmol). The reaction mixture was heated to 70° C. for 4 hours, after which, TLC (silica, EtOAc/PE 40-60 2:3) indicated complete consumption of the starting material. The mixture was cooled, 20 ml of water was slowly added followed by 10 drops of AcOH and extraction with 2×200 ml of EtOAc. The combined organic layers were washed with 20 ml of water, 20 ml of brine, dried over magnesium sulfate and evaporated to give 1.34 g of 3-(3-bromo-4-methylphenyl)-3-oxopropionic acid ethyl ester, which was used without further purification. 1 H-NMR (CDCl3): δ 8.15 (s, 1H), 7.80 (d, 1H), 7.40 (d, 1H), 4.20 (q, 2H), 3.90 (s, 2H), 2.50 (s, 3H), 1.30 (t, 3H).
[0190] A solution of 776 mg (4.70 mmol) of benzothiazol-2-yl-hydrazine and 1.34 g (4.70 mmol) of 3-(3-bromo-4-methylphenyl)-3-oxopropionic acid ethyl ester in 15 ml of ethanol was refluxed overnight under a nitrogen atmosphere, cooled, the solids were filtered, washed with a little cold EtOH and dried to give 1.80 g (4.66 mmol, 99%) of 2-benzothiazol-2-yl-5-(3-bromo-4-methylphenyl)-1,2-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 12.90 (bs, 1H), 8.10 (s, 1H), 8.05 (d, 1H), 7.90 (d, 1H), 7.80 (d, 1H), 7.50 (m, 2H), 7.40 (t, 1H), 6.15 (s, 1H), 2.40 (s, 3H).
[0191] To a solution of 630 mg (1.63 mmol) of 2-benzothiazol-2-yl-5-(3-bromo-4-methylphenyl)-1,2-dihydropyrazol-3-one in 10 ml of THF was added N,N-dimethylformamide dimethylacetal (240 μl, 1.79 mmol). The reaction was stirred for 2 hours at room temperature under a nitrogen atmosphere. The solids were filtered off, washed with diethyl ether and dried to give 610 mg (1.38 mmol, 85%) of 2-benzothiazol-2-yl-5-(3-bromo-4-methylphenyl)-4-[1-dimethylaminomethylidene]-2,4-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 8.00 (d, 1H), 7.80 (m, 2H), 7.70 (s, 1H), 7.50 (m, 2H), 7.45 (t, 1H), 7.30 (t, 1H), 3.70 (s, 3H), 3.40 (s, 3H), 2.40 (s, 3H).
[0192] A suspension of 250 mg (0.583 mmol) of 2-benzothiazol-2-yl-5-(3-bromo-4-methylphenyl)-4-[1-dimethylaminomethylidene]-2,4-dihydropyrazol-3-one in 5 ml EtOH and 5 ml of 25% aqueous ammonia solution was heated to 60° C. overnight. After cooling to room temperature, the solids were filtered, washed with a little EtOH and dried to give 185 mg (0.448 mmol, 77%) of 4-[1-aminomethylidene]-2-benzothiazol-2-yl-5-(3-bromo-4-methylphenyl)-2,4-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 9.50 (bs, 2H), 8.10 (s, 1H), 8.05 (d, 1H), 7.95 (s, 1H), 7.85 (d, 1H),7.65 (d, 1H), 7.50 (m, 2H), 7.35 (t, 1H), 2.40 (s, 3H).
Example 13
Preparation of 4-[1-Aminomethylidene]-5-benzo[b]thiophen-2-yl-2-benzothiazol-2-yl-2,4-dihydropyrazol-3-one
[0193] To a suspension of 452 mg NaH (11.30 mmol, 60% dispersion in mineral oil) in 30 ml of dry THF under a nitrogen atmosphere was slowly added diethyl carbonate (1.38 ml, 11.30 mmol) and 2-acetylbenzo[b]thiophene (1.00 g, 5.67 mmol). The reaction mixture was heated to 70° C. for 3 hours, cooled, 20 ml of water was slowly added followed by 10 drops of AcOH and the mixture was extracted with 3×200 ml of EtOAc. The combined organic layers were washed with 20 ml of water, 100 ml of brine, dried over magnesium sulfate and evaporated to give 1.47 g of 3-benzo[b]thiophen-2-yl-3-oxopropionic acid ethyl ester, which was used without further purification. 1 H-NMR (DMSO-d6): δ 8.20 (s, 1H), 8.05 (2d, 2H), 7.55 (t, 1H), 7.50 (t, 1H), 4.25 (s, 2H), 4.10 (q, 2H), 1.20 (t, 3H).
[0194] A solution of 665 mg (4.03 mmol) of benzothiazol-2-yl-hydrazine and 1.0 g (4.70 mmol) of 3-benzo[b]thiophen-2-yl-3-oxopropionic acid ethyl ester in 10 ml of ethanol and 2 ml of HOAc was refluxed overnight under a nitrogen atmosphere, cooled, the solids were filtered, washed with a little cold EtOH and dried to give 240 mg (0.689 mmol, 17%) of 5-benzo[b]thiophen-2-yl-2-benzothiazol-2-yl-1,2-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 12.90 (bs, 1H), 8.10-7.80 (m, 5H), 7.55 (t, 1H), 7.40 (m, 3H), 6.10 (s, 1H).
[0195] To a solution of 400 mg (1.15 mmol) of 5-benzo[b]thiophen-2-yl-2-benzothiazol-2-yl-1,2-dihydropyrazol-3-one in 10 ml of THF was added N,N-dimethylformamide dimethylacetal (170 μl, 1.26 mmol). The reaction was stirred overnight at room temperature under a nitrogen atmosphere. The solids were filtered off, washed with THF and dried to give 286 mg (0.707 mmol, 61%) of 5-benzo[b]thiophen-2-yl-2-benzothiazol-2-yl-4-[1-dimethylaminomethylidene]-2,4-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 8.10 (s, 1H), 8.05 (m, 2H), 7.90 (m, 3H), 7.50 (m, 3H), 7.35 (t, 1H), 3.75 (s, 3H), 3.55 (s, 3H).
[0196] A suspension of 100 mg (0.247 mmol) of 5-benzo[b]thiophen-2-yl-2-benzothiazol-2-yl-4-[1-dimethylaminomethylidene]-2,4-dihydropyrazol-3-one in 4 ml EtOH and 4 ml of 25% aqueous ammonia solution was heated to 60° C. for 2 hours. After cooling to room temperature, the solids were filtered, washed with a little EtOH and dried to give 55 mg (0.146 mmol, 59%) of 4-[1-aminomethylidene]-5-benzo[b]thiophen-2-yl-2-benzothiazol-2-yl-2,4-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 9.70 (bs, 2H), 8.50 (s, 1H), 8.10 (s, 1H), 8.05 (m, 2H), 7.90 (m, 2H), 7.50 (m, 3H), 7.35 (t, 1H).
Example 14
Preparation of 4-[1-Aminomethylidene]-2-benzothiazol-2-yl-5-thiophen-2-yl-2,4-dihydropyrazol-3-one
[0197] To a suspension of 630 mg NaH (15.85 mmol, 60% dispersion in mineral oil) in 40 ml of dry toluene under a nitrogen atmosphere was slowly added diethyl carbonate (1.92 ml, 15.85 mmol) and 2-acetylthiophene (1.00 g, 7.93 mmol). The reaction mixture was heated to 70° C. for 1 hour, cooled, 200 ml of water was slowly added followed by 2 ml of AcOH and the mixture was extracted with 3×200 ml of EtOAc. The combined organic layers were washed with 100 ml of water, 300 ml of brine, dried over magnesium sulfate and evaporated to give a crude oil that was purified by column chromatography (silica, 10% EtOAc in PE 40-60) to give 1.00 g (5.04 mmol, 64%) of 3-thiophen-2-yl-3-oxopropionic acid ethyl ester. 1 H-NMR (CDCl3): δ 8.15 (s, 1H), 7.55 (m, 1H), 7.35 (m, 1H), 4.20 (q, 2H), 3.90 (s, 2H), 1.25 (t, 3H).
[0198] A solution of 870 mg (5.25 mmol) of benzothiazol-2-yl-hydrazine and 1.04 g (5.25 mmol) of 3-thiophen-2-yl-3-oxopropionic acid ethyl ester in 15 ml of ethanol was refluxed for 18 hours under a nitrogen atmosphere, cooled, the solids were filtered, washed with a little cold EtOH and dried to give 1.38 g (4.61 mmol, 88%) of 2-benzothiazol-2-yl-5-thiophen-2-yl-1,2-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 12.90 (bs, 1H), 8.05 (d, 1H), 7.90 (d, 1H), 7.65 (m, 2H), 7.50 (t, 1H), 7.40 (t, 1H), 7.10 (s, 1H), 5.95 (s, 1H).
[0199] To a solution of 720 mg (2.41 mmol) of 2-benzothiazol-2-yl-5-thiophen-2-yl-1,2-dihydropyrazol-3-one in 10 ml of THF was added N,N-dimethylformamide dimethylacetal (350 μl, 2.56 mmol). The reaction was stirred for 2 hours at room temperature under a nitrogen atmosphere. Diethyl ether was added to induce precipitation, after which, the solids were filtered off, washed with diethyl ether and dried to give 753 mg (2.12 mmol, 88%) of 2-benzothiazol-2-yl-4-[1-dimethylaminomethylidene]-5-thiophen-2-yl-2,4-dihydropyrazol-3-one as a mixture of isomers. In order to obtain one of the isomers pure, 5 ml of DCM was added to the solid isomeric mixture, stirred thoroughly and the liquid decanted from the remaining solids. The liquid was concentrated, the solids filtered and washed with 2 ml of DCM. The combined solids after two DCM washing cycles weighed 82 mg and consisted of one single isomer. 1 H-NMR (DMSO-d6): δ 8.00 (m, 2H), 7.85 (m, 1H), 7.75 (s, 1H), 7.50 (s, 1H), 7.45 (m, 1H), 7.30 (m, 1H), 7.25 (s, 1H), 3.75 (s, 3H), 3.50 (s, 3H).
[0200] A suspension of 500 mg (1.41 mmol) of 2-benzothiazol-2-yl-4-[1-dimethylaminomethylidene]-5-thiophen-2-yl-2,4-dihydropyrazol-3-one in 5 ml EtOH and 5 ml of 25% aqueous ammonia solution was heated to 60° C. for 1 hour. After cooling to room temperature, the solids were filtered, washed with a little EtOH and dried to give 357 mg (1.09 mmol, 78%) of 4-[1-aminomethylidene]-2-benzothiazol-2-yl-5-thiophen-2-yl-2,4-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 9.40 (bs, 2H), 8.30 (s, 1H), 8.05 (d, 1H), 7.90 (d, 1H), 7.75 (d, 1H), 7.65 (m, 1H), 7.50 (t, 1H), 7.35 (t, 1H), 7.25 (m, 1H).
Example 15
Preparation of 4-[1-Aminomethylidene]-2-benzothiazol-2-yl-5-(5-bromothiophen-2-yl)-2,4-dihydropyrazol-3-one
[0201] To a suspension of 597 mg NaH (14.92 mmol, 60% dispersion in mineral oil) in 75 ml of dry THF under a nitrogen atmosphere was slowly added diethyl carbonate (1.81 ml, 14.92 mmol) and 2-acetyl-5-bromothiophene (1.53 g, 7.46 mmol). The reaction mixture was heated to 70° C. for 2 hours, cooled, poured into iced water and acidified with AcOH. The mixture was extracted with EtOAc twice and the combined organic layers were washed with water, brine, dried over magnesium sulfate and evaporated to give 1.82 g (6.57 mmol, 88%) of 3-(5-bromothiophen-2-yl)-3-oxopropionic acid ethyl ester. 1 H-NMR (CDCl3): δ 7.5 (d, 1H), 7.30 (s, 1H), 7.15 (d, 1H), 4.20 (q, 2H), 3.85 (s, 2H), 1.25 (t, 3H).
[0202] A solution of 1.08 g (6.57 mmol) of benzothiazol-2-yl-hydrazine and 1.82 g (6.57 mmol) of 3-(5-bromothiophen-2-yl)-3-oxopropionic acid ethyl ester in 25 ml of ethanol containing 5 ml of AcOH was refluxed overnight under a nitrogen atmosphere, cooled, the solids were filtered, washed with a little cold EtOH and dried to give 1.58 g (4.18 mmol, 64%) of 2-benzothiazol-2-yl-5-(5-bromothiophen-2-yl)-1,2-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 13.00 (bs, 1H), 8.05 (d, 1H), 7.90 (d, 1H), 7.50 (m, 2H), 7.40 (t, 1H), 7.30 (s, 1H), 6.05 (s, 1H).
[0203] To a solution of 793 mg (2.10 mmol) of 2-benzothiazol-2-yl-5-(5-bromothiophen-2-yl)-1,2-dihydropyrazol-3-one in 15 ml of THF was added N,N-dimethylformamide dimethylacetal (292 μl, 2.20 mmol). The reaction was stirred for 15 minutes at room temperature under a nitrogen atmosphere. The solids were filtered off, washed with THF and dried to give 621 mg (1.43 mmol, 68%) of 2-benzothiazol-2-yl-5-(5-bromothiophen-2-yl)-4-[1-dimethylaminomethylidene]-2,4-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 8.00 (d, 1H), 7.95 (s, 1H), 7.85 (d, 1H), 7.45 (t, 1H), 7.40-7.30 (m, 3H), 3.70 (s, 3H), 3.45 (s, 3H).
[0204] A suspension of 260 mg (0.60 mmol) of 2-benzothiazol-2-yl-5-(5-bromothiophen-2-yl)-4-[1-dimethylaminomethylidene]-2,4-dihydropyrazol-3-one in 10 ml 7N ammonia solution in MeOH was stirred at room temperature in a closed flask for 2 days followed by evaporation of the solvent to give 241 mg (0.59 mmol, 99%) of 4-[1-aminomethylidene]-2-benzothiazol-2-yl-5-(5-bromothiophen-2-yl)-2,4-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 9.60 (bs, 2H), 8.30 (s, 1H), 8.05 (d, 1H), 7.90 (d, 1H), 7.55 (m, 1H), 7.50 (t, 1H), 7.35 (m, 2H).
Example 16
4-[1-Aminomethylidene]-2-benzothiazol-2-yl-5-(3-bromophenyl)-2,4-dihydropyrazol-3-one
[0205] A solution of 609 mg (3.69 mmol) of benzothiazol-2-yl-hydrazine and 1.00 g (3.69 mmol) of 3-(3-bromophenyl)-3-oxopropionic acid ethyl ester in 20 ml of EtOH was refluxed overnight under a nitrogen atmosphere, cooled, 2 ml of water was added and the solids were filtered, washed with EtOH and dried to give 1.23 g (3.30 mmol, 90%) of 2-benzothiazol-2-yl-5-(3-bromophenyl)-1,2-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 12.90 (bs, 1H), 8.10 (m, 2H), 7.90 (m, 2H), 7.65 (m, 1H), 7.50-7.30 (m, 3H), 6.20 (s, 1H).
[0206] To a solution of 470 mg (1.26 mmol) of 2-benzothiazol-2-yl-5-(3-bromophenyl)-1,2-dihydropyrazol-3-one in 10 ml of THF was added N,N-dimethylformamide dimethylacetal (185 μl, 1.39 mmol). The reaction was stirred overnight at room temperature under a nitrogen atmosphere. Diethyl ether was added and the solids were filtered off, washed with diethyl ether and dried to give 487 mg (1.13 mmol, 90%) of 2-benzothiazol-2-yl-5-(3-bromophenyl)-4-[1-dimethylaminomethylidene]-2,4-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 8.00 (d, 1H), 7.80 (m, 2H), 7.70 (m, 2H), 7.65 (d, 1H), 7.45 (2t, 2H), 7.35 (t, 1H), 3.70 (s, 3H), 3.40 (s, 3H).
[0207] A suspension of 467 mg (1.09 mmol) of 2-benzothiazol-2-yl-5-(3-bromophenyl)-4-[1-dimethylaminomethylidene]-2,4-dihydropyrazol-3-one in 10 ml 7N NH3 in MeOH was heated in a pressure vessel to 100° C. overnight. After cooling to room temperature, the solids were filtered, washed with a little EtOH and dried to give 382 mg (0.957 mmol, 88%) of 4-[1-aminomethylidene]-2-benzothiazol-2-yl-5-(3-bromophenyl)-2,4-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 9.60 (bs, 2H), 8.10 (s, 1H), 8.00 (d, 1H), 7.90 (d, 1H), 7.80 (s, 1H),7.70 (m, 1H), 7.55 (m, 2H), 7.45 (t, 1H), 7.30 (t, 1H).
Example 17
4-[1-Aminomethylidene]-2-benzothiazol-2-yl-5-(3-iodophenyl)-2,4-dihydropyrazol-3-one
[0208] A solution of 519 mg (3.14 mmol) of benzothiazol-2-yl-hydrazine and 1.00 g (3.14 mmol) of 3-(3-iodophenyl)-3-oxopropionic acid ethyl ester in 20 ml of EtOH was refluxed overnight under a nitrogen atmosphere, cooled, 2 ml of water was added and the solids were filtered, washed with EtOH and dried to give 1.14 g (2.71 mmol, 86%) of 2-benzothiazol-2-yl-5-(3-iodophenyl)-1,2-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 13.00 (bs, 1H), 8.25 (s, 1H), 8.05 (d, 1H), 7.90 (m, 2H), 7.80 (m, 1H), 7.50 (t, 1H), 7.40 (t, 1H), 7.30 (t, 1H), 6.20 (s, 1H).
[0209] To a solution of 393 mg (0.94 mmol) of 2-benzothiazol-2-yl-5-(3-iodophenyl)-1,2-dihydropyrazol-3-one in 20 ml of THF was added N,N-dimethylformamide dimethylacetal (137 μl, 1.03 mmol). The reaction was stirred for 1 hour at room temperature under a nitrogen atmosphere. Diethyl ether was added and the solids were filtered off, washed with diethyl ether and dried to give 424 mg (0.89 mmol, 95%) of 2-benzothiazol-2-yl-5-(3-iodophenyl)-4-[1-dimethylaminomethylidene]-2,4-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 8.00 (m, 2H), 7.90 (d, 1H), 7.80 (d, 1H), 7.70 (s, 1H), 7.60 (d, 1H), 7.40 (t, 1H), 7.30 (m, 2H), 3.70 (s, 3H), 3.40 (s, 3H).
[0210] A suspension of 196 mg (0.413 mmol) of 2-benzothiazol-2-yl-5-(3-iodophenyl)-4-[1-dimethylaminomethylidene]-2,4-dihydropyrazol-3-one in 3 ml 7N NH3 in MeOH was heated to 50° C. for 1.5 hours and left to cool overnight. The solids were filtered, washed with a little EtOH and dried to give 137 mg (0.307 mmol, 74%) of 4-[1-aminomethylidene]-2-benzothiazol-2-yl-5-(3-iodophenyl)-2,4-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 9.50 (bs, 2H), 8.10 (s, 1H), 8.00 (m, 2H), 7.85 (m, 2H), 7.80 (d, 1H), 7.45 (t, 1H), 7.30 (m, 2H).
Example 18
4-[1-Aminomethylidene]-2-benzothiazol-2-yl-5-(3-fluorophenyl)-2,4-dihydropyrazol-3-one
[0211] A solution of 786 mg (4.76 mmol) of benzothiazol-2-yl-hydrazine and 1.00 g (4.76 mmol) of 3-(3-fluorophenyl)-3-oxopropionic acid ethyl ester in 25 ml of EtOH was refluxed for 5 hours under a nitrogen atmosphere, cooled and the solids were filtered, washed with EtOH and dried to give 870 mg (2.79 mmol, 59%) of 2-benzothiazol-2-yl-5-(3-fluorophenyl)-1,2-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 13.00 (bs, 1H), 8.10 (d, 1H), 7.90 (d, 1H), 7.75 (m, 2H), 7.50 (m, 2H), 7.40 (t, 1H), 7.30 (m, 1H), 6.20 (s, 1H).
[0212] To a solution of 480 mg (1.54 mmol) of 2-benzothiazol-2-yl-5-(3-fluorophenyl)-1,2-dihydropyrazol-3-one in 10 ml of THF was added N,N-dimethylformamide dimethylacetal (225 μl, 1.70 mmol). The reaction was stirred for 3 hours at room temperature under a nitrogen atmosphere. Diethyl ether was added and the solids were filtered off, washed with diethyl ether and dried to give 520 mg (1.42 mmol, 92%) of 2-benzothiazol-2-yl-5-(3-fluorophenyl)-4-[1-dimethylaminomethylidene]-2,4-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 8.00 (d, 1H), 7.80 (d, 1H), 7.70 (s, 1H), 7.60 (m, 1H), 7.50-7.40 (m, 3H), 7.40-7.30 (m, 2H), 3.70 (s, 3H), 3.40 (s, 3H).
[0213] A suspension of 360 mg (0.819 mmol) of 2-benzothiazol-2-yl-5-(3-fluorophenyl)-4-[1-dimethylaminomethylidene]-2,4-dihydropyrazol-3-one in 3 ml 7N NH3 in MeOH was heated in a pressure vessel to 100° C. overnight. After cooling to room temperature the solids were filtered, washed with a little EtOH and dried to give 249 mg (0.736 mmol, 90%) of 4-[1-aminomethylidene]-2-benzothiazol-2-yl-5-(3-fluorophenyl)-2,4-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 9.40 (bs, 2H), 8.10 (s, 1H), 8.00 (d, 1H), 7.85 (d, 1H), 7.60 (m, 3H), 7.45 (t, 1H), 7.35 (m, 2H).
Example 19
4-[1-Aminomethylidene]-2-benzothiazol-2-yl-5-(3-t-butylphenyl)-2,4-dihydropyrazol-3-one
[0214] To a suspension of 984 mg NaH (24.60 mmol, 60% dispersion in mineral oil) in 15 ml of dry benzene under a nitrogen atmosphere was slowly added diethyl carbonate (2.10 ml, 16.40 mmol) and 3-t-butylacetophenone (1.45 g, 8.20 mmol). The reaction mixture was heated to reflux for 30 minutes. The mixture was cooled to room temperature, 3 ml of AcOH was slowly added followed by water and extraction with EtOAc. The organic layer was dried over magnesium sulfate, evaporated and the residue was purified by column chromatography (silica, PE (40-60)/EtOAc 20:1) to give 1.45 g (5.84 mmol, 71%) of 3-(3-t-butylphenyl)-3-oxopropionic acid ethyl ester.
[0215] A solution of 964 mg (5.84 mmol) of benzothiazol-2-yl-hydrazine and 1.45 g (5.84 mmol) of 3-(3-t-butylphenyl)-3-oxopropionic acid ethyl ester in 5 ml of EtOH and 5 ml of HOAc was refluxed overnight under a nitrogen atmosphere, cooled and the solids were filtered, washed with EtOH and dried to give 1.70 g (4.86 mmol, 83%) of 2-benzothiazol-2-yl-5-(3-t-butylphenyl)-1,2-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 13.05 (bs, 1H), 8.10 (d, 1H), 7.90 (m, 2H), 7.70 (d, 1H), 7.55-7.30 (m, 4H), 6.10 (s, 1H), 1.35 (s, 9H).
[0216] To a solution of 1.00 g (2.86 mmol) of 2-benzothiazol-2-yl-5-(3-t-butylphenyl)-1,2-dihydropyrazol-3-one in 20 ml of THF was added N,N-dimethylformamide dimethylacetal (4.20 μl, 3.15 mmol). The reaction was stirred for 3 hours at room temperature under a nitrogen atmosphere, the solids were filtered off, washed with diethyl ether and dried to give 690 mg (1.70 mmol, 60%) of 2-benzothiazol-2-yl-5-(3-t-butylphenyl)-4-[1-dimethylaminomethylidene]-2,4-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 8.00 (d, 1H), 7.80 (d, 1H), 7.65 (s, 1H), 7.60 (s, 1H), 7.55 (m, 1H), 7.45 (m, 3H), 7.30 (t, 1H), 3.70 (s, 3H), 3.40 (s, 3H), 1.35 (s, 9H).
[0217] A suspension of 150 mg (0.371 mmol) of 2-benzothiazol-2-yl-5-(3-t-butylphenyl)-4-[1-dimethylaminomethylidene]-2,4-dihydropyrazol-3-one in 5 ml 7N NH3 in MeOH was heated to 60° C. for 2 hours. After cooling to room temperature the solids were filtered, washed with a little EtOH and dried to give 114 mg (0.302 mmol, 82%) of 4-[1-aminomethylidene]-2-benzothiazol-2-yl-5-(3-t-butylphenyl)-2,4-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 9.45 (bs, 2H), 8.05 (d, 1H), 7.95 (s, 1H), 7.85 (d, 1H), 7.70 (s, 1H), 7.60-7.40 (m, 3H), 7.30 (m, 2H), 1.35 (s, 9H).
Example 20
4-[1-Aminomethylidene]-2-(6-methoxybenzothiazol-2-yl)-5-phenyl-2,4-dihydropyrazol-3-one
[0218] A solution of 1.33 g (6.81 mmol) of (6-methoxybenzothiazol-2-yl)-hydrazine and 1.44 g (7.49 mmol) of ethyl benzoylacetate in 40 ml of EtOH was refluxed overnight under a nitrogen atmosphere. The solids were filtered off, washed with EtOH and dried to give 1.96 g (6.06 mmol, 89%) of 2-(6-methoxybenzothiazol-2-yl)-5-phenyl-1,2-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 12.85 (bs, 1H), 7.85 (m, 2H), 8.00 (d, 1H), 7.65 (d, 1H), 7.45 (m, 2H), 7.10 (d, 1h), 6.10 (s, 1H), 3.80 (s, 3H).
[0219] To a solution of 364 mg (1.13 mmol) of 2-(6-methoxybenzothiazol-2-yl)-5-phenyl-1,2-dihydropyrazol-3-one in 15 ml of THF was added N,N-dimethylformamide dimethylacetal (164 μl, 1.24 mmol). The reaction was stirred overnight at room temperature under a nitrogen atmosphere, after which, the solids were filtered off, washed with diethyl ether and dried to give 372 mg (0.983 mmol, 87%) of 2-(6-methoxybenzothiazol-2-yl)-4-[1-dimethylaminomethylidene]-5-phenyl-2,4-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 7.70-7.45 (m, 8H), 7.00 (d, 1H), 3.80 (s, 3H), 3.70 (s, 3H), 3.40 (s, 3H).
[0220] A suspension of 240 mg (0.634 mmol) of 2-(6-methoxybenzothiazol-2-yl)-4-[1-dimethylaminomethylidene]-5-phenyl-2,4-dihydropyrazol-3-one in 10 ml 7N NH3 in MeOH was heated to 100° C. in a pressure vessel overnight. After cooling to room temperature, the solids were filtered, washed with a little EtOH and dried to give 192 mg (0.548 mmol, 86%) of 4-[1-aminomethylidene]-2-(6-methoxybenzothiazol-2-yl)-5-phenyl-2,4-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 9.45 (bs, 2H), 8.00 (bs, 1H), 7.70 (m, 3H), 7.60 (s, 1H), 7.50 (m, 3H), 7.05 (d, 1H), 3.80 (s, 3H).
Example 21
4-[1-Aminomethylidene]-2-benzothiazol-2-yl-5-(3-bromothiophen-2-yl)-2,4-dihydropyrazol-3-one
[0221] To a suspension of 628 mg NaH (15.70 mmol, 60% dispersion in mineral oil) in 25 ml of THF under a nitrogen atmosphere was slowly added diethyl carbonate (1.90 ml, 15.70 mmol) and 1-(3-bromo-thiophen-2-yl)-ethanone (1.61 g, 7.85 mmol). The reaction mixture was heated to 70° C. for 2 hours, cooled to room temperature poured into ice water followed by some AcOH and extracted with 2× EtOAc. The combined organic layers were washed with water 3×, washed with brine, dried over magnesium sulfate, evaporated and the residue was purified by column chromatography (silica, 25% EtOAc in PE (40/60) to give 1.54 g (5.84 mmol, 71%) of 3-(3-bromothiophen-2-yl)-3-oxo-propionic acid ethyl ester.
[0222] A solution of 918 mg (5.56 mmol) of benzothiazol-2-yl-hydrazine and 1.54 g (5.56 mmol) of 3-(3-bromothiophen-2-yl)-3-oxo-propionic acid ethyl ester in 25 ml of EtOH/AcOH (1:1) was refluxed overnight under a nitrogen atmosphere, cooled, the solids were filtered off, washed with EtOH and dried to give 711 mg (1.88 mmol, 34%) of 2-benzothiazol-2-yl-5-(3-bromothiophen-2-yl)-1,2-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 13.00 (bs, 1H), 8.10 (d, 1H), 7.90 (d, 1H), 7.70 (s, 1H), 7.50 (t, 1H), 7.40 (t, 1H), 7.20 (m, 1h), 6.30 (s, 1H).
[0223] To a solution of 700 mg (1.85 mmol) of 2-benzothiazol-2-yl-5-(3-bromothiophen-2-yl)-1,2-dihydropyrazol-3-one in 7 ml of THF was added N,N-dimethylformamide dimethylacetal (258 μl, 1.94 mmol). The reaction was stirred for 1 hour at room temperature under a nitrogen atmosphere, after which, the solids were filtered off, washed with diethyl ether and dried to give 550 mg (1.26 mmol, 69%) of 2-benzothiazol-2-yl-5-(3-bromothiophen-2-yl)-4-[1-dimethylaminomethylidene]-2,4-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 8.00 (d, 1H), 7.90 (d, 1H), 7.80 (d, 1H), 7.60 (s, 1H), 7.45 (t, 1H), 7.30 (m, 2H), 3.80 (s, 3H), 3.40 (s, 3H).
[0224] A suspension of 210 mg (0.485 mmol) of 2-benzothiazol-2-yl-5-(3-bromothiophen-2-yl)-4-[1-dimethylaminomethylidene]-2,4-dihydropyrazol-3-one in 5 ml 7N NH3 in MeOH was heated to 60° C. overnight. After cooling to room temperature, the solids were filtered, washed with a little EtOH and dried to give 198 mg (0.472 mmol, 97%) of 4-[1-aminomethylidene]-2-benzothiazol-2-yl-5-(3-bromothiophen-2-yl)-2,4-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 9.25 (bs, 2H), 8.05 (d, 1H), 7.85 (m, 3H), 7.45 (t, 1H), 7.30 (m, 2H).
Example 22
2-Benzothiazol-2-yl-4-[1-methylaminomethylidene]-5-thiophen-2-yl-2,4-dihydropyrazol-3-one
[0225] To a suspension of 628 mg NaH (15.70 mmol, 60% dispersion in mineral oil) in 10 ml of THF under a nitrogen atmosphere was slowly added diethyl carbonate (1.90 ml, 15.70 mmol) and 2-acetylthiophene (1.00 g, 7.92 mmol). The reaction mixture was heated to 70° C. for 1 hour, cooled to room temperature poured into ice water, AcOH was added and the reaction mixture was with extracted twice with diethyl ether. The combined organic layers were washed with water, brine, dried over magnesium sulfate, evaporated and the residue was purified by column chromatography (silica, DCM) to give 1.27 g (6.41 mmol, 80%) of 3-oxo-3-thiophen-2-yl-propionic acid ethyl ester.
[0226] A solution of 1.06 g (6.41 mmol) of benzothiazol-2-yl-hydrazine and 1.27 g (6.41 mmol) of 3-oxo-3-thiophen-2-yl-propionic acid ethyl ester in 15 ml of EtOH was refluxed overnight under a nitrogen atmosphere, cooled, the solids were filtered off, washed with EtOH and dried to give 1.30 g (4.34 mmol, 68%) of 2-benzothiazol-2-yl-5-thiophen-2-yl-1,2-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 13.00 (bs, 1H), 8.05 (d, 1H), 7.90 (d, 1H), 7.70 (m, 2H), 7.50 (t, 1H), 7.40 (t, 1H), 7.20 (s, 1h), 6.00 (s, 1H).
[0227] To a solution of 137 mg (0.458 mmol) of 2-benzothiazol-2-yl-5-thiophen-2-yl-1,2-dihydropyrazol-3-one in 6 ml of THF was added N,N-dimethylformamide dimethylacetal (64 μl, 0.480 mmol). The reaction was stirred for 10 minutes at room temperature under a nitrogen atmosphere, after which, the solids were filtered off, washed with diethyl ether and dried to give 162 mg (0.458 mmol, 100%) of 2-benzothiazol-2-yl-4-[1-dimethylaminomethylidene]-5-thiophen-2-yl-2,4-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 8.00 (m, 2H), 7.85 (d, 1H), 7.75 (d, 1H), 7.55 (m, 1H), 7.45 (t, 1H), 7.30 (t, 1H), 7.20 (m, 1H), 3.80 (s, 3H), 3.45 (s, 3H).
[0228] A suspension of 162 mg (0.458 mmol) of 2-benzothiazol-2-yl-4-[1-dimethylaminomethylidene]-5-thiophen-2-yl-2,4-dihydropyrazol-3-one in 5 ml of 33% MeNH2 in EtOH was stirred at room temperature for 1.5 hours, the solids were filtered, washed with EtOH and dried to give 47 mg (0.138 mmol, 30%) of 2-benzothiazol-2-yl-4-[1-methylaminomethylidene]-5-thiophen-2-yl-2,4-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 9.95 (bs, 1H), 8.20 (s, 1H), 8.00 (d, 1H), 7.85 (d, 1H), 7.75 (m, 2H), 7.45 (t, 1H), 7.35 (t, 1H), 7.20 (s, 1H), 3.30 (s, 3H).
Example 23
2-Benzothiazol-2-yl-5-methyl-4-[1-piperidin-1-ylmethylidene]-2,4-dihydropyrazol-3-one
[0229] A solution of 2.00 g (12.10 mmol) of benzothiazol-2-ylhydrazine and 1.62 ml (12.71 mmol) of ethyl acetoacetate in 40 ml of acetic acid was refluxed under a nitrogen atmosphere for 2.5 hours and stirred at room temperature overnight. 50 ml of water was added and the precipitate was collected by filtration, washed with water and dried to give 2.68 g (11.59 mmol, 96%) of 2-benzothiazol-2-yl-5-methyl-1,2-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 12.80 (bs, 1H), 8.00 (d, 1H), 7.80 (d, 1H), 7.50 (t, 1H), 7.35 (t, 1H), 5.25 (s, 1H), 2.20 (s, 3H).
[0230] To a suspension of 220 mg (0.951 mmol) of 2-benzothiazol-2-yl-5-methyl-1,2-dihydropyrazol-3-one in 20 ml toluene was added N,N-dimethylformamide dimethylacetal (135 μl, 1.00 mmol). The reaction was stirred for 4 hours at room temperature under a nitrogen atmosphere, after which time, the solvent was evaporated and the remaining solids were washed with diethyl ether and dried to give 180 mg (0.629 mmol, 66%) of 2-benzothiazol-2-yl-4-[1-dimethylaminomethylidene]-5-methyl-2,4-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 7.95 (d, 1H), 7.75 (d, 1H), 7.65 (s, 1H), 7.40 (t, 1H), 7.25 (t, 1H), 3.75 (s, 3H), 3.40 (s, 3H), 2.20 (s, 3H).
[0231] To a suspension of 1.80 g (6.29 mmol) of 2-benzothiazol-2-yl-4-[1-dimethylaminomethylidene]-5-methyl-2,4-dihydropyrazol-3-one in a mixture of 15 ml of toluene and 10 ml of DMF was added 5 ml of a 4N NaOH solution. The reaction mixture was stirred under a nitrogen atmosphere at room temperature for 4 hours, after which time, the solids were filtered off and dried in vacuo to give 2-benzothiazol-2-yl-5-methyl-3-oxo-2,3-dihydro-1H-pyrazole-4-carbaldehyde (6.29 mmol; 100%). 1 H-NMR (DMSO-d6): δ 9.30 (s, 1H), 8.45 (s, 1H), 7.90 (d, 1H), 7.70 (d, 1H), 7.40 (t, 1H), 7.20 (t, 1H), 2.20 (2, 3H).
[0232] A mixture of 160 mg (0.617 mmol) of 2-benzothiazol-2-yl-5-methyl-3-oxo-2,3-dihydro-1H-pyrazole-4-carbaldehyde, piperidine (720 μl, 7.35 mmol) and 2 drops of concentrated HCl was refluxed overnight under a nitrogen atmosphere, cooled, evaporated to dryness and the residue purified by column chromatography (silica, 4% methanol in dichloromethane) to give 100 mg (0.306 mmol, 50%) of 2-benzothiazol-2-yl-5-methyl-4-[1-piperidin-1-yl-methylidene]-2,4-dihydropyrazol-3-one. 1 H-NMR (DMSO-d6): δ 7.95 (d, 1H), 7.75 (d, 1H), 7.65 (s, 1H), 7.40 (t, 1H), 7.25 (t, 1H), 4.50 (bs, 2H), 3.75 (bs, 2H), 2.00 (s, 3H), 1.70 (bs, 4H), 1.65 (bs, 2H).
Example 24
Biological Methods
[0233] The PC-3 prostate cancer cell line (ATCC# CRL-1435) was maintained in RPMI-1640 medium (Invitrogen, 31870), supplemented with 10% Fetal Bovine Serum (Sigma, F7524), L-Glutamine (Invitrogen 25030-024). Cells were split once a week at a 1:10 ratio.
Example 25
Cell Invasion Assay
[0234] For cell invasion assays, PC3 cells were incubated in the presence of a compound according to the invention (10 μM) for 4 days, prior to the invasion assay. Forty thousand cells were seeded into BD Biocoat Matrigel Invasion chambers (8 micron; BD 354480) in serum-free medium. The invasion chamber was placed in a 24-well containing medium with 10% fetal calf serum as chemo-attractant. As a control, the same amount of cells was seeded in 24-well culture plates. After 48 hours incubation, cells in the invasion chamber were removed by aspiration and cleaning the inner compartment with a cotton swab. The invasion chamber was then put into CellTiter-GLO (CTG, Promega-G7571) cell viability reagent, incubated for 15 minutes, and then analyzed on a Victor3 luminometer. Cell invasion was calculated as the CTG activity on the lower part of the membrane divided by the CTG activity of the cells grown in a 24 well plate. Inhibition of cell invasion by a specific compound was estimated by comparing the amount of cell invasion of compound-treated cells versus DMSO treated cells.
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A compound having the structure according to formula III
wherein:
X is NH or S; R 1 is H or (1C-4C)alkyl; R 2 is (1C-4C)alkyl, phenyl or a monocyclic aromatic ring having one or more N—, O— or S— atoms in the ring, which alkyl, phenyl or aromatic ring is optionally substituted with one or more groups selected from (1C-4C)alkyl, (1C-4C)alkyloxy, halo(1C-4C)alkyl, halo(1C-4C)alkyloxy, phenyloxy, phenylthio, halogen, or nitro; R 3 and R 4 are each independently H, (1C-6C)alkyl, (2C-6C) alkenyl, (2C-6C)alkynyl, cyano, (3C-6C)cycloalkyl, phenyl, a monocyclic aromatic ring having one or more N—, O— or S— atoms in the ring, a monocyclic non-aromatic ring having one or more N—, O— or S— atoms in the ring, each optionally substituted with hydroxyl, (1C-4C)alkoxy, phenyl, cycloalkyl, piperidyl, piperazinyl, furyl, thienyl, pirazinyl, pyrrolyl, 2H-pyrrolyl, pyrazolyl, isoxazolyl, isothiazolyl, pyrrolidonyl, pyrrolinyl, imidazolinyl, imidazolyl, a monocyclic aromatic ring having one or more N—, O— or S— atoms in the ring, whereby each of these optional substituents is optionally further substituted with (1C-4C)alkyl, (1C-4C)alkyloxy, halo(1C-4C)alkyl, halo(1C-4C)alkyloxy, halogen, nitro or (1C-2C)dioxol forming a ring; or R 3 and R 4 form together pyrrolyl, imidazolyl, pyrazolyl, pyrrolidinyl, pyrrolinylimidazolidinyl, imidazolinyl, piperidyl, piperazinylmorpholinyl, each optionally substituted with (1C-6C)alkyl, phenyl(1C-4C)alkyl, phenylketo(1C-4C)alkyl; R 5 is H, Cl, F, Br, Me, NO 2 , t-butyl, OCF 3 , OCH 3 , CF 3 ; R 6 is H, (1C-4C)alkyl, (1C-4C)alkyloxy, halo(1C-4C)alkyl, halo(1C-4C)alkyloxy, nitro or halogen; R 7 is H, F, Cl, Br, Me, NO 2 , t-butyl, OCF 3 , OCH 3 , CF 3 ; or pharmaceutically acceptable addition salts thereof for use in treatments of carcinoma, in particular, to delay, prevent or reverse metastasis in prostate cancer.
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FIELD
[0001] The technology herein relates to video games, and more particularly to special game player modes that temporarily increase the capability of game characters to perform tasks. In more detail, the technology herein relates to a hyper mode that imbues a game character with invulnerability, strength or power while simultaneously creating a risk of adverse consequences.
BACKGROUND AND SUMMARY
[0002] We are all intrigued by what it would be like to have special powers. Superman, Spiderman and Batman cartoons, comic books, radio shows, television shows and motion pictures have captured the imagination of generations of youngsters. But the idea of human-like entities having invulnerability and special powers extends back into the dim mists of ancient history. The Greeks worshiped gods on Mount Olympus with special powers, and Homer wrote about warriors such as Achilles who was invulnerable except for his heel.
[0003] Video games have continued this long tradition by providing special modes that enhance the game character capabilities. If a game character completes certain challenges, he or she may be given a period of strength or invulnerability that will allow game character to accomplish “super-human” tasks. Some games have even provided evolutionary processes by which game characters can transform such as from a caterpillar to a butterfly and leave the ground to accomplish wonderful things up in the sky.
[0004] While much work and investigation has been done in the past to make video and computer game play more interesting, further improvements and interesting new features are typically sought after.
[0005] The technology herein provides a special game player mode (“hyper-mode”) which provides a game player with a period of strength or invulnerability. When a game player has entered the “hyper-mode”, a power meter is displayed on the screen. The power meter provides an indication of a power reservoir the game character can use to accomplish one or more tasks. In one specific exemplary illustrative non-limiting implementation, the power meter provides a power reservoir indication that the game character uses up by firing one or more weapons, and thus functions as sort of an “ammo” (ammunition) gauge.
[0006] In the exemplary illustrative non-limiting implementation, the game character can use up the power reservoir indicated by the power meter by firing a weapon. Meanwhile, however, the game automatically and continually replenishes the power reservoir at a predetermined rate. If the amount of power contained within the power reservoir ever exceeds a predetermined threshold based on such continual replenishment, the game player suffers a detrimental impact. In one exemplary illustrative non-limiting implementation, the game character dies whenever a power overload occurs.
[0007] In one exemplary illustrative non-limiting implementation, such as a fighting game, a game character in the “hyper mode” is invulnerable and can attack enemies without fear of being injured or killed. The displayed power meter continually shows an available reservoir of fire power that the game character can use to fire weapons at the enemy. If the power meter falls to zero showing complete depletion, the game character loses the benefit of the invulnerability provided by hyper mode and once again becomes vulnerable to enemy attack. Meanwhile, however, the power reservoir is constantly refilled at a predetermined rate (the rate may be beyond the game player's control). If the capacity of the power meter is exceeded, the game character is destroyed by his own instability.
[0008] In one exemplary illustrative non-limiting implementation, the same or similar power meter can be used for normal mode game play as well as hyper mode game play. In the normal mode, the power meter or other indicator displays an amount of power or life remaining. One block or graduation of the indicated power meter could, for example, corresponding to some number of score points such as 100 points. In one exemplary illustrative non-limiting implementation, the game player can enter into hyper mode at will by using for example one block or graduation of power or life indicated by the power meter.
[0009] In one exemplary illustrative non-limiting implementation, upon entering the hyper mode, the hyper mode gauge displays remaining energy that the game player can use to fire weapons at enemies. The hyper mode may or may not have a preset duration of a particular amount of time. The duration of hypermode decreases as the amount of energy indicated on the gauge decreases. Thus, for example, if the game player uses up the energy indicated by the gauge by firing his or her weapons often, he or she may decrease how much time the game character enjoys the benefits of hyper mode. However, the game may automatically replenish the energy indicated by the gauge at a predetermined rate, and so the amount of energy indicated by the gauge will increase if the game player does not fire weapons for awhile. If the gauge ever exceeds a maximum capacity threshold after the character enters hyper mode, the game is over.
[0010] In the exemplary illustrative non-limiting implementation, the game player must carefully shoot game objects while watching the hyper mode gauge to ensure the gauge does not ever become overfilled or “maxed out”. If the amount of energy indicated by the gauge is ever completely depleted, hyper mode is over and the game player is no longer imbued with special powers such as for example vulnerability. On the other hand, if the amount of energy indicated by the gauge ever exceeds a predetermined maximum, the game character may suffer a setback or other negative event including for example destruction.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] These and other features and advantages of exemplary illustrative non-limiting implementations will be better and more completely understood by referring to the following detailed description in conjunction with the drawings of which:
[0012] FIG. 1 shows an exemplary external view of a non-limiting interactive computer graphics system in the form of a home video game apparatus for executing a game program;
[0013] FIG. 2 is a block diagram showing an internal structure of the game apparatus;
[0014] FIGS. 3A , 3 B and 4 show different views of an exemplary illustrative non-limiting handheld controller for the video game system of FIG. 1 ;
[0015] FIG. 5 is a block diagram of an exemplary illustrative non-limiting implementation of the handheld controller;
[0016] FIG. 6 shows an example illustrative non-limiting general game display;
[0017] FIG. 7 shows an example illustrative non-limiting hyper mode game display; and
[0018] FIG. 8 is a flowchart of exemplary illustrative non-limiting program control steps.
DETAILED DESCRIPTION
[0019] Techniques described herein can be performed on any type of computer graphics system including a personal computer, a home video game machine, a portable video game machine, a networked server and display, a cellular telephone, a personal digital assistant, or any other type of device or arrangement having computation and graphical display capabilities. One exemplary illustrative non-limiting implementation includes a home video game system such as the Nintendo Wii 3D video game system, a Nintendo DS or other 3D capable interactive computer graphics display system. One exemplary illustrative non-limiting implementation is described below, but other implementations are possible.
Exemplary Video Game Platform
[0020] FIG. 1 shows a non-limiting example game system 10 including a game console 100 , a television 102 and a controller 107 .
[0021] Game console 100 executes a game program or other application stored on optical disc 104 inserted into slot 105 formed in housing 110 thereof. The result of the execution of the game program or other application is displayed on display 101 of television 102 to which game console 100 is connected by cable 106 . Audio associated with the game program or other application is output via speakers 109 of television 102 . While an optical disk is shown in FIG. 1 for use in storing video game software, the game program or other application may alternatively or additionally be stored on other storage media such as semiconductor memories, magneto-optical memories, magnetic memories and the like and/or downloaded over a network or by other means.
[0022] Controller 107 wirelessly transmits data such as game control data to the game console 100 . The game control data may be generated using an operation section of controller 107 having, for example, a plurality of operation buttons, a key, a stick and the like. Controller 107 may also wirelessly receive data transmitted from game console 100 . Any one of various wireless protocols such as Bluetooth (registered trademark) may be used for the wireless transmissions between controller 107 and game console 100 .
[0023] As discussed below, controller 107 also includes an imaging information calculation section for capturing and processing images from light-emitting devices 108 a and 108 b . Preferably, a center point between light-emitting devices 108 a and 108 b is aligned with a vertical center line of television 101 . The images from light-emitting devices 108 a and 108 b can be used to determine a direction in which controller 107 is pointing as well as a distance of controller 107 from display 101 . By way of example without limitation, light-emitting devices 108 a and 108 b may be implemented as two LED modules (hereinafter, referred to as “markers”) provided in the vicinity of a display screen of television 102 . The markers each output infrared light and the imaging information calculation section of controller 107 detects the light output from the LED modules to determine a direction in which controller 107 is pointing and a distance of controller 107 from display 101 as mentioned above. As will become apparent from the description below, various implementations of the system and method for simulating the striking of an object described herein do not require use such markers.
[0024] Although markers 108 a and 108 b are shown in FIG. 1 as being above television 100 , they may also be positioned below television 100 or in other configurations.
[0025] With reference to the block diagram of FIG. 2 , game console 100 includes a RISC central processing unit (CPU) 204 for executing various types of applications including (but not limited to) video game programs. CPU 204 executes a boot program stored in a boot ROM (not shown) to initialize game console 100 and then executes an application (or applications) stored on optical disc 104 which is inserted in optical disk drive 208 . User-accessible eject button 210 provided on housing 110 of game console 100 may be used to eject an optical disk from disk drive 208 .
[0026] In one example implementation, optical disk drive 208 receives both optical disks of a first type (e.g., of a first size and/or of a first data structure, etc.) containing applications developed for execution by CPU 204 and graphics processor 216 and optical disks of a second type (e.g., of a second size and/or a second data structure) containing applications originally developed for execution by a different CPU and/or graphics processor. For example, the optical disks of the second type may be applications originally developed for the Nintendo GameCube platform.
[0027] CPU 204 is connected to system LSI 202 that includes graphics processing unit (GPU) 216 with an associated graphics memory 220 , audio digital signal processor (DSP) 218 , internal main memory 222 and input/output (IO) processor 224 .
[0028] IO processor 224 of system LSI 202 is connected to one or more USB ports 226 , one or more standard memory card slots (connectors) 228 , WiFi module 230 , flash memory 232 and wireless controller module 240 .
[0029] USB ports 226 are used to connect a wide variety of external devices to game console 100 . These devices include by way of example without limitation game controllers, keyboards, storage devices such as external hard-disk drives, printers, digital cameras, and the like. USB ports 226 may also be used for wired network (e.g., LAN) connections. In one example implementation, two USB ports 226 are provided.
[0030] Standard memory card slots (connectors) 228 are adapted to receive industry-standard-type memory cards (e.g., SD memory cards). In one example implementation, one memory card slot 228 is provided. These memory cards are generally used as data carriers. For example, a player may store game data for a particular game on a memory card and bring the memory card to a friend's house to play the game on the friend's game console. The memory cards may also be used to transfer data between the game console and personal computers, digital cameras, and the like.
[0031] WiFi module 230 enables game console 100 to be connected to a wireless access point. The access point may provide internet connectivity for on-line gaming with players at other locations (with or without voice chat capabilities), as well as web browsing, e-mail, file downloads (including game downloads) and many other types of on-line activities. In some implementations, WiFi module may also be used for communication with other game devices such as suitably-equipped hand-held game devices. Module 230 is referred to herein as “WiFi”, which is generally used in connection with the family of IEEE 802.11 specifications. However, game console 100 may of course alternatively or additionally use wireless modules that conform with other wireless standards.
[0032] Flash memory 232 stores, by way of example without limitation, game save data, system files, internal applications for the console and downloaded data (such as games).
[0033] Wireless controller module 240 receives signals wirelessly transmitted from one or more controllers 107 and provides these received signals to IO processor 224 . The signals transmitted by controller 107 to wireless controller module 240 may include signals generated by controller 107 itself as well as by other devices that may be connected to controller 107 . By way of example, some games may utilize separate right- and left-hand inputs. For such games, another controller (not shown) may be connected to controller 107 and controller 107 could transmit to wireless controller module 240 signals generated by itself and by the other controller.
[0034] Wireless controller module 240 may also wirelessly transmit signals to controller 107 . By way of example without limitation, controller 107 (and/or another game controller connected thereto) may be provided with vibration circuitry and vibration circuitry control signals may be sent via wireless controller module 240 to control the vibration circuitry. By way of further example without limitation, controller 107 may be provided with (or be connected to) a speaker (not shown) and audio signals for output from this speaker may be wirelessly communicated to controller 107 via wireless controller module 240 . By way of still further example without limitation, controller 107 may be provided with (or be connected to) a display device (not shown) and display signals for output from this display device may be wirelessly communicated to controller 107 via wireless controller module 240 .
[0035] Proprietary memory card slots 246 are adapted to receive proprietary memory cards. In one example implementation, two such slots are provided. These proprietary memory cards have some non-standard feature such as a non-standard connector or a non-standard memory architecture. For example, one or more of the memory card slots 246 may be adapted to receive memory cards developed for the Nintendo GameCube platform. In this case, memory cards inserted in such slots can transfer data from games developed for the GameCube platform. In an example implementation, memory card slots 246 may be used for read-only access to the memory cards inserted therein and limitations may be placed on whether data on these memory cards can be copied or transferred to other storage media such as standard memory cards inserted into slots 228 .
[0036] One or more controller connectors 244 are adapted for wired connection to respective game controllers. In one example implementation, four such connectors are provided for wired connection to game controllers for the Nintendo GameCube platform. Alternatively, connectors 244 may be connected to respective wireless receivers that receive signals from wireless game controllers. These connectors enable players, among other things, to use controllers for the Nintendo GameCube platform when an optical disk for a game developed for this platform is inserted into optical disk drive 208 .
[0037] A connector 248 is provided for connecting game console 100 to DC power derived, for example, from an ordinary wall outlet. Of course, the power may be derived from one or more batteries.
[0038] GPU 216 performs image processing based on instructions from CPU 204 . GPU 216 includes, for example, circuitry for performing calculations necessary for displaying three-dimensional (3D) graphics. GPU 216 performs image processing using graphics memory 220 dedicated for image processing and a part of internal main memory 222 . GPU 216 generates image data for output to television 102 by audio/video connector 214 via audio/video IC (interface) 212 .
[0039] Audio DSP 218 performs audio processing based on instructions from CPU 204 . The audio generated by audio DSP 218 is output to television 102 by audio/video connector 214 via audio/video IC 212 .
[0040] External main memory 206 and internal main memory 222 are storage areas directly accessible by CPU 204 . For example, these memories can store an application program such as a game program read from optical disc 104 by the CPU 204 , various types of data or the like.
[0041] ROM/RTC 238 includes a real-time clock and preferably runs off of an internal battery (not shown) so as to be usable even if no external power is supplied. ROM/RTC 238 also may include a boot ROM and SRAM usable by the console.
[0042] Power button 242 is used to power game console 100 on and off. In one example implementation, power button 242 must be depressed for a specified time (e.g., one or two seconds) to turn the consoled off so as to reduce the possibility of inadvertently turn-off. Reset button 244 is used to reset (reboot) game console 100 .
[0043] With reference to FIGS. 3 and 4 , example controller 107 includes a housing 301 on which operating controls 302 a - 302 h are provided. Housing 301 has a generally parallelepiped shape and is sized to be conveniently holdable in a player's hand. Cross-switch 302 a is provided at the center of a forward part of a top surface of the housing 301 . Cross-switch 302 a is a cross-shaped four-direction push switch which includes operation portions corresponding to the directions designated by the arrows (front, rear, right and left), which are respectively located on cross-shaped projecting portions. A player selects one of the front, rear, right and left directions by pressing one of the operation portions of the cross-switch 302 a . By actuating cross-switch 302 a , the player can, for example, move a character in different directions in a virtual game world.
[0044] Cross-switch 302 a is described by way of example and other types of operation sections may be used. By way of example without limitation, a composite switch including a push switch with a ring-shaped four-direction operation section and a center switch may be used. By way of further example without limitation, an inclinable stick projecting from the top surface of housing 301 that outputs signals in accordance with the inclining direction of the stick may be used. By way of still further example without limitation, a horizontally slidable disc-shaped member that outputs signals in accordance with the sliding direction of the disc-shaped member may be used. By way of still further example without limitation, a touch pad may be used. By way of still further example without limitation, separate switches corresponding to at least four directions (e.g., front, rear, right and left) that output respective signals when pressed by a player may be used.
[0045] Buttons (or keys) 302 b through 302 g are provided rearward of cross-switch 302 a on the top surface of housing 301 . Buttons 302 b through 302 g are operation devices that output respective signals when a player presses them. For example, buttons 302 b through 302 d are respectively an “X” button, a “Y” button and a “B” button and buttons 302 e through 302 g are respectively a select switch, a menu switch and a start switch, for example. Generally, buttons 302 b through 302 g are assigned various functions in accordance with the application being executed by game console 100 . In an exemplary arrangement shown in FIG. 3 , buttons 302 b through 302 d are linearly arranged along a front-to-back centerline of the top surface of housing 301 . Buttons 302 e through 302 g are linearly arranged along a left-to-right line between buttons 302 b and 302 d . Button 302 f may be recessed from a top surface of housing 701 to reduce the possibility of inadvertent pressing by a player grasping controller 107 .
[0046] Button 302 h is provided forward of cross-switch 302 a on the top surface of the housing 301 . Button 302 h is a power switch for remote on-off switching of the power to game console 100 . Button 302 h may also be recessed from a top surface of housing 301 to reduce the possibility of inadvertent pressing by a player.
[0047] A plurality (e.g., four) of LEDs 304 is provided rearward of button 302 c on the top surface of housing 301 . Controller 107 is assigned a controller type (number) so as to be distinguishable from the other controllers used with game console 100 and LEDs may 304 may be used to provide a player a visual indication of this assigned controller number. For example, when controller 107 transmits signals to wireless controller module 240 , one of the plurality of LEDs corresponding to the controller type is lit up.
[0048] With reference to FIG. 3B , a recessed portion 308 is formed on a bottom surface of housing 301 . Recessed portion 308 is positioned so as to receive an index finger or middle finger of a player holding controller 107 . A button 302 i is provided on a rear, sloped surface 308 a of the recessed portion. Button 302 i functions, for example, as an “A” button which can be used, by way of illustration, as a trigger switch in a shooting game.
[0049] As shown in FIG. 4 , an imaging element 305 a is provided on a front surface of controller housing 301 . Imaging element 305 a is part of an imaging information calculation section of controller 107 that analyzes image data received from markers 108 a and 108 b . Imaging information calculation section 305 has a maximum sampling period of, for example, about 200 frames/sec., and therefore can trace and analyze even relatively fast motion of controller 107 . The techniques described herein of simulating the striking of an object can be achieved without using information from imaging information calculation section 305 , and thus further detailed description of the operation of this section is omitted. Additional details may be found in Application No. 60/716,937, entitled “VIDEO GAME SYSTEM WITH WIRELESS MODULAR HANDHELD CONTROLLER,” filed on Sep. 15, 2005; 60/732,648, entitled “INFORMATION PROCESSING PROGRAM,” filed on Nov. 3, 2005; and application No. 60/732,649, entitled “INFORMATION PROCESSING SYSTEM AND PROGRAM THEREFOR,” filed on Nov. 3, 2005. The entire contents of each of these applications are incorporated herein.
[0050] Connector 303 is provided on a rear surface of controller housing 301 . Connector 303 is used to connect devices to controller 107 . For example, a second controller of similar or different configuration may be connected to controller 107 via connector 303 in order to allow a player to play games using game control inputs from both hands. Other devices including game controllers for other game consoles, input devices such as keyboards, keypads and touchpads and output devices such as speakers and displays may be connected to controller 107 using connector 303 .
[0051] For ease of explanation in what follows, a coordinate system for controller 107 will be defined. As shown in FIGS. 3 and 4 , a left-handed X, Y, Z coordinate system has been defined for controller 107 . Of course, this coordinate system is described by way of example without limitation and the systems and methods described herein are equally applicable when other coordinate systems are used.
[0052] As shown in the block diagram of FIG. 5 , controller 107 includes a three-axis, linear acceleration sensor 507 that detects linear acceleration in three directions, i.e., the up/down direction (Z-axis shown in FIGS. 3 and 4 ), the left/right direction (X-axis shown in FIGS. 3 and 4 ), and the forward/backward direction (Y-axis shown in FIGS. 3 and 4 ). Alternatively, a two-axis linear accelerometer that only detects linear acceleration along each of the Y-axis and Z-axis may be used or a one-axis linear accelerometer that only detects linear acceleration along the Z-axis may be used. Generally speaking, the accelerometer arrangement (e.g., three-axis or two-axis) will depend on the type of control signals desired. As a non-limiting example, the three-axis or two-axis linear accelerometer may be of the type available from Analog Devices, Inc. or STMicroelectronics N.V. Preferably, acceleration sensor 507 is an electrostatic capacitance or capacitance-coupling type that is based on silicon micro-machined MEMS (micro-electromechanical systems) technology. However, any other suitable accelerometer technology (e.g., piezoelectric type or piezoresistance type) now existing or later developed may be used to provide three-axis or two-axis linear acceleration sensor 507 .
[0053] As one skilled in the art understands, linear accelerometers, as used in acceleration sensor 507 , are only capable of detecting acceleration along a straight line corresponding to each axis of the acceleration sensor. In other words, the direct output of acceleration sensor 507 is limited to signals indicative of linear acceleration (static or dynamic) along each of the two or three axes thereof. As a result, acceleration sensor 507 cannot directly detect movement along a non-linear (e.g. arcuate) path, rotation, rotational movement, angular displacement, tilt, position, attitude or any other physical characteristic.
[0054] However, through additional processing of the linear acceleration signals output from acceleration sensor 507 , additional information relating to controller 107 can be inferred or calculated (i.e., determined), as one skilled in the art will readily understand from the description herein. For example, by detecting static, linear acceleration (i.e., gravity), the linear acceleration output of acceleration sensor 507 can be used to determine tilt of the object relative to the gravity vector by correlating tilt angles with detected linear acceleration. In this way, acceleration sensor 507 can be used in combination with micro-computer 502 of controller 107 (or another processor) to determine tilt, attitude or position of controller 107 . Similarly, various movements and/or positions of controller 107 can be calculated through processing of the linear acceleration signals generated by acceleration sensor 507 when controller 107 containing acceleration sensor 307 is subjected to dynamic accelerations by, for example, the hand of a user, as will be explained in detail below.
[0055] In another embodiment, acceleration sensor 507 may include an embedded signal processor or other type of dedicated processor for performing any desired processing of the acceleration signals output from the accelerometers therein prior to outputting signals to micro-computer 502 . For example, the embedded or dedicated processor could convert the detected acceleration signal to a corresponding tilt angle (or other desired parameter) when the acceleration sensor is intended to detect static acceleration (i.e., gravity).
[0056] Returning to FIG. 5 , image information calculation section 505 of controller 107 includes infrared filter 528 , lens 529 , imaging element 305 a and image processing circuit 530 . Infrared filter 528 allows only infrared light to pass therethrough from the light that is incident on the front surface of controller 107 . Lens 529 collects and focuses the infrared light from infrared filter 528 on imaging element 305 a . Imaging element 305 a is a solid-state imaging device such as, for example, a CMOS sensor or a CCD. Imaging element 305 a captures images of the infrared light from markers 108 a and 108 b collected by lens 309 . Accordingly, imaging element 305 a captures images of only the infrared light that has passed through infrared filter 528 and generates image data based thereon. This image data is processed by image processing circuit 520 which detects an area thereof having high brightness, and, based on this detecting, outputs processing result data representing the detected coordinate position and size of the area to communication section 506 . From this information, the direction in which controller 107 is pointing and the distance of controller 107 from display 101 can be determined.
[0057] Vibration circuit 512 may also be included in controller 107 . Vibration circuit 512 may be, for example, a vibration motor or a solenoid. Controller 107 is vibrated by actuation of the vibration circuit 512 (e.g., in response to signals from game console 100 ), and the vibration is conveyed to the hand of the player holding controller 107 . Thus, a so-called vibration-responsive game may be realized.
[0058] As described above, acceleration sensor 507 detects and outputs the acceleration in the form of components of three axial directions of controller 107 , i.e., the components of the up-down direction (Z-axis direction), the left-right direction (X-axis direction), and the front-rear direction (the Y-axis direction) of controller 107 . Data representing the acceleration as the components of the three axial directions detected by acceleration sensor 507 is output to communication section 506 . Based on the acceleration data which is output from acceleration sensor 507 , a motion of controller 107 can be determined.
[0059] Communication section 506 includes micro-computer 502 , memory 503 , wireless module 504 and antenna 505 . Micro-computer 502 controls wireless module 504 for transmitting and receiving data while using memory 503 as a storage area during processing. Micro-computer 502 is supplied with data including operation signals (e.g., cross-switch, button or key data) from operation section 302 , acceleration signals in the three axial directions (X-axis, Y-axis and Z-axis direction acceleration data) from acceleration sensor 507 , and processing result data from imaging information calculation section 505 . Micro-computer 502 temporarily stores the data supplied thereto in memory 503 as transmission data for transmission to game console 100 . The wireless transmission from communication section 506 to game console 100 is performed at a predetermined time interval. Because game processing is generally performed at a cycle of 1/60 sec. (16.7 ms), the wireless transmission is preferably performed at a cycle of a shorter time period. For example, a communication section structured using Bluetooth (registered trademark) technology can have a cycle of 5 ms. At the transmission time, micro-computer 502 outputs the transmission data stored in memory 503 as a series of operation information to wireless module 504 . Wireless module 504 uses, for example, Bluetooth (registered trademark) technology to send the operation information from antenna 505 as a carrier wave signal having a specified frequency. Thus, operation signal data from operation section 302 , the X-axis, Y-axis and Z-axis direction acceleration data from acceleration sensor 507 , and the processing result data from imaging information calculation section 505 are transmitted from controller 107 . Game console 100 receives the carrier wave signal and demodulates or decodes the carrier wave signal to obtain the operation information (e.g., the operation signal data, the X-axis, Y-axis and Z-axis direction acceleration data, and the processing result data). Based on this received data and the application currently being executed, CPU 204 of game console 100 performs application processing. If communication section 506 is structured using Bluetooth (registered trademark) technology, controller 107 can also receive data wirelessly transmitted thereto from devices including game console 100 .
[0060] The exemplary illustrative non-limiting system described above can be used to execute software stored on optical disk 104 or in other memory that controls it to interactive generate displays on display 101 of a progressively deformed object in response to user input provided via controller 107 . Exemplary illustrative non-limiting software controlled techniques for generating such displays will now be described.
Example Hyper Mode Game Play
[0061] FIG. 6 shows an example screen display 1002 of a first person shooter type combat game. Other types of games including driving games, space games, adventure games, sports games or any other type of game could also be used. In the example shown, a power or life meter or gauge 1004 is displayed on display 1002 . Gauge 1004 includes a block indicator 1006 and a power gauge indicator 1008 . The block indicator 1006 can display for example a block of life or power (one block may correspond to some number of points such as for example 100 points). The power gauge indicator 1008 reflects the amount of power a player has available. Blocks can be earned by accomplishing particular tasks within the game for example.
[0062] In one exemplary illustrative non-limiting implementation, the game indicator 1008 is similar to a thermometer or for example the type of graphical display provided by an audio graphic equalizer. One can readily tell by looking at the gauge how much power a game player has and how much power has been depleted. In one example non-limiting implementation, the gauge level rises (e.g., moves to the right or upwards) as the amount of stored power in a power reservoir increases and moves to the left or downwards as the amount of power decreases. Generally, the game player wishes to maintain sufficient power as indicated by the power gauge to accomplish gaming tasks.
[0063] FIG. 6 also shows a weapon 1010 . In the exemplary illustrative non-limiting implementation, each time the game character fires weapon 1010 , the power indicated by the gauge 1008 decreases. If the gauge ever falls to zero level and thus becomes completely depleted, the game character may no longer be able to fire weapon 1010 and can no longer attack enemies. The game character can obtain power for display by indicator 1008 automatically as time goes by and/or by accomplishing certain tasks.
[0064] In one exemplary illustrative non-limiting implementation, the game player can choose to enter a special mode called “hyper mode” by depressing a control or menu selection. In one exemplary illustrative non-limiting implementation, it may cost the game character some power (one block) to enter hyper mode. However, certain benefits are achieved in hyper mode. For example, in one exemplary illustrative non-limiting implementation, the game character becomes less vulnerable or invulnerable to enemy attack whenever the game character is in hyper mode.
[0065] FIG. 7 shows an example illustrative non-limiting hyper mode game display. In this example illustration, the gauge 1004 continues to provide a gauge indicator 1008 indicating the amount of power available and stored in a power reservoir. In the example shown, the “C 1 ” part of the gauge indicator 1008 indicates the remaining energy available for shooting a weapon, and the “C 2 ” portion of the gauge indicator indicates the amount of energy that has been used or depleted. In one exemplary illustrative non-limiting implementation, when the game character first enters hyper mode, the gauge indicator 1008 is filled to an intermediate level. Each time the game player fires weapon 1010 , the amount of power indicated by gauge indicator 1008 decreases. If the “C 1 ” bar indicator ever falls to zero, meaning that the energy has been entirely depleted, hyper mode is over and the game character again becomes vulnerable. However, if the game player does not fire weapon 1010 for a while, the game play automatically replenishes the energy within the indicator gauge 1008 and the “C 1 ” bar increases in size.
[0066] In the exemplary illustrative non-limiting implementation, if the “C 1 ” bar every exceeds a predetermined level (e.g., extends over the entirety of the gauge to indicate for example maximum capacity has been exceeded), the game is over.
[0067] In the exemplary illustrative non-limiting implementation, the game player must carefully shoot game objects with weapons 1010 while watching the indicator gauge 1008 carefully so that it never exceeds its capacity. The game player must thus maintain a situation such that both a “C 1 ” and a “C 2 ” portion of the gauge exists in the indication in order to maintain the game character within hyper mode but not causing a “game over” situation. This provides an interesting ebb and flow to the game action. Inexperienced players may immediately recognize the danger in remaining in hyper mode and try and leave hyper mode as rapidly as possible in order to eliminate the danger of “game over.” More experienced players will recognize the advantages in terms of invulnerability or other beneficial effects of remaining in hyper mode as long as possible but must always be mindful of the danger of a “game over” should the power meter indicate energy capacity has been exceeded. The experienced player can fire a weapon periodically to decrease energy levels but does not want to deplete the energy so much that hyper mode will be over or so that there will be no power left for firing a weapon defensively. A game player will thus constantly be conducting a risk/benefit analysis in which weapon firing will increase the likelihood of leaving hyper mode but may also prevent instability that could lead to destruction. The “shoot and recharge, shoot and recharge” ebb and flow strategies that experienced players will adopt provide an interesting and fun addition to a first person shooter or other game.
[0068] FIG. 8 is a flowchart of exemplary illustrative non-limiting program control steps. The gauge is displayed at block 1102 . As time passes, the gauge level is recharged (blocks 1104 , 1106 ). The gauge level is depleted each time the player fires a weapon (block 1108 , 1110 ). If the gauge level ever exceeds a predetermined maximum, the game is over (blocks 1112 , 1114 ). If the gauge level is ever completed depleted, hyper mode is exited and the player returns to normal game play (blocks 1116 , 1118 ).
[0069] While the technology herein has been described in connection with exemplary illustrative non-limiting implementations, the invention is not to be limited by the disclosure. For example, while the exemplary illustrative non-limiting implementation displays a gauge, other forms of indication are possible such as brightness or sound. The special powers existing in hypermode can be any time of benefit including ability to score more easily, ability to accomplish any sort of task, or any special condition or characteristic. The adverse consequence of exceeding maximum power could be any adverse consequence. The invention is intended to be defined by the claims and to cover all corresponding and equivalent arrangements whether or not specifically disclosed herein.
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A power or life meter is displayed in a video game. Firing a weapon depletes the indicated power. Meanwhile, the power is recharged at a predetermined rate. If the indicated power exceeds capacity, the game character is adversely impacted. If the indicated power is completely depleted, the game character loses a benefit.
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CROSS-REFERENCE TO RELATED APPLICATIONS
Priority of our U.S. Provisional Patent Application Serial No. 60/110,233, filed Nov. 30, 1998, incorporated herein by reference, is hereby claimed.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
The government has rights in this invention, as it was made in performance of work under Office of Naval Research Cooperative Agreement No. N00014-94-2-0011.
REFERENCE TO A “MICROFICHE APPENDIX”
Not applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to aluminum alloys. More particularly, the present invention relates to corrosion-resistant aluminum alloys.
2. General Background of the Invention
A good background of the invention can be found in the paper entitled “Feasibility study for development of novel corrosion resistant age hardenable Al—Cr—X alloys for maritime applications” attached to the above-referenced provisional patent application, which paper is incorporated herein by reference.
BRIEF SUMMARY OF THE INVENTION
The apparatus of the present invention solves the problems confronted in the art in a simple and straightforward manner. What is provided are corrosion-resistant aluminum alloys including scandium and magnesium. More information about the present invention can be found in the attached paper entitled “Attachment G—Development of High Strength Corrosion Resistant Al—Sc—X Alloys for Maritime Applications”, which paper is incorporated herein by reference.
DETAILED DESCRIPTION OF THE INVENTION
The final report (copy attached) of this study is available from the GCRMTC. Of all the rare earths, Sc has been known to be the most potent strengthener for aluminum alloys. It has been observed in the study that Sc not only strengthens aluminum alloys but also greatly improves their corrosion-resistance. However, its limited supply and high cost restricted its use in the past. This restriction has eased lately because of its availability from Ukraine. As a result, the use of Sc in strengthening aluminum alloys has attracted the attention of manufacturers and researchers in recent times. The available commercial Sc-containing aluminum alloys are modifications of traditional aluminum alloys with a small amount of Sc. The specific composition of the aluminum alloys that is planned to be studied (in particular, the exclusion of corrosion-prone elements) is totally a novel concept. At present no laboratory known is approaching the corrosion problem in aluminum alloys with similar concepts.
Objectives:
The overall objective is to evaluate further selected mechanical, electrochemical (corrosion), and weld properties of a promising high-strength corrosion-resistant alloy system based on the AlMgScCrNi system.
Abstract of Approach: This project requires the direct participation of an aluminum foundry. Proposals will not be considered without this participation.
Task 1: Determination of selected basic mechanical properties such as tensile strength, yield strength, elastic modulus, elongation, work-hardening coefficient, fracture (chevron-notch short bar test) toughness, and impact strength.
Task 2: Evaluation of selected corrosion characteristics including general corrosion, localized corrosion, stress-corrosion and exfoliation.
Task 3: Determination of the weldability of the new alloy system and evaluation of strength and corrosion characteristics of the weldment.
Task 4: Determination of thermomechanical processing parameters (prior deformation, time and temperature of heat treatment) for optimization of strength and corrosion resistance.
Task 5: Modification, if necessary, of the composition of the experimental alloys with other rare earths (Zr, Mo, etc.) to further improve their strength properties and corrosion resistance.
Applicable ASTM or MIL Standards will be followed in carrying out the above tasks. In the absence of such standards, established research methologies will be used to perform a certain number of tasks. They include:
Slow strain rate (SSR) testing and acoustic emission (AE) fracture wave detection for stress corrosion cracking Several electrochemical techniques including impedance-spectroscopy for corrosion evaluation.
Additionally, attempts should be made to obtain information on the microstructure of various alloys as a function of their heat treatment and composition. The techniques to be used for this purpose may include differential scanning colorimetry (DSC), scanning electron microscopy (SEM), and energy-dispersive x-ray analysis (EDXA). Structure dictates properties. Thus, the structural information will be of value in selecting appropriate parameters for alloy composition and heat treatment. The SEM and EDXA should also be utilized to characterize the weldment structure, the corrosion-induced changes in the alloy, and in weldments, as well as to obtain fractographic information from specimens that failed during mechanical and stress-corrosion testing.
In all stages of the proposed research, alloys that are traditional and popular (2024-T3, 5052-T3, 6061-T6, 7072 and 7075-TT6) must be studied for control and comparison.
Schedule:
A contract term of one to two years is envisioned as necessary to complete the project objectives. The proposal may be written as a multi-year project (1, 2 or 3 years), but review and re-approval will be required for each continuation year.
Deliverables:
Further research should allow a “fine-tuning” of the composition and processing parameters of the experimental alloy system and should lead to the development of an alloy system superior to existing alloys in mechanical properties, corrosion resistance, and weldability. The deliverable for this project will be a prototype aluminum alloy that will include documentation of the alloy's chemical composition, mechanical, electrical, thermal, corrosion, etc properties, manufacturing procedures, quality control, and applications.
A provisional U.S. Patent application has been filed on this material through the GCRMTC. The developed alloy specifications will be available to metal producers, users, and other interested parties from the GCRMTC.
A report must be prepared to allow for marketing the project's deliverables throughout the US.
A presentation must be prepared for and delivered to at least two technical societies or trade show meetings after approval by the GCRMTC.
An article describing this work must be written in conjunction with the year end report and submitted for publication to at least one technical or trade journal after approval by the GCRMTC.
Materials for a half day marketing seminar, including audio/video material to be presented at two or more locations with the purpose of promoting the use of this project's deliverables. This program should be given in collaboration with the contractor and the GCRMTC.
Equipment including sensors, computers, etc. used to conduct the project must be delivered to the GCRMTC upon completion of the project unless specific arrangements are made for the continued operation of the equipment in conjunction with GCRMTC and UNO through a similar program.
Software, object and source code, developed for the project must be delivered to the GCRMTC (one copy) with a royalty free license for the State of Louisiana, UNO, and the US Government.
Software purchased for the project must be delivered to the GCRMTC upon completion of the project.
The contractor must present a status report of the project at the University of New Orleans on a semi-annual basis. Additionally, written quarterly and annual status reports and periodic input for the MANTECH Database system, in the format specified by the GCRMTC, will be required.
The apparatus of the present invention can comprise a ship, aircraft, or marine structure made of the alloy of the present invention for use in halide-containing water. The apparatus of the present invention can be used in water containing chloride.
Other embodiments of the present invention are described in the paper entitled “Feasibility study for development of novel corrosion resistant age hardenable Al—Cr—X alloys for maritime applications”.
All measurements disclosed herein are at standard temperature and pressure, at sea level on Earth, unless indicated otherwise.
The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims.
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A corrosion-resistant aluminum alloy includes 91%-95.7% by weight aluminum, 0.5%-1% by weight scandium, 3%-5% by weight magnesium, 0.5%-2% by weight nickel, and 0.3%-1% by weight chromium.
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CLAIM OF PRIORITY
This application is a divisional of U.S. patent application Ser. No. 11/394,831 which was filed on Mar. 31, 2006 (now U.S. Pat. No. 7,692,295).
TECHNICAL FIELD
The invention relates to the field of microelectronics and more particularly, but not exclusively, to packaging wireless communications devices.
BACKGROUND
The evolution of integrated circuit designs has resulted in higher operating frequency, increased numbers of transistors, and physically smaller devices. This continuing trend has generated ever increasing area densities of integrated circuits and electrical connections. The trend has also resulted in higher packing densities of components on printed circuit boards and a constrained design space within which system designers may find suitable solutions. Physically smaller devices have also become increasingly mobile.
At the same time, wireless communication standards have proliferated as has the requirement that mobile devices remain networked. Consequently, many mobile devices include a radio transceiver capable of communicating according to one or more of a multitude of communication standards. Each different wireless communication standard serves a different type of network. For example, a personal area network (PAN), such as Blue Tooth (BT), wirelessly maintains device connectivity over a range of several feet. A separate wireless standard, such as IEEE 802.11a/b/g (Wi-Fi), maintains device connectivity over a local area network (LAN) that ranges from several feet to several tens of feet.
A typical radio transceiver includes several functional blocks spread among several integrated circuit packages. Further, separate packages often each contain an integrated circuit designed for a separate purpose and fabricated using a different process than that for the integrated circuit of neighboring packages. For example, one integrated circuit may be largely for processing an analog signal while another may largely be for computationally intense processing of a digital signal. The fabrication process of each integrated circuit usually depends on the desired functionality of the integrated circuit, for example, an analog circuit generally is formed from a process that differs from that used to fabricate a computationally intense digital circuit. Further, isolating the various circuits from one another to prevent electromagnetic interference may often be a goal of the designer. Thus, the various functional blocks of a typical radio transceiver are often spread among several die packaged separately.
Each package has a multitude of power, ground, and signal connections which affects package placement relative to one another. Generally, increasing the number of electrical connections on a package increases the area surrounding the package where trace routing density does not allow for placement of other packages. Thus, spreading functional blocks among several packages limits the diminishment in physical size of the radio transceiver, which in turn limits the physical size of the device in which the radio transceiver is integrated.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a block diagram of a prior art radio transceiver application.
FIG. 2 illustrates a block diagram of an exemplary single package radio transceiver application.
FIG. 3 illustrates a cross-sectional view of an exemplary single package radio transceiver.
FIG. 4 illustrates (1) an exemplary array of solder balls for coupling a single package radio transceiver to a printed circuit board and (2) an exemplary array of solder pads on a printed circuit board to which a single package radio transceiver may be coupled.
FIG. 5 illustrates an embodiment of a method of packaging a single package radio transceiver.
FIG. 6 illustrates a system schematic that incorporates an embodiment of a single package radio transceiver.
DETAILED DESCRIPTION
Herein disclosed are a package, a method of packaging, and a system including the package for an integrated, multi-die radio transceiver.
In the following detailed description, reference is made to the accompanying drawings which form a part hereof wherein like numerals designate like parts throughout, and in which is shown, by way of illustration, specific embodiments in which the invention may be practiced. Other embodiments may be utilized, and structural or logical changes may be made, without departing from the intended scope of the embodiments presented. It should also be noted that directions and references (e.g., up, down, top, bottom, primary side, backside, etc.) may be used to facilitate the discussion of the drawings and are not intended to restrict the application of the embodiments of this invention. Therefore, the following detailed description is not to be taken in a limiting sense and the scope of the embodiments of the present invention is defined by the appended claims and their equivalents.
Description of a Radio Transceiver
Please refer to FIG. 1 for a functional block diagram of a typical prior art radio transceiver application.
A typical radio transceiver usually includes several separate functional blocks, including a Front End Module (FEM) 106 , a Radio Frequency Integrated Circuit (RFIC) 108 , and a Base Band/Communication Processor 112 , that electrically couple to application specific circuitry 118 . The typical radio transceiver spreads the several functional blocks among different die and integrated circuit packages. The FEM 106 generally processes a radio frequency (RF) signal collected from an antenna 104 . The FEM 106 may include a low noise amplifier for small signal receiver gain larger than about 90 dB or a power amplifier for output power in excess of about 17 dBm or about 50 mW, and passive frequency selection circuits. The FEM 106 processes the RF signal before communicating a signal to the RFIC 108 for mixed signal processing. The RFIC 108 usually converts the RF signal from the FEM 106 to a digital signal and passes the digital signal to a Base Band/Communication Processor 112 . The Base Band/Communication Processor 112 generally communicates with application specific circuitry 118 that often includes an application processor 122 coupled to user interface peripherals 126 and a system memory 120 . In some instances, the Base Band/Communication Processor 112 is coupled to a memory 110 which may be on a separate die, or integrated into the die of the Base Band/Communication Processor 112 . Power consumption for the application processor may be managed by power management circuitry 124 . The RFIC 108 may also receive a signal input gathered from a Global Positioning System Receiver (GPS Receiver) 114 .
The FEM 106 and RFIC 108 are often on different die because of functional differences between the circuits that may not be easily achieved through the same die fabrication process. The Base Band/Communication Processor 112 may typically perform computationally intensive operations and therefore be fabricated using yet another process that differs from either of those used to fabricate the FEM 106 or the RFIC 108 . Further, the different die will often be packaged separately, although some prior art radio transceivers have integrated the FEM 106 and RFIC 108 within the same package, as indicated by the Prior Art Wireless Integration block 102 . Usually, the GPS Receiver 114 will also be packaged separately from other die. Further, the reference oscillator (crystal) 116 will generally be in a different package due to its sensitivity to temperature variance.
Current packages that integrate the FEM 106 and RFIC 108 use arrays use arrays of solder bumps on the individual die to couple the die to a package substrate. Further, the die are each disposed on the substrate in a substantially two-dimensional layout. A radio frequency transceiver integrated in a single package may address many shortcomings of present radio frequency transceivers. Because the different die will often be packaged separately, current system costs will often be higher than if the various die could be included in a single package. Further, because present systems continue to evolve to smaller form factors, a radio frequency transceiver integrated into a single package may help a system designer to achieve a desired overall system size that by itself being is smaller than a radio frequency transceiver spread among several packages.
Integration of a Radio Transceiver in a Single Package
FIG. 2 illustrates a functional block diagram of a system 200 using a radio frequency transceiver 202 wherein the radio frequency transceiver 202 is integrated into a single integrated circuit package, shown as 300 in FIG. 3 and further described below. The radio frequency transceiver 202 includes an antenna 204 , an FEM (analog) 206 , an RFIC (mixed analog/digital) 208 , and a Base Band/Communication Processor (digital) 212 . The reference oscillator (crystal) 216 resides outside the integrated circuit package 300 because of its sensitivity to temperature and mechanical stress, both of which are often unavoidable during package assembly. Some embodiments of the radio frequency transceiver 202 also include a memory 210 coupled to the Base Band/Communication Processor 212 . Other embodiments of the radio frequency transceiver 202 may be capable of receiving input from other types of receivers, for example, a global positioning system receiver 214 . The signal collected by the alternative receiver 214 is transmitted to the RFIC 208 . The digital output of the Base Band/Communication Processor 212 couples to an application specific integrated circuit 218 that includes an application processor 222 . Further, the application processor 222 couples to a memory 220 , power management circuitry 224 , and any peripherals 226 . The peripherals 226 often include one or more of the following: an input/output interface, a user interface, an audio, a video, and an audio/video interface.
The application processor 222 often defines the standard used by the radio frequency transceiver 202 . Exemplary standards may include, by way of example and not limitation, a definition for a personal area network (PAN), such as Blue Tooth (BT), that wirelessly maintains device connectivity over a range of several feet, a local area network (LAN) that ranges from several feet to several tens of feet such as IEEE 802.11a/b/g (Wi-Fi), a metropolitan area network (MAN) such as (Wi-Max), and a wide area network (WAN), for example a cellular network.
An exemplary embodiment of a package 300 that integrates a radio frequency transceiver 202 is illustrated by FIG. 3 and utilizes die stacking, or packaging in a third dimension, to alleviate many of the aforementioned problems, such as limited diminishment in size and increased packaging costs, associated with prior art two-dimensional layouts. The integrated radio frequency transceiver 202 in a single package 300 includes an antenna 204 formed by a copper stud 322 and a stack of a first die 306 and a second die 310 coupled to the package substrate 328 , to which is also coupled a third die 302 .
In the embodiment of FIG. 3 , the third die 302 forms a front end module 206 and is coupled to the substrate 328 though solder bumps 304 . The third die may be formed substantially of gallium arsenide, silicon on sapphire, or silicon germanium. The second die 310 forms a Base Band/Communication Processor 210 and mechanically couples to the first die 306 that includes a radio frequency integrated circuit (RFIC) 208 . The first die 306 is electrically coupled to the substrate 328 , often through solder bumps 308 . For first die 306 sizes less than approximately 3.5 mm×3.5 mm underfill may often not be used. Larger first die 306 may utilize underfill. The second die 310 is electrically coupled to the substrate 328 through wire bonds 312 . One method of mechanically coupling the first die 306 and second die 310 includes using an interface bonding agent 314 , for example an epoxy. Many interface bonding agents 314 other than epoxy are known, e.g., RTV rubbers. The package 300 includes an antenna 204 formed of a copper stud 322 that couples to a package cover 334 that may act also as a heat spreader. Also included in the embodiment illustrated by FIG. 3 is a fourth die 316 on which is formed memory 210 . The fourth die 316 couples to the circuitry of the second die 310 through a direct chip attach formed of solder bumps 318 and underfill 320 . Some embodiments of underfill 320 may include an adhesive tape or epoxy. Passive components 330 and 332 , such as inductor based components used for tuning, may be located at convenient locations on the substrate 328 if they are not included in the die 306 including the RFIC 208 . The passive components 330 and 332 may include high speed switching components formed on depleted CMOS devices, thereby enabling reconfigurable adaptive passive circuits. The package substrate 328 may have solder mask defined pads for surface mount components, and immersion gold plating may be used on the pads.
The embodiment of the package 300 shown includes an array of solder balls 326 that may be used to electrically and mechanically couple the package 300 to a printed circuit board (not shown). Some of the solder balls 326 may be arranged in groups 324 that will collapse and coalesce during reflow, and form a large area connection convenient for grounding the package 300 . FIG. 4 illustrates a substrate 402 of a package 400 with an array of signal solder balls 404 and an array of ground solder balls 408 . The signal solder balls are distributed using a ball to ball pitch 406 that maintains the integrity of each solder ball 404 . The solder balls 408 used for grounding are distributed with a narrower pitch 410 such that on reflow the balls coalesce to form a larger area connection. The embodiment shown by FIG. 4 includes solder balls 412 that may be used for power, ground, additional signals, or merely additional structural support without any electrical connectivity. A printed circuit board 414 may include arrays of exposed pads 416 and 418 similar to the arrays of solder balls. For example, the pitch 420 between exposed pads for the signals may be substantially similar to the pitch 406 for the signal solder balls 404 . Ground pads 418 may be a single large area of exposed metal, or an array of large exposed areas, similar to those shown. The substrate 414 may have outer metal layer thicknesses of approximately 35 μm and inner metal layer thickness ranging from approximately 60 μm to 150 μm.
A Single Package Radio Transceiver Assembly Method
FIG. 5 illustrates an exemplary method of integrating a multiple die in a single integrated circuit package. The method illustrated may be used to package a combination of die wherein some of the die forming the radio transceiver are stacked and form a three dimensional integration. For example, the method of FIG. 5 includes soldering a first die to a package substrate having a layer of electrical traces and another layer of dielectric material 502 . A method similar to one illustrated by FIG. 5 also includes mechanically coupling a second die to the first 504 . To achieve a functional die stack, wire bonds electrically couple the second die to the package substrate 506 .
As mentioned, the method illustrated by FIG. 5 results in a substantially integrated radio frequency transceiver. The method illustrated by FIG. 5 may be used to form a radio frequency transceiver capable of communicating according to any of a multitude of wireless standards that cover operation of networks ranging from personal area networks or local area networks to metropolitan area networks or wide area networks. Consequently, FIG. 5 illustrates forming an antenna electrically coupled to the substrate 508 and soldering a third die to the substrate, wherein the antenna, first, second, and third die substantially form a radio transceiver 510 . The third die will often be substantially formed of gallium arsenide, silicon on sapphire, or silicon germanium, although other materials may often work as well.
In a radio frequency transceiver of the type whose assembly process is illustrated by FIG. 5 , the second die substantially forms the often heavily computational, digital circuits of a base band communication processor. Some embodiments of a radio frequency transceiver couple memory to the digital circuits of the base band communication processor. Some of those embodiments may use a separate die for the memory and couple the memory die to the second die that substantially includes the digital circuits of the base band communications processor. A method of assembly, as illustrated by FIG. 5 , may couple the memory die to the second die prior to mechanically coupling the second die to the first die 512 .
Further, radio frequency transceivers may often benefit from grounding through large area electrical ground connections. As described above, such connections may form when two or more solder balls collapse and coalesce during reflow and form an electrical connection with larger cross-sectional area than a single constituent solder ball 514 .
A System Embodiment that Includes a Single Package Radio Transceiver
FIG. 6 illustrates a schematic representation of one of many possible systems 60 that incorporate an embodiment of a single package radio transceiver 600 . In an embodiment, the package containing a radio frequency transceiver 600 may be an embodiment similar to that described in relation to FIG. 3 . In another embodiment, the package 600 may also be coupled to a sub assembly that includes a microprocessor. In a further alternate embodiment, the integrated circuit package may be coupled to a subassembly that includes an application specific integrated circuit (ASIC). Integrated circuits found in chipsets (e.g., graphics, sound, and control chipsets) or memory may also be packaged in accordance with embodiments described in relation to a microprocessor and ASIC, above.
For an embodiment similar to that depicted in FIG. 6 , the system 60 may also include a main memory 602 , a graphics processor 604 , a mass storage device 606 , and an input/output module 608 coupled to each other by way of a bus 610 , as shown. Examples of the memory 602 include but are not limited to static random access memory (SRAM) and dynamic random access memory (DRAM). Examples of the mass storage device 606 include but are not limited to a hard disk drive, a flash drive, a compact disk drive (CD), a digital versatile disk drive (DVD), and so forth. Examples of the input/output modules 608 include but are not limited to a keyboard, cursor control devices, a display, a network interface, and so forth. Examples of the bus 610 include but are not limited to a peripheral control interface (PCI) bus, PCI Express bus, Industry Standard Architecture (ISA) bus, and so forth. In various embodiments, the system 60 may be a wireless mobile phone, a personal digital assistant, a pocket PC, a tablet PC, a notebook PC, a desktop computer, a set-top box, an audio/video controller, a DVD player, a network router, a network switching device, a hand-held device, or a server.
Although specific embodiments have been illustrated and described herein for purposes of description of an embodiment, it will be appreciated by those of ordinary skill in the art that a wide variety of alternate and/or equivalent implementations calculated to achieve similar purposes may be substituted for the specific embodiments shown and described without departing from the scope of the present disclosure. For example, a processor and chipset may be integrated within a single package according to the package embodiments illustrated by the figures and described above, and claimed below. Alternatively, chipsets and memory may similarly be integrated, as may be graphics components and memory components.
Those with skill in the art will readily appreciate that the description above and claims below may be implemented using a very wide variety of embodiments. This detailed description is intended to cover any adaptations or variations of the embodiments discussed herein. Therefore, it is manifestly intended that this invention be limited only by the claims and the equivalents thereof.
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A method, apparatus and system with an autonomic, self-healing polymer capable of slowing crack propagation within the polymer and slowing delamination at a material interface.
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FIELD OF THE INVENTION
[0001] The invention is directed to a polymer thick film (PTF) silver conductor composition for use in Radio Frequency Identification Devices (RFID) and other applications. In one embodiment, the PTF silver composition is used as a screen-printed conductor on a flexible low temperature substrate, such as polyester, where the PTF silver composition functions as an antenna. This composition may further be used for any other application where extremely high conductivity and low resistivity is required.
BACKGROUND OF THE INVENTION
[0002] Polymer thick film silver compositions are used in RFID devices as well as other applications such as Membrane Touch Switches, Appliance Circuitry, or any uses where a high conductivity polymer thick film silver conductor is required. Such products are typically used as the printed antenna of the cell. An antenna pattern of the polymer thick film silver composition is printed on top of the appropriate substrate. RFID circuit performance is dependent on both the conductivity of the printed antenna and the resistance of the circuit. The lower the resistivity (inverse of conductivity) the better the performance of any polymer thick film composition used is such circuitry. It is desirable to use a composition that has low restivity and is suitable for coating at thicknesses necessary for RFID applications.
SUMMARY OF THE INVENTION
[0003] The present invention is directed to a polymer thick film composition comprising: (a) silver flake (b) organic medium comprising (1) organic polymeric binder; (2) solvent; and (3) printing aids that have low restivity. The composition may be processed at a time and temperature necessary to remove all solvent. Specifically, the composition comprises (a) 50-85% by weight silver flake with an average particle size of at least 3 microns, at least 10% of the particles greater than 7 microns, and stearic acid surfactant
[0000] (b) 15-50% by weight organic medium comprising
(1) 16-25% by weight vinyl copolymer resin (2) 75-84% by weight organic solvent.
[0006] The composition may also contain up to 1% by weight of gold, silver, copper, nickel, aluminum, platinum, palladium, molybdenum, tungsten, tantalum, tin, indium, lanthanum, gadolinium, boron, ruthenium, cobalt, titanium, yttrium, europium, gallium, sulfur, zinc, silicon, magnesium, barium, cerium, strontium, lead, antimony, conductive carbon, and combinations thereof.
[0007] The invention is further directed to method(s) of electrode formation on RFID or other circuits using such composition and to articles formed from such methods and/or composition.
DETAILED DESCRIPTION OF INVENTION
[0008] Generally, a thick film composition comprises a functional phase that imparts appropriate electrically functional properties to the composition. The functional phase comprises electrically functional powders dispersed in an organic medium that acts as a carrier for the functional phase. In general, a thick film composition is fired to burn out the organics and to impart the electrically functional properties. However, in the case of a polymer thick film composition, the organics remain as an integral part of the composition after drying. Such “organics” comprise polymer, resin or binder components of a thick film composition. These terms may be used interchangeably.
[0009] The main components of the thick film conductor composition are a conductor powder dispersed in an organic medium, which is comprised of polymer resin and solvent. The components are discussed herein below.
A. Conductor Powder
[0010] The electrically functional powders in the present thick film composition are Ag conductor powders and may comprise Ag metal powder, alloys of Ag metal powder, or mixtures thereof. The particle diameter, shape, and surfactant used on the metal powder are particularly important and have to be appropriate to the application method.
[0011] The particle size distribution of the metal particles is itself critical with respect to the effectiveness of the invention. As a practical matter, it is preferred that the particles size be in the range of 1 to 100 microns. The minimum particle size is within the range of 1-10 microns, such as 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 microns. The maximum size of the particles is within the range of 18-100 microns, such as 18, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95 or 100 microns. In one advantageous embodiment the silver flake ranges from 2-18 microns.
[0012] The metal particles are present at from 50-85% by weight of the total composition.
[0013] It is also important that a surfactant be used in the composition to facilitate the effective alignment of the flaked silver particles herein. Stearic acid is the preferred surfactant for the flaked silver.
[0014] Furthermore, it is well known in the art that small amounts of other metals may be added to silver conductor compositions to improve the properties of the conductor. Some examples of such metals include: gold, silver, copper, nickel, aluminum, platinum, palladium, molybdenum, tungsten, tantalum, tin, indium, lanthanum, gadolinium, boron, ruthenium, cobalt, titanium, yttrium, europium, gallium, sulfur, zinc, silicon, magnesium, barium, cerium, strontium, lead, antimony, conductive carbon, and combinations thereof and others common in the art of thick film compositions. The additional metal(s) may comprise up to about 1.0 percent by weight of the total composition.
B. Organic Medium
[0015] The powders herein are typically mixed with an organic medium (vehicle) by mechanical mixing to form a paste-like composition, called “polymer thick film silver compositions” or “pastes” herein, having suitable consistency and rheology for printing. A wide variety of inert liquids can be used as an organic medium. The organic medium must be one in which the solids are dispersible with an adequate degree of stability. The rheological properties of the medium must be such that they lend good application properties to the composition. Such properties include: dispersion of solids with an adequate degree of stability, good application of composition, appropriate viscosity, thixotropy, appropriate wet ability of the substrate and the solids, a good drying rate, and dried film strength sufficient to withstand rough handling.
[0016] The polymer resin of the present invention is particularly important. The resin used in the present invention is a vinyl co-polymer which allows high weight loading of silver flake and thus helps achieve both good adhesion to polyester substrates and low resistivity (high conductivity), two critical properties for silver electrodes in RFID circuitry.
[0017] Vinyl-copolymer is herein defined as polymers produced by polymerizing the vinyl group of a vinyl monomer with at least one co monomer. Suitable vinyl monomers include but are not limited to vinyl acetate, vinyl alcohol, vinyl chloride, vinylidene chloride and styrene. Suitable co monomers include but are not limited to a second vinyl monomer, acrylates and nitrides. Vinylidene chloride copolymer with at least one of vinyl chloride, acrylonitrile, alkyl acrylate is a suitable polymer resin.
[0018] The most widely used organic solvents found in thick film compositions are ethyl acetate and terpenes such as alpha- or beta-terpineol or mixtures thereof with other solvents such as kerosene, dibutylphthalate, butyl carbitol, butyl carbitol acetate, hexylene glycol and high boiling alcohols and alcohol esters. In addition, volatile liquids for promoting rapid hardening after application on the substrate can be included in the vehicle. In many embodiments of the present invention, solvents such as glycol ethers, ketones, esters and other solvents of like boiling points (in the range of 180° C. to 250° C.), and mixtures thereof may be used. In one advantageous embodiment the medium includes dibasic esters and C-11 ketone.
[0019] The medium comprises 16-25% by weight of the vinyl copolymer resin and 75-84% by weight organic solvent.
Application of Thick Films
[0020] The polymer thick film silver composition or paste herein is typically deposited on a substrate, such as a polyester, that is essentially impermeable to gases and moisture. The substrate can also be a sheet of flexible material, such as an impermeable plastic, such as a composite material made up of a combination of plastic sheet with optional metallic or dielectric layers deposited thereupon. In one embodiment, the substrate can be a build-up of layers inclusing metalized silver.
[0021] The deposition of the polymer thick film silver composition is performed in one embodiment by screen printing, and in other embodiments by deposition techniques such as stencil printing, syringe dispensing or coating techniques. In the case of screen-printing, the screen mesh size controls the thickness of deposited thick film.
[0022] The deposited thick film is dried or the organic solvent is evaporated, such as by exposure to heat, for example 10-15 min at 120-140° C.
[0023] The present composition particly suitable for RFID related uses because of its:
[0024] (1) Unusually low resistivity observed (4.6 milliohm/sq/mil); and
[0025] (2) The thickness of the print (9-10 microns using a 280 Stainless Steel screen) which is very important for RFID and other applications. The net result of (1) and (2) is very low circuit resistance, which is an extremely desirable and advantageous characteristic.
[0026] The present invention will be discussed in further detail by the below examples. The scope of the present invention, however, is not limited in any way by these examples.
EXAMPLE 1
[0027] The PTF silver electrode paste was prepared by mixing silver flake with an average particle size of 4 micron (range was 1-18 microns) that contains stearic acid as a surfactant, with an organic medium composed of a co-polymer of vinylidene chloride and acrylonitrile resin (also known as Saran F-310 resin, Dow Chemical, Midland, Mich.). The molecular weight of the resin was approximately 25,000. The surface area/weight ratio of the silver particles is in the range of 0.8-1.3 m 2 /g.
[0028] A solvent was used to dissolve the resin completely prior to adding the silver flake. That solvent was a 50/50 blend of DiBasic Esters (DuPont, Wilmington, Del.) and C-11 Ketone solvent (Eastman Chemical Company, Kingsport, Tenn.). A small amount of additional C-11 Ketone was added to the formulation.
[0029] The polymer thick film composition was:
[0000]
64.00%
Flaked Silver with Stearic Acid surfactant
35.50
Organic Medium (19.5% resin/80.5% solvent)
0.50
C-11 Solvent
[0030] This composition was mixed for 30 minutes on a planetary mixer. The composition was then transferred to a three-roll mill where it was subjected to a first pass at 150 PSI and a second pass at 250 PSI. At this point, the composition was used to screen print a silver pattern on polyester. Using a 280 mesh stainless steel screen, a series of lines were printed, and the silver paste was dried at 140° C. for 15 min. in a forced air box oven. The resistivity was then measured as 4.6 milliohm/sq/mil at a thickness of 10 microns. As a comparison, a standard composition such as DuPont product 5025 was measured as 13.6 milliohm/sq/mil. Another high conductivity standard product such as DuPont 5028 showed 9.8 milliohm/sq/mil, which is 2× higher resistivity than the example given above. This unexpectedly large improvement (lowering) in resistivity, a key property for all silver compositions, enables it to be used for most applications and improves RFID antenna performance. Also note that the value observed, 4.6 mohm/sq/mil, is approaching that of high temperature fired (850° C.) silver conductors. A comparison table appears below:
[0000]
Adhesion
to
Resistivity
Silver Composition
Polyester
mohm/sq/mil
5025
Good
13.6
5028
Good
9.8
Example 1
Excellent
4.6
High Temp.
Not
1.5
(850° C.) Ag
applicable
EXAMPLE 2
[0031] Another PTF silver composition was prepared, except that the surfactant on the silver flake was changed from stearic acid to oleic acid. All other properties of the formulation, silver powder distribution, and the subsequent processing were the same as Example 1. That is, the same organic medium was used as in Example 1. The normalized resistivity for this composition was 42.8 mohm/sq/mil. It is apparent that a change in surfactant chemistry on the silver flake has a significant (negative) impact on the resistivity of the composition.
EXAMPLE 3
[0032] Another PTF silver composition was prepared except that the particle size distribution was shifted to smaller particles. Here, the average particle size was reduced to approximately 2 microns and there were virtually no particles greater than 7 microns. The surfactant of Example 2, oleic acid, was used on the silver flake. All other processing conditions were the same as example 1. The normalized resistivity for this composition was 20.2 mohm/sq/mil again showing the criticality of the particle size of the silver chosen and the surfactant used.
EXAMPLE 4
[0033] Another PTF silver composition was prepared as per Example 1 except the resin used was changed from the vinyl co-polymer described in Example 1 to a thermoplastic polyester resin of molecular weight 25000. All other conditions and processing were the same. The normalized resistivity measured was 22.7 mohm/sq/mil establishing the criticality of the resin used in Example 1 in concert with the silver powder.
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Disclosed are thick film silver compositions comprised of silver flake and organic medium useful in radio frequency identification devices (RFID). The invention is further directed to method(s) of antenna formation using RFID circuits or other circuits using polymer thick film (PTF).
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TECHNOLOGICAL FIELD
The present disclosure relates generally to the field of zinc/nickel plating on metal substrates. More specifically, the present disclosure relates to methods for improving the removal of zinc/nickel plating from metal substrates, including the removal of zinc/nickel plating from steel substrates.
BACKGROUND
In the electrochemical plating field, it is often desirable to strip plating from plated metals. However, many of the known stripping agents are costly and/or difficult to control. In addition, many known stripping agents are hazardous.
For example, the use of cadmium plating for steel parts has long been known. However, the recent categorization of cadmium as a carcinogen has led industry to seek an alternative plating for cadmium. Zinc/nickel alloy plating has been seen as a useful alternative to cadmium plating. Unfortunately, processes using zinc/nickel alloy plating have had their potential utility as a cadmium replacement impacted by the lack of a reliable and convenient stripping solution for the removal of the zinc/nickel alloy plating from substrates, including steel substrates.
Known cadmium plating stripping agents (from steel substrates) typically undergo a chemical reaction that imparts atomic hydrogen to the steel substrate. This is due to the use of ammonium nitrate (which generates hydrogen) in cadmium stripping solutions. The hydrogen-rich environment is not desirable for plated steel being “stripped” of its plating, causing hydrogen-based embrittlement of the steel base metal substrate. Such embrittlement makes the stripped steel unusable for many structurally dependent end uses, and further complicates steel processing, as the embrittled steel must undergo remedial processes such as, for example, baking to become useful for contemplated end uses.
The use of acid-type stripping agents in plating (and stripping) processes also imparts hydrogen to the stripping environment (stripping tanks), resulting in the same above-discussed embrittlement issues relative to the underlying steel base metal. In addition, acid-type stripping agents will further undesirably attack steel substrates.
A useful and effective solution that would act to remove or “strip” plating such as, for example, zinc/nickel alloy plating from metal substrate surfaces, without embrittling or attacking the metal substrate, and would allow for the reuse of the substrate, and eliminate the need for processes to remediate the metal substrates (e.g. baking procedures), would otherwise be highly advantageous.
BRIEF SUMMARY
The present disclosure relates methods and systems for removing zinc/nickel alloy plating from metal substrates, particularly steel substrates. The disclosure also relates to stripping solutions comprising a basic compound, particularly mixtures of a base, such as, for example, sodium hydroxide (NaOH), potassium hydroxide (KOH), etc., and an amine, such as, for example, triethanolamine (C 6 H 15 NO 3 , or “TEA”), N-aminoethylethanolamine, ethylenediamine, diethylenetriamine, triethylenetetramine, tetraethylenepentamine, pentathylenehexamine, and combinations thereof, and methods and systems for replenishing zinc/nickel plating solutions, as well as plated components using such replenished plating solutions.
Accordingly, one aspect of the present disclosure relates to a method for removing zinc/nickel alloy plating from a substrate. The method comprises immersing a plated substrate into a solution comprising a basic compound and an amine, for a predetermined period of time, with the plated substrate comprising a zinc/nickel alloy plating, and removing the zinc/nickel plating from the substrate.
According to a further aspect, either before, after, or concurrently with the step of removing the zinc/nickel plating from the substrate, removing debris that is attached to the substrate is removed from the substrate by rinsing, wiping, applying ultrasound, applying agitation or combinations thereof.
In a further aspect, the solution is maintained at a temperature of from about 60° F. to about 200° F. In a further aspect, the solution is maintained at room temperature.
In a still further aspect, the basic compound comprises sodium hydroxide, potassium hydroxide, and combinations thereof.
In a still further aspect, the basic compound is maintained in the solution at a concentration of from about 10% to about 35% by weight.
In another aspect, the amine comprises triethanolamine (TEA), triethanolamine (C 6 H 15 NO 3 , or “TEA”), N-aminoethylethanolamine, ethylenediamine, diethylenetriamine, triethylenetetramine, tetraethylenepentamine, pentathylenehexamine, and combinations thereof.
In yet another aspect, the amine is maintained in the solution at a concentration of from about 1% to about 25% by weight.
In a further aspect, the solution is maintained at a pH of greater than about 11. In another aspect, the solution is maintained at a pH of from about 11 to about 14. In another aspect, the solution is replenished with the basic compound/amine combination whenever a decrease in stripping rate is observed.
According to a further aspect, the substrate comprises steel, stainless steel, aluminum, aluminum alloy, titanium, titanium alloy, copper, copper alloy, and combinations thereof. According to further aspects, processes of the present disclosure may be applied to stripping zinc/nickel alloy plating that also comprises chromates.
In another aspect, the present disclosure relates to a solution for removing zinc/nickel alloy plating from a substrate, with the solution comprising a basic compound in an amount of from about 10% to 35% by weight, and an amine in an amount of from about 1% to about 25% by weight.
In a further aspect, the solution is maintained at a pH greater than about 11. In another aspect, the solution is maintained at a pH of from about 11 to about 14. In another aspect, the solution is replenished with the basic compound/amine combination whenever a decrease in stripping rate is observed.
In yet another aspect, the solution comprises sodium hydroxide, potassium hydroxide, and combinations thereof, etc.
In a further aspect, the amine comprises triethanolamine (TEA), N-aminoethylethanolamine, ethylenediamine, diethylenetriamine, triethylenetetramine, tetraethylenepentamine, pentathylenehexamine, and combinations thereof.
In yet another aspect, the substrate comprises steel, stainless steel, aluminum, aluminum alloy, titanium, titanium alloy, copper, copper alloy, and combinations thereof.
In another aspect, the present disclosure relates to a method for replenishing a zinc/nickel alloy plating solution comprising zinc ions and nickel ions comprising immersing a plated substrate into a solution comprising a basic compound and an amine for a predetermined time, with the plated substrate comprising a zinc/nickel alloy plating, and removing zinc ions and nickel ions from the plated substrate.
In another aspect, the solution is maintained at a temperature of from about 60° F. to about 200° F. In a further aspect, the solution is maintained at room temperature.
In a still further aspect, the basic compound comprises sodium hydroxide, potassium hydroxide, and combinations thereof, at a concentration of from about 10% to about 35% by weight.
In yet another aspect, the amine comprises triethanolamine (TEA), N-aminoethylethanolamine, ethylenediamine, diethylenetriamine, triethylenetetramine, tetraethylenepentamine, pentathylenehexamine, and combinations thereof.
According to a further aspect, the substrate comprises steel, stainless steel, aluminum, aluminum alloy, titanium, titanium alloy, copper, copper alloy, and combinations thereof.
According to another aspect, the replenishing method comprises immersing a plated substrate into a plating solution comprising a basic compound alone, or in the presence of an amine for a predetermined time with no electrical current applied, with the plated substrate comprising a zinc/nickel alloy plating, and removing zinc ions and nickel ions from the substrate, with the zinc ions and nickel ions that are removed from the substrate used to replenish the plating solution. In this aspect, a zinc/nickel plating solution is actually being used as a zinc/nickel stripping solution (with no electrical current applied) and stripped zinc ions and nickel ions from the stripped zinc/nickel plating replenishes the zinc/nickel plating solution, saving the expense of conventional replenishing of expensive metal ions to the plating solution. In other words, through the use of the same zinc/nickel plating solution “off cycle” as a zinc/nickel stripping solution, the expensive zinc and metal ions are “recycled” or “reclaimed” into the zinc/nickel plating solution from the zinc/nickel plating stripped from a zinc/nickel-plated substrate.
In another aspect, the present disclosure relates to a plating solution for plating zinc/nickel-containing alloy onto a substrate, with the plating solution comprising an amount of basic compound in an amount of from about 10% to about 35% by weight, wherein an amount of zinc ions and nickel ions are replenished to the plating solution by immersing a substrate plated with a zinc/nickel alloy, stripping zinc ions and nickel ions from the substrate, and returning the zinc ions and nickel ions to the plating solution.
In yet another aspect, the present disclosure relates to a plating solution for plating zinc/nickel-containing alloy onto a substrate, with the plating solution comprising an amount of basic compound in an amount of from about 10% to about 35% by weight, and an amine in an amount of from about 1% to about 25% by weight, wherein an amount of zinc ions and nickel ions are replenished to the plating solution by immersing a substrate plated with a zinc/nickel alloy, stripping zinc ions and nickel ions from the substrate, and returning the zinc ions and nickel ions to the plating solution.
In yet another aspect, the basic compound comprises sodium hydroxide, potassium hydroxide and combinations thereof.
In still another aspect, the amine comprises triethanolamine (TEA), N-aminoethylethanolamine, ethylenediamine, diethylenetriamine, triethylenetetramine, tetraethylenepentamine, pentathylenehexamine, and combinations thereof.
In still another aspect, the substrate comprises steel, aluminum, aluminum alloy, titanium, titanium alloy, copper, copper alloy, stainless steel, and combinations thereof.
In another aspect, a component comprises a zinc/nickel alloy plated substrate.
In a further aspect, an object comprises the component comprising the zinc/nickel alloy plated substrate.
In yet another aspect, an object comprising the component comprising the zinc/nickel alloy substrate is, for example, an aircraft, a vehicle, and a stationary object.
BRIEF DESCRIPTION OF THE DRAWINGS
Having thus described variations of the disclosure in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:
FIG. 1 is a flow chart showing an aspect of the present disclosure; and
FIG. 2 is drawing of an aircraft comprising parts plated using reclaimed zinc and nickel according to aspects of the present disclosure.
DETAILED DESCRIPTION
Known stripping solutions that remove Zn/Ni alloy plating from substrates often comprise ammonium nitrate that generate hydrogen that can undesirably embrittle the substrate, resulting in the need to remediate the substrate by further processing the stripped substrate (e.g. baking processes) before the substrate can be re-used.
According to an aspect of the present disclosure, a basic compound-containing stripping solution that is highly basic, along with the addition of an amine, has now been shown to efficiently, reliably and cost-effectively strip zinc/nickel plating from metal substrates, without imparting any embrittlement to the metal substrate. According to one aspect, the basic compound comprises a compound such as, for example, sodium hydroxide, potassium hydroxide and combinations thereof in an amount of from about 10 to about 35% by weight. In a further aspect, the amine comprises, for example, triethanolamine (TEA), N-aminoethylethanolamine, ethylenediamine, diethylenetriamine, triethylenetetramine, tetraethylenepentamine, pentathylenehexamine, and combinations thereof in an amount of from about 1 to about 25% by weight. According to one embodiment, sodium hydroxide is provided to a solution along with TEA. By using a non-acidic stripping solution (and thus preventing the generation of hydrogen to the stripping solution system), hydrogen embrittlement and other attack of a metal substrate, such as, for example, steel, is significantly minimized, and/or substantially eliminated. While a solution having a basicity (basic pH) of greater than at least about 11 (and in one aspect a solution with a pH from about 11 to about 14) has now been shown to work as a zinc/nickel stripping solution, it now also has been demonstrated that, as the solution basicity increases, and an amine such as, for example, N-aminoethylethanolamine, ethylenediamine, diethylenetriamine, triethylenetetramine, tetraethylenepentamine, pentathylenehexamine, and combinations thereof, is introduced to the stripping solution, the stripping time decreases significantly (and the stripping rate increases significantly). Without being bound by any particular theory, it is believed to be advantageous to maintain the pH as high as possible, (e.g., greater than about 11), without thickening the solution to the point of an unusable viscosity.
FIG. 1 is a flow chart showing one aspect of the present disclosure. According to process 10 , a substrate that has been plated with a Zn/Ni alloy plating 12 is subjected to a step of immersing the substrate 12 into a solution comprising a basic compound and an amine maintained at a pH of from about 11 to about 14, 14 . Optionally, the solution comprising a basic compound and an amine 14 may be subjected to a one of two heating steps; 1) the solution comprising a basic compound and an amine is heated to a temperature above room temperature before the substrate is immersed in the solution 16 a ; or 2) the solution comprising a basic compound and an amine is heated to a temperature above room temperature after the substrate is immersed in the solution 16 b . Room temperature is understood to be an ambient temperature of from about 65° F. to about 85° F. The substrate is then left immersed in the solution comprising a basic compound and an amine for a predetermined amount of time (not shown) and Zn/Ni alloy plating is removed from the substrate surface 17 . It is understood by those skilled in the field that the stripping time will depend upon the thickness of the Zi/Ni alloy plating being stripped. Concurrently with, or subsequent to, the removal of the Zn/Ni alloy plating being stripped from the substrate, “smut” or other debris is often formed on the substrate surface. As a result, the stripped substrate is then subjected to a step to remove debris from the substrate surface 18 .
EXAMPLES
Experiments were conducted to determine the effectiveness of a stripping solution comprising sodium hydroxide/triethanolamine to remove zinc/nickel alloy plating from steel substrate test specimens plated with a zinc/nickel alloy. Test specimen steel substrates were 4130 steel cut into 1″×4″ rectangles, having a thickness of about 0.04″. The test specimens were plated with approximately 1 mil (0.001″) zinc/nickel alloy. The test specimens were then immersed in various stripping solutions. The selected stripping solution and the results obtained are shown below in Table 1. Room temperature is understood to be a temperature of from about 65 to 85° F.
TABLE 1
Agitation
Solution
Stripping Time
Y/N
Temperature ° F.
Ammonium
Approx. 24
hours
N
Room Temp.
Nitrate/H 2 O
150 g/l
Ammonium
4-5
hours
N
Room Temp.
Nitrate/H 2 O
240 g/l
Ammonium
20
min.
Y
Room Temp. (pH
Nitrate/H 2 O
adjusted to 8.0
312 g/l
with Ammonium
Hydroxide
Turco Alkaline Rust
30
min.
N
160
Remover - MAC
240 g/l
Turco Alkaline Rust
70
min.
N
Room Temp.
Remover - MAC
240 g/l
Sodium Hydroxide
70
min.
N
Room Temp.
240 g/l
Sodium Hydroxide
30
min.
N
Room Temp.
20% by weight
Sodium
15
min.
N
Room Temp.
Hydroxide/TEA
20%/15% by weight
Zn/Ni Plating
12
hours
N
Room Temp.
solution (Dipsol)
[Dipsol of America,
Livonia, Mich.]
The systems and methods set forth herein are contemplated for use with producing zinc/nickel alloy plated components for use in manned or unmanned vehicles or objects of any type or in any field of operation, such as in a terrestrial and/or non-terrestrial and/or marine or submarine setting. A non-exhaustive list of contemplated objects include, manned and unmanned aircraft, spacecraft, satellites, terrestrial, non-terrestrial vehicles, and surface and sub-surface water-borne vehicles, etc., as well as stationary objects. FIG. 2 shows an aircraft 20 comprising a fuselage panel 24 from a fuselage section 22 . Fuselage section 22 comprises component parts (not shown) that may themselves comprise a substrate material plated with a Zn/Ni alloy plating solution that has been at least partially replenished with zinc and nickel that has been recovered and introduced into the plating tank/bath by immersing a substrate plated with Zn/Ni alloy and then stripping the Zn/Ni alloy plating from the substrate.
When introducing elements of the present disclosure or exemplary aspects or embodiment(s) thereof, the articles “a,” “an,” “the” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,” “including” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. While the preferred variations and alternatives of the present disclosure have been illustrated and described, it will be appreciated that various changes and substitutions can be made therein without departing from the spirit and scope of the disclosure. Although specific aspects have been described, the details of these aspects are not to be construed as limitations.
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The present disclosure relates generally to the field of electroplating and electroless plating. More specifically, the present disclosure relates to plating solutions and plating removal/stripping solutions for stripping zinc/nickel alloy plating from substrates.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is based and claims priority on Provisional Application Serial No. 60/329,190, filed on Oct. 12, 2001, the contents of which are fully incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a vacuum oven, to a system incorporating the same, and to a method of using the same, and more specifically to a vacuum oven that is portable and that can be moved while maintaining vacuum and to a modular system incorporating the same.
[0003] Chips and sensitive electronic components many times need to be worked on in an inert clean environment. To accomplish this, glove box/oven systems have been developed. Typically a glove box is a fully enclosed hermetically sealed box. An operator accesses the inside of the box through gloves attached to a side of the box.
[0004] An oven is attached to an end of the box. The interface between the oven and the box is also hermetically sealed to ensure an air tight seal. The oven can be opened at opposite ends. In this regard, the oven can be opened at its end attached to the glove box and at its opposite end.
[0005] Sensitive electronic equipment or items, as for example pacemakers, have to be sealed or welded in an inert environment. To accomplish this, the item is placed into the oven by opening the end of the oven not attached to the box. The oven is then closed and the item is heated under a predetermined vacuum i.e., it undergoes a vacuum bake cycle to get rid of moisture and impurities. Once the vacuum bake cycle is completed, the vacuum oven is back filled from the glove box and the end of the oven interfacing with the glove box is opened. The item is then moved into the glove box where the operator can work on it, as for example weld it.
[0006] The problem with current glove box/oven systems is that while the item is undergoing a vacuum bake cycle, other items cannot be brought into the glove box for processing. As such, use of the glove box is dependent on whether or not the oven is being used. Consequently, in a manufacturing setting, multiple glove box/oven systems are required to increase productivity. As a result, the manufacturing costs of the products processed through such glove box/oven systems are increased.
[0007] As such, an oven and a system are required that will allow the vacuum bake of items in locations away from the glove box or other clean air space and which can then be transported while maintaining vacuum into the glove box. In this regard, multiple items may be baked in one or more ovens and can be operated on using a single glove box or a single clean air space.
SUMMARY OF THE INVENTION
[0008] A vacuum oven for decontaminating items, a system incorporation multiple such vacuum ovens and a method of operating such system are provided. The ovens are portable. They can have a vacuum drawn in them and can be heated by being coupled to a vacuum and a power source, respectively at a first location and then be decoupled from the vacuum and power sources and moved to a second location such as a glove box or clean room while still maintaining a vacuum.
[0009] An exemplary embodiment oven includes a hollow body having an opening providing access to an interior of the body and at least one removable shelf fitted in the body. A heater such as a heating pad is coupled to the shelf. A power interface is coupled to the heater and is releasably coupled to an external power source separate from the body. A vacuum valve is coupled to the body and releasably couples to an external vacuum source. A door is coupled to the body for covering the opening and sealing against the body by vacuum. The exemplary embodiment oven can be incorporated in a system.
[0010] An exemplary embodiment system includes a rack having at least a bay for receiving a vacuum oven in each bay. Each bay has a vacuum valve and a power interface mounted therein. The vacuum valve controls the vacuum being drawn from a vacuum source. A vacuum oven is slidably fitted in the bay and is releaseably coupled to the rack, the power interface and vacuum source.
[0011] An exemplary method for decontaminating items using the exemplary oven of the present invention includes placing the items to be decontaminated in the interior of the oven and coupling the oven to a vacuum source for drawing vacuum in the oven. The oven interior is heated heating the items to a predetermined temperature for decontaminating. The oven is then decoupled from the vacuum source and moved to a work area where the vacuum in the oven is released and the oven door is opened providing access to the decontaminated items.
[0012] An exemplary method for operating multiple ovens in an exemplary system of the present invention for decontaminating items includes providing a rack having a plurality of bays and coupling a vacuum source and a power source to the plurality of bays. A first vacuum oven having a first items to be decontaminated in it is mounted in a first bay and the vacuum source and power source are coupled to the first vacuum oven. A vacuum is drawn in the interior of the first oven to a predetermined vacuum level and the interior of the first vacuum oven is heated to a predetermined temperature for decontaminating the first set of items. A second vacuum oven having a second set of items to be decontaminated in it is mounted in a second bay and the vacuum source and power source are coupled to the second vacuum oven. A vacuum is drawn in the interior of the second vacuum oven to a predetermined vacuum level and the interior of the second vacuum oven is heated to a predetermined temperature, for decontaminating the second set of items. One or both vacuum ovens may be removed from its corresponding bay while maintaining a vacuum. The second vacuum oven may be mounted in the rack and operated before or after the vacuum and temperature in the first vacuum oven reach their predetermined level and temperature, respectively, or while the vacuum and temperature in the first vacuum oven is ramping up to the predetermined level and temperature, respectively.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] [0013]FIG. 1 is a perspective partial cut-away view of an exemplary oven of the present invention.
[0014] [0014]FIG. 2A is an end view of the exemplary oven shown in FIG. 1.
[0015] [0015]FIG. 2B is a partial end side view of the oven shown in FIG. 1.
[0016] [0016]FIG. 2C is a perspective cut-away view of a pin with insulator sleeve assembly which extends from the rear wall of the oven shown in FIG. 1.
[0017] [0017]FIG. 2D is a partial end assembly view of the oven shown in FIG. 1 incorporating a keying system.
[0018] [0018]FIG. 3 is a perspective upside-down view of a shelf with heating pad for incorporation in the oven shown in FIG. 1.
[0019] [0019]FIGS. 4A and 4B are perspective rear and front views, respectively, of the oven body with rear end wall of the oven shown in FIG. 1.
[0020] [0020]FIG. 5 is a perspective view of a system having a rack incorporating the oven shown in FIG. 1, a controller, and a computer.
[0021] [0021]FIG. 6 is a front view of the system shown in FIG. 5.
[0022] [0022]FIG. 7 is a partial cut-away perspective view of the rack shown in FIG. 5.
[0023] [0023]FIG. 8 is a perspective view of a manifold valve assembly incorporated in the rack shown in FIG. 7.
DETAILED DESCRIPTION
[0024] A vacuum oven, a system incorporating one or more of such ovens and a method of operating such ovens and system are provided. In an exemplary embodiment, an oven 10 of the present invention comprises a generally hollow elongated body 12 having four rectangular sides 14 , one end wall 16 fixed to one end of the body and a door 18 at the other end 20 of the body for providing access to the interior of the body, as shown in FIG. 1. In an exemplary embodiment, the body 12 is extruded from aluminum. The end wall 16 is welded to the body. In alternate embodiments, the body may have other shapes, as for example, it may be a cylindrical. For descriptive purposes, however, the oven of the present invention is described herein in relation with an oven having a hollow body formed by four generally rectangular sides. The exemplary embodiment oven described herein is 6″ wide, by 6″ high by 18″ long. Applicants have discovered that these dimensions provide optimum accommodations for most items typically treated by such ovens.
[0025] It should be noted that the terms “front,” “rear,” “top,” “bottom,” “upper,” “lower,” “uppermost,” and “lowermost” are used herein for descriptive purposes to recite relative positions of various parts without limiting the location the parts to such positions.
[0026] The oven is designed to accommodate one or multiple shelves 22 which can be heated. In an exemplary embodiment, the shelves are formed from aluminum. To accommodate the shelves, two opposite side supports 24 are fitted in the oven, each having a slot 26 for accommodating each shelf 22 . The slots are formed on the same location in each support. The supports are placed inside the oven against opposite sidewalls 28 of the oven 10 , such that the slots are facing each other. In the exemplary embodiment, the oven supports are formed from Teflon® for allowing the shelves to slide easily along the slots on the supports. In addition, the oven supports provide thermal insulation to the oven, eliminating the need to insulate the oven from the outside for keeping the outer surface temperature of the oven at a safe level for handling. In an alternate exemplary embodiment, the slots may be formed on the inner surfaces of the sidewalls 28 thus not requiring the supports. In other exemplary embodiments, one or more shelves may be slidably fitted in the oven or may be fixed in the oven. For illustrative purposes, the exemplary oven is described as having three shelves, an upper shelf 22 c which is fixed in place and two lower removable shelves which are slidably fitted in the oven. The upper shelf 22 c is used for heating while intermediate shelf 22 b and lower shelf 22 a are used for heating and for supporting the items to be heated. Use of the upper shelf 22 c allows for similar heating of space 23 b between the upper shelf 22 c and intermediate shelf 22 b as of space 23 a between the intermediate shelf and the lower shelf oven. Similar heating control is possible since both spaces 23 a and 23 b are bounded by two heating shelves.
[0027] In an exemplary embodiment, the shelves are heated by incorporating a heating pad 30 adhered to one side of each shelf as shown in FIG. 3. In other exemplary embodiments, other heaters such as heating elements may be used. In an exemplary embodiment, heating pads are used formed from silicon rubber. The heating pad of each shelf is connected to an interface assembly 32 which provides an interface for providing power for heating the heating pad and thus, the shelf. A thermocouple 37 is incorporated on the heating pad for measuring temperature. The thermocouple 37 is coupled to thermocouple plug 34 which provides an interface for the thermocouple 37 . The heating pad includes an overtemperature thermostatic switch 36 . The overtemperature thermostatic switch shuts off power to the heating pad when the temperature of the heating pad or heater exceeds a predetermined temperature.
[0028] In alternate exemplary embodiments, a heater such as a heating pad may be mounted on an upper inner surface of the oven such as the oven upper wall, thus not requiring a separate upper shelf just for heating.
[0029] In an exemplary embodiment oven, when each of the intermediate and lower shelves is completely inserted into the oven along the slots 26 on the supports 24 , each shelf's thermocouple plug 34 mates with a thermocouple interface 40 . In the exemplary embodiment the thermocouple interface is a thermocouple heavy duty connector made by Omega Engineering, Inc. of Stamford, Conn. Each shelf thermocouple interface 40 is coupled to a thermocouple connector 42 . In the exemplary embodiment shown in FIG. 1, the thermocouple connectors are external of the oven and are mounted on a rear top surface of the oven. Morever, in the exemplary embodiment, as each removable shelf is fitted into the oven, the interface assembly 32 of each shelf mates with a connector 47 which is coupled to openings 44 formed on the rear wall 16 of the oven. In the exemplary embodiment oven, each interface assembly 32 comprises two spring loaded conductive pins 49 . Each connector 47 comprises two banana plugs 48 which penetrate openings 44 and interface with the conductive pins 49 (FIGS. 2A, 2C, 2 D and 4 A) when the shelves are pushed into position in the oven. The spring loaded pins provide for a reliable connection between the interface assembly of a shelf and the corresponding banana plugs of the connector 47 . Preferably, the plugs 48 are surrounded by an insulating sleeve 51 as for example shown in FIG. 2C. The insulating sleeve fits into the openings 44 (FIG. 4A) formed on the rear wall of the oven sealing the openings air tight while allowing for penetration by the banana plugs. In an alternate embodiment, instead of banana plugs, the interface assembly may contain sockets that mate against the openings 44 .
[0030] In the exemplary embodiment, the upper shelf 22 c which is fixed to the oven is connected to connector 45 . In an alternate exemplary embodiment instead of a connector 45 , an interface assembly 32 is incorporated in the fixed shelf which is connected to a connector 47 as described in relation to the removable shelves. A two-way valve 50 is coupled to a fitting 52 coupled to the rear end wall 16 of the oven as for example shown in FIGS. 2A and 2B. A disc 54 is coupled to the end of the two-way valve 50 opposite the rear wall. An opening 56 is formed through the disc. The two-way valve 50 and fitting 52 provide access from the opening 56 formed through the disc to the interior of the oven through opening 57 formed on the rear wall 16 (FIG. 4A). The two-way valve controls the flow through the fitting. The two-way valve is preferably a solenoid type valve and is coupled to a connector 59 which in the exemplary embodiment is external of the oven as shown in FIG. 1.
[0031] In the exemplary embodiment shown in FIG. 1, a lip 60 extends radially outward from the sides of the oven front end and surrounds the oven front end. The lip defines a flange surface 62 surrounding the front end of the oven. A groove 64 is formed on the upper surface 65 of the lip as shown in FIGS. 1, 4A and 4 B. The door 18 has sufficient dimensions such that its entire surface proximate its perimeter mates with the flange surface of the lip.
[0032] A bracket 66 is attached or fastened to the upper end 67 of the door and has a lip portion 68 extending therefrom for mating with the groove 64 formed on the upper surface 65 of the lip as shown in FIG. 1. In this regard, the door can be hanged at the groove by using the bracket 66 . In an alternate embodiment, the bracket may be integrally formed with the door. By hanging the door to the body, the door may easily be completely removed from the body so as to provide unimpeded access to the oven interior. In a further alternate exemplary embodiment, the door may be hingeably connected to the oven body.
[0033] To provide a seal between the door and the lip, in the exemplary embodiment, a groove 70 is formed on the flange surface of the lip extending around the entire perimeter of the oven end (FIGS. 1 and 4B). An O-ring seal (not shown) is fitted within the groove. In an alternate embodiment, the groove for accommodating the O-ring seal may be formed on the surface of the door mating with the flange surface of the lip.
[0034] In the exemplary embodiment, a handle 72 is formed on the door to allow for easy installation (i.e., hanging) and removal of the door from the oven. A valve 74 is also fitted through the door extending outward to relieve vacuum and provides access to the interior of the oven through the door.
[0035] A carrying handle 76 is coupled to the oven body and preferably an upper side of the body to facilitate the carrying the transportation of the oven.
[0036] In an exemplary embodiment, the oven is mounted on a rack 80 as for example shown in FIG. 5. The rack may accommodate one or multiple ovens forming a system. For descriptive purposes, a rack that can accommodate six ovens is described herein. Each oven is slid into an opening 82 formed on the rack (FIG. 6). The rack comprises rails 84 which extend from each opening and define bays, as for example bays 86 , to support the ovens (FIG. 7). Each rail defines a corner of a bay 86 into which the oven is slid for mounting. To reduce the friction between an oven and the rails when sliding, low coefficient of friction nylon feet 88 may be mounted on either side of the lower surface of the oven for interfacing with the two lower rails of a bay (FIG. 1). In an alternate exemplary embodiment, low friction members such as feet may be mounted on the racks. Alternatively, the racks may be made from a low friction material.
[0037] At its rear end, each bay includes appropriate connectors for connecting with the various connectors of the oven such as the thermocouple connectors, the connector 45 , the two way valve connector and the interface assembly. In the exemplary embodiment, a connector 90 is located at the rear end of each bay for connecting with the thermocouple connectors 42 , the two-way valve connector 59 and the connector 45 . The connector 90 is connected to a controller 91 which is controlled by a processor such as a computer 93 (FIG. 5). The connector 90 provides paths for receiving temperature indicative signals from the thermocouples 37 of each shelf and provides paths for providing power to the two-way valve connector 59 for controlling the two-way valve 50 and to the heating pad of the upper shelf 22 c for heating the upper shelf. A shelf connector 92 is also located on the rear of each bay to connect with the interface assemblies 32 . The shelf connector 92 is also connected to the controller 91 and provides a path for providing power to the heating pad of each shelf via the interface assemblies 32 . All of the connectors allow for quick connection and disconnection with their corresponding connectors and assemblies on the oven.
[0038] In the exemplary system, a manifold valve assembly 94 is also located on the end of each bay (FIGS. 7 and 8). An exemplary manifold valve assembly is shown in FIG. 8 and comprises a manifold 96 . A three-way valve 98 is mounted on one end of the manifold via a fitting 100 . A suction cup 102 is mounted on another end of the manifold via a fitting 104 . A passage 106 provides a path from the suction cup to the three-way valve.
[0039] The suction cup is positioned on a bay to engage the disc 54 extending from the rear wall of an oven such that the passage 106 extending to the suction cup communicates with the opening 56 formed through the disc when the oven is mounted in the bay.
[0040] The three-way valve has a port 108 which is connected to a vacuum source 110 and a relief port 112 for relieving vacuum. The three-way valve may also be a solenoid valve and is also coupled to the controller 91 . An exemplary three-way solenoid valve is manufactured by ASCO (Automatic Switch Co.).
[0041] Once the oven is mounted within its bay, the disc 56 mates with the suction cup 102 and a vacuum may be applied to the oven via the three-way and two-way valves. The two-way and three-way valves are controlled by the controller. The controller also individually controls the amount of power available to each of the interface assemblies for heating each of the shelves. The controller control of the valves and power may be manual through the use of the computer or may be automated. For example, the controller may be programmed to control temperature and vacuum ramp up and to maintain the temperature and vacuum in the oven at preselected levels. The temperature of each shelf is ascertained by the controller from signals received from the thermocouples and registered on the computer.
[0042] Once the oven is mounted on its appropriate bay and vacuum is applied, the vacuum pulls the door 18 tightly against the oven body 12 compressing the O-ring seal, fitted in the groove 70 on the flange surface, between the door and the flange surface, creating an air tight seal. Consequently, a latch is not required for keeping the door closed.
[0043] As the vacuum is applied, the suction cup engages and seals against the disc 54 . Thus, to remove the oven without losing the vacuum in the oven, the two-way valve is closed while a vacuum is being drawn through the three-way valve. The three-way valve is then closed. Afterwards, the three-way valve relieves the vacuum in the manifold 96 through the relief port 112 so that the vacuum between the suction cup and disc is broken allowing for the withdrawal of the oven from the rack.
[0044] In an exemplary embodiment, all the ovens mounted into the rack are coupled to the same vacuum source. This alleviates the need to incorporate individual vacuum pumps and/or vacuum sources which are expensive. Consequently, the cost of the system is significantly reduced. Alternatively, multiple vacuum sources may be used.
[0045] Ovens may be installed into the rack at will and may be started at will. Each newly installed oven, however, may contain an atmosphere that may contaminate the other already installed ovens if they are not isolated when the newly installed oven is connected to the vacuum source. As such, it is necessary to use the three-way and the two-way valves to sequence the operation of the vacuum source to each of the ovens to avoid loss of vacuum in an evacuated oven.
[0046] In an exemplary operations sequence, the oven is mounted into the appropriate bay in the rack. The items to be decontaminated are placed on the oven shelves as appropriate, and the door is hung on the oven. The items may be placed in the oven prior to mounting or after mounting of the oven in the rack. The bay containing the new oven is selected on the computer. The selection may be made via the keyboard, mouse or touch screen. The operator then sends instructions via the computer to start the oven and may enter a data file name to identify the oven. If the other ovens have not finished the initial heat up and vacuum cycle, the system waits for the other ovens to reach their required temperature and vacuum. Then, the two-way valves on all the other ovens are closed and the three-way valve and then two-way valve on the newly installed oven are opened. Vacuum is spooled on the newly installed oven for a certain period of time and is checked to see if the vacuum level within a predetermined period of time has reached a desired level. For example, a typical value may be one millitor. If the vacuum does not reach the desired level, then an error is flagged and the process is stopped. If the vacuum does reach the desired level, then the two-way valve on the newly installed oven is closed.
[0047] The two-way valves on the other ovens which are in cycle mode (i.e. are being heated and evacuated) are opened, and heat is applied to the newly installed oven shelves until the temperature of the shelves reaches a desired level. The two-way valves are then closed on the other ovens. The two-way valve is then opened on the newly installed oven until the proper vacuum level is achieved. Once the proper vacuum level is achieved, the two-way valves on the other ovens are opened. When the bake cycle is completed on the newly installed oven, the two-way valve on the newly installed oven is closed and then the three-way valve is closed. This entire process may be automated through programming. An exemplary software that may be used to run the system is LABVIEW by National Instruments.
[0048] To remove the oven, the three-way valve opens the release port 112 so as to relieve the vacuum between the two-way valve and the three-way valve so as to allow the oven to slide out of the rack. The oven with the items may be then mated with or inserted in glove box, or it may be taken to a clean room where the vacuum oven is back filled with appropriate gas, e.g., the environment found in the glove box or clean room, and the door 18 is opened for removing the items treated by the oven. To back fill the vacuum oven so as to allow the door to open, the valve 74 coupled to the door is opened.
[0049] If it is desired that a specific oven is always mated with a specific bay in the rack, a key 120 (FIG. 2D) may be coupled to the rear of the oven that is accepted by a complementary key in a desired bay. For example, the key may have specific ports 124 arranged in a specific pattern that accommodate specific pins arranged in the same pattern and coupled to the rear and of the desired bay.
[0050] It should be noted that the exemplary oven, system and method have been described in relation to exemplary embodiments. It should be understood that the inventive oven, system and method are not limited to the exemplary embodiments. For example, other types of connectors and valves then those described may be used. For example, a female connector may be incorporated on the oven and a complementary male connector may be incorporated on the bay to connect with the female connector and vice versa. Moreover, the suction cup may be incorporated on the end of the fitting 52 extending from the oven instead of the disc 54 and the disc may incorporated at the end of the fitting 104 instead of the suction cup 102 .
[0051] Although the present invention has been described and illustrated to respect the exemplary embodiments thereof, it is to be understood that it is not to be so limited, since changes and modifications may be made therein which are within the full intended scope of this invention as hereinafter claimed.
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A vacuum oven for decontaminating items, a system incorporating multiple vacuum ovens and a method of operating such system are provided. The ovens are portable. They can have a vacuum drawn in them and can be heated by being coupled to a vacuum and a power source, respectively at a first location and then be decoupled from the vacuum and power sources and moved to a second location such as a glove box or clean room while still maintaining a vacuum.
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[0001] This application is a continuation in part application of my patent application bearing Ser. No. 10/799,968 filed on 10 Mar. 2004, which is a continuation application from my patent application bearing Ser. No. 09/594,528 filed on 14 Jun. 2000, now U.S. Pat. No. 6,735,926, which is a continuation in part application of my application bearing Ser. No. 09/954,905 filed on 3 Apr. 1998, now U.S. Pat. No. 6,101, 791.
BACKGROUND OF THE INVENTION
[0002] This invention relates to an apparatus and method for imprinting a vial. More particularly, but not by way of limitation, this invention relates to an offset printing system and method for printing onto a vial.
[0003] A method of producing a series of interconnected vials was disclosed in my co-pending continuation-in-part patent application bearing Ser. No. 10/799,968, filed on 10 Mar. 2004 which is incorporated herein by reference. The vials produced by the method and apparatus are interconnected. The vials can be filled with a material. In one preferred embodiment, the vials can be filled with a medicine. The vials can then be heat sealed so that the material is held within a self-contained unit.
[0004] Users of the vials will require information of the type of material contained within the container. In the situations wherein the vials contain medicine, certain information such as type of medicine, dosage amount, manufacturer, expiration date, etc. is very important. Additionally, the number of vials filled and the lot from which material originated is also very important. Prior art techniques including printing onto a label, and then placing the label onto the vial. However, this is undesirable for several reasons. First, the placement of the labels onto the vials is a highly inefficient and time consuming. Additionally, the type of ink used must not be toxic or environmentally unsafe since the ink has a possibility of contaminating the material contained within vial, or alternatively, the ink making the outer portion of the vial unsanitary.
[0005] Hence, there is a need for an apparatus to imprint onto a vial. There is a further need to imprint onto a series of interconnected vials. Still further, there is a need to imprint a label that is safe to the user and the environment. There is also a need to print onto a plastic article that is irregular in size and shape. These and many other needs will be met by the following invention.
SUMMARY OF THE INVENTION
[0006] An apparatus for imprinting vials is disclosed, and wherein the vials are connected in a series. The apparatus comprise a hopper for holding the vials, and a bowl feeder for positioning the vials onto a track. The apparatus further comprises a conveyor belt for moving the vials, with the conveyor having a mandrel for receiving an open end of the vials. The mandrel contains a plurality of receiving post for receiving the vials, and wherein the receiving post are of an oblong cross-sectional area and wherein a base portion of the receiving post has a greater cross-sectional area than a head portion of the receiving post.
[0007] The apparatus further comprises a vial depressor for depressing the vial onto the receiving post of the mandrel. A first offset inking transfer device for printing a first ink pattern onto the vials is included along with a first ultra violent dryer positioned to receive the vials from the first offset inking transfer device and provide for drying of the ink pattern from the first offset inking transfer device.
[0008] In one embodiment, the vial depressor comprises a first wheel rotatably connected to a second wheel, and wherein the top of the vials will abut a space created between the first wheel and the second wheel. The apparatus may further comprise an air cooler device for cooling the air and directing the cool air onto the vials in order to cool the vials. The apparatus also comprise a vial remover comprising a plate positioned on the underside of the conveyor and down stream of the first ultra dryer so that the vials are removed from the mandrel. The apparatus may also include a photo-eye device, positioned downstream of the bowl feeder, for determining whether the vials are positioned on the conveyor and transmitting a signal in order to halt the conveyor if the vials are improperly positioned on the conveyor.
[0009] In one preferred embodiment, a laser engraver is included in order to engrave an alpha numeric number onto the vial. Also, a flame treater means, positioned downstream of the vial depressor so that the vials are heat treated in preparation of the printing of the ink pattern on the vials is also included.
[0010] In the preferred embodiment, a second offset inking transfer device for printing a second ink pattern onto the vials is included along with a second ultra violent dryer positioned to receive the vials and provide for drying of the ink pattern from the second offset ink transfer device.
[0011] A method of imprinting a series of interconnected vials is also disclosed. The method comprises providing the series of interconnected vials onto a track, and placing the vials onto a mandrel having a plurality of receiving post, for receiving the vials. The receiving post are of oblong cross-sectional area and have a base portion that has a greater cross-sectional area than a head portion of the receiving post.
[0012] The method further includes depressing the vials onto the mandrel with a vial depressor for depressing the vial onto the receiving post of the mandrel. Next, the vials are imprinted with a first offset inking transfer device, and the ink is cured with a first ultra violent dryer. The method further includes printing onto the vials with a second offset inking transfer device, curing the ink with a second dryer, and removing the vials with a vial remover. In one preferred embodiment, the vial remover comprises a plate positioned on the underside of the conveyor and down stream of the first dryer so that the vials are removed from the mandrel. The method may further include cooling the vials.
[0013] In one preferred embodiment, the vial depressor comprises a first wheel rotatably connected to a second wheel, and wherein the top of the vials will abut a space created between the first wheel and the second wheel, and the step of depressing the vials includes abutting the first and the second wheel against a top portion of the vials so that the vials are captured on the mandrels.
[0014] An advantage of the present invention includes use of an offset inking transfer device which is a fast and efficient technique for printing onto plastic vials. Another advantage is that the process herein described allows for mass labeling production i.e. significant production quantity in a minor amount of time.
[0015] Yet another advantage is that the labels are treated with ultra violent dryer so that toxins are eliminated from the surface of the vials. Another advantage is that the vials, with printed labels, can be used for medical purposes. For instance, a liquid medicine can be placed within the vials, and the vials can be sealed. Then, the user can twist the top of the vial and open the vial. This can all be done since the ink of the printed material has been properly cured. Another advantage is that the ultra violent dryers make the ink impermeable in the plastic which is important health and safety issue.
[0016] A feature of the invention is that a conveyor belt is used to transporting the vials for printing and treating. Another feature is that a specially designed mandrel carries the vials on the conveyor. Still another feature is the design of the mandrel in conjunction with the vial depressor captures the vial on the mandrel for printing.
[0017] Yet another feature is the ultra violent light that cures the ink after printing. Another feature is the laser engraver that engraves the vials with various pertinent information. Another feature is the use of an air cooler for cooling the vials after the printing. Still yet another feature is that in preferred embodiment, multiple printing stations are provided. Yet another feature is the flame treater prepares the plastic for imprinting. Still yet another feature is the photo-eye confirms the proper placement of the vials on the mandrel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is an isometric view of a preferred embodiment of the vial string of the present invention.
[0019] FIG. 2 is a top view of the vial string seen in FIG. 1 .
[0020] FIG. 3 is an isometric view of a preferred embodiment of the mandrel with receiver post used in this invention.
[0021] FIG. 4 is an exploded view of the mandrel and receiver post seen in FIG. 3 .
[0022] FIG. 5 is a perspective view of the most preferred embodiment of the printing system herein disclosed.
[0023] FIG. 6 is a top view of a preferred embodiment of the in-line feed assembly and the vial depressor used in this invention.
[0024] FIG. 7 is a side view of the in-line feed assembly and the vial depressor seen in FIG. 6 .
[0025] FIG. 8 is a partial front view of the vial depressor with the wheels depressing the vial string onto the mandrel.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] Referring now to FIG. 1 , an isometric view of a preferred embodiment of the vial string 2 of the present invention will now be described. This application is a continuation in part application of my patent application bearing Ser. No. 10/799,968 filed on 10 Mar. 2004, which is a continuation application from my patent application bearing Ser. No. 09/594,528 filed on 14 Jun. 2000, now U.S. Pat. No. 6,735,926, which is a continuation in part application of my application bearing Ser. No. 09/954,905 filed on 3 Apr. 1998, now U.S. Pat. No. 6,101,791, and wherein the co-pending application Ser. No. 10/799,968 is incorporated herein by express reference. Additionally, U.S. Design Patent D460,175 is also incorporated herein by express reference. As per the teachings of these references, a vial string 2 is produced, and wherein the vial string 2 , in one preferred embodiment, contains a string of five (5) interconnected vials.
[0027] The vials have a closed top portion 4 and an open bottom portion 6 . After production of the vial string 2 , the bottom portion 6 is generally an oblong shaped opening, and as per the teachings of this invention, the bottom portion can be filled with a material, such as a medicine, and thereafter, the bottom portion 6 can be heat sealed to form a closed container. In order to use the material, such as liquid medicine, within the vial, the user would simply twist the top portion 4 thereby opening the vial to the contents therein.
[0028] FIG. 1 shows five (5) vials interconnected. It should be understood that the present invention is applicable to an individual vial to a string that contains over a dozen interconnected vials. The vials are interconnected via the interconnecting arms 8 . The vials are constructed of a plastic, and in one preferred embodiment, the plastic can be purchased from Dow Chemical Company under the trade name Metallocene Resin PT 1450.
[0029] Referring now to FIG. 2 , a top view of the vial string 2 seen in FIG. 1 will now be described. The view of FIG. 2 depicts the oblong shape opening of the bottom portion 6 . It should be noted that the invention herein described is also applicable to vials that have other shaped openings; however, the shape of the body of the vials will need to be matched by the body of the mandrel.
[0030] Thus, in FIG. 3 , which is an isometric view of a preferred embodiment of the mandrel 10 , the receiver post 12 will be configured so that the vial string 2 fits thereon. As seen in FIG. 3 ., the mandrel 10 consists of a plurality of receiver post 14 a, 14 b, 14 c, 14 d, 14 e. The receiver post have a pointy top portion 16 that extends to an elongated body 18 which in turn extends to an expanded bottom portion 20 (sometimes referred to as the bottom flare 20 ). The expanded bottom portion 20 is generally in the shape of the bottom portion 6 of the vial, which in the preferred embodiment will be an oblong shape seen in FIG. 2 . Returning to FIG. 3 , once the vials 2 are placed onto the mandrel 10 , the inner part of the bottom portion 6 of the vials will abut the outer part of the expanded bottom portion 20 of the receiver post, as will be further described later in the application.
[0031] FIG. 4 is an exploded view of the mandrel 10 and receiver post 14 a - 14 e seen in FIG. 3 . As shown, the receiver post 14 a - 14 e contain a leg extensions 22 a, 22 b, 22 c, 22 d, 22 e, and wherein the mandrel 10 contains a fastener sleeve 24 . As seen in FIG. 4 , the leg extension 22 will fit into the fastener sleeve 24 , and wherein the leg extensions will be attached to the fastener sleeve 24 via fastener means such as nuts and bolts, such as the bolt 25 . The fastener sleeve 24 will be attached to a shell 26 via conventional means, and the shell 26 will in turn be attached to the drive blocks 28 , 30 . The drive blocks 28 , 30 will have the pallet shafts 32 , 34 disposed there through, and wherein the blocks 28 , 30 will be attached to the conveyor belt so that the mandrel 10 can be transported.
[0032] Referring now to FIG. 5 , a perspective view of the most preferred embodiment of the printing system 50 will now be described. The system 50 includes the conveyor belt 52 , and wherein a plurality of mandrels are operatively attached to the conveyor belt. For instance, mandrel 10 is shown attached on the conveyor belt 52 . Approximately fifty (50) mandrels are shown attached to the conveyor belt 52 in FIG. 5 . The conveyor belt 52 is mounted on a support table 53 . As noted earlier, a string of vials consist of five (5) vials. A plurality of vial strings will be fed from a hopper “H” to the in-feed mechanism 54 , and wherein the in-feed mechanism 54 aligns the string of vials onto a track 56 . The in-feed mechanism 54 will be described in greater detail later in the application.
[0033] From the track 56 , the vial strings will dropped onto the mandrels. A vial depressor 58 will act to depress and capture the vial string onto the mandrel. The vial depressor 58 contains a wheel means that lowers onto the top of the vial string thereby lowering the vial string onto the mandrel, as will be described in further detail later in the application. After the string of vials are placed onto the mandrel, the conveyor will transport the vial string to a flame treater means 60 for heating the surface of the vials in preparation for the offset printing process. A flame treater means 60 is commercially available from Apex Machine Company under the name Flame Treater.
[0034] After the string of vials has been heat treated, the conveyor belt 52 will transport the vial string to the first offset inking transfer device 62 (sometimes referred to as the first printing station 62 ), wherein the offset inking transfer device 62 is commercially available from Apex Machine Company. The first printing station 62 may print a base coat and other preliminary images. Next, the conveyor belt 52 will transport the vial string to the ultra violent dryer means 64 for drying of the ink pattern from the first printing station 62 . The ultra violent dryer means 64 is commercially available from Apex Machine Company.
[0035] The conveyor belt 52 will then transport the vial string to the second offset inking transfer device 66 (sometimes referred to as the second printing station 66 ), wherein the offset inking transfer devices 62 , 66 are commercially available from Apex Machine Company. The second printing station 66 may print a pattern and alphanumeric information beneficial to end users of the vials. Next, the conveyor belt 52 will transport the vial string to the ultra violent dryer means 68 for drying of the ink pattern from the second printing station 66 . The ultra violent dryer means 64 , 68 are commercially available from Apex Machine Company.
[0036] The conveyor belt 52 will then loop around on the underside of the support table 53 . A means for removing the vials from the mandrels is provided. More specifically, once the conveyor belt 52 loops onto the under side of support table 53 , a removal plate 70 is provided, and wherein the removal plate 70 will wedge between the mandrel and the vial. As shown in FIG. 5 , the plate 70 is set off at an angle (as seen by angled member “M”); therefore, as the conveyor belt 52 continues its loop about the table 53 , the plate 70 will act to remove the vial string from the mandrel. The vial strings will then fall onto the transporter 72 , and wherein the transporter 72 is also a conveyor belt assembly. An air cooler device 74 is operatively associated with the transporter 72 , and wherein the air cooler device cools the air and directs the cool air onto the vials. In this way, the ink is cooled, thereby preventing sticking of the vial string together which could result in harming the print pattern, or disrupting the packaging process.
[0037] Referring now to FIG. 6 , a top view of a preferred embodiment of the in-line feed assembly 80 and the vial depressor 82 will now be described. The in-line feed assembly 80 includes the track 84 that will contain the array of vials, seen generally at 86 . The array of vials 86 consist of lined up string of vials, and wherein the string of vials comprises five (5) individual vials, as noted earlier. The hopper “H” will deliver the string of vials to the track 84 . The track 84 is a conveyor means, and the array of vials is transported to the realignment means 90 for pushing a string of vials off of the track 84 and onto the mandrel, and wherein the mandrel is similar in construction and purpose as mandrel 10 previously discussed.
[0038] The means for transporting the array of vials on track 84 is use of a plurality of air jet nozzles 94 , 96 , 98 , 100 , and wherein air is delivered to the jet nozzles via conduit 102 . Hence, the air pressure produced by the jet nozzles causes the array of vials to advance. The jet nozzles will be energized intermittently, and wherein the timing of the air supply is by the photo-eye sensor means for determining whether the vials are positioned on the conveyor and transmitting a signal in order to halt the conveyor if the vials are improperly positioned on the conveyor.
[0039] Referring now to FIG. 7 , a side view of the in-line feed assembly 80 and the vial depressor 82 seen in FIG. 6 will now be described. The realignment means 90 consist of a piston 106 that will extend outward so that the vial string on the track 84 will be directed to a second track 108 , and wherein the second track 108 will then direct the vial string onto the mandrel. As seen in FIG. 6 , a belt transporter 110 is provided for moving the vial strings to the mandrels. More specially, the belt transporter 110 in the most preferred embodiment comprises a first pulley 112 , a second pulley 114 , and a third pulley 116 , and the belt 118 , which is wrapped about the three gears. The belt 118 will have notches 120 a, 120 b, 120 c, 120 d, 120 e, and wherein the notches are spaced at a distance equal to the length of the vial string. In this way, each notch will engage with an individual vial string. As the gears rotate, the belt 118 will also rotate which in turn will allow for the advancement of the vial string along the track 108 . From the belt transporter 110 , the vial strings will drop from the second track 108 to the mandrel 92 . As noted earlier, the mandrel 92 is operatively attached to the conveyor belt 52 of the printing system 50 .
[0040] FIG. 6 further shows the vial depressor 82 . The vial depressor 82 consist of a first wheel 122 and the second wheel 124 . The two wheels are attached via shaft 126 and the bushing 128 . In the most preferred embodiment, the wheels 122 , 124 can each independently rotate. The shaft 126 is attached to a tamper hydraulic cylinder 130 via the tamper arm 132 . The hydraulic cylinder will extend a piston (not shown in this figure) that will raise and lower arm 132 , which in turn will raiser and lower the wheels 124 and 128 . The wheels 122 , 124 , in the most preferred embodiment, are constructed of a hard plastic.
[0041] Hence, the conveyor belt transports the mandrel 92 through the process of printing to the vials and curing the ink on the vials, and then removing the vials from the mandrels, as previously described.
[0042] As shown in FIG. 7 , the array of vials 86 are positioned within the track 84 . As noted earlier, the array of vials 86 consist of aligned strings of interconnected vials. The string of vials fed onto the track are obtained from the hopper H. The air jet nozzles 94 - 100 move the vial strings along the track 84 , and wherein the commands for energizing the air pressure to the nozzles 94 - 100 is controlled via the photo-eye sensor means 104 , as previously discussed.
[0043] Once the vial string is properly positioned, the piston 106 will extend and push the vial string onto the second track 108 . Next, the belt transporter 110 , and in particular the belt 118 will engage with the vial string via a notch (such as notch 120 a ) on the belt 118 . The vial string will be dropped onto the mandrel, and in particular, onto the post of the mandrel. The track will advance the mandrel through the vial depressor 82 . The vial depressor 82 will also raise and lower in synchronicity with the mandrel movement on the conveyor belt 52 . In FIG. 8 , a partial front view of the vial depressor 82 shows the wheels 122 , 124 depressing the vial string onto the mandrel 92 .
[0044] As shown, the chamferred surfaces 134 , 136 will abut the top portion of the vial string thereby depressing the vial string onto the mandrel. More specifically, due to the flared bottom portion of the receiving post, the vial string will fit snugly so that the vial string is captured on the mandrel. Once the mandrel 92 is past the vial depressor 82 , the wheels 122 , 124 will lift via hydraulic cylinder 130 . When the next mandrel is in the proper position, the vial depressor 82 , and in particular the hydraulic cylinder 130 will cause the wheels 122 , 124 to lower and another vial string can be captured on the mandrel.
[0045] As noted earlier, the vial remover means for removing the vials from the mandrel is also disclosed, and wherein the vial remover means is for ejecting the vials from the mandrel after the printing process is completed. The vial string is separated from the member “M” seen in 5.
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An apparatus and method for printing onto vials. The vials are connected in a series, the vials having an open end and a closed end. The apparatus comprises a conveyor belt for moving the vials, the conveyor having a mandrel for receiving the open end of the vials, the mandrel containing a plurality of receiving post, for receiving the vials. The apparatus further includes a vial depressor for depressing the vial onto the receiving post of the mandrel, a first offset inking transfer device for printing a first ink pattern onto the vials, and a first ultra violent dryer positioned to receive the vials from the first offset inking transfer device and provide for drying of the ink pattern from the first offset inking transfer device.
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TECHNICAL FIELD
[0001] The present disclosure relates to a height-adjustable table stand, and particularly a height-adjustable table stand powered by a solar cell panel.
BACKGROUND
[0002] In known height-adjustable table stands, a height-adjusting arrangement is adapted to provide a vertical movement of the table stand by use of an electric motor. In EP2019606 A2, a height-adjustable table is disclosed, comprising an electric motor for providing vertical movement of a linear actuator, and control means for controlling the operation of the electric motor.
[0003] The height-adjusting arrangements in known table stands are supplied with electricity from a domestic electricity supply system, i.e. connected to a power socket. When furnishing a room or an office, the location of power sockets must be taken into consideration when placing the table stand. In some occasions, the table stand may not be possible to place at a wanted position due to the location of power sockets.
[0004] Consequently, there is a need for a height-adjustable table stand with a height-adjusting arrangement that is independent of power supply from a domestic electricity supply system.
SUMMARY
[0005] It is an object of the present invention to provide an improved solution that alleviates the mentioned drawbacks with present devices. Furthermore, it is an object to provide a height-adjustable table stand that can be electrically operated independent of power supply from a domestic electricity supply system.
[0006] This is achieved by providing a height-adjustable table stand comprising a height-adjusting arrangement for adjusting the height of the table stand, wherein the height-adjusting arrangement comprises at least one leg, each leg having an inner tubular member and an outer tubular member arranged for telescopic movement relative to each other. The height-adjusting arrangement further comprises a linear actuator coupled to said tubular members and adapted to provide the telescopic movement between the tubular members, an electric motor connected to the linear actuator and adapted to operate the linear actuator for providing telescopic movement between the tubular members, and a control device for controlling the operation of the electric motor. The table stand further comprises a solar panel connected to the height-adjusting arrangement for providing power to the electric motor.
[0007] By providing the table stand with a solar panel for powering the electric motor, the table stand may be operated without any connection to a domestic electricity supply system, or to any other power source. When placing the table stand in a room, the placement may not be dependent on the location of power sockets in the room. The solar panel may be connected to the height-adjusting arrangement via a cable. The solar panel may be placed such that it receives sufficient light. The cable may be connected to the electric motor. The cable may be connected to the control device. The control device may provide electric current to the electric motor to control the operation of the electric motor. The control device may control the direction of rotation of the electric motor. The electric motor may be connected to the linear actuator in a leg. The electric motor may be connected to each linear actuator in each leg. When the electric motor is rotated, the linear actuator may be rotated such that it converts the rotational movement to a linear movement. The linear movement of the linear actuator may provide the telescopic movement between the inner and the outer tubular member in the leg. The electric motor may be adapted to be powered by an electric current provided by the solar panel.
[0008] In one embodiment, the height-adjusting arrangement may further comprise a battery for storing power generated by the solar panel, and wherein the battery provides power to the electric motor.
[0009] By providing a battery between the solar panel and the electric motor, the solar panel may charge the battery during time when the electric motor is not operated. Most of the time, the electric motor is not operated, and thereby the solar panel may charge the battery during a long time before the power stored in the battery is needed for powering the electric motor. A solar panel with less capacity may be used with the height-adjusting arrangement when a battery stores the power generated by the solar panel, than if the solar panel would power the electric motor directly. Further, a stronger electric motor may be used, that needs more electric current than the current generated by the solar panel, when using a battery than if the solar panel would power the electric motor directly. Since the electric motor is used rather rarely and during a short period, the power stored in the battery may be used for other purposes, separate from the height-adjusting arrangement, during the time when the electric motor is not operated.
[0010] In another embodiment, the table may further comprise a power providing means connected to the battery for providing power to an additional device, such as a computer.
[0011] The additional device may further be other devices such as a lamp, a screen, a charger or the like. During the time when the electric motor is not operated the battery may provide power to an additional device, separate from the height-adjusting arrangement. For instance, the battery may charge a lap top computer during the time when the electric motor is not operated. The battery or the power providing means may be provided with means that controls that the battery does not provide power to an additional device if the power level in the battery is below a predetermined level. The predetermined power level may correspond to a power level needed for powering the electric motor such that the table stand may be raised or lowered. The power providing means may be provided with a switch that may enable or disable the powering of an additional device. The disabling of the powering of an additional device may be performed by the switch as a response to the power level in the battery reaching the predetermined level, or to the electric motor being operated. The enabling of the powering of an additional device may be performed by the switch as a response to the power level in the battery reaching above the predetermined level, or to the operation of the electric motor being terminated. The predetermined level may be two separate predetermined levels for the disabling and the enabling operation by the switch. The power providing means may be located adjacent to the battery. The power providing means may be a box provided with power sockets for connecting of an additional device. The power providing means may further be mounted on top of a table top attached to the table stand.
[0012] In one embodiment, a predetermined power level of the battery may be set corresponding to an amount of power needed for a raising or lowering operation of the height-adjusting arrangement, and wherein the power providing means connected to the battery may be adapted to terminate the powering of an additional device when the predetermined power level of the battery is reached.
[0013] When an additional device, such as a computer, a lamp, a screen, a charger or the like, is connected to the battery via the power providing means, the power level of the battery may be monitored, such that not all power in the battery is consumed. By setting a predetermined power level, corresponding to the power level needed for operating the height-adjusting arrangement, and terminating the powering of any additional device when that predetermined power level is reached, a scenario wherein the battery contains less power than needed for a height-adjusting operation may be avoided. The power providing means may be adapted to switch the powering of the additional device back on when the battery is charged such that the power level is above the predetermined power level. The powering of the additional device may be switch back on when the battery is charged to a power level that is a specified amount above the predetermined power level.
[0014] In a further embodiment, the table may further comprise an induction device powered by the battery.
[0015] The induction device may be used for powering a device adapted for induction powering. The induction device may provide a magnetic field such that an electric current is created in the device adapted for induction powering. The device adapted for induction powering may be a battery that is adapted for being charged by induction. The solar panel may then generate power that is used for powering a device adapted for induction powering. The table stand may be provided with a controlling means that control that the powering of the induction device is terminated when the power level in the battery is below a predetermined level. The controlling means may further terminate the powering of the induction device when the electric motor is operated.
[0016] In one embodiment, the battery may further comprise means for coupling the battery to a battery charger for charging the battery.
[0017] Thereby, the battery may be charged by a battery charger as well as by the solar panel. The power for charging the battery may be provided by a domestic electricity supply system. The battery may thereby temporarily be connected to a domestic electricity supply system for being charged.
[0018] In a further embodiment, the solar panel may be mounted on a horizontal surface of the table.
[0019] The solar panel may thereby be attached to the table stand at a fixed position. The table stand may be provided with a table top, such that the fixed position of the solar panel may be at a horizontal surface of the table stand such as the table top. The position of the solar panel may be adapted for receiving a sufficient amount of light.
[0020] In another embodiment, the solar panel may be moveable relative to the height-adjusting arrangement.
[0021] Thereby, the solar panel may be placed at a location that is separated from the table stand. The solar panel may be placed at a location that is optimal for the solar panel to produce electric current. The solar panel may for instance be placed at a window to receive light. The solar panel may be connected to the height-adjusting arrangement via a cable. The solar panel may be provided with fastening means for arranging the solar panel at a location that provides sufficient light. The fastening means may adapt the solar panel to be arranged at a window to receive light.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The invention will in the following be described in more detail with reference to the enclosed drawings, wherein:
[0023] FIG. 1 a shows a perspective view of a table with a height-adjustable table stand according to an embodiment of the invention,
[0024] FIG. 1 b shows a perspective view of a table with a height-adjustable table stand according to another embodiment of the invention,
[0025] FIG. 1 c shows a perspective view of a table with a height-adjustable table stand according to yet another embodiment of the invention,
[0026] FIG. 2 a shows a perspective view of a table with a height-adjustable table stand according to another embodiment of the invention, and
[0027] FIG. 2 b shows a perspective view of a table with a height-adjustable table stand according to yet another embodiment of the invention.
DESCRIPTION OF EMBODIMENTS
[0028] The present invention will be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. In the drawings, like numbers refer to like elements.
[0029] FIG. 1 a illustrates a height-adjustable table 100 comprising a table top 6 and a table stand 1 . The table stand 1 comprises a height-adjusting arrangement. The height-adjusting arrangement comprises two legs 2 each comprising an inner tube 3 and an outer tube 4 . The inner and the outer tubes 3 , 4 are arranged for telescopic movement relative to each other. Inside the tubes 3 , 4 , a linear actuator (not shown) is provided. The linear actuator is in one end attached to the inner tube 3 and in the other end attached to the outer tube 4 . The linear actuator provides the telescopic movement between the inner tube 3 and the outer tube 4 when the linear actuator is rotated. The leg 2 further comprises a top part 5 a and a bottom part 5 b. The top part 5 a attaches the leg to the table top 6 . The bottom part 5 b functions as a foot for the table stand 1 when the table 100 stands on a surface.
[0030] An electric motor 12 is connected to the linear actuator. The electric motor 12 rotates the linear actuator such that a linear telescopic movement of the inner tube 3 and the outer tube 4 is provided. The electric motor 12 is an electric direct current motor preferably adapted for a voltage in the range of 12-40 V.
[0031] A control device 13 is provided for control of the operation of the electric motor 12 . The control device 13 is mounted underneath the table top 6 for easy access for a user. The control device 13 is connected to the electric motor 12 via a cable 13 a. The control device 13 is provided with two buttons, one for raising the table and one for lowering the table. The two buttons control the direction of rotation of the electric motor 12 , and thereby the direction of rotation of the linear actuator. The linear actuator then elongates or retracts depending of the direction of rotation of the electric motor 12 .
[0032] The electric motor 12 is powered by a battery 11 via a cable 11 a . The battery 11 is charged by a solar panel 10 . The solar panel 10 is connected to the battery 11 via a cable 10 a. The solar panel 10 is moveable relative to the battery 11 , the electric motor 12 and the table top 6 . The solar panel 10 may thereby be placed at various locations such as at a window, near a lamp or on the table top 6 . The cable 10 a has a length that provides a mobility of the solar panel 10 to a location separate from the table 100 . The length of the cable 10 a is preferably at least 2 meters. The cable 10 a is only attached at its end portions. At one end portion, the cable 10 a is attached to the solar panel 10 , and at the other end portion the cable 10 a is attached to the battery 11 .
[0033] The battery 11 is mounted on an underside of the table top 6 . The battery 11 is connected to the electric motor 12 . The battery 11 and the electric motor 12 could be placed in one integrated unit. The battery 11 may be provided with a connector (not shown) for connecting the battery 11 to a battery charger. The battery charger could charge the battery in a similar way as the solar panel 10 charges the battery 11 . The battery charger may be connectable to a domestic electricity supply system. The battery 11 may further be provided with means for powering an additional device such as a computer, a lamp, a screen, a phone or the like.
[0034] When the electric motor 12 is operated via the control device 13 , the powering of an additional device is disconnected. Thereby, all available power in the battery 11 and from the solar panel 10 is available for the electric motor 12 .
[0035] Further, the power level in the battery 11 is monitored such that a predetermined power level is detected. The predetermined power level corresponds to a power level needed for powering the electric motor 12 during a raising or lowering operation of the height-adjustable table 1 . When the predetermined power level in the battery 11 is detected, the powering of any additional device is terminated. Thereby, there will always be a sufficient amount of power in the battery 11 even when the battery 11 also powers other devices than the electric motor 12 . When the battery 11 is charged by the solar panel 10 or a battery charger, such that the power level in the battery is above the predetermined power level, the powering of the additional device is switched back on.
[0036] FIG. 1 b illustrates a height-adjustable table 100 similar as in FIG. 1 a , wherein the table stand 1 is provided with an induction device 14 . The induction device 14 is mounted on the table top 6 and connected to the battery 11 . The induction device 14 is powered by the battery 11 . The induction device 14 is used for powering a device adapted for induction powering. Such device adapted for induction powering may be a battery in an electric device such as a phone, a computer or the like.
[0037] When the electric motor 12 is operated via the control device 13 , the powering of an additional device and/or the induction device is disconnected. Thereby, all available power in the battery 11 and from the solar panel 10 is available for the electric motor 12 .
[0038] When the predetermined power level in the battery 11 is detected, the powering of the induction device 14 and/or any other additional device is terminated. Thereby, there will always be a sufficient amount of power in the battery 11 even when the battery 11 also powers other devices than the electric motor 12 . When the battery 11 is charged by the solar panel 10 or a battery charger, such that the power level in the battery is above the predetermined power level, the powering of the additional device and/or the induction device is switch back on.
[0039] The table stand 1 further comprises a power providing means 15 connected to the battery 11 via a cable 15 a. The power providing means 15 is mounted on top of the table top 6 . The power providing means may be provided with power sockets or other connecting means for connecting an additional device adapted to be powered via the power providing means 15 . The power providing means 15 controls the powering of any additional device connected to the power providing means 15 . The power providing means could also control the powering of the induction device 14 . The power providing means 15 comprises a switch that enables or disables the powering of an additional device. The enabling and disabling of the powering of an additional device is performed as a response to the power level in the battery 11 reaching a predetermined level, or to that the electric motor 12 is operated. In one embodiment, the switch disables the powering of an additional device when the battery level reaches below a first predetermined level. Further, the switch enables the powering of an additional device when the battery level reaches above a second predetermined level, wherein the second predetermined level is higher than the first predetermined level.
[0040] FIG. 1 c illustrates a height-adjustable table 100 similar as in FIG. 1 a , but wherein the solar panel 10 is mounted on the table top 6 . The solar panel 10 mounted on the table top 6 is connected to the battery 11 via a cable.
[0041] FIG. 2 a illustrates a height-adjustable table 200 comprising a table top 6 and a height-adjustable table stand 20 with a height-adjusting arrangement comprising two legs 2 , an electric motor 12 and a solar panel 10 . The solar panel 10 is connected directly to the electric motor 12 via a cable. The solar panel 10 is moveable relative to the electric motor 12 and the table top 6 . The solar panel 10 may be placed at various locations to receive light for producing electric current to the electric motor 12 . The electric motor 12 is operated by the control device 13 . When a button on the control device 13 is pressed, the electric motor 12 rotates the linear actuator in a leg 2 . The electric current for the operation of the electric motor 12 is produced by the solar panel 10 .
[0042] FIG. 2 b illustrates a height-adjustable table 200 similar as in FIG. 2 a , but wherein the solar panel 10 is mounted on the table top 6 . The solar panel 10 mounted on the table top 6 is connected to the electric motor 12 via a cable.
[0043] In the drawings and specification, there have been disclosed preferred embodiments and examples of the invention and, although specific terms are employed, they are used in a generic and descriptive sense only and not for the purpose of limitation, the scope of the invention being set forth in the following claims.
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The present invention relates to a height-adjustable table stand ( 1 ) comprising a height-adjusting arrangement for adjusting the height of the table, wherein the height-adjusting arrangement comprises at least one leg ( 2 ), each leg having an inner tubular member ( 3 ) and an outer tubular member ( 4 ) arranged for telescopic movement relative to each other. The height-adjusting arrangement further comprises a linear actuator coupled to said tubular members ( 3, 4 ) and adapted to provide the telescopic movement between the tubular members, an electric motor ( 12 ) connected to the linear actuator and adapted to operate the linear actuator for providing telescopic movement between the tubular members, and a control device ( 13 ) for controlling the operation of the electric motor ( 12 ). The table stand ( 1 ) further comprises a solar panel ( 10 ) connected to the height-adjusting arrangement for providing power to the electric motor ( 12 ).
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BACKGROUND
[0001] The invention relates to an apparatus for packaging dosed quantities of solid drug portions. In particular, the invention relates to an apparatus for packaging dosed quantities of solid drug portions with enhanced serviceability.
[0002] It is advantageous to package dosed quantities of solid drug portions, such as tablets and pills, in bags or other types of packaging, wherein the solid drug portions in each bag are packed separately per ingestion. The bags are provided with user information, such as the day and time of day the solid drug portions have to be taken. The bags for one particular user are usually attached to each other and supplied rolled up in a dispenser box.
[0003] The filling of individual packages with dosed quantities of solid drug portions (batches) is increasingly being automated. A known apparatus for dosing solid drug portions for final packaging in individual packages comprises a plurality of supply means respectively provided with different types of solid drug portion. After reading or entering a solid drug portion prescription, the supply means relevant to the prescription are opened in order to allow a dosed quantity of solid drug portions to drop into a central fall duct positioned under the supply means. At the bottom of the fall duct the selectively released solid drug portions are received in a packaging, such as a bag, after which the packaging is closed. Providing the packaging with user information can be realized prior to or following filling of the packaging. 60 packages per minute can be made up in this automated manner. The known apparatus does however have several drawbacks. A significant drawback of the known apparatus is that the filling capacity of the apparatus depends to a considerable extent on, and is limited by, the (longest) drop time of the solid drug portions in the fall duct, whereby the filling capacity of the known apparatus is limited and cannot be increased. However, owing to the permanently increasing demand for solid drug portions there is a need in practice to provide more packages of a dosed quantity of solid drug portions per unit time.
[0004] Undisclosed Dutch patent application NL2007384 discloses an apparatus for packaging dosed quantities of solid drug portions, comprising a plurality of dosing stations for dispensing a dosed quantity of solid drug portions, at least one first endless conveyor for moving along at least some of the number of dosing stations a plurality of fall ducts coupled to the first conveyor, wherein each fall duct is adapted to guide a dosed quantity of solid drug portions delivered by at least one supply means, at least one second endless conveyor for displacing a plurality of collecting means coupled to the second conveyor, wherein each collecting means is adapted to receive solid drug portions guided through a fall duct, at least one dispensing station for transferring solid drug portions collected by each collecting means to a packaging for closing, and at least one packaging station for closing the packaging provided with the dosed quantity of solid drug portions.
[0005] The apparatus in accordance with NL2007384 has a very high throughput, i.e. a very high number of solid drug portions is guided by the fall ducts. Due to the vast number of solid drug portions guided though the fall ducts, the inner surface of the fall ducts is contaminated with the residues of solid drug portions over time. These residues can be transported to the collecting means and from the collecting means to the bags for the user. To prevent such unwanted transport of residues, the fall ducts have to be cleaned on a regular basis. Before cleaning the fall ducts they have to be removed from the apparatus which is time-consuming and requires a undesirable machine shutdown.
[0006] It is therefore the object of the present application to enhance the serviceability of an apparatus for packaging dosed quantities of solid drug portions.
[0007] This object is solved by an apparatus for packaging dosed quantities of solid drug portions, comprising
[0008] a plurality of dosing stations, each dosing station having an output opening for dispensing solid drug portions, the dosing stations being arranged in a plurality of vertical or inclined columns,
[0009] and collecting means for collecting dosed quantities of solid drug portions dispensed by the dosing stations and for forwarding the dosed quantities of solid drug portions to a packaging means,
[0010] wherein a plurality of fall ducts is arranged for guiding the solid drug portions from the output openings of the dosing stations of a vertical or inclined column to the collecting means, each fall duct having an outlet and a number of inlet openings, the output openings of the dosing stations being aligned with the inlet openings of the fall ducts when a fall duct is positioned adjacent to a column of dosing stations.
[0011] Each fall duct consist of at least a first part and a second part, forming the fall duct when the parts are assembled, wherein the parts being detachably connected together so that the parts can be detached for maintenance and cleaning purposes.
[0012] By providing the fall ducts in accordance with the present invention, the serviceability is greatly enhanced as it is no longer necessary to remove the complete fall ducts. For maintenance purposes one part of the fall ducts can be removed and the inner surfaces of the parts can be cleaned.
[0013] The input openings can be formed when the first and the second part of the fall ducts are assembled, i.e. each of the parts of the fall ducts provides a number of “partial openings” of the input openings. It is however preferred that one part of the fall ducts comprises the input openings as such a configuration of the parts of the fall ducts eliminates the need of aligning the partial openings of the first and the second parts of the fall ducts.
[0014] While the exact configuration of fall ducts depends of the overall structure of the apparatus, it is preferred that the first and the second part of the fall ducts are provided as a base part and a front part, wherein the base part is arranged so as to be connected to a mounting element of the apparatus and the front part is arranged such that it is detachably connected to the base part.
[0015] The fall ducts may be stationary, i.e. mounted at specified positions within the apparatus. In this case the collecting means may also be stationary. Using stationary fall ducts/collecting means has the disadvantage that the number of dosing stations assigned to one fall duct/collecting means is limited by the length of the fall duct and/or the size of the dosing station (assuming that the dosing stations are also stationary).
[0016] To enhance the number of dosing stations which can dispense a dosed quantity of solid drug portions into a given fall duct, the dosing stations can be movable along a conveyor. However, as it is preferred to use a high number of dosing stations this approach would require a very complex design.
[0017] It is therefore preferred that the fall ducts are movable along the columns of dosing stations, wherein the base part of the fall ducts is connected to a mounting element of a first conveyor for moving the fall ducts along the columns of dosing stations, and wherein the collecting means are connected to a second conveyor for moving the collecting means together with the fall ducts.
[0018] During the movement, the input openings of the fall ducts are aligned with the output openings of the dosing stations of a column. As soon as the openings are aligned, dosed quantities of solid drug portions can be released from the dosing stations.
[0019] The collecting means, which are connected to the second conveyor, are moved, at least as long as portions are received through the fall ducts, in line with the fall ducts, i.e. one fall duct is aligned to one collecting means.
[0020] Using mobile collecting means, which in fact function as temporary packages, enables multiple solid drug portion prescriptions to be collected in parallel (simultaneously) instead of serially (successively), whereby the capacity for filling packages can be increased substantially. Particularly advantageous here is that the fall ducts are also given a mobile form and can thus co-displace, preferably at substantially the same movement speed and in the same displacement direction, with the mobile collecting means, this resulting in further time gain and increase in capacity.
[0021] While the dosed quantities of solid drug portions drop through the fall duct, the fall duct and an underlying collecting means can be moved further in a continuous manner, usually in the direction of one or more following dosing stations. The following dosing stations can, depending on the prescription to be followed, optionally be activated for the purpose of dispensing a dosed quantity of solid drug portions in the fall duct. In other words, a given fall duct (in line with its collecting means) is moved along the vertical columns of dosing stations and when passing the dosing stations they can be activated. By moving the fall ducts along the vertical columns of dosing stations the number of portions which can dispensed in a given collecting means is greatly enhanced making it possible that even complex and unusual prescriptions can be compiled.
[0022] The first conveyor for moving the fall ducts along the vertical columns of dosing stations can comprise one or more conveyor belts, wherein the base parts of the fall ducts are connected to the conveyor belts. Depending on the number of conveyor belts and the length of the fall ducts it is preferred that a mounting beam is arranged between and connected to the base part of each fall duct and the first conveyor. Such a mounting beam can enhance the stability and using the mounting beam allows a wider range of available materials for the fall ducts as the stability requirements for the fall ducts are not that strict when using a mounting beam.
[0023] It is preferred that the base part is detachably connected to the mounting beam and/or the mounting beam is detachably connected to the first conveyor to further enhance the serviceability of the apparatus allowing a replacement of separate parts.
[0024] The contamination of the fall ducts depends on their length and the number of dosing stations dispensing portions into the fall ducts. In the case that the vertical columns of dosing stations comprise a significant number of dosing stations, the lower section of a fall duct is more contaminated than the upper section of a fall duct as more portions are guided through the lower section. It is therefore preferred that the front parts of the fall ducts comprise a plurality of sub-parts, wherein each sub-part can be detached individually.
[0025] The front parts of the fall ducts comprise a plurality of input opening and these input openings are, at least temporarily, aligned with the output openings of corresponding dosing stations. To prevent portions from higher dosing stations entering the output openings of lower dosing stations via an input opening of the front part, the base parts of the fall ducts comprise a number of constrictions, arranged above corresponding input openings in the front parts of the fall ducts to guide falling portions away from the input openings of the front parts and the output openings of dosing stations. Furthermore, the constrictions reduce the fall speed of the individual portions within the fall ducts reducing the risk of damage to the portions.
[0026] Maintenance of the fall ducts can be initiated after a given period of time. However, such a constant period might be too short or too long with regards to some of the fall ducts (e.g. for those fall ducts guiding common solid drug portions like mild painkillers). It is therefore preferred that a fall duct comprises a sensor for monitoring the surface characteristics within the fall duct, the sensor being coupled with a control unit arranged within the apparatus.
[0027] Alternatively, the number of portions guided through a fall duct can be counted, and depending on the number of guided portions, maintenance can be initiated. For this alternative, a sensor is arranged at the base of a fall duct monitoring the number of solid drug portions being guided through it, the sensor being coupled with a control unit arranged within the apparatus.
[0028] To prevent the deposition of solid drug portion residues or other residues, it is preferred that the inner surfaces of the fall ducts are coated with a non-stick coating.
[0029] Each collecting means is adapted to collect one prescription associated with one patient. A prescription consists of a predefined quantity and type of solid drug portions formed by tablets or pills and the like. A supply of different types of solid drug portions is held in different dosing stations. The distance between each dosing station and fall ducts co-acting with each dosing station is preferably substantially constant, so that the (fall) time required for transferring solid drug portions from the dosing stations to the adjacent fall ducts is substantially the same, this making it possible to move the collecting means at substantially constant speed. It is however also possible to envisage having the transport speed of the fall ducts and the collecting means depend on the prescriptions to be compiled, and therefore on the dosing stations to be addressed, which can also result in a further increase in the filling capacity.
[0030] The dosing stations generally take a stationary form. It is advantageous here for the plurality of dosing stations to be positioned adjacent to each other, this enabling simultaneous filling of the plurality of collecting means. It is also advantageous for the plurality of dosing stations to be positioned above each other, whereby multiple types of solid drug portion can be dispensed simultaneously to the same fall duct and subsequently to the same collecting means, this also enhancing the filling frequency of the apparatus.
[0031] It is particularly advantageous here for at least a number of the dosing stations to be arranged in a matrix structure with dosing stations arranged in multiple horizontal rows and dosing stations arranged in multiple vertical columns. It is advantageous here for the dosing stations to be positioned as closely as possible to each other, which in addition to saving volume also results in time gains during filling of the collecting means.
[0032] It is further possible to envisage applying a plurality of matrix structures of dosing stations in order to further increase capacity. In a particular embodiment the apparatus comprises two matrix structures, wherein each matrix structure comprises a plurality of dosing stations arranged in rows and columns, and wherein dispensing sides of the dosing stations of the two matrix structures face toward each other. Owing to such an orientation at least a number of fall ducts are enclosed by the two matrix structures.
[0033] By causing movement of the fall ducts along the two matrix structures of dosing stations, and in this way along all dosing stations, the required drug portions can be collected in relatively efficient manner.
[0034] In one embodiment, the first endless conveyor comprises two parallel endless conveyor belts. In order to stabilize the movement of the fall ducts it is usually advantageous for the apparatus to comprise a plurality of substantially parallel oriented first conveyor belts, wherein each fall duct is connected to a plurality of first conveyor belts. This stability, and particularly the stability in the vertical direction, can be further increased when the apparatus comprises at least one stationary guide, such as a rail, for guiding the movement of the fall ducts.
[0035] In one embodiment, the system comprises drive means for driving the first endless conveyor and the second endless conveyor with the same transport speed.
[0036] The drive means preferably comprise at least one electric motor. It is advantageous for the drive means to be adapted for simultaneous driving both the first conveyor and the second conveyor. It is possible for this purpose to envisage the at least one first conveyor and the at least one second conveyor being coupled mechanically to each other. This coupling is preferably such that both types of conveyor are moved in the same direction and at the same movement speed. In this way a constant alignment between the fall ducts and the collecting means can be guaranteed as far as possible.
[0037] A collecting means and a fall duct lying above may be physically connected to each other or even manufactured in one piece. Alternatively, a collecting means and a fall duct lying above may not be physically connected to each as the decoupling of the two components enhances the flexibility of the apparatus.
[0038] Physically separating the collecting means from the fall ducts makes it possible to guide the collecting means away from the fall ducts. In a preferred embodiment, the physical length of the second conveyor is greater than the length of the first conveyor so that the number of collecting means coupled to the second conveyor is greater than the number of fall ducts coupled to the first conveyor. This makes it possible to guide the collecting means along one or more other types of (special) dosing stations for direct dispensing of solid drug portions to the collecting means, that is to say not via the fall ducts.
[0039] A collecting means will generally be deemed as a solid drug portion carriage functioning for the purpose of collecting a prescription and transporting the collected solid drug portions to the dispensing and packaging station. It is usually advantageous here for an upper side of each collecting means to take an open form and be adapted to receive a dosed quantity of solid drug portions falling out of a dosing station via a fall duct. The collecting means hereby also serve the function of a collecting tray.
[0040] An underside of each collecting means preferably comprises a controllable closing element to enable removal of the solid drug portions from the collecting means. The closing element can be mechanically controllable in the dispensing station. The closing element is however preferably controllable in contactless manner, more preferably by applying magnetism. At least a part of the closing element must however be given a magnetic or magnetisable form for this purpose. Operation of the closing element of such a type can for instance be realized by applying an electromagnet or permanent magnet in the packaging station. In an advantageous embodiment the collecting means comprises biasing means, such as for instance a compression spring, for urging the closing element in the direction of a closed state, whereby erroneous opening of the closing element can be prevented. The dispensing station can in fact form part of the packaging station, wherein dispensing of solid drug portions collected in a collecting means to a packaging for closing can be followed almost immediately by closing of said packaging.
[0041] Since each collecting means collects its own prescription, it is desirable to know the location of the fall ducts and the collecting means relative to the dosing stations. For this purpose, use can be made of a calibrating module for calibrating the position of at least one fall duct relative to the first conveyor and/or at least one collecting means relative to the second conveyor. The apparatus can be calibrated by determining a reference or calibration point of at least one fall duct and/or collecting means, since the sequence and the transport speed of the fall ducts and the collecting means are pre-known, as is the length of the first conveyor and the second conveyor. Recognition of a fall duct and/or collecting means by the calibrating module can for instance take place by providing the fall duct and/or collecting means with a unique label. It is however also possible to deem the fall duct and/or collecting means detected at a determined moment by the calibrating module as fall duct and/or collecting means serving as reference.
[0042] The packaging station is preferably adapted to seal the packaging. Sealing is understood to mean substantially medium-tight closure of the packaging in order to enable the best possible preservation of the packaged solid drug portions. A (plastic) foil will generally be applied as packaging material and the seal will be formed by a welding process. A separate adhesive, in particular glue, can optionally be applied instead of a weld for the purpose of sealing the packaging. The packaging station is more preferably adapted to realize at least one longitudinal seal and at least one transverse seal, whereby bags are formed which are mutually connected and which in this way form a strip. Because the packaging station is preferably adapted to realize a transverse seal, the length of the bag to be formed can be determined and preferably made dependent on the number and/or the type of solid drug portions to be packaged in a bag. The packaging station will generally be placed a (horizontal) distance from the dosing stations, whereby heat generated by the packaging station will not be transferred, or hardly so, to the dosing stations and the solid drug portions held therein, this increasing the shelf-life of the solid drug portions. The packaging station is usually also provided with a printer for arranging a specific label on each formed packaging.
[0043] Each dosing station preferably comprises at least one supply means for solid drug portions, e.g. in tablet form or capsule form or the like, and a dosing element connecting to the at least one supply means. The dosing station as such is usually also referred to as a canister. The dosing element is adapted to separate one or more single solid drug portions from the solid drug portions present in the supply means. Dosing can take place by selectively removing the separated solid drug portions, generally by allowing them to fall, from the dosing element.
[0044] In an advantageous embodiment the dosing element is displaceable relative to the supply means between a loading state, in which a receiving space of the dosing element connects to a delivery opening of the supply means, and an unloading state in which the dosing element covers the delivery opening and is adapted to deliver the separated solid drug portion to a collecting means coupled to the conveyor. The dosing element will generally be of substantially cylindrical form, wherein the one or more receiving spaces are arranged in the cylindrical dosing element, wherein each receiving space is generally adapted to temporarily hold one solid drug portion. Such a dosing element is usually also referred to as an individualizing wheel. By means of axial rotation of the cylindrical dosing element the dosing element can be displaced between a loading state, in which a receiving space of the dosing element is aligned with a delivery opening of the supply means, and an unloading state in which the dosing element covers the delivery opening and is adapted to deliver the separated tablet to a fall duct coupled to the first conveyor.
[0045] The number of collecting means is preferably greater than the number of columns of dosing stations. In a typical embodiment of the apparatus according to the invention the apparatus comprises up to 3,000 columns of dosing stations and up to 4,500 collecting means. In a preferred embodiment the apparatus comprises 500 columns of dosing stations and 750 collecting means.
[0046] The apparatus comprises a control unit for controlling at least the packaging station, the dosing stations, the at least one first conveyor and the at least one second conveyor and the sensors which might be arranged in the fall ducts. It is advantageous here for the control unit to be adapted to determine, on the basis of a desired dosed quantity of solid drug portions, a dosed quantity of solid drug portions to be successively dispensed through time by a plurality of dosing stations via the fall ducts to the collecting means. Because prescriptions are taken as starting point, a logistical conversion must be made to a—most efficient—method of filling the collecting means, which conversion can be made using the control unit. The control unit can here be coupled or even form part of a computer provided with a computer program, the computer program being adapted to determine a filling schedule for filling the collecting means and subsequently the packages in the packaging station.
BRIEF DESCRIPTION OF THE DRAWINGS
[0047] The invention will be described on the basis of non-limitative exemplary embodiments shown in the following figures. Herein:
[0048] FIG. 1 is a first perspective view of an apparatus according to the invention for transporting dosed quantities of solid drug portions from a plurality of dosing stations to a packaging station,
[0049] FIG. 2 is a second perspective view of the apparatus according to FIG. 1 ,
[0050] FIG. 3 is a bottom view of the apparatus according to FIG. 1 ,
[0051] FIG. 4 is a side view of the apparatus according to FIG. 1 ,
[0052] FIG. 5 is a perspective view of the apparatus 1 as shown in FIGS. 1-4 ,
[0053] FIG. 6 is a perspective rear view of a dosing station for use in a apparatus as shown in FIGS. 1-4 ,
[0054] FIG. 7 is a perspective front view of the dosing station as shown in FIG. 6 ,
[0055] FIG. 8 is a perspective view of a collecting means for use in a apparatus 1 as shown in FIGS. 1-4 ,
[0056] FIG. 9 is a side view of the collecting means according to FIG. 8 ,
[0057] FIG. 10 is a perspective front view of the dispensing and packaging station as applied in the apparatus as shown in FIGS. 1-4 ,
[0058] FIG. 11 is a perspective rear view of the dispensing and packaging station according to FIG. 10 ,
[0059] FIG. 12 shows a fall duct as applied in the apparatus according to FIGS. 1-4 ,
[0060] FIG. 13 shows a side view of an embodiment of a fall duct as applied in the apparatus,
[0061] FIG. 14 shows an explosion view of the fall duct according to FIG. 13 ,
[0062] FIG. 15 shows a perspective view of the base part of the fall duct according to FIGS. 13 and 14 ,
[0063] FIG. 16 shows a perspective rear view of the fall duct according to FIG. 13 , and
[0064] FIG. 17 shows another explosion view of the fall duct according to FIG. 13 .
DETAILED DESCRIPTION
[0065] FIGS. 1 and 2 show different perspective views, FIG. 3 shows a bottom view and FIG. 4 shows a side view of a apparatus 1 according to the invention. Apparatus 1 comprises a support structure 4 (frame) to which a plurality of dosing stations 2 is connected in stationary, releasable manner. Each dosing station 2 is adapted to hold a supply of one type of solid drug portions. Different dosing stations 2 will generally hold a supply of different types of solid drug portions, although it is also possible that frequently-dosed solid drug portions are held by a plurality of dosing stations 2 . The majority of the number of applied dosing stations 2 are arranged in two matrix structures 5 (of which only a single matrix structure is shown in the figure), which matrix structures 5 together enclose a part of a first endless conveyor, wherein this first conveyor is provided by two first horizontally running conveyor belts 6 a , 6 b for fall ducts 7 . In this embodiment, fall ducts 7 are mounted releasably on mounting elements 8 forming part of both first conveyor belts 6 a , 6 b . In the shown embodiment only a few fall ducts 7 are shown, although in practice each mounting element 8 will generally be connected to a fall duct 7 , whereby the first conveyor belts 6 a , 6 b are provided all the way round with fall ducts 7 . In accordance with the invention the fall ducts 7 comprise at least a first and a second part. These parts are not shown in the FIGS. 1 , 2 and 3 but in the FIGS. 6-17 to not overload the separate figures.
[0066] The first conveyor belts 6 a , 6 b are driven by drive wheels 9 which are coupled by means of a vertical shaft 10 to an electric motor 11 . In order to be able to counter slippage of conveyor belts 6 a , 6 b the running surfaces 12 of the drive wheels take a profiled form. Through driving of the first conveyor belts 6 a , 6 b the fall ducts 7 can be guided along the dosing stations 2 arranged in matrix structures 5 for the purpose of receiving dosed quantities of solid drug portions dispensed by dosing stations 2 .
[0067] In the shown embodiment each fall duct 7 comprises two parts, a front part 7 a and a base part 7 b , and is adapted for simultaneous co-action with a plurality of dosing stations 2 positioned above each other. Each front part 7 a is provided with a number of input openings 13 (see FIG. 12 ) corresponding to the number of dosing stations 2 with which fall duct 7 will simultaneously co-act. As can be seen from FIGS. 13-17 the base part 7 b of a fall duct 7 is also provided with several constrictions 14 for limiting the maximum length of the free fall of falling solid drug portions, in order to limit the falling speed, and thereby limit damage to the falling solid drug portions. Use is generally made here of a maximum free-fall length of 20 cm. The constrictions 14 also guide falling solid drug portion away from the input openings 13 of the front part 7 a of a fall duct (and therefore from the output opening of the dosing stations) to prevent falling solid drug portion from entering an output opening 13 of a dosing station and sticking there.
[0068] The apparatus 1 also comprises a second conveyor belt 15 provided with mounting elements 16 on which a plurality of collecting means 17 , also referred to as solid drug portion carriages, are releasably mounted. Each mounting element 16 will generally be provided here with a collecting means 17 adapted for temporary storage of a dosed quantity of solid drug portions made up in accordance with a prescription. Not all collecting means 17 are shown in the figures. The second conveyor belt 15 is coupled mechanically to first conveyor belts 6 a , 6 b and is also driven by electric motor 11 , wherein the direction of displacement and displacement speed of conveyor belts 6 a , 6 b , 15 are the same. It is moreover advantageous for the first conveyor belts 6 a , 6 b and the second conveyor belt 15 to be mutually aligned, wherein mounting elements 8 , 16 lie in a substantially vertical line (directly under each other). The distance between adjacent mounting elements 8 , 16 amounts to 80 mm, this substantially corresponding to the width of collecting means 17 , fall ducts 7 and dosing stations 2 .
[0069] Collecting means 17 are adapted to receive solid drug portions falling through fall ducts 7 . Each fall duct 7 is provided for this purpose with a passage opening for falling solid drug portions on the underside. In accordance with this embodiment, for a part of the conveying route each collecting means 17 will be positioned here directly under a fall duct 7 . In order to be able to prevent as far as possible sagging of conveyor belts 6 a , 6 b , 15 due to the weight of fall ducts 7 and collecting means 17 respectively, conveyor belts 6 a , 6 b are tensioned under a bias of about 600 N. Conveyor belts 6 a , 6 b , 15 are generally manufactured from a relatively strong plastic such as nylon. As shown in the figures, the second conveyor belt 15 is longer than each of the first conveyor belts 6 a , 6 b.
[0070] Collecting means 17 will then be guided in the direction of the dispensing and packaging station 3 where the solid drug portions collected in accordance with prescription are removed from collecting means 17 , wherein the solid drug portions are transferred to an opened foil packaging 18 . In packaging station 3 the foil packaging 18 will be successively sealed and provided with specific (user) information. The overall control of apparatus 1 is realized by applying a control unit 19 .
[0071] FIG. 5 is a perspective view of support structure 4 provided with conveyor belts 6 a , 6 b , 15 of apparatus 1 as shown in FIGS. 1-4 , this in fact forming the heart of the apparatus 1 on which fall ducts 7 and collecting means 17 are mounted and around which dosing stations 2 are then positioned on both longitudinal sides of support structure 4 .
[0072] FIG. 6 is a perspective rear view of a dosing station 2 for use in a apparatus 1 as shown in FIGS. 1-4 . Dosing station 2 is also referred to as a canister, formed by a unit which can be coupled releasably to support structure 4 and which comprises a housing 20 and a cover 21 closing the housing 20 . The housing is preferably manufactured at least partially from a transparent material so that the degree of filling of dosing station 2 can be determined without opening dosing station 2 . An outer side of housing 20 is provided with a receiving space 22 for a tablet or pill corresponding to tablets or pills held in the housing. Receiving space 22 is covered by means of a transparent cover element 23 . An operator can hereby see immediately with which tablets or pills the dosing station 2 has to be filled. In the perspective front view of dosing station 2 as shown in FIG. 7 the housing 20 is shown partially transparently in order to make visible the inner mechanism of dosing station 2 . Accommodated as shown in housing 20 is an axially rotatable individualizing wheel 24 which is releasably connected to housing 20 and which is adapted during axial rotation to separate a single tablet or single pill which can subsequently be removed from housing 20 via a fall guide 25 arranged in the housing and can be transferred to a passage opening of a fall duct 7 connecting onto fall guide 25 . Individualizing wheel 24 is provided here with a plurality of receiving spaces 26 for pills or tablets distributed over the edge periphery. The size of receiving spaces 26 can generally be adapted to the size of the pills or tablets to be held in supply. Individualizing wheel 24 can be rotated axially by means of an electric motor 27 also accommodated in housing 20 . Arranged in fall guide 25 is a sensor 28 which can detect the moment at which a pill or tablet for separation falls, and thereby also whether housing 20 has been emptied. Dosing stations 2 are visible from an outer side of apparatus 1 and accessible for possible replenishment of dosing stations 2 . Housing 20 will generally be provided with multiple LEDs (not shown) to enable indication of the current status of dosing station 2 , and particularly in the case that dosing station 2 has to be replenished or is functioning incorrectly.
[0073] FIG. 8 is a perspective view and FIG. 9 is a side view of a collecting means 17 for use in apparatus 1 as shown in FIGS. 1-4 . Collecting means 17 comprises here a mating mounting element 29 for co-action with mounting element 16 of the second conveyor belt 15 . In order to increase the stability of collecting means 17 , the collecting means 17 also comprises two securing gutters 30 a , 30 b for clamping or at least engaging round the second conveyor belt 15 . An upper side of collecting means 17 takes an opened form and has a funnel-like shape so that it can receive solid drug portions falling out of a fall duct 7 . An underside of collecting means 17 is provided with a pivotable closing element 31 provided with an operating tongue via which the closing element 31 can be pivoted to enable opening, and thereby unloading, of collecting means 17 . Collecting means 17 will generally be provided with a biasing element (not shown), such as a compression spring, in order to urge closing element 31 in the direction of the position closing the collecting means 17 , whereby erroneous opening of collecting means 17 can be prevented.
[0074] FIGS. 10 and 11 show a perspective front view and perspective rear view of the dispensing and packaging station 3 as applied in apparatus 1 as shown in FIGS. 1-4 . Packaging station 3 comprises a foil roll 32 which can be unwound by means of an electric motor 33 , after which the unwound foil 34 is guided via a plurality of guide rollers 35 in the direction of the collecting means 17 to be emptied. The transport direction of foil 34 is indicated by means of arrows in both FIGS. 10 and 11 . Before foil 34 is transported below a collecting means 17 for emptying, foil 34 is provided with a longitudinal fold, whereby a V-shaped fold 36 is created in which the solid drug portions can be received following opening of collecting means 17 . Foil 34 can be provided with two transverse seals and a longitudinal seal to enable complete sealing of packaging 18 . Applied in making the longitudinal seal are two heat bars 37 , of which only one heat bar 37 is shown, and which press on either side of the two foil parts to be attached to each other, whereby the foil parts fuse together and the longitudinal seal is formed. It is advantageous here for each heat bar 37 to engage foil 34 via a stationary strip manufactured from plastic, in particular Teflon or displaceable band 38 in order to prevent adhesion of heat bars 37 to the foil. The transverse seals are also created by two upright rotatable heat bars 39 which co-act with each other and press the foil parts against each other in realizing a transverse seal. Packaging 18 can optionally be further provided with a label. Successive packages 18 remain mutually connected in the first instance and together form a packaging strip.
[0075] FIG. 12 shows a fall duct 7 , the base part 7 b being provided with two mating mounting elements 40 a , 40 b for co-action with mounting elements 8 of the two first conveyor belts 6 a , 6 b as applied in an apparatus 1 according to any of the FIGS. 1-4 . A particular feature however of the fall duct 7 shown in FIG. 12 is that the fall duct 7 (in this embodiment the base part 7 b of the fall duct) is provided with an additional central guide element 41 for co-action with a stationary guide 42 which can be attached to support structure 4 of apparatus 1 , whereby additional stability is imparted to fall duct 7 and both first conveyor belts 6 a , 6 b.
[0076] FIGS. 13-17 show various views of an embodiment of a fall duct (or at least a part of the fall duct) in accordance with the present invention, wherein the shown embodiment differs from the embodiment shown in the FIGS. 1-12 . As mentioned above, a fall duct comprises at least two parts and in the shown embodiment the at least two parts are provided as base part 7 b and front part 7 a . The base part 7 b is detachably connected to a mounting beam 52 which is detachably connected to a (not shown) conveyor belt of the first conveyor. The front part 7 a comprises a plurality of input openings 13 which have a kind of funnel shape. The (not shown) dosing stations release dosed quantities of solid drug portions which leave the dosing stations via the output openings and enter the front parts 7 a of a fall ducts 7 via an input openings 13 . The shape/configuration of the input openings is not essential as long as it is ensured that any kind of solid drug portion can pass through it. For example, the input openings can be formed as simple openings in the front part as it is implied in FIG. 12 .
[0077] The front part 7 a of the shown fall duct is detachably connected to the base part 7 b of the fall duct 7 . In the shown embodiment the front part 7 a comprises a number of retainer means 50 a and the base part 7 b comprises a number of mating openings 50 b which have a shape of a long hole in the shown embodiment. The front part 7 a is also secured by a latching element 50 c located at the upper part of the fall duct.
[0078] To detach the front part 7 a , the latching element is released and the front part is raised and drawn away from the base part 7 b . To assemble the fall duct (for example after both parts have been cleaned) the procedure is performed in reverse.
[0079] The base part 7 b of the fall duct 7 comprises a number of constrictions 14 which limit the falling speed of the solid drug portion and prevent falling solid drug portion from entering an output opening of a dosing station by guiding the falling solid drug portion away from the input openings of the front part/the output openings of the dosing stations.
[0080] In the shown embodiment the base part 7 b of a fall duct comprises two sensors 53 , 54 (see FIG. 17 ). Sensor 54 is arranged at the lower section of the base part 7 a and is arranged to monitor the number of falling solid drug portion. The sensor is coupled with the (not shown) control unit, and the control unit may, depending on the number of solid drug portion units that have passed the sensor 54 , initiate maintenance of the fall duct in which the sensor is arranged.
[0081] The sensor 53 is arranged somewhere within the base part 7 b of a fall duct and is adapted to monitor the contamination of the inner surface of the base part. As soon as such contamination exceeds a predetermined limit, the control unit, to which the sensor 53 is also coupled, may initiate maintenance.
[0082] It will be apparent that the invention is not limited to the exemplary embodiments shown and described here, but that numerous variants which will be self-evident to the skilled person in this field are possible within the scope of the appended claims.
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An apparatus for dispensing and packaging dosed quantities of solid drug portions is provided. The apparatus includes multiple dosing stations, each dosing station having an output opening for dispensing solid drug portions, a collector for collecting dosed quantities of solid drug portions dispensed by the dosing stations and forwarding the dosed quantities of solid drug portions to a packager, and multiple fall ducts configured to guide the solid drug portions from the output openings to the collector, each fall duct having an outlet and a number of inlet openings, the output openings of the dosing stations being aligned with the inlet openings of the fall ducts when a fall duct ( 7 ) is positioned adjacent to a column of dosing stations. Each fall duct includes a first part and a second part detachably connected together.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of patent application Ser. No. 12/483,542, filed Jun. 12, 2009, which is a continuation-in-part of patent application Ser. No. 11/939,165, filed Nov. 13, 2007, now abandoned.
FIELD OF THE INVENTION
The present invention is related to devices and methods for cooling heat-producing equipment, and more specifically, is related to devices for cooling heat-producing electronic equipment arranged in a row of cabinets.
BACKGROUND OF THE INVENTION
Referring to FIG. 1 and the Cartesian coordinate system which comprises an x axis 102 , a y axis 104 , and a z axis 106 that are mutually orthogonal, a known air-cooling apparatus 100 , described in U.S. Pat. No. 7,085,133, which is incorporated by reference herein in its entirety, includes a row of cabinets 108 , including cabinets 110 , 112 , 114 , 116 arrayed along the x axis 102 . The row of cabinets 108 includes a first cabinet 110 located at the +x end of the row and a last cabinet 116 located at the −x end of the row. An arbitrary number of additional interior cabinets, such as cabinets 112 and 114 shown in FIG. 1 , are positioned between the first cabinet 110 and the last cabinet 116 .
An intake end-plenum 118 , which includes a sloping wall 120 , abuts the row of cabinets 108 at an upstream face 110 a of the first cabinet 110 to direct cooled air thereto. An exhaust end-plenum 122 , which includes a sloping wall 124 , is adjacent to a downstream face 116 b of the last cabinet 116 to direct exhaust air therefrom. Interposed between each pair of adjacent cabinets is a combined-plenum unit 126 that comprises both an intake plenum 128 and an exhaust plenum 130 . Within each combined-plenum unit 126 , the intake plenum 128 and the exhaust plenum 130 are separated from each other by a sloping wall 132 . The combined plenum units 126 are mounted to the cabinets 110 , 112 , and 114 such that the exhaust plenums 130 thereof abut the cabinets' downstream surfaces 110 b , 112 b , and 114 b respectively, and the intake plenums 128 thereof abut the cabinets' upstream surfaces 112 a , 114 a , and 116 a , respectively. Each cabinet 110 , 112 , 114 , 116 contains heat-producing electronics 134 arranged to allow airflow parallel to the x direction 102 . Therefore, air-moving devices 136 in each cabinet are arranged to induce and encourage an S-shaped airflow 138 . This type of cooling means is used, for example, in IBM®'s Bluegene®/L and Bluegene®/P supercomputers. The abutted row 108 of cabinets 110 , 112 , 114 , 116 and plenums 118 , 122 , 126 stand in a room 140 on a raised floor 142 that is above and substantially parallel to a sub-floor 144 . The raised floor 142 typically comprises a regular two-dimensional array of removable tiles 146 having pitch p in the x 102 and y 104 directions. Cooling air 148 is supplied to an under-floor space 150 between the raised floor 142 and the sub-floor 144 by a plurality of air-conditioning units 152 that are also known in the art.
Cooling one of the interior cabinets 112 , 114 is accomplished by the S-shaped air-stream 138 passing through a hole 154 in the raised floor, and thereafter through the intake plenum 128 . Drawn by the air-moving devices 136 , the S-shaped air stream 138 travels over the heat-producing electronics 134 , exiting the cabinet through the exhaust plenum 130 . After the S-shaped air-stream 138 exits the exhaust plenum 130 , it is returned to an open top surface 156 of the air conditioning units 152 . Cooling of the first cabinet 110 or last cabinet 116 is similar to that for interior cabinets 114 , except that the air enters the first cabinet 110 through the intake end plenum 118 , and air exits the last cabinet 116 through the exhaust end plenum 122 .
The known cooling apparatus 100 is deficient because it imposes at least the following several requirements on the room 140 and on the design of the cabinets 110 , 112 , 114 , 116 . First, each cabinet must be fed by an airflow rate V sufficient to keep all the cabinet's internal electronics 134 sufficiently cool. For cabinets that dissipate large quantities of heat, this requirement is often burdensome on the infrastructure of the room 140 because it requires significant investment in air-conditioning units 152 , a large under-floor space 150 , and a disruption of airflow patterns to other, already-existing equipment in the room.
Second, at the interface between any of the intake plenums 118 , 128 and the abutting cabinets 110 , 112 , 114 , 116 where the air-stream 138 first turns, the flow must be managed carefully, with appropriately designed turning aids, to avoid stagnation regions causing the electronics 134 to reach higher temperatures. This requirement is difficult to achieve in designing the cabinet, and despite best design efforts may be defeated by unusual raised-floor conditions, such as those where the distance between the raised floor 142 and the sub-floor 144 is too small, or where the hole 154 is partially obstructed by either structural members of the raised floor 142 or by equipment such as wires in under-floor space 150 .
Third, in order to achieve high packing density of cabinets, the combined plenum unit 126 must be narrow. Thus, air must flow vertically through a relatively narrow intake plenum 128 and exhaust plenum 130 . This requirement inevitably incurs pressure loss, leading to reduced flow rate V and increased temperature of the electronics 134 .
Fourth, holes 154 must be cut in the raised floor 142 underneath each of the intake plenums 118 and 128 . To avoid non-uniform flow leading to hotspots in the cabinet, the holes 154 must not be obstructed by structural members supporting the raised floor. Unobstructed holes are difficult to insure for all installations, because raised-floors are not standard worldwide, for example, the pitch p of the removable tiles 146 may differ from country to country.
Therefore, a need exists for an improved cooling apparatus and method of cooling a row of cabinets 108 that houses electronic equipment 134 . It would be desirable, without sacrificing airflow through any particular item of the electronics 134 , for the cooling apparatus to operate with the least possible total airflow, thereby minimizing both the cost of air-conditioning equipment 152 and the level of acoustical noise in the room 140 . Further, it would be desirable to minimize constricted air passageways, such as the narrow plenums 128 and 130 , that unduly limit airflow. Moreover, it would be desirable to avoid turns in the airflow path, such as those in the S-shaped airflow path 138 , thereby to eliminate hotspots caused by flow non-uniformities and boundary-layer separation. Finally, it would be desirable to improve cabinet-packing density by minimizing the amount of space devoted exclusively to air handling, such as that occupied by plenums 118 , 122 , and 126 .
SUMMARY OF THE INVENTION
In an aspect of the invention, a cooling apparatus includes a plurality of heat-producing devices positioned in a plurality of cabinets arranged in a row allowing flow of a first fluid through the heat-producing devices and cabinets. The flow of the first fluid is directed from an upstream end of the row to a downstream end of the row such that an upstream heat-exchanger side abuts a downstream cabinet side the cabinets positioned in spaced relation to each other and defining a space therebetween. A plurality of heat exchangers are positioned at least partially in the spaces between the cabinets and adjacent to the cabinets. Thereby the cabinets and the heat exchangers alternate in the rows, each heat exchanger allowing flow of a second fluid therethrough for cooling the first fluid. At least one fluid-moving device positioned adjacent the heat-producing devices for encouraging the flow of the first fluid through the cabinets' heat-producing devices and through the heat exchangers, thereby encouraging the transfer of heat from the first fluid to the second fluid in the heat exchangers.
In a related aspect, at least one fluid-moving device is positioned between the heat-producing devices of each cabinet and the heat exchanger immediately downstream of the heat-producing device.
In a related aspect, the apparatus further includes a first fluid-moving device positioned between the heat-producing device and the heat exchanger, and a second fluid-moving device is positioned between the heat exchanger and the cabinet immediately downstream of the heat exchanger.
In a related aspect, the apparatus further includes a plurality of first fluid-moving devices positioned between the heat-producing devices and a plurality of heat exchangers, and a plurality of second fluid-moving devices each positioned between the heat exchangers and a front of the plurality of cabinets. In an embodiment of the apparatus, the first fluid may be air. Further, the heat-producing devices may be electronic devices, and further may be heat-producing devices such as computers or computer processors.
In a related aspect, a plenum is positioned at an upstream side of a first cabinet of the plurality of cabinets for directing incoming ambient air.
In a related aspect, a first plenum is positioned at an upstream side of a first cabinet of the plurality of cabinets for guiding the direction of incoming ambient air, and a second plenum is positioned at a downstream side of a last cabinet of the plurality of cabinets for guiding the direction of outgoing ambient air.
In a related aspect, the second fluid is water. In another embodiment of the invention, the heat exchanger includes ingress and egress tubes carrying the second fluid, to remove heat from the first fluid. In another embodiment, the flow of the first fluid is directed in a closed loop.
In a related aspect, the apparatus further includes a plurality of fluid-moving devices positioned adjacent an upstream side and a downstream side of the heat-producing devices for encouraging flow of the first fluid through the cabinets' heat-producing devices and through the heat exchangers.
In a related aspect, the apparatus further includes a vertical barrier dividing the cabinets into a front portion and a rear portion, and circulating the first fluid in a closed loop between the front and rear portions. Additionally, the apparatus may include a horizontal barrier dividing the cabinets into an upper portion and a lower portion, and circulating the first fluid in a closed loop between the upper and lower portions.
In another aspect of the invention, a cooling system in an enclosed room includes a plurality of heat-producing devices positioned in a plurality of cabinets arranged in a row allowing a flow of a first fluid through the heat-producing devices and cabinets. The flow of the first fluid is directed from an upstream end of the row to a downstream end of the row, and the cabinets are positioned in spaced relation to each other and define a space therebetween. A plurality of heat exchangers are positioned at least partially in the spaces between the cabinets and adjacent to the cabinets. Thereby, the cabinets and the heat exchangers alternate in the rows such that an upstream heat-exchanger side abuts a downstream cabinet side, and each heat exchanger allows flow of a second fluid therethrough for cooling the first fluid. At least one fluid-moving device is positioned adjacent the heat-producing devices for encouraging the flow of the first fluid through the cabinets' heat-producing devices and through the heat exchangers, thereby encouraging in each of the heat exchangers a transfer of heat from the first fluid to the second fluid. A first plenum adjacent an upstream side of a first cabinet for directing the flow of the first fluid as it enters the row of cabinets. A last plenum adjacent a downstream side of a last cabinet for directing the flow of the first fluid exiting the row of cabinets.
In a related aspect, the first fluid is cycled in a closed loop within the enclosed room. In an alternative embodiment, the system further comprises a raised floor in the enclosed room, wherein the raised floor supports the plurality of cabinets, and the first fluid is directed through holes in the raised floor. In a further aspect, each of the heat exchangers provide, at its downstream side, a temperature of the first fluid that is substantially the same as the temperature of the first fluid when entering the upstream side of the first cabinet.
In another aspect, a method for cooling includes: (a) positioning a plurality of heat-producing devices in a plurality of cabinets arranged in a row; (b) positioning a plurality of heat exchangers in a space between the cabinets and adjacent to the cabinets, thereby alternating the cabinets and the heat exchangers in the row; (c) directing flow of a first fluid through the heat-producing devices, cabinets, and heat exchangers for cooling the first fluid; and (d) positioning a plurality of fluid-moving devices adjacent the heat-producing devices for encouraging flow of the first fluid through the cabinets' heat-producing devices and through the heat exchangers, thereby encouraging heat transfer from the first fluid to a second fluid in each of the heat exchangers.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects, features and advantages of the present invention will become apparent from the following detailed description of illustrative embodiments thereof, which is to be read in connection with the accompanying drawings, in which:
FIG. 1 is a front elevational view of a prior art cooling apparatus depicting a row of cabinets with interleaved airflow plenums;
FIG. 2 is a front elevational view of a cooling apparatus according to an embodiment of the present invention depicting heat exchangers between cabinets in a row;
FIG. 3 is a front elevational view of an apparatus according to another embodiment of the invention depicting differently arranged plenums;
FIG. 4 is a front elevational view of an apparatus according to another embodiment of the invention without a plenum on the air-intake end of the row of cabinets;
FIG. 5 is a front elevational view of an apparatus according to another embodiment of the invention without plenums at either the air-intake end or the air-exhaust end of the row of cabinets;
FIG. 6 is a front elevational view of an apparatus according to another embodiment of the invention depicting differently arranged plenums;
FIG. 7 is a front elevational view of an apparatus according to another embodiment of the invention depicting first and second air-moving devices;
FIG. 8 is a plan view of an apparatus according to another embodiment of the invention depicting a vertical barrier for dividing the cabinets and heat exchangers into front and rear portons; and
FIG. 9 is a front elevational view of an apparatus according to another embodiment of the invention depicting a horizontal barrier for dividing the cabinets and heat exchangers into upper and lower portions.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 2 , an illustrative embodiment of a cooling apparatus 200 according to the present invention uses the same reference numerals for like elements as the prior art apparatus 100 shown in FIG. 1 . However, the apparatus 200 differs from the prior art apparatus 100 in at least two significant ways. First, on the downstream faces of each cabinet 110 , 112 , 114 , 116 , the present invention employs, in contrast to the prior art air plenums 126 , 122 , a series of air-to-water heat exchangers 210 , 212 , 214 , 216 . Second, the present invention uses, in place of the prior art's multiple S-shaped air paths 138 , a single, row-wise airflow path 218 that travels substantially in the −x direction, straight through an entire flow-through row 220 . The flow-through row 220 comprises the cabinets 110 , 112 , 114 , 116 ; the heat exchangers 210 , 212 , 214 , 216 , and optionally an intake plenum and an exhaust plenum such as a bottom-intake plenum 222 , and a bottom-exhaust plenum 224 , respectively.
The heat exchangers 210 , 212 , 214 , 216 make possible the row-wise airflow path 218 . Referring to the graph 244 of air temperature vs. horizontal coordinate x at the top of FIG. 2 , the heat-producing electronics in cabinet 110 cause the temperature of the air circulating along air path 218 to rise from T 0 to T 1 as it traverses cabinet 110 from the cabinet's upstream face 110 a at x=x 0 to the downstream face 110 b at x=x 1 . The air-to-water heat exchanger 210 is typically a tube-and-fin heat exchanger well known in the art, wherein warm air passes over the heat-exchanger's fins and a cold liquid flows in the heat exchanger's tubes, thereby allowing heat to be transferred from the air to the liquid. The liquid is supplied to each heat exchanger from an external liquid-chilling system via a supply pipe 240 , and is returned to the liquid-chilling system via a return pipe 242 . Therefore, in traversing the heat exchanger 210 from x 1 to x 2 , the temperature of the air, being cooled by the externally chilled liquid, drops from T 1 to T 0 . Thus, the combination of cabinet 110 and heat exchanger 210 is thermally neutral for the air. This air-temperature cycle is repeated for subsequent cabinets and heat exchangers: the air is warmed to temperature T 1 a second time while traversing cabinet 112 in the region x 2 to x 3 , is cooled a second time to temperature T 0 by the heat exchanger 212 in the region x 3 to x 4 , is warmed a third time to temperature T 1 while traversing cabinet 114 in the region x 4 to x 5 , is cooled a third time to temperature T 0 by heat exchanger 214 in the region x 5 to x 6 , is warmed a fourth time to temperature T 1 by cabinet 116 in the region x 6 to x 7 , and is finally cooled a fourth time to temperature T 0 by heat exchanger 216 in the region x 7 to x 8 . Thus, the entire flow-through row 220 is thermally neutral for the air; that is, the air returns to the under-floor space 150 at temperature T 0 , ready to repeat the cycle. Because the air path 218 is closed, the temperatures T 0 and T 1 will automatically float to whatever values cause equilibrium to occur. Thus, it is necessary to choose heat exchangers 210 , 212 , 214 , 216 and air-moving devices 136 such that acceptable temperatures are obtained for the worst-case heat dissipation of electronics 134 . Heat exchanges 210 , 212 , 214 , 216 are described in U.S. patent application Ser. No. 11/939,165, filed Nov. 13, 2007, now abandoned, the disclosure of which is hereby incorporated herein by reference in its entirety. Temperature control of a cooling fluid is also discussed in copending U.S. patent application Ser. No. 12/483,542, filed Jun. 12, 2009, the disclosure of which is hereby incorporated herein by reference in its entirety.
Again referring to FIG. 2 , the row-wise airflow path 218 is now described in detail. Air enters the first cabinet 110 from the under-floor space 150 , flowing upward through row-intake hole 226 in the raised-floor 142 , and through the perforated metal screen 228 , which may be necessary, depending on the nature of the electronics, to prevent the escape of electromagnetic radiation therefrom into the room 140 . The row-wise airflow path 218 moves upward through the bottom-intake plenum 222 to the first cabinet 110 of the flow-through row 220 . The air-moving devices 136 within the cabinets 110 , 112 , 114 , 116 encourage the row-wise airflow path 218 through each cabinet 110 , 112 , 114 , 116 , and thereby through the entire flow-through row 220 . An intake-end wall 230 of the bottom-intake plenum 222 may, if desired, slant inward toward the top of the first cabinet 110 , inasmuch as upper cross-sections of the intake plenum 222 handle far less airflow than lower cross-sections, and thus require less cross-sectional area. Alternatively, the intake-end wall 230 may be substantially vertical, or removed altogether. In the latter case, the flow-through row 220 draws air from the room 140 rather than from the under-floor space 150 .
The row-wise airflow path 218 exits the last cabinet 116 of the flow-through row 220 , flowing downward through a perforated-metal exhaust screen 232 whose function is similar to that of the perforated-metal intake screen 228 , downward through a row-exhaust hole 234 in the raised-floor 142 , and thereby into the under-floor space 150 . An exhaust-end wall 236 of the bottom-exhaust end plenum 224 may, if desired, slant outward toward the bottom of the last cabinet 116 , inasmuch as upper cross-sections of the bottom-exhaust plenum 224 handle far less airflow than lower cross-sections, and thus require less cross-sectional area. Alternatively, the exhaust-end wall 230 may be substantially vertical, or removed altogether. In the latter case, the flow-through row 220 exhausts air to the room 140 rather than to the under-floor space 150 .
Referring to FIG. 3 , another embodiment of the invention is a cooling apparatus 300 that includes a top-exhaust plenum 324 instead of the bottom-exhaust plenum 224 previously shown in FIG. 2 . The top-exhaust plenum 324 is identical to bottom-exhaust plenum 224 except that it is rotated 180 degrees about the x axis, such that top-exhaust plenum 324 is wide at the top, by virtue of a sloping end wall 336 , thereby to accommodate greater airflow at upper cross sections than at lower cross sections In the cooling apparatus 300 , a row-wise airflow 318 behaves as in cooling apparatus 200 , except that in apparatus 300 , the airflow 318 exits the row 220 flowing upward through the top-exhaust end plenum 324 , which has an opening 334 at the top. A perforated metal exhaust screen 332 at the top of top-exhaust plenum 324 serves the same purpose as screen 232 in plenum 224 , as discussed previously. As with the apparatus 200 shown in FIG. 2 , and also pertaining to the embodiments shown in FIGS. 4, 6 and 7 , depending on the nature of the electronics 134 , it may not be necessary to include the perforated metal screen 332 to prevent the escape of electromagnetic radiation from the flow-through row 220 .
Referring to FIG. 4 , another alternative embodiment of the invention is a cooling apparatus 400 , where no intake plenum is used. In this embodiment, airflow 418 enters the flow-through row of cabinets 220 directly from the room 140 . The airflow exits the apparatus 400 as in the apparatus 300 shown in FIG. 3 . Pertaining to this embodiment as well as to that shown on FIG. 5 , to prevent the escape of electromagnetic radiation from the flow-through row 220 , it may be necessary, depending on the nature of the electronics 134 , to affix to the upstream surface 110 a of the first cabinet 110 a perforated metal screen 428 , through which air flows immediately prior to entering cabinet 110 .
Referring to FIG. 5 , another alternative embodiment of the invention is a cooling apparatus 500 where no intake-end plenum or exhaust-end plenum is used. In this embodiment, airflow 518 exhausts from the last cabinet 116 directly to the room 140 . Airflow 518 is otherwise identical to airflow 418 discussed with reference to FIG. 4 . To prevent the escape of electromagnetic radiation from the flow-through row 220 , it may be necessary, depending on the nature of the electronics 134 , to affix to the downstream surface 116 b of the last cabinet 116 a perforated metal screen 532 .
Referring to FIG. 6 , another alternative embodiment of the invention is cooling apparatus 600 , where a top-intake end plenum 622 and the top-exhaust end plenum 324 are used. The top-intake plenum 622 is identical to the bottom-intake plenum 222 , shown in FIG. 2 , except that it is rotated 180 degrees about the x axis, such that the top-intake plenum 622 is wide at the top, by virtue of a sloping end wall 630 , thereby to accommodate greater airflow at upper cross sections than at lower cross sections. In this embodiment, an airflow 618 enters the flow-through row 220 downward through the top-intake end plenum 622 and exits the flow-through row 220 upward through the top-exhaust end plenum 324 .
Referring to FIG. 7 , another embodiment of the invention is a cooling apparatus 700 , which is similar to the apparatus 200 shown in FIG. 2 . However, in the apparatus 700 shown in FIG. 7 , the heat-exchanger 210 is replaced by a heat-exchanger assembly 710 that comprises, in addition to the heat exchanger 210 , an array of air-moving devices 760 , such as axial-flow fans. Likewise, the heat exchangers 212 , 214 , and 216 shown in FIG. 2 are replaced, in apparatus 700 , by heat-exchanger assemblies 712 , 714 , 716 respectively, which comprise, in addition to heat exchangers 212 , 214 , and 216 respectively, air-moving devices 762 , 764 , and 766 respectively. Thus, the cooling apparatus 700 includes air-moving devices 760 , 762 , 764 , 766 that supplement the air-moving devices 136 within the cabinets 110 , 112 , 114 , 116 . Alternatively, depending, for example, on the cost and pressure-rise requirements of the cooling system and on the space required by the electronics, the air-moving devices 760 , 762 , 764 , 766 may replace the air-moving devices 136 contained within the cabinets 110 , 112 , 114 , 116 .
The heat-exchanger assemblies 710 , 712 , 714 , 716 , although described above for use with the airflow arrangement of the cooling apparatus 200 shown in FIG. 2 , may also be used with any of the other airflow arrangements, as shown in cooling apparatuses 300 , 400 , 500 , and 600 of FIGS. 3-6 , respectively.
Referring to FIG. 8 , another embodiment of the invention is a cooling apparatus 800 , wherein each of the cabinets 110 , 112 , 114 , 116 is internally divided into a front portion 802 and a rear portion 804 . Note that FIG. 8 is a plan view, as specified by the orientation of the x, y, and z axes 102 , 104 , 106 respectively, whereas FIGS. 1-7 and 9 are front elevational views. In each cabinet, the portions 802 , 804 are separated from each other by a vertical cabinet barrier 806 that substantially prevents air flow across it. The barrier 806 lies substantially parallel to an xz plane spanned by the x and z axes. Likewise, each of the heat-exchangers 210 , 212 , 214 , 216 comprises, in this embodiment, a vertical heat-exchanger barrier 808 that substantially prevents airflow across it. The cabinet barriers 806 and the heat-exchanger barriers 808 are substantially co-planar. A first closed-end plenum 810 is abutted to the upstream face 110 a of the first cabinet 110 , and a second closed-end plenum 812 is abutted to a downstream face 216 b of the heat exchanger 216 . Front air-moving devices 814 in the front portion 802 of the cabinets 110 , 112 , 114 , 116 are configured to drive a closed-horizontal-loop air-stream 818 in the −x direction, while rear air-moving devices 816 in the rear portion 804 of the cabinets 110 , 112 , 114 , 116 are configured to drive the closed-horizontal-loop air stream 818 in the +x direction, such that the air stream 818 circulates in a closed loop about the vertical z axis 106 . That is, the closed-horizontal-loop air-stream 818 flows toward +x in the rear portion 804 of the cabinets 100 , 112 , 114 , 116 and heat exchangers 210 , 212 , 214 , 216 , then toward −y in the first closed-end plenum 810 , then toward −x in the front portion 802 of the cabinets and heat exchangers, and finally toward +y in the second closed-end plenum 812 , thus completing a closed loop. This closed-loop embodiment is advantageous because it imposes no air-handling burden on the room 140 , and because it provides very quiet operation of the air moving devices 814 , 816 , particularly when the cabinets 110 , 112 , 114 , 116 , heat-exchanger assemblies 210 , 212 , 214 , 216 , and closed-end plenums 810 , 812 are acoustically insulated, because people in the room 140 are shielded from the noise of air movers and flowing air.
Again referring to the apparatus 800 shown in FIG. 8 , it should be noted that the closed-horizontal-loop air stream 818 , at its +x end, traverses two sets of heat-producing electronics 134 , in the rear portion 804 of the first cabinet 110 and in the front portion 802 of the first cabinet 110 , without any intervening heat exchanger to cool the air. If this causes the air to become unacceptably warm in the front portion 802 of cabinet 110 , so as to compromise cooling of the electronics 134 therein, then an additional heat exchanger identical to 210 may be abutted to the +x surface of the first cabinet 110 .
Referring to FIG. 9 , another embodiment of the invention is a cooling apparatus 900 , wherein each of the cabinets 110 , 112 , 114 , 116 is internally divided into a lower portion 902 and an upper portion 904 . In each cabinet, the portions 902 , 904 are separated from each other by a horizontal cabinet barrier 906 that substantially prevents air flow across it. Barrier 906 lies substantially parallel to an xy plane spanned by the x and y axes Likewise, each of the heat-exchangers 210 , 212 , 214 , 216 comprises, in this embodiment, a horizontal heat-exchanger barrier 908 that substantially prevents air flow across it. The cabinet barriers 906 and the heat-exchanger barriers 908 are substantially co-planar. A first closed-end plenum 910 is abutted to the upstream face 110 a of the first cabinet 110 , and a second closed-end plenum 912 is abutted to a downstream face 216 b of the heat exchanger 216 . Lower air-moving devices 914 in the lower portion 902 of the cabinets 110 , 112 , 114 , 116 are configured to drive a closed-vertical-loop air-stream 918 in the −x direction, while upper air-moving devices 916 in the upper portion 904 of the cabinets 110 , 112 , 114 , 116 are configured to drive the closed-vertical-loop air stream 918 in the +x direction, such that the air stream 918 circulates in a closed loop about the horizontal y axis 104 . More specifically, the closed-horizontal-loop air-stream 918 flows toward +x in the upper portion 904 of the cabinets 100 , 112 , 114 , 116 and heat exchangers 210 , 212 , 214 , 216 , then toward −z in the first closed-end plenum 810 , then toward −x in the lower portion 902 of the cabinets and heat exchangers, and finally toward +y in the second closed-end plenum 812 , thus completing a closed loop. This closed-loop embodiment, shown in FIG. 9 , is advantageous for the same acoustic reason described earlier in connection with apparatus 800 shown in FIG. 8 .
Again referring to the apparatus 900 shown in FIG. 9 , it should be noted that the closed-horizontal-loop air stream 918 , at its +x end, traverses two sets of heat-producing electronics 134 , in the upper portion 904 of the first cabinet 110 and in the lower portion 902 of the first cabinet 110 , without any intervening heat exchanger to cool the air. If this causes the air to become unacceptably warm in the lower portion 902 of cabinet 110 so as to compromise cooling of the electronics 134 therein, then an additional heat exchanger identical to 210 may be abutted to the +x surface of the first cabinet 110 .
Additionally, other embodiments and variations are possible keeping with the spirit and scope of the invention, for example, although the embodiments presented herein have included “air-to-water heat exchangers”, the heat exchangers may use other fluids. In another example, the water supply and return pipes 240 , 242 may enter the heat-exchangers 210 , 212 , 214 , 216 from the top rather than from the bottom.
All the embodiments of the current invention, including those represented as cooling apparatuses 200 , 300 , 400 , 500 , 600 , 700 , 800 , and 900 , shown in FIGS. 2-9 , respectively, have a number of significant advantages over the prior-art apparatus 100 shown in FIG. 1 , including those discussed hereinafter. A first advantage is that the total airflow required in the room 140 , and the associated acoustical noise, are greatly reduced by the invention vis-à-vis the prior art, leading to greater acoustical comfort for humans in the room 140 , and to less disruption of airflow if the room houses an existing installation of other equipment. Quantitatively, if volumetric flow rate V of air is required to cool each cabinet, and there are N cabinets in a row, then the prior art requires a total flow rate of NV per row, whereas the present invention which requires only V per row. This is a factor of N improvement that allows installation of such cabinets in buildings unable to support large amounts of airflow, and also reduces the total amount of airflow noise.
Second, many fewer air-conditioning units 152 are required in the room 140 by the invention than by the prior art, leading to lower capital investment in air-conditioning units 152 and lower energy cost to drive air-moving devices therein. According to the invention, the heat load of electronics 134 is transferred from the air locally to water flowing in pipes 240 , 242 of heat exchangers 210 , 212 , 214 , 216 . Therefore, the flow-through row 220 puts no thermal load on the room 140 , and thus requires only minimal air-conditioning for general dehumidification, and ancillary heat loads. In contrast, the prior-art row 108 dissipates all its heat load to the room, thus requiring, if the number of cabinets and the power dissipation therein is large, a great number of air-conditioning units 152 .
Third, the prior-art's narrow airflow plenums 126 , shown in FIG. 1 , are eliminated. Such narrow plenums are required by the prior art to achieve compact packaging along the flow-through row 220 , and to insure that the holes 154 in the raised floor 142 match the periodicity p of the raised-floor tiles 146 . However, air velocity is high in the narrow airflow plenums 126 , typically much larger than in the cabinet itself, because the cross-sectional area normal to the airstream is much smaller in the plenum than in the cabinet. Thus pressure drop in the airflow plenums 126 is large, and airflow rate through the prior-art electronics 134 is thereby restricted, increasing the temperature therein and reducing the lifetime and performance thereof. In the invention, this source of pressure drop is eliminated. Some pressure loss occurs in the invention's heat exchangers 210 , 212 , 214 , 216 , but because the cross-sectional area of the heat exchanger is large, air velocity is low, and therefore pressure drop is relatively small.
Fourth, flow non-uniformities that occur in the prior art are eliminated. Specifically, the narrowness of the prior art's airflow plenums 126 cause flow separation at locations near the upstream faces 110 a , 112 a , 114 a , 116 a of the cabinets wherever the airflow cannot negotiate a tight turn around a sharp edge. In the wake of such separation is a stagnation region of very-low-velocity airflow that causes very high temperatures of the electronics 134 therein. The tendency to separate may be minimized by widening the prior-art combined plenums 126 , but this is highly undesirable in the prior art, because of the desire to achieve a compact footprint of the row 108 of cabinets and plenums, and because of the aforementioned requirement to match the periodicity of the holes 154 with the pitch p of the removable tiles 146 . In contrast, embodiments 400 and 500 of the current invention require no air turn upstream of any electronics 134 , so the problem of flow separation is completely eliminated. All other embodiments require just one air turn per row 220 , upstream of the first cabinet 110 . Because the invention has only one intake plenum per row 220 rather than one intake plenum per cabinet as in the prior art, beneficial widening of the intake plenum, mentioned above, has, for the invention, much less impact on the footprint of a row 220 than a similar widening would have for the prior-art row 108 . That is, widening each of the prior-art's inlet plenums ( 118 and 128 ) by an amount d widens the prior-art cabinet row 108 by an amount Nd, where N is the number of cabinets per row. In contrast, widening the invention's intake end plenum ( 222 or 622 , depending on the embodiment) by the same amount d widens the invention's flow-through row 220 merely by d, a factor-of-N improvement over the prior art.
Fifth, the prior art's need to turn the air twice in each cabinet 110 , 112 , 114 , 116 is eliminated by the invention. By replacing the prior-art's S-shaped air-streams 138 , with the single, row-wise airflow path 218 most or all of the air turns are eliminated. Specifically, instead of two 90-degree turns per cabinet in the prior-art apparatus 100 , there are only four turns per row in apparatuses 200 , 700 , 800 , and 900 ; only two turns per row in apparatuses 300 and 600 ; only one turn per row in apparatus 400 ; and zero turns per row in apparatus 500 . Fewer turns is desirable because turning air incurs pressure drop and thereby reduces airflow, raising the temperature, shortening the life and compromising the performance of the electronics 134 .
Sixth, compared to the prior art, the invention provides additional space for air-moving devices. As shown by apparatus 700 in FIG. 7 , an air-to-water heat exchanger specified by this invention, such as 210 , need not occupy the entire space between the adjacent cabinets 110 and 112 ; instead, some of this space may be occupied by the array of air-moving devices 760 , which either supplement or replace the air-moving devices 136 internal to cabinet 110 . If air-moving devices 760 , 762 , 764 , 766 supplement air-moving devices 136 , then the pressure rise of the system (and hence the air velocity) is greatly increased, a benefit that may be used either to reduce the temperature of the electronics, or to cool more electronics or more powerful electronics. If, instead, the air-moving devices 760 , 762 , 764 , 766 replace air-moving devices 136 , then the space vacated by 136 may beneficially be used to house more electronics 134 in cabinet 110 .
Seventh, the periodic, large airflow holes 154 in the raised floor 142 of the prior-art apparatus 100 are eliminated by this invention, thereby reducing the system's dependence on the pitch p of removable tiles 146 of the raised floor 142 . For example, in apparatus 200 shown in FIG. 2 , pitch C of cabinets along a row, defined as C η x 8 −x 6 η x 6 −x 4 η x 4 −x 2 η x 2 −x 0 , is substantially unconstrained by the pitch p of the raised-floor tiles 95 , because the only holes therein are small holes for the supply and return pipes 240 and 242 . However, in the prior art, the holes 154 are large, and thus it is more important that the cabinet pitch C and the tile pitch p be more closely synchronized, to avoid interfering with struts that support the raised floor 142 . Toward this end, in the prior art, C and p are preferably related by a simple proportion such as mC=np where m and n are small integer such as (m, n)=(1,2) or (m, n)=(2,3). No such restriction applies to the invention.
Eighth, redundancy of the air-moving devices 136 is improved by the invention vis-à-vis the prior art. Specifically, along a flow-through row of cabinets 220 , air-moving devices 136 sharing a common streamline back each other up, such that failure of a single air-moving device 136 is much less significant than for the prior-art's separate, S-shaped airstreams 138 , wherein failure of an air-moving device can cause the temperature of nearby electronics to rise. For apparatus 700 , similar redundancy is achieved for the supplementary, or alternative, series of air movers 762 , 764 , 766 , 768 .
Ninth, the invention improves cabinet-packing density vis-à-vis the prior art, thereby saving valuable floor space and also improving electrical-signaling performance between cabinets by allowing shorter cables. Specifically, the stream-wise (x) dimension of one of the heat exchangers assemblies 210 , 212 , 214 , 216 is typically far smaller than the x dimension of one of the prior art's combined plenum units 126 , because the heat-exchanger's x dimension need only be large enough to accommodate tubes and fins to transfer heat from air to water, whereas the combined plenum unit's x dimension must be large enough to accommodate, through the intake plenum 128 and the exhaust plenum 130 , the large volumetric flow-rate of air, denoted V, that is needed to cool electronics 134 . For example, in the IBM® BlueGene/P® supercomputer, which comprises electronics 134 in each cabinet dissipating as much as 40 kW, and whose (x, y, z) cabinet dimensions are (70 cm, 89 cm, 180 cm), the x dimension of one of the heat exchangers 210 , 212 , 214 , 216 need only be 10 cm, whereas the x dimension of the combined plenum unit 126 must be 52 cm in order to accommodate V=2.35 m3/s (5000 CFM). Thus, cooling BlueGene/P according to the current invention saves about 42 cm of width per cabinet, which is about 47% of the width of the cabinet itself.
Thereby, the present invention clearly is advantageous for at least the reasons above in use with a supercomputer requiring rows of cabinets such as IBM®'s BLUEGENE®, by the single stream of air flowing through a row of cabinets, passing alternately through cabinets and heat exchangers, instead of flowing air separately through each cabinet.
While the present invention has been particularly shown and described with respect to preferred embodiments thereof, it will be understood by those skilled in the art that changes in forms and details may be made without departing from the spirit and scope of the present application. It is therefore intended that the present invention not be limited to the exact forms and details described and illustrated herein, but falls within the scope of the appended claims.
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A cooling apparatus and method including a plurality of heat-producing devices positioned in a plurality of cabinets arranged in a row that allows flow of a first fluid through the heat-producing devices and cabinets where the flow is directed from an upstream end of the row to a downstream end of the row. The cabinets have a space therebetween wherein a heat exchanger is positioned between and adjacent to the cabinets, thereby the cabinets and heat exchangers alternate in the row. Each heat exchanger allows flow of a second fluid therethrough for cooling the first fluid. A fluid-moving device is positioned adjacent the heat-producing devices for encouraging flow of the first fluid through the cabinets' heat-producing devices and through the heat exchangers, thereby encouraging heat transfer in each of the heat exchangers from the first fluid to the second fluid.
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CROSS REFERENCE TO RELATED APPLICATION
This application is based on and incorporates herein by reference Japanese Patent Application No. 2007-90429 filed on Mar. 30, 2007.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an air/fuel ratio control system for an internal combustion engine having a function of controlling an air/fuel ratio in each cylinder based on output of an air/fuel ratio sensor disposed in an exhaust air merging portion of the engine.
2. Description of Related Art
In most recent electronically controlled internal combustion engines, an air/fuel ratio sensor is disposed in an exhaust gas passage for detecting an air/fuel ratio of exhaust gas, and air/fuel ratio F/B control, whereby an air/fuel ratio (e.g., fuel injection quantity) in each cylinder is equally F/B (feedback) controlled such that an air/fuel ratio detected in the air/fuel ratio sensor accords with a target air/fuel ratio, is performed.
Furthermore, as described in JP2005-337194A, for example, the air/fuel ratio in each cylinder is estimated using a model, in which a detection value (air/fuel ratio at the exhaust air merging portion) of an air/fuel ratio sensor disposed in an exhaust air merging portion where exhaust gases from cylinders merge together is related with the air/fuel ratio in each cylinder. Based on the estimation result, each-cylinder air/fuel ratio control, whereby the air/fuel ratio (e.g., fuel injection quantity) in each cylinder is controlled so that a variation of the air/fuel ratios among the cylinders is small, is performed in order to improve air/fuel ratio control accuracy.
Also, as described, for example, in JP 2004-3513A corresponding to U.S. Pat. No. 5,672,817, in order to make an abnormal diagnosis of the air/fuel ratio sensor, an output change rate of the air/fuel ratio sensor in a predetermined period after the fuel injection cut-off in the engine is started is calculated as a responsivity detection value. Then, the output change rate of the air/fuel ratio sensor is compared with an abnormity determination value, to determine whether the air/fuel ratio sensor is abnormal (deterioration in responsivity).
Generally, although an abnormal electrical connection (e.g., a broken wire and a short circuit) in the air/fuel ratio sensor can be determined immediately after the engine is started (e.g., after an ignition switch is turned on), it cannot be determined, for example, whether the responsivity of the air/fuel ratio sensor is abnormal until the engine is in a predetermined operating condition (e.g., fuel injection cut-off state). In a system in which the air/fuel ratio F/B control, whereby the air/fuel ratio in each cylinder is equally controlled based on output of the air/fuel ratio sensor, is executed, the air/fuel ratio F/B control is started early on after the engine is started to reduce exhaust gas emission. Therefore, the air/fuel ratio F/B control is started at the time that a predetermined execution condition for the air/fuel ratio F/B control (e.g., the air/fuel ratio sensor is in an active state) is satisfied even before it is determined whether the responsivity of the air/fuel ratio sensor is abnormal. Then, if it is determined that the responsivity of the air/fuel ratio sensor is abnormal, the air/fuel ratio F/B control is forbidden at that point.
However, in the each-cylinder air/fuel ratio control, whereby the air/fuel ratio in each cylinder is controlled based on the output of the air/fuel ratio sensor, the air/fuel ratio in each cylinder is accurately estimated from the output of the air/fuel ratio sensor through the inverse operation, for example. Accordingly, the air/fuel ratio at the exhaust air merging portion varying with combustion in each cylinder needs to be detected in fast response in the air/fuel ratio sensor. As a result, higher-level responsivity of the air/fuel ratio sensor than general air/fuel ratio F/B control is required. When the each-cylinder air/fuel ratio control is started before it is determined whether the responsivity of the air/fuel ratio sensor is abnormal similar to the general air/fuel ratio F/B control, the each-cylinder air/fuel ratio control may be performed with the responsivity of the air/fuel ratio sensor deteriorated below the required level. In consequence, control accuracy in the each-cylinder air/fuel ratio control is deteriorated, and thereby the variation of the air/fuel ratios among the cylinders is large. Thus, a problem that exhaust gas emission is deteriorated is created.
SUMMARY OF THE INVENTION
The present invention addresses the above disadvantages. Thus, it is an objective of the present invention to provide an air/fuel ratio control system for an internal combustion engine, which prevents execution of each-cylinder air/fuel ratio control when an air/fuel ratio sensor is in an abnormal condition and thereby performs the each-cylinder air/fuel ratio control accurately.
To achieve the objective of the present invention, there is provided an air/fuel ratio control system for an internal combustion engine, which has a plurality of cylinders and an air/fuel ratio sensor. The air/fuel ratio sensor is disposed at an exhaust gas merging portion of an exhaust passage where exhaust gas discharged from the plurality of cylinders merges together. The air/fuel ratio control system includes an air/fuel ratio control means, an abnormality diagnosis means, and an enabling means. The air/fuel ratio control means is for individually controlling an air/fuel ratio of each of the plurality of cylinders based on an output of the air/fuel ratio sensor. The abnormality diagnosis means is for determining whether an abnormality of the air/fuel ratio sensor exists. The enabling means is for enabling the air/fuel ratio control means to execute the controlling of the air/fuel ratio of each of the plurality of cylinders when the abnormality diagnosis means determines that the abnormality of the air/fuel ratio sensor does not exist after starting of the engine.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention, together with additional objectives, features and advantages thereof, will be best understood from the following description, the appended claims and the accompanying drawings in which:
FIG. 1 is a schematic view illustrating a configuration of an overall engine control system according to an embodiment of the invention; and
FIG. 2 is a flowchart illustrating a processing flow in an air/fuel ratio control routine according to the embodiment.
DETAILED DESCRIPTION OF THE INVENTION
An embodiment of the invention is described below. Firstly, a schematic configuration of an overall engine control system is described with reference to FIG. 1 .
An air cleaner 13 is disposed in an uppermost stream portion of an intake pipe 12 of an inline four-cylinder engine 11 , which is an internal-combustion engine. An air flow meter 14 is disposed on a downstream side of the air cleaner 13 for detecting an amount of intake air. A throttle valve 15 and a throttle opening degree sensor 16 are disposed on a downstream side of the air flow meter 14 . An opening degree of the throttle valve 15 is regulated by a motor or the like. The throttle opening degree sensor 16 detects opening degree (throttle opening degree) of the throttle valve 15 .
A surge tank 17 is disposed on a downstream side of the throttle valve 15 . An intake pipe pressure sensor 18 is disposed on the surge tank 17 for detecting intake pipe pressure. An intake manifold 19 is formed from the surge tank 17 for introducing air into each cylinder of the engine 11 . A fuel injection valve 20 is attached near an intake port of the intake manifold 19 of each cylinder for injecting fuel. Fuel in a fuel tank 21 is delivered to a delivery pipe 23 by a fuel pump 22 when the engine 11 is in operation. Fuel is injected from the fuel injection valve 20 of each cylinder every injection timing for each cylinder. A fuel pressure sensor 24 is attached to the delivery pipe 23 for detecting pressure of fuel (fuel pressure).
Variable valve timing mechanisms 27 , 28 are disposed in the engine 11 for varying opening/closing timings of an intake valve 25 and an exhaust valve 26 , respectively. An intake cam angle sensor 31 and an exhaust cam angle sensor 32 , and a crank angle sensor 33 are disposed in the engine 11 . The intake cam angle sensor 31 and the exhaust cam angle sensor 32 output cam angle signals in synchronization with respective rotations of an intake cam shaft 29 and an exhaust cam shaft 30 . The crank angle sensor 33 outputs a pulse of a crank angle signal at every predetermined crank angle (e.g., 30° CA) in synchronization with rotation of a crankshaft of the engine 11 .
An air/fuel ratio sensor 37 is disposed at an exhaust air merging portion 36 where an exhaust manifold 35 for each cylinder of the engine 11 merges together. The air/fuel ratio sensor 37 detects an air/fuel ratio of exhaust gas. A catalyst 38 such as a three-way catalyst is disposed on a downstream side of the air/fuel ratio sensor 37 . The catalyst 38 purifies carbon monoxide (CO), hydrocarbon (HC), and nitrogen oxide (NOx) in exhaust gas.
Output of various sensors such as the air/fuel ratio sensor 37 is inputted into an engine control circuit (hereinafter referred to as ECU) 40 . The ECU 40 mainly includes a microcomputer, and controls a fuel injection quantity or ignition timing of the fuel injection valve 20 of each cylinder according to an operating condition of the engine 11 by executing various engine control programs stored in a read-only memory (storage medium) integrated into the ECU 40 .
The ECU 40 serves as an abnormality diagnosis means by executing various air/fuel ratio sensor abnormal diagnosis routines (not shown). The ECU 40 determines whether the air/fuel ratio sensor 37 (a sensor element and a heater) has an abnormal electrical connection (e.g., a broken wire and a short circuit), and whether the air/fuel ratio sensor 37 has an abnormal responsivity and active time (time it takes for the air/fuel ratio sensor 37 to go into an active state).
The abnormal diagnosis of responsivity of the air/fuel ratio sensor 37 may be made in the following manner. For example, when the air/fuel ratio sensor 37 is in an idle state after it has gone into the active state, lean control whereby an air/fuel ratio of exhaust gas is varied in a lean direction and rich control whereby the air/fuel ratio of exhaust gas is varied in a rich direction are alternately performed. Then, an output variation of the air/fuel ratio sensor 37 in a predetermined period during the lean control and an output variation of the air/fuel ratio sensor 37 in a predetermined period during the rich control are respectively compared with an abnormity determination value, to determine whether the responsivity of the air/fuel ratio sensor 37 is abnormal.
Alternatively, when fuel injection is cut off after the air/fuel ratio sensor 37 has gone into the active state, an output change rate of the air/fuel ratio sensor 37 in a predetermined period after the fuel injection cut-off is started is calculated. Then, the output change rate of the air/fuel ratio sensor 37 is compared with an abnormity determination value, to determine whether the responsivity of the air/fuel ratio sensor 37 is abnormal. In addition, a response time after the fuel injection cut-off is started until an output of the air/fuel ratio sensor 37 reaches a predetermined value may be measured. Then, the response time is compared with an abnormity determination value to determine whether the responsivity of the air/fuel ratio sensor 37 is abnormal.
Furthermore, the ECU 40 performs the following air/fuel ratio control by executing an air/fuel ratio control routine (to be described in greater detail hereinafter) shown in FIG. 2 .
When it is determined that the air/fuel ratio sensor 37 does not have the abnormal electrical connection, air/fuel ratio F/B (feedback) control is started at the time when a predetermined execution condition for the air/fuel ratio F/B control is satisfied, even before the abnormal diagnosis of the active time of the air/fuel ratio sensor 37 and the abnormal diagnosis of responsivity of the air/fuel ratio sensor 37 are ended (before it is determined whether the active time of the air/fuel ratio sensor 37 is abnormal and whether the responsivity of the air/fuel ratio sensor 37 is abnormal).
According to the air/fuel ratio F/B control, an air/fuel ratio F/B correction amount is calculated such that an air/fuel ratio detected in the air/fuel ratio sensor 37 when the engine 11 is in operation accords with a target air/fuel ratio. Then, by equally correcting a fuel injection quantity in each cylinder using the air/fuel ratio F/B correction amount, an air/fuel ratio of an air-fuel mixture supplied to each cylinder is equally corrected.
After this, the abnormal diagnosis of the active time of the air/fuel ratio sensor 37 and the abnormal diagnosis of responsivity of the air/fuel ratio sensor 37 are ended, and accordingly when it is determined that the air/fuel ratio sensor 37 is normal (the active time of the air/fuel ratio sensor 37 is not abnormal and the responsivity of the air/fuel ratio sensor 37 is not abnormal), air/fuel ratio F/B control for each cylinder is started at the time when a predetermined execution condition for the air/fuel ratio F/B control for each cylinder is satisfied.
According to the air/fuel ratio F/B control for each cylinder, an air/fuel ratio in each cylinder is estimated based on a detection value in the air/fuel ratio sensor 37 when the engine 11 is in operation using a model, in which the detection value in the air/fuel ratio sensor 37 (an air/fuel ratio of exhaust gas flowing at the exhaust air merging portion 36 ) is related with the air/fuel ratio in each cylinder. By calculating a difference between an estimated air/fuel ratio in each cylinder and a reference air/fuel ratio (an average value of estimated air/fuel ratios for all cylinders or a control target value), a variation of the air/fuel ratios among the cylinders is calculated. Then, the air/fuel ratio F/B correction amount is calculated for each cylinder such that the variation of the air/fuel ratios among the cylinders is small. Based on the calculated air/fuel ratio F/B correction amount, the fuel injection quantity in each cylinder is corrected for each cylinder. Accordingly, the variation of the air/fuel ratios among the cylinders is controlled to be small by correcting the air/fuel ratio of the air-fuel mixture supplied to each cylinder for each cylinder.
After the air/fuel ratio F/B control for each cylinder is started, both the air/fuel ratio F/B control and the air/fuel ratio F/B control for each cylinder may be executed. Alternatively, the air/fuel ratio F/B control is stopped so that only the air/fuel ratio F/B control for each cylinder may be executed.
The air/fuel ratio control in the present embodiment is performed in the ECU 40 according to the air/fuel ratio control routine shown in FIG. 2 . Processing in the routine is described below.
The air/fuel ratio control routine shown in FIG. 2 is executed at predetermined intervals while the ECU 40 is turned on, and serves as a second air/fuel ratio control means and an air/fuel ratio control means (first air/fuel ratio control means). When the routine is started, a basic fuel injection quantity is calculated at step 101 based on an operating condition of the engine 11 (e.g., a rotational speed of the engine 11 and a load).
After this, control proceeds to step 102 , where it is determined whether the air/fuel ratio sensor 37 has the abnormal electrical connection. If it is determined that the air/fuel ratio sensor 37 has the abnormal electrical connection, the air/fuel ratio F/B control is forbidden, and the air/fuel ratio F/B control for each cylinder is forbidden (steps 107 , 112 ).
If it is determined at step 102 that the air/fuel ratio sensor 37 does not have the abnormal electrical connection, control proceeds to step 103 , where it is determined whether the abnormal diagnosis of the active time of the air/fuel ratio sensor 37 and the abnormal diagnosis of responsivity of the air/fuel ratio sensor 37 are ended. If it is determined that these abnormal diagnoses are ended, control proceeds to step 104 , where it is determined whether the air/fuel ratio sensor 37 is normal (the active time of the air/fuel ratio sensor 37 is not abnormal and the responsivity of the air/fuel ratio sensor 37 is not abnormal).
If it is determined at step 103 that the abnormal diagnosis of the active time of the air/fuel ratio sensor 37 and the abnormal diagnosis of responsivity of the air/fuel ratio sensor 37 are not ended (it is not yet determined whether the active time of the air/fuel ratio sensor 37 is abnormal and whether the responsivity of the air/fuel ratio sensor 37 is abnormal), or if it is determined at step 104 that the air/fuel ratio sensor 37 is normal, control proceeds to step 105 . At step 105 , it is determined whether the execution condition for the air/fuel ratio F/B control is satisfied. If it is determined at step 105 that the execution condition for the air/fuel ratio F/B control is satisfied, control proceeds to step 106 , where the air/fuel ratio F/B control is executed.
If it is determined at step 103 that the abnormal diagnosis of the active time of the air/fuel ratio sensor 37 and the abnormal diagnosis of responsivity of the air/fuel ratio sensor 37 are ended, and if it is determined at step 104 that the air/fuel ratio sensor 37 is abnormal (at least one of the active time and responsivity of the air/fuel ratio sensor 37 is abnormal), the air/fuel ratio F/B control is forbidden, and the air/fuel ratio F/B control for each cylinder is forbidden (steps 107 , 112 ).
At step 108 , it is determined whether the abnormal diagnosis of the active time of the air/fuel ratio sensor 37 and the abnormal diagnosis of responsivity of the air/fuel ratio sensor 37 are ended. If it is determined that the abnormal diagnosis of the active time of the air/fuel ratio sensor 37 and the abnormal diagnosis of responsivity of the air/fuel ratio sensor 37 are ended, control proceeds to step 109 , where it is determined whether the air/fuel ratio sensor 37 is normal.
If it is determined at step 108 that the abnormal diagnosis of the active time of the air/fuel ratio sensor 37 and the abnormal diagnosis of responsivity of the air/fuel ratio sensor 37 are not ended, or if it is determined at step 109 that the air/fuel ratio sensor 37 is abnormal, control proceeds to step 112 , where the air/fuel ratio F/B control for each cylinder is forbidden.
If it is determined at step 108 that the abnormal diagnosis of the active time of the air/fuel ratio sensor 37 and the abnormal diagnosis of responsivity of the air/fuel ratio sensor 37 are ended, and if it is determined at step 109 that the air/fuel ratio sensor 37 is normal, control proceeds to step 110 , where it is determined whether the execution condition for the air/fuel ratio F/B control for each cylinder is satisfied. If it is determined that the execution condition for the air/fuel ratio F/B control for each cylinder is satisfied, control proceeds to step 111 , where the air/fuel ratio f/B control for each cylinder is executed. In this case, both the air/fuel ratio F/B control and the air/fuel ratio F/B control for each cylinder may be executed. Alternatively, the air/fuel ratio F/B control is stopped so that only the air/fuel ratio F/B control for each cylinder may be executed.
After this, control proceeds to step 113 , the basic fuel injection quantity for each cylinder is equally corrected using the air/fuel ratio F/B correction amount in the air/fuel ratio F/B control, and the basic fuel injection quantity for each cylinder is corrected using the air/fuel ratio F/B correction amount calculated for each cylinder in the air/fuel ratio F/B control for each cylinder, to calculate a final fuel injection quantity for each cylinder.
In the present embodiment, the air/fuel ratio F/B control for each cylinder is started at the time when the execution condition for the air/fuel ratio F/B control for each cylinder is satisfied after the determinations are made that the air/fuel ratio sensor 37 does not have the abnormal electrical connection, the abnormal diagnosis of the active time of the air/fuel ratio sensor 37 and the abnormal diagnosis of responsivity of the air/fuel ratio sensor 37 are ended, and that the air/fuel ratio sensor 37 is normal. A flow from step 109 (Yes) to step 111 via step 110 corresponds to an enabling means (first enabling means). Accordingly, execution of the air/fuel ratio F/B control for each cylinder when the air/fuel ratio sensor 37 is abnormal is prevented, and the air/fuel ratio F/B control for each cylinder is started after it is confirmed that the air/fuel ratio sensor 37 is normal. As a result, the air/fuel ratio F/B control for each cylinder is accurately executed.
Furthermore, when it is determined that the air/fuel ratio sensor 37 does not have the abnormal electrical connection, air/fuel ratio F/B control is started at the time when the execution condition for the air/fuel ratio F/B control is satisfied, even before the abnormal diagnosis of the active time of the air/fuel ratio sensor 37 and the abnormal diagnosis of responsivity of the air/fuel ratio sensor 37 are ended. A flow from step 103 (No) to step 106 via step 105 corresponds to a second enabling means. Accordingly, before the air/fuel ratio F/B control for each cylinder is started, exhaust gas emission is reduced by controlling the air/fuel ratio in each cylinder by the air/fuel ratio F/B control.
In addition, if it is determined that at least one of the active time and responsivity of the air/fuel ratio sensor 37 is abnormal, the air/fuel ratio F/B control and the air/fuel ratio F/B control for each cylinder are forbidden. However, even though the heater of the air/fuel ratio sensor 37 breaks down and thereby the active time of the air/fuel ratio sensor 37 becomes abnormal, for example, the air/fuel ratio F/B control and the air/fuel ratio F/B control for each cylinder are accurately executed after the air/fuel ratio sensor 37 is activated by exhaust heat as long as the responsivity of the air/fuel ratio sensor 37 is normal. Therefore, in such a case, the air/fuel ratio F/B control and the air/fuel ratio F/B control for each cylinder may be executed when it is determined that the responsivity of the activated air/fuel ratio sensor 37 is normal, regardless of whether the active time of the air/fuel ratio sensor 37 is abnormal.
Additional advantages and modifications will readily occur to those skilled in the art. The invention in its broader terms is therefore not limited to the specific details, representative apparatus, and illustrative examples shown and described.
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An air/fuel ratio control system is provided for an internal combustion engine having a plurality of cylinders and an air/fuel ratio sensor. The air/fuel ratio sensor is disposed at an exhaust gas merging portion of an exhaust passage where exhaust gas discharged from the plurality of cylinders merges together. The system includes an air/fuel ratio control device, an abnormality diagnosis device, and an enabling device. The air/fuel ratio control device individually controls an air/fuel ratio of each of the plurality of cylinders based on an output of the air/fuel ratio sensor. The abnormality diagnosis device determines whether abnormality of the air/fuel ratio sensor exists. The enabling device enables the air/fuel ratio control device to execute the controlling of the air/fuel ratio of each of the plurality of cylinders when the abnormality diagnosis device determines that the abnormality of the air/fuel ratio sensor does not exist after starting of the engine.
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BACKGROUND OF THE INVENTION
This invention relates to heating enclosures such as ovens. In particular it pertains to heating sources designed to produce temperature gradients across objects placed within such enclosures. In even greater particularity this invention is designed to produce such gradients by either radiation and/or convection.
Ovens have been used in the past to simulate weathering and ageing problems. Past ovens have been essentially convection ovens controlled by a single temperature location on the item.
Many items that are subject to field conditions have their useful life limited by the unevenness of heating and cooling which produce temperature gradients within the item. Among the many thermal sources effecting an object outdoors are sun, sky, clouds, wind, ground radiation, reflected solar radiation, and so forth. The net effect of these thermal forcing functions are temperature gradients throughout the object.
Furthermore, these gradients are rarely stable since the thermal sources are subject to constant change, the sun angle constantly changes, the wind fluctuates, and so forth. Thus to adequately field test items, simulation ovens have to be capable of providing different heat sources from different angles.
SUMMARY OF THE INVENTION
The present invention provides a way to induce variable temperature gradients in objects equal to those found in field conditions. The simulation oven is divided into as many heating sections as desired. Each section contains a temperature monitoring system which in turn regulates the relative temperature of each section as compared to the others.
The temperature monitoring system includes either a cam temperature control or other form of automatic temperature selection so that variable heating and cooling effects can be duplicated.
The use of at least one blower permits convection heating effects to be duplicated in addition to the radiation effects from the heating sections.
An object of this invention is to provide an oven with relative temperature control around an object within the oven. A further object is to duplicate the same relevant temperature gradients in the object that would occur in actual field conditons. Another object of the invention is to provide a simulation oven capable of both radiation and convection heating effects.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a drawing of the present invention with eight sections;
FIG. 2 is a drawing of an individual heating section including a temperature monitoring system and a heater-cooler system;
FIGS. 3A 3B and 3C are examples of other possible oven configurations; and
FIG. 4 is a partial table of a test scenario for the eight section oven shown in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows an oven enclosure 10 which is divided into individual heating sections 12. In this particular drawing eight (8) such sections are shown and are labelled T 1 through T 8 . Forced air convection through the oven can be created by any suitable device such as blower 14.
FIG. 2 shows an individual heating section 12 which is the thermal radiator from which the item under test derives its temperature. Heating section 12 can be shaped to allow as many or as few panels as desired in an oven. The encasing material can be any suitable material for the actual temperature range desired. Temperature in the heating section 12 is sensed by thermocouple 16. The output of thermocouple 16 is fed to temperature control 18 forming a temperature monitor.
A working fluid such as oil is driven by pump 20 through the heating section 12. Throttle valve 22 is regulated by temperature control 18. To produce gradient variations such as diurnal cycles, temperature control 18 can be a cam drive or other timed sequence control in addition to temperature regulator for a predetermined level. Of course the actual gradient variations are due to the combined effects of adjoining sections. The oil is pumped through heater-cooler 24 for temperature stability.
In an alternative embodiment, not shown, heater-cooler 24 can be regulated directly by temperature control 18.
FIG. 3A, 3B and 3C show other forms possible for different numbers of heating sections 12. FIG. 3A is triangular, FIG. 3B rectangular, and FIG. 3C emphasizes the wide range of configurations possible to cover the possible effects that can be studied.
FIG. 4 is an example of what has been discussed above. Referring back to FIG. 1, oven enclosure 10 with eight (8) heating sections 12 labelled T 1 through T 8 , a table 40 is provided with relative temperature conditions, HOT to COLD, for the heating sections 12.
Since it is the temperature gradient which is important vice the actual temperature, each situation from A to N is given relative to the heating sections 12 of the enclosure. In situation A, T 1 and T 8 are the hottest while T 4 and T 5 are the coldest. This is similar to the temperature an item sitting on the ground would experience shortly after sunrise, with T 1 and T 8 being the top and T 4 and T 5 the bottom. Situation B would then correspond to a slightly later time. This progression would continue until situation N which corresponds to a time just before sunrise.
Actual location of items in the oven can be varied by any of the well known methods of support. In general, suspension in the center of enclosure 10 is the easiest to control, however, additional variations in gradients can be achieved by varying position within enclosure 10.
One method of support is shown in FIG. 1. Brackets 30 support a two rail track 32 which runs the length of the oven. A tray 34 slides on track 32 and holds items to be heated. The length of brackets 30 can be varied, permitting an item to be placed anywhere in the oven.
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An oven with temperature-independent sections permits objects placed withint to experience the uneven heating and temperature gradient problems associated with real life conditions. The number of sections can vary depending on the gradients desired.
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FIELD OF THE INVENTION
The invention relates generally to drop detection in a medical liquid drop chamber and, more specifically, concerns a drop detection method and apparatus for use in an ambulatory or household environment.
BACKGROUND OF THE INVENTION
Medical drop chambers are used in various medical devices for metering and monitoring the flow rate of a fluid being administered to a patient. In a given drop chamber, each drop has a uniform volume of fluid. Therefore, by counting the number of drops falling in a given time period, the flow rate can be calculated easily. Such drop chambers are used, for example, in gravity-driven or pump-driven infusion systems.
Devices are known in the art for automatically sensing the drops in a chamber. These may, for example, be connected to circuits that can compute and display the flow rate or to alarms that indicate when the flow rate is too high or too low. These drop detectors are often optical sensors that react to a drop breaking optical communication between a light source and a sensor. In a controlled environment, such as a hospital, few outside conditions affect the optical sensors. The ambient light is fairly uniform throughout the environment and the drop chamber is relatively immobile and usually kept upright.
However, in either an ambulatory or household environment, several factors that may affect the optical sensors must be handled properly by the drop sensor to avoid false readings or alarms. These factors include widely varying ambient light conditions and excessive movement and tilting of the drop chamber, especially in ambulatory situations. False readings caused by these factors are a major reason for physicians' reluctance to use the ambulatory devices. It has therefore been a goal in the art that the drop detectors be capable of increased sensitivity to the drops, while being immune to the ambient light variation or movement and change in orientation of the chamber.
U.S. Pat. No. 4,720,636 to Benner, Jr. discloses a drop detection structure and detection circuitry that includes two photodetectors, one for sensing a decrease in light caused by a drop passing in front of it, and another for detecting an increase in light caused when a drop passes nearby and reflects additional light. A drop would pass nearby, for example, if the chamber were tilted. However, in the event of a very high tilt angle, coherent drops are not always formed. The liquid may enter the chamber and immediately spread onto the interior surface of the chamber, rather than falling to the bottom of the chamber
U.S. Pat. No. 4,718,896 to Arndt et al. discloses a drop detector that includes an array of light emitter/sensor pairs arranged to detect drops falling at angles of up to 30 degrees from the normal, vertical orientation. Tilt angles greater than 30 degrees are found in everyday use of the medical devices containing these detectors, rendering the detectors of this patent only partially effective.
It is thus an object of the invention to provide an improved drop detector for a liquid drop chamber which is capable of detecting drops in a variety of conditions and applications, without causing false readouts or alarms.
It is a further object of the invention to provide an improved drop detector that is immune to changes in ambient light.
It is a further object of the invention to provide an improved drop detector that can detect drops at tilt angles of up to 80 degrees from the normal, vertical positioning of the drop chamber.
It is a still further object of the invention that the improved drop detector be constructed of readily available components and be cost-efficient and relatively inexpensive to manufacture.
In accordance with the invention, a drop detector circuit is provided that includes a rectangular photodiode for detecting drops passing by its optical sensing path, and a DC signal blocking element, preferably a capacitor, is electrically interposed between the photodiode and amplifiers to block amplification of signals caused by ambient light. After amplification, the signals are passed through a low pass filter and a differentiator circuit to further block signals caused by undesirable factors.
The foregoing and other objects and advantages of this invention will be appreciated more fully upon reading the following detailed description of a preferred embodiment in conjunction with the appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The preferred embodiments of the invention are described herein with reference to the appended drawings, wherein:
FIG. 1 is a perspective view illustrating the manner in which an ambulatory patient could use a drop detection apparatus embodying the invention;
FIG. 2 is a functional block diagram of a drop detection apparatus embodying the invention;
FIG. 3 is a circuit schematic diagram showing a drop detection circuit according to invention;
FIG. 4 is a perspective view of a portion of the infusion device, showing a mounting receptacle for a drop detector assembly.
FIG. 5 is a perspective view of a drop chamber and drop detector assembly, showing the optical path coverage of the drop detector;
FIG. 6 is a waveform diagram representing typical input and output of a portion of a circuit as in FIG. 3;
FIG. 7 illustrates typical output waveforms of a circuit as in FIG. 3; and
FIG. 8 is a flowchart representing the drop discrimination process utilized in an apparatus embodying the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1, a medical infusion device worn by a patient is generally designated by the reference numeral 10. The infusion device includes a pump for the enteral administration of fluids. It is to be understood that while the preferred embodiment is shown for a medical infusion device, the invention can be similarly used with any device making use of a drop chamber.
As can be seen in FIG. 1, the device is capable of being attached to the belt of a patient 11 in use, while the patient 11 is completely ambulatory. The device is thus subjected to significant tilting, jarring, and accelerations that must be accurately compensated for in the internal mechanisms and circuits of the device 10.
The block diagram of FIG. 2 represents the electrical interaction of the major electronic and electromechanical components of the device 10 and shows signal connections. A keypad 12 allows operator input of device parameters, such as fluid flow rate, which are sent to a microprocessor 14. The microprocessor 14, in turn, provides information to the patient on a display 16 and controls a motor-driven pump 18. Drop detector 20, described in detail below, has a drop chamber which is interposed in the fluid flow path between a fluid supply (not shown) and the pump 18. A sensor monitoring the drop chamber detects the flow of fluid through the drop chamber and sends corresponding signals to drop detection electronics 21. The electronics 21 filter unwanted components in the signals from the detector 20 and pass the remainder to the microprocessor 14. The microprocessor 14 also returns control signals to the electronics 21, as described below.
In operation, the pump 18 feeds fluid for the patient at a rate set into the device by means of the keypad 12 and maintained by the microprocessor 14. All of the fluid that the pump 18 feeds to the patient 11 must pass through a drop chamber and no dripping occurs if the pump stops feeding fluid. Since the fluid can pass through the drop chamber only in the form of drops of fixed volume, the drop count is therefore an extremely accurate measure of the quantity of fluid supplied to the patient. Accurate drop detection therefore permits accurate metering of fluid flow and accurate control of the pump by the microprocessor 14.
Drop detector 20 includes a yoke 36 (see FIG. 4), which is mounted on device 10 and a drop chamber 22 (see FIG. 5), which is removably received within yoke 36, thus supporting the drop chamber 22 in the infusion device 10. Yoke 36 has a passageway 36a, which receives drop chamber 22 in an upright position. Two infrared light emitting diodes 38, preferably Seimens SFH 485-2 IRLEDs 38 are mounted side-by-side, so as to face into passageway 36a and drop chamber 22. Diodes 38 are preferably directed along lines intersecting the axis of the drop chamber 22 and form an angle of 20 degrees. They are also preferably offset from the top of the drop chamber 22 by one-third of its height.
FIG. 5 illustrates the removable drop chamber 22, connected in series with and interrupting a delivery tube 24 that runs from a fluid source (not shown) to a patient (11 in FIG. 1). Fluid enters the drop chamber 22 from the top portion 26 of the tube 24 as shown in FIG. 5 and exits the chamber 22 through the bottom portion 28. The drop chamber 22 is a sealed unit, except for the entrance and exit portions 26,28 of the tube 24, which penetrate the top and bottom of the chamber 22, respectively. The chamber 22 has a generally frusto-conical light-transmissive sidewall 30, with the smaller diameter at its bottom. The top portion 26 of the tube extends partially into the chamber 22, creating a drop formation area 32. Fluid accumulates at this area 32, until it forms a complete drop, which then falls to the bottom of the chamber 22.
When the chamber 22 is tilted, as often happens when the infusion device 10 is used in an ambulatory manner shown in FIG. 1, the drops will not fall to the bottom of the chamber 22, but will fall onto the side of the sloped sidewall 30 of the chamber 22. The tilt angle determines where the drop will hit the sidewall 30. At tilt angles above 70 degrees from vertical, the drops do not even fall, but tend to form a puddle on the sidewall 30 at position 34.
Mounted within the yoke 36 on the opposite side of the drop chamber 22 from the IRLEDs 38 is a rectangular photodiode 40, preferably a Vactec VTS 3092 photodiode, measuring 0.6 by 0.1 inches. It is mounted with its length parallel to the horizontal plane. The result of having two IRLEDs 38 opposite a single photodiode 40 is to create a triangular optical path 41 that can be broken by a drop passing through any portion of the horizontal cross section of the chamber 22 (as shown in FIG. 5). If a drop contacts the sidewall 30 of the chamber 22 and then slides down the wall 30, regardless of which side it travels on, the drop will pass through the optical path between the two IRLEDs 38 and the photodiode 40. Because the yoke 36 that holds the drop chamber 22 and the photodiode 40 is not sealed (as the drop chamber 22 and tube 24 are removable), ambient light is constantly detected by the photodiode 40, as well as light from the IRLEDs 38. This will be discussed in greater detail below.
With a high tilt angle of the drop chamber 22 and varying ambient light conditions, the changes in light actually caused by drops can be relatively small and difficult to detect with the photodiode 40. To compensate for these conditions, the photodiode 40 is preferably connected to a drop detection circuit 41, schematically illustrated in FIG. 3. The drop detection circuit filters out any unwanted portions of the signal from the photodiode 40 and amplifies the remainder of the signal, which is presumably caused by drop flow. The microprocessor 14 processes the output signal from the circuit 41 to determine if proper flow is occurring and control pump 18 and display 16 accordingly.
The drop detection circuit 41 shown in FIG. 3 includes a driver circuit 42 that powers the two IRLEDs 38 and preferably provides a constant current supply to the IRLEDs 38 to maintain constant optical output. Any variation in the optical output would add unwanted signals to the photodiode 40, so constant optical output is important. A detector circuit 44 receives electrical signals from the photodiode 40 and converts them to a signal indicating whether or not a drop is flowing.
The detector circuit 44 includes an operational amplifier 46, which amplifies the signal from the photodiode 40, after which it is applied to a lowpass filter 47. Filter 47 is a switched capacitor lowpass filter, preferably a National Semiconductor Corporation LMF60-100. It filters out any components of the signal above a nominal cut-off frequency that is determined by an input clock signal 48 from the microprocessor 14 of the infusion device 10.
The drop rate is directly proportional to the speed of the pump motor, which is constant and controlled by the microprocessor. The flow rate (i.e. number of drops per unit time) is varied by starting and stopping the pump motor for different time periods. The microprocessor thus produces a filter clock signal 48 to control the cut-off frequency of the filter 47, based on this known speed and drop rate. In the preferred embodiment, the filter clock is at 350 Hz, and filter 47 is designed to divide the filter clock by 100 to derive a cutoff frequency of 3.5 hz.
Connected in series between the photodiode 40 and lowpass filter 47 is a capacitor C1. This capacitor blocks the DC component of the voltage produced by the photodiode 40, which is typically developed in response to the ambient light level. Only variable signals, such as those caused by drops, are passed to the filter 47. Some changes in ambient light may also produce signals that will pass through the capacitor to the filter 47. However, the cutoff frequency determined by the microprocessor tends to limit the filter's passband narrowly to only signals produced by drops.
Blocking the DC component of the signal from photodiode 40 also allows the relatively weak signals from the photodiode to be amplified with a much higher gain than would normally be possible. If the gain of the operational amplifier 46 in filter 47 (approximately 70) were applied to the signals of conventional drop photodetectors, the amplifier 46 would saturate.
After amplification and filtering, the signals are passed through a differentiator circuit 49. The effect of this circuit 49 on the signals is illustrated in FIG. 6, wherein the upper waveform 6a represents typical output of the lowpass filter 47, which is input to the circuit 49, and lower waveform 6b represents the output of the circuit 49. As can be seen in FIG. 6, the circuit outputs a positive pulse in response to a negative slope of waveform 6a, preferably a slope greater than 0.3 volts per second, which has been found to be a reliable indicator of drop flow. The duration of the positive pulse equals the duration of the negative slope of waveform 6a.
The signals are then passed through logic invertor 50 and on to the microprocessor 14. For the microprocessor 14 to consider signals from the drop detection circuit 44 as representing a valid drop, there must be a rising edge, a falling edge and a subsequent minimal hold time, preferably 50 milliseconds. As seen in FIG. 7, at least three different types of inputs from the drop detection circuit 44 to the microprocessor 14 will result in a valid drop being detected.
In waveform 7a of FIG. 7, a long positive pulse is followed by the necessary hold time. This can occur when the drop chamber 22 is tilted at a high angle and a drop slides down the side of the drop chamber 22 past the photodiode more slowly than if it had fallen to the bottom of the chamber 22.
In waveform 7b of FIG. 7, a narrow positive pulse is followed by the requisite hold time. This represents a drop passing quickly past the photodiode, such as when the chamber 22 is in its proper vertical position.
In waveform 7c of FIG. 7, several narrow positive pulses are followed by the requisite hold time. This can represent any of various conditions, one of which is a drop bounding from excessive agitation of the infusion device 10.
FIG. 8 is a flowchart representing the process performed by microprocessor 14 to determine if a valid drop has occurred, based upon signals such as those illustrated in FIG. 7. Processor 14 performs this routine every 1.36 msec. on an interrupt basis. The microprocessor 14 makes use of three software flags to keep track of the transitions in the signal received from drop detection electronics 21. The flag DROP 13 ACK is raised upon the occurrence of a negative transition if not previously set. The second and third flags reflect past states of DROP -- DETECT the bit in microprocessor 14 memory that shows the status of drop detection electronics 21. Flag LAST -- DROP shows the status of DROP -- DETECT at the end of the previous iteration; flag THIS -- DROP shows that status of DROP -- DETECT at the end of the current iteration.
Referring to the flowchart of FIG. 8, the present routine is entered at block 110. Timer T -- HOLD is tested at block 112 to determine if 50 msec has passed since the last transition of DROP -- DETECT. If 50 msec has passed, the software tests LAST -- DROP in block 114 to get the status of DROP -- DETECT in the previous iteration, otherwise execution passes to block 120. If LAST -- DROP is low at block 114, DROP -- ACK is tested in block 118, otherwise execution passes to block 120. If DROP -- ACK is high at block 118, execution passes to block 120. This signifies that the drop has already been acknowledged and counted by the microprocessor 14, as will be seen below.
Flags THIS -- DROP and LAST -- DROP are compared at block 120. If they are not equal, a transition of DROP -- DETECT has occurred, and DROP -- ACK and T -- HOLD are reset at block 124, and execution passes to block 126; if they are equal, T -- HOLD is incremented, and execution continues at block 126.
At block 126, LAST -- DROP is set equal to THIS -- DROP and then THIS -- DROP is set equal to DROP -- DETECT. The routine then ends at block 128.
It should be appreciated that, in operation, it will require many passes through the process illustrated in FIG. 8 to detect the occurrence of a valid drop. For example, should waveform 7a of FIG. 7 be encountered, DROP -- ACK will be set to 1 at block 118 upon the occurrence of a negative-going transition followed by a 50 msec hold. Thereafter, blocks 112, 120, 122 and 126 are performed in repeated sequential passes until a positive transition is seen by block 120. In the next pass through the routine, blocks 112, 120, 122 or 124, and 126 are performed until T -- HOLD exceeds 50 msec. At this point, a valid drop is detected, and DROP -- ACK is set until the next transition of DROP -- DETECT.
When a waveform such as waveform 7b in FIG. 7 is encountered, it is handled in precisely the same manner as just described, except that the negative transition is detected much sooner than it was with respect to waveform 7a.
Should a signal such as waveform 7c be encountered, the initial positive- and negative-going transitions are handled in the same manner as they were from waveform 7a. Whenever a transition occurs in DROP -- DETECT as tested in block 120, T-HOLD and DROP -- ACK are reset in block 124. This action will continue until no transitions are detected within a 50 msec window. The state of LAST -- DROP is then tested in block 114; if low, DROP -- ACK is tested in block 116. If DROP -- ACK is low, a valid drop is counted by the microprocessor 14 and DROP -- ACK is set in block 118.
From the above description of the preferred embodiments, it can be seen that the effect of movement and tilting of the drop chamber 22 on the output of the detection electronics is eliminated, while the effect of changes in ambient light are minimized. As a result, a drop chamber 22 may be accurately monitored in an ambulatory and changing environment.
While the disclosed embodiment of the invention is fully capable of achieving the results desired, it is to be understood that this embodiment has been shown and described for purposes of illustration only and not for purposes of limitation. Moreover, those skilled in the art will appreciate that many additions, modifications and substitutions are possible without departing from the scope and spirit of the invention as defined by the accompanying claims.
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A drop detector circuit and method are provided for a drop detector of the type including a drop chamber and an electro-optical sensor. A photodiode detects drops passing through its optical sensing path, and a capacitor is connected between the photodiode and an amplifier to block the DC component of the diode signal. After amplification, the signal is passed through a low pass filter to further block signals caused by undesirable factors. The cutoff frequency of the low pass filter is controlled by a microprocessor that controls the pump that pumps liquid from the drop chamber.
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BACKGROUND OF THE INVENTION
The present invention relates to memory devices and methods of operation thereof, and more particularly, to buffer circuits and methods of operation thereof.
Synchronous dynamic random access memory (SDRAM) devices typically output memory cell data in synchronization with a clock signal in response to an external command, e.g., a read command, that is received in synchronization with an external clock signal. The number of clock cycles occurring between the external command, which is synchronized with the external clock signal, and the output of data, which is synchronized with the clock signal, is often referred to as a latency number.
It may be desirable for an SDRAM device to operate over a range of clock frequencies. The maximum clock frequency of an SDRAM may be constrained by limits on minimum delay, jitter and skew of output data produced by the SDRAM. To increase the operating frequency of the SDRAM, latency in operation of output buffers may be introduced to allow sense amplifiers and other circuitry within the SDRAM to stabilize. However, when an SDRAM that operates with a latency designed for a relatively high clock frequency is operated at a relatively low clock frequency, the latency may introduce unnecessary delay in access time.
FIGS. 1 and 2 illustrates a part of a conventional SDRAM 1 and exemplary operations thereof. Memory cell data is transmitted through an internal circuit 2 to a data line DIO, and on to an output pad DQ via a latch circuit LAT 1 and an output buffer 3 . The signal applied to the output buffer is delayed by a time Del 1 , which is predominantly introduced by the internal circuit 2 . A data hold signal hold is asserted to a logic high level, so that the memory cell data on the data line DIO is transmitted to the output buffer 3 .
Referring to FIG. 2, first, second and third time intervals are defined, each corresponding to approximately a half the clock cycle of a clock signal (CLK). The first, second and third intervals denote latency intervals, i.e., latency may be determined according to which among the first, second and third intervals the delay time Del 1 of FIG. 1 falls, with the first interval representing a latency of 1, the second interval representing a latency of 1.5, and the third interval representing a latency of 2. For example, as shown in FIG. 2, memory cell data having a delay time Del 1 falling within the third interval following the rising edge of the clock signal CLK that coincides with a data read command READ is transmitted to the data line DIO with a latency of 2. Accordingly, valid data of the memory cell data is output to the output pad DQ two clock cycles after the rising edge of the clock signal CLK that coincides with the data read command READ.
Still referring to FIG. 2, if the SDRAM 1 that operates with a latency of 2 for a relatively high frequency clock CLK as described above is used with a lower clock frequency CLK_ 1 , however, memory cell data which has passed through the internal circuit block 2 arrives at the data line DIO delayed by the delay time Del 1 after the rising edge of a clock signal CLK_ 1 that coincides with the data read command READ. Under these conditions, a time loss T LOSS with respect to the operation with the higher frequency clock signal CLK may be incurred. This may degrade operating performance.
SUMMARY OF THE INVENTION
According to embodiments of the present invention, a latency determination circuit includes a latency interval definition circuit that receives a clock signal and that generates at least one latency interval defining signal that defines at least one latency interval. A latency indication circuit receives the at least one latency interval defining signal and a test signal that is delayed a predetermined delay with respect to the clock signal and generates a latency indicating signal therefrom. The latency determination circuit may further include a test signal generation circuit configured to receive the clock signal and operative to produce the test signal therefrom.
In some embodiments of the present invention, the test signal generation circuit is configured to receive a control signal and to generate the test signal therefrom such that the test signal is delayed the predetermined delay with respect to a next occurring feature, e.g., edge, of the clock signal following assertion of the control signal. The test signal generation circuit may include a synchronization circuit that receives the control signal and the clock signal and that generates a synchronized control signal from the control signal, and a delay circuit that produces the test signal from the synchronized control signal.
In other embodiments of the present invention, the latency interval definition circuit is operative to successively generate respective edges in respective ones of a plurality of latency interval defining signals responsive to successive edges of the clock signal. The latency interval definition circuit may be responsive to a control signal and operative to successively generate the respective edges in the respective ones of the plurality of latency interval defining signals following transition of a control signal to a predetermined logic level. In other embodiments of the present invention, the latency indication circuit is operative to assert a first latency indicating signal responsive to the test signal transitioning to a predetermined logic state before a first edge of the successively generated edges and to assert a second latency indicating signal responsive to the test signal transitioning to the predetermined logic state between the first edge and an immediately succeeding second edge of the successively generated edges.
According to still other embodiments of the present invention, a variable delay buffer circuit, as might be used in a synchronous DRAM, includes a buffer circuit that receives an input signal and generates an output signal therefrom responsive to an output enable signal. An output enable signal generation circuit receives a latency indicating signal and generates the output enable signal responsive to the command signal with a delay that is based on the latency indicating signal. A latency interval definition circuit receives a clock signal and generates at least one latency interval defining signal that defines at least one latency interval. A latency indication circuit receives the at least one latency interval defining signal and a test signal that is delayed a predetermined delay with respect to the clock signal and generates the latency indicating signal therefrom. The predetermined delay may approximate, for example, a sum of a delay associated with the buffer circuit and a delay associated with a circuit that provides the input signal to the buffer circuit.
Related methods are also discussed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic block diagram illustrating a data output circuit in a conventional SDRAM.
FIG. 2 is a timing diagram illustrating exemplary operations of the circuit of FIG. 1 .
FIG. 3 is a schematic diagram illustrating a latency determination circuit according to embodiments of the present invention.
FIG. 4 is a schematic diagram illustrating a latency interval definition circuit according to embodiments of the present invention.
FIG. 5 is a schematic diagram illustrating a double edge triggered (DET) flip-flop according to embodiments of the present invention.
FIG. 6 is a timing diagram graphically illustrating operations of a latency determination circuit according to embodiments of the present invention.
FIG. 7 is a schematic diagram illustrating a latency indication circuit according to embodiments of the present invention.
FIG. 8 is a schematic diagram illustrating a variable latency buffer circuit according to embodiments of the present invention.
FIG. 9 is a timing diagram graphically illustrating exemplary operations of the variable latency buffer circuit of FIG. 8 according to embodiments of the present invention.
FIG. 10 is a schematic diagram illustrating an output enable signal generation circuit according to embodiments of the present invention.
DETAILED DESCRIPTION
The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout.
FIG. 3 illustrates a latency determination circuit 4 according to embodiments of the present invention. The latency determination circuit 4 , which may be used, for example, in a memory device such as an SDRAM, includes a synchronization circuit 5 , a delay circuit 10 , a latency interval definition circuit 20 and a latency indication circuit 30 . The synchronization circuit 5 receives a control signal STRT and generates a synchronized control signal iSTRT therefrom that is synchronized to a clock signal CLK. The control signal STRT may be provided, for example, from an external source or by the logical operation of an internal mode register that stores system application information within an SDRAM or other memory device.
As shown, the synchronization circuit 5 includes a D flip-flop 6 that receives the control signal STRT at a data input terminal D, such that the synchronized control signal iSTRT is produced at an output terminal Q of the flip-flop 6 in response to the clock signal CLK. An inverter 7 has its input terminal connected to the input terminal D of the flip-flop 6 and its output terminal connected to the gate terminal of a transistor 8 . The control signal iSTRT is applied to the drain terminal of the transistor 8 , and a ground voltage is applied to the source terminal of the transistor 8 . When the control signal STRT is at a logic low level, the transistor 8 is turned on, forcing the synchronized control signal iSTRT to a logic low level. After the control signal STRT is asserted to a logic high level, the synchronized control signal iSTRT subsequently goes high in response to a positive-going edge of the clock signal CLK.
The delay circuit 10 receives the synchronized control signal iSTRT and generates a test signal Del 2 that that is delayed a predetermined delay time. As shown, the delay circuit 10 includes a first delay circuit 11 that receives the synchronized control signal iSTRT and produces an output signal Del 1 therefrom, and a second delay circuit 12 that receives the output signal Del 1 and produces the test signal Del 2 therefrom. The delay introduced by the first delay circuit 12 may be, for example, a time corresponding to the delay introduced by an internal circuit such as the internal circuit 2 of FIG. 1, while the delay introduced by the second delay circuit 12 may be, for example, a delay associated with other operations, such as delay introduced by an output buffer.
Still referring to FIG. 3, the latency interval definition circuit 20 receives the control signal STRT and the clock signal CLK and generates latency interval defining signals L 1 , L 2 , L 3 , . . . , Ln. FIG. 4 illustrates a latency interval determination circuit 20 ′ according to embodiments of the present invention. The latency interval definition circuit 20 ′ includes a plurality of serially connected double edge triggered (DET) flip-flops 21 , 22 , . . . , 25 that are clocked by the clock signal CLK. A first flip-flop 21 receives the control signal STRT at its input terminal D and produces a first latency interval defining signal L 0 therefrom at its output terminal Q responsive to the clock signal CLK. A second flip-flop 22 receives the first latency interval defining signal L 0 at its input terminal D, and produces a second latency interval defining signal L 1 at its output terminal Q responsive to the clock signal CLK. Similarly, third, fourth and fifth flip-flops 23 , 24 , 25 produce third, fourth and fifth latency interval determining signals L 2 , L 3 , L 4 . Although FIG. 4 illustrates only five-latency interval determining signals L 0 , L 1 , L 2 , L 3 , L 4 , it will be appreciated that other numbers of latency interval defining signals may be produced.
An example of a DET flip-flop circuit 521 that may be used with the present invention is shown in FIG. 5 . Such a DET flip-flop circuit is described in IEEE JOURNAL OF SOLID-STATE CIRCUITS, Vol. 26, No. 8, August 1991. In the DET flip-flop circuit 521 , an input terminal D and a clock signal terminal CLK are connected to a positive edge triggered circuit PET and to a negative edge triggered circuit NET. The positive edge triggered circuit PET includes transistors 41 , 42 , . . . , 49 . The negative edge triggered circuit includes transistors 51 , 52 , . . . 59 .
The positive edge triggered circuit PET latches the logic level at the input terminal D on a positive edge of a clock signal at the clock terminal CLK to generate an output signal at an output terminal Q. In particular, when the logic level at the input terminal D is a logic high, the transistor 43 is turned on, driving a node A to a logic low level. This turns off the transistor 45 . The transistor 44 is turned on in response to a logic low level in the clock signal CLK, driving the node M to a logic high level. The transistor 44 is turned off in response to a subsequent high level for the clock signal CLK, but the node M remains at the high level state. The transistor 49 is turned on by the high level of the node M, and the logic levels of the output signals Q′ and Q become a logic low level and a logic high level, respectively, in response to the logic high level for the clock signal CLK.
When the logic level of the input terminal D is a logic low, the transistor 41 is turned on, and the transistor 43 is turned off. The transistor 42 is turned on in response to a logic low level for the clock signal CLK, so that the node A is driven to a logic high level. The transistor 42 is turned off by next high level clock of the signal CLK, but the node A remains at the logic high level. The transistor 45 is turned on by the logic high level node A. The transistor 46 is turned on in response to the high level of the clock signal CLK, so that the node M is driving to a logic low level. The transistor 47 is turned on by the low level of the node M, so that the levels of the output signals Q′ and Q are a logic high level and a logic low level, respectively. The negative edge triggered circuit NET latches the logic level at the input terminal D at a negative edge of the clock signal CLK. The operation of the negative edge triggered circuit NET is similar to that of the positive edge triggered circuit PET, and will not be described in further detail.
FIG. 6 illustrates exemplary operations of the latency determination circuit 4 of FIG. 3 . The logic level of the control signal STRT received by the latency interval definition circuit 20 is latched at an edge of the clock signal CLK. When the control signal STRT transitions to a high level and remains high during a subsequent positive edge of the clock signal CLK, a positive edge is generated in the first latency interval defining signal L 0 . In response to a subsequent negative edge of the clock signal CLK, an edge is then generated in the second latency interval defining signal L 2 . Edges are successively generated in respective ones of the third, fourth and fifth latency interval defining signals L 2 , L 3 , L 4 upon successive edges of the clock signal CLK.
Still referring to FIG. 6, the synchronized control signal iSTRT transitions to a logic high level responsive to a high level for the control signal STRT and a positive edge of the clock signal CLK. As shown, the output signal Del 1 is driven high after a delay d 0 , and the test signal Del 2 is driven high after a delay d 1 +d 2 +d 3 , which may correspond a sum of a delay time d 1 of an output buffer, a setup time d 2 of the output buffer, and a delay time d 3 of a latch included in the latency interval definition circuit 20 of FIG. 3 . As shown, the test signal Del 2 is driven high during a latency interval defined by the fourth and fifth latency interval defining signals L 3 , L 4 . This causes a latency-indicating signal CL 2 (corresponding to a latency of 2) to be asserted by the latency indication circuit 30 .
FIG. 7 illustrates a latency indication circuit 30 ′ according to embodiments of the present invention. The latency indication circuit 30 ′ receives the latency interval defining signals L 1 , L 2 , L 3 and L 4 and the test signal Del 2 , and generates the latency indication signals CL 1 , CL 1 . 5 , CL 2 , CL 2 . 5 therefrom. In particular, the latency indicating circuit 30 ′ includes D flip-flops 31 , 32 , 33 , 34 that receive respective ones of the latency interval defining signals L 1 , L 2 , L 3 , L 4 . Respective transistors 35 , 36 , 37 and 38 are connected to the output nodes 61 , 62 , 63 , 64 of the respective D-flip-flops 31 , 32 , 33 , 34 . An inverter 73 receives the control signal STRT and drives the gate terminals of the transistors 35 , 36 , 37 , 38 . The output nodes 61 , 62 , 63 , 64 of the D-flip-flops 31 , 32 , 33 , 34 are connected to respective 2-input NOR gates 69 , 70 , 71 , 72 via respective inverters 65 , 66 , 67 , 68 . The output nodes 62 , 63 , 64 of the D-flip-flops 32 , 33 , 34 are also connected respective ones of the 2-input NOR gates 69 , 70 , 71 , while the 2 -input NOR gate 72 is connected to a signal ground. The 2-input NOR gates 69 , 70 , 71 , 72 produce respective ones of the latency indicating signals CL 1 , CL 1 . 5 , CL 2 , CL 2 . 5 .
Referring to FIG. 7 in conjunction with FIG. 6, when the control signal STRT is at a logic low level, the transistors 35 , 36 , 37 , 38 are turned on, so that the output nodes 61 , 62 , 63 , 64 of the D-flip-flops 31 , 32 , 33 , 34 are driven to logic low levels, initializing the latency indicating signals CL 1 , CL 1 . 5 , CL 2 , CL 2 . 5 to logic low levels. Thereafter, when the logic level of the test signal Del 2 transitions to a logic high level, the D-flip-flops 31 , 32 , 33 , 34 latch the logic levels of respective ones of the latency interval defining signals L 1 , L 2 , L 3 , L 4 . As shown in FIG. 6, when the test signal Del 2 goes high, the logic levels of the latency interval defining signals L 1 , L 2 , L 3 are high, such that the output nodes 61 , 62 , 63 of the D-flip-flops 31 , 32 , 33 are latched to logic high levels. However, the logic level of the latency interval defining signal L 4 is low, causing the output node 64 of the D-flip-flop 64 to remain at a logic low level. This causes the third latency indicating signal CL 2 to be a logic high, while the first, second and fourth latency indicating signals CL 1 , CL 1 . 5 , CL 2 . 5 are at a logic low.
FIG. 8 illustrates a variable latency buffer circuit 90 according to embodiments of the present invention. The variable latency buffer circuit 90 includes a buffer circuit 91 that receives an input signal DIO and that generates an output signal DQ therefrom responsive to an output enable signal TRST. As shown, the buffer circuit 91 includes an inverter 92 that receives the input signal DIO, a NAND gate 93 that receives the input signal DIO and the output enable signal TRST, and an AND gate 94 that receives an output signal produced by the inverter 92 and the output enable signal TRST. The NAND gate 93 produces an output signal that is applied to a gate terminal of a transistor 95 , and the AND gate 94 produces an output signal that is applied to a gate terminal of a transistor 96 . The variable latency buffer circuit 90 also includes an output enable signal generation circuit 80 that generates the output enable signal TRST responsive to a clock signal CLK and a command signal CMD, with a timing that is controlled responsive to a plurality of latency indicating signals CL 1 , CL 1 . 5 , CL 2 , CL 2 . 5 generated by a latency determination circuit 4 , such as the latency determination circuit 4 of FIG. 3 .
FIG. 10 illustrates an output enable signal generation circuit 80 ′ according to embodiments of the present invention. The output enable signal generation circuit 80 ′ includes a plurality of serially connected dual edge triggered (DET) flip-flops 81 , 82 , . . . , 85 that are clocked by a clock signal CLK. A first flip-flop 81 receives a command signal CMD, and the serially connected flip-flops 81 , 82 , . . . , 85 generate respective output signals L 0 ′, L 1 ′, . . . , L 4 ′ responsive to the command signal CMD and the clock signal CLK. The output signals L 1 ′, L 2 ′, . . . , L 4 ′ are passed to respective switches 86 , 87 , 88 , 89 that are opened and closed responsive to latency indicating signals CL 1 , CL 1 . 5 , CL 2 , CL 2 . 5 to generate an output enable signal TRST with appropriate delay. For example, as shown, assertion of the latency indication signal CL 2 closes the switch 88 , causing the output enable signal TRST to be generated from the output signal L 3 ′ produced by the flip-flop 84 .
Referring now to the timing diagram of FIG. 9 in conjunction with FIG. 8, assertion of the output enable signal TRST allows data D 0 , D 1 , . . . , D 3 on the data line DIO to be transferred to the output terminal DQ. The output enable signal TRST is activated in response to a command CMD, with a delay d that is controlled by the latency indicating signals CL 1 , CL 1 . 5 , CL 2 , CL, 2 . 5 , which, as described above, are generated responsive to the frequency of the clock signal CLK. Accordingly, in embodiments of the present invention, latency may be adjusted responsive to clock frequency such that unnecessary delay at lower clock frequencies may be reduced.
In the drawings and specification, there have been disclosed typical preferred embodiments of the invention and, although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being set forth in the following claims.
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A variable delay buffer circuit, as might be used in a synchronous DRAM, includes a buffer circuit that receives an input signal and generates an output signal therefrom responsive to an output enable signal. An output enable signal generation circuit receives a latency indicating signal and generates the output enable signal responsive to a command signal with a delay that is based on the latency indicating signal. A latency interval definition circuit receives a clock signal and generates at least one latency interval defining signal that defines at least one latency interval. A latency indication circuit receives the at least one latency interval defining signal and a test signal that is delayed a predetermined delay with respect to the clock signal and generates the latency indicating signal therefrom. Related methods are also discussed.
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This is a continuation of application Ser. No. 08/237,076, filed on May 3, 1994, now U.S. Pat. No. 5,493,970.
FIELD OF THE INVENTION
The present invention relates generally to a method and apparatus for regulating the distribution of ink in a printing machine. More specifically, the present invention is directed towards an undershot inking unit and an associated method for regulating the ink distribution in a variable speed printing machine.
BACKGROUND OF THE INVENTION
In sheet-fed offset printing machines, the supply of printing ink is generally accomplished by means of an undershot inking unit. Undershot inking units comprise an ink fountain and associated metering devices, such as ink-metering elements or undivided ink doctor blades; an ink fountain roller; an intermittent ductor roller, and one or more inking rollers. By means of the metering elements, the ink layer thickness on the ink fountain roller is adjusted in accordance with the requirements of the printing machine. The intermittent ductor roller, as a result of periodic contact with the ink fountain roller, removes a strip of ink of a certain length from the ink fountain roller and transfers the ink onto the first inking roller. This first inking roller is usually designed as an axially reciprocating distributor roller for contacting further inking rollers through traversing movements of adjustable stroke and/or frequency. By means of these further inking rollers, the ink quantity fed by the ductor roller splits and correspondingly leads to an inking of the printing regions on the printing form or plate located on the plate cylinder.
Typically, the intermittent ductor roller is rotatably journalled in a pair of pivotable bearing levers. Each of the pivotable bearing levers is coupled with a cam follower roller drive, by which an intermittent or pendulating movement of the ductor roller between the ink fountain roller and the distributor roller is achieved. The cam disk of the intermittent ductor roller drive usually is driven directly from the printing mechanism, with a corresponding reduction in rotational speed (such as a 3:1 reduction). Thus, a ductor stroke, or pendulating movement of the ductor roller between the ink fountain roller and the inking roller, occurs with respect to a corresponding number of revolutions of the plate cylinder (such as 3).
The ink fountain roller can have a mechanical drive derived from the printing mechanism, or it may have a controllable electrical drive. In conventional undershot inking units, the rotational speed of the ink fountain roller is dependent upon the printing speed of the printing machine, and may vary continuously or incrementally with the printing speed. Such conventional ink fountain rollers are described in U.S. Pat. No. 4,007,683 and in EP 518,234 A1 and EP 264,838 B1.
The amount of ink fed to the inking roller in such conventional devices is controlled by regulating the rotational contact angle, or contact time, of the ductor roller on the ink fountain roller so as to regulate the ductor-strip width. Regulation of the ductor-strip width is accomplished either by adjusting the design of the cam disk for the ductor roller drive by means of adjustable control planes, or by modulating the speed of the ink fountain roller. Where the ductor-strip width is regulated by modulation of the ink fountain roller, the rotational speed of the ink fountain roller is determined by the speed of the printing machine and by independent adjustment. Thus, the characteristic curve by which the rotational speed of the ink fountain roller is coupled with the printing machine speed is varied. Where the ductor-strip width is adjusted by means of a variable cam disk, the coupling of the rotational speed of the ink fountain roller with the speed of the printing machine is obtained by an invariable characteristic curve. EP 264,838 B1 discloses the regulation of the ductor-strip width by regulating the ink fountain roller speed by means of a switching drive, which controls the step width of the ink fountain roller. The drive of the ductor roller and the corresponding switching drive for the ink fountain roller operate in phase in such manner that the rotation of the ink fountain roller occurs in the phase of contact with the ductor roller.
The distribution of ink is typically determined during setup of the printing machine. This generally occurs at a relatively low printing speed, such as 5,000 sheets per hour with a conventional offset printing machine. During actual production, however, the production speeds of such machines can be greater than 15,000 sheets per hour. When the undershot inking unit has been calibrated at a lower printing speed, it is invariably observed that the ink densities detected on a print check strip and in the image decrease as a whole. The ink density changes from low to high production speed are typically quite significant in the prior art machines. This effect is know as ink fall-off.
Conventional inking mechanisms have thus far been unable to resolve the problem of ink fall-off. The present invention seeks to provide an apparatus and associated method for overcoming the problems associated with conventional inking mechanisms in this regard.
BRIEF SUMMARY OF THE INVENTION
The present invention provides an undershot inking unit in which the rotational contact angle, or contact time, of the distributor roller on the ink fountain roller is varied according to the printing unit speed. The speed of the ink fountain roller is controlled independently of the printing speed, and may be maintained at a constant speed or driven stepwise at a constant stepping frequency and rotational speed for all printing unit speeds. In contrast to conventional inking mechanisms, the ductor-strip width remains constant for all printing speeds, and the feed of ink is regulated by allowing the ductor to be thrown more or less frequently onto the ink fountain roller at an adjustable rotational contact angle. This is accomplished by a pair of coaxial cams that are rotatably adjustable with respect to each other. Each cam has a predominant circumferential contour and a subordinate circumferential contour. By adjusting the relative rotational position of the cams, the rotational contact angle of the ductor roller on the ink foundation roller is varied according to the printing unit speed. The present invention thus alleviates the problem of ink fall-off in a manner heretofore unknown to the art.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of an undershot inking unit for a printing machine according to the present invention.
FIG. 2 is a characteristic curve for the drive of the ink fountain roller as a function of the printing speed.
FIG. 3 is a characteristic curve of the rotational contact angle of the ductor roller on the ink fountain roller as a function of the printing speed.
FIG. 4 is schematic illustration of the cam discs for the ductor roller drive according to the present invention.
FIG. 5 is a side profile view of a first cam of the ductor roller drive in an undershot inking unit according to the present invention.
FIG. 6 is a side profile view of a second cam of the ductor roller drive in an undershot inking unit according to the present invention.
FIG. 7 is a side elevation view of the coaxially mounted first and second cams in the ductor roller drive of the undershot inking unit according to the present invention.
FIG. 8 is a front elevation view of the ductor roller drive illustrated in FIG. 7.
FIG. 9 is a graphical representation of the change in rotational contact angle as it corresponds to the change in printing machine speed.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
According to the invention, the rotational contact angle of the ductor roller for removing an amount of ink from the ink fountain roller is chosen as a function of the printing speed. The dependence of the rotational contact angle on the printing speed may be represented linearly. Alternately, the dependence of the contact angle on the printing speed can be nonlinear in whole or in part. The characteristic curve can be determined empirically or theoretically.
The present invention further utilizes the knowledge that inks used in offset printing technology have pronounced non-Newtonian properties. Because the ink fountain roller is driven at a speed independent from the printing speed, the inks possess the same properties regardless of the printing speed.
Preferably, the speed of the ink fountain roller is maintained independently from the printing speed. However, the present invention also contemplates an inking unit in which the rotational speed of the ink fountain roller can be adjusted by the operator to a higher or lower speed, thus increasing or decreasing the ductor strip width.
In a preferred embodiment of the present invention, the change of the rotational contact angle of the ductor roller on the ink fountain roller is initiated by a certain number of machine revolutions (angle degrees) before the change of the printing speed. For example, if the operator desires to increase the printing speed from 5,000 to 15,000 sheets per hour, then the contact angle is first adjusted to the proper value provided for at 15,000 sheets per hour. After a certain number of machine revolutions, the speed of the printing machine is then increased to 15,000 sheets per hour. A similar procedure takes place when the operator desires to decrease the speed of the printing machine.
The number of revolutions by which the initiation of the speed change is offset by the change of the contact angle is ascertained by a number of factors, for example, the ductor rhythm, the geometry of the inking mechanism, and the geometry of the printing unit. This number is determined by counting the number of revolutions of the printing mechanism must occur until a layer thickness change of ink on the first distributor roller brings about a corresponding layer thickness change on one of the ink applicator rollers. As a reference, the ink applicator roller can be chosen which causes the perceptually greatest ink application to the printing plate or the ink applicator roller which conditions the shortest and thus also the least number of machine degrees that bring about an inking change from the distributor roller to the ink applicator roller. The number of revolutions that the printing machine must go through until an inking change initiated on the printing plate results in a change on the printing sheet or printing zone also must be taken into account. Preferably, the change of the contact angle following an input command to change the printing speed is initiated at the same angular position of the ductor gear, for example, when the ductor roller bears on the distributor roller.
Any suitable drive for altering the rotational contact angle of the ductor roller on the ink fountain roller may be used in accordance with the present invention. In a preferred embodiment, the ductor roller is driven by means of a pair of adjustable cam disks driven by the printing mechanism. The drive comprises two adjacent cam disks with common axes of rotation, which are driven in common from the printing or inking mechanism. On the outer contours of these cam disks runs a cam follower roller, biased under spring force, which is coupled to a lever arm of the ductor roller. The camming of the cam follower roller running along the combined contour of the pair of cams generates the intermittent pendulating movement of the ductor roller.
With reference to FIG. 1, an ink fountain roller 1 cooperates with an ink fountain 2 and conventional ink metering elements (not shown) mounted on the underside of an ink fountain 2. Preferably, the ink fountain roller 1 is directly coupled with a motor M with the interposition of a suitable reduction gear (not shown). The motor M is controlled by an electronic drive shown schematically at A. FIG. 2 illustrates one graphic representation of the motor speed (ordinate) as a function of the printing speed (abscissa). Because the ink fountain roller 1 has a constant value or stepping frequency independent of the printing speed, the electronic drive A is not coupled to the control of the remaining printing machine except for purposes of increasing or decreasing the rotational speed setting. Increased and decreased speeds are illustrated in FIG. 2 as broken lines, and yield larger or smaller ductor strip widths, respectively.
With further reference to FIG. 1, the ink fountain roller 1 is followed in the direction of ink transport by a ductor roller 3 which is journalled at each end on pivotable bearing arms 5, which are carried in a side frame F of the printing machine or inking unit. Attached to the second end of bearing arm 5 is mounted a cam follower roller 6 which is biased under the force of a spring 7 onto the outer contours of two adjacently mounted cam disks 8, 9.
In the illustrated embodiment, the ductor roller 3 is followed by an inking roller or first distributor roller 4, which is in contact with further inking rollers generally depicted in FIG. 1. By means of the ductor roller cam drive, the ductor roller 3 oscillates with an intermittent movement between the ink fountain roller 1 and the distributor roller 4. The distributor roller 4 may be a non-traversing inking roller, or, via an adjustable axial traversing drive, as a distributor roller adjustable in the amount of the axial traversing stroke.
With reference to FIGS. 1 and 4, the two cams 8, 9 are driven with the interposition of an adjusting gear 10 by the printing unit or by the inking unit, there being provided also a suitable reducing gear (not shown). FIG. 1 is a schematic representation only, and the cam disks may actually be constructed such that cam disk 8, the main cam, is driven directly by the printing or inking unit and the cam disk 9, the adjusting cam, is arranged rotatably with respect to cam disk 8 and parallel thereto.
As illustrated schematically in FIG. 4, both cam disks 8 and 9 have a predominant circumferential contour U and a subordinate circumferential contour V connected via two S-form transitions. The predominate circumferential contour U has a large radius of curvature relative to the subordinate circumferential contour V, which has a small radius of curvature. By superimposing the cam disks 8 and 9 according to FIGS. 1 and 4, an adjustable control cam results. The cam follower roller 6 runs on the circumferential contour U of the cam disk 8 and/or cam disk 9 and in the remaining region depending on the relative position of the cam disks.
In the schematic representation of FIG. 1, the common subordinate circumferential contour V of the cam disks 8, 9 is effective to the throw of the ductor roller 3 onto the ink fountain roller 1. The adjustability of the cam disks 8, 9 relative to one another with simultaneous drive of the printing unit or inking unit over the adjusting gear 10 is designated in each case with an arrow C. The direction of rotation of the control cam is also represented with an arrow R in FIG. 1.
A preferred structure for cam disks 8 and 9 is illustrated in FIGS. 5-8. Cam disk 9 preferably has in angular range WU a predominant circumferential contour U p , an intermediate circumferential contour U i , and a subordinate circumferential contour V. The predominant circumferential contour U p is arranged to control the contact angle of the ductor roller 3 on the distributor roller 4. In other words, the cam disk 8 preferably has two radii and the cam disk 9 has three radii. When the cam follower roller 6 runs on the middle radius of the control cam formed by cams 8, 9, then the ductor roller 3 is located in an intermediate position between but out of engagement with the ink fountain roller 1 and the distributor roller 3.
Because only cam disk 9 has a predominate circumferential contour U p which controls the contact of ductor roller 3 with the distributor roller 4, the control cam formed by cams 8, 9 ensures that the contact angle of the ductor roller 3 on the distributor roller 4 becomes independent of the turning of cam disks 8, 9. The ductor roller 3 thus always executes the same number of revolutions, or fractions thereof, in contact with the distributor roller 4, regardless of the relative positions of cam disks 8, 9. Designated as WU or WV in FIGS. 5-8 are the contact angles with respect to a revolution of the cam disks 8, 9 of the ductor roller 3 on the distributor roller 4 or on ink fountain roller 1 respectively. As is evident from FIG. 7, the contact angle WV of the ductor roller 3 on the ink fountain roller 1 is variable, but the contact angle WU of the ductor roller 3 on the distributor roller 4 remains constant regardless of the relative rotational position of cams 8, 9.
In a preferred embodiment, adjusting gear 10 is actuated by a servomotor 11, as illustrated in FIG. 1. The servomotor 11 receives its setting signals from a control S, and further receives setting signals over an indicated signal line an information datum on the printing speed, for example, in the form of a tacho-signal or of a printing speed proportional impulse sequence. Coupled to the control S is a characteristic-curve storage unit K, in which are stored the turning of the cam disks 8, 9 to be brought about by the servomotor 11 over the adjusting gear 10 relatively to one another as the ordinate values as a function of the printing speed as the abscissa value.
FIG. 3 is a characteristic curve of the rotational contact angle of the ductor roller 3 on the ink fountain roller 1 as a function of the printing speed. Because the rotational contact angle of the ductor roller 3 on the ink fountain roller 1 corresponds to the relative position of cams 8 and 9, FIG. 3 may also represent the relative rotational position of cams 8 and 9 if the ordinate is correspondingly scaled.
FIG. 9 shows two diagrams of the course of the contact angle WV of the ductor roller 3 on the ink fountain roller 1 as a function of the machine angle MW as well as the machine speed MG as a function of the machine angle MW. At point W1 a command is input for the increasing of the machine speed from MG1 to MG2. At point W2 of the machine angle, a driving-up of the bearing angle WV occurs from WV1 to WV2. This occurs, for example, when the ductor roller 3 contacts the distributor roller 4. Only at point W3 of the machine angle MW does the initiation of the raising of the machine speed MG from the staring value MG1 to the intended value MG2 occur. Thus, with respect to the machine angle MW, the driving-up of the machine speed MG and altogether the contact angle value W3-W1 occurs with a prearranged amount of delay.
A complementary procedure occurs when the machine speed is reduced from a higher value to a lower value. The contact angle of the ductor roller in this case slopes downward between points W2 and W3, and the machine speed slopes downward after point W3.
While particular embodiments of the invention have been shown and described, it will of course be understood that the invention is not limited thereto since modifications may be made by those skilled in the art, particularly in light of the foregoing teachings. It is, therefore, contemplated by the appended claims to cover any such modifications as incorporate those features which constitute the essential features of these improvements within the true spirit and scope of the invention. All references cited are herein incorporated by reference in their entireties.
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An undershot inking unit and associated method are disclosed. The undershot inking unit includes an ink fountain roller that is controlled independently of the printing speed of the printing machine, and in which the rotational contact angle of the distributor roller on the ink fountain roller is varied according to the printing unit speed. The method comprises controlling the rotational speed of the ink fountain roller independently of the printing speed of the printing machine; and varying the rotational contact angle of the intermittent ductor roller on the ink fountain roller according to the printing speed of the printing machine. In a preferred embodiment, the apparatus includes two coaxial cams rotatably adjustable with respect to each other. Each cam includes a predominant circumferential contour and a subordinate circumferential contour. By adjusting the relative rotational position of the cams, the rotational contact angle of the ductor roller on the ink foundation roller is varied according to the printing unit speed.
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This application is a division of application Ser. No. 08/730,945, filed Oct. 16, 1996, now U.S. Pat. No. 5,819,524.
TECHNICAL FIELD
This invention relates to the general fields of gaseous fuel compression and fuel control in terms of both systems and methods and more particularly to an improved system and method that utilizes a helical flow compressor/turbine permanent magnet motor/generator to compress and control gaseous fuel used by a turbogenerator.
BACKGROUND OF THE INVENTION
When a turbogenerator utilizes gaseous fuel to generate electricity, it is typically using natural gas from a natural gas pipeline. If the natural gas pipeline is in a residential or commercial area, the gas pressure is probably about two-tenths of a pound per square inch above atmospheric pressure (0.2 psig). The natural gas pipeline pressure is kept this low in residentially and commercially zoned areas for fire safety reasons. A line leak or line break at higher pressures could release massive amounts of natural gas into populated areas with the attendant risk of explosion and fire. In industrial locations, the natural gas pipeline pressure can be anywhere from twenty (20) psig to sixty (60) psig. Each natural gas pipeline has its own gas pressure standard. The utilities that supply these pipelines make little warranty of what that pressure will be or that it will be maintained at a relatively constant level.
A turbogenerator may need natural gas supplied to its combustor nozzle manifold at a pressure as low as one (1) psig when the turbogenerator is being started or at a pressure as high as forty (40) psig when the turbogenerator is being operated at full speed and at fill output power. One type of turbogenerator can operate and generate power at any speed between twenty-five thousand (25,000) rpm and one hundred thousand (100,000) rpm. Over this speed range, the gaseous fuel supply pressure requirements (in psig) can vary by twenty-five-to-one (25:1) and the gaseous fuel supply flow requirements can vary by twenty-to-one (20:1). The turbogenerator speed, combustion temperature and output power are controlled by the fuel pressure and the fuel flow rate established by the turbogenerator fuel control system. The pressure and flow of the gas delivered to the turbogenerator manifold must be precisely controlled (e.g. to within 0.01%) to adequately control the turbogenerator speed, combustion temperature and output power.
A fuel control system for a turbogenerator needs to be able to reduce the natural gas pressure when the turbogenerator is being started or operated at low speed and low output power. But this fuel control system must also be able to increase the natural gas pressure when the turbogenerator is operated at high speed and high output power. Thus, the fuel control system must have gas compression capability to increase the gas pressure. But it can reduce the gas pressure with either valves using Joule-Thompson expansion (which is wasteful of power) or with a turbine (which recovers the energy of the expanding natural gas and converts this into electrical power).
Most conventional gaseous fuel compression and control systems for turbogenerators utilize an oil lubricated reciprocating compressor driven by a three (3) phase, sixty (60) cycle induction motor to boost the natural gas pressure from whatever line pressure is available to a pressure of about one hundred (100) psig. There is typically an accumulator tank and a pressure sensor at the discharge of the reciprocating compressor. When the discharge pressure reaches about one hundred (100) psig, the pressure sensor turns the compressor motor off. The accumulator supplies the required turbogenerator gas flow when the compressor motor is turned off. The accumulator pressure decays with time until the pressure sensor determines that the pressure is below about sixty (60) psig, at which time it turns the compressor motor on again. Once again the pressure rises to about one hundred (100) psig at which point the pressure sensor turns the compressor motor off. This process of pressure ramp up and pressure decay (from sixty (60) psig to one hundred (100) psig and back) continues as long as the turbogenerator is in operation. The compressor/accumulator discharge gas pressure is too high and poorly regulated for direct use by a turbogenerator. This pressure is regulated downward to match the requirements of the turbogenerator by a very precise mass flow control valve.
The mass flow control valve typically has a mass flow sensor that is insensitive to gas pressure, gas density, or gas temperature. The valve is a servosystem in its own right, adjusting its internal electromechanical orifice to prevent accumulator pressure variations from affecting the mass flow rate of natural gas delivered to the turbogenerator and to assure that the mass flow delivered to the turbogenerator is that commanded by the turbogenerator computer. The turbogenerator computer monitors the output power currently being demanded of the turbogenerator by the electrical load, computes the required changes in turbogenerator speed and combustion temperature required to supply that power, limits turbogenerator speed and combustion temperature to safe levels, then computes the mass flow of fuel required to achieve the latest desired turbogenerator speed and combustion temperature. The mass flow control valve is then commanded to deliver this mass flow rate.
The use of oil lubricated reciprocating compressors, fixed speed compressor motors, accumulators, on-off pressure control, mass flow control valves, etc. in conventional fuel control systems results in numerous shortcomings:
The fuel control system can be as large and heavy as the turbogenerator it supplies with gas and controls.
The fuel control system can be as expensive as the turbogenerator it supplies with gas and controls.
An oil coalescing filter with an oil return to the compressor oil sump as well as a depth filter are needed at the discharge of the compressor to prevent oil from contaminating the natural gas lines leading to the turbogenerator as well as contaminating the turbogenerator's nozzles, combustor and catalyst.
If the oil coalescing filter and depth filter allow oil vapors or oil droplets to reach the natural gas lines leading to the turbogenerator, oil condensation and coalescing will allow liquid oil to plug these lines resulting in severe turbogenerator speed surges.
If the oil coalescing filter and depth filter allow oil vapors or oil droplets to reach the turbogenerator's nozzles or combustor, varnish build up will affect combustion adversely.
If the oil coalescing filter and depth filter allow oil vapors or oil droplets to reach any catalyst used by the turbogenerator in its combustion or post combustion emissions control, the catalyst will be poisoned and will cease to function.
The compressor needs periodic servicing to check its oil level, top off its oil level and to change its oil. The filters require checking and periodic replacement.
Turning the compressor on and off to control accumulator tank pressure shortens the compressor and motor life.
The rings, rotary seals and sliding surfaces of the compressor wear and thus limit compressor life.
The rotary seals of some compressor types can leak natural gas, especially after the passage of time and accumulated wear.
The compressor produces pressure pulsations each time its piston strokes. These pulsations have to be overcome by compressing the gas to a higher pressure than would otherwise be needed (wasting power) and by the use of an accumulator tank and a fast acting mass flow control valve having a very high gain servosystem.
The compressor/accumulator discharge pressure ramps up and decays down as the compressor is turned on and turned off to control accumulator tank pressure. These pressure variations also have to be overcome by compressing the gas to a higher pressure than would otherwise be needed (wasting power) and by the use of an accumulator tank and a fast acting mass flow control valve having a very high gain servosystem.
The accumulator tank is large, heavy, and of at least medium cost.
The mass flow control valve is expensive, complicated, prone to calibration drift, prone to sealing problems, prone to particle contamination, prone to friction induced hysterisis problems for some versions, adversely affected by electrical noise emanating from the turbogenerator (due to its high servosystem gains), and is of questionable reliability.
Compressing the natural gas to a pressure far above that needed by the turbogenerator in order to have enough pressure differential across the mass flow control valve for the valve to operate well is very wasteful of natural gas compression power.
To avoid the aforementioned shortcomings of most conventional gaseous fuel compression and control systems, it is necessary to use a rotary compressor that is not oil lubricated, does not have rubbing shaft seals, and does not have sliding surfaces. Centrifugal compressors do meet these requirements. However, centrifugal compressors operate best (with high efficiencies) when they have a high throughput flow rate and a low pressure rise relative to their tip speed. These operating conditions are characterized as high specific-speed conditions. Under these conditions, a centrifugal compressor can operate with an efficiency on the order of seventy-eight percent (78%). But the flow rate and pressure rise requirements for the compressor in the gaseous fuel compression and control system are for a low specific-speed compressor (low throughput flow rate and high pressure rise relative to the compressor's tip speed). A centrifugal compressor operating under these conditions would have an efficiency of less than twenty percent (20%). Under these conditions it would require a very large number of centrifugal compressors in series (e.g. ten (10)) to produce the same pressure rise for a given tip speed as could one (1) helical flow compressor. A helical flow compressor is an attractive candidate for this application. A helical flow turbine can perform the function of the mass flow control valve while additionally generating electrical power when the natural gas line pressure is greater than that needed by the turbogenerator. If a helical flow machine is used that can function as both a compressor and a turbine, the natural gas need only be compressed to forty (40) psig instead of to one hundred (100) psig, thereby saving power.
A helical flow compressor/turbine operating as a compressor is a high-speed rotating machine that accomplishes compression by imparting a velocity head to each fluid particle as it passes through the machine's impeller blades and then converting that velocity head into a pressure head in a stator channel that functions as a vaneless diffuser. While in this respect a helical flow compressor has some characteristics in common with a centrifugal compressor, the primary flow in a helical flow compressor is peripheral and asymmetrical, while in a centrifugal compressor, the primary flow is radial and symmetrical. The fluid particles passing through a helical flow compressor travel around the periphery of the helical flow compressor impeller within a generally horseshoe shaped stator channel. Within this channel, the fluid particles travel along helical streamlines, the centerline of the helix coinciding with the center of the curved stator channel. This flow pattern causes each fluid particle to pass through the impeller blades or buckets many times while the fluid particles are traveling through the helical flow compressor, each time acquiring kinetic energy. After each pass through the impeller blades, the fluid particles reenter the adjacent stator channel where they convert their kinetic energy into potential energy and a resulting peripheral pressure gradient in the stator channel. The multiple passes through the impeller blades (regenerative flow pattern) allows a helical flow compressor to produce discharge heads of up to fifteen (15) times those produced by a centrifugal compressor operating at equal tip speeds. A helical flow compressor operating at low specific-speed and at its best flow can have efficiencies of about fifty-five percent (55%) with curved blades and can have efficiencies of about thirty-eight percent (38%) with straight radial blades.
A helical flow compressor can be utilized as a turbine by supplying it with a high pressure working fluid, dropping fluid pressure through the machine, and extracting the resulting shaft horsepower with a generator. Hence the term "compressor/turbine" which is used throughout this application.
Among the advantages of a helical flow compressor or a helical flow turbine are:
(a) simple, reliable design with only one rotating assembly;
(b) stable, surge-free operation over a wide range of operating conditions (i.e. from full flow to no flow);
(c) long life (e.g., 40,000 hours) limited mainly by their bearings;
(d) freedom from wear product and oil contamination since there are no rubbing or lubricated surfaces utilized;
(e) fewer stages required when compared to a centrifigal compressor; and
(f) higher operating efficiencies when compared to a very low specific-speed (high head pressure, low impeller speed, low flow) centrifugal compressor.
The flow in a helical flow compressor can be visualized as two fluid streams which first merge and then divide as they pass through the compressor. One fluid stream travels within the impeller buckets and endlessly circles the compressor. The second fluid stream enters the compressor radially through the inlet port and then moves into the horseshoe shaped stator channel which is adjacent to the impeller buckets. Here the fluids in the two streams merge and mix. The stator channel and impeller bucket streams continue to exchange fluid while the stator channel fluid stream is drawn around the compressor by the impeller motion. When the stator channel fluid stream has traveled around most of the compressor periphery, its further circular travel is blocked by the stripper plate. The stator channel fluid stream then turns radially outward and exits from the compressor through the discharge port. The remaining impeller bucket fluid stream passes through the stripper plate within the buckets and merges with the fluid just entering the compressor/turbine.
The fluid in the impeller buckets of a helical flow compressor travels around the compressor at a peripheral velocity which is essentially equal to the impeller blade velocity. It thus experiences a strong centrifugal force which tends to drive it radially outward, out of the buckets. The fluid in the adjacent stator channel travels at an average peripheral velocity of between five (5) and ninety-nine (99) percent of the impeller blade velocity, depending upon the compressor discharge flow. It thus experiences an inertial force which is much less than that experienced by the fluid in the impeller buckets. Since these two inertial forces oppose each other and are unequal, the fluid occupying the impeller buckets and the stator channel is driven into a circulating or regenerative flow. The fluid in the impeller buckets is driven radially outward and "upward" into the stator channel. The fluid in the stator channel is displaced and forced radially inward and "downward" into the impeller bucket.
The fluid in the impeller buckets of a helical flow turbine travels around the turbine at a peripheral velocity which is essentially equal to the impeller blade velocity. It thus experiences a strong centrifugal force which would like to drive it radially outward if unopposed by other forces. The fluid in the adjacent stator channel travels at an average peripheral velocity of between one hundred and one percent (101%) and two hundred percent (200%) of the impeller blade velocity, depending upon the compressor discharge flow. It thus experiences a centrifugal force which is much greater than that experienced by the fluid in the impeller buckets. Since these two inertial forces oppose each other and are unequal, the fluid occupying the impeller buckets and the stator channel is driven into a circulating or regenerative flow. The fluid in the impeller buckets is driven radially inward and "upward" into the stator channel. The fluid in the stator channel is displaced and forced radially outward and "downward" into the impeller bucket.
While the fluid in either a helical flow compressor or helical flow turbine is traveling regeneratively, it is also traveling peripherally around the stator-impeller channel. Thus, each fluid particle passing through a helical flow compressor travels along a helical streamline, the centerline of the helix coinciding with the center of the generally horseshoe shaped stator-impeller channel.
SUMMARY OF THE INVENTION
In the present invention, the gaseous fuel compression and control system and method utilizes a helical flow compressor/turbine integrated with a permanent magnet motor/generator and driven by a torque controlling inverter to compress or expand gaseous fuels, to precisely control fuel pressure and fuel flow delivered to a turbogenerator, and to precisely control the speed, the combustion or turbine exhaust temperature and the electrical power output of the turbogenerator.
The gaseous fuel compression and control system can be comprised of (in order of inline connection and gas flow): 1) a connection to a natural gas pipe line, 2) a solenoid actuated inlet shut-off valve, 3) an optional low pressure helical flow compressor/turbine permanent magnet motor/generator module (used if the natural gas pipeline pressure is very low), 4) a high pressure helical flow compressor/turbine permanent magnet motor/generator module, 5) a discharge pressure sensor, 6) a solenoid actuated outlet shut-off valve, 7) a connection to the turbogenerator's combustor nozzle manifold, and 8) a computer control system that sets the turbogenerator's inverter and motor/generator speed, monitors the turbogeneratores power output and turbine discharge temperatures, sets the helical flow compressor/turbine shaft torque, and monitors the helical flow compressor/turbine shaft speed.
The method of gaseous fuel compression and control includes establishing the turbogenerator speed required based upon the power load requirements of the turbogenerator, establishing the turbogenerator combustion or turbine exhaust temperature required based upon the power load requirements of the turbogenerator, establishing the gaseous fuel pressure requirements to produce the established turbogenerator speed and temperature, and commanding the helical flow compressor/turbine to produce the established gaseous fuel pressure by controlling the torque or the speed of the helical flow compressor/turbine permanent magnet motor/generator.
The gaseous fuel compression and control system for a turbogenerator includes a helical flow compressor/turbine for supplying pressurized gaseous fuel to the gaseous fuel nozzles of the turbogenerator combustor with the turbogenerator compressor supplying compressed air to the turbogenerator combustor. A motor, such as a permanent magnet motor, drives the helical flow compressor/turbine. A helical flow compressor/turbine motor inverter drive provides electrical power to the motor and receives operational phase and speed data from the motor. The inverter drive also receives maximum speed and command torque control signals from the turbogenerator power controller which receives a speed feedback signal from the helical flow compressor/turbine motor inverter drive. A turbogenerator speed signal and a turbine exhaust gas temperature signal are provided to the turbogenerator power controller from the turbogenerator.
The helical flow compressor/turbine system is typically thirty (30) to forty (40) times smaller than systems with reciprocating compressors; consumes about one-third (1/3) of the energy than other gaseous fuel compression systems use; does not require the use of an accumulator; does not compress the gaseous fuel to a pressure that is higher than is needed by the turbogenerator and then throw the extra pressure away through regulation; does not cycle on and off; does-not operate in a pulsed mode; and is very fast and responsive having low inertia impeller wheels and being controlled by the same computer that controls the entire turbogenerator combustion process.
The helical flow compressor/turbine, typically having multiple compression stages, is driven at high speed on the order of thirty six thousand (36,000) rpm by a permanent magnet motor generator. It is designed to produce very high pressure for a given impeller tip speed. A conventional centrifugal compressor passes gaseous fuel such as natural gas through its impeller blade to impart kinetic energy to the gaseous fuel. That kinetic energy or velocity energy is then converted to pressure energy in a diffuser channel. This happens only once as the gaseous fuel goes through the compressor. In order to obtain a large pressure rise, you either have to have an extremely high speed impeller with a very large diameter, or you have to have a large number of compression stages (on the order of forty (40)).
A helical flow compressor/turbine also takes inlet gaseous fuel into its impeller blades where it picks up kinetic energy or velocity energy and then the gaseous fuel goes into a stator channel (which is in effect a vaneless diffuser) where the kinetic energy is converted into pressure energy. While this happens only once in the typical centrifugal compressor, it typically happens twelve (12) to fifteen (15) times in a helical flow compressor/turbine. Thus, you can obtain about twelve (12) to fifteen (15) times as much pressure rise in a single stage of a helical flow compressor/turbine as you can obtain in a single stage of a centrifugal compressor.
The helical flow compressor/turbine is also designed to produce very low flows whereas the centrifugal compressor requires higher flows for greater efficiency. Because of this, centrifugal compressors operating at high flows have higher efficiencies than helical flow compressor/turbines running at their best efficiencies. When, however, you compare centrifugal compressors with helical flow compressor/turbines with the same low flows, helical flow compressor/turbines actually have higher efficiencies. A centrifugal compressor operating at its best operating condition would be operating at about a seventy eight percent (78%) efficiency. The centrifugal compressor would, however, be operating at its best flow which will be well above the flows needed by the turbogenerator. The helical flow compressor/turbine operating at its best flow can have efficiencies with curved blades of about fifty five percent (55%) and with straight blades of about thirty eight percent (38%). The efficiency of the helical flow compressor/turbine with straight blades for the flows required by the turbogenerator is about twenty five percent (25%) and with curved blades may be slightly over thirty percent (30%). On the other hand, the centrifugal compressor efficiency under similar conditions would be under twenty percent (20%) because it would be operating at such a low flow, well below where it is designed to operate at. At these low flows, there is a lot of scroll leakage losses in the centrifugal compressor.
The helical flow compressor/turbine has a lightweight wheel or impeller for a given throughput flow rate and pressure rise. The centrifugal compressor will be somewhat heavier with less ability to accelerate and decelerate than the helical flow compressor/turbine. If both a centrifugal compressor and a helical flow compressor/turbine were designed to provide what the turbogenerator requires, the impeller of the helical flow compressor/turbine would be much lighter and much easier to accelerate and decelerate than the impeller of the centrifugal compressor and the centrifugal compressor system would have many more stages.
Since the pressure of the gaseous fuel introduced into the turbogenerator combustor is a function of the helical flow compressor/turbine shaft torque and shaft speed, the fuel control system computer can control the inverter which controls the motor which controls the compressor and effectively allows the computer to control either the pressure or the flow of the helical flow compressor/turbine which is compressing gaseous fuel. In a helical flow compressor/turbine driven by a permanent magnet motor, or by an induction motor, you can control the torque the motor produces or control the motor speed or a mix of the two. Typically in this application, the torque is controlled since that controls the pressure rise of the compressor. Since the buckets have a known cross sectional area at a known radius to the center of the compressor/turbine motor shaft, there is a known pressure rise for a given motor torque. The gaseous fuel to the turbogenerator can therefore be effectively controlled.
The turbogenerator should be able to operate on whatever gaseous fuel you have available in a pipeline, anywhere from six (6) inches water gauge at the low end to about fifty (50) psi gauge pressure at the top end. If your initial gas pressure is too high, the helical flow compressor/turbine can be operated in a reverse direction to function as a turbine and reduce the pressure coming into the turbogenerator so that you get the amount of fuel you need for initial ignition. After ignition, combustion produces heat and combustion gas flow that drives the turbine and accelerates the turbogenerator which raises the pressure of the turbogenerator compressor. As the turbogenerator compressor increases the pressure of the combustion air, you will also need to increase the gaseous fuel pressure to keep it somewhat higher so that there is a positive flow of gaseous fuel to the combustor nozzles. If for any reason the turbogenerator gets to a speed so as to produce more turbogenerator compressor discharge pressure than the gaseous fuel pressure, the gaseous fuel flow will stop and no gaseous fuel will enter the turbogenerator combustor and the turbogenerator goes down in speed. This in fact constitutes a speed control mechanism which works extremely well.
A conventional gaseous fuel compression and control system controls the fuel mass flow rate delivered to the turbogenerator but not the pressure of the fuel delivered to the turbogenerator. If the flow is held constant, the turbogenerator speed can run away when the electric power load suddenly drops off. If the electrical load coming out of the turbogenerator drops off, more torque is available from the turbine to accelerate the wheel. The problem is controlling the speed in the system based upon controlling the mass flow of gaseous fuel. Only a high speed, high gain servosystem can prevent speed surges if fuel flow is controlled rather that fuel pressure.
In the present invention, the pressure rather than the mass flow of the gaseous fuel is controlled and set to a pressure such as twenty five (25) psi gauge. The turbogenerator will automatically accelerate if the compressor discharge pressure is less than twenty three and one-half (231/2) psi gauge. At that point, the turbogenerator is getting the amount of fuel it needs to run. With a drop off of load at the turbogenerator, the most that the turbogenerator speed can increase is that change in speed associated with an increase of one and one-half (11/2) psi in compressor discharge pressure. The speed goes up about three percent (3%) or four percent (4%) (considered to be a speed error) and stabilizes out as the gaseous fuel flow naturally drops down. Essentially what the computer based control logic does is reduce this small error by using a limited amount of gain or by using limited authority integration reducing this small error to essentially zero with small variations in fuel pressure. This makes a stable servocontrol.
With prior art technology, there is almost no gain in the turbogenerator by virtue of the fuel pneumatics and the compressed air pneumatics, the gain is all in the computer that is controlling the gaseous fuel and that's a hard thing to do. What is done in the present invention is to use the turbogenerator as a moderate gain servosystem on its own right. If you control the fuel pressure, you control the turbogenerator speed within a five percent (5%) tolerance range for a wide range of output power. The turbogenerator keeps itself from overspeeding and enables the system to get by with a very low gain (thus stable) servosystem that is computer based. Noting the power that the customer wants electrically, the computer goes to look-up tables to determine the speed and temperature at which the turbogenerator should be operating to produce that power. Another look-up table determines what pressure the gaseous fuel should have to be consistent with that selected turbogenerator speed and temperature. The fuel pressure is then commanded to be equal to that level by changing the speed of the helical flow compressor/turbine or by changing the torque of the helical flow compressor/turbine motor. These conditions are obtained with a very small error because the prediction algorithms can be extremely accurate. A very small authority or limited gain integral proportional controller algorithm can trim out the last errors in speed, exhaust gas temperature, or output power.
A gaseous fuel compression and control system based on the present invention stabilizes much faster than systems with reciprocating compressors and mass flow control valves. It has been demonstrated that this system can control a turbogenerator over a speed range of twenty four thousand (24,000) rpm to ninety six thousand (96,000) rpm and can control the turbogenerator speed to within ten (10) rpm and that it can also control the turbine exhaust temperature to within two (2) degrees Fahrenheit. It is a very friendly system which does not overshoot and is capable of overcoming many of the difficulties of prior systems.
It is therefore the principle objective of the present invention to provide an improved gaseous fuel compression and control system and method for a turbogenerator.
It is another object of the present invention to provide a gaseous fuel compression and control system having means to compress gaseous fuel from natural gas line pressure to the pressure required by the turbogenerator combustor.
It is another objective of the present invention to provide a gaseous fuel compression and control system that utilizes a helical flow compressor to compress and raise the pressure of the gaseous fuel.
It is another objective of the present invention to provide a gaseous fuel compression and control system that utilizes a helical flow turbine to expand and reduce the pressure of the gaseous fuel.
It is another objective of the present invention to provide a gaseous fuel compression and control system that utilizes a helical flow compressor/turbine that can both compress (raise the pressure) and expand (lower the pressure) of the gaseous fuel.
It is another objective of the present invention to provide a gaseous fuel compression and control system that utilizes a helical flow compressor/turbine integrated with a permanent magnet motor/generator and an inverter that can utilize electrical energy to compress the gaseous fuel when the gaseous fuel supply pressure is less than that needed by the turbogenerator.
It is another objective of the present invention to provide a gaseous fuel compression and control system that utilizes a helical flow compressor/turbine integrated with a permanent magnet motor/generator and a four quadrant inverter that can generate electrical power when the gaseous fuel supply pressure is greater than that needed by the turbogenerator.
It is another objective of the present invention to provide a gaseous fuel compression and control system that utilizes a helical flow compressor/turbine permanent magnet motor/generator that can shift or transition smoothly from generating electrical power while expanding or reducing the pressure of the gaseous fuel to utilizing electrical power to compress or increase the pressure of the gaseous fuel in response to changes in the natural gas line pressure or changes in the fuel pressure and/or fuel flow required by the turbogenerator.
It is another objective of the present invention to provide a gaseous fuel compression and control system that utilizes a helical flow compressor/turbine permanent magnet motor/generator and associated inverter that can precisely control the shaft torque of the helical flow compressor/turbine permanent magnet motor/generator.
It is another objective of the present invention to provide a gaseous fuel compression and control system that utilizes a helical flow compressor/turbine permanent magnet motor/generator and associated inverter that can precisely monitor the shaft speed of the helical flow compressor/turbine permanent magnet motor/generator.
It is another objective of the present invention to provide a gaseous fuel compression and control system that utilizes a helical flow compressor/turbine permanent magnet motor/generator and associated inverter that can precisely control and/or monitor both the shaft torque and the shaft speed of the helical flow compressor/turbine permanent magnet motor/generator.
It is another objective of the present invention to provide a gaseous fuel compression and control system that utilizes a helical flow compressor/turbine integrated with a permanent magnet motor/generator and a torque controlling inverter that can inherently control the change in gas pressure across the compressor/turbine (since pressure change is nominally proportional to torque).
It is another objective of the present invention to provide a gaseous fuel compression and control system that utilizes a helical flow compressor/turbine integrated with a permanent magnet motor/generator and a torque controlling inverter with speed output data that can inherently control and/or monitor and/or provide data to compute the change in gas energy as the gaseous fuel passes through the helical flow compressor/turbine (since gas energy change is related to the product of shaft speed times shaft torque).
It is another objective of the present invention to provide a gaseous fuel compression and control system that utilizes a helical flow compressor/turbine integrated with a permanent magnet motor/generator and a torque controlling inverter with speed output data that can provide information to compute gaseous fuel flow rate.
It is another objective of the present invention to provide a gaseous fuel compression and control system that utilizes a compressor/turbine that is not susceptible to fluid dynamic instabilities such as stall or surge (such as are experienced by centrifugal compressors when flows are low, speeds are low and pressure changes across the compressor are large) or to any other pressure or flow discontinuities in the pressure/flow profile.
It is another objective of the present invention to provide a gaseous fuel compression and control system that utilizes a rotary compressor/turbine that produces a large pressure change with low rotor tip speed.
It is another objective of the present invention to provide a gaseous fuel compression and control system that utilizes a rotary compressor/turbine that can quickly and continuously adjust its gaseous fuel discharge flow rate to match changing pipeline or turbogenerator conditions. This requires low inertia impeller wheel(s).
It is another objective of the present invention to provide a gaseous fuel compression and control system that utilizes a rotary compressor/turbine that operates with reasonable efficiency when its specific-speed is low (i.e. when pressure change is high, tip speed is low and flow rate is low).
It is another objective of the present invention to provide a gaseous fuel compression and control system that utilizes a motor/generator that is efficient.
It is another objective of the present invention to provide a gaseous fuel compression and control system that utilizes a helical flow compressor/turbine that can be configured as a single stage, a two stage, or a three stage rotary machine.
It is another objective of the present invention to provide a gaseous fuel compression and control system that does not utilize a flow control valve downstream of the gaseous fuel compressor.
It is another objective of the present invention to provide a gaseous fuel compression and control system that does not compress the gaseous fuel to a pressure substantially above the pressure required by the turbogenerator since such high pressure compression would waste gas compression energy.
It is another objective of the present invention to provide a gaseous fuel compression and control system that compresses the gaseous fuel only to the pressure required by the turbogenerator (thus saving energy).
It is another objective of the present invention to provide a gaseous fuel compression and control system that has no gas storage but compresses the gaseous fuel only when it is needed.
It is another objective of the present invention to provide a gaseous fuel compression and control system that does not require an accumulator tank.
It is another objective of the present invention to provide a gaseous fuel compression and control system that does not require the compressor to be turned on and off in order to control its discharge pressure when the natural gas pipeline pressure changes or the gas pressure flow required by the turbogenerator changes.
It is another objective of the present invention to provide a gaseous fuel compression and control system that does not utilize a compressor having pressure or flow pulsations in its discharge gas flow.
It is another objective of the present invention to provide a gaseous fuel compression and control system that does not utilize a compressor having pistons.
It is another objective of the present invention to provide a gaseous fuel compression and control system that does not utilize a compressor having rubbing or sliding surfaces.
It is another objective of the present invention to provide a gaseous fuel compression and control system that does not utilize a compressor having rotary shaft seals.
It is another objective of the present invention to provide a gaseous fuel compression and control system that does not utilize a compressor that can have oil droplets or oil vapor entrained in its discharge gas flow.
It is another objective of the present invention to provide a gaseous fuel compression and control system that does not utilize a compressor having oil lubrication.
BRIEF DESCRIPTION OF THE DRAWINGS
Having thus described the present invention in general terms, reference will now be made to the accompanying drawings in which:
FIG. 1 is a plan view of a turbogenerator set utilizing the gaseous fuel compression and control system and method of the present invention;
FIG. 2 is a perspective view, partially cut away, of a turbogenerator for the turbogenerator set of FIG. 1;
FIG. 3 is a block diagram, partially schematic, view of the gaseous fuel compression and control system and method of the present invention;
FIG. 4 is an end view of a two stage helical flow compressor/turbine permanent magnet motor/generator for use in the gaseous fuel compression and control system and method of the present invention;
FIG. 5 is a cross sectional view of the helical flow compressor/turbine permanent magnet motor/generator of FIG. 4 taken along line 5--5;
FIG. 6 is a cross sectional view of the helical flow compressor/turbine permanent magnet motor/generator of FIG. 4 taken along line 6--6;
FIG. 7 is an enlarged sectional view of the helical flow compressor/turbine permanent magnet motor/generator of FIG. 4 illustrating the crossover of gaseous fuel from the low pressure stage to the high pressure stage;
FIG. 8 is an enlarged partial plan view of the helical flow compressor/turbine impeller having straight radial blades and illustrating the flow of fluid therethrough;
FIG. 9 is an enlarged partial plan view of a helical flow compressor/turbine impeller having curved blades;
FIG. 10 is an exploded perspective view of a stator channel plate of the helical flow compressor/turbine permanent magnet motor/generator of FIG. 4;
FIG. 11 is an enlarged sectional view of a portion of FIG. 7 illustrating fluid flow streamlines in the impeller blades and helical flow stator channels;
FIG. 12 is a schematic representation of the flow of fluid through a helical flow compressor/turbine;
FIG. 13 is a block diagram, partially schematic, view of the gaseous fuel compression and control system and method of the present invention illustrating two (2) helical flow compressor/turbines in series;
FIG. 14 is an alternate schematic representation of the gaseous fuel compression and control system and method of the present invention; and
FIG. 15 is a graph of the pressure versus flow characteristics of a helical flow compressor.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A turbogenerator set 10 utilizing the gaseous fuel compression and control system and method of the present invention is illustrated in FIG. 1. A mounting platform 11 supports the turbogenerator 12, associated ducts 13, helical flow compressor/turbine permanent magnet motor/generator 14, turbogenerator set power controller 15, and line commutated inverter 16 (in two (2) enclosures).
The turbogenerator 12 is illustrated in detail in FIG. 2 and generally comprises a permanent magnet generator 20, a power head 21, a combustor 22 and a recuperator (or heat exchanger) 23.
The permanent magnet generator 20 includes a permanent magnet rotor or sleeve 26, having a permanent magnet disposed therein, rotatably supported within a permanent magnet stator 27 by a pair of spaced journal bearings. Radial permanent magnet stator cooling fins 28 are enclosed in an outer cylindrical sleeve 29 to form an annular air flow passage which cools the permanent magnet stator 27 and thereby preheats the air passing through on its way to the power head 21.
The power head 21 of the turbogenerator 12 includes compressor 30, turbine 31, and bearing rotor 32 through which the tie rod 33 to the permanent magnet rotor 26 passes. The compressor 30, having compressor impeller or wheel 34 which receives preheated air from the annular air flow passage in cylindrical sleeve 29 around the permanent magnet stator 27, is driven by the turbine 31 having turbine wheel 35 which receives heated exhaust gases from the combustor 22 supplied with air from recuperator 23. The compressor wheel 34 and turbine wheel 35 are supported on a bearing shaft or rotor 32 having a radially extending bearing rotor thrust disk 36. The bearing rotor 32 is rotatably supported by a single journal bearing within the center bearing housing 37 while the bearing rotor thrust disk 36 at the compressor end of the bearing rotor 32 is rotatably supported by a bilateral thrust bearing.
Intake air is drawn through the permanent magnet generator 20 by the compressor 30 which increases the pressure of the air and forces it into the recuperator 23. In the recuperator 23, exhaust heat from the turbine 31 is used to preheat the air before it enters the combustor 22 where the preheated air is mixed with fuel and burned. The combustion gases are then expanded in the turbine 31 which drives the compressor 30 and the permanent magnet rotor 26 of the permanent magnet generator 20 which is mounted on the same shaft as the turbine 31. The expanded turbine exhaust gases are then passed through the recuperator 23 before being discharged from the turbogenerator 12.
As illustrated in FIG. 3, the helical flow compressor/turbine 14, having motor 42, includes a gaseous fuel inlet 40 to provide a gaseous fuel such as natural gas to the helical flow compressor/turbine 14 at line pressure and a gaseous fuel outlet 41 to provide elevated pressure gaseous fuel to the combustor 22 via nozzles 24. While the helical flow compressor/turbine motor 42 can be an induction motor, it would preferably be a permanent magnet motor which could also function as a permanent magnet generator. A helical flow compressor/turbine motor inverter drive 43 provides three (3) phase electrical power to the helical flow compressor/turbine motor 42 via electrical connection 44 and receives operational speed and phase data from the helical flow compressor/turbine motor 42 via electrical connection 45.
The helical flow compressor/turbine motor inverter drive 43 receives torque control signals and maximum speed control signals 46 from the turbogenerator set power controller 15. The turbogenerator set power controller 15, which includes a central processing unit, receives helical flow compressor/turbine motor/generator speed and current (torque is proportional to current) feedback signal 47 from the helical flow compressor/turbine motor inverter drive 43. A turbogenerator turbine exhaust gas temperature signal 50 from thermocouple 51 in the turbogenerator turbine exhaust gas duct 52 is also provided to the turbogenerator set power controller 15.
The combustor 22 also includes a plurality of compressed air inlets 53 which provide pressurized air from the turbogenerator compressor 30 to the combustor 22. One or both of the gaseous fuel inlet 40 or gaseous fuel outlet 41 of the gaseous fuel helical flow compressor/turbine 14 may include a pressure sensor. Gaseous fuel inlet pressure sensor 55 and gaseous fuel outlet pressure sensor 56 can provide pressure data to the turbogenerator set power controller 15 via lines 57 and 58, respectively. While both a gaseous fuel inlet pressure sensor 55 and a gaseous fuel outlet pressure sensor 56 are illustrated, only one may be required since if one pressure value is sensed, the other pressure value can be accurately calculated. Further, the gaseous fuel helical flow compressor/turbine 14 of the present invention is completely functional with or without pressure sensors in either or both of the gaseous fuel inlet 40 or the gaseous fuel outlet 41.
The turbogenerator permanent magnet generator 20 exchanges three phase data with the turbogenerator set power controller 15 via lines 17, 18, and 19. Included in this data would be turbogenerator speed data.
The helical flow compressor/turbine permanent magnet motor/generator 14 is illustrated in detail in FIGS. 4-11. While it is shown in a two (2) compression stage configuration, it should be recognized that the helical flow compressor/turbine 14 may have a single compression stage or as many as three (3) compression stages. The helical flow compressor/turbine permanent magnet motor/generator is described in additional detail in U.S. patent application Ser. No. 08/730,946, filed Oct. 16, 1996 by Robert W. Bosley, Ronald F. Miller, and Joel B. Wacknov entitled "Helical Flow Compressor/Turbine Permanent Magnet Motor/Generator", assigned to the same assignee as this application, and is herein incorporated by reference.
A two (2) stage helical flow compressor/turbine permanent magnet motor/generator is illustrated in FIGS. 4-6 and includes a fluid inlet 56 to provide fluid to the helical flow compressor/turbine of the helical flow compressor/turbine permanent magnet motor/generator and a fluid outlet 58 to remove fluid from the helical flow compressor/turbine of the helical flow compressor/turbine permanent motor/generator.
The helical flow compressor/turbine permanent magnet motor/generator includes a shaft 60 rotatably supported by bearings 61 and 62. The position of bearing 62 is maintained by two (2) back-to-back Belleville type washers 65 which also prevent rotation of the outer bearing race. Low pressure stage impeller 63 and high pressure stage impeller 64 are mounted at one end of the shaft 60, while permanent magnet rotor 67 is mounted at the opposite end thereof between bearings 61 and 62. The bearing 61 is held by bearing retainer 68 while bearing 62 is held by bearing retainer 66. A bore seal tube 70 extends between bearing retainer 68 and bearing retainer 66. An O-ring or gasket 71 may be provided in each of the bearing retainers 68 and 66 at both ends of the bore seal tube 70.
Low pressure stripper plate 76 and high pressure stripper plate 77 are disposed radially outward from low pressure impeller 63 and high pressure impeller 64, respectively. The permanent magnet rotor 67 on the shaft 60 is disposed to rotate within permanent magnet stator 166 which is disposed in the permanent magnet housing 69.
The low pressure impeller 63 is disposed to rotate between the low pressure stator channel plate 72 and the mid stator channel plate 73 while the high pressure impeller 64 is disposed to rotate between the mid stator channel plate 73 and the high pressure stator channel plate 74. Low pressure stripper plate 76 has a thickness slightly greater than the thickness of low pressure impeller 63 to provide a running clearance for the low pressure impeller 63 between low pressure stator channel plate 72 and mid stator channel plate 73 while high pressure stripper plate 77 has a thickness slightly greater than the thickness of high pressure impeller 64 to provide a running clearance for the high pressure impeller 64 between mid stator channel plate 73 and high pressure stator channel plate 74.
The low pressure stator channel plate 72 includes a generally horseshoe shaped fluid flow stator channel 78 having an inlet to receive fluid from the fluid inlet 56. The mid stator channel plate 73 includes a low pressure generally horseshoe shaped fluid flow stator channel 80 on the low pressure side thereof and a high pressure generally horseshoe shaped fluid flow stator channel 81 on the high pressure side thereof. The low pressure generally horseshoe shaped fluid flow stator channel 80 on the low pressure side of the mid stator channel plate 73 mirrors the generally horseshoe shaped fluid flow stator channel 78 in the low pressure stator channel plate 72. The high pressure stator channel plate 74 includes a generally horseshoe shaped fluid flow stator channel 82 which mirrors the high pressure generally horseshoe shaped fluid flow stator channel 81 on the high pressure side of mid stator channel plate 73.
Each of the stator channels include an inlet and an outlet disposed radially outward from the channel. The inlets and outlets of the low pressure stator channel plate generally horseshoe shaped fluid flow stator channel 78 and mid helical flow stator channel plate low pressure generally horseshoe shaped fluid flow stator channel 80 are axially aligned as are the inlets and outlets of mid helical flow stator channel plate high pressure generally horseshoe shaped fluid flow stator channel 81 and high pressure stator channel plate generally horseshoe shaped fluid flow stator channel 82.
The gaseous fluid inlet 56 extends through both the low pressure stator channel plate 72 and low pressure stripper plate 76 to the inlets of both of the low pressure stator channel plate generally horseshoe shaped fluid flow stator channel 78 and the mid helical flow stator channel plate low pressure generally horseshoe shaped fluid flow stator channel 80. The gaseous fluid outlet 58 extends from the outlets of both the mid helical flow stator channel plate high pressure generally horseshoe shaped fluid flow stator channel 81 and the high pressure stator channel plate generally horseshoe shaped fluid flow stator channel 82 through the high pressure stator channel plate 74, through the high pressure stripper plate 77, through the mid stator channel plate 73, through the low pressure stripper plate 76, and finally through the low pressure stator channel plate 72.
The crossover from the low pressure compression stage to the high pressure compression stage is illustrated in FIG. 7. Both of the outlets from the low pressure stator channel plate generally horseshoe shaped fluid flow stator channel 78 and mid helical flow stator channel plate low pressure generally horseshoe shaped fluid flow stator channel 80 provide partially compressed fluid to the crossover 88 which in turn provides the partially compressed fluid to both inlets of mid helical flow stator channel plate high pressure generally horseshoe shaped fluid flow stator channel 81 and high pressure stator channel plate generally horseshoe shaped fluid flow stator channel 82.
The impeller blades or buckets are best illustrated in FIGS. 8, 9, and 11. The radial outward edge of the low pressure impeller 63 includes a plurality of low pressure blades 90 while the high pressure impeller 64 also includes a plurality of high pressure blades 91. While these blades 90 and 91 may be radially straight as shown in FIG. 8, there may be specific applications and/or operating conditions where curved blades may be more appropriate or required.
FIG. 9 illustrates a portion of a helical flow compressor/turbine impeller having a plurality of curved blades 71. The curved blade base or root 75 has less of a curve than the leading edge 79 thereof. The curved blade tip 82, at both the root 75 and leading edge 79 would be generally radial.
The fluid flow stator channels are best illustrated in FIG. 10 which shows the stator channel plate 73. The generally horseshoe shaped stator channel 80 is shown along with inlet 85 and outlet 86. The inlet 85 and outlet 86 would normally be relatively displaced approximately thirty (30) degrees. An alignment or locator hole 87 is provided in each of the low pressure stator channel plate 72, the mid stator channel plate 73 and the high pressure stator channel plate 74 as well as stripper plates 76 and 77. The inlet 85 is connected to the generally horseshoe shaped stator channel 80 by a converging nozzle passage 95 that converts fluid pressure energy into fluid velocity energy. Likewise, the other end of the generally horseshoe shaped stator channel 80 is connected to the outlet 86 by a diverging diffuser passage 96 that converts fluid velocity energy into fluid pressure energy. The fluid flow outlet for the generally horseshoe shaped stator channel 81 is shown as 99.
The depth and cross-sectional flow area of fluid flow stator channel 80 are tapered preferably so that the peripheral flow velocity need not vary as fluid pressure and density vary along the fluid flow channel. When compressing, the depth of the fluid flow stator channel 80 decreases from inlet to outlet as the pressure and density increases. Converging nozzle passage 95 and diverging diffuser passage 96 allow efficient conversion of fluid pressure energy into fluid velocity energy and vice versa.
In a helical flow compressor/turbine operating as a compressor, fluid enters the inlet port, is accelerated as it passes through the converging nozzle passage, is split into two (2) flow paths by a stripper plate, then enters the end of a generally horseshoe shaped stator channel axially adjacent to the impeller blades. The fluid is then directed radially inward to the root of the impeller blades by a pressure gradient, accelerated through and out of the blades by centrifugal force, from where it reenters the fluid flow stator channel. During this time the fluid has been traveling tangentially around the periphery of the helical flow compressor/turbine. As a result of this, the helical flow is established as best shown in FIGS. 8, 11, and 12.
The helical flow compressor/turbine is a regenerative type of machine in which the working fluid, in this case gaseous fuel, passes several times through a single impeller between the time it enters and leaves a given compression stage. The fluid energy rise per stage of compression is a function of the number of regenerations (up to fifteen) times the fluid energy rise during each passage through the impeller.
FIG. 11 shows the flow through the impeller blades and the fluid flow stator channels by means of streamlines 39. On the other hand, FIG. 12 schematically illustrates the helical flow around the center of the impeller-stator channel. The turning of the flow is illustrated by a ribbon of streamlines in FIG. 12. The generally circular line in FIG. 12 represents the center of the impeller-stator channel.
When the helical flow compressor/turbine functions as a compressor, the gaseous file, upon leaving the impeller, has a greater tangential velocity than the gaseous fuel in the fluid flow stator channel. This high kinetic energy gaseous fuel decelerates and convert its kinetic or velocity energy into a potential or pressure energy and generates a pressure gradient around the fluid flow stator channel periphery. The gaseous fuel in the fluid flow stator channel, having less peripheral velocity than the gaseous fuel in the impeller blades, experiences a lower centrifugal force induced radial pressure gradient. Hence, there is a net radial pressure gradient in the fluid flow stator channel to direct the gaseous fuel to the impeller root and create regenerative flow.
FIG. 13 illustrates the fuel compression and control system of the present invention having two (2) helical flow compressor/turbines 14' and 14" in series. Each helical flow compressor/turbine 14' and 14" has a separate inverter drive 43' and 43" respectively which receives maximum speed and maximum torque control signals 46' and 46" from turbogenerator set power controller 15'. Partially compressed gaseous fuel is taken from the outlet 41' of the first helical flow compressor/turbine 14' and delivered to the inlet 40" of the second helical flow compressor/turbine 14" by gaseous fuel line 94.
An alternate representation of the helical flow compressor/turbine gaseous fuel compression and control system of the present invention is illustrated in FIG. 14. The elements common with FIG. 3 are preceded by the numeral 1 in FIG. 14; for example the helical flow compressor/turbine 14 of FIG. 3 is designated as helical flow compressor/turbine 114 in FIG. 14. In addition, the helical flow compressor/turbine motor inverter drive 143 is shown as receiving two hundred forty (240) volt electrical power via electrical supply line 195; and receiving a motor drive enable discrete signal 196 and speed/torque mode discrete signal 197 both from the turbogenerator set power controller 115. A fuel shutoff signal 198 from the turbogenerator set power controller 115 is provided to the fuel shutoff valve 199 between the gaseous fuel outlet pressure sensor 156 and turbogenerator 112. A fuel inlet shutoff valve 198 is provided in fuel inlet line 140.
FIG. 15 is a graph of the pressure rise across a single stage helical flow compressor versus fluid flow rate through the compressor for constant impeller speed. The dashed straight line is provided to illustrate the slope or curve of the pressure rise line.
The turbogenerator 12 is able to operate on whatever gaseous fuel is available in a pipeline, anywhere from six (6) inches water gauge at the low end to about fifty (50) psi gauge pressure at the top end. If the initial natural gas pressure is too high, the helical flow compressor/turbine 14 can be operated in a reverse direction to function as a turbine and reduce the pressure coming into the turbogenerator 12 so that the amount of fuel needed for initial ignition is obtained. That ignition then produces heat and turbine torque that accelerates the turbogenerator 12 which raises the pressure of the turbogenerator compressor 30. As the turbogenerator compressor 30 increases the pressure of the combustion air, the gaseous fuel pressure must be correspondingly increased to keep it somewhat higher so that there is a positive flow of gaseous fuel to the combustor nozzle injectors.
In order to start the system, the helical flow compressor/turbine motor 42 would normally be run backwards to overcome the upstream pressure of the gaseous fuel. The backward speed of the helical flow compressor/turbine 14 would be slowly reduced until there is a positive fuel flow to the combustor nozzle injectors while the turbogenerator is maintained at a constant speed ideal for the igniters. Light-off will occur when the correct fuel air ratio, a function of the combustion process, is achieved. Before light-of, the speed of the helical flow compressor/turbine is the controlling factor. After light-off, the controlling factor will be exhaust gas temperature during the remainder of the starting process. Once the light-off is completed the system will switch to a torque control mode.
The natural gas header pressure that is needed to operate the turbogenerator has to be extremely low for ignition. As the turbogenerator speed increases, the turbogenerator's compressor discharge pressure will increase up to as high as thirty seven (37) psi gauge. The natural gas pressure in the header that feeds the combustor nozzle injectors needs to be between three-tenths (0.3) psi above turbogenerator compressor discharge pressure to approximately a pound or pound and a half above turbogenerator compressor discharge pressure in order to accommodate gaseous fuel line losses or pressure drops in the various components in the gaseous fuel line to the combustor nozzle injectors.
For example, if the natural gas line pressure is twenty (20) psi gauge when you want to light-off, the pressure will have to be reduced by seventeen (17) or eighteen (18) psi when the turbogenerator is turning on low speed. As the turbogenerator speed increases, the pressure that goes into the header can be increased, that is the pressure needs to be reduced less. Ignition typically will occur while the helical flow compressor/turbine is still turning backwards and reducing pressure. It is only after the helical flow compressor/turbine ceases to function as a turbine and starts to function as a compressor that the system can function in a speed control mode.
When the helical flow compressor/turbine is operating at near zero speed, there is a very low gain in terms of the pressure rise since pressure rise is a function of speed squared. Once, however, the system is run in a torque control mode, the system is much more forgiving since any incremental change in torque will produce a well defined change in helical flow compressor discharge pressure. This system is capable of operating in either a speed or torque control mode particularly if it is operating open loop. As currently configured, the system operates in a speed control mode for start up and a torque control mode for turbogenerator closed-loop exhaust gas temperature (egt) and speed control operation. With pressure sensors both upstream and downstream of the helical flow compressor/turbine, pressure rises can be detected and gains can be scheduled. The pressure sensors also permit fault diagnostics to advise if the helical flow compressor/turbine is leaking or if the extra pressure doesn't meet your requirements, for example, if the inlet gaseous fuel pressure is not within your specification range, Alternately, however, the pressure sensors can be simulated by virtue of algorithms.
Once you have light-off, exhaust gas temperature increases. If the turbogenerator speed is known, turbogenerator compressor discharge pressure can be calculated as can the gaseous fuel pressure. The gaseous fuel pipeline pressure normally does not change over a short period of time. Gaseous fuel pipeline pressure will, however, change significantly from winter to summer and even from night to day. If the gaseous fuel pipeline pressure is known, it is a simple matter to calculate what helical flow compressor/turbine speed is required to obtain the gaseous fuel pressure at the header for the combustor nozzle injectors. With header pressure known, the turbogenerator speed for any mode will be known. There is a direct relationship between helical flow compressor/turbine speed and turbogenerator speed for any turbogenerator load.
The torque on the helical flow compressor/turbine motor, a function of the helical flow compressor/turbine permanent magnet motor current, can readily be monitored. Alternately, the helical flow compressor/turbine can run with the impellers turning but no torque in the helical flow compressor/turbine motor or a torque from the helical flow compressor/turbine motor which is simply providing power for the bearings and windage drag. The system inherently includes four feedback signals. These are the speed of the turbogenerator which provides compressor discharge pressure, the turbogenerator output power, turbine exhaust gas temperature and ambient air temperature. When operating at any given condition and a change in power is required, even before a change in command is provided to the helical flow compressor/turbine, the change of conditions to satisfy the new power demand is known. In other words, it is not necessary to wait for an error to determine what is required to correct the error. This enables a less limited slew rate and permits more aggressive damping which means less overshoot risk and less authority for the integral controls,
In addition, there may be hardware implemented shutdown limits as a back-up to the software limits and software which are in the system. While the limits of the software based limits are reached long before you actually hit the limits, the hardwired limits are really a strong safety clamp.
When the system is being operated at a constant speed and experiences an increase in load, the speed will start to drop until the gaseous fuel flow is increased to maintain a constant speed of the turbogenerator. When higher fuel flow is requested, a command is provided to the helical flow compressor/turbine to increase its speed to compensate for the change in power required. In an open loop, the speed is increased and then trimmed back to operate at peak efficiency. Unless the system is directly connected to a utility or can receive significant electrical power from batteries, turbogenerator output power cannot instantaneously be increased since output fuel flow cannot instantaneously be increased since turbogenerator turbine inlet temperature cannot instantaneously be increased.
The system will have both a transient temperature limit and a steady state temperature limit. The transient temperature limits will be higher than the steady state temperature limits so that a low transient change can be accommodated without any significant drop-off in turbogenerator speed. Energy is required to accelerate the helical flow compressor/turbine impellers and that energy has to come from somewhere. It is either taken from thermal energy or delivered energy or any combination of the two. The helical flow compressor/turbine has a lightweight impeller and thus has a better transient response time than other compressors.
If the turbogenerator load suddenly drops off significantly, the energy stored in the turbogenerator recuperator may require some kind of off-load bank, such as an electrical resistance bank to dissipate that energy. In stand-alone applications, a programmable device like a human interface will program a minimum load setting and a maximum load setting to prevent operating above a certain selected speed. Alternately, a valve can be utilized to simply dump discharge air pressure. It is simple to shut down the system if there is no longer any load by closing a solenoid valve upstream of the helical flow compressor/turbine. If you shut off the gaseous fuel flow, the system will essentially coast down to zero speed.
In deference to the hydrodynamic bearings on the turbogenerator, the system would normally be run down gradually or after a shut down the system would be restarted to run at a lower speed such as thirty thousand (30,000) or forty thousand (40,000) rpm to dissipate any heat remaining in the recuperator.
In most conventional systems, there would be a separate gaseous fuel helical flow compressor/turbine and a separate fuel metering valve. The system of the present invention eliminates the requirement for a separate metering valve. The helical flow compressor/turbine can effectively serve both functions of flow control and pressure control. By combining the fuel pressure and fuel flow control in the helical flow compressor/turbine, it is possible to maintain turbogenerator speed within plus or minus ten (10) rpm over a speed range of from approximately twenty four thousand (24,000) rpm to approximately ninety six thousand (96,000) rpm with a turbine exhaust gas temperature control within two (2) to three (3) degrees Fahrenheit. By primarily setting up pressure control such that a very small change in turbogenerator speed makes a big change in flow, the turbogenerator essentially stabilizes itself. Previous systems where the gaseous fuel compressor is run directly off the turbogenerator shaft with some kind of gear reduction, cannot even approximate this capability.
In order to provide a better understanding of the present invention, provided below are a series of sequential steps in a typical system operation of a system having an inlet shutoff valve, no inlet pressure sensor, a helical flow compressor/turbine permanent magnet motor/generator, an outlet pressure sensor and an outlet shutoff valve;
1. With inlet valve shut, open outlet valve.
2. Calibrate the outlet pressure sensor against atmospheric pressure.
3. Close outlet valve, pause, open inlet valve.
4. Using the just calibrated pressure sensor, determine the natural gas line pressure.
5. Close inlet valve.
6. Using the just calibrated pressure sensor to monitor pressure decay, determine if there are any gas leaks in the gaseous fuel compression and control system.
7. Compute the direction of rotation (usually backward) and approximate speed that the helical flow compressor/turbine must operate at (usually as a turbine) to provide the correct natural gas control system discharge pressure (usually about one psig) for combustor ignition at the turbogenerator ignition speed (usually about 16,000 rpm) for the current natural gas line pressure.
8. With outlet shut-off valve closed, set the helical flow compressor/turbine direction of rotation and speed to the computed value.
9. Trim the helical flow compressor/turbine speed to obtain the desired gaseous fuel control system discharge pressure for ignition (determined during previous start-ups) using the just calibrated pressure sensor.
10. Accelerate the turbogenerator to the ignition speed using available electric power, the turbogenerator's inverter and the turbogenerator's motor/generator operated as a motor.
11. Open the outlet shut-off valve.
12. Turn on the combustor ignitor.
13. Monitor the turbine discharge temperature for evidence of ignition.
14. If ignition does not occur in a short period (e.g. 1/2 second), increase fuel control discharge pressure at a predetermine pressure versus time rate by changing the speed of the helical flow compressor/turbine (typically reducing its backward speed).
15. When ignition occurs (as evidenced by an increase in turbine discharge temperature), computer log the fuel control discharge pressure at which ignition occurred so that on the subsequent start cycles, this updated pressure can be set in step 9.
16. Turn off the combustor ignitor.
17. Accelerate the turbogenerator at a predetermined rate (speed versus time) until it reaches a speed moderately above the self sustaining speed (usually about 25,000 rpm) using available electric power, the turbogenerator's inverter and the turbogenerator's motor/generator operated as a motor. During this acceleration, the electrical power input to the turbogenerator's motor will decline as the turbogenerator's combustion driven turbine generates increasing shaft torque and power. During this acceleration the turbogenerator's centrifugal compressor discharge pressure increases (nominally with the square of turbogenerator speed). The fuel control system must deliver natural gas to the combustor nozzles at a pressure slightly above the centrifugal compressor's discharge pressure in order for the fuel to enter the combustor and sustain combustion. Fuel flow rate, combustion temperature and turbine torque are strong functions of the small difference between the fuel control discharge pressure and the centrifugal compressor discharge pressure. There is, therefore, a relatively stable turbogenerator speed (that varies slightly with turbogenerator output power) for every level of fuel control discharge pressure. Thus, during this acceleration the fuel control system must continually adjust the helical flow compressor/turbine shaft torque direction and level so as to assure the desired turbine discharge temperature which is predefined as a function of turbogenerator speed.
18. When the turbogenerator has reached a speed at which no electrical power is required to accelerate it at the desired rate, continue to accelerate the turbogenerator to a yet higher speed with no electrical power being either utilized by or generated by the turbogenerator's permanent magnet motor/generator but rather utilizing for acceleration the combustion driven turbine torque. During this acceleration the fuel control system must set the helical flow compressor/turbine shaft torque direction and level so as to assure that the turbine discharge temperature is held within an acceptable range which is defined as a function of turbogenerator speed (too low and flame out occurs, too high and structural damage can occur) and so as to assure that the desired speed versus time and maximum speed setting are achieved.
19. Connect electrical load to the turbogenerator's generator either directly or through its inverter.
20. This step of the operation sequence represents the normal operating condition for the gaseous fuel compression and control system and for the turbogenerator. The fuel control system must continually adjust the helical flow compressor/turbine shaft torque direction and level so as to assure that the desired turbine discharge temperature is held near the maximum value for each turbogenerator speed using a slow servocontrol loop and is held at the desired turbogenerator speed for the current output power using a fast servocontrol loop.
Most turbogenerators operating with a low natural gas pressure will utilize a reciprocating compressor with a sixty (60) cycle phase motor to pump up the natural gas pressure to somewhere in the range of one hundred (100) psi gauge. This one hundred (100) psi gas is then stored in a pressure vessel or accumulator. An accumulator is required because the reciprocating compressor produces pressure pulsations and flow pulsations which, if applied directly to the combustor nozzles, could produce combustor rumble and/or blow out the combustor flame. A large accumulator will smooth out these pulsations or variations. In addition, the reciprocating compressor is cycled on and off since if run continuously it would continue to build up pressure. For example, the reciprocating compressor would run until the pressure in the accumulator reached one hundred ten (110) psi and then would be shut off until the pressure went down to eighty (80) psi when it again would be turned on. The accumulator is required to compensate for this on/off cycling which is of considerably longer duration than the pressure pulsations from the reciprocating compressor.
Once the accumulator has a stabilized natural gas pressure, the pressure must be reduced in a pressure regulator to a pressure which will always be below the lowest pressure in the accumulator. A flow control valve is then used to determine the natural gas flow to the combustor nozzle injectors. The flow control valve is usually computer controlled with the computer receiving information about turbogenerator speed, turbine exhaust gas temperature, and required turbogenerator power. The amount of natural gas flowing through the flow control valve would be a function of these three (3) parameters and their rate of change.
This type of system is relatively complicated and throws a lot of energy away by first compressing to a higher pressure than is required and then reducing the natural gas pressure to that which is actually required. It is also a fairly large system and requires a lot of power to produce the natural gas compression. Further, reciprocating compressors are typically oil lubricated and thus require oil removal systems. If the oil removal systems do not function to prevent oil from getting into the combustion process, the surface and walls of the combustor can be contaminated and varnish can build up on the nozzle injectors and other combustor components.
The helical flow compressor/turbine system of the present invention overcomes all of the above disadvantages of a reciprocating gaseous fuel compressor system.
While specific embodiments of the invention have been illustrated and described, it is to be understood that these are provided by way of example only and that the invention is not to be construed as being limited thereto but only by the proper scope of the following claims.
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A gaseous fuel compression and control system is disclosed which utilizes a helical flow compressor/turbine integrated with a permanent magnet motor/generator and driven by a torque controlling inverter to compress or expand gaseous fuels, precisely control fuel pressure and flow, and precisely control the operations (speed, combustion temperature and output power) of a gaseous fuel fired turbogenerator.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The instant application is a continuation-in-part application of U.S. application Ser. No. 10/124,045 entitled Medication Dispensing Apparatus Override check and Communication System filed Apr. 16, 2002 and assigned to the same assignee as the present invention.
BACKGROUND OF THE INVENTION
[0002] A wide variety of apparatus are used in healthcare facilities for the dispensing and inventory of medications and medical supplies. For example, U.S. Pat. No. 5,520,450 discloses a supply station with an internal computer. The supply station is comprised of a cabinet having a plurality of lockable doors. Information is provided to a computer which unlocks the doors. The computer may be used to simultaneously and automatically update a patient's record, billing information and hospital inventory. The relevant data may be displayed on a display or printed on a sheet of paper by a printer connected to the computer. Other examples of computer controlled dispensing apparatus are found in U.S. Pat. No. 5,346,297, U.S. Pat. No. 5,905,653 and U.S. Pat. No. 5,745,366.
[0003] Such computer controlled dispensing apparatus have been developed in response to a number of problems existing in hospitals and other healthcare institutions. More particularly, computer controlled dispensing apparatus are operated according to programming that addresses problems such as the removal of medications by unauthorized personnel, dispensing the wrong medication for a patient, inaccurate record keeping, to name a few.
[0004] The AcuDose-Rx dispensing cabinet available from McKesson Automation Inc. of Pittsburgh, Pennsylvania is an example of a computer controlled cabinet programmed to address the aforementioned problems. The user must first logon to the computer (thereby identifying who is removing medications). The user then identifies a patient and is presented with a list a medications that has been approved for administering to the identified patient (thereby addressing the problem of incorrect dispensing). Records are kept for each dispensing event thereby creating an audit trail.
[0005] To ensure the safe and accurate dispensing and administration of medications, a pharmacist reviews each prescription or medication order against that patient's medication profile and other relevant patient information to identify such items as therapeutic duplication in the patient's medication regimen; appropriateness of the drug, dose, frequency, and route of administration; medication allergies or sensitivities; potentially significant drug-drug, drug-food, drug-lab, and drug-disease interactions; contraindications to use; any organizational criteria for use; and other relevant medication-related issues or concerns. If a question or concern arises, the pharmacist contacts the person who prescribed the medication.
[0006] Many computer controlled dispensing apparatus have a “medication order profile interface” system that requires that all new medication orders for patients be entered into a pharmacy information system, where they are checked as discussed above. After the pharmacy information system completes the necessary clinical checks, data must be transmitted to the dispensing apparatus before the nurse is free to access the medication in the dispensing apparatus. That is done to ensure that medications are not dispensed and subsequently administered without a prior review by a pharmacist.
[0007] Problems can arise, however, when a pharmacist is not available to provide the necessary review. In many institutions, pharmacists are not available around the clock, although patients may be admitted at any time. Additionally, an emergency may arise or a doctor may write a STAT order. Under such circumstances, when a healthcare provider, typically a nurse, must retrieve medication from the dispensing apparatus, the patient may not be recognized by the dispensing apparatus, or the desired medication may not yet be approved for the patient. As a result, to enable a dispense to occur, the nurse must exit the normal dispensing routine by entering an override mode, emergency mode, or the like. Unfortunately, in such alternative modes, control is lost over why the dispensing operation is needed, for whom, and the like. That loss of control and information has been recognized by the Joint Commission on Accreditation of Healthcare Organizations (JCAHO). In its proposed medication use standards, JCAHO provides that when a pharmacist is not on the premises, nurses can administer any medication needed for the patient without a pharmacist' prior review if the healthcare institution has developed an alternative system for medication order review that minimizes the impact of skipping the pharmacist' review prior to administration. At a minimum, that must include the following: a retrospective review of the medication orders by the pharmacist as soon as a pharmacist is available; a review of the medication order by a qualified healthcare professional prior to administration of the medication for appropriateness against a database of information (e.g., drug interaction reference and drug profile); and an ongoing analysis and monitoring of the process for the incidence of medication errors as compared to the incidence of medication errors when the pharmacy is open. The need exists for a medication dispensing and administering apparatus that facilitates dispensing events in a controlled, traceable manner in situations where an event is requested for medication not approved for a patient.
SUMMARY OF THE INVENTION
[0008] The present invention is directed to a method of dispensing or administering medications which requires prompting the user for a reason if the user wants to dispense or intends to administer a medication that is not on the patient' medication profile. For example, a patient may be in severe discomfort, or some other condition exists, that requires dispensing and administration of a medication not approved by a pharmacist for the patient. The method prompts the user to supply a reason (exception) for the dispensing or administering that can be used to create an audit trail. The method may include identifying a patient, accessing a medication profile for the identified patient, selecting a medication for the identified patient, the selected medication not having been reviewed against the patient' medication profile, prompting the user to identify an exception, and reviewing the exception to determine its acceptability. If the exception is acceptable, access to a dispensing apparatus' storage compartment(s) for the purpose of dispensing the medication may be granted and a record of the dispensing event is created, or the healthcare giver may administer the medication and a record of the administration is created. If the exception is not acceptable, a record of the request to dispense or the request to administer is created. The method may further include transferring the override requests and override events to a database containing pharmacy orders. The requests, events, and orders may be sorted according to a predetermined criterion, and presented to a pharmacist for review.
[0009] The present invention prevents dispensing and warns against administering medications when the medication has not been approved for the patient and no acceptable reason exists for not waiting until a pharmacist can make the necessary review. If an acceptable reason exists for dispensing/administering before the necessary review by a pharmacist has taken place, the present invention provides documentation and an audit trail of the reasons for the event. With electronic collection and distribution of events or requests for events, efficiencies and cost savings are enabled. Further, that information can be sent to centralized 24/7 pharmacies that provide after-hours services to institutions that are not staffed in off hours, thereby insuring compliance even with reduced hours and staff. Those advantages and benefits, and others, will be apparent from the description below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] For the present invention to be easily understood and readily practiced, the present invention will now be described, for purposes of illustration and not limitation, in conjunction with the following figures, wherein:
[0011] [0011]FIG. 1 is a diagram illustrating the relationship between a centralized storage location and, among other things, a plurality of storage locations;
[0012] [0012]FIG. 2 is one example of apparatus located at a decentralized location implementing a closed system for performing dispensing operations;
[0013] [0013]FIG. 3 is a flow chart illustrating a method of dispensing for a patient according to the present invention;
[0014] [0014]FIG. 4 is an exemplary screen illustrating one way of prompting a user for information;
[0015] [0015]FIG. 5 is an illustration of a type of handheld scanner/administration device with which the present invention may be used;
[0016] [0016]FIG. 6 is a flow chart illustrating a method of administering for a patient which may be used in conjunction with the device of FIG. 5; and
[0017] [0017]FIG. 7 is a flow chart illustrating a method of communicating and processing override events.
DESCRIPTION OF THE INVENTION
[0018] [0018]FIG. 1 is a diagram illustrating the relationship between a centralized storage location 10 and various inventory destinations, including a plurality of decentralized storage locations 12 - 1 , 12 - 2 through 12 - n , patients 13 , and a remote facility 14 . Each of the decentralized storage locations 12 - 1 through 12 - n is capable of dispensing items stored at the location. The items may include medications, controlled medical supplies, medical supplies or items of a nature consistent with the facility in which the system illustrated in FIG. 1 is located. Items may be dispensed directly from centralized storage location 10 to patients 13 , or from the centralized storage location 10 to a remote facility 14 . Data typically flows from the decentralized storage locations 12 - 1 through 12 - n to the centralized storage location 10 . In response to that data, items are typically moved from the central storage location 10 to the decentralized storage locations 12 - 1 through 12 - n or to the remote facility 14 to restock such locations to either replenish dispensed items or to stock new items. Decentralized locations could include satellite pharmacies, computerized medication cabinets, stationary/mobile medication carts, nurse servers, remote hospital pharmacies, supply closets, supply cabinets, etc. Supplies can be reordered from distributors based on levels of stock in the centralized storage location 10 .
[0019] [0019]FIG. 2 illustrates one example of an apparatus that may be located at any of the decentralized locations 12 - 1 through 12 - n . The apparatus illustrated in FIG. 3 is comprised of an AcuDose-Rx™ cabinet 26 and an AcuDose-Rx™ auxiliary cabinet 28 available from McKesson Automation Inc. A supply tower 30 is also illustrated. A control computer 32 controls the operation of the cabinet 26 , auxiliary cabinet 28 , and supply tower 30 . The control computer 32 is also in communication with a central database (not shown). The reader will understand that the present invention is not limited to the AcuDose-Rx™ cabinet 26 , but rather the method of the present invention may be implemented on any type of computer controlled dispensing apparatus.
[0020] Turning now to FIG. 6, a flow chart illustrating a method which may be practiced on the handheld device 65 illustrated in FIG. 5 is shown. * * * To perform a dispensing operation a user logs onto the control computer 32 at step 36 . In that manner, the computer receives information identifying the user. The user information is compared to stored information at step 38 . At step 40 a patient is identified. The information could be entered on a keypad, either by name or by an ID number, the information could be scanned, selected from a pick list, or any other known method of entering the patient information. In that manner, the computer receives information identifying the patient.
[0021] At step 42 a medication profile for the patient is displayed. The display may include all of the medications which have been approved by a pharmacist for administration to the patient. For a normal dispensing event, not shown in detail but represented by the box 43 , the user then selects from the displayed medications. However, if the medication has been ordered on a STAT or emergency basis, it may not be displayed at step 42 . The user then selects at step 44 an override mode. The use of the phrase “override mode” is not intended to limit the present invention. In the vernacular of the AcuDose cabinet, when a user wishes to select a medication not in the patient's medication profile, the override mode is enabled. Sometimes a patient has not yet been admitted on the system, thus requiring creation of a patient record prior to proceeding. In those cases, the user is taken directly to the list of medications available for dispensing. Other cabinet manufacturers may use other terminology. The concept is that the user wishes to select a medication for dispensing which is not on the patient's medication profile or, in other words, the user wishes to dispense a medication prior to review by a pharmacist or other qualified healthcare provider, regardless of whether that is referred to as an override mode, an emergency mode, or any other phrase specific to a particular manufacturer.
[0022] At step 46 , the control computer 32 displays a list of medications available for dispensing. The list could include all of the medications in the various cabinets, auxiliary cabinets, supply towers and the like under the control of the control computer 32 , or some set of that list for which the particular user has authority to dispense. At step 48 , the user selects the desired medication or medications. Selection could be via a touch screen, entry through a keypad, or any other known method of entering information for enabling the selection. In that manner, the control computer receives information identifying a medication to dispense. At step 50 the user is prompted to enter information. The information being entered may be variously described as an “exception” to the general rule that a medication cannot be dispensed unless the order has been reviewed by a pharmacist or the “reasons” why the dispense is necessary. There are two recognized exceptions for when an nurse can dispense prior to a pharmacists review, e.g. in the override mode. The first is a situation in which a physician or other qualified healthcare provider controls the ordering, dispensing and administration of the medication, such as in an operating room, endoscopy suite, or an emergency room. The second exception is for those emergencies when there is not sufficient time to obtain the necessary review. Those include STAT orders or those orders where the clinical status of the patient would be significantly compromised by the delay that would result from waiting for a pharmacist's review. Not all first orders meet these criteria.
[0023] An example of an exemplary screen 60 used to prompt the user to provide the required information is illustrated in FIG. 4. In FIG. 4, two exceptions acceptable to an organization such as JCAHO are illustrated: physician controlled dispensing 62 and STAT order 64 . The curser may be placed in the appropriate box and a keystroke entered. However, the information may be input in any known way such as selecting a reason or exception from a pick list, or the like. The exceptions or reasons shown to the user may be hard coded by the manufacturer, soft coded to allow the user to create the text, or customizable hard code, where the user selects which exceptions from among numerous exceptions will be displayed, or any other known manner.
[0024] In addition to a listing of various exceptions a text box 66 may be provided. The text box may be used to record textual information which the nurse wishes to add to the record. In an alternative embodiment, the textbox may be used in place of a list. In that embodiment, the text in the text box is subjected to character recognition followed by a search for keywords to determine if the exception or reason for the dispense is adequate. A reason for dispensing each medication selected at step 48 must be provided at step 50 .
[0025] At step 52 , an evaluation is made to determine if the reasons input at step 50 are sufficient. For example, if one of the reasons is an exception recognized by a committee such as JCAHO, and the box 62 , 64 next to that reason has been selected, then the process continues at step 54 where the “override” event is stored and a dispensing event takes place at step 58 . It should be recognized that the analysis performed at step 52 will depend to a large degree on the type of information input at step 50 . For example, if at step 50 the user's only options are to choose amongst acceptable exceptions, then perhaps the only analysis that needs to be performed at step 52 is whether one of the exceptions has been selected. If, however, at step 50 the user is prompted to select from a list of numerous exceptions, some of which are acceptable and some of which are not, it may be necessary at step 52 to determine if an acceptable exception has been selected. In yet another embodiment, where all that is provided is a text box, at step 52 it may be necessary to perform character recognition, and then perform an analysis upon the recognized characters to determine if the proper keywords or phrases have been used for a recognized exception. The present invention is not to be limited by the manner in which the user is prompted to input reasons at step 50 and the manner in which those reasons are evaluated at step 52 .
[0026] It should also be noted that code may be provided for disabling steps 50 and 52 . For example, in a hospital or other healthcare institution in which procedures are already in place to properly document dispenses in an “override” mode, the institution may choose to disable steps 50 and 52 and proceed directly to storage of the override event 54 and dispensing at step 58 as soon as the user selects the medications at step 48 .
[0027] Assuming that the reasons were acceptable at step 52 , as noted the override event is stored at step 54 . Thereafter, a dispensing event occurs at step 58 and the process returns to step 56 . If the reasons were unacceptable at step 52 , the override request is stored at step 60 and the process continues with step 56 .
[0028] After an override request has been stored at step 60 , or a dispensing event has occurred at step 58 , one important aspect from the healthcare institution's perspective is to have a pharmacist review either the override request or the override event as soon as possible. That may be implemented in at least two ways. First, the records of the override requests and override events may be printed, for example, at a pharmacy computer, or if an electronic pharmacy system is available, the records of the override requests and override events may be forwarded to the pharmacy system, as will be described in greater detail in conjunction with FIG. 7.
[0029] The previous paragraphs describe how a dispensing event for a patient may be performed in conjunction with a medication not listed on the patient's profile. A similar situation may arise when a medication which is not on a patient's profile is to be administered. The administration of medication may be controlled through the use of a scanner/administrating device 65 of the type illustrated in FIG. 5. Such devices are commercially available. An example of one such device is sold under the name AcuScan-Rx by McKesson Automation Inc. of Pittsburgh, Pennsylvania. The device 65 is capable of receiving information about a patient, for example through scanning a patient's bracelet, selecting a patient from a pick list, or entering patient ID information. The device 65 may include an RF transmitting device allowing the device 65 to be in real time communication with a database which may be located at the centralized location, hospital pharmacy, or other location. Other types of scanner/administrating devices may require docking in a base station before communicating with the database.
[0030] Turning now to FIG. 6, a flow chart illustrating a method which may be practiced on the handheld device 65 illustrated in FIG. 5 is shown. To perform an administering operation a user logs into the computer controlled handheld device 65 at step 86 . In that manner, the computer (not shown) of the device 65 receives information identifying the user. The handheld device 65 displays a patient list at step 88 . At step 90 a patient is identified. The information could be entered on a keypad, either by name or by an ID number, the information could be scanned, selected from a pick list, or any other known method of entering the patient information. In that manner, the computer of the handheld device 65 receives information identifying the patient.
[0031] At step 92 a medication profile for the patient is displayed. The display may include all of the medications which have been approved by a pharmacist for administration to the patient. For a normal administering event, not shown, the user then selects from the displayed medications. However, if the medication has been ordered on a STAT or emergency basis, it may not be displayed at step 92 . The user then selects at step 94 an override mode. The use of the phrase “override mode” is not intended to limit the present invention. In the vernacular of an AcuScan Rx handheld device, when a user wishes to select a medication not in the patient's medication profile, the override mode is enabled. Sometimes a patient has not yet been admitted on the system, thus requiring creation of a patient record prior to proceeding. In those cases, the user is taken directly to the list of medications available for administering. Other manufacturers may use other terminology. The concept is that the user wishes to select a medication for administering which is not on the patient's medication profile or, in other words, the user wishes to administer a medication prior to review by a pharmacist or other qualified healthcare provider, regardless of whether that is referred to as an override mode, an emergency mode, or any other phrase specific to a particular manufacturer.
[0032] At step 96 , the handheld device 65 displays a list of medications available for administering. The list could include all of the medications in the various cabinets, auxiliary cabinets, supply towers and the like in communication with the handheld device 65 , or some set of that list for which the particular user has authority to administer. Typically, at this point, the healthcare worker has already dispensed or otherwise obtained the medication that is to be administered. At step 98 , the user selects the desired medication or medications from the list. Selection could be via a touch screen, entry through a keypad, or any other known method of entering information for enabling the selection. In that manner, the handheld device 65 receives information identifying a medication to be administered.
[0033] At step 100 the user is prompted to enter information. The information being entered at step 102 may be variously described as an “exception” to the general rule that a medication cannot be administered unless the order has been reviewed by a pharmacist or the “reasons” why the administering is necessary. There are two recognized exceptions for when an nurse can administer prior to a pharmacists review, e.g. in the override mode. The first is a situation in which a physician or other qualified healthcare provider controls the ordering, dispensing and administration of the medication, such as in an operating room, endoscopy suite, or an emergency room. The second exception is for those emergencies when there is not sufficient time to obtain the necessary review. Those include STAT orders or those orders where the clinical status of the patient would be significantly compromised by the delay that would result from waiting for a pharmacist's review. Not all first orders meet these criteria. The exemplary screen 60 illustrated in FIG. 4 and described in conjunction with the process of FIG. 3 may also be used in conjunction with the process of FIG. 6.
[0034] At step 104 , an evaluation is made to determine if the reasons input at step 102 are sufficient. For example, if one of the reasons is an exception recognized by a committee such as JCAHO, and the box 62 , 64 (see FIG. 4) next to that reason has been selected, then the process continues at step 106 where the “override” event is stored and an administering event takes place at step 108 . It should be recognized that the analysis performed at step 104 will depend to a large degree on the type of information input at step 102 . For example, if at step 102 the user's only options are to choose amongst acceptable exceptions, then perhaps the only analysis that needs to be performed at step 104 is whether one of the exceptions has been selected. If, however, at step 100 the user is prompted to select from a list of numerous exceptions, some of which are acceptable and some of which are not, it may be necessary at step 104 to determine if an acceptable exception has been selected. In yet another embodiment, where all that is provided is a text box, at step 104 it may be necessary to perform character recognition, and then perform an analysis upon the recognized characters to determine if the proper keywords or phrases have been used for a recognized exception. The present invention is not to be limited by the manner in which the user is prompted at step 100 and inputs reasons at step 102 and the manner in which those reasons are evaluated at step 104 .
[0035] It should also be noted that code may be provided for disabling steps 100 , 102 and 104 . For example, in a hospital or other healthcare institution in which procedures are already in place to properly document administerings in an “override” mode, the institution may choose to disable steps 100 , 102 and 104 and proceed directly to storage of the override event 106 and administering at step 108 as soon as the user selects the medications at step 98 . In other circumstances, for example if computer controlled dispensing devices are used in a healthcare facility, it may not be necessary or desirable to duplicate the audit trial at the time of administering if an audit trial was created at the time of dispensing.
[0036] Assuming that the reasons were acceptable at step 104 , as noted the override event is stored at step 106 . Thereafter, an administering event occurs at step 108 and the process returns to step 110 . If the reasons were unacceptable at step 104 , the override request is stored at step 112 and the process continues with step 110 .
[0037] After an override request has been stored at step 112 , or an administering event has occurred at step 108 , one important aspect from the healthcare institution's perspective is to have a pharmacist review either the override request or the override event as soon as possible. That may be implemented in at least two ways. First, the records of the override requests and override events may be printed, for example, at a pharmacy computer, or if an electronic pharmacy system is available, the records of the override requests and override events may be forwarded to the pharmacy system, as will be described in greater detail in conjunction with FIG. 7.
[0038] In FIG. 7, a flow chart illustrating another method according to the present invention is illustrated. In FIG. 7, records for each override request stored at step 60 in FIG. 3 or step 112 in FIG. 6, and records of each override event stored at step 54 in FIG. 3 and step 106 in FIG. 6, are monitored at step 68 . A decision is made at step 70 if a pharmacy workstation 110 exists. If there is no pharmacy workstation 110 , then the override requests and override events are printed at step 72 , preferably at a pharmacy printer 112 , so that they may be reviewed by a pharmacist as soon as practicable. If there is a pharmacy workstation 110 , then the records representative of the override requests and override events are added to the workstation queue at step 74 .
[0039] The workstation queue may be created, in the first instance, by commercially available products such as the Pyxis Connect product available from Pyxis Corporation or the MedDirect product available from McKesson Automation, Inc. as represented by block 76 . The MedDirect product is an automated system for communicating medication orders and for managing documents. Using imaging technology, the MedDirect product delivers clear, scanned medication order images directly to the hospital pharmacy, where they can be viewed simultaneously with the pharmacy information system. Once the order is reviewed and approved by a pharmacist, it is entered in the pharmacy information system and made available for profile dispensing and administering by, for example, the AcuDose cabinet 26 (FIG. 2) or the AcuScan Rx handheld device (FIG. 5), respectively. At step 74 , certain logic or rules may be applied to the queue to sort or reorder the queue. For example, records representative of override events may be placed at the front of the queue.
[0040] At step 78 , the user selects a record from the queue to review. At step 80 , a user, typically a pharmacist, will review the override events and/or approve override requests. The pharmacist may optionally input orders into a pharmacy information system . At step 82 , the override requests and override events are archived for later review by a decision support system or the like as represented by step 84 .
[0041] A hospital may received a type I recommendation from an organization such as JCAHO because nurses are accessing medication dispensing and administering apparatus for first doses of medication. Implementation of the present invention provides a hospital with evidence that policy and procedures are being adhered to, as well as providing an audit trail of all override activities associated with computer-controlled medication dispensing and administering apparatus.
[0042] Having the present invention integrated into computer-controlled medication dispensing and administering apparatus provides an electronic transfer of the information immediately, or based on a time delay, to a location where a pharmacist is available, thus creating efficiencies and cost savings. With electronic collection and distribution of the override information, that information can be sent to centralized 24/7 pharmacies that provide after-hours services to institutions that are not staffed in off hours, thereby insuring compliance even with reduced hours and staff. Electronic communications systems can be attached, such as cell phones, beepers, and e-mail to provide notification to pharmacists of the need to address override events and/or requests. More sophisticated wireless PDAs (personal digital assistants) can actually be connected to such systems, alerting pharmacists of the need to address override events and/or requests, allowing them to review the collected information, and providing approval transactions from remote locations.
[0043] Patient safety is ultimately enhanced when computer-controlled medication dispensing and administering apparatus incorporate the present invention so as to aid caregivers during overrides. Providing the means of enforcing and auditing hospital policy and procedures directly contributes to overall patient safety in compliance with JCAHO recommendations.
[0044] Many hospitals may have both systems in place, that is, computer controlled medication dispensing and administering apparatus. The caregiver may foreseeable have to go through the override process twice. That is, they may have to override at the dispensing cabinet and override again at the handheld device for administering. This may result in the creation of two records. Some institutions may choose to have two records. Other institutions may choose to suppress the second record. The choice to suppress a record may be an option of the handheld device 65 provided to the user at step 100 in FIG. 6.
[0045] While the present invention has been described in conjunction with preferred embodiments thereof, those of ordinary skill in the art will recognize that many modifications and variations may be implemented while still falling within the scope of the present invention. Other types of dispensing and administrating devices may be used, and process steps may be substituted for those described in the preferred embodiment while remaining within the scope of the present invention. The description of presently preferred embodiments is not intended to limit the scope of the present invention, which is defined by the following claims.
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The present invention is directed to a method of dispensing or administering medications which requires prompting the user for a reason if the user wants to dispense or intends to administer a medication that is not on the patient's medication profile. For example, a patient may be in severe discomfort, or some other condition exists, that requires dispensing and administration of a medication not approved by a pharmacist for the patient. The method prompts the user to supply a reason (exception) for the dispensing or administering that can be used to create an audit trail. The method may include identifying a patient, accessing a medication profile for the identified patient, selecting a medication for the identified patient, the selected medication not having been reviewed against the patient's medication profile, prompting the user to identify an exception, and reviewing the exception to determine its acceptability. If the exception is acceptable, access to a dispensing apparatus' storage compartment(s) for the purpose of dispensing the medication may be granted and a record of the dispensing event is created, or the healthcare giver may administer the medication and a record of the administration is created. If the exception is not acceptable, a record of the request to dispense or the request to administer is created. The method may further include transferring the override requests and override events to a database containing pharmacy orders. The requests, events, and orders may be sorted according to a predetermined criterion, and presented to a pharmacist for review.
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CROSS RELATED APPLICATION
This application is a divisional of application Ser. No. 11/559,564 filed Nov. 14, 2006, the entirety of which application is incorporated by reference.
BACKGROUND OF THE INVENTION
This invention relates generally to nuclear reactors and, more particularly, to assemblies and methods for reinforcing piping for coolant spray within reactor pressure vessel of such reactor.
A reactor pressure vessel (RPV) of a boiling water reactor (BWR) typically has a generally cylindrical shape and is closed at both ends, e.g., by a bottom head and a removable top head. A core shroud typically surrounds the core and is supported by a shroud support structure.
Boiling water reactors generally include piping for core spray cooling water. Core spray piping is used to deliver water from outside the RPV to core spray spargers inside the RPV. The core spray piping and spargers deliver coolant water to the reactor core.
The core spray cooling water is typically supplied to the reactor core region through a sparger T-box which penetrates the shroud wall. The distal end of the sparger T-box is internal to the shroud and is capped by a flat cover plate welded to the distal end of the sparger T-box. A piping tee is formed by the welded union of the sparger T-box, sparger T-box cover plate, and two sparger pipes.
The welded unions between the T-box, cover plate and sparger pipes are susceptible to cracking. There is a risk that the cracks in these welds may propagate by progressing circumferentially around the welded joint. If circumferential cracking occurs in the welded unions, unpredictable cooling water leakage may result.
Intergranular stress corrosion cracking (IGSCC) occurs in reactor components exposed to high temperature water, such as structural members, piping, fasteners, and welds. The reactor components are subject to a variety of stresses associated with differences in thermal expansion, the operating pressure needed for the containment of the reactor cooling water, and other stress sources such as residual stresses from welding, cold working and other inhomogeneous metal treatments. Water chemistry, welding, heat treatment and radiation can increase the susceptibility of metal in a component to IGSCC.
There is a long felt need for a method and means to reinforce welded joints. Reinforcement helps prevent separation of the welded piping joints. It would be desirable to provide a clamping system to provide structural integrity to the sparger T-box and hold the welded joints together in the event of weld failure.
BRIEF DESCRIPTION OF THE INVENTION
The core spray piping systems in operating BWRs are of welded construction. Welds in the spray piping are susceptible to IGSCC. A repair or reinforcement clamping device has been developed that structurally supports welded joints between the core spray sparger T-box, sparger piping, and T-box cover plate. A reinforcing clamp has been developed that structurally replaces or reinforces the cover plate weld and sparger pipe welds of the sparger T-box. The clamp attaches to the T-box without substantial modification of the T-box.
A core spray sparger T-box clamp for a sparger T-box in a shroud of a nuclear reactor pressure vessel, the sparger T-box clamp includes: an anchor plate substantially aligned with a closed end of the T-box; a carrier plate slidably secured to a first side of the anchor plate and engages the T-box; a saddle bracket is secured to second side of the anchor plate and engages with the T-box, wherein the second side of the anchor plate is opposite to the first side, and a pair of clamp blocks on opposite sides of the anchor plate attach to a respective sparger pipe welded to the T-box.
The core spray sparger T-box may be latched to the T-box clamp by a first location pin extending into the bottom of a sidewall of the T-box and extending from the saddle bracket and a second location pin extending from the carrier plate into the top of the T-box sidewall, wherein the first location pin is parallel to the second location pin. The first location pin and the second location pin may extend vertically. The carrier plate may further include a vertical tongue that slides into a slot in the anchor plate and the tongue is parallel to a location pin. The carrier plate may include a horizontal arm having an arched lower surface conforming to a cylindrical sidewall of the T-box and the lower surface extends from the sidewall to beyond the T-box.
The saddle bracket may include a horizontal arm having an arched upper surface conforming to a cylindrical sidewall of the T-box and a tongue extending across the horizontal arm adapted to fit into a groove in a lower edge of the anchor plate. The horizontal arm of the saddle bracket includes a vertical locating pin extending into the T-box to latch the saddle bracket to the T-box. The saddle bracket may be secured to the anchor plate by at least one cap screw extending through the tongue and into a threaded aperture in the anchor plate.
The anchor plate further includes at least one threaded aperture orthogonal to an end plate of the T-box and a bearing plate bolt(s) turned into each of the threaded apertures. A bearing plate is rotatably attached to the ends of the bearing plate bolt(s). Turning the bolts, extends the bearing plate from the anchor plate to abut the bearing plate against the cover plate of a T-box.
A core spray sparger T-box clamp has been developed for a sparger T-box in a shroud of a nuclear reactor pressure vessel, the sparger T-box clamp comprising: an anchor plate assembly including an anchor plate, a bearing plate bolt extending through the anchor plate and a bearing plate attached to a distal end of the bearing plate bolt, wherein the bearing plate abuts an cover plate of the T-box; a carrier plate slidably secured to a first side of the anchor plate and latched to the T-box by a locating pin, and a saddle bracket secured to a second side of the anchor plate, wherein the second side of the anchor plate is opposite to the first side, and said saddle bracket is latched to the T-box by a second location pin.
A method has been developed for attaching a core spray sparger T-box clamp for a sparger T-box in a shroud of a nuclear reactor pressure vessel, the method comprising: attaching a saddle bracket to the underside side of the anchor plate; securing an assembly of the saddle bracket and anchor plate to a bottom surface of the T-box, and attaching a carrier plate to the anchor plate by a carrier bolt and latching the carrier plate to an upper surface of the T-box. The method may further include slidably mounting clamp blocks to the sides of the anchor plate and bolting the clamp blocks to sparger pipes welded to the T-box.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective, partial cut away view of a reactor pressure vessel (RPV) of a boiling water nuclear reactor.
FIG. 2 is a perspective view of a portion of a T-box and sparger pipes viewed from the inside of the RPV.
FIG. 3 is a perspective view of a T-box clamp assembly fastened to the T-box assembly in the RPV.
FIG. 4 is an exploded, front perspective view of the clamp assembly.
FIG. 5 is an exploded, rear perspective view of the clamp assembly.
FIG. 6 is a perspective view of a saddle bracket.
FIG. 7 is a perspective view of a carrier plate.
FIGS. 8 and 9 are perspective views of the sparger T-box and sparger piping showing modifications made for the clamp assembly.
FIG. 10 is a perspective view of the clamp assembly ready to be inserted into a RPV.
FIG. 11 is a perspective view of the clamping assembly on an installation tool.
DETAILED DESCRIPTION OF THE INVENTION
A core spray sparger T-box clamp assembly which attaches to a core spray sparger T-box and connecting sparger piping has been developed. The clamp assembly structurally replaces or reinforces welds that attach the T-box cover plate and sparger pipes to a sparger T-box.
FIG. 1 is a partial cross-sectional and cut-away view of a reactor pressure vessel (RPV) of a boiling water nuclear reactor. FIG. 1 illustrates a shroud and shows the spatial arrangement of a downcomer piping, elbow and thermal sleeve 17 attachment to the shroud. A reactor pressure vessel (RPV) 10 includes a vessel wall 12 and a shroud 14 which surrounds the reactor core (not shown) of RPV 10 . An annulus 13 may be formed between vessel wall 12 and shroud 14 . The space within the annulus may be limited, as most reactor support piping may be located within the annulus.
When there is a loss of coolant to the RPV, cooling water is delivered to the reactor core through a core spray distribution header which includes a horizontal section (not shown) and a vertical section commonly referred to as a downcomer pipe 16 . The downcomer pipe 16 may include a lower elbow 18 extending through a thermal sleeve 17 and passing through an aperture 20 (hidden by the thermal sleeve) in the wall of the shroud 14 . A piping segment connects to the lower elbow, and extends through the shroud wall and to a sparger T-box 22 on the inside surface of the shroud wall. The T-box is attached to internal sparger pipes 24 , 26 , that extend circumferentially around the inside wall of the shroud 14 .
FIG. 2 is perspective view of the inside wall of the shroud 14 , the sparger T-box 22 and the sparger pipes 24 , 26 that extend circumferentially around the shroud wall. A sparger T-box 22 provides cooling water to the core region through an opening 20 in the wall of the core shroud 14 . The T-box 22 is welded to, for example, a cover plate 30 and to opposite ends of a sparger pipe 26 . A distal end of the sparger T-box is inside the shroud 14 . The cover plate 30 is a flat plate welded to the distal end of the sparger T-box. The opposite ends of the sparger pipes 26 commonly of smaller bore than the T-box are welded to the sparger T-box 22 . The sparger pipe 26 ends are welded 32 to openings provided in the sidewall 34 of the sparger T-box 22 . A piping tee is formed by the welded union of the sparger T-box, sparger T-box cover plate, and the two segments of a sparger pipe.
The welded joints 32 between the T-box 22 and cover plate 30 and the T-box and sparger pipe 26 are susceptible to cracking. The weld cracking may propagate through the wall of the T-box or circumferentially around the cover plate or pipes. The cracking may lead to unpredictable leakage of coolant water from the T-box into the shroud. A preemptive repair and reinforcement clamp assembly has been developed to prevent separation of the welded joints, even if the cracking through the joints becomes excessive.
FIG. 3 is a perspective view of a core spray sparger T-box clamp assembly 36 that attaches to the sparger T-box and the opposite ends of sparger pipe 26 . The clamp assembly reinforces the welds 32 between the opposite ends of sparger pipe 26 , the cover plate 30 and the T-box 22 . If cracks develop in the welds 32 , the clamp assembly 36 holds the pipes, T-box and cover plate together, inhibits crack propagation and prevents or minimizes coolant water leakage.
The core spray sparger T-box clamp assembly 36 includes an anchor plate 38 , a first clamp block 40 and a second clamp block 42 . The anchor plate 38 is between the clamp blocks 40 , 42 , and positioned in front of the cover plate 30 of the T-box. The blocks 40 , 42 connect to opposite sides of the anchor plate. Dove-tail joints between the clamp blocks 40 , 42 and the anchor plate 38 secure the blocks to the anchor plate and permit the clamp blocks to slide relative to the anchor plate. The clamp blocks may be slid back on the anchor plate, such that the blocks and their T-bolts 74 ( FIG. 4 ) are retracted away from the T-box and sparger pipes as the assembly is fitted onto the T-box. Once the anchor plate is secured to the T-box, the T-bolt nuts are rotated which brings the sealing collar 76 to bear against the curved surface of the sparger pipe and moves clamp blocks 40 , 42 into a parallel alignment with the anchor plate.
The clamp blocks 40 , 42 are attached to the sparger pipes by T-bolts 74 ( FIG. 4 ) and T-bolt nuts 44 . The T-bolts extend through apertures 80 ( FIG. 8 ) in the sparger pipe 26 . A threaded end of each bolt projects through an aperture in the clamp blocks 40 , 42 . The sealing collar 76 that interfaces with the sparger pipe prevents water leakage around the bolt. The T-bolt nuts 44 screw onto the threaded T-bolts and secure the clamp blocks to the pipes. The head of the bolt has a racetrack shape to slide into a corresponding slot aperture 80 in the pipe. The bolt is turned 90 degrees to be locked in the pipe. A sealing collar 76 is inserted on the bolt shaft and the shaft is inserted into a smooth bore hole 78 in the clamp block. A recess in the front face of the block is coaxial with the bolt hole and provides a seat for the T-bolt nut 44 . A coaxial recess is also provided in the back face of the block to provide a seat for the sealing collar. The bottoms of both coaxial recesses have a semispherical shape to accommodate small amounts of articulation by the T-bolt and sealing collar as they interface with the sparger pipe. Ratchet springs 80 prevent the nuts from turning and fit into slots on the front of the clamp blocks 40 , 42 . The clamp blocks and a similar anchor plate are described in US Published Patent Application 2006/0082139 A1, which is commonly owned with this application and incorporated by reference herein in its entirety.
FIG. 4 is an exploded view of the core spray sparger clamp assembly 36 showing a front and top view of the clamp. FIG. 5 is an exploded view of the core spray sparger clamp assembly 36 showing a rear and bottom view of the clamp.
The anchor plate 38 is secured to the T-box sidewall by a carrier plate 46 and the saddle bracket 48 . The anchor plate is positioned in front of the T-box and biases a bearing plate 31 against the cover plate 30 of the T-box.
Before being placed in a RPV, the anchor plate 38 is assembled with a clamp block assembly. The clamp block assembly is comprised of the clamp blocks, T-bolts, sealing collars, T-bolt nuts and retaining springs. During this initial assembly the clamp blocks may be shifted back with respect to the anchor plate and the T-bolts are rotated 90 degrees and retracted into the blocks (until they bear against the inside surface of the sparger pipes). The saddle bracket 48 ( FIG. 4 ) is attached to a bottom of the anchor plate and the carrier plate may be loosely attached to the top of the anchor plate with a carrier bolt 50 . The assembly 36 of the anchor plate, clamp blocks and saddle bracket (and optionally the carrier bracket) is lowered into the water of the reactor and moved over the T-box. A lifting tool may be secured to engage lifting apertures 45 in the anchor plate so that the assembly 36 may be lowered into the RPV and fitted over the T-box and sparger pipes. Once the assembly 36 is secured to the T-box, the lifting tool may be removed by releasing the attachment to the lifting apertures 45 .
The bearing plate is biased against the cover plate and secures the cover plate in the event of cracks in the weld between the cover plate and T-box. The bearing plate 31 is connected to the anchor plate 38 by bearing plate bolts 70 that extend through threaded holes in the anchor plate and are rotatably coupled to recesses 71 in the front face of the bearing plate 31 . The front nose of the bolts 70 include a necked down region that fits into the recesses 71 and are secured in the recesses by dowels 73 . The dowels 73 fit in apertures in the anchor plate and latch the nose of the bearing bolts in the bearing plate. The bearing bolts rotate to move the bearing plate towards the T-box cover plate. A latch spring 72 may lock the rotational position of each bearing plate bolt to ensure that the force applied to the cover plate by the bearing plate does not lessen over a prolonged operational period of the RPV. The latch springs may each seat in a respective slot on the face of the anchor plate 38 .
FIG. 6 is a perspective view of the saddle bracket 48 . The saddle bracket 48 has a tongue 62 that fits into a slot in the bottom of the anchor plate 38 . The tongue and slot of the saddle bracket may extend entirely or partially the width of the saddle bracket and bottom edge of anchor plate, e.g., one-half the width of the saddle bracket. Cap screws extend through holes in the saddle bracket and into threaded holes in the slot on the bottom of the anchor plate. Dowell pins 65 insert into the saddle bracket to lock the cap screws in place. The cap screws attach the saddle bracket to the anchor plate before the clamp assembly 36 is placed in the RPV.
The saddle bracket includes a vertically upright locating pin 66 that is secured by a dowel 68 . The metallic locating pin 66 is relatively thick and resistant to shear stress. The saddle bracket has an arch shaped upper surface 69 that conforms to and seats against a lower surface of the sidewall 34 of the T-box. As the saddle bracket (along with the anchor plate and the rest of the assembly 36 ) is moved vertically upward against the T-box, the pin 66 fits in an aperture 82 ( FIG. 9 ) in the lower surface of the sidewall 34 of the T-box. The pin secures the T-box to the saddle bracket and the anchor plate.
FIG. 7 is a perspective view of the carrier plate 46 . The carrier plate is typically rigidly fixed to the anchor plate after the anchor plate and saddle bracket have been fitted to the front and bottom of the T-box. A tongue 54 on the carrier plate 46 slides downward into a slot 52 ( FIG. 4 ) of the anchor plate 38 . A carrier bolt 50 extends down through the carrier plate and screws into a corresponding threaded hole in the anchor plate at the bottom of the slot 52 . The carrier bolt has a relatively long threaded section to allow the carrier plate to be shifted upwards with respect to the anchor plate as the clamp assembly 36 is positioned on and attached to the T-box. The carrier bolt is secured with a latch spring 84 that prevents the bolt from turning out of its threaded hole during prolonged operation of the RPV. The latch spring is seated in a slot on top of the carrier plate.
As the tongue 54 of the carrier plate moves into the anchor plate, the arc-shaped lower surface 55 on the carrier plate seats on an upper surface of the sidewall 34 of the T-box. A locating pin 58 extending vertically downward from the carrier plate fits in an aperture 82 ( FIG. 8 ) on the upper surface of the T-box sidewall. The pin 58 secures the carrier plate (and the anchor plate) to the T-box. The pin is secured to the carrier plate by a dowel 60 that fits in hole in the carrier plate.
FIGS. 8 and 9 are perspective views of the inside of the shroud 14 and a T-box 22 and opposite ends of the sparger pipe 26 are modified to receive the core spray clamp assembly. FIG. 8 shows a top, front perspective view of the modifications needed to the T-box and sparger pipes to receive the clamp assembly, and FIG. 9 shows a bottom, front perspective view of the assembly. The modification to the sparger pipes include machining, e.g., electric discharge machining (EDM), slots 80 in the front surface of the pipes at locations near the T-box. The slots 80 in the pipes are to be aligned with the bolt holes in the clamp blocks 40 , 42 . The slots 80 in the pipes receive the racetrack shaped heads of the T-bolts which extend through the slots into the hollow interior of the pipe. After being inserted in the pipe, the bolt heads are rotated 90 degrees to bear on the inside surface of the sparger pipe. The modification to the T-box is to machine, e.g., EDM, upper and lower holes 82 in sidewall 34 of the T-box. The upper hole 82 in an upper surface of the sidewall receives, e.g., an clearance fit, the locating pin 58 for the carrier plate. A lower hole 82 on a bottom surface of the sidewall 34 receives the locating pin 66 of the saddle bracket.
FIG. 10 shows the clamp assembly 36 ready to be lowered into the RPV and fitted over a T-box. The clamp blocks 42 , 44 are retracted with respect to the anchor plate 38 so that the ends of the T-bolts 74 will clear the sparger pipes as the assembly 36 is moved over the T-box. The saddle bracket 48 is secured to the bottom of the anchor plate. The carrier plate 46 is attached by the carrier bolt 50 , but the carrier plate may be loosely attached (during installation) to the anchor plate so that the plate may be lowered, and is spaced upward to allow a clearance with respect to the sparger T-box. The tongue 54 of the carrier plate may or may not be partially inserted in the slot 52 of the anchor plate during installation of the anchor plate on the T-box.
FIG. 11 is a perspective view of the clamp assembly 36 loaded on an installation tool 86 which lowers the clamp assembly in the RPV and positions the assembly on the T-box. The lowering tool 86 has a rectangular frame 87 with a loading attachment 88 that is releasably connected to a crane that lowers the tool 86 and clamp assembly 36 in the RPV. The frame 87 includes a rectangular base 90 that supports gearing and tubular screw driver receivers 92 that are used to rotate the T-bolt nuts and bearing plate bolts. The clamp assembly 36 is attached to an installation bracket 94 on the front of the frame 87 that includes bolts that secure the clamp assembly to the tooling apertures 45 on the anchor plate. After the clamp assembly 36 is secured to the T-box, gearing and tubular screw driver receivers 96 release the bolts from the clamp assembly and allow the installation tool to be removed.
The clamp assembly 36 (with retracted clamp blocks and with the carrier plate spaced from the anchor plate) is lowered into the RPV by the lowering tool 86 . The clamp assembly is positioned in front of and slightly below the T-box so that the pin 66 on the saddle bracket can clear the sidewall of the T-box. During clamp assembly installation, the bearing plate is in a retracted position, e.g., the bearing plate abuts the anchor plate, and by so doing is not yet in contact with the cover plate of the T-box. The clamp blocks 40 , 42 are still in a retracted position so that the ends of the T-bolts 74 can pass over the sparger pipes as they are moved into alignment with the slots 80 in the pipes.
After being positioned in front of the T-box, the clamp assembly is moved towards the T-box until the locating pin 66 of the saddle bracket is aligned with the aperture 82 on the bottom of the sidewall of the T-box. The clamp assembly is shifted upwards to seat the saddle bracket surface 69 and the pin 66 on the T-box. The carrier bolt 50 is turned to lower the carrier plate into the anchor plate, and to seat the carrier plate or face 55 and the pin 58 on the upper portion of the sidewall of the T-box. The pin 58 of the carrier plate fits in aperture 82 of the T-box sidewall. The anchor plate is secured to the T-box by the clamping action of the carrier plate and saddle bracket and the pins that connect these plates to the sidewall of the T-box.
After the carrier plate and saddle bracket are latched by their respective locating pins to the T-box, the bearing plate bolts 70 are turned to advance the bearing plate 31 towards the cover plate 30 . The bearing plate bolts are turned by corresponding gearing and tubular screw driver receivers 92 in the installation tool. The bearing plate bolts are turned to advance the bearing plate towards the cover plate of the T-box. The bearing plate secures the cover plate in the T-box, especially if cracks form in the weld between the cover plate and T-box.
The first and second clamp blocks 40 , 42 are secured to sparger pipes by the T-bolts 74 . The head of each bolt is race track shaped is inserted into a corresponding slot 80 in the sparger pipe. The T-bolt is secured to the sparger piping by rotating the T-bolt nuts. As the nuts rotate, the T-bolts rotate 90 degrees in concert with the nuts. A key feature on the T-bolt then interfaces with internal features in the bore of the sealing collar, which prevent further rotation of the T-bolt. Further rotation of the T-bolt nut pulls the head of the T-bolt into contact with the inside surface of the sparger pipe. This action also advances the clamp blocks 40 , 42 into alignment with the anchor plate and cause the sealing collars to seal against the slots in the sparger pipes. Recesses in the front and back faces of the block are coaxial with the bolt hole and provide a seat for the T-bolt nut 44 and sealing collar 76 . Ratchet springs 80 prevent the nuts from turning and fit into slots on the front of the clamp blocks 40 , 42 .
The sparger T-box clamp assembly 36 restrains the core spray sparger pipes and limits movement of these pipes relative to the position of the sparger T-box 22 in the event that the attaching welds 32 crack circumferentially. The saddle bracket 48 is attached to the anchor plate 38 by socket head cap screws 64 through a tongue and groove joint. This tongue and groove joint prevents shear loading of the cap screws. The carrier plate 46 interfaces with the anchor plate 38 through a T-slot, e.g., tongue on carrier plate and slot in anchor plate. The T-slot permits vertical relative motion between the carrier plate and anchor plate. The locating pin 58 is held captive in the carrier plate by a dowel pin 60 , which is press-fit into the carrier plate. The preload imposed by the carrier bolt 50 provides a clamping force on the sparger T-box aligned with the cylindrical holes 82 in the sidewall of the T-box. The load path of this clamping force is applied through the saddle bracket 48 to the anchor plate and into the carrier bolt 50 and carrier plate 46 . The carrier plate incorporates a latch spring 84 whose teeth ratchet on the opposing teeth of the carrier bolt. This action allows rotation of the carrier bolt only in the direction which increases mechanical preload in the carrier bolt. Latch springs 72 and ratchet springs 80 prevent loosening of the bearing plate bolts 70 and T-bolt nuts 44 .
The above described core spray sparger T-box clamp assembly provides structural integrity to the sparger T-box and to hold together the welded joints of the T-box, cover plate and sparger pipes in the event that one or more welds should fail.
While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.
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A method for attaching a core spray sparger T-box clamp for a sparger T-box in a shroud of a nuclear reactor pressure vessel assembling the anchor plate, bearing plate and saddle bracket; positioning the assembly of the anchor plate, bearing plate and saddle bracket in front of the T-box such that the saddle bracket is below a sidewall of the T-box; elevating the assembly to seat the saddle bracket against a lower surface of the sidewall and sliding a locating pin on the saddle bracket into an aperture in the sidewall; lowering a carrier plate onto an upper surface of the sidewall and attaching the carrier plate to the anchor plate, wherein a locating pin on the carrier plate slides into an aperture on the upper surface, and advancing the bearing plate to the T-box to bias a bearing plate against a cover plate of the T-box.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application No. 61/692210, filed Aug. 22, 2012, which is hereby incorporated by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
PARTIES TO A JOINT RESEARCH AGREEMENT
[0003] Not Applicable
REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISK APPENDIX
[0004] Not Applicable
BACKGROUND OF THE INVENTION
[0005] The invention relates generally to basketball and other sports nets and in particular to decorative enhancements for such nets. Nets used in basketball at all levels of competition are generally plain, with the strands or chains being undecorated. At most, the net strands may be presented in a particular color or combination of colors. Similarly, while backboards often present team indicia, the net itself generally represents an unused space for carrying decorations, particularly team indicia or marketing indicia. A system is needed for providing decorations and indicia to the net itself.
SUMMARY OF THE INVENTION
[0006] Accordingly, the invention is directed to a system of decorations which may be applied to a basketball net to enhance the net's decorative appeal. Coloration of the net strands or links may be placed in any combination with decorative fill material placed between the strands and links, a decorative lattice surrounding the exterior surface of the net, or decorative patches affixed to the exterior of the net. Each type of decorative surface may be printed, embroidered, dyed, or otherwise decorated with any combination of colors, patterns, designs, or indicia.
[0007] Additional features and advantages of the invention will be set forth in the description which follows, and will be apparent from the description, or may be learned by practice of the invention. The foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The accompanying drawings are included to provide a further understanding of the invention and are incorporated into and constitute a part of the specification. They illustrate the invention and, together with the description, serve to explain the principles of the invention.
[0009] FIG. 1 shows a front view of the first exemplary embodiment, showing the net 10 , rim 11 , first color material 12 , second color material 13 , links 14 , strands 15 , and spaces 16 .
[0010] FIG. 2 shows a front view of the second exemplary embodiment, showing the net 20 , rim 21 , and flexible lattice 22 .
[0011] FIG. 3 shows a front view of the third exemplary embodiment, showing the net 30 , rim 31 , fill material 32 , spaces 33 , strands 34 , and links 35 .
[0012] FIG. 4 shows a front view of the fourth exemplary embodiment, showing the net 40 , rim 41 , and patch 42 .
DETAILED DESCRIPTION OF THE INVENTION
[0013] Referring now to the invention in more detail, the invention is directed to a system of decorative enhancements for basketball nets or other net-like structures for use in sports or in other applications. FIGS. 1-4 show several exemplary embodiments, each demonstrating one or more features of the system, which may be applied to a particular basketball net in any combination.
[0014] FIG. 1 shows the first exemplary embodiment. In the first exemplary embodiment, a net 10 is suspended from a rim 11 . The rim 11 may be any regulation or non-regulation size, and is preferably made of a high strength metal material, such as steel or other material as is or may become customary for basketball rims. The net 10 is preferably a weave of nylon, cotton, or hemp fibers or metal chain other material as may be suitably flexible and durable. The net 10 may be woven in any fashion suitable for creating a generally cylindrical net (many such methods being well-known in the prior art), preferably in a manner customary for basketball nets.
[0015] The net 10 may be produced in any color or combination or pattern of colors, as distinct from a neutral or un-colored material (e.g. un-dyed fiber or unfinished metal), depending on the color needs of the particular embodiment, such as the display of particular colors associated with the “home team” at the venue where the net 10 is to be installed. Any means of applying color to the net 10 may be employed; for example fiber nets may be dyed according to a suitable dyeing method for the particular fiber (many such methods are known in the prior art). Metal chain nets may be painted, powder coated, or anodized and dyed to apply desired colors.
[0016] Referring still to the first exemplary embodiment of FIG. 1 , the net 10 is made up of strands 15 and links 14 ; the strands 15 are lengths of linear material, and the links 14 are the points of intersection and attachment, whether by interweaving or fixing flexible lines, interlinking chain links, or other attachment means. The strands 15 and links 14 of the net 10 define a plurality of spaces 16 , which may be filled with a flat, flexible material, such as woven fabric. The fill material may alternate colors, for example between a first color material 12 and a second color material 13 . The fill material may also be printed, embroidered, or otherwise decorated with a pattern, design, design, symbol, logo, or other indicia. The fill material may be affixed to the net 10 with stitching, adhesives, or other fasteners between the perimeter of the fill material and the surrounding strands 15 and links 14 .
[0017] FIG. 2 shows the second exemplary embodiment. In the second exemplary embodiment, a net 20 is suspended from a rim 21 ; the net 20 and rim 21 are similar to the net 10 and rim 11 of the first exemplary embodiment in all aspects and possible variations. In the second exemplary embodiment, a flexible lattice 22 is affixed to the outside surface of the net 10 . The flexible lattice 22 may be made of a fabric material, and may be affixed to the net 20 with stitching, adhesives, or other appropriate fastening means. The flexible lattice 22 preferably matches the external form of the net 20 when the net 20 is in a neutral hanging position. The flexible lattice 22 may partially cover the exterior surface of the net 20 according to a diamond pattern as shown in FIG. 2 , or may follow a different geometric pattern, or may be asymmetric following no pattern at all, or may completely cover the exterior surface of the net 20 . The flexible lattice 20 may be printed or otherwise decorated with any combination of colors, designs, patterns, or indicia.
[0018] FIG. 3 shows the third exemplary embodiment. In the third exemplary embodiment, a net 30 is suspended from a rim 31 ; the net 30 and rim 31 are similar to the net 10 and rim 11 of the first exemplary embodiment in all aspects and possible variations. In the third exemplary embodiment, some, but not all, of the spaces 33 between the strands 34 and links 35 of the net 30 are filled with a flat, flexible fill material 32 , which may be printed or otherwise decorated with any combination of colors, patterns, designs, or indicia. The spaces 33 may alternate unfilled spaces and spaces filled by fill material 32 as shown, or may follow any pattern or be placed asymmetrically. Each piece of fill material 32 may be affixed to its surrounding strands 34 and links 35 by appropriate fasteners for the material of the net 30 ; for example a flexible fiber net 30 may be sewn to the fill material 32 , and a chain net 30 may be affixed to the fill material 32 by adhesive.
[0019] FIG. 4 shows the fourth exemplary embodiment. In the fourth exemplary embodiment, a net 40 is suspended from a rim 41 ; the net 40 and rim 41 are similar to the net 10 and rim 11 of the first exemplary embodiment in all aspects and possible variations. In the fourth exemplary embodiment, a patch 42 of flat flexible material, which may be affixed to the net 40 by stitching, adhesives or other appropriate fastening means. Any number of patches 42 may be applied to the net 40 . The patch 42 may be printed, embroidered, or otherwise decorated with any combination of colors, patterns, designs, or indicia.
[0020] The first color material 12 , second color material 13 , links 14 , strands 15 , flexible lattice 22 , fill material 32 , strands 34 , links 35 , and patch 42 would preferably be manufactured from flexible, durable materials that are easily cleaned, such as plastic, acetate, nylon, cotton fabric, and cotton-polyester blend fabric. Components, component sizes, and materials listed above are preferable, but artisans will recognize that alternate components and materials could be selected without altering the scope of the invention.
[0021] While the foregoing written description of the invention enables one of ordinary skill to make and use what is presently considered to be the best mode thereof, those of ordinary skill in the art will understand and appreciate the existence of variations, combinations, and equivalents of the specific embodiment, method, and examples herein. The invention should, therefore, not be limited by the above described embodiment, method, and examples, but by all embodiments and methods within the scope and spirit of the invention.
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A system of decorations may be applied to a basketball net to enhance the net's decorative appeal. Coloration of the net strands or links may be placed in any combination with decorative fill material placed between the strands and links, a decorative lattice surrounding the exterior surface of the net, or decorative patches affixed to the exterior of the net. Each type of decorative surface may be printed, embroidered, dyed, or otherwise decorated with any combination of colors, patterns, designs, or indicia.
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CROSS-REFERENCE TO RELATED APPLICATION
The present application is related to and claims priority from prior provisional application Ser. No. 61/783,071, filed Mar. 14, 2013 which application is incorporated herein by reference.
COPYRIGHT NOTICE
A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever. 37 CFR 1.71(d).
The following includes information that may be useful in understanding the present invention(s). It is not an admission that any of the information provided herein is prior art, or material, to the presently described or claimed inventions, or that any publication or document that is specifically or implicitly referenced is prior art.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to the field of transport devices and more specifically relates to supply backpacks or go-bag with detachable pet carriers.
2. Description of the Related Art
Many individuals in modern society enjoy the companionship of one or more pets. Often pets become beloved members of an owner's family, making their health and safety top priorities for owners. Traveling can be stressful for a pet, making the pet unpredictable and difficult to control. An upset pet often causes an owner unwanted difficulties when transporting the pet. Gathering supplies needed to care for both a pet and its owner can be time-consuming, and a risk exists in potentially forgetting or misplacing an item necessary to the comfort and/or survival of the pet, the owner, or both. Emergency situations such as those requiring evacuations tend to escalate anxiety associated with collecting and transporting beloved pets and important supplies, thereby increasing the likelihood of forgetting a critical element. In such an emergency situation, individuals having to simultaneously control a pet, transport supplies, and flee to safety often find themselves in a precarious position.
Various attempts have been made to solve the above-mentioned problems such as those found in U.S. Pat. Nos. 7,617,797; 2011/0278338; 7,594,569; 6,286,461; 2007/0095872; 6,701,871; 7,210,426; 8,505,789; and 2012/0292355. This prior art is representative of transport devices. None of the above inventions and patents, taken either singly or in combination, is seen to describe the invention as claimed.
Ideally, a hands-free supply backpack or go-bag with a detachable pet carrier should be versatile, durable, user-friendly and, yet, would operate reliably and be manufactured at a modest expense. Thus, a need exists for a reliable supply backpack with detachable pet carrier system to increase the convenience of simultaneously transporting pets and provisions and to avoid the above-mentioned problems.
BRIEF SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the known transport device art, the present invention provides a novel supply backpack with detachable pet carrier system. The general purpose of the present invention, which will be described subsequently in greater detail, is to provide convenient simultaneous transport of pets and provisions.
A supply backpack with detachable pet carrier system is disclosed herein preferably comprising: a pack and at least one carrier. The pack comprises an outer shell, an interior volume, and a plurality of adjustable and removable carrying straps. The carrier comprises an outside casing, an inner void, and a plurality of adjustable and removable tote straps. Ideally, a pet may be secured within a carrier, and the carrier may be secured to the pack in order for a user to conveniently protect and transport the pet and various supplies.
The packs outer shell is defined by: a forward wall, a rear wall, a right wall, a left wall, a bottom surface, and a top surface—the joining of which effectively defines the interior volume. In preferred embodiments, the forward wall of the pack is releasably engageable with at least one of: the rear wall, the right wall, the left wall, the top surface, and/or the bottom surface in such a manner as to essentially seal the pack. Alternatively, the forward wall may be disengaged in order to allow a user access to the interior volume of the pack. For storage purposes, the pack comprises a plurality of both interior storage compartments and exterior anchoring elements.
The carrier's outside casing is defined by: a front face, a back face, a right face, a left face, a bed, and an upper face—the joining of which effectively defines the inner void. The upper face and/or front face of the carrier are each releasably engageable with at least one of: the back face, the right face, the left face, and/or the bed in such a manner as to essentially seal the carrier. Alternatively, the upper face and/or front face may be disengaged in order to allow a user access to the inner void of the carrier. Ideally, the carrier is removably attachable to the pack via at least one connector—the bed of the carrier having an attacher, and the top surface of the pack comprising a lip having a receiver. The lip effectively secures and stabilizes the carrier atop the pack.
The carrier comprises a plurality of ventilation apertures for providing fresh air and viewing portals for a pet enclosed therein. In order to calm and protect a pet enclosed within the carrier, these ventilation apertures may be covered and/or sealed by at least one of a plurality of retractable flaps attached to at least one of: the front face, the back face, the right face, the left face, and alternately the upper face of the carrier. In order to secure any retracted flap, the carrier additionally comprises a plurality of fasteners.
A method of using the supply backpack with detachable pet carrier system is also described herein preferably comprising the steps of: securing a pet within a carrier; connecting the carrier to a pack; and wearing the pack for a period of use. The method preferably further comprises the steps of: removing the carrier from the pack; releasing the pet from the carrier; and reconnecting the carrier to the pack for storage until further use.
The present invention holds significant improvements and serves as a transport device system. For purposes of summarizing the invention, certain aspects, advantages, and novel features of the invention have been described herein. It is to be understood that not necessarily all such advantages may be achieved in accordance with any one particular embodiment of the invention. Thus, the invention may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other advantages as may be taught or suggested herein. The features of the invention which are believed to be novel are particularly pointed out and distinctly claimed in the concluding portion of the specification. These and other features, aspects, and advantages of the present invention will become better understood with reference to the following drawings and detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
The figures which accompany the written portion of this specification illustrate embodiments and method(s) of use for the present invention, Max Pet Carrier Systems, constructed and operative according to the teachings of the present invention.
FIGS. 1A and 1B show perspective views illustrating a supply backpack with detachable pet carrier system according to an embodiment of the present invention.
FIG. 2 is a perspective view illustrating the supply backpack with detachable pet carrier system according to an embodiment of the present invention of FIGS. 1A and 1B .
FIG. 3 is a perspective view illustrating the supply backpack with detachable pet carrier system according to an embodiment of the present invention of FIGS. 1A-2 .
FIGS. 4A-4C are perspective views illustrating the supply backpack with detachable pet carrier system according to an embodiment of the present invention of FIGS. 1A-2 .
FIG. 5 is a flowchart illustrating a method of use for the supply backpack with detachable pet carrier system according to an embodiment of the present invention of FIGS. 1A-4C .
The various embodiments of the present invention will hereinafter be described in conjunction with the appended drawings, wherein like designations denote like elements.
DETAILED DESCRIPTION
As discussed above, embodiments of the present invention relate to a transport device and more particularly to a Max Pet Carrier System as used to improve the convenience of simultaneously transporting pets and provisions.
Referring now to the drawings by numerals of reference, there are shown in FIGS. 1A and 1B perspective views illustrating supply backpack with detachable pet carrier system 100 according to an embodiment of the present invention.
Supply backpack with detachable pet carrier system 100 preferably comprises: pack 105 and at least one carrier 155 , wherein carrier 155 is preferably removably attachable to pack 105 so as to allow a user to secure a pet within carrier 155 and secure carrier 155 to pack 105 in a manner that provides protection and transport of the pet for a duration of at least one use. Within this particular embodiment, supply backpack with detachable pet carrier system 100 preferably comprises a single carrier 155 removably attachable to pack 105 . In other embodiments, a plurality of carrier(s) 155 may be used to secure multiple pets. Also within this embodiment, pack 105 preferably comprises outer shell 110 having a cushioned back support; interior volume 145 ; and a plurality of carrying strap(s) 150 . Also within this embodiment, carrier 155 preferably comprises outside casing 160 ; inner void 195 ; and a plurality of tote strap(s) 198 .
Within this particular embodiment shown, each carrying strap 150 and each tote strap 198 may preferably be both adjustable and removable from pack 105 and carrier 155 , respectively. In other embodiments, each carrying strap 150 and each tote strap 198 may be permanently affixed to pack 105 and carrier 155 , respectively. Alternately, a mix of permanently-affixed and releasably-attachable carrying strap(s) 150 and tote strap(s) 198 may be used, according to the preferences and needs of a user.
Carrying strap(s) 150 of the present embodiment may preferably comprise: at least one padded waist belt; and dual cushioned shoulder belts arranged in a manner so as to allow a user to wear one or both carrying strap(s) 150 over one or both shoulders in order to facilitate transport of pack 105 . Tote strap(s) 198 of the present embodiment may preferably comprise: a single cushioned shoulder belt; and at least one, but preferably two, hand-held handles. Within the present embodiment, each tote strap 198 may preferably be releasably attachable to carrier 155 via clips, lobster clasps, snaps, buttons, or similar attachment means. In other embodiments, each carrying strap 150 and each tote strap 198 may comprise any of a number of various types of straps, belts, hand-held handles, chest straps, retractable straps, and the like. Those with ordinary skill in the art will now appreciate that upon reading this specification and by their understanding the art of transport devices as described herein, methods of constructing and attaching straps and handles of transport devices will be understood by those knowledgeable in such art.
Carrying strap(s) 150 and tote strap(s) 198 of the present embodiment may preferably be releasably attachable to pack 105 and carrier 155 , respectively, in such a manner as to allow the configuration of the attachment of carrying strap(s) 150 and tote strap(s) 198 to be altered according to the needs and preferences of a user. Additionally, pack 105 may preferably comprise any number of bedding belt(s) 115 . Pack 105 of the present embodiment preferably comprises two bedding belt(s) 115 to effectively secure bedding such as sleeping bags, blankets, foam pads, and the like to pack 105 for transport. Upon reading this specification, it should be appreciated that, under appropriate circumstances, considering such issues as user preferences, design preference, structural requirements, marketing preferences, cost, available materials, technological advances, etc., other strap and belt arrangements such as, for example, ties, elastomeric bands, hook-and-loop fasteners, etc., may be sufficient.
Supply backpack with detachable pet carrier system 100 of the present embodiment preferably accommodates small pets, and in other versions it may accommodate medium and/or large pets. Also within the present embodiment, tote strap(s) 198 may preferably be attached to carrier 155 to facilitate transport of carrier 155 independently of pack 105 and may be removed from carrier 155 when carrier 155 is connected to pack 105 . In this way, carrier 155 may be independently used to transport a pet in a motor vehicle, in an airplane cabin, on public transit vehicles, and the like. In other embodiments, supply backpack with detachable pet carrier system 100 may comprise pack 105 having integral carrier 155 as opposed to a removably-attachable carrier 155 .
Referring now to FIG. 2 , a perspective view illustrating supply backpack with detachable pet carrier system 100 according to an embodiment of the present invention of FIGS. 1A and 1B .
Supply backpack with detachable pet carrier system 100 may preferably comprise: pack 105 having top surface 220 and carrier 155 having bed 225 . Bed 225 of carrier 155 may preferably be removably coupleable to top surface 220 of pack 105 via at least one connector 200 having attacher 205 and receiver 210 . In the present embodiment, connector 200 may preferably comprise snaps. Ideally, bed 225 of carrier 155 preferably comprises attacher 205 , and top surface 220 of pack 105 may preferably comprise lip 215 having receiver 210 . Upon reading this specification, it should be appreciated that, under appropriate circumstances, considering such issues as user preferences, design preference, structural requirements, marketing preferences, cost, available materials, technological advances, etc., other connecting and fastening arrangements such as, for example, side-release buckles, frame-and-prong buckles, hook-and-loop fasters, zippers, buttons, hook-and-eye closures, etc., may be sufficient.
In preferred embodiments, lip 215 essentially extends vertically from top surface 220 of pack 105 in a manner so as to effectively provide stability to the joining of carrier 155 and pack 105 . Ideally, lip 215 matches bed 225 of carrier 155 in shape and may preferably be incrementally larger than bed 225 of carrier 155 in such a manner as to accommodate bed 225 of carrier 155 within the confines of lip 215 . In this way, carrier 155 may be friction-fit within lip 215 when carrier 155 is attached to pack 105 . In other embodiments, lip 215 may be collapsible and/or removable from pack 105 when carrier 155 is not attached to pack 105 . In other embodiments, carrier 155 may be joined to pack 105 in alternate orientations/positions such as: beneath pack 105 ; along the left or right sides of pack 105 ; within pack 105 ; and the like. Those with ordinary skill in the art will now appreciate that upon reading this specification and by their understanding the art of transport devices as described herein, methods of constructing and connecting transport devices will be understood by those knowledgeable in such art.
Pack 105 and carrier 155 may preferably comprise waterproof nylon to protect both pets and supplies contained therein. Alternatively, water-resistant and non-waterproof materials may be used to construct pack 105 and carrier 155 . In some embodiments, both pack 105 and carrier 155 may comprise molded rubber bases to protect the waterproof nylon from wear and tears. Both pack 105 and carrier 155 preferably comprise safety reflectors affixed to at least one, but preferably all, exterior surfaces of both pack 105 and carrier 155 to enhance the safety of a user. Upon reading this specification, it should be appreciated that, under appropriate circumstances, considering such issues as user preferences, design preference, structural requirements, marketing preferences, cost, available materials, technological advances, etc., other material component arrangements such as, for example, canvas, cotton, polyester, plastic, etc., may be sufficient. Those with ordinary skill in the art will now appreciate that upon reading this specification and by their understanding the art of transport devices as described herein, methods of constructing and waterproofing transport devices will be understood by those knowledgeable in such art.
FIG. 3 is a perspective view illustrating supply backpack with detachable pet carrier system 100 according to an embodiment of the present invention of FIGS. 1A-2 .
Pack 105 may comprise outer shell 110 , which is preferably defined by forward wall 305 , rear wall 310 , right wall 315 , left wall 320 , bottom surface 325 , and top surface 220 . The joining of forward wall 305 , rear wall 310 , right wall 315 , left wall 320 , bottom surface 325 , and top surface 220 preferably defines interior volume 145 . Forward wall 305 of pack 105 may preferably be releasably engageable with at least one of: rear wall 310 , right wall 315 , left wall 320 , bottom surface 325 , and top surface 220 . As such, the disengagement of forward wall 305 essentially creates an access point that allows a user access to interior volume 145 of pack 105 . Forward wall 305 may preferably be releasably engaged using a zipper. Upon reading this specification, it should be appreciated that, under appropriate circumstances, considering such issues as user preferences, design preference, structural requirements, marketing preferences, cost, available materials, technological advances, etc., other fastening and securing arrangements such as, for example, hook-and-loop fasteners, snaps, buttons, hook-and-eye closures, etc., may be sufficient.
Interior volume 145 of the present embodiment may comprise a single chamber to provide storage for a user's supplies. In other embodiments, interior volume 145 may comprise a plurality of chambers. In some embodiments, an engagement of forward wall 305 , rear wall 310 , right wall 315 , left wall 320 , bottom surface 325 , and top surface 220 may be interrupted in a plurality of locations in such a manner as to create a corresponding number of access points into a single chamber and alternately into a plurality of chambers of interior volume 145 . Those with ordinary skill in the art will now appreciate that upon reading this specification and by their understanding the art of transport devices as described herein, methods of constructing transport devices will be understood by those knowledgeable in such art.
Pack 105 preferably comprises a plurality of storage compartment(s) 335 within interior volume 145 for storing and transporting supplies of various shapes and sizes. Pack 105 may also comprise storage compartment(s) 335 along any exterior surface of pack 105 . Additionally, pack 105 preferably comprises a plurality of anchoring element(s) 340 along any exterior surface of pack 105 to secure supplies to pack. Pack 105 may also comprise anchoring element(s) 340 within interior volume 145 . In preferred embodiments, pack 105 may also comprise an assortment of standard supplies with pre-assigned storage compartment(s) 335 each sized and shaped to accommodate its corresponding standard supply article. First aid kits, flashlights, space blankets, and the like may constitute the aforementioned standard supplies. Upon reading this specification, it should be appreciated that, under appropriate circumstances, considering such issues as user preferences, design preference, structural requirements, marketing preferences, cost, available materials, technological advances, etc., other fastening and securing arrangements such as, for example, mesh pockets, straps, clips, snaps, etc., may be sufficient. Those with ordinary skill in the art will now appreciate that upon reading this specification and by their understanding the art of transport devices as described herein, methods of constructing and compartmentalizing transport devices will be understood by those knowledgeable in such art.
Within this particular embodiment, pack 105 preferably assumes the size and shape of standard transport devices typically worn on the back of a user. In other embodiments, however, pack 105 may assume any of a plurality of alternate shapes and sizes, such as: duffle bag, messenger bag, suitcase, and the like. Similarly, carrier 155 of the present embodiment preferably assumes the shape of a small cube. In other embodiments, however, carrier 155 may assume any of a plurality of alternate shapes and sizes. In alternate embodiments, pack 105 and carrier 155 may comprise: wheels; telescoping handles; plastic, lightweight metal, foam, or inflatable support frames; and/or any similar enhancements to the function of supply backpack with detachable pet carrier system 100 . Those with ordinary skill in the art will now appreciate that upon reading this specification and by their understanding the art of transport devices as described herein, methods of constructing transport devices will be understood by those knowledgeable in such art.
Referring now to FIGS. 4A-4C , perspective views illustrating supply backpack with detachable pet carrier system 100 according to an embodiment of the present invention of FIGS. 1A-2 .
Carrier 155 may comprise outside casing 160 , which is preferably defined by front face 405 , back face 410 , right face 415 , left face 420 , bed 225 , and upper face 425 . The joining of front face 405 , back face 410 , right face 415 , left face 420 , bed 225 , and upper face 425 preferably defines inner void 195 . Upper face 425 and front face 405 may preferably be releasably engageable with at least one of: back face 410 , right face 415 , left face 420 , and bed 225 . As such, the disengagement of upper face 425 , separately from or in combination with front face 405 , essentially creates an access point that allows a user access to inner void 195 of carrier 155 to insert, tend to, and remove a pet from carrier 155 . Upper face 425 and front face 405 may preferably be releasably engaged using a zipper. Upon reading this specification, it should be appreciated that, under appropriate circumstances, considering such issues as user preferences, design preference, structural requirements, marketing preferences, cost, available materials, technological advances, etc., other fastening and securing arrangements such as, for example, hook-and-loop fasteners, snaps, buttons, hook-and-eye closures, etc., may be sufficient. Those with ordinary skill in the art will now appreciate that upon reading this specification and by their understanding the art of transport devices as described herein, methods of constructing transport devices will be understood by those knowledgeable in such art.
Bed 225 of carrier 155 may preferably be concave in shape and comprise at least one removable liner 435 . Liner 435 may preferably comprise an absorbent core, thereby essentially providing comfort to a pet enclosed within carrier 155 and effectively containing excretions made by the pet enclosed within carrier 155 . Liner 435 may comprise a single layer and may alternately be multi-layered. Liner 435 may be disposable and alternately reusable in order to meet the needs and preferences of a user. Upon reading this specification, it should be appreciated that, under appropriate circumstances, considering such issues as user preferences, design preference, structural requirements, marketing preferences, cost, available materials, technological advances, etc., other absorbent article arrangements such as, for example, cotton, bamboo, hemp, microfiber, cellulose wadding, etc., may be sufficient. Those with ordinary skill in the art will now appreciate that upon reading this specification and by their understanding the art of absorbent articles as described herein, methods of constructing absorbent articles will be understood by those knowledgeable in such art.
Carrier 155 preferably comprises a plurality of ventilation aperture(s) 440 , which essentially act in a capacity of fresh air openings and viewing portals for a pet enclosed in carrier 155 . In the present embodiment, front face 405 , back face 410 , right face 415 , and left face 420 may each have at least one ventilation aperture 440 . Alternatively, upper face 425 may also comprise at least one ventilation aperture 440 . Characteristics of ventilation aperture(s) 440 such as size, shape, number, position, orientation, and the like are variable in order to suit the needs and preferences of a user. In preferred embodiments, ventilation aperture(s) 440 may exist as mesh-covered openings in carrier 155 . Upon reading this specification, it should be appreciated that, under appropriate circumstances, considering such issues as user preferences, design preference, structural requirements, marketing preferences, cost, available materials, technological advances, etc., other window opening arrangements such as, for example, uncovered openings, bar-covered openings, etc., may be sufficient.
In preferred embodiments, carrier 155 may comprise a plurality of retractable flap(s) 445 . At least one flap 445 may preferably be attached to front face 405 , back face 410 , right face 415 , left face 420 , and alternately upper face 425 , in a manner so as to correspond to any ventilation aperture(s) 440 existing within carrier 155 . In some embodiments, flap(s) 445 may be removably connected to carrier 155 to be stored when not in use. When in an extended state, each flap 445 may essentially cover and/or seal any corresponding ventilation aperture(s) 440 . When in a retracted state, each flap 445 may essentially expose any corresponding ventilation aperture(s) 440 . In either an extended or a retracted state, each flap 445 may preferably be secured by at least one fastener 450 . Fastener(s) 450 of the present embodiment may comprise hook-and-loop fasteners. Upon reading this specification, it should be appreciated that, under appropriate circumstances, considering such issues as user preferences, design preference, structural requirements, marketing preferences, cost, available materials, technological advances, etc., other fastening and securing arrangements such as, for example, ties, clips, snaps, buttons, etc., may be sufficient.
To enhance storage capabilities of supply backpack with detachable pet carrier system 100 , carrier 155 may comprise storage compartment(s) 335 and/or anchoring element(s) 340 within inner void 195 or along outside casing 160 . In some embodiments, carrier 155 may be collapsible for storage. In yet other embodiments, carrier 155 may comprise integral expandable pockets to add to the overall size and capacity of carrier 155 . In still other embodiments, carrier 155 may comprise securing means within inner void 195 to tether a pet enclosed within carrier 155 to prevent escape of the pet when upper face 425 and/or front face 405 are disengaged. Those with ordinary skill in the art will now appreciate that upon reading this specification and by their understanding the art of transport devices as described herein, methods of constructing transport devices will be understood by those knowledgeable in such art.
Supply backpack with detachable pet carrier system 100 may be sold as kit 240 comprising the following parts: at least one pack 105 ; at least one carrier 155 ; at least one carrying strap 150 ; at least one tote strap 198 ; and at least one set of user instructions. Supply backpack with detachable pet carrier system 100 may be manufactured and provided for sale in a wide variety of sizes and shapes for a wide assortment of applications. Upon reading this specification, it should be appreciated that, under appropriate circumstances, considering such issues as design preference, user preferences, marketing preferences, cost, structural requirements, available materials, technological advances, etc., other kit contents or arrangements such as, for example, including more or less components, customized parts, different color combinations, parts may be sold separately, etc., may be sufficient.
FIG. 5 is flowchart 550 illustrating method of use 500 for supply backpack with detachable pet carrier system 100 according to an embodiment of the present invention of FIGS. 1A-4C .
A method of using (at least hereby enabling method of use 500 ) a supply backpack with detachable pet carrier system 100 preferably comprises the steps of: step one 501 securing a pet within carrier 155 ; step two 502 connecting carrier 155 to pack 105 ; step three 503 wearing pack 105 for a period of use. The method of use 500 preferably further comprises the steps of: step four 504 removing carrier 155 from pack 105 ; step five 505 releasing the pet from carrier 155 ; and step six 506 reconnecting carrier 155 to pack 105 for storage until further use.
It should be noted that step two 502 , step four 504 , and step six 506 are optional steps and may not be implemented in all cases. Optional steps of method 500 are illustrated using dotted lines in FIG. 5 so as to distinguish them from the other steps of method 500 .
It should be noted that the steps described in the method of use can be carried out in many different orders according to user preference. The use of “step of” should not be interpreted as “step for”, in the claims herein and is not intended to invoke the provisions of 35 U.S.C. §112, ¶ 6. Upon reading this specification, it should be appreciated that, under appropriate circumstances, considering such issues as design preference, user preferences, marketing preferences, cost, structural requirements, available materials, technological advances, etc., other methods of use arrangements such as, for example, different orders within above-mentioned list, elimination or addition of certain steps, including or excluding certain maintenance steps, etc., may be sufficient.
The embodiments of the invention described herein are exemplary and numerous modifications, variations and rearrangements can be readily envisioned to achieve substantially equivalent results, all of which are intended to be embraced within the spirit and scope of the invention. Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientist, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application.
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A supply backpack with detachable pet carrier system to increase the convenience of simultaneously transporting pets and provisions. Max Pet Carrier Systems is a versatile supply backpack with detachable pet carrier system having a wearable pack with shoulder straps and an attachable pet carrier with a removable tote strap. By enclosing a pet within a carrier and attaching the carrier to a pack, a user is able to quickly and efficiently pack and transport the pet and any necessary supplies. Such a convenient transport system is especially useful in emergency evacuation situations.
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BACKGROUND OF THE INVENTION
This is a continuation-in-part of the co-pending patent application of like inventor, Ihor Wyslotsky, entitled "Improved Multiple Component Pressurized Package For Articles And Methods Of Pressurization Thereof", Ser. No. 543,033, filed on 6/25/1990.
The present invention relates in general to packaging elements, and more particularly to an improved strippable seal mechanism, such as may be useable in connection with packaging for a wide variety of goods and products, including industrial products, medical products, small items, comestible products, including prepared meats, inter alia.
In the prior art, there has been a wide proliferation of packages made from various polymeric materials including many different sizes, shapes, textures and properties. With polymeric packaging, as with other packaging, reliable and easily operable access mechanisms are required in order to make the contents of the package readily and easily available to the user. Of course, access mechanisms for such packages have varied depending on the type of package (e.g., barrier, pressurized, evacuated, etc.), the type of contents, the intended use of the contents, the reusability and/or recloseability required for the package (e.g., depending upon whether all the contents are used at one time, etc.)--as well as a host of other factors.
In some prior art applications utilizing polymeric packaging, the access mechanism provided to such packaging has added unnecessary costs to the price of the packaging. In other instances, the access mechanism provided to the user has proved to have been less than technically adequate, and upon utilization has resulted in damage to the contents or to the package structure, such as for example, in making the packaging non-recloseable. Yet other access mechanisms such packaging have resulted in non-structural damage to the aesthetics of the packaging and/or to the visual indicia contained upon the package, such as indicating its source of origin, instructions to the user, advertising or promotional material, etc.
In view of the above defects, difficulties and/or deficiencies of prior art packaging and access mechanisms for such packaging, it is a material object of the improved strippable seal mechanism of the present invention to alleviate materially those defects, difficulties and/or deficiencies.
These and other objects of the improved strippable seal mechanism of the present invention will become more apparent upon the review of the following disclosure of the present invention.
SUMMARY OF THE INVENTION
The improved strippable seal mechanism of the present invention, in certain broad embodiments, includes first and second polymeric webs, each having an exterior and interior surface. The interior surface of at least one of the first and second polymeric webs has a substantially adhesive surface thereon for fixedly, but separably adhering to the interior surface of the other polymeric web. Additionally, one of the first and second polymeric webs has at least one line of reduced strength disposed at the exterior surface thereof.
A manually grippable tab is disposed adjacent to and operatively connected to the line of reduced strength at the exterior surface of one of the polymeric webs. The line of reduced strength may comprise a groove cut into the exterior surface of the polymeric web. The manually grippable tab operates in conjunction with the line of reduced strength by means of directing a peel force along the line of reduced strength to delaminate the first and second polymeric webs. In various alternative embodiments, the first and second polymeric webs may either or each comprise laminates, and the delamination which occurs (incident to the use of the manually grippable tab and its accompanying peeling force) may serve to delaminate a polymeric web per se, rather than separating one polymeric web from the other.
The improved strippable seal mechanism of the present invention may be better understood in conjunction with the following brief description of the drawing, detailed description of preferred embodiments, appended claims and accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
The improved strippable seal mechanism of the present invention is set forth in the accompanying drawing, and in which:
FIG. 1 is an enlarged transverse cross-sectional view of an upper heated seal bar containing an indentation mechanism and a lower seal bar, which may be heated, with first and second polymeric webs disposed therebetween, each of which is a laminate of several layers, and illustrating the operation by which lines of reduced strength are disposed into the polymeric web;
FIG. 2 is an enlarged transverse cross-sectional view of such first and second polymeric webs as shown in FIG. 1, and showing the operation of the peel force directed along the lines of reduced weakness there comprising grooves and further showing delamination of one of the polymeric web laminates; and
FIG. 3 is a greatly enlarged cross-sectional view of one of the first and second polymeric webs showing its laminated structure, and including in such embodiment a sealant layer, a barrier layer, a tie layer, and a primary plastic layer.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The improved strippable seal mechanism of the present invention includes first and second polymeric webs. The first polymeric web has a first polymeric web exterior and interior surface, with the interior surface thereof having a substantially adhesive surface thereon for fixedly adhering to another surface. In certain embodiments, the adhesive surface disposed on the interior surface of one of the first and second polymeric webs may separably adhere to another surface.
Such corresponding second polymeric web is disposed in facing laminated contact with the first polymeric web and has second polymeric web exterior and interior surfaces, with the interior surface having a substantially adhesive surface thereon for fixedly adhering the first polymeric web interior surface to the second polymeric web interior surface.
One of the first polymeric web and second polymeric web has at least one line of reduced strength disposed at the exterior surface thereof. A manually grippable tab is disposed adjacent to and in operative connection with a line reduced strength of the exterior surface of one of the polymeric webs. The manually grippable tab is utilized to direct a peel force to one of the first and second polymeric webs for delamination along the line(s) of reduced strength. In certain preferred embodiments, two lines of reduced strength are disposed in spaced array in the polymeric web to permit a strip to be pulled from a portion of the polymeric web which is disposed between the two lines of reduced strength.
In some preferred embodiments, at least one of the first and second polymeric webs is a laminate. Such laminate may comprise a primary plastic layer and a barrier layer. Such barrier layer is preferably disposed interiorly of the primary plastic layer. A sealant layer may also, in other embodiments, be disposed interiorly of the barrier layer. Such sealant layer may preferably comprise the adhesive surface. In other preferred embodiments, a tie layer may be disposed between the primary plastic layer and the barrier layer. Each of the first polymeric web and the second polymeric web may include a tie layer. One of the polymeric web tie layers has a lower peel strength than the other such tie layer. The first and second polymeric web tie layers may comprise a film blend of ethyl-vinyl acetate and linear low density polyethylene. One of the polymeric web tie layers may comprise a blend of approximately 26% ethyl-vinyl acetate in low linear density polyethylene. The other of the polymeric web tie layers may preferably comprise a blend of approximately 18% ethyl-vinyl acetate in low linear density polyethylene. Thus, one of such tie layers may have a peel strength of approximately 1800 grams per inch of width thereof, based upon its 26% blend. The other tie layer (and in certain embodiments, the lower tie layer of the lower polymeric web) may have a peel strength of approximately 1000-1200 grams per inch of width thereof for an 18% blend. In such preferred embodiments, the tie layer of greater peel strength is disposed on the polymeric web having the manually grippable tab thereon, which structure assures delamination of the other, oppositely disposed polymeric web at the tie layer thereof, which is of lower peel strength.
At least one of the lines of reduced strength may comprise a groove which is disposed to a substantial depth into the exterior surface of one of the first polymeric web and second polymeric web. Such line of reduced strength may comprise a groove which is disposed to a substantial depth in the exterior surface of a primary plastic layer. The groove, in preferred embodiments, is substantially V-shaped in transverse cross-section. A first raised shoulder portion may be disposed immediately laterally of the groove for supplementally directing the stripping of the polymeric web along the groove in the exterior surface of one of the polymeric webs. A second raised shoulder may be disposed medially of the groove for further supplementally directing the stripping of the polymeric web along the groove of the exterior surface of one of the polymeric webs.
The exterior surface of one of the first polymeric web and second polymer web preferably comprises a thermoplastic polymeric material which is capable of receiving a heated knife thereunto for melting a groove therewithin to form the line of reduced strength.
Referring now to the drawing, the improved strippable seal mechanism generally 10 of the present invention includes first and second polymeric webs generally 12, 14, as shown in FIGS. 1 and 2. First polymeric web 12 has a first polymeric web exterior surface 16 and interior surface 18, with interior surface 18 thereof having a substantial adhesive means thereon for fixedly adhering to another surface. In certain embodiments, the adhesive means disposed on interior surface 18 of first polymeric web 12 may comprise a sealant layer 20, and may separably adhere to another surface.
Such corresponding second polymeric web 14 is disposed in facing laminated contact with first polymeric web 12 and has second polymeric web exterior and interior surfaces 22, 24 with interior surface 24 having substantially adhesive means thereon for fixedly adhering first polymeric web interior surface 18 to second polymeric web interior surface 24. Such adhesive means may comprise a sealant layer 26 for such second polymeric web 14.
As shown in FIGS. 1 and 2, first polymeric web 12 has a pair of lines of reduced strength in the form of grooves 28, 30 disposed at the interior surface 18 thereof. A manually grippable tab is disposed adjacent to and in operative connection with grooves 28, 30, and is utilized to direct a peel force to one of the first and second polymeric webs 12, 14 for delamination along the lines of reduced strength.
As shown in FIGS. 1, 2 and 3, first and second polymeric webs 12, 14 are laminates. Such laminates respectively have primary plastic layers 32, 34 and barrier layers 36, 37. Such barrier layer 36 is shown as disposed interiorly of primary plastic layer 32. Sealant layers 20, 26 are disposed interiorly of respective barrier layers 36, 38. In other preferred embodiments, respective tie layers 38, 40 are disposed respectively between primary plastic layers 32, 34 and barrier layers 36, 37. One of the polymeric web tie layers 40 has a lower peel strength than the other such tie layer 38. First and second polymeric web tie layers 38, 40 may comprise a film blend of ethyl-vinyl acetate and linear low density polyethylene. Polymeric web tie layer 38 may comprise a blend of approximately 26% of the ethyl-vinyl acetate in low linear density polyethylene. The other of the polymeric web tie layers 40 may preferably comprise a blend of approximately 18% ethyl-vinyl acetate in low linear density polyethylene. Thus, first polymeric web tie layer 38 may have a peel strength of approximately 1800 grams per inch of width thereof, based upon its 26% blend. Second polymeric web tie layer 40 may have, for example, a peel strength of approximately 1000-1200 grams per inch of width thereof. In such preferred embodiments, the tie layer 38 of greater peel strength is disposed on the polymeric web having the manually grippable tab thereon, which structure assures delamination of the other oppositely disposed polymeric web at the tie layer 40 thereof, which is of lower peel strength.
As shown in FIGS. 1 and 2, the lines of reduced strength comprises grooves 28, 30 which are disposed to a substantial depth into the exterior surface 16 of first polymeric web 12. The grooves 28, 30 are substantially V-shaped in transverse cross-section. Raised shoulder portions 42 may be disposed immediately laterally and medially of grooves 28, 30 for supplementally directing the stripping of the polymeric web along grooves 28, 30 in exterior surface 16 of polymeric web 12.
Exterior surface 16 of first polymeric web 12 preferably comprises a thermoplastic polymeric material which is capable of receiving a heated knife generally 44 thereunto for melting grooves 28, 30 therewithin. As shown in FIG. 1, heated knife 44 includes a pair of heated knife blades 46, 46 disposed in spaced array and separated by a heat source bar 48, which is supplied by a heat source 50. Heat source 50 may comprise a conduit for circulating a heated liquid 52 therewithin. Such heated knife 44 may also include a pair of cold heels 54, 54 disposed exteriorly of knife blades 46, 46.
The basic and novel characteristics of the improved methods and apparatus of the present invention will be readily understood from the foregoing disclosure by those skilled in the art. It will become readily apparent that various changes and modifications may be made in the form, construction and arrangement of the improved apparatus of the present invention, and in the steps of the inventive methods hereof, which various respective inventions are as set forth hereinabove without departing from the spirit and scope of such inventions. Accordingly, the preferred and alternative embodiments of the present invention set forth hereinabove are not intended to limit such spirit and scope in any way.
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The improved strippable seal mechanism inclues first and second polymeric webs each having an exterior and interior surface. The interior surface of at least one of the first and second polymeric webs polymeric webs has a substantially adhesive surface thereon for fixedly but separably adhering to the other polymeric web's interior surface. One of the first and second polymeric webs has at least one line of reduced strength disposed at the exterior surface thereof. A manually grippable tab is disposed adjacent to and operatively connected to the line of reduced strength at the exterior surface of one of the polymeric webs. The manually grippable tab operates in conjunction with the line of reduced strength to direct a peel force along the line of reduced strength to delaminate one of the first and seocnd polymeric webs.
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This is a continuation of application Ser. No. 08/492,698 filed Jun. 20, 1995, abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention:
The present invention relates to a magnetic tape recording and reproducing apparatus suitable for use in a data recording and reproducing apparatus called a data streamer.
2. Description of the Related Art:
There have been developed various kinds of recording and reproducing apparatus each of which records digital data on a magnetic tape and reproduces the recorded data by using a magnetic head disposed on a rotary head drum. The recording and reproducing apparatus using the rotary head drum records data such that tracks slanted relative to the longitudinal direction of the magnetic tape are successively formed.
In this case, since it is usually required upon reproduction to effect a tracking control for controlling the magnetic head to accurately trace the tracks formed on the magnetic tape and hence to accurately control a tape travel system, the rotation phase of the rotary head drum and an arrangement of the recording and reproducing apparatus becomes complicated. Moreover, since it is necessary to widen a track width to the extent that the magnetic head can trace the track accurately, this necessity to widen the track width becomes a bar to an increase of the recording density with which data are recorded on the magnetic tape.
In order to solve the above problem, the assignee of this application developed a recording and reproducing apparatus which can reproduce recorded data from a magnetic tape accurately in a so-called non-tracking system in which the tracking control and so on are not required. FIG. 1 shows an arrangement of a rotary head drum 1 of the recording and reproducing apparatus. A magnetic head A R and a magnetic head B are disposed at predetermined positions adjacent or close to each other on the rotary head drum 1. In this case, the magnetic head A R and the magnetic head B have azimuth angles which are different from each other. The magnetic head A R is used only for recording, and the magnetic head B is used for both recording and reproduction. A magnetic head A P used only for reproduction is disposed on the rotary head drum 1 at a position which is 180° apart from the magnetic head B, i.e., opposite thereto on the same diameter of the rotary head drum 1. An azimuth angle of the magnetic head A P is set equal to that of the magnetic head A R used only for recording. A magnetic tape T is wrapped around the rotary head drum 1 and brought in contact therewith for about 100°.
A process carried out when the recording and reproducing apparatus records data will be described with reference to FIGS. 2A to 2C and 4. Initially, the magnetic tape T is traveled at a constant speed and the rotary head drum 1 is rotated at a predetermined speed. While the rotary head drum 1 makes a first rotation, as shown in FIG. 2A, the magnetic head A R scans the magnetic tape T and records data thereon (this recording is represented by a reference symbol Ra in FIG. 2A) to form a slant track Ta of one recording azimuth angle as shown in FIG. 4. While the rotary head drum 1 makes a second rotation, as shown in FIG. 2B, the magnetic head B scans the magnetic tape T and records data thereon (this recording is represented by a reference symbol Rb in FIG. 2B) to form a slant track Tb of the other recording azimuth angle as shown in FIG. 4 at a portion adjacent to the track Ta. Hereinafter, the tracks Ta and Tb are alternately formed during every one rotation of the rotary head drum 1.
In this case, as shown in FIGS. 2A and 2B, while the rotary drum head 1 is rotated and one of the magnetic heads A R and B records data on the magnetic tape T, the other of the two does not record data thereon. The magnetic head A P used only for the reproduction is not used during the recording as shown in FIG. 2C.
Subsequently, a process carried out when the recording and reproducing apparatus reproduces data will be described with reference to FIGS. 3A to 3C and 4. Similar to the recording process in this case, the magnetic tape T is traveled at a constant speed and the rotary head drum 1 is rotated at a predetermined speed (which is the same as that used upon the recording). While the rotary head drum 1 makes a first rotation, as shown in FIG. 3B, the magnetic head B scans the magnetic tape T and reproduces data therefrom (this reproduction is represented by a reference symbol Pa in FIG. 3B). After the reproduction Pa is carried out and the rotary head drum 1 is rotated by about 180°, as shown in FIG. 3C, the magnetic head A P scans the magnetic tape T and reproduces data therefrom (this reproduction is represented by a reference symbol Pb in FIG. 3C). Respective loci of the magnetic heads B and A P produced when they trace the tracks in the reproduction Pa and the reproduction Pb are loci La and Lb not shown in FIG. 4.
While the rotary head drum 1 makes a second rotation, as shown in FIG. 3B, the magnetic head B scans the magnetic tape T and reproduces data therefrom (this reproduction is represented by a reference symbol Pc in FIG. 3B). After the reproduction Pc is carried out and the rotary head drum 1 is rotated by about 180°, as shown in FIG. 3C, the magnetic head A P scans the magnetic tape T and reproduces data therefrom (this reproduction is represented by a reference symbol Pd in FIG. 3C). At this time, not shown in FIG. 4, respective loci Lc, Ld of the magnetic heads B and A P during the reproduction Pc and the reproduction Pd are displaced from the loci La, Lb by an amount of about one-track width. The magnetic head A R used only for recording is not used during the reproduction as shown in FIG. 3A. A comparison between the recording process shown in FIGS. 2A to 2C and the reproduction process shown in FIGS. 3A to 3C reveals that in the reproduction process data is reproduced with a density that is twice as high as that of the recording density.
When such reproduction is carried out, a signal reproduced from the track Ta with one recording azimuth angle is obtained in the reproduction Pa and the reproduction Pc carried out by the magnetic head B, and a signal reproduced from the track Tb with the other recording azimuth angle is obtained in the reproduction Pb and the reproduction Pd carried out by the magnetic head A P . Since the tracking control is not effected during the reproduction in this system, in that the loci of the magnetic heads B and A P do not correspond to the tracks formed on the magnetic tape T as shown in FIG. 4, it is possible to substantially obtain a complete recording signal of one track Ta by synthesizing the signals obtained by the reproduction Pa and the reproduction Pc. Similarly, it is possible to substantially obtain a complete recording signal of one track Tb by synthesizing the signals obtained by the reproduction Pb and the reproduction Pd.
When data is reproduced with a density that is twice as high as the recording density as described above, it is possible to reproduce recording signals accurately without tracking control. Accordingly, in this non-tracking system, it is possible to set a track width regardless of the tracking control upon the reproduction, and it is possible to realize a high recording density. In the above-mentioned example, although data is reproduced at a density that is twice as high as the recording density, the rotary head drum 1 is rotated at the same constant speed during both the recording and reproduction processes. Therefore, it is possible to simplify an arrangement of a drive system for the rotary head drum 1.
When a signal recorded by the recording and reproducing apparatus of this system is an audio signal, even if a signal obtained by such a reproduction process has a blank portion, a signal at the blank portion is estimated by interpolation to obtain an audio signal sufficient to be used in the reproduction process. However, when data such as a computer program or the like is recorded, it is necessary to completely prevent reproduced signal from having a blank. The above necessity is not satisfied by the recording and reproduction processes of the recording and reproducing apparatus of the above system. Moreover, when data such as a computer program or the like is recorded, it is necessary to record such recording data which is completely free from any blank portion.
SUMMARY OF THE INVENTION
In view of such aspects, it is an object of the present invention that data such as a computer program or the like can be recorded and reproduced accurately in a recording and reproducing apparatus of a non-tracking system which can improve a recording density under a simple control.
According to a first aspect of the present invention, a recording and reproducing apparatus for recording and reproducing a data signal on and from a magnetic tape includes a rotary head drum, first and second magnetic heads, third and fourth magnetic heads, data processing means, data signal decoding means, and control means. A magnetic tape is wrapped around the rotary drum so as to be slanted at a predetermined angle. The first and second magnetic heads are provided on the rotary drum at positions apart from each other by a predetermined rotational angle and have a first azimuth angle. The third and fourth magnetic heads are provided on the rotary drum at positions apart from each other by a predetermined rotational angle and have a second azimuth angle different from the first azimuth angle. The data processing means adds address data to each recording unit of the data signal and outputs the data signal as a recording signal. The data signal decoding means decodes the data signal from the recorded signals reproduced by the first, second, third and fourth magnetic heads based on the address data included in the recording signal. The control means, upon the recording, supplies the recording signal to the first magnetic head and the second magnetic head alternately at each rotation of the rotary drum to record the same on the magnetic tape and, upon the reproduction, supplies the recorded signals reproduced by the first, second, third and fourth magnetic heads to the data signal decoding means.
According to a second aspect of the present invention, the data processing means adds an error correction code to each of the recording units of the data signal to output the data signal as the recording signal.
According to a third aspect of the present invention, the recording and reproducing apparatus further includes error detecting means for detecting an error of the recording signal by using the error correction code. Upon recording, the control means controls the third and fourth magnetic heads to reproduce recording signals recorded on the magnetic tape by the first and second magnetic heads and discriminates a recorded state of the recording signal on the magnetic tape by supplying the reproduced recording signal to the error detecting means.
According to a fourth aspect of the present invention, the data signal is supplied from external equipment. The recording and reproducing apparatus further includes storage means for storing address data of a recorded signal determined by the error detecting means as one having no error, and error reporting means for supplying an address of a data signal whose address data is not stored in the storage means as an address of a data signal having an error to the external equipment upon the end of recording.
According to a fifth aspect of the present invention, the recording unit is set smaller than one track.
According to a sixth aspect of the present invention, a transfer speed of the magnetic tape and a rotation speed of the rotary drum upon recording are set equal to those upon reproduction.
According to a seventh aspect of the present invention, reproduction of a non-tracking system is carried out upon reproduction.
According to an eighth aspect of the present invention, the recording and reproducing apparatus for recording and reproducing the data signal on and from the magnetic tape includes the rotary drum, the first and second magnetic heads, the third and fourth magnetic heads, the data processing means, the data signal decoding means, the error detection means, and the control means. The magnetic tape is wrapped around the rotary drum so as to be slanted at a predetermined angle. The first and second magnetic heads are provided on the rotary drum at positions apart from each other by a predetermined rotational angle and have the first azimuth angle. The third and fourth magnetic heads are provided on the rotary drum at positions apart from each other by a predetermined rotational angle and have the second azimuth angle different from the first azimuth angle. The data processing means adds address data and an error correction code to each recording unit of a data signal and outputs the data signal as the recording signal. The data signal decoding means decodes the data signal from the recorded signals reproduced by the first, second, third and fourth magnetic heads based on the address data included in the recording signal. The error detection means detects an error of the recording signal by using the error correction code. Upon recording, the control means supplies the recording signal to the first magnetic head and the second magnetic head alternately at each rotation of the rotary drum to record the same on the magnetic tape, controls the third and fourth magnetic heads to reproduce recording signals recorded on the magnetic tape by the first and second magnetic heads, and discriminates the recorded state of the recording signal on the magnetic tape by supplying the reproduced recording signal to the error detecting means.
According to a ninth aspect of the present invention, the data signal is supplied from external equipment. The recording and reproducing apparatus further includes storage means for storing address data of a recorded signal determined by the error detecting means as one having no error, and error reporting means for supplying an address of the data signal whose address data is not stored in the storage means as an address of the data signal having the error to the external equipment upon the end of recording.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram used to explain an arrangement of a rotary head drum according to a prior art;
FIGS. 2A to 2C are diagrams showing timings of a recording process according to the prior art;
FIGS. 3A to 3C are diagrams showing timings of a reproducing process according to the prior art;
FIG. 4 is a diagram used to explain a recording and reproduction state according to the prior art by using a track pattern on a magnetic tape;
FIG. 5 is a diagram showing an arrangement of a data streamer according to the present invention;
FIG. 6 is a diagram showing a system arrangement according to the present invention;
FIG. 7 is a diagram used to explain an arrangement of a rotary head drum according to the present invention;
FIG. 8 is a diagram used to explain how magnetic heads according to the present invention trace tracks;
FIGS. 9A to 9D are diagrams showing timings of a recording process according to the present invention;
FIG. 10 is a diagram used to explain a recorded state according to the present invention;
FIGS. 11A to 11D are diagrams showing timings of a reproducing process according to the present invention;
FIG. 12 is a diagram used to explain an arrangement of areas of a memory according to the present invention;
FIG. 13 is a diagram used to explain loci of the magnetic heads on a magnetic tape upon reproduction according to the present invention; and
FIGS. 14A to 14M are diagrams showing a data reproduction state according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
An embodiment according to the present invention will hereinafter be described with reference to FIGS. 5 through 14.
In this embodiment, the present invention is applied to a data streamer for recording and reproducing data used for a computer. FIG. 5 shows an arrangement of the data streamer, and FIG. 6 shows an arrangement of an external equipment (such as a host computer or the like) connected to the data streamer.
The arrangement of the data streamer will be described with reference to FIG. 5 initially. An interface 12 supplies data supplied thereto from an external equipment to a data processing circuit 13. The data processing circuit 13 is connected with a data processing memory 14 and converts the data supplied thereto from an external equipment into recording data. Specifically, the data processing circuit 13 divides the data supplied thereto from the external equipment into predetermined data blocks and adds data of a block number and an error correction code to the actual data of each of the data blocks. The data processing circuit 13 converts the reproduced data into output data. The data processing circuit 13 is operated under the control of a central processing unit (CPU) 21, i.e., a microcomputer which controls the operations of the respective units of the data streamer.
The recording data obtained by the data processing circuit 13 is subjected to a modulation processing for the recording by a modulation circuit 15 to obtain a recording RF signal. The recording RF signal is supplied to RF amplifiers 16, 17. In this case, each of the recording data of a one-track amount is alternately supplied to the RF amplifiers 16, 17 (data of a one track amount is formed of plural blocks). The RF amplifier 16 is connected through a rotary transducer 18 with magnetic heads A1, A2 in a rotary head drum (not shown in FIG. 5). The recording RF signal amplified by the RF amplifier 16 is supplied to the magnetic head A1 which records the recording RF signal on a magnetic tape (not shown in FIG. 5). The RF amplifier 17 is connected through the rotary transducer 18 with magnetic heads B1, B2 in the rotary head drum. The recording RF signal amplified by the RF amplifier 17 is supplied to the magnetic head B1 which records the recording RF signal on the magnetic tape.
Signals reproduced by the magnetic heads A1, A2 are supplied through the rotary transducer 18 to the RF amplifier 16. A detector circuit 19 demodulates the reproduced RF signal obtained in the RF amplifier 16 by amplifying the reproduced signals, detecting the reproduced data and its clock component, and supplying them to the data processing circuit 13.
Further, signals reproduced by the magnetic heads B1, B2 are supplied through the rotary transducer 18 to the RF amplifier 17. A detector circuit 20 demodulates the reproduced RF signal obtained in the RF amplifier 17 by amplifying the reproduced signals, detecting the reproduced data and its clock component, and supplying them to the data processing circuit 13.
The data processing circuit 13 carries out a synthesizing process in which reproduced data is restored to data of one track each by using the data memory 14. The data processing circuit 13 also carries out an error detection processing and an error correction processing by using the error correction code added to the reproduced data. When data of one track is completely restored through the above-mentioned processings, the data of one track is supplied to the interface 12 together with the clock and they are transmitted from the interface 12 to an external equipment.
In this embodiment, when data is recorded by using the magnetic heads A1, B1, the recorded data is reproduced by using the magnetic heads A2, B2 soon after being recorded. Further, the data processing circuit 13 is supplied with the data reproduced by the magnetic heads A2, B2 and subjects each of blocks of the reproduced data to error detection by using the error correction code included in the reproduced data. The data processing circuit 13 adds data indicative of whether or not there is a detected error with address data of each block and supplies the former through the interface 12 to an external equipment.
The CPU 21 of this embodiment is connected with a RAM 22 which stores a control program and so on. In accordance with a command from the CPU 21, a rotary head drum motor 24 is rotated at a predetermined speed under the control of a drum motor driver circuit 23. In this case, a frequency generator (FG) 25 detects a rotation state of the rotary head drum. A control motor 27 for wrapping the magnetic tape around the rotary head drum and so on is driven under the control of a control motor driver circuit 26 in accordance with a command from the CPU 21. In this case, a sensor 28 detects a wound state of the magnetic tape and so on.
FIG. 7 shows an arrangement of magnetic heads on a rotary head drum 11 according to this embodiment. The magnetic heads A1, B1 are disposed on the rotary head drum 11 at respective predetermined positions close to each other. The magnetic heads A1, B1 have different azimuth angles. The magnetic heads A1, B1 are attached to positions displaced from each other by one track amount in the height direction of the rotary head drum 11. The magnetic heads A1, B1 are used for both recording and reproduction.
Magnetic heads A2, B2 are used only for reproduction, and are respectively disposed at positions which are close to each other and 180° apart from the magnetic heads A1, B1, i.e., opposite thereto on the same diameters of the drum. The magnetic heads A2, B2 also have different azimuth angles. The magnetic heads B1, B2 are attached to positions displaced from each other by one track amount in the height direction of the rotary head drum 11. The magnetic heads A1, A2 have the same azimuth angle, and the magnetic heads B1, B2 have the same azimuth angle.
One pair of the magnetic heads A1, B1 and the other pair of the magnetic heads A2, B2 are disposed from each other by several track amounts (six tracks in this embodiment) in the height direction of the rotary head drum 11. The magnetic tape T is wound around the rotary head drum 1 for about 100°.
Since the four magnetic heads are disposed on the rotary head drum 11 as described above, the magnetic heads scan the tracks as shown in FIG. 8 when the rotary head drum 11 makes one rotation. Specifically, when the rotary head drum 11 makes one rotation and the magnetic head A1 scans a track on a locus La1 shown in FIG. 8, the magnetic head B1 scans a track immediately succeeding the track scanned by the magnetic head A1 in the tape travel direction a on a locus Lb1. The magnetic head A2 scans on a locus La2 shown in FIG. 8, six tracks succeeding from the track scanned by the magnetic head A1 in the tape travel direction a. The magnetic head B2 scans on a locus Lb2 shown in FIG. 8 six tracks succeeding from the track scanned by the magnetic head B1 in the tape travel direction a.
This embodiment employs a system in which the magnetic tape is recorded and reproduced in both directions. When a tape cassette housing a magnetic tape is loaded into a data streamer with the front surface of the cassette being faced upward, an upper portion of the magnetic tape is used for recording and reproduction in one direction. When the tape cassette is loaded thereinto with the front surface of the cassette being faced downward, a lower portion of the magnetic tape is used for recording and reproduction in the other direction. Figures showing tape patterns, e.g., FIG. 8 and so on, show only recording and reproduction patterns in one direction.
This embodiment does not employ a tracking control for adjusting the scanning loci of the magnetic heads to the recording tracks when data is reproduced.
FIG. 6 shows an arrangement of the external equipment connected to the data streamer having the above-mentioned arrangement. The data streamer 10 is connected through a data converting apparatus 30 to a host computer 40. The host computer 40 includes a central processing unit (CPU) 41 which is the main arithmetic processing unit of the host computer 40, a memory 42 for storing data used in the arithmetic processing, and a disc unit 43 which is a large-capacity data storage unit using some suitable means such as a hard disc or the like. The disc unit 43 is connected through an interface 44 to bus lines used for transmitting data to respective units. The bus lines include a bus line for transmitting data and a bus line for transmitting address data of the transmission data. The respective bus lines are connected to an interface 45 for connecting the data converting apparatus 30 to the host computer 40.
The data converting apparatus 30 converts data transmitted thereto from the interface 45 of the host computer 40 into data having an arrangement the data streamer 10 can receive, and transmits the converted data to the interface 12, shown in FIG. 5, of the data streamer 10. The data converting apparatus 30 converts data transmitted from the interface 12 of the data streamer 10 into data having an arrangement the host computer 40 can receive, and transmits the converted data to the interface 44 of the host computer 40.
There will be described herein a process carried out when the data streamer according to this embodiment records data supplied from the host computer 40 on the magnetic tape. FIG. 9 shows a recording timing according to the present invention. While the rotary head drum 11 makes a first rotation, as shown in FIGS. 9C and 9D, the magnetic heads A2, B2 respectively reproduce two adjacent tracks at timings P1, P2 at which the magnetic heads A2, B2 scan the magnetic tape T (in this case, when the recording is started, the magnetic heads A2, B2 reproduce portions with no recording track). As shown in FIG. 9A, the magnetic head A1 records data of one track amount on the magnetic tape T at a timing R1 where the magnetic head A1 scans the magnetic tape T. At this same time, as shown in FIG. 9B, the magnetic head B1 does not record data even at a timing which the magnetic head B1 scans the magnetic tape T.
While the rotary head drum 11 makes the next rotation, as shown in FIGS. 9C, 9D, the magnetic heads A2, B2 respectively reproduces two adjacent tracks at timings P3, P4 at which the magnetic heads A2, B2 scan the magnetic tape T. As shown in FIG. 9B, the magnetic head B1 records data of one track amount on the magnetic tape T at a timing R2 where the magnetic head B1 scans the magnetic tape T. At this same time, as shown in FIG. 9A, the magnetic head A1 does not record data even at a timing at which the magnetic head A1 scans the magnetic tape T.
As described above, each time the rotary head drum 11 makes one rotation, data of one track amount is recorded. Since the magnetic heads A1, B1 having different azimuth angles are alternately used for the recording at this time, a track having one azimuth angle and a track having the other azimuth angle are alternately formed.
Since the magnetic heads A2, B2 other than the magnetic heads A1, B1 which record data, reproduce data, recorded signals are immediately reproduced. In this embodiment, as shown in FIG. 8, tracks scanned by the recording heads A2, B2 are six-tracks behind from the tracks scanned by the magnetic heads A1, B1 in the tape travel direction a, respectively. Therefore, after each of the magnetic heads A1, B1 records six tracks since the start of the recording, recorded signals are reproduced by the magnetic heads A2, B2 and thereafter recorded signals on tracks which are six-tracks behind from tracks being recorded in the tape travel direction a are reproduced thereby.
Reproduced data, detected from signals reproduced during the recording, are supplied to the data processing circuit 13 as shown in FIG. 5. The data processing circuit 13 subjects each block of the reproduced data to error detection by using the error correction code included in the reproduced data. When the error correction code is not detected in a block, the data processing circuit 13 transmits the address data (a track number and a block number) of the block through the interface 12 to the data converting apparatus 30 as shown in FIG. 6. Since the transmitted block has had no error detected, it is natural that its address data has already been detected from the reproduced data. The data converting apparatus 30 stores the transmitted address data. If it is detected that a block has an error, address data of the block is not transmitted to the data converting apparatus 30. Thus, it is possible for the data converting apparatus 30 to detect a block having an error.
When the recording of data of one unit supplied from the host computer 40 onto the magnetic tape T is finished, the data converting apparatus 30 issues to the host computer 40 a command to transmit the data of the block having an error to the data converting apparatus 30 therefrom again. Specifically, the data converting apparatus 30 transmits the address data of the block having the error to the host computer 40. The data converting apparatus 30 transmits the data output from the host computer 40 in accordance with the command to the data streamer 10 to record the data on the magnetic tape T again. At this time, similarly, as shown in FIGS. 9A to 9D, recorded signals are immediately reproduced, the data processing circuit 13 subjects the reproduced data to the error detection and the data converting apparatus 30 detects whether or not each of blocks of the reproduced data has a recording error. If the recording error is detected, then the data converting apparatus 30 repeats a processing for recording the same data on the magnetic tape T.
In such recording, as shown in FIG. 10, when data D1 of one unit is recorded on a predetermined portion of the magnetic tape T, of that recorded data D1, data having an error is recorded again as data D1' or data D1" on a portion succeeding the portion where the data D1 is recorded. The data D1' or data D1" recorded again at this time is not only data of the block which had the error but also data adjacent to the data of the block so as to set the data D1', D1" as at least data of a several-track amount.
Since the above-mentioned recording process is carried out, the data supplied to the data streamer 10 can be reliably recorded on the magnetic tape T. Therefore, it is possible to reliably store the data. In this case, since the signals reproduced soon after recording are subjected to error correction by only using the error correction code, it is easy to determine whether or not a block includes an error without resorting to any processes such as checking the recorded data and the reproduced data with each other, or the like. Therefore, it is possible to reliably record data with circuits having simple arrangements.
While the portions of data having the errors are recorded on another portion of the magnetic tape T as shown in FIG. 10, when the data D1, D1' and D1" are reproduced, it is possible to reproduce that data D1, D1' and D1" as continuous data of one unit by controlling positions from which the data is reproduced in response to the state of the errors under the control of the data converting apparatus 30 (or the host computer 40).
There will be described with reference to FIG. 11 a process in which the data streamer 10, according to this embodiment, reproduces recorded data from the magnetic tape T and supplies reproduced data to the host computer 40. FIG. 11 shows a reproduction timing according to the present invention. While the rotary head drum 11 makes a first rotation, as shown in FIG. 11C and 11D, the magnetic heads A2, B2 respectively reproduce two adjacent tracks from the magnetic tape T at timings P11, P12 where the magnetic heads A2, B2 scan the magnetic tape T. As shown in FIGS. 11A and 11B, the magnetic heads A1, B1 respectively reproduce two adjacent tracks at timings P13, P14 where the magnetic heads A1, B1 scan the magnetic tape T. The timings P13, P14 are six-track widths prior to the timings P11, P12.
While the rotary head drum 11 makes the next rotation, similarly, as shown in FIG. 11C and 11D, the magnetic heads A2, B2 respectively reproduce two adjacent tracks from the magnetic tape T at timings P15, P16 where the magnetic heads A2, B2 scan the magnetic tape T. Then, as shown in FIGS. 11A and 11B, the magnetic heads A1, B1 respectively reproduce two adjacent tracks at timings P17, P18 where the magnetic heads A1, B1 scan the magnetic tape T.
Thereafter, the reproduction with all four of the magnetic heads A1, A2, B1 and B2 is repeated at every rotation of the rotary head drum 11.
Reproduced data detected from the reproduction RF signal is written in the data memory 14 connected to the data processing circuit 13. An arrangement of the data memory 14 will be described. The data memory 14 according to this embodiment has a memory storage area of a 128 track amount as shown in FIG. 12. After data is successively written in the areas from the area of track number 0 to the area of a track number 127, the data is written in the area of track number 0 again, i.e., the storage area of 128 track amount is used circularly.
When the magnetic head A1 reproduces a signal recorded on the track of track number 2 at a certain timing, data reproduced at this time is stored at a corresponding block position in the area of track number 2 in the data memory 14. A signal of a track reproduced by the magnetic head A2 at the timing is a recorded signal of the track of track number 8, six-track widths behind the track reproduced by magnetic head A1 at the same timing. Reproduced data of the track of track number 8 is stored at a corresponding block position in the area of track number 8. In this case, even if data reproduced by the magnetic head A1 is already stored in the area of the track number 8, data reproduced by the magnetic head A2 is written therein to update the data.
When the above reproduction process is carried out, the data recorded on each of the tracks of the magnetic tape T is reproduced with a density which is four times higher than the recording density and a scanning density of the reproducing heads obtained upon reproduction is also sufficiently higher. Therefore, it becomes possible to completely reproduce the data recorded on the magnetic tape. This will hereinafter be described with reference to FIG. 13 which shows an example of an actual reproduction state. As shown in FIG. 13, tracks on which data is recorded, i.e., tracks TA1, TB1, TA2, TB2, . . . are formed on the magnetic tape T. In this case, the tracks TA1, TA2, . . . have a recording azimuth angle which allows the magnetic heads A1, A2 to reproduce the tracks TA1, TA2, . . ., and the tracks TB1, TB2, . . . have a recording azimuth angle which allows the magnetic heads B1, B2 to reproduce the tracks TB1, TB2.
The track TA2 having the recording azimuth angle which allows the magnetic heads A1, A2 to reproduce the track TA2 will mainly be described. It is assumed that initially, the magnetic head A1 scans the magnetic tape on a locus 1, and the magnetic head A1 scans the magnetic tape on a locus 2 after one rotation of the rotary head drum 11. Thereafter, the magnetic head A1 successively scans the magnetic tape on loci 3, 4 . . . at every rotation of the rotary head drum 11. At this time, the loci 1, 2, 3, and 4 are displaced at an interval of one track pitch.
It is assumed that after the rotary head drum 11 makes six rotations since the magnetic head A1 initially scanned the magnetic tape T on the locus 1, the magnetic head A2 scans the magnetic tape T on a locus 1', which is substantially the same as the locus 1, and the magnetic head A2 scans the magnetic tape T on a locus 2' after the rotary head drum 11 makes one more rotation. The magnetic head A2 successively scans the magnetic tape T on loci 3', 4' . . . at every rotation of the rotary head drum 11. These loci are slightly slanted relative to the tracks as shown in FIG. 13.
In such scanning, when the magnetic tape T is scanned by the magnetic head A1 on the loci 1, 2, 3, 4, respective RF signals are reproduced as shown in FIGS. 14A, 14B, 14C and 14D. Specifically, as shown in FIG. 14A, a little part of the signal of the track TA2 is reproduced at the beginning of the scanning on the locus 1, and a signal of the track TA1 is reproduced in the rest of the scanning on the locus 1. As shown in FIG. 14B, the signal of the track TA2 is initially reproduced in the scanning on the locus 2, and a little part of the signal of the track TA1 is reproduced in an end part of the scanning on the locus 2. As shown in FIG. 14C, a little part of the signal of the track TA3 is reproduced at the beginning of the scanning on the locus 3, and a signal of the track TA2 is reproduced in the rest of the scanning on the locus 3. As shown in FIG. 14D, the signal of the track TA3 is initially reproduced in the scanning on the locus 4, and a little part of the signal of the track TA2 is reproduced in an end part of the scanning on the locus 4.
It is assumed that data composing one track is divided into 24 blocks at this time. Block numbers of the data of track TA2 detected in the scanning on the locus 1 are assigned as the block numbers 1 to 5 as shown in FIG. 14E. Block numbers of the data of track TA2 detected in the scanning on the locus 2 are assigned as the block numbers 4 to 13 as shown in FIG. 14F. Block numbers of the data of track TA2 detected in the scanning on the locus 3 are assigned as the block numbers 12 to 19 as shown in FIG. 14G. Block numbers of data of the track TA2 detected in the scanning on the locus 4 are assigned as the block numbers 21 to 24 as shown in FIG. 14H.
In this case, it is assumed that data of block number 7 is blanked due to a reproduction error in the scanning on the locus 2, and data of block number 20 is not reproduced in the scanning on any locus.
Data of each of the blocks is stored in the storage area of track TA2 of the data memory 14 connected to the data processing circuit 13 as follows. As shown in FIG. 14I, data of the block numbers 1 to 5 is initially stored in the storage area as data reproduced in the scanning on the locus 1. Thereafter, as the magnetic tape is scanned further, data of the block number of the block which can be reproduced is written therein, and data of the each of block numbers is successively stored in an order as shown in FIGS. 14J to 14L. When the scanning on the loci 1 to 4 is finished, data of the block numbers 7 and 20 blank.
In this embodiment, the magnetic head A2 scans the magnetic tape T again on loci 1', 2', 3', 4' substantially similar to the loci 1 to 4. In the scanning on the loci 1', 2', 3', 4', the data of block numbers 7 and 20 are reproduced and then data of all the blocks forming the track A2 is finally obtained.
Data of the track TB1, TB2, . . . can similarly be reproduced by using the magnetic heads B1, B2. Thus, the recorded data is reproduced with a density which is four times as high as that of the recording density.
While in this embodiment the magnetic heads A2, B2 are positionally displaced from the magnetic heads A1, B1 by a six-track amount in the height direction of the rotary head drum so as to scan the magnetic tape on the loci substantially similar to the loci on which the magnetic heads A1, B1 scan the magnetic tape to reproduce the data, the present invention is not limited thereto. The magnetic heads A2, B2 may be disposed at the same level as the magnetic heads A1, B1 in the height direction of the rotary head drum. It is unnecessary to displace the magnetic heads A2, B2 from the magnetic heads A1, B1 by an amount of tracks of an integral multiple in the height direction of the rotary head drum. Specifically, it is sufficient to reproduce data in the non-tracking system by using all four of the magnetic heads, the magnetic heads A1, A2, B1, B2.
Since the data is reproduced at a density which is four times as high as that of the recording density, there is increased the possibility that the data recorded on the magnetic tape can be reproduced completely. Accordingly, the data streamer according to this embodiment becomes highly reliable. In this case, since in this embodiment the rotary head drum 11 is rotated at the same constant speed when data is both recorded and reproduced, it is possible to control the rotation of the rotary head drum under the same condition when data is both recorded and reproduced. Therefore, it is possible to simplify an arrangement of a control system for controlling the rotary head drum 11. Since the non-tracking system allowing a higher recording density with which data is recorded on the magnetic tape is employed in this embodiment, it is possible to realize with a simple arrangement a data streamer which can both record data with high recording density and reproduce data with high density.
While the present invention is applied to a data streamer for recording and reproducing data used for a computer in the above embodiment, the present invention is not limited thereto and can be applied to a recording and reproducing apparatus for recording and reproducing other kinds of data, such as an audio signal or the like.
According to the present invention, since data is reproduced at a density which is four times higher than the recording density, it is possible to completely reproduce the recorded data with a sufficiently high scanning density. According to the present invention, since the rotary head drum 11 is rotated at the same constant speed when data is recorded and reproduced, it is possible to control the rotation of the rotary head drum 11 under the same condition when data is recorded and reproduced. Therefore, it is possible to simplify an arrangement of a control system for controlling the rotary head drum.
According to the present invention, since the magnetic heads A2, B2 other than the recording magnetic heads A1, B1 reproduce recorded data at the same time as when the magnetic heads A1, B1 record the data, and the error detection is carried out by using the error correction code included in the reproduced signal, it is possible to easily discriminate whether data is accurately recorded or not only by error detection, without resorting to the process of checking the recorded data and the reproduced data with each other.
Since the recorded signal whose recorded condition is determined as unsatisfactory in this case is recorded again on the magnetic tape T after a predetermined interval, it is possible to prevent a part of the recorded signal from being lacked.
Having described a preferred embodiment of the present invention with reference to the accompanying drawings, it is to be understood that the present invention is not limited to the above-mentioned embodiment and that various changes and modifications can be effected therein by one skilled in the art without departing from the spirit or scope of the novel concepts of the present invention as defined in the appended claims.
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A recording and reproducing apparatus for recording and reproducing a data signal on and from a magnetic tape includes a rotary head drum, first and second magnetic heads, third and fourth magnetic heads, a data processor, a data signal decoder, and controller. The magnetic tape is wrapped around the rotary head drum slanted at a predetermined angle. The first and second magnetic heads are provided on the rotary head drum at positions apart from each other by a predetermined rotational angle and have a first azimuth angle. The third and fourth magnetic heads are provided on the rotary head drum at positions apart from each other by a predetermined rotational angle and have a second azimuth angle different from the first azimuth angle. The data processor adds address data to each recording unit of a data signal and outputs the data signal as a recording signal. The data signal decoder decodes the data signal from recorded signals reproduced by the first, second, third, and fourth magnetic heads based on the address data included in the recorded signal. The controller, upon the recording, supplies the recording signal to the first magnetic head and the second magnetic head alternately at each rotation of the rotary head drum to record the same on the magnetic tape and, upon the reproduction, supplies the recorded signals reproduced by the first, second, third, and fourth magnetic heads to the data signal decoding means.
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This is a divisional of application Ser. No. 09/605,718, filed on Jun. 27, 2000, now U.S. Pat. No. 6,391,078.
The present invention relates to a biodegradable organic growth composition which is based on particulate coal.
BACKGROUND
The plant growth composition of the invention represents an improvement in the formulation described in U.S. Pat. No. 4,541,857, the contents of which are incorporated herein by reference.
U.S. Pat. No. 4,541,857 describes a plant fertilizer composition which comprises a mixture of particulate coal containing releasable plant nutrients, sodium molybdate which serves to release the plant nutrients in a form that plants can use, and one or more auxiliary agents selected from ferric sulfate, magnesium sulfate, sodium chloride, zinc sulfate, zinc chloride, copper sulfate, sulfur, hydrated sodium borate, brunt limestone and cobalt carbonate. The coal particulate has a maximum mesh size of about 100 mesh and comprises from about 50-75 weight percent of the total weight of the composition, the molybdate is present in an amount ranging from 0.001 to 0.100 percent by weight of the composition and the auxiliary agent(s) comprise the balance of the composition.
SUMMARY OF THE INVENTION
As indicated, the present invention provides certain improvements in the compositions described in U.S. Pat. No. 4,541,857. These improvements maintain the useful features of the composition described in the earlier patent but also result in further advantages as detailed hereinafter, including, for example, enhanced growth and yield of plants and expanded applicability and use of the composition.
An important modification in the compositions of U.S. Pat. No. 4,541,857 which the present invention provides is the use of a linear alcohol alkoxylate, e.g. a poly(ethylene oxide) ether with a C 12 -C 15 linear primary alcohol.
Other essential features of the present composition include the use of a substantial amount of sand and a small amount of water. Further features will also be evident from the more detailed description of the invention which follows.
DETAILED DESCRIPTION OF THE INVENTION
The plant growth composition of the invention consists essentially of the following components:
(1) 40-80%, preferably 70-80%, by weight of particulate coal;
(2) 0.01 to 1%, preferably 0.5 to 1%, by weight of sodium molybdate;
(3) from 0.2 to 2% by weight water;
(4) from 0.1 to 1% by weight of linear alcohol alkoxylate;
(5) from 0.001 to 4% by weight of magnesium sulfate; with
(6) the balance, usually in an amount of about 20-60% by weight of the overall composition, being sand.
The composition thus consists primarily of coal and sand in its preferred embodiment although molybdate, linear alcohol alkoxylate, magnesium sulfate and water, within the limits indicated, are also essential for the success of the invention.
Of the indicated components, the coal particulate is advantageously as described in the earlier U.S. Pat. No. 4,541,857 referred to above. Thus, the coal particulate may be of any type, for instance, anthracite, bituminous, sub-bituminous or lignite, and can be of varying quality all of which generally contain from about 0.5 to 3.0 percent of known nitrogen. Other plant nutrients present in coal and made available for use by plants in accordance with the present invention include iron, phosphorus, potassium, sulfur or sulfates, calcium, chloride and at least traces of manganese, copper, boron, cobalt, alumina and selenium. High sulfur content coal has been found to be particularly advantageous.
Advantageously, the coal is of 100 mesh particulate size or smaller, i.e. it is such that it passes through a 100 mesh Tyler Screen. Larger and smaller sizes can be effectively used ranging from, for example, −50 mesh to about −300 mesh. Particles larger than 100 mesh, however, tend to release plant nutrients more slowly. Hence, it is preferred to use a coal particulate of 100 mesh size or finer, i.e. particles which will pass through a 100 mesh Tyler Screen.
While any type of coal can be used, preferably one of high sulfur content, the coal composition specifically exemplified in U.S. Pat. No. 4,541,857 may be cited as typical for use herein. Such coal, on a dry basis, has the following ultimate analysis:
carbon:
73.19%
hydrogen:
5.05%
nitrogen:
1.32%
chlorine:
0.07%
sulfur:
4.50%
ash:
6.00% and
oxygen:
9.87%
This composition can also be defined on a mineral analysis-ignited
basis as follows:
phosphorus pentoxide:
0.26%
silica:
32.95%
ferric oxide:
33.09%
alumina:
22.13%
titania:
0.68%
lime:
2.66%
manganese:
0.52%
sulfur trixoide:
3.24%
potassium oxide:
1.43%
sodium oxide:
0.51% and
undetermined:
2.53%
As explained in U.S. Pat. No. 4,541,857, the sodium molybdate appears to function in some way to digest the coal particulate and to release plant nutrients from the particulate in a way which enables plants to effectively and advantageously use these nutrients. While the amount of molybdate can be varied and may in some instances fall outside the ranges earlier stated, depending on the nature and size of the coal particulate, best results appear to be obtainable when the molybdate content is in the range of 0.5-1% by weight of the total composition. More than this preferred amount can be used although it is believed that effective digestion of the coal is realized by using the molybdate in the amount indicated.
The linear alcohol alkoxylate is preferably a primary linear C 12 to C 15 alcohol, e.g. dodecyl alcohol or mixture thereof with other C 12 -C 15 alcohol, which has been ethoxylated, i.e. a polyethylene oxide ether of a primary linear alcohol, preferably a primary alcohol of 12-15 carbons. A preferred linear alcohol alkoxylate for use herein is available commercially as “Basic H” surfactant. This material, or its equivalent, may be used for present purposes.
As indicated, the composition should also contain a small amount of water, usually not more than about 2% by weight. It appears that this small amount of water facilitates the effect of the alkoxylate and also seems to help activate the plant growth elements of the coal component.
Any convenient source of sand may be used. The amount of sand employed can be varied and will depend, at least to some extent, on the nature and composition of the coal component, and the amounts of other materials present. However, generally speaking, the amount of sand in the composition will fall within the range earlier stated herein, i.e. 20-60% by weight.
Optimum results appear to be obtained with sand which includes small amounts, e.g. 0.001 to 0.01% by weight, of magnesium sulfate, copper sulfate and other similar trace metal sulfates.
In addition to any magnesium sulfate which may be included in the sand, it is useful to add magnesium sulfate in an amount of from 0.001 to 4% by weight of the composition.
The composition may be prepared in any convenient fashion. Preferably, however, the coal and sand are uniformly mixed together after which the sodium molybdate, alkoxylate and magnesium sulfate, in water are sprayed over the coal/sand mixture while stirring to insure uniformity. The product is then allowed to dry after which it may be bagged for later use or applied directly to the soil at the place of use.
As an alternative, the mixture of coal and sand may be placed at the site of use, e.g. around the base of a fruit tree, after which an aqueous mix of molybdate and alkoxylate is sprayed over the coal/sand mix. The magnesium sulfate may be included in the aqueous spray of alkoxylate and molybdate or it may be included in the coal/sand mix.
In a typical preparation, 1 to 4 ounces of sodium molybdate and up to 1 gallon of the alkoxylate, with or without magnesium sulfate, are mixed with 50 gallons, more or less, of water to form a spray mixture. This mixture is then sprayed over a dry mix of coal particulate and sand and magnesium sulfate. Advantageously the mixture of molybdate and alkoxylate in water is sprayed over a dry mix of coal, sand and magnesium sulfate after the dry mix has been applied to the field or soil where plant growth is desired although, as earlier noted, the entire composition, including the molybdate and alkoxylate, can be prepared before application to the field or soil. Whether pre-formed or prepared in situ, it appears that the spray of molybdate and alkoxylate helps to activate the nutrients or growth elements in the coal.
The composition of the invention is usable under most, if not all, soil conditions globally. An important advantage of the invention, as shown below, is that the composition appears to be able to convert soil which is unsatisfactory for agricultural purposes into soil which is highly useful. In extensive testing, the product has consistently exceeded yield by 50-100% per acre production as measured against conventionally available N—P—K fertilizers which are in common usage.
The invention is illustrated by the following examples:
EXAMPLE 1
70 lbs. of high-sulfur coal were pulverized to a particle size of −100 mesh and mixed with 25 lbs. of sand and 4 lbs. of magnesium sulfate. The resultant mix was then placed around the base of peach trees, untilled, growing in clay soil in Western Pennsylvania in the spring. Clay soil and the Western Pennsylvania climate are not generally favorable for growing peaches. The trees had been barren for 8 years.
After the dry mix was spread (not plowed) around the trees, the mixture was sprayed with a liquid composition comprising 50 gallons of water, 1 gallon Basic H type (polyethylene oxide ether of C 12 -C 15 primary alcohols) and 4 ounces of sodium molybdate. No pesticides, herbicides, insecticides or fungicides were used. The resulting peaches appeared to be flawless with excellent rich color and superior taste. The yield over the growing period (about 4 months) was so large per tree that wooden support stakes had to be used to prop the trees up under the weight of the fruit crop.
EXAMPLE 2
Example 1 was repeated except that, in this case, the composition was used with 30 year old apple trees which were past their prime and growing in clay soil in Pennsylvania. Although in this case the apple trees had previously borne fruit, the yield had been sparse. About 100 pounds of the composition spread around the base of the tree followed by spraying with the liquid mixture referred to in Example 1. The composition was applied around the trees in April. The trees blossomed in May and bore fruit by late summer. The yield of apples obtained was greatly increased over past years. The quality of the apples was also outstanding.
EXAMPLE 3
Improvements in yield, quality and size were also obtained when the experiment of Example 2 was repeated with stonehead cabbages grown in the same Pennsylvania clay soil. The expected normal cabbage diameter was about six inches. However, by applying the composition to the soil in the spring immediately after planting, cabbages that were fourteen inches in diameter were consistently obtained by mid-summer. Insect damage was essentially non-existent although no pesticide was applied. The indicated results were obtained notwithstanding the fact that weeds were intentionally not removed and consequently competed with the cabbage for soil nutrients.
It was noted, in conducting the tests referred to in the foregoing Examples, that earthworms tended to arrive during crop growth and remained in the soil, thereby functioning to nutritionally enrich the soil.
EXAMPLE 4
The growth composition of Example 1 was compared with a commercially available N—P—K fertilizer in a 24 acre corn field test. The field had been unusable for 40 to 50 years. It was located on a mountain and had 1 inch of soil before shale rock was encountered, representing the worst type of field test conditions. It was estimated that 4000 lbs. of limestone, 120 pounds of nitrogen and 180 pounds of phosphorus would have to be used on each acre to effectively grow corn on the site. However, it was decided to use only about 200 pounds per acre of the present composition with no lime.
Photographs were taken periodically. The N—P—K corn field, comprising a four-acre plot, failed as expected. No crop resulted on any of the four acres with stunted ears of shriveled “bread and butter” corn seen only sporadically. This was typical of prior results.
The adjoining portion of the test field, separated from the N—P—K corn plot by only 12 yards, involved 20 acres using a growth composition according to Example 1. All 20 acres yielded useful corn plants some of which stood 104 inches high. The crop was a complete success yielding an average of 100 bushels of perfectly shaped “bread and butter” corn per acre for each of the 20 test acres whereas, in the past, using lime and N—P—K fertilizer, the total yield was 50 bushels of corn for the entire 24 acre field. No pesticides or herbicides were used in the experiment, no stock damage or discoloration occurred; and the kernels of corn were found to be in perfect rows. Furthermore, in addition to the greatly increased yield per acre, significantly less growth composition according to the invention was used on the 20 acre tract than on the 4 acre failed N—P—K field.
The results of Example 4 indicate that the growth composition of the invention can be used for the production of corn on underused or farm lands which would otherwise be considered too poor to be useful. Such production could be highly valuable in, for example, ethanol production.
It will be appreciated that the amount of the present composition which is applied to the soil can be widely varied. It has been found that the application of 200 pounds of the composition, e.g. the composition of Example 1, per acre is usually effective to give the desired results. More or less than this amount can be used, the optimum amount for any particular situation being readily determined by varying the application and observing the results. The use of from about 100 to 300 pounds, or more, per acre is generally sufficient to obtain the desired results with something around 200 pounds per acre being preferred.
While the invention has been shown in the foregoing examples to improve the yield of fruit (apples and peaches), corn and cabbage, the invention is not limited to such fruits or vegetables. Similar improved results have been obtained with, for example, tomatoes, hay, alfalfa or the like. In another application of the invention, the composition has been used to grow effective grass cover over ground made bare by coal mine stripping. In that particular situation, it had previously been impossible to provide ground cover as required by state and Federal authorities. The composition of the invention was sprayed as an aqueous spray (hydroseeded) with grass seed over the ground and, in about two weeks time, complete ground cover was obtained.
Analysis of a composition according to the invention as used in the foregoing examples for percent solids, volatile solids, total carbon (Total C), total nitrogen (Total N), organic nitrogen (Org-N), ammonium nitrogen (NH 4 —N), phosphorus (P), potassium (K), magnesium (Mg), calcium (Ca), sodium (Na), cadmium (Cd), chromium (Cr), copper (Cu), lead (Pb), nickel (Ni), zinc (Zn) and boron (B) has given the following results:
Major Constituents (all values in percent by mass ± standard deviation)
Solids
95.9 ± 0.14
Volatiles
35.8 ± 4.7
Total C
22.7 ± 1.1
Total N
4.98 ± 0.16
Org N
3.17 ± 0.35
NH 4 —N
1.82 ± 0.50
P
2.1 ± 0.33
K
5.6 ± 0.69
Mg
2.1 ± 0.11
Ca
6.6 ± 0.35
Na
029 ± 0.02
Fe
0.63 ± 0.02
Al
2.1 ± 0.16
Mn
0.31 ± 0.02
Trace Elements (all values in mg/kg or ppm ± standard deviation)
Cd
0.46 ± 0.02
Cr
49.85 ± 4.59
Cu
9.35 ± 0.35
Pb
42.15 ± 2.05
Ni
1.5 ± 014
Zn
33.5 ± 2.19
B
184 ± 13
The Mo content was not determined in the analysis.
Based on the foregoing analysis, the composition could be viewed as a 5-5-7 (N—P—K) composition where N is presented as % N, P is presented as % P 2 O 5 and K is presented as % K 2 O, as is typical for fertilizer assays. The precise formulation is 5-4.8-6.8. Therefore, 10 dry tons of this material will supply 100 lbs. of Total N, and 2.4 dry tons of the material will supply 100 lbs. of P. None of the trace elements are present at concentrations that would pose a concern for land application of this material as a fertilizer. Although Cr, Pb and Zn concentrations are greater than 10 ppm, these values are not any higher than one would measure in unpolluted (pristine) soils because these elements are present in rock materials as well. The high concentration of organic C and N indicates that addition of the material to soil would increase the organic matter content of the soil, resulting in an overall improvement in soil quality, over and above that resulting from an equivalent amount of nutrient addition alone.
It will be appreciated from the foregoing that the composition of the invention offers a number of important advantages. For one thing, the composition, in addition to improving crop yields and functioning in less than optimum soil conditions, has the direct effect of enriching soil, not depleting it. As is well known, the use of N—P—K fertilizer has the opposite effect. Soils throughout the world have been severely depleted of nutrients, and polluted by the use of insecticides, herbicides, pesticides and fungicides over centuries of usage but especially during the past 50 years. Excessive, repeated and ever-increasing amounts of N—P—K (nitrogen, phosphate and potash) or artificial fertilizer have been required to yield crops from the depleted soil, all at ever-increasing cost and all this occurring while the quality of crops such as corn, tomato, watermelon or other vegetable or fruit, is diminished. Tests with the invention indicate that less of the growth compound is required per acre to match and exceed crop yields from artificial commercial fertilizer blends (N—P—K). Additionally, the present composition appears to minimize the need for pesticides, insecticides, herbicides and fungicides. This has been true with all crops tested from corn to cabbage, tomatoes, melons, peaches, apples, beans and other vegetables. In all testing to date, no pesticides or herbicides have been required or used on the crops. No negative side effects have been observed and, in fact, the opposite appears to be true in the resultant addition of nutrients to the soil and consequent improved crop yield.
In addition to reducing costs while improving plant growth results, the composition of the invention offers a number of other advantages. For example, the invention can be used to reclaim previously unusable soils, e.g. coal strip-mining and deep-mining soil. As a test, the composition of the invention as in Examples 1-4 was applied on the surface of “hot” or acidic soil resulting from a coal mining operation in Pennsylvania. Previous attempts to create ground cover as required by authorities had failed. However, effective ground cover was obtained over the area in about 10 days after application of the present composition.
As will be appreciated from the foregoing, advantages of the present composition include the following: it avoids the use of costly N—P—K fertilizers or the equivalent and the disadvantages of such fertilizers. It eliminates or reduces substantially the need for pesticides, herbicides and fungicides, the composition apparently tending to fend off such pests naturally. It appears to enable and promote more uniform water penetration in the soil making the nutrients released from the coal more available to the plant over a shorter period of time than possible with conventional fertilizers. Additionally, the present composition has no negative effect on soil pH, results in greener plant leaves, promotes sprouting of seeds, increases plant yield, promotes the appearance of earthworms which aid the nutrient enrichment of the soil, promotes larger, taller and thicker plants, crops and plant stalks; promotes more efficient water usage because it retains water in the soil thereby reducing soil erosion, water evaporation and water runoff, while separately promoting drainage in soil areas of excessive water accumulation and promotes water retention during dry weather, but, conversely, helps water leach through the soil in hot or dry weather.
Various modifications may be made in the invention as described above and as define in the following claims wherein.
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A bio-degradable plant growth composition consisting essentially of coal particulate, sodium molybdate, linear alcohol alkoxylate, magnesium sulphate, sand or other filler and water.
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CROSS-REFERENCE TO RELATED APPLICATIONS AND PRIORITY CLAIM
[0001] This application is a continuation of U.S. Non-Provisional application Ser. No. 13/228,491, entitled “EMBEDDING A NANOTUBE INSIDE A NANOPORE FOR DNA TRANSLOCATION”, filed Sep. 9, 2011, which is incorporated herein by reference in its entirety.
BACKGROUND
[0002] Exemplary embodiments relate to nanodevices, and more specifically, to providing a smooth inner surface for a nanopore by fixing a nanotube inside the nanopore.
[0003] Recently, there has been growing interest in applying nanopores as sensors for rapid analysis of biomolecules (e.g., polymers) such as deoxyribonucleic acid (DNA), ribonucleic acid (RNA), protein, etc. Emphasis has been given to applications of nanopores for DNA sequencing, as this technology holds the promise to reduce the cost of sequencing below $1000/human genome.
[0004] Nanopore sequencing is a technique for determining the order in which nucleotides occur on a strand of DNA. A nanopore is simply a small hole of the order of several nanometers in internal diameter. The theory behind nanopore sequencing has to do with what occurs when the nanopore is immersed in a conducting fluid and an electric potential (voltage) is applied across it: under these conditions, a slight electric current due to conduction of ions through the nanopore can be measured, and the amount of current is very sensitive to the size and shape of the nanopore. If single bases or strands of DNA pass (or part of the DNA molecule passes) through the nanopore, this can create a change in the magnitude of the current through the nanopore. Other electrical or optical sensors can also be put around the nanopore so that DNA bases can be differentiated while the DNA passes through the nanopore.
BRIEF SUMMARY
[0005] According to an exemplary embodiment, a method of embedding a nanotube in a nanopore is provided. The method includes configuring a reservoir including a membrane separating the reservoir into a first reservoir part and a second reservoir part, where the nanopore is formed through the membrane for connecting the first and second reservoir parts. The method includes filling the nanopore, the first reservoir part, and the second reservoir part with an ionic fluid, where a first electrode is dipped in the first reservoir part and a second electrode is dipped in the second reservoir part. Also, the method includes driving the nanotube into the nanopore using a voltage bias being applied to the first and second electrodes, to cause an inner surface of the nanopore to form a covalent bond to an outer surface of the nanotube via an organic coating.
[0006] Additional features are realized through the techniques of the present disclosure. Other systems, methods, apparatus, and/or computer program products according to other embodiments are described in detail herein and are considered a part of the claimed invention. For a better understanding of exemplary embodiments and features, refer to the description and to the drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0007] The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other features of the present disclosure are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
[0008] FIG. 1 depicts a cross-sectional schematic of a nanodevice with a nanopore embedded with a carbon nanotube according to an exemplary embodiment.
[0009] FIG. 2A illustrates an approach to embed a carbon nanotube inside a nanopore of a nanodevice according to an exemplary embodiment.
[0010] FIG. 2B illustrates the carbon nanotube attached/bonded to the inside of the nanopore according to an exemplary embodiment.
[0011] FIG. 2C illustrates the carbon nanotube attached to the inside of the nanopore after processing according to an exemplary embodiment.
[0012] FIG. 3A illustrates another approach to embed a carbon nanotube inside a nanopore of a nanodevice according to an exemplary embodiment.
[0013] FIG. 3B illustrates the carbon nanotube attached/bonded to the inside of the nanopore according to an exemplary embodiment.
[0014] FIG. 3C illustrates the carbon nanotube attached to the inside of the nanopore after processing according to an exemplary embodiment.
[0015] FIG. 4A illustrates an additional approach to embed a carbon nanotube inside a nanopore of a nanodevice according to an exemplary embodiment.
[0016] FIG. 4B illustrates the carbon nanotube attached/bonded to the inside of the nanopore according to an exemplary embodiment.
[0017] FIG. 4C illustrates the carbon nanotube attached to the inside of the nanopore after processing according to an exemplary embodiment.
[0018] FIG. 5 is a method for embedding a nanotube inside a nanopore according to an exemplary embodiment.
DETAILED DESCRIPTION
[0019] An issue in DNA sequencing is to control the translocation of the DNA through the nanopore. The surface roughness of the nanopore and the dangling bonds on the surface of the nanopore may present problems for DNA sequencing. After drilling a solid-state nanopore using an electron beam, the pore surface may exhibit nanometer scale corrugations (e.g., folds, wrinkles, groves, etc.). Similar to the scaling behavior of a self-affine rough surface, the smaller a nanopore is the rougher the inner pore surface is. Additionally, nanopores drilled using the same procedure may have different surface roughness, causing each pore to be unique. Thus, experiments that are performed using nanopores with rough surfaces and/or dangling bonds may likely (or may possibly) show inconsistent results because of the unpredictable interactions between DNA and the inner surface of the nanopore. For example, simulations show that the effective electric driving forces on DNA are different if the surface roughness of the same-sized nanopores is different.
[0020] Exemplary embodiments are configured to attach carbon nanotubes at the inner surface of the nanopore and leverage the smoothness of the inner surface of carbon nanotubes. This approach can eliminate the physical surface roughness as well as the dangling bonds at the inner surface of the nanopore, which are the sources of unpredictable interactions between DNA and the inner surface of the nanopore. Additionally, the chemical inertness of carbon nanotubes will be a potential benefit, such as by protecting the metal electrodes employed at the inner surface of the nanopore.
[0021] Now turning to the figures, FIG. 1 depicts a cross-sectional schematic of a nanodevice 100 with a nanopore embedded with a carbon nanotube according to an exemplary embodiment. The nanodevice 100 illustrates a DNA translocation setup. A membrane 150 is made of one or more insulating films 101 with a nanopore 103 formed through the insulating film 101 . A carbon nanotube 102 is embedded at the inner surface of the nanopore 103 . The insulating film 101 of the membrane 150 partitions a reservoir 104 into two reservoir parts, which are reservoir part 105 and reservoir part 106 . The reservoir 104 (including reservoir parts 105 and 106 ) and the nanopore 103 are then filled with ionic buffer/fluid 107 (e.g., such as a conductive fluid).
[0022] A polymer 108 such as a DNA molecule(s) is loaded into the nanopore 103 by an electrical voltage bias of the voltage source 109 , which is applied across the nanopore 103 via two electrochemical electrodes 110 and 111 . The electrodes 110 and 111 are respectively dipped in the ionic buffer 107 of the reservoir part 105 and the reservoir part 106 in the reservoir 104 .
[0023] There are various state of the art techniques for sensing DNA bases and controlling the motion of the DNA, and the roughness and the dangling bonds in a regular (state of the art) nanopore may pose a potential problem. However, the smooth inner surface of the nanotube 102 will provide a (very) smooth surface with no dangling bonds for characterization (i.e., nanopore sequencing of the DNA) and movement of the polymer 108 .
[0024] There may be many techniques with many different materials that can be utilized to make the nanodevice 100 shown in FIG. 1 . According to an exemplary embodiment, FIGS. 2A , 2 B, and 2 C illustrate one approach to embed a carbon nanotube inside a nanopore of a nanodevice 200 such as a chip. FIGS. 2A , 2 B, and 2 C depict a cross-sectional schematic of the nanodevice 200 . In FIG. 2A , a membrane 250 includes a substrate 201 (e.g., such as silicon), between membrane parts 202 and 203 . The membrane parts 202 and 203 may be made of a material (such as Si 3 N 4 (silicon nitride)) with a high etching selectivity with respect to the substrate 201 . The membrane part 202 may also contain other material layers, such as metal layers, etc., for any desired application. A window 255 is opened into the membrane part 203 using, e.g., reactive ion etching, and the substrate 201 will be etched through to the membrane part 202 ; etching through the window 255 of the membrane part 203 as well as through the substrate 201 will form a free-standing membrane part 260 of the membrane part 202 . In the case of a silicon substrate for the substrate 201 , the etchant could be KOH (potassium hydroxide) or TMAH (tetramethylammonium hydroxide) at 80° C. A nanopore 207 is made/formed through the free-standing membrane part 260 of the membrane part 202 . The membrane 250 (including the free-standing membrane part 260 ) partitions a reservoir 208 into reservoir part 209 and reservoir part 210 . The reservoir 208 (including reservoir parts 209 and 210 ) and the nanopore 207 formed through membrane part 202 are (then) filled with ionic buffer/fluid 211 . The nanopore 207 is a small aperture formed in, e.g., the free-standing membrane part 260 of the membrane part 202 .
[0025] As shown in FIG. 2A , the outer surface of a carbon nanotube 204 can be coated with an organic coating 205 . The organic coating 205 is configured to be covalently bonded to the inner surface of the nanopore 207 . The organic coating 205 and/or the carbon nanotube 204 is charged (by tuning the pH of the ionic buffer 211 ), such that the carbon nanotube 204 can be transported/driven into the nanopore 207 by the voltage source 109 applying a voltage bias to electrodes 110 and 111 , and then the carbon nanotube 204 can be covalently bonded to the inner surface of the nanopore 207 , as shown in FIG. 2B . Alternatively and/or additionally, a fluidic pressure adjustment device 280 can be communicatively connected to the reservoir part 210 via a port 282 , and a fluidic pressure adjustment device 285 can be communicatively connected to the reservoir part 209 via another port 284 in one implementation. To drive the carbon nanotube 204 (which can be charged or uncharged) into the nanopore 207 , the fluidic pressure adjustment device 280 is configured to apply a positive fluidic pressure to the reservoir part 210 and/or the fluidic pressure adjustment device 285 is configured to apply a negative fluidic pressure to the reservoir part 209 . The carbon nanotube 204 is driven into the nanopore 207 by the difference in fluidic pressure on both sides of the membrane 250 caused by fluidic pressure adjustment device 280 and 285 . Also, the carbon nanotube 204 can be driven into the nanopore 207 by the positive fluidic pressure of the fluidic pressure adjustment device 280 alone or by the negative fluidic pressure of the fluidic pressure adjustment device 285 alone. The fluidic pressure adjustment devices 280 and 285 may be pumps or syringes respectively linked via ports 282 and 284 to the reservoir parts 210 and 209 to apply the desired pressure.
[0026] The ionic buffer 107 and 211 in the reservoirs 104 and 208 can be any salt dissolved in any solvent (water or organic solvent) with any pH depending on the application. One example of the ionic buffer 107 and 211 includes a KCl (potassium chloride) solution in water with a pH range from 6-9 for DNA translocation. Accordingly, the electrodes 110 and 111 can be any electrodes for electrochemical reactions that match the salt and solvent. For example, Ag/AgCl electrodes can be a good match for the KCl solution in water.
[0027] As discussed further below, the organic coating 205 is a material having chemical properties that cause the organic coating 205 (applied to the carbon nanotube 204 ) to covalently bond to the inner surface material of the nanopore 207 . As a result of the covalent bond, the carbon nanotube 204 is securely attached to the nanopore 207 .
[0028] Once the carbon nanotube 204 is attached to the inner surface of nanopore 207 , both sides (e.g., top and bottom) of the membrane 250 (including the attached nanotube 204 ) can be processed/etched with O 2 (oxygen) plasma to tailor (e.g., remove) the parts of the carbon nanotube 204 that are extending outside of the nanopore 207 , as shown in FIG. 2C . In FIG. 2C , the height of the carbon nanotube 204 (e.g., the top and bottom) is aligned with the height of the membrane part 202 after the O 2 plasma processing. The polymer 108 (shown in FIG. 1 ) may be driven into the carbon nanotube 204 attached to the nanopore 207 for sequencing by a nanopore sequencer (not shown), and the sequencing occurs in the nanopore 207 (formed by the carbon nanotube 204 ) as understood by one skilled in the art.
[0029] Oxygen plasma etching is a form of plasma processing used to fabricate integrated circuits. As understood by one skilled in the art, it involves a high-speed stream of glow discharge (plasma) of an appropriate gas mixture being shot (in pulses) at a sample, such as at the membrane 250 . Although plasma etching is described, it is contemplated that other types of etching may be utilized as understood by one skilled in the art.
[0030] FIGS. 3A , 3 B, and 3 C illustrate another approach to embed a carbon nanotube inside a nanopore according to an exemplary embodiment. FIGS. 3A , 3 B, and 3 C depict a cross-sectional schematic of the nanodevice 300 .
[0031] In FIGS. 3A , 3 B, and 3 C, the inner surface of the nanopore 207 is coated with the organic coating 215 , which can bond to the carbon nanotube 204 . The description for FIGS. 3A , 3 B, and 3 C are the same as for FIGS. 2A , 2 B, and 2 C, except that the carbon nanotube 204 is initially uncoated because the coating is applied to the inner surface of the nanopore 207 , instead of on the carbon nanotube 204 (itself). The organic coating 215 in FIGS. 3A , 3 B, and 3 C may be the same material as the organic coating 205 in FIGS. 2A , 2 B, and 2 C in one implementation, and may be different materials in another implementation.
[0032] In FIG. 3A , the membrane 250 includes the substrate 201 , between membrane parts 202 and 203 , and window 255 is opened/etched into the membrane part 203 through the substrate 201 to the membrane part 202 to form the free-standing membrane part 260 of the membrane part 202 , as discussed above. The nanopore 207 is made/formed through the free-standing membrane part 260 . The membrane 250 (including the free-standing membrane part 260 ) partitions a reservoir 208 into reservoir part 209 and reservoir part 210 . The reservoir 208 (including reservoir parts 209 and 210 ) and the nanopore 207 formed through membrane part 202 are then filled with ionic buffer/fluid 211 as discussed above.
[0033] Unlike FIG. 2A , the outer surface of the carbon nanotube 204 is not coated with the organic coating 205 in FIG. 3A . Instead, the inner surface of the nanopore 207 is coated with the organic coating 215 . The organic coating 215 is configured to covalently bond to the outer surface of the uncoated carbon nanotube 204 . If the carbon nanotube 204 is charged (by tuning the pH of the ionic buffer 211 filling the reservoir 208 ), the carbon nanotube 204 can be transported into the nanopore 207 by a voltage bias applied to electrodes 110 and 110 via the voltage source 109 . Also, the carbon nanotube 204 can be driven into the nanopore 207 by the difference in fluidic pressure on both sides of the membrane 250 applied by positive and negative pressures of the fluidic pressure adjustment devices 280 and 285 . Once the carbon nanotube 204 is driven into the nanopore 207 , the carbon nanotube 204 can be covalently bonded to the inner surface of the nanopore 207 via the organic coating 215 , as shown in FIG. 3B . The organic coating 215 is a material having chemical properties that cause the organic coating 215 (applied to the nanopore 207 ) to covalently bond to the outer surface material of the uncoated carbon nanotube 204 . As a result of this covalent bond, the carbon nanotube 204 is securely attached to the nanopore 207 .
[0034] Once the carbon nanotube 204 is attached to the inner surface of nanopore 207 , both sides of the membrane 250 (including the attached nanotube 204 ) can be processed with O 2 plasma to tailor (e.g., remove) the extending parts of the carbon nanotube 204 that extend outside of the nanopore 207 , as shown in FIG. 3C . In FIG. 3C , the height of the carbon nanotube 204 is aligned to the height of the membrane part 202 after O 2 plasma processing. The polymer 108 (shown in FIG. 1 ) may be driven into the carbon nanotube 204 attached to the nanopore 207 for sequencing as understood by one skilled in the art.
[0035] FIGS. 4A , 4 B, and 4 C illustrate an additional approach to embed a carbon nanotube inside a nanopore according to an exemplary embodiment. FIGS. 4A , 4 B, and 4 C depict a cross-sectional schematic of the nanodevice 400 which illustrates a combination of the approaches discussed in FIGS. 2A , 2 B, 2 C, 3 A, 3 B, and 3 C.
[0036] In FIGS. 4A , 4 B, and 4 C, the inner surface of the nanopore 207 is coated with an organic coating 206 , while the outer surface of the carbon nanotube 204 is coated with the organic coating 205 . The organic coating 205 is chemically configured to covalently bond to the organic coating 206 . Additionally, the organic coating 205 is chemically configured to bond to the carbon nanotube 204 , and the organic coating 206 is chemically configured to bond to the inner surface of the nanopore 207 . The organic coating 205 is different from the organic coating 206 in one implementation. In another implementation, the organic coating 205 can be the same material as the organic coating 206 .
[0037] When the organic coating 205 and/or carbon nanotube 204 is charged (by tuning the pH of the ionic buffer), the carbon nanotube 204 can be transported into the nanopore 207 by a voltage bias applied to electrodes 110 and 110 via the voltage source 109 . Also, the carbon nanotube 204 can be driven into the nanopore 207 by the difference in fluidic pressure on both sides of the membrane 250 applied by the positive and negative pressures of the fluidic pressure adjustment devices 280 and 285 . Once the carbon nanotube 204 coated in the organic coating 205 is driven into the nanopore 207 coated in the organic coating 206 , the carbon nanotube 204 can be covalently bonded to the inner surface of the nanopore 207 via the organic coatings 205 206 , as shown in FIG. 4B . The organic coating 205 is a material having chemical properties that cause the organic coating 205 (applied to the carbon nanotube 204 ) to covalently bond to the outer surface material of the carbon nanotube 204 and to the organic coating 206 . Similarly, the organic coating 206 is a material having chemical properties that cause the organic coating 206 (applied to the nanopore 207 ) to covalently bond to the outer surface material of the carbon nanotube 204 and to the organic coating 205 . As a result of the covalent bonding, the carbon nanotube 204 is securely attached to the nanopore 207 .
[0038] As mentioned above, once the carbon nanotube 204 is attached to the inner surface of nanopore 207 , both sides of the membrane 250 (including the attached nanotube 204 ) can be processed with O 2 plasma to tailor (e.g., remove) the extending parts of the carbon nanotube 204 that extend outside of the nanopore 207 , as shown in FIG. 4C . In FIG. 4C , the height of the carbon nanotube 204 is aligned to the height of the membrane part 202 after O 2 plasma processing. In one implementation, the height of the carbon nanotube 204 may be slightly less than, more than, or about the same as the height of the membrane part 202 (forming the nanopore 207 ) based on the desired precision of the O 2 plasma processing. The polymer 108 (shown in FIG. 1 ) may be driven into the carbon nanotube 204 attached to the nanopore 207 for sequencing as understood by one skilled in the art.
[0039] Although exemplary embodiments described above may be directed to carbon nanotubes, it should be appreciated that the disclosure is not restricted to nanopores with carbon nanotubes. Rather, exemplary embodiments may be applicable for attaching other types of nanotubes to the inside surface of nanopores utilizing the techniques as discussed herein. Additionally, exemplary embodiments are not limited to embedding nanotubes into nanopores, and nanotubes may be embedded into other structures such as vias, nanochannels, etc., as understood by one skilled in the art.
[0040] FIG. 5 illustrates a method 500 for embedding a nanotube in a nanopore in accordance with an exemplary embodiment. Reference can be made to FIGS. 1 , 2 A, 2 B, 2 C, 3 A, 3 B, 3 C, 4 A, 4 B, and 4 C.
[0041] A reservoir (e.g., reservoir 104 , 208 ) is configured to include a membrane (e.g., membrane 150 , 250 ) separating the reservoir into a first reservoir part (e.g., reservoir part 105 , 210 ) and a second reservoir part (e.g., reservoir part 106 , 209 ) in which the nanopore (e.g., nanopore 103 , 207 ) is formed through the membrane for connecting the first and second reservoir parts at block 505 .
[0042] The nanopore, the first reservoir part, and the second reservoir part are filled with an ionic fluid (e.g., ionic fluid 107 , 211 ) at block 510 . A first electrode (e.g., electrode 110 ) is dipped in the first reservoir part at block 515 , and a second electrode (e.g., electrode 111 ) is dipped in the second reservoir part at block 520 .
[0043] At block 525 , the nanotube is driven into the nanopore to cause an inner surface of the nanopore (e.g., nanopore 103 , 207 ) to form a covalent bond to an outer surface of the nanotube (e.g., nanotube 102 , 204 ) via an organic coating (e.g., organic coating 205 , 206 , 215 ), in response to a voltage bias being applied (e.g., by the voltage source 109 ) to the first and second electrodes (e.g., electrodes 110 and 111 ). Also, the carbon nanotube 204 can be driven into the nanopore 207 by the difference in fluidic pressure on both sides of the membrane 250 applied by the positive and negative pressures of the fluidic pressure adjustment devices 280 and 285 .
[0044] The inner surface of the nanopore 207 may be coated with the organic coating (e.g., organic coating 215 in FIG. 3A or organic coating 206 in FIG. 4A ) to form the covalent bond to the outer surface of the nanotube 204 . Also, the outer surface of the nanotube 204 may be coated with the organic coating 205 to form the covalent bond to the inner surface of the nanopore 207 .
[0045] In one case, both the inner surface of the nanopore 207 and the outer surface of the nanotube 204 are coated with the organic coating (e.g., the organic coatings 205 and 206 may be the same material in FIGS. 4A , 4 B, and 4 C), such that the organic coating on the inner surface of the nanopore 207 and the organic coating on the outer surface of the nanotube 204 cause the covalent bond in response to the voltage source 109 driving the nanotube 204 into the nanopore 207 .
[0046] In another case, the inner surface of the nanopore 207 is coated with the organic coating and the outer surface of the nanotube is coated with another organic coating (e.g., the organic coatings 205 and 206 may be different materials in FIGS. 4A , 4 B, and 4 C), such that the organic coating on the inner surface of the nanopore and the other organic coating on the outer surface of the nanotube cause the covalent bond in response to the voltage source 109 driving the nanotube into the nanopore.
[0047] The covalent bond via the organic coating causes the nanotube 102 , 204 to be physically attached to the nanopore 103 , 207 formed in the membrane 150 , 250 , and both sides (e.g., top and bottom) of the membrane 150 , 250 are processed such that a height of the nanotube corresponds to a height of a layer (e.g., membrane part 202 ) of the membrane 250 as shown in FIGS. 2C , 3 C, and 4 C.
[0048] For explanatory purposes, various examples of the organic coatings 205 , 206 , and 215 are discussed below. It is understood that the chemical molecules of the organic coatings 205 , 206 , and 215 discussed below are not meant to be limited.
[0049] The organic coating 205 can be prepared by reaction of aryldiazonium salts with the carbon nanotube 204 . In this reaction, the diazonium salts are reduced by electron transfer from the carbon nanotube 204 to diazonium salts and results in the expulsion of one molecule of nitrogen and formation of a carbon-carbon bond between aryl compound and the carbon nanotube 204 . This is a widely used reaction for functionalization of carbon nanotubes with a variety of aryl compounds mainly because of the simplicity of the reaction and the wide range of arydiazonium salts available through their corresponding arylamines. The reaction of aryldiazonium salts with the carbon nanotube 204 takes place either in aqueous solution or an organic solvent like dichloroethane, chloroform, toluene, dimethylformamide, etc. The reaction of aryldiazonium salts with the carbon nanotube 204 is very fast (e.g., completed within a few minutes) and takes place at room temperature. The preferred, but not required, diazonium salts are those with an additional functionality which can form strong bonds with metal oxides or nitrides inside the nanopore 207 . The additional functionality (to form strong bonds with metal oxides or nitrides inside the nanopore 207 ) can be chosen from carboxylic acids (—CO 2 H), hydroxamic acids (—CONHOH), or phosphonic acids (—PO 3 H 2 ).
[0050] In FIGS. 3A , 3 B, and 3 C, the organic coating 215 is a bifunctional compound/molecule in which one functionality is a diazonium salt and the other functionality can be chosen from hydroxamic acid or phosphonic acid. When the nanopore 207 with inside walls of metal oxide or metal nitride is immersed in a solution of this bifunctional compound/molecule, the inner surface of the nanopore 207 is coated with the self-assembled monolayer of this bifunctional compound/molecule through hydroxamic acid or phosphonic acid functionality and exposes the diazonium functional group; the diazonium functional group can react with the uncoated carbon nanotube 204 (as shown in FIGS. 3B and 3C ) to form a covalent bond, therefore immobilizing the carbon nanotube 204 inside the nanopore 207 .
[0051] In FIGS. 4A , 4 B, and 4 C, both the carbon nanotube 204 and nanopore 207 are coated with organic monolayers (i.e., organic coatings 205 and 206 respectively). In the case of the carbon nanotube 204 , the organic coating 205 is achieved by reaction of the carbon nanotube 204 with bifunctional diazonium salts which have either alcohol or amine groups, and the organic coating 206 inside the nanopore 207 is a bifunctional molecule having a functional group which forms a bond inside the nanopore 207 wall (e.g., hydroxamic acid or phosphonic acid) and the second exposed functionality which forms a covalent bond through condensation with exposed functionality of the carbon nanotube 204 (e.g. carboxylic acid). For example, the nanopore 207 can be coated with 4-carboxybenzylphosphonic acid by immersion of the nanopore 207 in a dilute (1-5 mmolar) solution of the latter in water or alcohol. After rinsing with the same solvent, the inside of the nanopore 207 (the wall or portion of the nanopore wall must be of metal oxide or nitride) is coated with a self assembled monolayer of 4-carboxybenzylphosphonic acid in a way that phosphonic acid forms covalent bonds with metal oxide or nitride and exposes the carboxylic acid functionality. In the second step, the functionalized carbon nanotube 204 having an alcohol or amine functionality is pulled inside the nanopore 207 and with the aid of a dehydrating agent (which must be present in the salt solution) the two functionalities of carboxylic acid and alcohol (or amine) undergo dehydration to form carboxylic ester (or carboxamide) resulting in immobilization of carbon nanotube 204 . An example of the dehydrating agent (which is also water soluble and can be used in this environment) is N-(3-dimethylaminopropyl)-N′-ethylcarbodiimide hydrochloride. In FIGS. 4B and 4C , after the organic coating 205 and 206 react with each other to form an ester or amide, the joined coatings are designated as 270 .
[0052] For the reaction (corresponding to FIGS. 2A , 2 B, and 2 C) when the nanopore 207 is uncoated and the carbon nanotube 204 is coated (with organic coating 205 as discussed above), the organic coating 205 is achieved by the reaction of a bifunctional aryldiazonium salt. For example, 4-aminobenzylphosphonic acid is treated with nitrosonium tetrafluoroborate to form corresponding diazonium salt. A solution of this diazonium salt is added to an aqueous dispersion of carbon nanotubes containing small (0.1-1%) amount of surfactant (e.g., sodium dodecylsulfate or sodium cholate). After stiffing at room temperature for 30 minutes, the carbon nanotube 204 is functionalized with benzylphsophonic acid. An aqueous solution of the functionalized carbon nanotube 204 obtained above containing 0.1% anionic surfactant is pulled into nanopore 207 (as shown in FIGS. 2A , 2 B, 2 C) where the phosphonic acid functionality reacts with the surface of metal oxide (or nitride) inside the nanopore 207 to form a covalent bond.
[0053] For the reaction (corresponding to FIGS. 3A , 3 B, and 3 C) when the nanopore 207 is coated (with organic coating 215 ) and the carbon nanotube 204 is uncoated, the inside of the nanopore 207 is coated (organic coating 215 ) with bifunctional arylamine, e.g., 4-aminophenylhydroxamic acid by immersion of the nanopore 207 in a dilute (1-5 mmolar) solution of the amine in ethanol. After sometime (e.g., 1-24 hours, preferably 1-2 hours) the substrate (forming the nanopore 207 ) is removed and rinsed with ethanol. This step results in self assembly of 4-aminophenylhydroxamic acid on the inside wall of nanopore 207 by formation of covalent bonds through hydroxamic acid functionality with metal oxide (or nitride) of the nanopore 207 and exposing arylamine functionality. Next, the coated nanopore 207 is treated with a dilute solution of nitrosonium ion (e.g., a solution of nitrosonium tetrafluoroborate or dilute solution of sodium nitrite in dilute hydrochloric acid) resulting in transformation of the amine group to diazonium salt. In the last step, the uncoated carbon nanotube 204 in salt solution is pulled into the coated nanopore 207 which will react with diazonium functionality of the self assembled monolayer and form carbon-carbon bond to immobilize the carbon nanotube 204 inside the nanopore 207 .
[0054] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, element components, and/or groups thereof.
[0055] The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention. The embodiment was chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated
[0056] The flow diagrams depicted herein are just one example. There may be many variations to this diagram or the steps (or operations) described therein without departing from the spirit of the invention. For instance, the steps may be performed in a differing order or steps may be added, deleted or modified. All of these variations are considered a part of the claimed invention.
[0057] While the exemplary embodiments of the invention have been described, it will be understood that those skilled in the art, both now and in the future, may make various improvements and enhancements which fall within the scope of the claims which follow. These claims should be construed to maintain the proper protection for the invention first described.
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A technique for embedding a nanotube in a nanopore is provided. A membrane separates a reservoir into a first reservoir part and a second reservoir part, and the nanopore is formed through the membrane for connecting the first and second reservoir parts. An ionic fluid fills the nanopore, the first reservoir part, and the second reservoir part. A first electrode is dipped in the first reservoir part, and a second electrode is dipped in the second reservoir part. Driving the nanotube into the nanopore causes an inner surface of the nanopore to form a covalent bond to an outer surface of the nanotube via an organic coating so that the inner surface of the nanotube will be the new nanopore with a super smooth surface for studying bio-molecules while they translocate through the nanotube.
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RELATED APPLICATIONS
The present application is a National Phase entry of PCT Application No. PCT/GB2014/000214, filed Jun. 5, 2014, which claims the benefit of EP Application No. 13250085.1, filed Jul. 23, 2013, each of which is incorporated herein by reference in its entirety.
TECHNICAL FIELD
Embodiments relate to a reverse powering system for telecommunications nodes. Embodiments provide a signaling mechanism between a power sink (ANU) and a power source arranged such that sufficient power is always available in a remote unit both from an individual line perspective and the global powering requirement of the ANU.
BACKGROUND
In a Fiber-to-the-Distribution Point (FttDP) system each remote node (Access Network Unit—ANU, also known as Distribution Point Unit—DPU), which provides the interface between the optical domain and the wired electrical connection into the customer premises, may be powered from an electricity supply located in the customers' premises, using the wired electrical connection. Several customers may be connected to the ANU and each could be operating under different power sink conditions depending upon the services that each customer is consuming.
International Patent specifications WO2009/138710, WO2009/138711, and WO2010/082016 describe a power supply system in which the power supply to be delivered by each user connected to an ANU is controlled such that users connected over short drop lengths provide proportionately more power to the ANU than those connected over longer drops. This reduces energy losses, because of the lower power losses on shorter (lower resistance) electrical connections (Power loss=I 2 R, with R (resistance) proportional to the length of wire through which the current passes).
The reduced power draw on the longer connections also compensates those customers on the longer connections for the generally slower DSL service possible over the longer lines. However, the system described in the earlier references was isolated from the element management of the ANU and the state of the CPE (battery backup).
It is common for the ANU or distribution point to be located in a relatively inaccessible location such as on a pole, or in a locked curbside cabinet, and only accessible to trained and authorized personnel of the telecommunications service provider. It is therefore not practical to make adjustments to their settings manually, so a setting procedure is required that can be operated using control signals transmitted from a remote location.
When a connection is operational, signaling between the customer premises equipment and the ANU can be achieved using a management channel in the xDSL (digital subscriber line) protocols. However, at system start-up or following an interruption in connection there is no xDSL operating, and therefore no means of controlling the power collection function. Without power, the xDSL protocols cannot be used to communicate with the customer premises equipment to initiate the power collection function.
SUMMARY
Embodiments provide for much greater control of the reverse powering system, in particular during start-up. According to a first aspect of embodiments, there is provided a power insertion system for a telecommunications interface unit for controlling the transmission of electrical power over a telecommunications connection between the interface unit and another interface unit, the power insertion unit comprising a control system for processing control signals controlling the power delivered over the telecommunications connection, and comprising a modem for the transmission of control messages between the interface units, the modem being configured to operate during a dormant phase using a communications protocol capable of operation on power scavenged by one of the interface units from the other interface unit over a high impedance connection indicative that the connection is intact, to allow the transmission of control messages between the interface units to initiate an active phase in which a larger power output can be transmitted over the telecommunications connection from the power-collecting telecommunications interface unit to the power-receiving telecommunications interface unit.
Two interface units, each having such a modem, can communicate with each other to deliver power to one of them from a power supply connected to the other. These will be referred to respectively as the power-receiving unit (or “sink”) and the power-collecting unit (or “source”). The power-receiving unit (“sink”) may be an optical network termination point for converting between electrical signals and optical signals. In use, during the dormant phase, the “sink” is not connected to an electricity supply other than the very low power (high impedance) connection from the source unit, and its modem operates on power scavenged from the telecommunications connection to power the modem. The source modem is connected to a power supply, but its modem should nevertheless operate on the low power protocol in order that the sink modem can co-operate with it.
In one advantageous arrangement, the low-power protocol is only used to set up the power delivery system, to allow a second, high speed, connection to then operate once the full power supply has been initiated.
In one advantageous arrangement, the power collecting unit transmits a beacon signal when it is connected to a power supply, and the power receiving unit, when in a standby mode, monitors the telecommunications connection for such beacons and responds when it detects one. The power-collecting unit is therefore required to use only a small amount of power when in the “standby” mode, until it is connected to a power supply. This can typically be provided by a battery.
The control system may also be configured to exchange signals in the event of a loss of power, either intentional or otherwise, at the power-collecting unit, in order to manage a “graceful” shutdown and return the power-receiving unit into the standby mode.
According to another aspect of embodiments, there is provided a method of controlling transmission of electrical power, over a telecommunications connection, to a power-receiving telecommunications interface unit from a power-collecting telecommunications interface unit connectable to a power supply, wherein during a dormant phase a high impedance connection is provided between the interface units indicative that the connection is intact, and an active phase is initiated by transmitting control messages between the interface units using a communications protocol capable of operation on power scavenged by the power-receiving interface unit from the high impedance circuit, the control messages initiating the transmission of a larger power output over the telecommunications connection from the power-collecting telecommunications interface unit to the power-receiving telecommunications interface unit.
In one advantageous arrangement, the power signaling system is integrated into the start-up protocol and also into the element management of the ANU so that OSS systems are aware of the current state of ANU system power, for example if the CPE has lost its local mains power feed and is currently operating in standby battery backup mode.
BRIEF DESCRIPTION OF THE DRAWINGS
An embodiment will now be described, by way of example, with reference to the accompanying drawings in which:
FIG. 1 illustrates a Fiber-to-the-Distribution-Point installation.
FIG. 2 shows a conventional distribution point in more detail.
FIG. 3 shows a conventional customer premises system in more detail.
FIG. 4 shows a distribution point modified according to an embodiment.
FIG. 5 shows a customer premises system modified according to an embodiment.
FIG. 6 shows a variant of the distribution point modified according to an embodiment.
FIG. 7 is a sequence diagram depicting a start-up process performed by an embodiment.
FIG. 8 is a sequence diagram depicting power-down processes performed by an embodiment.
DETAILED DESCRIPTION
FIG. 1 shows a typical a Fiber-to-the-Distribution-Point (FttDP) architecture with a Gigabit Passive Optical Network (GPON) backhaul. The optical line termination (OLT) 11 of the GPON is located in a Central Office 12 and is connected to a remote distribution point (DPU) 22 via the optical fiber/PON infrastructure 10 . The DPU is typically located on a pole, with an overhead drop wire 14 connecting to the individual customer premises 15 .
The DPU 22 is connected to the network-side of the master-socket (network termination equipment—NTE) 16 in the customers' premises (NTE) via the existing copper drop wire 14 . The customer premises equipment 32 is connected to the customer-side of the NTE. The customer premises equipment 32 comprises a number of elements 33 - 39 (shown in more detail in FIG. 3 ) communicating with each other and the DPU 22 through the home wiring network 17 . These include a Reverse Power Feed (RPF) source 38 and a baseband voice service which is generated by an Analogue Terminal Adapter (ATA) 33 .
Typically, a remote power feed will conflict with the d.c. signaling which is usually used in analogue telephony (“plain old telephone service”—POTS) to signal off-hook and on-hook telephone conditions, so when such a power feed is provided, it is necessary to provide a special adapter 30 known as a POTS Signaling Dongle (PSD) to each normal telephone handset 13 . These devices co-operate with the ATA 33 in order to allow the POTS signaling to be carried in the presence of a d.c. remote power feed. Some versions also generate the ringing signal for the attached telephone handset 13 .
Throughout FIGS. 2 to 5 , the suffixes “O” and “R” are used respectively for the network (“Office”) end and the customer (“Remote”) end.
FIG. 2 shows the distribution point 22 of FIG. 1 in more detail, and FIG. 3 likewise depicts the customer premises equipment 32 . These are connected to each other by the drop wire 14 , at the interfaces marked respectively U O and U r . In particular, FIGS. 2 and 3 depict the management entities located respectively in the DPU 22 and the Customer Premises 32 .
The DPU 22 comprises an optical network unit (ONU) 21 for converting between optical signals conveyed over the optical fiber backhaul 10 through a backhaul termination 20 and xDSL signaling conveyed through an “xDSL terminating unit O” (XTU-O) 24 to the drop wire 14 .
In the CPE 32 corresponding components are used to convert xDSL signals into signals usable by the end-user. In particular, the xDSL terminating unit-R (XTU-R) 34 acts as a modem for the xDSL service whilst the Analog terminal adapter (ATA) 33 in the xDSL network termination unit 31 co-operates with the POTS adapter 30 connected to a standard telephone 31 to allow normal voiceband traffic. A service splitter 39 separates traffic for the ATA 33 and traffic for the network termination 34
Electrical power is required to operate the ONU 21 . As the connection to the central office 12 is by way of an optical, not electrical, connection it is not possible to power the DPU, nor the customer premises equipment 32 , from the central office 12 as is conventional. Nor is it generally convenient to install a dedicated supply to the DPU 22 , which may be located at some distance from a suitable mains feed. Instead, electrical power is drawn from an input 18 connected to a power insertion unit 38 in the customer premises equipment 32 , and used to power both the XTU-R 34 in the network termination 31 of the customer premises equipment 32 , and the XTU-O 24 in the optical network unit 21 of the distribution point 22 .
Power is delivered to the DPU 22 from the power insertion unit 38 in the customer premises equipment 32 by way of the same electrical drop wire 14 that carries communications data. At each end of the drop wire 14 a respective power splitter 27 , 37 is provided which separates the power supply from the xDSL or other communications streams. In a typical arrangement, the xDSL is carried as an ac modulation summed with a dc power supply.
The power drawn by the DPU 22 is extracted by an extraction unit 28 .
The CPE 32 is provided with a battery 36 to maintain service in the event of failure of the power input 18 . Similarly, the DPU 22 is provided with a battery 26 and power combiner 23 to maintain service in the event of failure of the customer premises equipment 32 or the connection 14 . Respective power management systems 25 , 35 control the flow of electrical power between the various electrical components. In particular they may be used to control how much of the power required to operate the equipment in the distribution point 22 should be drawn from each of several customer premises 32 , taking into account factors such as the number of operational customer premises equipments currently capable of delivering power, the volume of traffic each is carrying, and electrical losses in each of the respective drop wire connections 14 .
In normal use, management information can be transmitted between the power management systems 25 , 35 of the DPU 22 and the or each customer premises equipment 32 via the same DSL service that is used for data transmission, i.e., using the “xDSL terminating unit O” (XTU-O) 24 and “xDSL terminating unit R” (XTU-R) 34 .
This same system can also be used to monitor and control power usage from the CPE 32 to DPU 22 and also interface generally the RPF sub-system with the element management of the system. This power control/monitoring system is especially useful in the case of mains power failure at the CPE and operating is occurring under battery power, i.e., the power system can ‘tell’ the XTU-O 24 and XTU-R 34 to operate in a low-power state.
However, the power management system cannot be operated over the xDSL system unless that system is in operation. When the customer premises equipment is first started up, or restarted after being switched off, or after reconnection of the drop wire 14 , the xDSL system cannot operate until the DPU 22 is drawing power through the power extraction unit. In particular, when the system is in the initiation phase another signaling and transmission system is required to coordinate the delivery of electrical power from the CPE 32 to the DPU 22 . Such an arrangement is depicted in FIGS. 4 and 5 , which respectively illustrate the modifications made to the distribution point of FIG. 2 and the customer equipment of FIG. 3 in order to put embodiments into effect.
A principal difference is the provision of a respective secondary communications modem 45 , 55 in each of the power extraction unit 28 in the distribution point 22 and the power insertion unit 38 in the customer premises equipment 32 .
FIGS. 4 and 5 show the respective power signaling modems 45 , 55 in the DPU 22 and the CPE 32 . Both modems are connected via the respective power splitters 27 , 37 which perform a frequency division duplexing arrangement to split/merge the signaling from the DSL systems 21 , 31 used for data transport and the d.c. powering arrangement 28 , 38 . Both signaling modems are also connected to the respective management entities 25 , 35 at each location.
Until the power initialization system is fully operational, the remote power signaling modem 45 in the DPU can only operate in a low power mode using scavenged power, that is power transmitted from the CPE to the remote unit before the remote unit has ‘officially’ come to life. Typically the CPE would might supply a small current and voltage (a few milliwatts—i.e., the remote node presents a very high impedance) to indicate that the connection is present. The secondary communications modem 45 in the remote unit 22 is arranged to operate on the low power available in such a situation. The secondary communications modem 55 in the customer premises equipment 32 is not subject to such power constraints, as it will only be required to operate when the user requires it, at which time it is connected to a power supply 18 . It is therefore convenient for the customer premises system to control the operation of embodiments, and to transmit instructions to the distribution point, rather than vice versa.
An alternative approach is depicted in FIG. 6 , and is possible if a POTS (traditional telephony) connection 40 is available on the network side 11 of the distribution point 22 , as is often the case in the legacy network. In this approach, the POTS line 40 can be connected to the remote unit 22 . This is connected to the drop wire connection 14 through the power splitter 27 . As shown, a POTS adapter 43 and service splitter 29 are also provided so that traditional voice calls can be carried over the “copper” POTS service if desired, or as a contingency to ensure basic telephony service is still available in the event of a power failure.
The signaling modems 45 , 55 may communicate between each other using any suitable protocol, for example the “1-wire protocol” developed by Dallas Semiconductor Corp. This system includes a parasitic powering capability at the remote device, so no separate power supply is required at the remote end in order for communication to commence. This signaling could be used to communicate to the CPE that a suitable device is present at the remote end and that reverse powering can commence. The data-rate of this technique is sufficiently low that it would not interfere with the G.hs (handshake) signaling that the G.fast or VDSL2 would use in establishing the full xDSL connection.
Alternatively, G.hs tones could be used for the remote power signaling system. In this case the protocol would have to be incorporated into the xDSL chipsets.
A method of operation is depicted in FIG. 7 and FIG. 8 . As depicted in FIG. 7 , when the CPE is first powered up (at 70 ), the CPE secondary modem 55 sends out a scan signal 71 to the DPU 22 seeking a response from the corresponding secondary modem 45 in the DPU. At this stage only a low voltage is applied to the line (say 20V) which is current limited to say 60 mA. If no response is received, the scan signal is repeated ( 710 , 711 . . . ), until either a response is received or the system is powered down again.
If a secondary modem 45 is present in the DPU, it returns an acknowledgement signal 72 to the CPE secondary modem 55 . This acknowledgement 72 indicates to the modem 55 that the modem 45 (and thus the power extraction unit 28 ) is present on the line, and that the power output across the connection 14 can safely be increased without damage to other components in the DPU or further into the network (as would be the case, for example, if only a standard POTS connection were connected to the DPU 22 )
The secondary modem 55 in the CPE 32 next increases the source voltage and increases its current limit (e.g., 60V, 350 mA), thus allowing normal operation of the remote unit 45 . The remote unit 45 , detecting the increased voltage, initiates a training process 74 to initiate the power insertion and extraction processors 38 , 28 , in particular to match the impedances so that the power drawn matches the power delivered. The signaling system monitors the power that is being transmitted over the link 14 and reports this to the element management system 35 .
FIG. 8 depicts processes that occur should the CPE power insertion unit 38 detect a failure of the power supply 19 (at 75 ), it switches to battery backup mode ( 76 ), and transmits a signal ( 77 ) to the DPU 22 to cause the XTU-O 24 to switch into a ‘Low Power Mode’, in which the data rate is reduced significantly in order to save power consumption in both the CPE 32 and the DPU 22 . This will allow the battery life to be extended to allow a low bitrate (or analogue) ‘lifeline’ service to be maintained either using the POTS connection 40 ( FIG. 6 ) if one is present or, otherwise, using the optical link 10 , 20 , 24 in a low power mode. When the power 18 is restored to the CPE 32 this is signaled from the CPE to the DPU 22 ( 79 ) to allow the remote unit 24 to revert back to normal operating conditions.
During deliberate power-down of the CPE 32 (step 75 ), sufficient energy is stored in its battery 36 or a capacitor to enable a message 777 to be sent to the remote unit 28 which causes it to be powered down gracefully, and also instructs the element manager 45 to switch to the standby listening mode, to await a beacon 71 from the CPE 32 indicating that it has powered up again.
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To initiate the transmission of electrical power over a telecommunications connection from a power-collecting telecommunications interface unit such as a customer premises equipment, connectable to a power supply, to a power-receiving unit such as a curbside electrical/optical interface, when a connection is first established, or the collecting unit is first powered up, or in order to re-establish connection after a power outage, control signals are transmitted between low-power modems in the interface units using a low-power communications protocol. This allows the controlled initiation of a larger power output and a higher speed exchange of data once the full telecommunications connection has been established. A low-powered beacon signal is transmitted over the telecommunications connection by the power-collecting telecommunications interface unit on connection to a power supply, for detection by the power-receiving telecommunications interface unit. In the event of a loss of power at the input, the low power modem initiates power management control signals to cause the power-receiving telecommunications interface to shut down certain functions in order to preserve backup power for essential “lifeline” services.
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CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims the benefit of prior filed provisional application, Appl. No. 61/360,105, filed Jun. 30, 2010, pursuant to 35 U.S.C. 119(e), the subject matter of which is incorporated herein by reference.
[0002] This application claims the benefit of prior filed provisional application, Appl. No. 61/375,486, filed Aug. 20, 2010, pursuant to 35 U.S.C. 119(e), the subject matter of which is incorporated herein by reference.
[0003] This application claims the benefit of prior filed provisional application, Appl. No. 61/407,620, filed Oct. 28, 2010, pursuant to 35 U.S.C. 119(e), the subject matter of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0004] The present invention relates to the field of oil and gas drilling and in particular to apparatuses for the containment and control of the flow of hydrocarbons from oil and gas wells.
[0005] An inherent risk in oil and gas exploration is the unintended release of oil or gas into the environment. A common cause for these releases are sudden pressure variations during the drilling process (so called kicks), usually caused by influx of formation fluids into the well bore. If the formation fluids are allowed to reach the surface, well tools and other drilling material may be blown out of the wellbore. These blowouts may result in destruction of the drilling equipment and injury or death to rig personnel. The main tool to prevent spills from these pressure variations used today are blowout preventers which essentially represent sealing devices to seal off the wellbore until active measures can be taken to control the kick. However, even with blowout preventers in place, the risk of oil spills remains. Spills can still occur due to material failure of the blowout preventer resulting from excessive pressure or accidental disruption of conducting components such as riser pipes, as well as catastrophic destruction of drilling platforms. Once a spill has occurred, measures must be taken to contain it. In previously occurring oil spills those measures have included the permanent sealing of the wellbore with filling material, and capturing the spilling oil by temporary capping of the well.
[0006] It has been recognized that known blowout preventer systems are susceptible to leaks due to material failure under high pressure. Especially in deep sea oil drilling, blowout preventers are subjected to enormous stress from external hydrostatic pressure of seawater and formation fluid pressure of the wellbore. Blowout preventers commonly used today consist of many interconnected parts with gaskets meant to seal leakage of formation fluids through the sites of interconnection. An example for a typical blowout preventer used in oil exploration is U.S. Pat. No. 7,300,0033. The high stress exerted on the interconnecting spaces and gaskets makes these elements sites for potential leaks. In addition, current blowout preventer systems lack the ability to detect the build up of gas at the wellbore and relay this information to drilling personnel. Further, it has been generally recognized that current systems for emergency containment and recovery of oil spills are inadequate. An example for such a system is the apparatus used during the oil spill from the Moncado oil well in the Gulf of Mexico in 2010. The apparatus used in the Moncado oil spill essentially represents a dome designed to enclose the ruptured oil pipe. At its top this dome can be connected to a riser pipe. After placement of the device over the ruptured pipe of the Moncado well, hydrates formed due to low temperature, and accumulated in the upper region of the dome, preventing oil flow from the device into the riser pipe. Since the hydrates are lighter than water they also caused the device to become buoyant and float upwards. The attempt to contain the Moncado well and recover the spilling oil using the containment structure eventually failed. Further, emergency containment systems currently in use do not have the ability to regulate oil flow in real time but can only operate on an on or off basis.
[0007] It would therefore be desirable and advantageous to provide an improved blow-out preventer and oil spill recovery management system to obviate prior shortcomings of other systems and to provide a system in which stress on the device from formation fluid pressure is minimized, which is able to detect gas build up during drilling operations at the wellbore, and which is better adapted to respond to emergency oil spills.
SUMMARY OF THE INVENTION
[0008] In some embodiments the invention relates to an apparatus for containing and controlling the flow of hydrocarbons from a bore well or other earth formation, comprising:
[0009] An apparatus for containing and controlling the flow of hydrocarbons from a wellbore or other earth formation, comprising:
a housing enclosing a receiving and distribution chamber, said receiving and distribution chamber in fluid communication with and sealably connected to a top vertical tubular member and a bottom vertical tubular member, said top and bottom tubular members extending from said receiving and distribution chamber to the exterior of said housing, said top vertical tubular member having an inner tubular member comprising means for moving said inner tubular member along the axis of said top vertical tubular member, said inner tubular member adapted upon movement to sealably connect or disconnect, said bottom vertical tubular member to said top vertical tubular member, a cone aperture adapted to prevent or allow the flow of liquid into said top tubular member, at least one outlet passage between said receiving and distribution chamber and the exterior of said housing, valve means adapted to permit or prevent the flow of liquid through at least one of said outlet passages and, pump means adapted to facilitate the flow of hydrocarbons through at least one of said outlet passages.
[0016] In other embodiments the invention relates to an apparatus for containing and controlling the flow of hydrocarbons from a bore well or other earth formation, comprising:
a housing enclosing a receiving and distribution chamber, said housing comprising at least two layers, said layers having a space in between them, said receiving and distribution chamber in fluid communication with and sealably connected to a top vertical tubular member and a bottom vertical tubular member, said top and bottom tubular members extending from said receiving and distribution chamber to the exterior of said housing, said top vertical tubular member having an inner tubular member comprising means for moving said inner tubular member along the axis of said top vertical tubular member, said inner tubular member adapted upon movement to sealably connect or disconnect, said bottom vertical tubular member to said top vertical tubular member, a cone aperture adapted to prevent or allow the flow of liquid into said top tubular member, at least one outlet passage between said receiving and distribution chamber and the exterior of said housing, valve means adapted to permit or prevent the flow of liquid through at least one of said outlet passages and, pump means adapted to facilitate the flow of hydrocarbons through at least one of said outlet passages.
[0023] In some embodiments the invention relates to a method for containing and controlling the flow of hydrocarbons from a well bore or other earth formation using an apparatus comprising a housing enclosing a receiving and distribution chamber, said housing comprising at least two layers, said layers having a space in between them, said receiving and distribution chamber in fluid communication with and sealably connected to a top vertical tubular member and a bottom vertical tubular member, said top and bottom tubular members extending from said receiving and distribution chamber to the exterior of said housing, said top tubular member having an inner tubular member comprising means for moving said inner tubular member along the axis of said top vertical tubular member, said inner tubular member adapted upon movement to sealably connect or disconnect, said bottom vertical tubular member to said top vertical tubular member,
a cone aperture adapted to prevent or allow the flow of liquid into said top tubular member, at least one outlet passage between said receiving and distribution chamber and the exterior of said housing, valve means adapted to permit or prevent the flow of liquid through at least one of said outlet passages and, pump means adapted to facilitate the flow of hydrocarbons through at least one of said outlet passages the method comprising bringing said apparatus in contact with a well bore to allow hydrocarbons to enter said receiving and distribution chamber through said bottom vertical tubular member.
[0030] The present invention resolves prior art problems by diverting and distributing oil flow entering the device evenly towards outlet passages and by relieving excess pressure through blowout relieve vents, thereby minimizing the stress exerted on the device from formation fluid pressure. Further, the system solves the problem of hydrate build up and other complications that may be related to temperature encountered in prior art emergency oil spill recovery systems by providing insulation of the device to maintain a standard temperature of pressure. In addition the system provides features that allow for real time management of oil flow once the system is deployed. Further, the system provides sensors for detecting gas build up at the wellbore and means to relay this information to drilling personnel, and therefore allows early detection of a possible kick in the wellbore.
BRIEF DESCRIPTION OF THE DRAWING
[0031] Other features and advantages of the present invention will be more readily apparent upon reading the following description of currently preferred exemplified embodiments of the invention with reference to the accompanying drawing, in which:
[0032] FIG. 1 is a perspective view of the system in accordance with one embodiment of the invention;
[0033] FIG. 1A is a perspective view of a hose deployment set including buoy, coiled hose canister, clamps and air supply for buoy, in accordance with one embodiment of the invention;
[0034] FIG. 2 is a vertical section view of the system in accordance with one embodiment of the invention;
[0035] FIG. 2A is a vertical section view of the core pipe with inner sleeve pipe, cone aperture and handle bar in accordance with one embodiment of the invention;
[0036] FIG. 2 C/ 2 D is a vertical section view of latches for handle bars of the sleeve pipe in accordance with one embodiment of the invention;
[0037] FIG. 3 is a horizontal section view of the system with volume channel arches in accordance with one embodiment of the invention;
[0038] FIG. 4 is a horizontal section view of the system in accordance with one embodiment of the invention;
[0039] FIG. 5 is a horizontal section view of the system with quadruple aqueduct in accordance with one embodiment of the invention;
[0040] FIG. 6 is a horizontal section view of the system with quadruple aqueduct in accordance with one embodiment of the invention.
[0041] FIG. 7 is an elevational view of the system at an onshore drilling operation in accordance with one embodiment of the invention;
[0042] FIG. 8 is a vertical section view of the system in accordance with one embodiment of the invention;
[0043] FIG. 9 is a horizontal section view of the system with quadruple aqueduct in accordance with one embodiment of the invention;
[0044] FIG. 10 is an elevational view of the system in deployment mode in accordance with one embodiment of the invention, and
[0045] FIG. 11 is a vertical section view of solid state construction of the system in accordance with one embodiment of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0046] Throughout all the Figures, same or corresponding elements are generally indicated by same reference numerals.
[0047] Turning now to the drawing, and in particular to FIG. 2 , there is shown a vertical section view of the Cap and Tap system according to an embodiment of the present invention with the housing ( 28 ) enclosing the receiving and distribution chamber ( 14 ) with sensors for fluid level, volume, pressure, escaped gas meter and analyzer ( 14 a ). On its top the receiving and distribution chamber ( 14 ) is connected to the core pipe ( 13 a ) that leads to the main viaduct ( 1 ). The core pipe contains an inner sleeve pipe ( 13 b ) and has a cone aperture ( 13 c ) and a handle bar ( 13 d ). On the bottom, the receiving and distribution chamber ( 14 ) is connected to the pipe threshold ( 17 ). Hydraulic pump managed ducts ( 16 ) lead from the receiving and distribution chamber ( 14 ) to the hydraulic pump platform ( 15 ). Hydraulic pump managed output pipes ( 10 ) lead from the hydraulic pump platform to the exterior of the housing ( 28 ). Volume pressure blowout relief vents ( 8 ) lead from the receiving and distribution chamber to the exterior of the housing.
[0048] In the embodiment of the invention depicted in FIG. 2 the position of the inner sleeve pipe ( 13 b ) can be changed by moving it along the axis of the core pipe ( 13 a ). By moving the inner sleeve pipe ( 13 b ), operation of the invention can be changed between two alternative modes. When the sleeve pipe is in the up-position (as shown in FIG. 2 ), the cone aperture ( 13 c ) is in the closed configuration, preventing oil flow into the core pipe. In this instance, incoming oil enters the receiving and distribution chamber ( 14 ) and is distributed evenly within the chamber by the cone aperture. The oil is distributed from the receiving and distribution chamber ( 14 ) through the hydraulic pump managed ducts ( 16 ) and eventually to the output pipes ( 10 ). The sensors ( 14 a ) of the receiving and distribution chamber ( 14 ) are connected to a regulatory circuit ( 18 ) that in turn is connected to actuators which in turn are mechanically connected to valves adapted to permit or prevent flow of oil through the blowout relief vents. In case the pressure in the receiving and distribution chamber reaches a preset value a signal is distributed by the sensors ( 14 a ), to the regulatory circuit ( 18 ) which in turn activates the actuators to open the valves of the blowout relief vents to relief pressure.
[0049] To operate the invention in the alternative mode the sleeve pipe is moved downward until it reaches the drill collar. Upon downward movement of the inner sleeve the cone aperture opens and remains in open configuration. Ideally, the inner sleeve pipe has an inner diameter relative to the outer diameter of the pipe threshold ( 17 ) that allows for a sealing engagement when the sleeve pipe is moved over the pipe threshold ( 17 ). In this instance oil is not allowed to enter the receiving and distribution chamber ( 14 ) but is directed to the main aqueduct ( 1 ). The Sleeve pipe can either be moved pneumatically or manually with the handle bars. In particular, the handle bars are useful to overcome unforeseen obstructions such as mud or rocks or water log or corrosion.
[0050] The embodiment shown in FIG. 2 also includes means that assist in positioning the device relative to a target area e.g. a well bore. Lights ( 4 A) and camera ( 4 B) are positioned preferably at the lower part of the device. Centering sensors and cameras ( 12 ) are positioned in close proximity to the drill collar to aid in centering the device on the ruptured pipe. Camera and centering sensors ( 12 ) are connected to a control circuit to allow for calculation of position of the drill collar with respect to the ruptured pipe. The embodiment may also include anchoring means ( 11 ) to anchor the device to the ground once deployment is complete.
[0051] Another embodiment of the invention is shown in FIG. 8 . This embodiment comprises a retractable conduit pipe ( 24 ) to allow use of the invention in regular drilling operations. The retractable conduit pipe of the embodiment in FIG. 8 replaces the inner sleeve pipe of the embodiment shown in FIG. 2 . During regular drilling operations the conduit pipe ( 24 ) passes through the core pipe and the pipe threshold into the wellbore. The drill collar ( 22 ), drill string ( 23 ) and drill bit ( 21 ) are positioned within the conduit pipe ( 24 ). During regular drilling operations the blowout relief vents ( 8 ) and the Hydraulic pump managed ducts are in closed position and not in use. The embodiment shown in FIG. 8 also comprises sensor means ( 14 a ) for detecting and measuring gas leakage in the wellbore.
[0052] FIG. 1 Is a perspective view of the system in accordance with one embodiment of the invention. As shown in FIG. 1 one advantageous embodiment may include a hose deployment set for one or more output pipes and/or relief vents. The deployment set is shown in more detail in FIG. 1A . Each set comprises a hose or other conducting means ( 32 ), an inflatable floating device ( 30 ), a source of compressed air ( 31 ) for the inflatable floating device, and clamping means to connect to receiving storage facilities. The hose terminal that is proximal to the apparatus is connected to the output pipes or relief vents whereas the distal terminal of the hose is attached to the inflatable floating device, source of compressed air and clamps. Robotic arms ( 7 ) are attached to the outside of the housing and include tools that can be used to replace and/or repair components of the device. A door ( 27 ) gives access to the robotic arm chamber. Embodiments of the invention that are used offshore, may also include a propeller ( 34 ) to allow for changing the position of the device relative to a target area or as an independent submersible unit/vehicle upon deployment.
[0053] FIG. 10 shows an example of a method to deploy an embodiment of the invention. A scaffold ( 20 ) as shown in FIG. 10 may be placed over the target site e.g. a ruptured pipe. The apparatus is then lowered into the scaffold towards the ruptured pipe. Eyes for cable hooks ( 3 ) (see FIG. 1 ) may be used to attach means for suspending the apparatus. Cameras, lights and pipe centering sensors are used to guide the apparatus to the ruptured pipe. Once the ruptured pipe has been encapsulated by the pipe threshold, anchor means are activated to anchor the apparatus to the ground. A person with skill in the art will appreciate other methods to bring the apparatus into contact with a target site such as a ruptured pipe. For example, the apparatus may be lowered to the target site without the help of a scaffold depending on conditions such as water drift, wind, etc at the site of deployment. In case no scaffold is used, the apparatus may be lowered to the ocean floor manually or with the assistance microcontrollers as an independent submersible unit or vehicle.
[0054] FIG. 12 shows another embodiment of the invention. This embodiment comprises a mud/slurry pipe ( 35 ) through which drilling mud and other drilling fluids can be conducted to the drill head. Further, the embodiment shown in FIG. 12 comprises formation fluid vents ( 36 ) located at the base of the housing of the device to manage influx of formation fluids used in the drilling process such as water, mud, or foam. The purpose of the formation fluid vent is also to maintain desirable pressure levels at the drilling pipe and to prevent ballooning at the wellbore during drilling.
[0055] The housing of the system can be designed using any material or arrangement of components which are commonly used in the art to achieve maintenance of structural integrity under conditions commonly encountered during oil exploration. A preferred material for the housing is solid-state stainless steel. The housing can comprise several layers. In the preferred embodiment shown in FIG. ( 2 ) the housing comprises three layers, internal housing layer A, middle layer B and external layer C. The space between layer A and B accommodates the connectivity apparatus. In order to remove air pockets that could destabilize the CAT system the space between layer A and B may be filled with injectable plastic material to remove air pockets. The space between layer C and D can be filled with injectable insulation to maintain standard temperature of pressure. In another preferred embodiment the housing comprises a fourth layer D in addition to the three layers shown for the embodiment of FIG. ( 2 ) above. In the embodiment, with the fourth layer D, the space between layer C and D can be filled with ballast material such as water or mud.
[0056] The number and shape of the receiving and distribution chamber(s) may vary. One preferred embodiment shown in FIG. 2 has a single chamber wherein the shape of the inner surface of the chamber resembles that of an open torus with the top and bottom opening of the torus forming the attachment points for the core pipe and the pipe threshold respectively. In another embodiment shown in FIG. 5 and FIG. 6 , four receiving and distribution chambers may be present. In the embodiment shown in FIG. 5 and FIG. 6 the inner surface of each individual receiving and distribution chamber represents that of an ellipsoid. All four chambers are in fluid communication with each other and are sealably connected to the core pipe on their top and to the pipe threshold on their bottom.
[0057] In a particular embodiment the receiving and distribution chambers may also include sensor means for measuring the pressure and flow of gas or oil in the chamber. The sensor means may be any structure or device known in the art to measure the pressure of liquids or gas including but not limited to piezoresistive, capacitive, electromagnetic, piezoelectric, optical or potentiometric sensors.
[0058] The number of output pipes and blowout relief vents may vary in different embodiments. An example of an embodiment with 8 output pipes and 8 blowout relief vents is shown in FIG. 3 and FIG. 4 . FIG. 3 and FIG. 4 show that one advantageous way of arranging the output pipes and relief vents with regard to the receiving and distribution chamber is to use substantially even spacing between each output pipe and between each relief vent respectively. However, the spacing between each of the output pipes and between each of the relief vents does not have to be even.
[0059] The cone aperture may be any device or structure that is able to alternatively allow or prevent oil flow into the main aqueduct and which achieves the purpose of distributing incoming volume evenly when in a configuration to prevent oil flow into the main aqueduct. In one preferred embodiment the cone aperture comprises triangular members that are hingedly attached to the outside of the core pipe in such a way that when the edges of the triangular members are in contact with each other flow of oil or gas through the core pipe is prevented. In one embodiment the cone aperture may also include sensor means adapted to measure pressure and volume distribution of liquid or gas entering the receiving and distribution chamber. The sensor means may be any structure or device known in the art to measure the pressure of liquids or gas including but not limited to piezoresistive, capacitive, electromagnetic, piezoelectric, optical or potentiometric sensors. In yet another embodiment, parts of the members comprising the cone aperture may be magnetic such as to facilitate bringing the edges of the individual members in contact with each other.
[0060] The means for moving the inner sleeve pipe can be any device or structure known in the art to achieve moving the sleeve pipe, including but not limited to hydraulically operated systems.
[0061] While the invention has been illustrated and described as embodied in blow-out preventer and oil spill recovery management, it is not intended to be limited to the details shown since various modifications and structural changes may be made without departing in any way from the spirit of the present invention. The embodiments were chosen and described in order to best explain the principles of the invention and practical application to thereby enable a person skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated.
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An apparatus for containing and controlling the flow of hydrocarbons from a bore well or other earth formation including in certain aspects a housing enclosing a receiving and distribution chamber, said receiving and distribution chamber in fluid communication with and sealably connected to a top vertical tubular member and a bottom vertical tubular member, said top and bottom tubular members extending from said receiving and distribution chamber to the exterior of said housing, a cone aperture adapted to prevent or allow the flow of liquid into said top tubular member, at least one outlet passage between said receiving and distribution chamber and the exterior of said housing, valve means adapted to permit or prevent the flow of liquid through at least one of said outlet passages and, pump means adapted to facilitate the flow of hydrocarbons through at least one of said outlet passages.
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This application is a continuation of application Ser. No. 07/086,647, filed Aug. 18, 1987, now abandoned.
BACKGROUND TO THE INVENTION
This invention relates to an exercising machine.
Exercising machines are known in which a person exercises against his own mass on a inclined railed system. A sliding board moves on rollers along the rail system and a person positioned on the board can cause it to move up and down by manipulating handles at the ends of ropes attached to a system of pulleys. The rail is hooked to a support structure at various elevations to increase or decrease the difficulty of exercising.
Known inclined exercising machines are relatively heavy and occupy a lot of space during exercising and in storage.
SUMMARY OF THE INVENTION
The present invention provides exercising machine comprising a frame including a rail system spanning a pair of stands, a sliding board movable along the rail system between a forward and a rearward position, a rope carrying a pair of handles attached to a system of pulleys on the board and the frame so that pulling on the rope causes the board to move towards its forward position, and at least one elastic element extending between attachment points and the rope and pulley system causing the velocity ratio between the handles and the board to be at least 3:1.
Also the system of pulleys may include a pair of first and second pulleys fixed to a bar transverse to the forward stand, a third pulley on the forward stand and a pair of fourth and fifth pulleys spaced apart at the forward end of the board, the rope being looped around the first pulley, then around the fourth pulley, around the third pulley, around the fifth pulley and finally around the second pulley.
Alternatively, or in addition the system of pulleys may include four pulleys mounted on a bar transverse to the forward stand, being first to fourth pulleys and fifth, sixth and seventh pulleys mounted on the forward end of the board, the rope being looped from the first, to the fifth, to the second, to the sixth, to the third, to the seventh and finally around the fourth pulleys.
Preferably there are a pair of elastic members, conveniently in the form of endless bands extending between the forward end of the board and the rearward stand.
In one form of the invention there is a sub axle at each side of the rearward stand for looping of an endless band, the board is fitted with a stub axle which registers with that on the stand when the board is in its rearward position, and there are a plurality of endless bands on each side which can act between the forward axle on the board and the axle on the rearward stand or be parked between the axles on the board.
The forward stand, the rail system and a connection between the rearward stand and the bottom of the forward stand preferably form a triangle, the forward end of the rail system being adjustable along the forward stand and there being transverse supports preventing the machine from falling sideways.
The rail system may comprise a beam and the forward stand may be a post with a connection being a pair of parallel struts extending between and pivoted to the transverse supports.
The forward stand preferably tilts between a position normal to which the surface on which the machine rests and towards the rearward end of the beam at angles less than 90°.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an exercising machine according to the invention;
FIG. 2 is an enlarged fragmentary view of a part of the machine shown in FIG. 1;
FIG. 3 is also an enlarged fragmentary view of a different part;
FIG. 4 is a top view showing a conventional rope and pulley arrangement;
FIG. 5 is a top view showing a rope and pulley arrangement provided by the invention;
FIG. 6 is a side view of the machine in a folded position;
FIG. 7 is a rear view;
FIG. 8 is a perspective view from the side of another exercising machine
FIG. 9 is a front perspective view of the machine; and
FIG. 10 is a rear view of the machine.
DESCRIPTION OF EMBODIMENTS
The principal structural elements of the machine illustrated in FIGS. 1 to 7 are a stand or leg 10, a rail or beam 11 and a pair of struts 12. The lower end of the beam 11 is secured to a boss 13 which is in turn secured to a stand or bar 14 which in use rests on the floor. Handles 15 attached to the bar 15 are used as foot or hand rests for some exercises and may also be used for moving the apparatus.
The leg 10 is fitted with a top bar 16 sometimes serving as a handle and a bottom bar 17 which mounted in use rests on the floor. The struts 12 extend between the bars 14 and 17. At the bar 14 (see FIG. 2) the strut 12 is formed with a head 18 pivotally in the bracket 19. At the bar 17 (see FIG. 3) each strut 12 is formed with a ball head 21 detachably engaging with a bracket 22 formed with a semispheroidal seat for the head 21. Thus at the bar 17 the struts can also pivot.
The upper end of the beam 11 is pinned by a pin 30 to a bracket 24 fitted with rollers 25 engaged with the leg 10. The leg 10 is formed on its rear face with a series of holes which can be engaged by a spring-biased plunger operated by a knob 26 (see FIG. 7).
A board 27 runs on the beam 11 by means of rollers not shown. The length of the board is greater than one-half the length of the beam, as depicted in FIGS. 1 and 7. An exerciser manipulates a rope and pulley system while he is positioned on the board 27 to move the board up and down. The system is described later on.
For a given exercise and often for a given exerciser, the beam 11 has to be positioned at a given angle to the floor on which the bars 14 and 16 rest. To change the angle of the beam 11, the knob 26 is pulled and the bracket 24 is moved along the length of the leg 10 until the beam 11 has the desired inclination. The knob 26 is released for the plunger to enter an appropriate hole in the leg 10. In the process of changing the inclination of the beam 11, the inclination of the leg 10 relatively to the floor also changes. Effectively the lower end of the beam pivots about the pins 19 while the lower end of the leg 10 pivots about the centres of the ball heads 21. The geometry is such that in use, the leg 10 always forms an angle of less than 90° with the floor. However low down on the leg 10 there is a hole 31 for the plunger in which position the leg 10 is at 90° to the floor. In this position the struts 12 may be realeased from the brackets 22 so that the leg 10 may be folded down on the board 27. The assembly may now be lifted by the handles 15 to the position shown in FIGS. 6 and 7 to stand on the bar 17 and feet 28 projecting from foot rests 33 are attached to the beam 11.
A pair of rubber endless bands 44 are strung between axles 45 and 46 on the board and the boss 13 to bias the board 27 to the lower end of the beam.
FIG. 4 shows a configuration of a rope 40 as used in the prior art. In this case the rope 40 passes around pulleys 41 on the board 27 and around pulleys 42 on the foot rests 33. This gives a velocity ratio of 1:1 so that to achieve a given arm movement or rope pull the board has to move a considerable distance on the beam 11.
FIGS. 1 and 5 show an arrangement where the velocity ratio is increased to 2:1 with a reduction in the stroke of the board 27. In this case the rope 40 also passes around a pulley 43.
The exercising machine of FIGS. 1 to 7 does not require the massive support structure of the prior art. Also with the rubber band and pulley system of FIGS. 1 and 5 the length of the beam 11 is reduced. Adjusting the top of the beam is easy as the operator does not have to carry a large mass or push and pull on the foot of the beam. Damage to the floor is minimized.
The principal structural elements of another embodiment illustrated in FIGS. 8 to 10 are a forward leg 10, a beam 11 and a rearward leg. The leg 10 extends upwardly from a base bar 17 resting on the floor in normal use.
Projecting from the leg 10 are a pair of foot rests 34 and a top arm 35. The beam 11 serving as a rail is fixed to the leg 10 at an angle as can be seen from FIG. 8.
At its rearward end the beam 11 is fixed to the boss 13 resting on a base bar 14. The bar 14 may serve as a handle for manipulating the machine and the boss 13 and the bar 14 form a rearward stand.
A board 27 runs on the beam 11 by means of rollers. As shown, the forward end of the beam is lifted off the ground to a greater extent than the rearward end so that there is a gravity bias on the board 27 to cause it to assume a rearward position. However, the main bias is caused by two pairs of endless rubber bands 44 and 43 looped around stub axles 45 at the forward end of the board 27 and stub axles 46 projecting from the boss 13. To move the board forward the bands 44 and 43 are required to be stretched. There is also a pair of rearward stub axles 47 on the board 27. With the board 27 in its rearward position, the stub axles 46 and 47 are aligned. In a given case the bands 43 and 44 may be parked or stored on the stub axles 47. As shown the bands 43 are parked so that only the bands 44 resist the movement of the board 27.
As shown there are two pairs of bands 44 and 43, but in principle the number of bands could be increased to increase the resistance of the machine.
Forward movement of the board is achieved by pulling on handles 52 attached to the ends of a rope 40. The latter may be threaded around pulleys on the arm 35 and the board 27. On the arm 35 there are pairs of outer pulleys 42 and inner pulleys 57. On the board 27 there are a central pulley 58 and flanking pulleys 59. For a velocity ratio of 3:1 the rope 40 is threaded as shown in FIGS. 8 to 10. In other words the rope 40 comes off the pulleys 42 and passes from a pulley 42 around a pulley 59, around a pulley 57 and in the reverse direction around the pulley 58 to the pulleys on the other side. The sequence is thus 42, 59, 57, 58, 57, 59, and 42. For a 2:1 velocity ratio the sequence would be 42, 59, 57, 57, 59 and 42 with the pulley 58 missed out.
The exercising machine of FIGS. 8 to 10 is easily stored by upending it to stand on the bar 17 and the arm 35. In that position it occupies very little space.
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An exercising machine having a board slidable on a beam has a rope and pulley system by means of which an exerciser sitting on the board pulls himself up an incline. To increase the resistance rubber bands are looped between axles and on the board and the beam respectively. In other embodiments other pulley systems are used and a plurality of bands may be used on each side of the machine.
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FIELD OF THE INVENTION
The present invention relates generally to fuel system control techniques, and more specifically to techniques for diagnosing failures and fault conditions in a fuel system.
BACKGROUND OF THE INVENTION
Electronically controlled high pressure fuel systems are known and commonly used in the automotive and heavy duty truck industries. Such systems may include a fuel pump operable to provide high pressure fuel to a collection unit that supplies the pressurized fuel to one or more fuel injectors. One or more pressure sensors are typically provided for monitoring and controlling the fuel pressure throughout the system.
An example of one such system is described in U.S. Pat. No. 5,678,521 to Thompson et al., which is assigned to the assignee of the present invention. The Thompson et al. fuel system includes a pair of cam driven high pressure fuel pumps operable to pump fuel from a low pressure fuel source to an accumulator. The accumulator passes the high pressure fuel to a single injection control valve which is electronically controllable to supply the fuel to a distributor unit. The distributor, in turn, distributes the fuel to any of a number of fuel injectors. The accumulator includes a pressure sensor for monitoring accumulator pressure. An electronic control unit monitors accumulator pressure, throttle position and engine speed, and is operable to control the operation of the fuel system in accordance therewith.
High pressure fuel systems of the type just described, while having many advantages over prior mechanical systems, have certain drawbacks associated therewith. For example, failure of electrical and/or mechanical components of the system may result in total system failure, in which case the engine is often shut down leaving the vehicle and occupant stranded. In severe cases, failure of such components can lead to catastrophic destruction of fuel system components.
What is therefore needed is a system for diagnosing faults and failures in an electronically controlled fuel system of the type just described. Such a system should ideally log fault codes indicative of fuel system related failures, and pressure sensor failures in particular, to assist in repair efforts, and should additionally provide for a limp home fueling operational mode so that the vehicle can be driven out of danger and/or to a repair facility.
SUMMARY OF THE INVENTION
The foregoing shortcomings of the prior art are addressed by the present invention. In accordance with one aspect of the present invention, apparatus for diagnosing a fuel system of an internal combustion engine comprises an accumulator receiving pressurized fuel from a source of pressurized fuel, means for sensing fuel pressure within the accumulator and producing a pressure signal corresponding thereto, the pressure signal having peak values corresponding to peak pressures of fuel supplied thereto by the source of pressurized fuel, and a control computer sampling a number of first pressure values each near a separate one of the peak values and determining a number of pressure error values each between a separate one of the number of first pressure values and a corresponding reference pressure, the control computer determining a variance of at least some of the number of pressure error values and incrementing an error counter if the variance exceeds a variance threshold.
In accordance with another aspect of the present invention, a method of diagnosing a fuel system of an internal combustion engine comprises the steps of supplying fuel from a source of pressurized fuel to an accumulator based on a target fuel pressure value, measuring a number of peak pressure values within the accumulator each near corresponding actual peak pressures therein resulting from the supplying step, determining a number of error pressure values each between a separate one of the peak pressure values and the target fuel pressure value, determining a variance of at least some of the number of error pressure values, and incrementing an error counter if the variance exceeds a variance threshold.
In accordance with either of the foregoing aspects, the error counter is decremented, preferably not below a predefined count value, if the variance is less than the variance threshold. If the error counter exceeds a predefined count value, a fault code is logged and a limp home fueling algorithm is preferably executed.
One object of the present invention is to provide an apparatus and method for diagnosing erratic pressure sensor related failures in an electronically controlled fuel system of an internal combustion engine.
Another object of the present invention is to provide such an apparatus and method that logs a fault code and executed a limp home fueling algorithm upon detection of erratic pressure sensor behavior.
These and other objects of the present invention will become more apparent from the following description of the preferred embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic illustration of a fuel system for an internal combustion engine and associated control system, in accordance with the present invention.
FIG. 2 is a block diagram illustration of some of the internal features of the control computer of FIG. 1 under normal operation thereof, as they relate to the present invention.
FIG. 3 is composed of FIGS. 3A-3G and illustrates waveform diagrams of normal operation of the fuel system and associated control system of FIG. 1.
FIG. 4 is a plot of pressure vs. crank angle of a normal pressure waveform associated with the accumulator of in FIG. 1 .
FIG. 5 is a plot of pressure vs. time of a normal pressure waveform and a target pressure waveform associated with the accumulator of FIG. 1.
FIG. 6 is a plot of pressure vs. time of an accumulator pressure waveform sensed by an erratic pressure sensor as compared with a target pressure waveform.
FIG. 7 is a plot of pressure vs. number of samples of target pressure, measured pressure and pressure error waveforms indicative of normal operation of the fuel system of FIG. 1.
FIG. 8 is a plot of pressure vs. number of samples of target pressure, measured pressure and pressure error waveforms indicative of erratic pressure sensor operation in the fuel system of FIG. 1.
FIG. 9 is a plot of variance vs. number of samples of target pressure variance, measured pressure variance and pressure error variance waveforms indicative of normal operation of the fuel system of FIG. 1.
FIG. 10 is a plot of variance vs. number of samples of target pressure variance, measured pressure variance and pressure error variance waveforms indicative of erratic pressure sensor operation of the fuel system of FIG. 1.
FIG. 11 is a plot of variance vs. number of samples comparing pressure error variance of a normally operating pressure sensor and an erratic pressure sensor, in the fuel system of FIG. 1.
FIG. 12 is a flowchart illustrating one preferred embodiment of a software algorithm for determining processed pressure error values, in accordance with the present invention.
FIG. 13 is a flowchart illustrating one preferred embodiment of a software algorithm for determining a variance of the processed pressure error values determined in accordance with FIG. 12, and for executing diagnostic features upon detection of erratic pressure sensor behavior, in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
For the purposes of promoting an understanding of the principles of the invention, reference will now be made to one preferred embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated embodiment, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.
Referring now to FIG. 1, a fuel system and associated control system 10, in accordance with the present invention, is shown. System 10 includes a fuel tank 12 or similar source of fuel 14 having a fuel flow path 15 extending into a low pressure fuel pump 16. Preferably, low pressure pump 16 is a known gear pump having a manually gear mechanism 18 and fuel pressure regulator 20. A fuel flow conduit 24a extends into a high pressure fuel pump 22 having a first (front) pump element 24b and a second (rear) pump element 24c. Pump elements 24b and 24c are mechanically driven by an engine drive mechanism 28 via cams 26a and 26b respectively. Fuel flow conduit 24a feeds a first pump control valve 30a having an output fuel flow conduit 24d connected to pump element 24b. Fuel flow conduit 24a is also connected to a fuel flow conduit 24e which feeds a second pump control valve 30b having an output fuel flow conduit 24f connected to pump element 24c. The first pump element 24b is connected to a high pressure fuel accumulator 34 via conduit 36a with a check valve 32a disposed therebetween. Likewise, the second pump element 24c is connected to accumulator 34 via conduit 36b with a check valve 32b disposed therebetween.
High pressure accumulator 34 is connected to an injection control valve 38 via conduit 40. Injection control valve 38 includes a drain conduit 42 and an output conduit 44 feeding an input 46 of a fuel distributor 48. Distributor 48 includes a number of output ports, wherein six such output ports 50 1 -50 6 are illustrated in FIG. 1. It is to be understood, however, that distributor 48 may include any number of output ports for distributing fuel to a number of fuel injectors or groups of fuel injectors. In FIG. 1, one such fuel injector 52 is connected to output port 50 2 via fuel flow path 54, wherein injector 52 has an injector output 56 for ejecting fuel into an engine cylinder.
System 10 is electronically controlled by a control computer 58 in response to a number of sensor and engine/vehicle operating conditions. An accelerator pedal 60 preferably includes an accelerator pedal position sensor (not shown) providing a signal indicative of accelerator pedal position or percentage to input IN1 of control computer 58 via signal path 62, although the present invention contemplates utilizing any known sensing mechanism to provide control computer 58 with a fuel demand signal from accelerator pedal 60. A known cruise control unit 64 provides a fuel demand signal to input IN2 of control computer 58 via signal path 66 indicative of desired vehicle speed when cruise control operation is selected as is known in the art.
An engine speed sensor 68 is connected to an input IN3 of control computer 58 via signal path 70, providing control computer 58 with a signal indicative of engine speed position. In one embodiment, engine speed sensor 68 is a known HALL effect sensor, although the present invention contemplates using any known sensor operable to sense engine speed and preferably engine position, such as a variable reluctance sensor. High pressure accumulator 34 includes a pressure sensor 72 connected thereto which is operable to sense pressure within the accumulator 34. Pressure sensor 72 provides a pressure signal indicative of accumulator pressure to input IN4 of control computer 58 via signal path 74. Preferably, pressure sensor 72 is a known pressure sensor, although the present invention contemplates utilizing any known device, mechanism or technique for providing control computer 58 with a signal indicative of fuel pressure within accumulator 34, conduit 36a, conduit 36b or conduit 40. Control computer 58 also includes a first output OUT1 connected to injection control valve 38 via signal path 76 and a second output 78 connected to pump control valves 30a and 30b via signal path 78. The general operation of fuel system 10 and associated control system will be described with reference to FIGS. 1-4.
Referring to FIGS. 1 and 2, some of the internal features of control computer 58, as they relate to the present invention, are illustrated. The accelerator pedal signal and cruise control signal enter control computer 58 via signal paths 62 and 66 respectively. As is known in the art, both signals are operator originated in accordance with desired fueling, and control computer 58 is responsive to either signal to correspondingly control the fuel system 10. Hereinafter, the accelerator pedal and/or cruise control signal will be referred to generically as a fuel demand signal. In any case, the fuel demand signal is provided to a fueling request conversion block 90 which converts the fuel demand signal to a fueling request signal in accordance with known techniques. Typically, fueling request conversion block 90 includes a number of fuel maps and is responsive to a number of engine/vehicle operating conditions, in addition to the fuel demand signal, to determine an appropriate fueling request value.
The fueling request value is provided to a reference pressure calculation block 92 which is responsive to the fueling request value to determine a reference pressure indicative of a desired accumulator pressure set point. The reference pressure is provided to an accumulator pressure control loop which provides a pump command signal on signal path 78 based on the reference pressure value and accumulator pressure provided by pressure sensor 72 on signal path 74. In one embodiment, the reference pressure value is provided to a positive input of a summing node Σ 1 which also has a negative input connected to signal path 74. An output of summing node Σ 1 is provided to a governor block 96, the output of which is connected to signal path 78. In one embodiment, governor block 96 includes a known PID governor, although the present invention contemplates utilizing other known governors or governor techniques.
The fueling request value is also provided to a reference speed calculation block 94 which is responsive to the fueling request value to determine a reference speed indicative of a desired engine speed. The reference speed is provided to an engine speed control loop which produces a fuel command value in accordance therewith, as is known in the art, based on the reference speed and actual engine speed provided by engine speed sensor 68 on signal path 70. In one embodiment, the reference speed value is provided to a positive input of a summing node Σ 2 which also has a negative input connected to signal path 70. An output of summing node Σ 2 is provided to a governor block 98, the output of which provides the fuel command value. In one embodiment, governor block 98 includes a known PID governor, although the present invention contemplates utilizing other known governors or governor techniques.
Control computer 58 also includes an ICV on time calculation block 100 which is operable to determine an "on time" for activating the injection control valve (ICV) 38 based on the actual accumulator pressure signal provided on signal path 74 and the fuel command provided by governor 98. The ICV on time calculation block 100 produces a fuel signal on signal path 76 for controlling activation/deactivation of the injector control valve 38.
Referring now to FIG. 3, which is composed of FIGS. 3A-3G, some of the general timing events of fuel system 10 are illustrated. Control computer 58 is operable to control fuel pressure within the accumulator 34 by controlling the pump control valves 24b and 24c. Control of one of the valves 24b will now be described, although it is to be understood that operation thereof applies identically to valve 24c. As the pump plunger retract within the pump element 24b under the action of cam 26a, fuel supplied by low pressure fuel pump 16 flows into the trapped volume of fuel pump element 24b as long as valve 30a is not energized. If valve 30a remains de-energized as the pump plunger rises, fuel within the trapped volume flows back out to low pressure fuel pump 16. When the pump control valve 30a is energized, the outward fuel flow path is closed and the fuel within the trapped volume of pump element 24b becomes pressurizes as the pump plunger rises. When the fuel pressure within the trapped volume reaches a specified pressure level, check valve 32a opens and the pressurized fuel within the trapped volume flows into the accumulator. Based upon a difference between the reference pressure (block 92 of FIG. 2) and the actual accumulator pressure (provided on signal path 74), the pressure control loop of FIG. 2 specifies the angle before pump plunger top dead center (TDC) at which the pump control valve 30a is energized. This angle will be referred to hereinafter as a valve close angle (VCA).
In one embodiment of fuel system 10, as illustrated in FIGS. 3B-3G, pump plunger TDC (shown in FIGS. 3D and 3F as front and rear cam respectively) and cylinder TDC (FIG. 3B) are aligned 60 crank degrees apart (FIG. 3C). The commanded VCA (pump command) may occur anywhere between zero and 120 degrees before pump plunger TDC (see FIGS. 3D-3G). When the difference between the reference pressure and actual accumulator pressure is large, the respective commanded VCA is large and vice versa. Examples of different commanded VCA's are illustrated in FIGS. 3E and 3G wherein pump command activation times are shown as having a pump activation delay time A and a pump activation time B. VCA's corresponding to 65 degrees and 30 degrees are shown in FIG. 3E by C and F respectively, and a VCA of 120 degrees is shown in FIG. 3G by D. If the actual accumulator pressure is greater than the reference pressure, the commanded VCA is automatically set at zero degrees, corresponding to no energization of the pump control valve 30a, as illustrated at E in FIG. 3G. Control computer 58 is further operable to activate the injection control valve 38 (to control fuel timing) and deactivate valve 38 (to control fueling amount) between pump plunger TDC and cylinder TDC as illustrated in FIGS. 3A, 3B, 3D and 3F. Further operational and structural details of fuel system 10 and associated control system are given in U.S. Pat. No. 5,678,521 to Thompson et al., which is assigned to the assignee of the present invention, the contents of which are incorporated herein by reference.
As fuel enters the accumulator 34, accumulator pressure begins to rise and reaches the reference pressure (FIG. 2) approximately 30 degrees after pump plunger TDC. Thirty degrees after pump plunger TDC of each pumping event, control computer 58 samples accumulator pressure and maintains such samples as peak accumulator pressure samples. Approximately 45-75 degrees after pump plunger TDC, control computer 58 activates the injection control valve 38 (FIG. 3A) to begin an injection event. As fuel is drawn out of the accumulator 38 resulting from activation of the injection control valve 38, the pressure in the accumulator decreases, and approximately 80 degrees after pump plunger TDC accumulator pressure reaches a minimum. Control computer 58 again samples accumulator pressure at 80 degrees after pump plunger TDC and maintains such samples valley accumulator pressure samples. A plot of accumulator pressure 110 vs. crank degrees, as contrasted with reference pressure 112, is illustrated in FIG. 4. FIG. 4 illustrates an accumulator pressure profile for one complete cam revolution of a six cylinder engine. As shown by waveform 110, the front (24b) and rear (24c) pump elements alternate operation, and control computer 58 samples six peak pressure values and six valley pressure values each cam revolution.
In accordance the present invention, control computer 58 is operable to monitor the accumulator pressure waveform, an example of which is illustrated in FIG. 4, and diagnose various fuel system related faults and failure conditions; particularly faults and failures associated with the operation of the pressure sensor 72. One example of such a fuel system fault or failure condition is a stuck in-range failure of pressure sensor 72, the details of which are described in co-pending U.S. patent application Ser. No. 09/033,379 filed by Stavnheim et al., entitled APPARATUS FOR DIAGNOSING FAILURES AND FAULT CONDITIONS IN A FUEL SYSTEM OF AN INTERNAL COMBUSTION ENGINE and assigned to the assignee of the present invention, the contents of which are incorporated herein by reference. However, the Stavnheim et al. application, as it relates to the detection of pressure sensor related failures, is concerned mainly with stuck in range pressure sensor failures and is therefore not operable to detect intermittent or erratic pressure sensor failures. The present invention is directed to diagnosing such intermittent or erratic pressure sensor failures by monitoring accumulator pressure, and computing a variance in a difference between the sensed accumulator pressure and reference pressure (or pressure setpoint). If the variance between the sensed accumulator pressure and pressure setpoint exceeds a predefined variance threshold for a calibratable number of variance values, computer 58 is operable to log a fault code therein and execute a limp home fueling algorithm directed at pressure sensor-related failures. An example of one particular limp home fueling algorithm useful with the present invention is described in co-pending U.S. patent application Ser. No. 09/033,338 filed by Olson et al., entitled APPARATUS FOR CONTROLLING A FUEL SYSTEM OF AN INTERNAL COMBUSTION ENGINE and assigned to the assignee of the present invention, the contents of which are incorporated herein by reference.
Referring now to FIG. 5, a plot of accumulator pressure 122 over time, preferably provided to input IN4 of control computer 58 via pressure sensor 72, is shown compared to a reference pressure (accumulator pressure setpoint) waveform 120, preferably provided by the reference pressure calculation block 92 of FIG. 2. Waveforms 120 and 122 are indicative of a normally operating fuel system 10, and it should be observed that actual accumulator pressure 122 tracks the reference pressure 120 fairly closely. Although the exact values of the set point waveform 120 and the measured pressure waveform 122 may be somewhat different at any given instant in time, the variability or rates at which they each change are very similar.
Referring now to FIG. 6, by contrast, a reference pressure waveform 130 is shown compared with an accumulator pressure waveform 132 indicative of a pressure sensor 72 exhibiting erratic operation. Erratic pressure sensor behavior is characterized by random and unpredictable transients which are independent of the pressure setpoint waveform 130. The random and varying pressure measurements contribute higher frequency components to the measured pressure signal 132. As seen in FIG. 6, it is the higher frequency components that distinguish waveform 132 from waveform 130, thereby indicating erratic pressure sensor operation. In accordance with the present invention, control computer 58 is accordingly operable to measure and compare the variability of the pressure setpoint waveform with the variability of the measured accumulator pressure waveform.
Referring now to FIGS. 12 and 13, one embodiment of a pair of software algorithms 200 and 250 for diagnosing erratic pressure sensor behavior, in accordance with the present invention, are shown. Algorithms 200 and 250 are preferably included within control computer 58 and are executed thereby many times per second as is known in the art. Preferably, algorithms 200 and 250 are executed simultaneously, and are operable to share information. With the aid of the waveform illustrations of FIGS. 7-11, details of algorithms 200 and 250 will now be described in detail.
Referring to FIG. 12, algorithm 200 begins at step 202 and at step 204, control computer 58 samples the current accumulator pressure setpoint, or reference pressure (REF), preferably provided by the reference pressure calculation block 92 of FIG. 2. Thereafter at step 206, control computer 58 is operable to sample the actual accumulator pressure (AP), preferably via the signal provided on signal path 74 by pressure sensor 72, near the peak pressure value (see FIG. 4) for the present pumping event as described hereinabove. Thereafter at step 208, control computer 58 is operable to compute a pressure error (PE) value based on the current pressure setpoint and current accumulator pressure values. Preferably, control computer 58 is operable to compute the PE value as an algebraic difference between the PE and AP values, although other more complicated difference formulas are contemplated by the present invention.
Algorithm execution continues from step 208 at step 210 where the pressure error value (PE) from step 208 is filtered to remove low frequency components therefrom. Preferably, control computer 58 is operable to provide such filtering in accordance with known software filtering techniques. In one embodiment, control computer 58 includes a high pass software filter having a cut off frequency that is set appropriately so as to remove any constant bias, yet pass the high frequency components indicative of erratic pressure sensor behavior. The remaining filtered pressure error signal (FPE) represents the high frequency components of the measured accumulator pressure signal which do not correspond with the computer commanded pressure setpoint. Thereafter at step 212, control computer 58 is operable to compute an absolute value of the current FPE value determined in step 210, resulting in an absolute valued filtered pressure error value (ABSFPE). Thereafter at step 214, the control computer 58 stores the current ABSFPE value therein for further processing in accordance with the software algorithm 250 of FIG. 13. From step 214, algorithm execution loops back to step 204. Algorithm 200 thus continuously produces a signal indicative of pre-processed (filtered and absolute valued) pressure error values.
Referring to FIG. 7, example waveforms of the sampled accumulator pressure setpoint values 140 (step 204 of algorithm 200), the sampled accumulator pressure values 142 (step 206 of algorithm 200) and the computed pressure error values 144 (step 208 of algorithm 200) are shown for a normally operating fuel system 10. By contrast, FIG. 8 shows example waveforms of the sampled accumulator pressure setpoint values 150, the sampled accumulator pressure values 152 and the computed pressure error values 154 for a pressure sensor 72 exhibiting erratic sensor behavior.
Referring now to FIG. 13, one embodiment of a software algorithm 250 for processing the stored ABSFPE values (step 214 of FIG. 12), is shown. Algorithm execution begins at step 252 and at step 254 control computer 58 sets a counter equal to an arbitrary value; zero in this case. Thereafter at step 256, control computer 58 determines whether a predefined number, N, of ABSFPE values are available for processing. In one embodiment, control computer 58 includes a queue which holds the ten most recent ABSFPE values, and computer 58 is operable to determine the variance of the pressure error values based on these 10 ABSFPE values. It is to be understood, however, that any number of recent ABSFPE values can be used for the variance computation, and the actual number used is a matter of design choice. In any case, if control computer 58 determines at step 256 that less than N (e.g. 10) ABSFPE samples are available, algorithm execution loops back on step 256 until algorithm 200 provides N such values. When at least N ABSFPE values are available, algorithm execution continues a step 258.
At step 258, control computer 58 computes a variance (VAR) of the N most recent ABSFPE samples. In one embodiment, control computer 58 is operable at step 258 to compute VAR as a simplified variance by summing the N samples. However, the present invention contemplates computing VAR in accordance with other known variance equations at step 258. By computing a simplified variance based on the 10 most recent ABSFPE samples, susceptibility to spurious noise is reduced; i.e. detection of erratic sensor behavior will require detection of a meaningful number of high frequency spikes.
Algorithm execution continues from step 258 at step 260 where control computer 58 tests the variance value VAR against a variance threshold TH, which is preferably calibratable. If, at step 260, control computer 58 determines that VAR is greater than TH, algorithm execution continues at step 262 where control computer 58 increments the error counter. If, at step 260, control computer 58 determines that VAR is less than or equal to the threshold TH, algorithm execution continues at step 264 where the control computer 58 decrements the error counter (preferably not below zero, however). From either of steps 260 or 264, algorithm execution continues at step 266.
At step 266, control computer 58 compares the error counter against a predefined (preferably calibratable) count value. If the error counter is less than the predefined count value, algorithm execution loops back to step 258 for calculation of another variance value. If, at step 266, control computer 58 determines that the error counter is greater than or equal to the predefined count value, algorithm execution continues at step 268 where control computer 58 logs a fault code therein indicative of an erratic pressure sensor failure. In one embodiment, the predefined count value is set at 36 counts, although the present invention contemplates utilizing other count values. Algorithm execution continues from step 268 at step 270 where control computer 58 is operable to execute a limp home fueling algorithm. Preferably, the limp home algorithm is directed to providing at least minimum fueling to sustain engine operation so that the vehicle may be driven out of danger and/or to a service/repair facility. One example of such a limp home algorithm is detailed in pending U.S. patent application Ser. No. 09/033,338, filed by Olson et al., entitled APPARATUS FOR CONTROLLING A FUEL SYSTEM OF AN INTERNAL COMBUSTION ENGINE and assigned to the assignee of the present invention, the contents of which have been incorporated herein by reference. Algorithm execution continues from step 270 at step 272 where algorithm execution is returned to its calling routine. Alternatively, step 270 may loop back to step 254 for continuous execution of algorithm 250.
Referring to FIG. 9, example waveforms of the variance in the sampled reference pressure values 160, the variance in the sampled accumulator pressure values 162 and the variance in the computed pressure error values 164 are shown for a normally operating fuel system 10. By contrast, FIG. 10 shows example waveforms of the variance in the sampled reference pressure values 170, the variance in the sampled accumulator pressure values 172 and the variance in the computed pressure error values 174 for a pressure sensor 72 exhibiting erratic sensor behavior. FIG. 11 shows a comparison of the variance in the computed pressure error values for a normally 180 operating fuel system 10 and for a pressure sensor 72 exhibiting erratic sensor behavior 182.
While the invention has been illustrated and described in detail in the foregoing drawings and description, the same is to be considered as illustrative and not restrictive in character, it being understood that only one preferred embodiment thereof has been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected.
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A fuel system includes a pair of electronically controllable high pressure fuel pumps operable to supply high pressure fuel from a lower pressure fuel source to a high pressure fuel accumulator having a pressure sensor associated therewith. The fuel collection chamber feeds an electronically controllable valve operable to dispense the high pressure fuel to a fuel distribution unit supplying fuel to a number of fuel injectors. A control computer is provided for controlling the high pressure fuel pump and valve in response to requested fueling, engine speed and fuel pressure provided by the pressure sensor. The accumulator pressure signal is processed in accordance with the present invention for diagnosing erratic pressure sensor failures. The control computer is operable to compute error pressure values based on differences between peak accumulator pressure values and a target pressure value, and compute pressure error variance values based on subsets of the pressure error values. A fault code is logged and a limp home fueling algorithm is executed if a predefined number of variance values exceed a variance threshold.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a plastic rivet consisting of a rivet body comprised of a flanged head and a leg member extending from the bottom of the head, and a pin which when inserted into an axial through-hole of the rivet expands the leg member.
2. Description of the Prior Art
Because of their convenience as fasteners for components requiring periodic inspection and maintenance, rivets of the type which can be fastened and unfastened by insertion and extraction of a pin into and from a rivet body are coming into increasingly wide use. The conventional rivet of this type has, however, not been entirely satisfactory. One problem has been that since the structure employed makes it difficult to obtain adequate expansion of the leg member by insertion of the pin it has been necessary to make the diameter of the axial through-hole close to the outer diameter of the leg member. As a result, a high degree of processing precision is required in forming the rivet body and, worse, the rivet is often unable to provide the tight fastening force that is desired.
Another problem with the conventional fastener has been that when a rivet in the fastened condition is to be unfastened by pushing the pin further into the rivet body, the pin is apt to come all the way out the other end of the rivet body and fall in among the other components of the device in which it is used. In this case, if the pin cannot be found it of course cannot be reused, but an even greater problem is that it may interfere with the operation of the device.
One of the reasons for these shortcomings of the conventional rivet is that since the leg member which is expanded by the insertion of the pin is formed to have a plurality of legs either by providing one or more cuts axially inward from the tip of the leg member or by a plurality of axial slits provided in the intermediate section of the leg member so that when the pin is inserted, all of the legs spread outward by the same amount.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a plastic rivet which is free from the shortcomings of the conventional rivet described above.
The present invention attains this object by providing a plastic rivet consisting of a rivet body comprised of a flanged head and a leg member extending from the bottom of the head, the rivet body having an axial hole extending through its entire length, and a pin which when inserted into an axial through-hole of the rivet body expands the leg member. The rivet is characterized in that the leg member is formed to have a movable leg by providing two slits running axially inward from the tip of the leg member, and the movable leg is provided on its inner surface with a tooth-like protuberance. The shank of the pin is provided with two V-shaped recesses spaced in the axial direction of the pin to leave a tooth-like protuberance therebetween, and the tip of the tooth-like protuberance of the pin is provided with a notch, whereby when the pin is inserted into the axial through-hole of the rivet body only the movable leg is deflected outward. With this arrangement, it is possible to realize a large spreading of the leg member and a large engaging force between the rivet and the plates or the like that it is used to fasten, while at the same time making it possible to carry out the leg spreading operation with a small pushing force exerted on the pin.
Moreover, in accordance with another feature of the present invention, the axial through-hole of the rivet is formed of a large-diameter portion at the head end thereof followed by a small-diameter portion continuing on to the tip, a shoulder being formed at the boundary between the large- and small-diameter portions. The pin is provided with a head of such size that, when the pin is inserted into the axial through-hole for the purpose of spreading the leg member, the head can fit into the large-diameter portion but abuts with and is stopped by the shoulder so that the pin is prevented from falling out from the tip end of the rivet body. There is thus no possibility of the pin getting lost in the device.
BRIEF EXPLANATION OF THE DRAWINGS
The other objects and characteristic features of this invention will become apparent to those skilled in the art as the disclosure is made in the following description of a preferred embodiment as illustrated in the accompanying drawing in which:
FIG. 1 is a sectional view taken along the longitudinal center of an embodiment of a rivet according to this invention showing the pin partially inserted into the rivet body.
FIG. 2 is a cross-sectional view taken along line II--II in FIG. 1.
FIG. 3 is a sectional view taken along the longitudinal center of the same embodiment showing the rivet in the fully fastened state.
FIG. 4 is a cross-sectional view taken along line III--III in FIG. 3.
FIG. 5 is a sectional view taken along the longitudinal center of the same embodiment showing the rivet in the released state.
FIG. 6 is a sectional view taken along the longitudinal center of the rivet body.
FIG. 7 is a bottom view of the rivet body.
FIG. 8 is a sectional view taken along the longitudinal center of the pin.
FIG. 9 is a bottom view of the pin.
FIG. 10 is a partially broken away perspective view of the pin.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the longitudinal sectional view of a rivet according to this invention shown in FIG. 1, the rivet is shown to consist of a rivet body 1 and a pin 2. In FIG. 1 the rivet is illustrated in the state ready for use, with the pin 2 partially inserted into the rivet body 1. FIG. 2 is a cross-sectional view taken along line II--II of FIG. 1.
Both the rivet body 1 and the pin 2 are formed of plastic. The rivet body 1 has a flanged head 3 and a rod-shaped leg member 4 which extends perpendicularly from the undersurface of the head 3. The rivet body 1 has an axial through-hole 5 running its full length, i.e. from the upper surface of the head 3 to the tip of the leg member 4.
The portion of the through-hole 5 extending from the opening in the head 3 to an intermediate point in the leg member 4 is formed as a large-diameter portion 5'. At the end of the large-diameter portion 5' is a shoulder 6, beyond which the wall of the leg member becomes thick and the through-hole 5 assumes a generally semicircular shape as best shown in FIG. 7.
As shown in FIGS. 6 and 7, the leg member 4 provided with the through-hole 5 is further provided with two slits 7 running inward from the tip of the leg member 4 in the direction of the head 3. These slits 7 separate off a part of the leg member 4 so as to form a movable leg 8 which is able to swing resiliently about the thin-walled region at its proximal end.
Being formed by the two slits 7 provided in the part of the leg member 4 wherein the through-hole 5 is of approximately semicircular cross-section, the movable leg 8 is positioned as opposed to a thick-walled portion of the leg member 4, and at the middle portion on the inner surface of the movable leg 8 there is formed a tooth-like protuberance 9, the inclined edges of which are aligned with the longitudinal direction of the leg member 4.
As will be explained in more detail later, this protuberance 9 is for opening the leg 8 by engagement with a protuberance on the pin 2. The protuberance 9 is rounded at its top for better sliding engagement and is formed to such height that in its normal (unflexed) state its top reaches the inner surface of the thick-walled portion.
The pin 2 is formed of a shank portion having a head 10 at its one end. The shank portion is given a semicircular cross section matched to the configuration of the through-hole 5 formed in the rivet body 1 and is provided at the center of its flat surface with a slide-groove 11 that runs from its tip to near the head 10 and has a width sufficient for admitting the top of the protuberance 9. In the longitudinal direction of the slide-groove 11 are formed first and second V-shaped recesses 12 and 13, so spaced as to leave a protuberance 14 standing between them. The top of the protuberance 14 is provided with a notch 15 for engagement with the top of the protuberance 9.
On the outer arcuate wall of the shank portion at positions removed from the upper opening of the slide-groove 11 are provided a pair of projections 16 for engagement with the slits 7 of the rivet body 1.
The pin 2 is made longer than the rivet body 1 and the head 10 is given a diameter such that it can enter freely into the large-diameter portion 5' of the through-hole 5.
The rivet of the foregoing structure is fabricated by first separately forming the rivet body 1 and the pin 2 for insertion therein. The shank of the pin 2 is then inserted tip first into the through-hole 5 of the rivet body 1 from the opening in the head. At this time, the shank is inserted so as to engage the protuberance 9 of the movable leg 8 with the slide-groove 11, and the projections 16 provided on the outer surface of the shank portion with the slits 7, whereafter the pin is pushed inward causing the floor of the slide-groove 11 to push the protuberance 9 outward until the first recess 12 formed in the pin 2 reaches the position of the protuberance 9 thus allowing the protuberance 9 to fall into engagement with the recess 12. This completes the fabrication of the rivet. The rivet in the completed state is shown in FIGS. 1 and 2.
Next, the manner in which the rivet is used to fasten together two plates P 1 and P 2 will be explained with respect to FIG. 5. The plates P 1 and P 2 are first provided with holes h 1 and h 2 large enough to admit the leg member 4 of the rivet body 1. The two holes are brought into registration and the leg member 4 of the rivet body 1, which at this time is combined with the pin 2, is inserted into the two holes from the side of the hole h 1 until the undersurface of the head 3 strikes against the outer surface of the plate P 1 . Next, the head 10 of the pin 2, which at this time projects outward from the outer surface of the head 3, is driven in with a mallet or the like to the point where the surfaces of the two heads 10 and 3 are flush with each other. As the shank portion of the pin 2 is driven in, the protuberance 14 advancing therewith rides on the protuberance 9, causing the movable leg 8 to bend outward around the point where it exits from the plate P 2 until, finally, the top of the protuberance 14 engages with the notch 15 in the top of the protuberance 9. The plates P 1 and P 2 are thus caught between the head 3 and the outwardly bent protuberance 9.
FIGS. 3 and 4 show this fastened state. It will be noted that the movable leg 8 is pushed outward by the protuberance 14 by an amount nearly equal to the height of the protuberance 14 so that the degree of opening is large, meaning that it is possible to realize a very great expansion in the effective outer diameter of the leg member 4.
If when the rivet is in this fastened state further pressure is applied to the head 10 of the pin 2 so as to cause the shank portion to advance further, the head 10 will progress into the large-diameter portion 5', causing the protuberance 9 to come free of the protuberance 14 and fall into the second recess 13. The protuberance 9 comes into full engagement with the second recess 13 at the time the bottom surface of the head 10 strikes against the shoulder 6. When this state is reached, the movable leg 8 is fully returned from its deflected state so that the effective outer diameter of the leg member 4 is restored to its normal size and the leg member 4 can be extracted from the holes h 1 and h 2 .
This unfastened state of the rivet is illustrated in FIG. 5, from which it will be clear that when the pin 2 is pushed in to unfasten the rivet, there is no danger of its falling out the other end since the head 10 thereof is stopped by abutment with the shoulder 6. As a result, the rivet can be extracted from the plate holes with the pin 2 held securely therein.
As the rivet according to the present invention has the structure described in the foregoing, the pin is prevented from falling out of the rivet body in the normal state by the engagement of the protuberance 9 of the movable leg 8 with the first recess 12 of the pin 2. The rivet is thus advantageous in that it can be handled as a single unit without danger of the pin and the rivet body becoming separated. On the other hand, it is also extremely advantageous in use since when it is to be used for fastening, the leg member 4 can be expanded merely by driving the pin 2 inward until its head 10 comes flush with the head 3 of the rivet body 1, and also since when it is to be extracted after once being fastened, it is only necessary to push the pin 2 further into the through-hole 5 to again reduce the effective diameter of the leg member and make it possible to pull out the rivet.
Moreover, in the rivet of the present invention the expansion of the leg member 4 by the insertion of the pin 2 does not involve the expansion of the leg member as a whole but only the deflection of the movable leg 8 formed separately from the remainder of the leg member by the provision of the slits 7. Therefore, as the expansion of the leg member can be easily realized by bending the movable leg about its proximal end, it is possible to realize a large expansion of the leg member with only a small pushing force. The large degree of spreading of the leg member obtainable in accordance with the present invention is highly advantageous not only in that it assures secure fastening but also in that it makes it easy to minimize the amount of processing error in the formation of the through-hole provided in the leg member.
Also, since the head 10 of the pin 2 strikes against the shoulder 6 when the pin 2 is pushed inward for unfastening the rivet, the pin 2 is prevented from falling out the far end of the leg member 4, meaning that since the pin is never lost it can always be reused and will never be a cause of malfunctioning of the device in which the rivet is used.
Moreover, in accordance with the present invention, when the pin 2 is inserted into the rivet body 1, the protuberance 9 of the movable leg 8 is engaged with the slide-groove 11 and, further, the projections 16 provided on the outer surface of the pin 2 are engaged with the slits 7 provided on opposite sides of the movable leg 8. Thus, as the pin 2 is always guided within the slide-groove 11 in the prescribed orientation, the protuberance 9 is always reliably guided to the top of the protuberance 14 to engage with the notch 15 and push the movable leg 8 outward to its open position. For the same reason, the protuberance is also reliably guided into the recess 13 at the time the rivet is unfastened. As seen from this, the present invention provides a very reliable rivet that invariably operates with precision so that there is no danger of a component or the like being insecurely fastened because the insertion of the pin into the rivet body failed to provide insufficient expansion of the leg member.
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A plastic rivet consisting of rivet body comprised of a flanged head and a leg member extending from the bottom of the head, the rivet body having an axial hole extending through its entire length, and a pin which when inserted into the through-hole, expands the leg member. The leg member of the rivet body is provided with a movable leg which is deflected outward when the pin is inserted into the through-hole of the rivet body so as, for example, to catch and hold a pair of plates through which the rivet body has been passed between the head of the rivet body and the deflected movable leg. Pushing the pin further into the rivet body causes the deflected movable leg to return to its normal position, whereby the fastening action of the rivet is released.
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This is a continuation-in-part application of U.S. patent application Ser. No. 103,227, filed Dec. 13, 1979.
BACKGROUND OF THE INVENTION
As of 1959, different techniques of Nuclear Magnetic Resonance (NMR) were being developed with respect to noninvasive, in-vivo methods for the observation and measurement of physiological processes and for diagnostics, for example, relating to hemodynamics. In 1968, NMR was for the first time applied to study the structure of intracellular water and the metabolism of cells; observations on extravasal water in myocardial and pulmonary tissue have been described in the study of cardiac infarction and pneumonoederma and a feasibility study for the diagnosis of ischemia has been reported. In 1971, application of NMR to cancer-research was initiated. Finally, in 1973 the development of various NMR-tomographic imaging processes, designated zeugmatography was originated. An article in "Nature", Vol. 270, p. 722 (1977) describes the achievement of a spatial resolution of 0.4×0.4×3.0 mm 3 . An X-ray computer tomogram of a human head is depicted in "Physics Today", Vol. 30/12, p. 32, December 1977. The NMR-zeugmatogram through a human radiocarpal joint, published simultaneous in the aforesaid article in "Nature" demonstrate comparable image qualities. Nevertheless about 100-times as much time (about 9 minutes) was required to accumulate the data for the latter.
One serious handicap of the above NMR-methods derives from having to take data at a signal-to-noise ratio much too close to one. Simultaneously, the observed volume has to encompass a much too large region of the sample for detailed and differentiated measurements. The described results may only be obtained by data accumulation and signal averaging techniques requiring an appreciable amount of time. A further uncertainty in the data during its accumulation is produced by a slightly shifting of the sample in reference to the observed control volume, due to involuntary movements, for instance, created by cardiac action or respiratory movement or the like. That all adds up to the described disadvantages of having to abserve in much too large regions of the sample and of requiring time-consuming techniques for multiple data accumulation and signal averaging.
The radiation exposure of the patient quite often approaches the range of permanent damage (radiation entrance dose ≳3 rad) during examination involving X-rays, angiography, computertomography or nuclear medical diagnostics. This constitutes a serious obstacle in utilizing these methods for medical check-ups, for screening and even for the validation of the course of therapeutic measures.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide improved methods and means for executing spin-echo measurements on samples, which have to remain at their own temperature and which have a non-negligible electrical conductivity. These are to be accomplished within a very small sub-region of that sample, precisely localized, applying only one single pulse sequence, achieving high sensitivity and appropriate signal-to-noise ratio as well as high resolution in space and in time.
It is another object of the present invention to provide methods and means for obtaining the desired diagnostic information having to evaluate only one single pulse sequence applied to any specific region of exploration (control volume). This was possible up to now only by time-consuming data accumulation and signal averaging over a large number of individual measurements because of the much smaller signal-to-noise ratio obtainable.
The described task may be performed by an NMR apparatus equipped appropriately for the determination of the density of some specific nuclides (with non-zero magnetic moment) in any well defined and precisely localized control volume within the region of exploration. Said apparatus comprises means for the automatic control of the position of the very small control volume, in reference to involuntary movements within the subject. Furthermore, it comprises means for the determination of both of the relaxation times, that is the characteristic time T 1 , known as the spin-lattice relaxation time as well as the spin-spin relaxation time, T 2 . Further means are provided for the measurement of the components of the tensor of diffusion and for the evaluation of the contraction (transformation) of the spin-spin relaxation time due to the hydrodynamic state of circulating blood within the control volume. The apparatus in accordance with the present invention is furthermore characterized by a detection coil as well as the total primary detection system operating at very low temperatures, preferably in the superconducting state and, in particular, in the temperature region of superfluid helium below about 1.85 K.
The apparatus comprises, according to one preferred embodiment of this invention, an electromagnet and/or a super-conducting magnet system producing a homogeneous magnetic field, persisting extremely constant in time. It comprises furthermore magnet coils for the generation of slowly variable three-dimensional linear and/or quadratic or of higher order magnetic field gradients for confining and controlling the region of resonance, the control volume. The remote control of the position of the region of resonance is furthermore conducted via these field gradients by compensating for involuntary periodic subject movements under the influence of cardiac action, respiratory movements, peristalsis and the like. The fluid dynamic analysis is also performed via these gradient fields. The apparatus further comprises a coil system and associated control equipment for the generation of fast varying three-dimensional pulsed magnetic field gradients for the determination of the components of the diffusion tensor and under certain conditions for the execution of hydrodynamic analysis.
A gradiometer coil of first or second order design is arranged for signal detection in the interior of said apparatus in accordance with this invention, preferably coaxial in reference to the transmission coil. The detection system is equipped in this particular embodiment with a SQUID (superconducting quantum interference device) and/or a preamplifier operating at the above mentioned low temperatures.
The present invention is directed to an improved technique "for the noninvasive, localized examination of . . . by spin-echo techniques". Spin-echo techniques are but one particular group of nuclear or gyromagnetic resonance experiments in which the sample (patient) is irradiated with radio frequency radiation at one time for excitation to reradiate a signal at a different later time (e.g. some microseconds later). This very circumstance sets up the opportunity for avoiding known problems and limitations such as are elaborated upon by D. I. Hoult and P. C. Lauterbur in J.Mag.Res. 34, 425 (1979). They attempt to demonstrate in particular that noise from the patient, set off by inductive losses during its rf-irradiation, will impede the reduction of noise within the primary detection system (especially within the detection coil). This is deffinitely not true if one separates the rf-irradiation sufficiently from the reradiation of the signal e.g. in time. The only possibility for improving the signal-to-noise ratio is to reduce the noise in the detection system, as the amplitude of the signal is limited by properties of the sample and requirements of geometrical resolution of the signal, which should emanate from preferably an as small as possible sub-region. All technical details described under preferred embodiments aim therefore at reducing the external und internal (Johnson) noise within the detection system in order to render signals measurable up to now not observable at all.
The principle of this invention is discovery and disclosure contrary to accepted teaching, of possibilities of lowering the noise level substantially.
To conduct by spin-echo techniques determinations of the density of nuclides, the relaxation times, and the components of the diffusion tensor is standard state-of-the-art (see e.g. T. C. Farrar and E. D. Becker: "Pulse and Fourier Transform NMR", Academic Press, N.Y. (1971)). Such measurements can be performed with much improved signal-to-noise ratio applying the disclosed techniques. Therefore, one can conduct these measurements also in much smaller sub-regions of the sample, i.e. more localized.
Up to now, different NMR-methods of determining the local density of nuclides with marginal signal-to-noise ratio yielded different NMR-imaging procedures, e.g., as shown by W. S. Moore et al. in U.S. Pat. No. 4,015,196 of Mar. 29, 1977, by A. N. Garroway et al. in U.S. Pat. No. 4,021,726 of May 3, 1977, by R. R. Ernst in U.S. Pat. No. 4,070,611 of Jan. 24, 1978, by P. Mansfield in U.S. Pat. No. 4,115,730 of Sept. 19, 1978 and by A. N. Garroway et al. in Journal of Physics C, vol. 7, no. 24, p. L 457 of Dec. 21, 1974. Some more specialized NMR-information is attempted to obtain without improved signal-to-noise ratio by R. V. Damadian in U.S. Pat. No. 3,789,832 of Feb. 5, 1974 and by Z. Abe et al. in U.S. Pat. No. 3,932,805 of Jan. 13, 1976. Somewhat improved attempts to obtain localized phosphorus spectra in-vivo were presented by T. R. Brown from Bell Labs. at the Vanderbilt NMR Imaging Symposium Oct. 26-27, 1980 and by Oxford Research Systems Topical Magnetic Resonance Spectroscopy. Both of these are attempting to improve signal-to-noise by observing more or less a complete organ, i.e. enlarging the signal emitting volume as much as possible. Up to that invention no attempt has been published to lower the noise-level in an in-vivo NMR-imaging experiment to such a degree that localized precision NMR-experiments, like phosphorus-spectra of something like a very small fraction of such an organ or blood flow analysis in a medium or small artery or vein in-vivo, should become feasible.
Taking NMR-spectra by pulse-techniques of samples, filling more or less the detection coil, is again state-of-the-art (see e.g. T. C. Farrar and E. D. Becker: "Pulse and Fourier Transform NMR", Academic Press, N.Y. (1971)).
It is known, that the sensitivity of NMR-measurements may be severely restricted by the conductivity of the sample. The electromagnetic rf radiation for the excitation of NMR induces eddy currents simultaneously in such a sample. These eddy currents contribute electromagnetic radiation which may compete with the one emanating from the sample due to the excited NMR. Therefore, simultaneous excitation of NMR and detection of its signal may be precluded. Only in spin-echo techniques one may let elapse sufficient time between the exciting rf pulse and the formation of the spin-echo within the sample for all other excitations to decay (relax) in the meantime. Thus only the NMR excitation will remain, as it is relaxing much more slowly. Among the faster decaying excitations are the inductive ones with their concomitant noise radiation. After their relaxation, they will not be able any more to compete with the signal from the spin-echo now under formation. Thus NMR signals unperturbed by "inductive noise" may be detected by the application of spin-echo techniques. The detection of spin-echoes has to compete under these conditions mainly with the thermal radiation according to Planck's law prevailing within the dewar vessel which encompasses the detector coil at low temperatures, which has to be designed preferably to perform as filter for electromagnetic radiation with an appropriate band-pass width around ω o and the internal thermal (Johnson) noise within the detector coil. Both of these noise sources decrease at lower temperatures, yielding very favorable conditions at superfluid helium of about 1.85 K. Spin-echo measurements are performed at one particular frequency ω o only. Further noise reduction in the detection of the spin-echoes may be accomplished by limiting the bandwidth of the detector, as done e.g. by the particular microwave circuit described later on. It becomes mandatory to screen off and to compensate for any magnetic and electromagnetic perturbations from the outside (in particular within that bandwidth) which may compete in strength (amplitude) with the spin-echoes to be detected.
The accomplished improvement in sensitivity and signal-to-noise ratio according to this invention are brought forth and characterized by:
(a) The detector coil system being designed in fashion of a first or second order gradiometer. It is therefore very insensitive to perturbing electromagnetic radiation from the surrounding (extraneous noise) but simultaneously highly sensitive to the internal, strongly inhomogeneous radiation field from the excited control volume.
(b) The entire primary detection circuit operating at very low temperatures in order to reduce its internal noise, preferably cooled below 1.85 K and thermally stabilized by superfluid helium.
(c) The detector coil system and the entire primary detection circuit (and if necessary the pertinent connecting lines too) being largely constructed either of ultra-high purity metals, like aluminum possessing an as large as possible resistance ratio; or, preferably, of appropriate superconductors and preferably of hard type II ones. These type II superconductors are selected preferably such, that the currents induced by spin-echo signals during the data acquisition time are conducted without dissipation in the "mixed state" and below the onset of "flux flow", as for instance is the case for Nb 3 Sn.
(d) The transmission and the detection coil systems being decoupled, that may be achieved in one preferred embodiment for instance by arranging the gradiometer coil coaxial and symmetric in the central homogeneous designed area of the field of the transmission coil. Different kinds of appropriate arrangements are feasible too. In another preferred embodiment the detector coil may be constructed of appropriately thin superconducting films. These may be transradiated through by the field pulses of the transmission coil (H 1 ) and the fast gradient field pulses comprised for instance within the Carr-Purcell-Meiboom-Gill pulse sequence (see T. C. Farrar & F. D. Becker: "Pulse and Fourier Transform NMR", Acad. Press, N.Y. (1971)). In a further preferred embodiment of this invention the superconducting detector coil is being driven normal temporary by above field pulses that may be tolerated because of the thermo-stabilization of the detector coil with superfluid helium.
(e) The H 0 -field being produced by an electro and/or superconducting magnet system preferably designed such that it conducts the return-flux of the H 0 -field within a soft-ferro-magnetic yoke (the magnetic circuit connecting the pole faces) which is surrounding and encompassing the field space between pole-faces as much as possible on all sides. By these means, extensive screening off external electromagnetic and magnetic perturbations is being effected. For a perfect stabilization of the H 0 -field its flux may be frozen in by an appropriately designed short-circuited superconducting magnet coil arranged inside of the excitation windings of said magnet system.
(f) Three mutually orthogonal pairs of superconducting short-circuited coils with a low number of windings being rigid attached to the outside of said yoke by non-magnetic supports in a fashion like Helmholtz-coils, such that the fluctuations of all external perturbation fields are compensated, especially during data acquisition times. The yoke and, appropriately, the H 0 -field, experience by these means from the instant on, at which these coils went superconducting, merely the at that instant resultant external field, but entirely constant in time.
(g) The coordinates in space of two or more anatomically prominent points of reference, as for instance vascular bifurcations in the organ of exploration, may be identified by a characteristic appearance of their signal in time and in space by the concomitant current settings for the production of the three slowly variable magnetic field gradients defining the position in space of the resonance volume. Involuntary periodic body movements of that organ or within it may thus be surveyed as function of time and space. Such involuntary periodic body movements are being produced for instance by cardiac action, respiratory movement and peristalsis. An appropriate affine transformation as function of time is derived from these coordinate movements. Spin-echo information obtained at different instances in reference to said body movements is therefore either reduced in geometry by appropriate interpolation to any arbitrary selected time or is depicted arranged according to its sequence in time or both. The position of the control volume in space also may be remotely controlled via this transformation in accordance with these body movements. It is possible by these means to take observations or perform measurements or both at one anatomically precisely defined site for an extended time, as well as to compensate and eliminate or both the effects of uncertain or poor spatial definition due to involuntary periodic body movements.
(h) The coil systems, providing the H 0 -, the H 1 -, as well as both of the gradient fields and the detector coil system, operate at described very low temperatures, preferably in the temperature range of superfluid helium below about 1.85 K. Thus all of these coil systems may be integrated into one single mechanically rigid unit. This is done in order to avoid perturbation effects originating from relative mechanical motions between these coil systems, as for instance, originating from vibrations or natural frequencies. In particular, all coil systems generating and stabilizing the H 0 -field and the detector coil system are operated in the superconducting state, while the transmitting coil system as well as both of the coil systems producing said field gradients are operated in the normal state of conduction being designed preferably out of ultra-high-purity metals, e.g. aluminum. One particular preferred embodiment for technical realization of such an integrated magnet system is being described e.g. in both of the U.S. Pat. Nos. 3,600,281 and 3,894,208, which describe techniques for moulding different coils into one rigid ceramic assembly permeable to superfluid helium
(i) The superconducting primary detection circuit is enclosed with appropriate superconducting materials for electromagnetic shielding, with the exception of the gradiometer coil. The latter itself is short circuited and galvanically decoupled by an appropriate array of fast switching (≧10 -7 s) thin film cryotrons (see Journal of Applied Physics, Vol. 30, p. 1458, 1959) during the transmission time of the individual H 1 -pulses and of gradient field pulses.
(j) The spin-echos are received in an appropriate fashion by the gradiometer coil as transient electromagnetic wave-trains of the pertinent Larmor-frequency ω o modulated in amplitude. These are coupled inductively by a flux-transformer into a microwave biased superconducting quantum intereference device (SQUID) system and are detected with an appropriately fast phase-sensitive detector in quadrature. Preferably a bias frequency in the range between one and a few hundred GHz are chosen as the amplitude of the output signal and the signal-to-noise ratio are increasing proportional to the pump frequency. These frequencies also yield flux transition times in the range of 10 -12 sec/φ o . The SQUID will be operated reflective to guarantee the necessary band width and preferably in the non-hysteric mode tuned off resonance for achieving its maximum flux sensitivity, as described by P. K. Hansma in the Journal of Applied Physics 44/9, p. 4191 (1973).
Further understanding of the present invention may best be obtained from consideration of the accompanying FIG. 2 later on, which discloses the principles of such a system.
Whereas the information obtainable by X-rays is contained in the picture, one may perform in addition to that with the NMR-apparatus according to this invention at any desirable position being depicted specific instantaneous molecular measurements precisely localized and entirely noninvasive. The latter yielding additional differential diagnostic information for instance on the presence of some particular isotopes, on benign and malign structures of tissue, on cellular metabolism, on the bonding state of cellular water and on its hydration at proteins, on the viscosity of intracellular liquids (enchylema), up to a complete hydrodynamic analysis (volume-pressure-time-characteristics, state of flow, velocity distribution and variation of the flow cross section, all as functions of space and time) of blood pulsating in some particular vessel or in the heart.
The distinct advantages of these NMR-methods practiced in accordance with the present invention for bio-physical and diagnostic applications are established: in one respect within their complete noninvasiveness, and on the other hand in the avoidance of any harmful (detrimental) consequences of the stationary and low frequency magnetic fields, as well as of the radio-frequency fields employed for examination. The rf-power absorption within the tissues amounts to about 10 -7 to 10 -9 W/cm 3 . It is therefore a few orders of magnitude smaller than the one being administered by diathermic therapy. The NMR-methods practiced thus according to the present invention facilitate not only the performance of the described molecular structure and kinetic measurements instantaneously to be conducted at any desired location of the human anatomy, but also render the possibility of producing two- and three-dimensional tomographic charts of the distribution of all of these properties in the fashion of zeugmatograms.
BRIEF DESCRIPTION OF THE DRAWINGS
Further understanding of characteristics, advantages and possibilities for application of the present invention may best be obtained from consideration of the accompanying drawings which disclose, in schematic form, a preferred embodiment of the invention:
FIG. 1a is a drawing showing the cross-section of one preferred embodiment of the apparatus according to this invention;
FIG. 1b is a drawing showing in the same view as depicted in FIG. 1a in a schematic fashion the arrangement and orientation of the different fields, produced by the coils of described equipment according to FIG. 1a.
FIG. 2 is a drawing showing a block diagram of the detection circuit of the equipment according to FIG. 1a with a gradiometer-detector-coil; and
FIG. 3 is a drawing, showing a block diagram of the pulse-NMR-spectrometer.
DETAILED DESCRIPTION
To further understanding of the present invention, reference is made to FIG. 1a wherein is shown the arrangement of the different coils for the production of the individual fields in reference to the test person 7. The electromagnet, expediently is laid out as a superconducting system, for generation of the homogeneous magnetic field H 0 in z-direction 8 being extremely constant in time. Its yoke is designated with 1 and its excitation windings by 2. The internal superconducting magnet for the final field stabilization is not shown for preserving the clarity of the drawing. The external superconducting Helmholtz-coil system for the compensation of external field fluctuations are indicated by HCx, HCy and HCz. The coil systems 5 and 4 for the respective generation of the slowly variable field gradients in x-direction and for the fast field gradient pulses in x-direction are also indicated. The analogous coil systems for the production of the corresponding field gradients in the y- and z-directions are not shown for preserving the clarity of the drawing.
In that context, W. Anderson in U.S. Pat. No. 3,199,021 of Aug. 3, 1965 and F. A. Nelson in U.S. Pat. Nos. 3,406,333 of Oct. 15, 1968 and in 3,450,952 of June 17, 1969 and H. E. Weaver, Jr. in U.S. Pat. No. 3,577,067 of May 4, 1971 and G. D. Kneip, Jr. in U.S. Pat. No. 4,173,775 of Nov. 6, 1979 present methods for improving the spatial and/or temporal homogeneity of a magnetic field for high-resolution NMR spectrometers. Superior techniques for achieving the for the application wanted homogeneity and temporal constancy and unperturbedness from the outside are outlined by "the magnetic joke" of the electromagnet, being designated in FIG. 1a with 1, ". . . is designed preferably such, that it forms a field space enclosed as much as possible entirely on all sides", "somewhat alike an iron crate of sufficient wall thickness for the field return flux and the external noise flux", and by ". . . its flux may be frozen in by an appropriately designed, short circuited superconducting magnet coil arranged inside of the excitation windings of said magnet system". Such a superconducting magnet is kept normal until H 0 produced by the electromagnet has reached its operating field strength. When it becomes superconducting it "takes over" the encompassed flux shielding off by compensating currents all field alterations from the outside. An entirely superconducting equivalent magnet system is described in FIG. 1 of the German application No. P 29 51 018.7.
The operation of the Helmholtz like coils for the compensation of all fluctuations in external perturbation fields proceeds analogously to the operation of the superconducting internal magnet, stabilizing (freezing-in) the H 0 field. H 1 is being produced by means of an RF-transmission coil 3. Coils 5 and 4--compare FIG. 1a with 1b--are for generation of the slowly variable field gradients 11 and the fast field gradient pulses 10 in x-direction, respectively. The intended position of the test person 7 within the apparatus in accordance with this invention is indicated in FIG. 1a too. The control volume, the region of observation and measurement, happens to be at the origin of the coordinate system due to the depicted disposition of the slowly variable field gradient 11 at FIG. 1b.
A gradiometer coil 6, in this particular preferred embodiment of the second order, comprises four windings. This arrangement acts like switching in series two gradiometers of the first order in opposition. Three orthogonal small single turn loops are arranged outside the region of influence of both of the field gradients 10 and 11 appropriately switched in series with the gradiometer for compensation of any remaining sensitivity towards fluctuations of external homogeneous magnetic fields in spite of a fabrication employing highest precision. Their sensitivity may be adjusted from the outside by small coaxially movable superconducting shielding cylinders. An array of fast switching (≈10 -7 s) thin film cryotrons A follows further on. It prevents any pick-up current from reaching into the SQUID during transmission times of H 1 -9 and field gradient pulses 10. Simultaneously it terminates the gradiometer dissipative. Super-currents within the gradiometer system, induced by spin-echos during its receiving period (data acquisition), are coupled, preferably, inductively by a flux transformer into the SQUID-detector by the field transfer coil B which, preferably, is toroidally surrounding the weak link (Josephson junction) C, being realized for instance by an appropriate point contact. An as large as possible amplification should preferably be achieved within the flux transfer circuit. Neither the described compensator nor the superconducting screens (which are shielding all electromagnetic and magnetic fields off the flux transformer with exception of said four gradiometer windings and off the compensator) are shown in order to preserve the clarity of the drawing.
J. P. Wikswo, Jr. describes in U.S. Pat. No. 3,980,076 of Sept. 14, 1976 a very sensitive technique for slow magnetic susceptibility changes, i.e. a very low frequency technique in which the gradiometer is being used to differentiate between an external inhomogeneous signal and an external homogeneous noise, both of very low frequency. This measurement is not NMR at all. In this invention, the gradiometer is being used to differentiate between an internal inhomogeneous rf-signal and an external homogeneous noise as well as for eliminating any induction from the rf-pulses from the transmission coil. This is a novel application for a gradiometer.
Further on the detection circuit comprises essentially in accordance with FIG. 2 a microwave generator 12 (klystron or gunn-oscilaltor), supplying microwave power for instance in the range of 10 -9 W via an attenuator 13, an isolator 14, a directional coupler 15 or such as a Josephson junction, externally dc-biasing a complementary junction or such as a dc-SQUID and suitable amplification, for example, with a GaAs-FET and an appropriate impedance transformer 16 preferably as a near optimum taper (see "Applied Physics", vol. 14, p. 161,1977) to the SQUID. Its point contact preferably may be generated of an adjustable Nb-point against a Nb-flat anvil. The microwaves reflected from the SQUID may for instance be amplified by tunnel-diode amplifiers 17, then rectified by a Schottky diode 18 and detected by a phase sensitive detector 19 preferably in quadrature. All microwave components being at least plated on their inside with appropriate superconductors, but preferably being produced of such metals, like for instance Nb or Nb 3 Sn, will be operated in accordance with this invention, with possibly the only exception of the generator 12, at temperatures within the range of their superconductivity but in particular at temperatures below 1.85 K, in order to reduce noise and thermal radiation effects to a minimum. The SQUID preferably operates in the non-hysteric mode tuned off resonance for achieving its maximum flux sensitivity. The compensation described in "Applied Physics", Vol. 14, p. 161 (1977) may be introduced into said microwave system in order to reduce system noise further on. The terminating impedances of this microwave system are at least refrigerated by helium vapor. The entire detection circuit is appropriately shielded from electromagnetic radiation by superconducting materials.
The pulse-NMR-spectrometer is shown schematically in FIG. 3. The dashed line 23 comprises the probe, encompassing the rf transmission coil 3, the detection coil 6, the sample 7 (e.g. the test person or patient), three pairs of coils 5 for the generation of the slowly variable field gradients 11 and three pairs of coils 4 for the generation of the fast field gradient pulses 10; both in either of the three directions x, y and z of a Cartesian co-ordinate system indicated at FIGS. 1a and 1b, respectively. This probe 23 is exposed to the homogeneous, in space and in time constant magnetic field in z-direction 8. As in standard pulse-NMR-spectrometers, the sample is subjected to a sequence of rf-pulses of appropriate energy and duration, e.g. a Meiboom-Gill-sequence as described in Rev. Sci. Intsr. 29, 688 (1958), from a standard rf-transmitter 24 via the transmission coil 3. The frequency of this rf radiation 9 is chosen with regard to the strength of the homogeneous field 8 in order to excite one desired magnetic resonance of one particular nuclide (e.g. protons or p 31 ) within the sample 7.
The probe 23 also contains an rf detection coil 6, e.g. a gradiometer coil, which will pick up the rf radiation (the spin-echos) emanating from that sample 7 due to above described excitation of NMR within that sample 7. This signal is amplified within rf receiver 25, whose pre-amplifier leading up to a phase sensitive detector 19 is shown in FIG. 2. A gating circuit which turns off the signal receiving during those periods when rf pulses or fast field gradient pulses are being transmitted is not shown in the drawing in detail.
The probe 23 also contains three pairs of coils 5 for subjecting the sample 7 to inhomogeneous magnetic fields 11, being slowly variable in space and time, superimposed on that homogeneous field 8. The variation in space and time of these gradient fields 11, operated by their control circuit 26, is such that but one particular chosen localized small volume remains unperturbed at the value of the homogeneous magnetic field 8 during one of the above mentioned rf pulse sequences and their concomitant spin-echo sequence. By these means the resonance signals (spin-echoes) being received are originating only from that localized unperturbed small volume of observation, being designated therefore as the control volume, the resonance volume or the "sensitive point". One particular method for operating such slowly variable field gradients is described by W. S. Hinshaw in J. Appl. Phys. 47/8, 3709 (1976).
Second and higher order field gradients are superimposed on that homogeneous field 8 instead of above linear field gradients by appropriately designed coils 5 in order to obtain a small but well defined volume of resonance, in particular having a small homogeneous field region at its center with edges at which the field changes rapidly. By these means it becomes feasible not only to apply the two-pulse π/2-π-pulse sequence to that resonance volume for obtaining one spin-echo from whose amplitude the spin density of some particular nuclide may be determined, e.g. the density of protons, C 13 , F 19 , Na 23 or P 31 , respectively, within said resonance volume. One may also apply multiple pulse sequences alike above mentioned Meiboom-Gill sequence to that resonance volume for the determination of the relaxation times. By inverse convolution with the appropriate field function NMR-spectra can be derived from such relaxation measurements.
Furthermore, one may superimpose an appropriate linear field gradient, being constant in space and time for the duration of one multi-pulse sequence on above in space and time slowly variable higher order field gradients. By these means a resonance volume having such a linear field gradient in one particular direction of space results. This provides the opportunity for the determination of the diffusion coefficient in that direction by the application of a multi-pulse π/2-π-π- . . . sequence as described for instance by Carr and Purcell in Phys. Rev. 94, 630 (1954). By these means the components of the diffusion tensor may be determined too.
Furthermore, from the contraction (transformation) which above spin-spin-relaxation function, produced preferentially by a multi-pulse Meiboom-Gill sequence, experiences due to coherent flow within said resonance volume the hydrodynamic state of motion of that fluid may be determined, as explained later on.
Furthermore, a sequence of short, preferentially of linear field gradient pulses yielding a field gradient in some fixed direction of the space may be superimposed on the resonance volume having a small homogeneous field region at its center simultaneously with a Meiboom-Gill multi-pulse sequence in such a manner that the first field gradient pulse is interposed between the initial π/2-pulse and the first π-pulse and the following field gradient pulses are each interposed between π-pulses and spin-echoes in a fashion as described by Stejskal and Tanner in J. Chem. Phys. 42/1, 288 (1965). By these means improved diffusion and flow measurements may be conducted. This sequence of field gradient pulses of short duration is produced by the pulse field gradient controls 27 and superimposed by three sets of each two fast field gradient pulse coils 4.
The compensation of involuntary periodic motions within (of) the patient starts from the fact that the current settings within the 3 pairs of coils for the generation of the slowly variable field gradients in the x-, y- and z-direction, designated by 5 in FIG. 1a, are directly correlated with the position and the size of the sensitive volume, the resonance volume or the point of observation. The knowledge of these currents in regard to any particular object under observation is therefore a measure of the objects coordinates in reference to the magnet, their changes with time a measure of the objects motion. Such an object has to emit a characteristic signal by which its presence within the sensitive volume becomes known, e.g. a characteristic peaking of the signals amplitude e.g. whenever a certain vascular bifurcation passes through the sensitive volume. Observing such objects for some time one may establish the periodicity of their individual motion. From such information one may extrapolate for the position of that object at any wanted time in the near future and for the associated coordinates and current settings. Thus one may place the point of observation at a predetermined position to take a measurement at a certain predetermined time, when the object in its periodic motion just passes through that position.
In the event that the object under observation is conducting a complex periodic motion in space, e.g. the expanding and contracting heart, then one needs to record the periodic motions of more than one of e.g. four reference points in order to derive the necessary mathematical equations describing the periodic motion of some other particular point at which a desired NMR-measurement is to be taken. In principle it is always possible either to determine ahead ot time the time a certain point passes through predetermined coordinates in its periodic motion or to follow in time the periodic motion of such a point itself, if one has arrived at a description of its periodic motion. Thus compensation for or elimination of involuntary motions may be effected by the observation of such regions.
The medical significance of an apparatus operating in accordance with the present invention is not only due to the attainable improvement in the quality of pictures and in the resolution of tomograms (zeugmatograms) depicting the topography of organs, blood-vessels, nerves, tissue and bones as well as of tumors, carcinoma and their metastases, of angiograms for instance of the cardiocoronaries or cerebral vasculature by means of variations in the spin density of protons and by means of their bonding state yielding variations in their relaxation times. But also possibilities are being provided to study quantitatively on one single patient individual correlations on local variations in relaxation times with physiological and pathological findings, for instance, for an early differential diagnosis of diverse carcinoma. Analogous attempts have been conducted to diagnose pulmonary oedema (see "Clinical Research" 24/3, p. 217A (1976) and "Physics in Canada", vol. 32, p. 33.9 (1976)).
Furthermore, the feasibility for observing in very small regions relaxation times, diffusion and spectra, by inverse convolution of the appropriate field function with the relaxation function, is to be expected for in-vivo studies of the cyto-metabolism and the innervation of neurones due to the enhancement of the sensitivity and of the signal-to-noise ratio in consequence of the low temperatures applied in accordance with the present invention. Analogous experiments, most of them in-vitro, have been conducted not only on protons (H 1 ) but also on H 2 , H 3L , C 13 , F 19 , Na 23 and P 31 -nuclei (see "NMR in Biology", ed. R. A. Dwek et al., Academic Press (1977)). The possibility to determine from one single measurement in an appropriate arrangement the coordinates in space, thus the direction and distance in space from which the observed excited rf-radiation is emanating, and the strength and the orientation in space of the dipole being equivalent to said source of rf-radiation, will be of decisive advantage. This is being utilized for instance at the observation of the vector magneto-cardiogram and the magneto-encephalogram. Such NMR-nuclei may make functional diagnostics appear feasible even in cases where a localization diagnostics does not produce any obvious pathological findings. Consequently, a diagnosis of osteoporosis appears feasible. This disease is characterized by a strong reduction of the volumetric density of the spongiosa in individual bones. Proceeding along with it is a strong local reduction on apatite 3Ca 3 (PO 4 ) 2 .Ca(Cl,F) 2 within the diseased bones in comparison with healthy ones in the same patient. The local variations on apatite may be analyzed quantitatively with the aid of F 19 and P 31 density distributions. It would be very advantageous for observations to cellular metabolism if K 39 and I 127 and possibly Li 7 also coulbe be added to the above mentioned NMR-indicators. In other experiments observations were already made with the aid of N 15 ,O 17 ,Al 27 ,Si 29 ,Cl 35 ,CD 113 ,Sn 119 and Pb 207 .
It has been demonstrated by means of H 1 -, C 13 - and P 31 -NMR, the lipid-bilayer of biological membranes to be a fluid system yet with highly anisotropic diffusion characteristics. At present the protein-lipid-boundary-layer interactions applying sophisticated spin-echo pulse sequences are being studied (see "Physical Review", vol. 185, p. 420 (1969)) in order to gain some insight into their selective permeability and their biochemical and physiological functions as well as into the mitochondrial electron transport and nervous conduction (in-nervations). Investigations have been made with the aid of P 31 -NMR-spectroscopy into the energy-transformation in physiological intact systems as for instance perfused muscles, heart or kidney by analysing the metabolism on hand of the catabolism (metabolite turnover) of ATP (adenosine triphosphate) in diverse "intact", "anoxic" and "ischaemic" conditions from the equilibria assumed (as a function of time) by the different metabolites as for instance phospho-creatine, inorganic phosphate, sugar phosphate and as of yet not identified resonances. The possibility of determining the hydrogen ion concentration (pH-value) within the cellular vicinity of the observed components by means of the applied NMR-methods have proved to be of particular advantage. The experiments with organs perfused by living animals has drawn attention to the possibility of performing with the equipment according to this invention on patients noninvasive in-vivo functional differential diagnostics of the metabolism of individual organs or of parts of it in order to diagnose dysfunction or cancer, or to observe the progress of an organ transplanation, or to validate the course of therapeutic measures with the aid of some pharmacon labeled by some particular NMR-indicator becoming effective and traceable locally in a particular organ.
The distinct differences in the relaxation times of circulating (flowing) blood and tissue create the possibility for generating not only NMR-tomographic pictures of the distribution of tissues within individual organs, as for instances, of the heart, or parts of the body as the head, but also of depicting their vascular systems such as in an angiogram.
With the equipment according to the present invention, the possibility exists of scanning the region of exploration in three dimentsions with the control volume. With appropriate information of that kind, for instance, an isometric projection of a three-dimensional angiogram may be constructed. Such could be a valuable tool for finding endangered areas of blood vessels, such as stenoses or aneurysms. That would be of particular value for an early diagnosis of arteriosclerosis. At these areas of such a blood vessel the in the following described hydrodynamic (fluid mechanics) measurements may be performed for arriving at a differential diagnosis of that circulatory disturbance. The same observations may be conducted for validation of therapeutic measures and medical screening and check-ups.
A further application of the apparatus in accordance with the present invention is based on recording the effluence-interferogram weighted by quantity of a spin population being Larmor-phase-coherent at the labeling time in an inhomogeneous magnetic field defined in space and time and belonging to a fluid discharging from its labeling field H 1 with differing velocities in a laminar or turbulent state of flow under stationary or pulsating conditions. That is an entirely novel technique for a complete hydrodynamic analysis of any streaming fluid, requiring no callbrations.
The NMR-experiment for the hydrodynamic analysis consists of a standard spin-spin relaxation determination by the application of a Meiboom-Gill-sequence (S. Meiboom and D. Gill: Rev. Sci. Instr. 29/8, 688 (1958)) to a flowing medium. This sequence is applied in the appended FIG. 2 to a stationary medium, while in FIGS. 1 and 3 the contraction transformation of the previous exponential decay brought about by the flowing medium is clearly visible. The initial amplitude of this signal is proportional to the number of the initially by the π/2-pulse labled spins, and therefore to the density of nuclides too. Its amplitude as function of time is proportional to the number of labeled spins still present at that particular time within the detection coil. An integral transform alike a Fourier transform displays the number of spins travelling at each velocity, the velocity spectrum (m(v)=dm/dv as function of v). Turbulence is detected from an analysis of an additional attenuation within that signal. The further evaluation of a single velocity spectrum as well as of a sequence of such in terms of its hydrodynamic information is explained further on.
By simple integration over this velocity spectrum is determined the initially the control volume occupying quantity of streaming fluid according to (with m the number of spins or the mass and v the velocity): ##EQU1## and the instantaneous mass flow rate (or analogous the instantaneous volume flow rate, the instantaneous within the unit of time through a certain cross section flowing blood volume) according to: ##EQU2## The instantaneous flow cross section or vascular cross section F follows accordingly: ##EQU3## with ρ the density of the blood and v its mean velocity, to be determined from the velocity spectrum.
Decisive for the evaluation of the transformed spin-spin relaxation function, diminished by the flow condition (hydrodynamic state) is the in-vivo measurement of the spin-lattice relaxation time of the blood circulating in the vessel under observation. Such may be derived from the attenuation of nutation pulses applied to the nuclear magnetization in adaptation of a method proposed by Zhernovoi and Latyshev in "Nuclear Magnetic Resonance in a Flowing Liquid", p. 132, Plenum Press (1965).
The hydrodynamics of the pulsatile circulating blood may be analysed by taking a sequence of rapidly each other succeeding spin-spin relaxation functions, yielding the instantaneous integral state of flow within observation times being short in comparison with 0.1 s therefore being independent of the transient motion of the observed fluid. The instantaneous velocity distributions as function of the pulsation yield the pulsating volume flow rate i of the circulating blood in the observed vessel. Its pulsating cross section F may be derived from these data as function of time. These again are yielding in turn the pulse wave rate c w , the wave volume flow rate i w and the volume modulus of elasticity χ
χ=ρ·c.sub.w.sup.2
The wave resistance, the impedance, ##EQU4## establishes the absolute systolic pressure ##EQU5##
The wave volume flow rate i w is equivalent with the cardiac systolic discharge volume observing the aorta ascendens. Analogously the entire pressure-volume-time-characteristics of the heart (aorta) or any particular blood vessel may be determined in-vivo completely noninvasive from such a sequence of instantaneous integral state of flow measurements.
While specific embodiments of the inventions have been shown and described in detail to illustrate the application of the principles of the inventions, it will be understood that the inventions may be embodied otherwise without departing from such principles.
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This invention relates to methods and means for improving the sensitivity and signal-to-noise ratio of spin-echo measurements on samples, which have to remain at their own temperature and which have a non-negligible electrical conductivity. These are applied to noninvasive, localized, in vivo examinations of endogeneous tissue, organs, bones, nerves and circulating blood in the course of medical check-ups as well as for differential diagnostics and for the validation of therapeutic measures. This equipment comprises a system of magnets and an arrangement of transmitting and receiving coils encompassing the test person (patient) preferably completely, but at least the region of exploration. Means for the excitation as well as specialized low temperature equipment for the detection of NMR-signals emanating from a very small subregion are provided.
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This application is a division of application Ser. No. 08/338,018 filed Nov. 10, 1994, now pending.
FIELD OF THE INVENTION
This invention is a surgical device. In particular, it is a catheter suitable for accessing a tissue target within the body, typically a target which is accessible through the vascular system. Central to the invention is the use of a stiffener ribbon, typically metallic, wound within the catheter body in such a way to create a catheter having an exceptionally thin wall and controlled stiffness. The stiffener ribbon is adhesively bonded to a flexible outer tubing member so to produce a catheter section which is very flexible but highly kink resistant.
The catheter sections made according to this invention may be used in conjunction with other catheter sections either using the concepts shown herein or made in other ways. Because of the effective strength and ability to retain a generally kink-free form, these catheters may be effectively used in sizes which are quite fine, e.g., 0.015" to 0.020" in diameter, and usable within typical vascular catheters.
BACKGROUND OF THE INVENTION
Catheters are increasingly used to access remote regions of the human body and, in doing so, delivering diagnostic or therapeutic agents to those sites. In particular, catheters which use the circulatory system as the pathway to these treatment sites are especially practical. Catheters are also used to access other regions of the body, e.g., genito-urinary regions, for a variety of therapeutic and diagnostic reasons. One such treatment of diseases of the circulatory system is via angioplasty (PCTA). Such a procedure uses catheters having balloons on their distal tips. It is similarly common that those catheters are used to deliver a radiopaque agent to the site in question prior to the PCTA procedure to view the problem prior to treatment.
Often the target which one desires to access by catheter is within a soft tissue such as the liver or the brain. These are difficult sites to reach. The catheter must be introduced through a large artery such as those found in the groin or in the neck and then be passed through ever-narrower regions of the arterial system until the catheter reaches the selected site. Often such pathways will wind back upon themselves in a multi-looped path. These catheters are difficult to design and to utilize in that they must be fairly stiff at their proximal end so to allow the pushing and manipulation of the catheter as it progresses through the body, and yet must be sufficiently flexible at the distal end to allow passage of the catheter tip through the loops and increasingly smaller blood vessels mentioned above and yet at the same time not cause significant trauma to the blood vessel or to the surrounding tissue. Further details on the problems and an early, but yet effective, way of designing a catheter for such a traversal may be found in U.S. Pat. No. 4,739,768, to Engelson. These catheters are designed to be used with a guidewire. A guidewire is simply a wire, typically of very sophisticated design, which is the "scout" for the catheter. The catheter fits over and slides along the guidewire as it passes through the vasculature. Said another way, the guidewire is used to select the proper path through the vasculature with the urging of the attending physician and the catheter slides along behind once the proper path is established.
There are other ways of causing a catheter to proceed through the human vasculature to a selected site, but a guidewire-aided catheter is considered to be both quite quick and somewhat more accurate than the other procedures. One such alternative procedure is the use of a flow-directed catheter. These devices often have a small balloon situated on the distal end of the catheter which may be alternately deflated and inflated as the need to select a route for the catheter is encountered.
This invention is an adaptable one and may be used in a variety of catheter formats. The invention utilizes the concept of adhesively combining one or more polymeric tubes with one or more spirally wound ribbons (each wound in the same direction) to control the stiffness of the resultant catheter section or body. The construction technique allows the production of catheter sections having very small diameters--diameters so small that the secondary catheters may be used interior to other vascular catheters, with or without guidewires. This catheter may be used in conjunction with a guidewire, but the catheter body may also be used as a flow-directed catheter with the attachment of a balloon or in combination with a specifically flexible tip, as is seen, for instance, in U.S. Pat. No. 5,336,205 to Zenzen et al., the entirety of which is incorporated by reference.
The use of ribbons in winding a catheter body is not a novel concept. Typical background patents are discussed below. However, none of these documents have used my concept to produce a catheter which has the physical capabilities of the catheter of this invention.
Multi-Wrap Catheters
There are a number of catheters discussed in the literature which utilize catheter bodies having multiply wrapped reinforcing material. These catheters include structures having braided bands or ones in which the spirally wound material is simply wound in one direction and the following layer or layers are wound in the other.
Crippendorf, U.S. Pat. No. 2,437,542, describes a "catheter-type instrument" which is typically used as a ureteral or urethral catheter. The physical design is said to be one having a distal section of greater flexibility and a proximal section of lesser flexibility. The device is made of intertwined threads of silk, cotton, or some synthetic fiber. It is made by impregnating a fabric-based tube with a stiffening medium which renders the tube stiff yet flexible. The thus-plasticized tubing is then dipped in some other medium to allow the formation of a flexible varnish-like layer. This latter material may be a tung oil base or a phenolic resin and a suitable plasticizer. There is no indication that this device is of the flexibility described herein. Additionally, it appears to be the type which is used in some region other than in the body's periphery or in its soft tissues.
Similarly, U.S. Pat. No. 3,416,531, to Edwards, shows a catheter having braiding-edge walls. The device further has additional layers of other polymers such as TEFLON and the like. The strands found in the braiding in the walls appear to be threads having circular cross-sections. There is no suggestion of constructing a device using ribbon materials. Furthermore, the device is shown to be fairly stiff in that it is designed so that it may be bent using a fairly large handle at its proximal end.
U.S. Pat. No. 3,924,632, to Cook, shows a catheter body utilizing fiberglass bands wrapped spirally for the length of the catheter. As is shown in FIG. 2 and the explanation of the FIG. at column 3, lines 12 and following, the catheter uses fiberglass bands which are braided, that is to say, bands which are spiralled in one direction cross over and under bands which are spiraled in the opposite direction. Additionally, it should be observed that FIG. 3 depicts a catheter shaft having both an inner lining or core 30 and an outer tube 35.
U.S. Pat. No. 4,425,919, to Alston, Jr. et al., shows a multilayered catheter assembly using multi-stranded flat wire braid. The braid 14 in FIG. 3 further covers an interior tubing or substrate 12.
U.S. Pat. No. 4,484,586 shows a method for the production of a hollow, conductive medical tubing. The conductive wires are placed in the walls of hollow tubing specifically for implantation in the human body, particularly for pacemaker leads. The tubing is preferably made of an annealed copper wire which has been coated with a body-compatible polymer such as a polyurethane or a silicone. After coating, the copper wire is wound into a tube. The wound substrate is then coated with still another polymer to produce a tubing having spiral conducting wires in its wall.
A document showing the use of a helically wound ribbon of flexible material in a catheter is U.S. Pat. No. 4,516,972, to Samson. This device is a guiding catheter and it may be produced from one or more wound ribbons. The preferred ribbon is an aramid material known as Kevlar 49. Again, this device is a device which must be fairly stiff. It is a device which is designed to take a "set" and remain in a particular configuration as another catheter is passed through it. It must be soft enough so as not to cause substantial trauma, but it is certainly not for use with a guidewire. It would not meet the flexibility criteria required of the inventive catheter described herein.
U.S. Pat. No. 4,806,182, to Rydell et al, shows a device using a stainless steel braid imbedded in its wall and having an inner layer of a polyfluorocarbon. The process also described therein is a way to laminate the polyfluorocarbon to a polyurethane inner layer so as to prevent delamination.
U.S. Pat. No. 4,832,681, to Lenck, shows a method and apparatus useful for artificial fertilization. The device itself is a long portion of tubing which, depending upon its specific materials of construction, may be made somewhat stiffer by the addition of a spiral reinforcement comprising stainless steel wire.
U.S. Pat. No. 4,981,478, to Evard et al., discloses a multi-sectioned or composite vascular catheter. The interior section of the catheter appears to have three sections making up the shaft. The most interior (and distal) section, 47, appears to be a pair of coils 13 and 24 having a polymeric tubing member 21 placed within it. The next, more proximal, section is 41, and FIG. 4 shows it to be "wrapped or braided" about the next inner layer discussed just above. The drawing does not show it to be braided but, instead, a series of spirally wrapped individual strands. Finally, the outermost tubular section of this catheter core is another fiber layer 49, of similar construction to the middle section 26 discussed just above. No suggestion is made that any of these multiple layers be simplified into a single, spirally-wrapped layer adhesively bound to an outer polymeric covering.
Another catheter showing the use of braided wire is shown in U.S. Pat. No. 5,037,404, to Gold et al. Mention is made in Gold et al of the concept of varying the pitch angle between wound strands so to result in a device having differing flexibilities at differing portions of the device. The differing flexibilities are caused by the difference in pitch angle. No mention is made of the use of ribbon, nor is any specific mention made of the particular uses to which the Gold et al. device may be placed.
U.S. Pat. No. 5,057,092, to Webster, Jr., shows a catheter device used to monitor cardiovascular electrical activity or to electrically stimulate the heart. The catheter uses braided helical members having a high modulus of elasticity, e.g., stainless steel. The braid is a fairly complicated, multi-component pattern shown very well in FIG. 2.
U.S. Pat. No. 5,176,660 shows the production of catheters having reinforcing strands in their sheath wall. The metallic strands are wound throughout the tubular sheath in a helical crossing pattern so to produce a substantially stronger sheath. The reinforcing filaments are used to increase the longitudinal stiffness of the catheter for good "pushability". The device appears to be quite strong and is wound at a tension of about 250,000 lb./in. 2 or more. The flat strands themselves are said to have a width of between 0.006 and 0.020 inches and a thickness of 0.0015 and 0.004 inches. There is no suggestion to use these concepts in devices having the flexibility and other configurations described below.
Another variation which utilizes a catheter wall having helically placed liquid crystal fibrils is found in U.S. Pat. No. 5,248,305, to Zdrahala. The catheter body is extruded through an annular die, having relatively rotating inner and outer mandrel dies. In this way, the tube containing the liquid crystal polymer plastic-containing material exhibits a bit of circumferential orientation due to the rotating die parts. At column 2, line 40 and following, the patent suggests that the rotation rate of the inner and outer walls of the die may be varied as the tube is extruded, with the result that various sections of the extruded tube exhibit differing stiffnesses.
U.S. Pat. No. 5,217,482 shows a balloon catheter having a stainless steel hypotube catheter shaft and a distal balloon. Certain sections of the device shown in the patent use a spiral ribbon of stainless steel secured to the outer sleeve by a suitable adhesive to act as a transition section from a section of very high stiffness to a section of comparatively low stiffness.
Japanese Kokai 05-220,225, owned by the Terumo Corporation, describes a catheter in which the torsional rigidity of the main body is varied by incorporating onto an inner tubular section 33, a wire layer which is tightly knitted at the proximal section of the catheter and more loosely knitted at a midsection.
Single-Layer. Reinforced Catheters
There are a variety of catheters which, unlike the devices discussed above, utilize but a single layer of reinforcing material.
For instance, U.S. Pat. No. 243,396 to Pfarre, patented in June of 1881, shows the use of a surgical tube having a wire helix situated within the tube wall. The wire helix is said to be vulcanized into the cover of the device.
U.S. Pat. No. 2,211,975, to Hendrickson, shows a similar device also comprising a stainless steel wire 15 embedded in the inner wall of a rubber catheter.
U.S. Pat. No. 3,757,768, to de Toledo, shows a "unitary, combined spring guide-catheter that includes an inner wall portion formed as a continuous helical spring with the helices in contact with each other and an outer wall portion formed from an inert plastic material enclosing the spring in such a manner as to become firmly bonded to the spring while having its outer surface smooth". There is no suggestion to separate the windings of the coil in any fashion.
U.S. Pat. No. 4,430,083 describes a catheter used for percutaneous administration of a thrombolytic agent directly to a clot in a coronary artery. The device itself is an elongated, flexible tube supported by helically wound wire having a specific cross-sectional shape. The wire is wound into a series of tight, contiguous coils to allow heat shrinking of tubing onto the outside of the wire of the shape of the outer surface of the wire as wound into the helix-provides the heat-shrunk tubing with footing for a tight fit.
U.S. Pat. No. 4,567,024, to Coneys, shows a catheter which employs a set of helical strips within the wall of the catheter. However, the helical strips are of a radiopaque material, e.g., fluorinated ethylenepropylene. It is not clear that the blended radiopaque material necessarily provides any physical benefit other than the ability to allow the catheter shaft to be seen when viewed with a fluoroscope.
U.S. Pat. No. 4,737,153, to Shimamura et al., describes a device which is characterized as a "reinforced therapeutic tube" and which uses a spiral reinforcing material embedded within the wall of the device.
U.S. Pat. No. 5,069,674, to Fearnot et al. (and its parent, U.S. Pat. No. 4,985,022), shows a small diameter epidural catheter having a distal tip made up of a stainless steel wire which is helically wound and placed within a tubular sheath or tube. There is no suggestion within the patent that the interior coil be made to adhere to the outer tubular sheath.
Similarly, U.S. Pat. No. 5,178,158, to de Toledo, shows what is characterized as a "convertible wire for use as a guidewire or catheter". The patent describes a structure which comprises an interior wire or spring section shown, in the drawings, to be of generally rectangular cross-section. Outer layers of the device include a polyamide sheath placed adjacent to the helical coil at the proximal end of the catheter (see column 4, lines 64 and following). The device also comprises an outer sheath 40 of Teflon that extends from the proximal end 12 to the distal end 14 of the device. The overlying sheath 40 may extend or overhang at the proximal or the distal end of the catheter. The distal tip portion 13 is said to be "flexible, soft, and floppy". There is no suggestion of utilizing an adhesive to bond the interior wire to the exterior tubing. The PCT Published Application corresponding to this patent is WO 92/07507.
U.S. Pat. 5,184,627 shows a guidewire suitable for infusion of medicaments to various sites along the guidewire. The guidewire is made up of a helically wound coil having a polyamide sheath enclosing its proximal portion and a Teflon sheath tightly covering the entire wire coil. The coil is closed at its distal end. There is no suggestion that the wire forming the helical core be adhesively attached to its outer coverings.
U.S. Pat. No. 5,313,967, to Lieber et al., shows a medical device a portion of which is a helical coil which, apparently, may include an outer plastic sheath in some variations. Apparently, a secondary helix of a somewhat similar design, in that it is formed by rotating a flat wire or the like along its longitudinal axis to form a screw-like configuration, is included within the helical coil to provide axial pushability and torque transmission.
The PCT application, WO 93/15785, to Sutton et al., describes kink-resistant tubing made up of a thin layer of an encapsulating material and a reinforcing coil. As is shown in the drawings, the supporting material is embedded within the wall of the tubing in each instance.
The PCT application bearing the number WO 93/05842, to Shin et al., shows a ribbon-wrapped catheter. The device is shown as a section of a dilatation catheter. The inner section 34 is a helically wound coil and is preferably a flat wire. See, page 6, lines 25 and following. The coil is then wrapped with a heat-shrunk jacket 34 formed of low-density polyethylene. A lubricious material such as a silicone coating may then be placed on the inner surface of the spring coil to "enhance handling of the guidewire". It is also said, on page 6 of the document, that the "entire spring coil, before it is wound or jacketed, may be coated with other materials such as Teflon to enhance lubricity or provide other advantages. In some embodiments, the spring coil has been plated with gold." The document does not suggest that the coil be made to adhere to the outer polymeric jacket using an adhesive.
Endoscope Structures
Various endoscopic structures, used primarily in sizes which are larger than endovascular catheters utilize structures including stiffener materials.
U.S. Pat. No. 4,676,229, to Krasnicki et al., describes an endoscopic structure 30 having an ultrathin walled tubular substrate 31 formed of a lubricious material such as TEFLON. The structure contains a filament supported substrate. The filament is coated with and embedded into a filler material, typically an elastomeric material. A highly lubricious outer coating 35, all as shown in FIG. 2, forms the outer layer of the device. FIG. 3 in Krasnicki et al., describes another variation of the endoscopic device in which a different selection of polymer tubing is utilized but the placement of the filamentary support remains varied in an intermediate material of an elastomer. In some variations of the device, the filament is strongly bonded to the inner tubular substrate using an adhesive 37 "such as an epoxy cement having sufficient bond strength to hold the filament to the substrate as it is deformed into a tight radius." See, column 3, lines 50 and following.
U.S. Pat. No. 4,899,787, to Ouchi et al. (and its foreign relative, German Offenlegungshrifft DE-3242449) describes a flexible tube for use in an endoscope having a flexible, basic tubular core structure made up of three parts. The three parts are an outer meshwork tube, an intermediate thermoplastic resin tube bonded to the outer meshwork tube, and an inner ribbon made of a stainless steel or the like which is adherent to the two polymeric and meshwork tubes such that the resin tube maintains an adherent compressive pressure in the finished flexible tube. The patent also suggests the production of an endoscope tube having "flexibility which varies in step-wise manner from one end of the tube to the other . . . and is produced! by integrally bonding two or more thermoplastic resin tube sections formed of respective resin materials having different hardnesses to outer surface of the tubular core structure . . .". See, column 2, lines 48 and following.
U.S. Pat. No. 5,180,376 describes an introducer sheath utilizing a thin, flat wire metal coil surrounded only on its exterior surface with a plastic tube of coating. The flat wire coil is placed there to lower the "resistance of the sheath to buckling while minimizing the wall thickness of the sheath." A variation using two counter-wound metal ribbons is also described. No suggestion of the use of an adhesive is made in the patent.
European Patent Application 0,098,100 describes a flexible tube for an endoscope which uses a helically wound metallic strip having a braided covering contiguous to the outer surface of the coil and having still further out a polymeric coating 9. Interior to the coil is a pair of slender flexible sheaths which are secured to a "front-end piece 10" by soldering.
Japanese Kokai 2-283,346, describes a flexible endoscope tube. The tubular outer shell is made up of two layers of a high molecular weight laminated material. The tube also has an inner layer of an elastic material and interior to it all is a metallic ribbon providing stiffening.
Japanese Kokai 03-023830, also shows the skin for flexible tube used in an endoscope which is made up of a braid 3 prepared by knitting a fine wire of a metal with a flexible portion 2 which is prepared by spirally winding an elastic belt sheet-like material and a skin 4 with which the whole outer surface of the device is covered. The document appears to emphasize the use of a particular polyester elastomer.
Japanese Kokai 5-56,910, appears to show a multi-layered endoscope tube made up of layers of the spiral wound metallic ribbon covered by a polymeric sheath.
French Patent Document 2,613,231, describes a medical probe used with an endoscope or for some other device used to stimulate the heart. The device appears to be a helix having a spacing between 0 and 0.25 mm (See page 4, line 20) preferably rectangular in cross section (See Page 4, Line 1) and of a multi-phase alloy such as M35N, SYNTACOBEN, or ELGELOY (See Page 4).
German Offenlegungshrifft DE-3642107 describes an endoscope tube, formed of a spiral tube, a braid formed of fibers interwoven into a net (which braid is fitted on the outer peripheral surface of the spiral tube), and a sheath covering the outer peripheral surface of the braid.
None of the noted devices have the structure required by the claims recited herein.
Other Anti-kinking Configurations
U.S. Pat. No. 5,222,949, to Kaldany, describes a tube in which a number-of circumferential bands are placed at regular intervals along a catheter shaft. The bands may be integrated into the wall of the catheter. A variety of methods for producing the bands in the tubular wall are discussed. These methods include periodically irradiating the wall to produce bands of a higher integral of cross-linking.
European Patent Application No. 0,421,650-A1 describes a method for producing a catheter from a roll of polymer film while incorporating other materials such as tinfoil elements or the like.
None of the documents cited above provides a structure required by the disclosure and claims recited below, particularly when the flexibility and ability to resist kinks is factored into the physical description of the devices.
SUMMARY OF THE INVENTION
This invention is a catheter section made up of one or more spirally wound stiffener ribbons adhesively attached to an outer polymeric covering.
The stiffener ribbon is, in its most basic form, a single strand of ribbon wound in a single direction. A number of ribbons of the same or differing sizes and compositions may also be used, but such ribbons are wound the same direction to form a single layer of ribbon and form a lumen from the distal to the proximal end of the catheter section. The ribbons are typically metallic but may be of other materials. I have found that a necessary portion of the invention is the requirement that the ribbons adhere to the outer covering. In this way, the kink resistance of the catheter section is established due to the lack of slippage between the cover and the spiral coil. The outer cover, in the regions between coil turns, retains a high level of patency. The absence of slippage prevents the formation of localized areas of larger spacing between coil turns and the resulting source of kinking sites.
The catheter sections of this invention may be formed into an integral catheter assembly. Wise choices of materials permit the catheter to be of a smaller overall diameter with a superior critical diameter. Indeed, one variation of this invention involves telescoping catheters with an inner catheter of this construction, perhaps with an inner guidewire. The catheter may be designed to integrate lubricious materials into the base design of a particular catheter product without adding extraneous thickness and stiffness The catheter may be wholly constructed of materials which are stable to radioactive sterilization procedures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows, in side view, a typical three section catheter.
FIG. 2 shows, in magnification, a section of the inner portion of one inventive section of this catheter.
FIG. 3 shows, in magnification and cross-section, a variation of the invention using two ribbons.
FIG. 4 shows, in magnified fractional view, a multisection catheter assembly.
FIGS. 5-8 show, in magnified cross-section, various catheters having sections of differing stiffness.
FIG. 9 shows, in cross-section, a combination of outer and inner catheter sections made according to the invention and an inner guidewire, all in slidable relationship to each other.
FIGS. 10A and 10B show details of methods for determining the "critical bend diameter" for a catheter.
DESCRIPTION OF THE INVENTION
This invention is a kink-resistant catheter section or a catheter. If a catheter, it is a composite device having at least one section including at least one helically wound ribbon stiffener coaxial to and adhesively attached to at least one polymeric outer section. The ribbon forms the inner lumen of the catheter section. The catheter is configured so that at least the distal portion of the catheter has a critical bend diameter of no more than 3.5 mm, preferably no more than 2.5 mm, more preferably no more than 1.5 mm, and most preferably no more than 1.0 mm. I have additionally found that the radial compression strength of the section is quite high as compared to distal sections found on comparable catheters.
A typical multi-section catheter (100) which may incorporate the concepts of this invention is shown in FIG. 1. Such a catheter is described in more detail in U.S. Pat. No. 4,739,768, to Engelson, (the entirety of which is incorporated by reference) and is particularly suitable for neurological and peripheral vascular applications. Clearly, then, it is also suitable for less demanding service such as might be encountered in access and treatment of the heart. One difficulty which has arisen as higher demands for length have been placed on these catheters is that the diameter of the distal section necessarily becomes smaller and smaller. This is so since the longer catheters must reach ever more smaller vascular areas. This smaller diameter requires a concomitant thinning of the wall section. The thinner section walls may kink or ripple when actively pushed along the guidewire or when vasoocclusive devices are pushed through the catheter's lumen. The typical configuration shown in FIG. 1 has a distal section (102) having significant flexibility, an intermediate section (104) which is typically less flexible, and a long proximal section (106) which in turn is least flexible. The distal section (102) is flexible and soft to allow deep penetration of the extraordinary convolutions of the neurological vasculature without trauma. Various known and often necessary accessories to the catheter assembly, e.g., one or more radiopaque bands (108) at the distal region to allow viewing of the position of the distal region under fluoroscopy and a luer assembly (110) for guidewire (112) and fluids access are also shown in FIG. 1. The typical dimensions of this catheter are:
Overall length: 60-200 cm
Proximal Section (106): 60-150 cm
Intermediate Section (104): 20-50 cm
Distal Section (102): 2.5-30 cm
Obviously, these dimensions are not particularly critical to this invention and are selected as a function of the malady treated and its site within the body. However, as will be discussed below, use of the spiral wound ribbon permits the walls of the catheter to be somewhat thinner with no diminution of performance, e.g., crush strength or flexibility, and, indeed, usually provides an improvement in performance.
FIG. 2 shows a magnified cross-section of a catheter body or section (200) showing the most basic aspects of one variation of the invention. As shown there, the catheter body or section has a helically wound ribbon (202) and an adhesive (204) on at least an outer portion of the ribbon (202). Typically, the outer tubing member (206) is polymeric. Preferably, the outer tubing member (206) is'produced of a polymer which is heat shrinkable onto the adhesive (204). Such polymers include known materials such as polyethylene, polyvinylchloride (PVC), ethylvinylacetate (EVA), polyethylene terephalate (PET), and their mixtures and copolymers. One very useful class of polymers are the thermoplastic elastomers, particularly polyesters. Typical of this class is HYTREL. Similarly, the adhesive (204) is desirably a thermoplastic which may be coated onto the inner lumen of the outer tubing member (206), the outer surface of the coil (as wound), the ribbon itself, or may be formed in situ by the use of a mixture of polymers such as polyethylene and EVA, which when heated to a proper temperature exude the EVA onto the ribbon. A very highly desirable combination--from an assembly point of view--is the use of an thermoplastic adhesive (204) having a softening temperature between the temperature for heat shrinking the outer tubing (206) onto the adhesive (204) and the melting temperature of that outer tubing (206).
I have found that an outer covering of EVA having a suitable softening/heat shrinking temperature is an excellent choice for securing a strong bond to the ribbon particularly with an adhesive such as polyester or polyimide. The EVA (obviously, with or without other mixed polymers and fillers) is typically extruded into a taking of an appropriate size and thickness and cross-linked to raise the melt temperature of the resultant tubing. The tubing is then inflated and, perhaps, stretched to give the included polymer molecular orientation. The tubing may then be heat-shrunk onto the catheter. A suitable EVA would have significant adhesive properties at about 300° F.
This is not to exclude the use of other polymers, depending on the section of the catheter in which the section is used. For instance, the tubing may be of any of a variety of polymers, variously stiff or flexible. For instance, if the section (200) is used as a proximal section, the outer tubing member (206) may be a polyimide, polyamides such as the Nylons, high density polyethylene (HDPE), polypropylene, polyvinylchloride, various fluoropolymers (for instance: PTFE, FEP, vinylidene fluoride, mixtures, alloys, copolymers, block copolymers, etc.), polysulfones or the like. Blends, alloys, mixtures, copolymers, block copolymers, of these materials are also suitable, if desired.
If a more flexible section is required, the outer tubing member (206) may be a polyurethane, low density polyethylene (LDPE), polyvinylchloride, THV, etc. and other polymers of suitable softness or modulus of elasticity.
Although it is quite difficult to accomplish, the inventive catheter design allows the use in the distal portion of the catheter, thin-walled tubing of inherently more slippery polymers, such as PTFE and FEP and their mixtures, which have the benefit of being lubricious but otherwise would have been used in a somewhat greater thickness. Production of a good adhesive joint between the helically wound ribbon (202) and the adhesive (204) is not an easy task. Clearly, greater thickness tubing of these polymers results in the resulting catheter section being somewhat stiffer. The wall thickness of the outer tubing member (206) may be as thin as 0.5 mil and as thick as 10 mil, depending upon catheter usage, portion of the catheter chosen, polymer choice, and the style of catheter.
Typically, the wall thickness of the tubing member will be between 0.5 and 3.0 mils. This dimension is obviously only a range and each catheter variation must be carefully designed for the specific purpose to which it is placed.
Preferred combinations of polymers for catheter configurations will also be discussed below. It should also be noted at this point that each of the polymers discussed herein may be used in conjunction with radiopaque material such as barium sulfate, bismuth trioxide, bismuth carbonate, powdered tungsten, powdered tantalum, or the like so that the location of the various pieces of tubing may be radiographically visualized within the vessel.
The spiral wound ribbon (202) shown in FIG. 2 may also be of a variety of different materials. Although metallic ribbons are preferred because of their strength-to-weight ratios, fibrous materials (both synthetic and natural) may also be used. Preferred, because of cost, strength, and ready availability are stainless steels (SS308, SS304, SS318, etc.) and tungsten alloys. In certain applications, particularly smaller diameter catheter sections, more malleable metals and alloys, e.g., gold, platinum, palladium, rhodium, etc. may be used. A platinum alloy with a few percent of tungsten is preferred partially because of its radiopacity.
The class of alloys known as super-elastic alloys is also a desirable selection. Preferred super-elastic alloys include the class of titanium/nickel materials known as nitinol--alloys discovered by the U.S. Navy Ordnance Laboratory. These materials are discussed at length in U.S. Pat. Nos. 3,174,851 to Buehler et al., 3,351,463 to Rozner et al., and 3,753,700 to Harrison et al. These alloys are not readily commercially available in the small ribbons required by the invention described here, but for very high performance catheters are excellent choices.
When using a superelastic alloy, an additional step is usually necessary to preserve the helical shape of the stiffening member. I have purchased nitinol wire and rolled it into a 1×4 mil ribbon. The ribbon is then helically wound onto a mandrel, usually metallic, of an appropriate size. The winding is then heated to a temperature of 650°-750° F. for a few minutes, presumably annealing the ribbon. The helical coil then retains its shape.
Metallic ribbons (202) that are suitable for use in this invention are desirably between 0.5 mil and 1.5 mil in thickness and 2.5 mil and 8.0 mil in width. By the term "ribbon", I intend to include elongated shapes, the cross-section of which are not square or round and may typically be rectangular, oval or semi-oval. They should have an aspect ratio of at least 0.5 (thickness/width). In any event, for superelastic alloys, particularly nitinol, the thickness and width may be somewhat finer, e.g., down to 0.30 mil and 1.0 mil, respectively. Currently available stainless steel ribbons include sizes of 1 mil×3 mil, 2 mil×6 mil, and 2 mil×8 mil.
Suitable non-metallic ribbons include high performance materials such as those made of polyaramids (e.g., KEVLAR) and carbon fibers.
It should be observed that the preferred manner of using non-metallic ribbons in this invention is typically in combination with metallic ribbons to allow "tuning" of the stiffness of the resulting composite.
Finally, in FIG. 2 may be seen an outer layer (208) of-a lubricious material such as a silicone or other, perhaps hydrophilic, material such as a polyvinylpyrrolidone composition. These compositions are well known and do not form a critical portion of the invention.
Typical of the catheter made using this invention are those in the 3 French to 5 French range. The inner diameter of such catheters is then 20 mils to 42 mils. However, I have made micro-catheters (discussed in more detail below) having outside diameters of 18 mils to 34 mils. The inner diameter of those catheters was 11 mils to 20 mils. The invention is not limited to such sizes, however.
FIG. 3 shows a variation of the inventive catheter (210) in which the cross-sections of the ribbons (212 & 214) are generally oval rather than rectangular than as shown in FIG. 2. Either cross-section is acceptable but the oval section has less of a tendency to bind with guidewires passing through the lumen. Additionally, the FIG. 3 variation shows the use of two ribbons (212 & 214) wound side-by-side so to form a single layer of ribbon inside the outer tubing cover (206). The dual ribbons may be of the same composition or of differing compositions. They may be of the same size or of differing sizes. The number of ribbons may be of any convenient configuration so long as the specific stiffness and kink-resisting criteria are met.
FIG. 4 shows another variation in which catheter sections made according to this invention are used in axial conjunction. Section (220) is generally as described in FIGS. 3 and 4 above, but section (222) is more proximal and enjoys two outer covering layers (224) and (226). Covering (224) is simply a proximal extension of the polymeric covering in section (220); polymeric covering (226) is placed directly on the outer surface of the helically-wound coil (228). As has been noted elsewhere, coil (228) may be the same as or different than the coil found in the more distal section (220). Other methods for changing the stiffness of various sections of a catheter made using sections of the inventive catheter section are shown in FIGS. 5, 6, and 7. For instance, FIG. 5 shows a distal section (230) having a helically-wound ribbon (232), an outer polymeric covering (234), and a radiopaque band (236). In this variation, the ribbon (232) is wound in such a fashion that adjacent turns are not contiguous. This allows the distal catheter section (230) to be quite flexible and kink-resistant. The intermediate section (238) retains the same outer covering (234), but the pitch of the coil has been narrowed so that the flexibility of the midsection (238) is not as high as was the distal section (230).
The most proximal section (240) has no helically-wound ribbon at all, but instead uses a variety of polymeric or other tubing materials to form the stiffest portion of the catheter assembly. In this instance, the outer layer remains as found in the most distal section (230) and the midsection (238). The inner layer in this instance is-a stiffer material, such as polyimide, polypropylene, or a stainless steel tube, known as a "hypotube".
FIG. 6 shows still another variation of forming the distal section of a catheter assembly which is flexible and yet provides a greater stiffness for other sections of the catheter assembly. For instance, in FIG. 6, the intermediate section (242) utilizes double layers of polymeric material, e.g., the outer tubing (234) (discussed above) on the outer surface and an inner tubing of similar or stiffer material (244) in contiguous relationship along the length of the section (242). The most proximal section (246) shows only a short overlap between stiff distal tube (248) (perhaps made of the polyimide, polypropylene, nylon, or hypotube materials discussed above) and the outer layer (234). This is a simple arrangement and may be used, for instance, where cost is at a premium.
FIG. 7 shows still a further variation in which the most distal section is a composite of polymeric layers (252) and a braid (254). The composition of the mid and proximal sections are not critical to the invention. They may be of one type or the other depending upon the requirements of the particular application. The most significant of benefits is accrued when, however, the distal section is of the type specified herein. Nevertheless, a variation shown in FIG. 8 depicts an instance in which the non-kinking criteria of this invention is applied in a mid-section. Catheter (256) uses a distal section having only tubing (260) extending distally of the mid-section (262). Mid-section (262) comprises both outer tubing (260) and helically-wound ribbon (264) easily held in place according to this invention. Proximal section (266) is made stiffer by incorporating multiple layers of tubing, as discussed above.
Although the exemplified catheter assemblies in FIGS. 1, 5, 6, 7, and 8 each utilize three sections, it should be understood that this invention is not so limited. The number of sections is selected by the designer when conceptualizing a specific use for a chosen device. Often, the optimum number of sections ends up being three simply because of the physiology of the human body, however, three or more may be involved in this invention. The sections additionally need not be of constant stiffness. They may also vary in stiffness--typically as the distal end of a section is approached, the section becomes more flexible.
As was noted above, I have found that use of this method of construction allows use of significantly smaller diameter catheters which still remain kink-free and yet are quite useable. For instance, FIG. 9 shows a short cross-section of a distal end of a vascular catheter (270) in which the outer section comprises an outer cover (206) and a helically-wound ribbon (204) generally as shown in FIG. 2. Within the lumen defined by a helically-wound coil (204) may be found yet a smaller catheter device covering (272) and a helically-wound coil (274). Again, it is desireable that helically-wound coil (274) and covering (272) be adhesively attached to each other to lessen the chance of any kinking taking place. Within the lumen of the inner catheter is a guidewire (276) which, just as an inner catheter (275), is slidable within outer catheter (270), is slidable within the inner catheter (275). For instance, a guidewire (276) may have an outside diameter of 5 to 7 mils in this distal region and the outer diameter of inner catheter (275) may have an outer diameter of 12 1/2 to 14 mils.
As was noted above, the most distal portion of the distal section of this catheter (and preferably other sections as well) have a critical bend diameter of no more than 3.5 mm, preferably no more than 2.5 mm, more preferably no more than 1.5 mm, and most preferably no more than 1.0 mm. To some extent, the critical band diameter is also dependent upon the diameter of the catheter section and its components. For instance, I have made 3 French catheter section of the type shown in FIG. 2 (of stainless steel ribbon) with critical bond diameters less than 2.5 mm. Similarly, I have made catheter sections such as the inner catheter (275) shown in FIG. 9 with an outer diameter of 0.018" (of platinum-tungsten alloy ribbon) with band diameters less than 1.0 mm.
The test we utilize for critical bend diameter determination uses a test shown schematically in FIGS. 10A and 10B.
In general, as shown in FIG. 10A, a catheter section (300) is placed between two plates (desirably of plastic or glass or the like for visibility) and often with an optional peg (302) to hold the catheter section (300) loop in place. The ends of the catheter are then pulled until a kink appears in the body of the catheter. Alternatively, the ratio of the outer diameters (major diameter:minor diameter) as measured at apex (304) reaches a value of 1.5. FIG. 10B shows the cross section of the catheter sector at (304) and further shows the manner in which the major diameter and the minor diameter are measured. These two methods provide comparable results although the latter method is more repeatable.
Many times herein, we refer to the "region" section of the catheter. Where the context permits, by "region" we mean within 15% of the point specified. For instance, "the distal region of the distal section" would refer to the most distal 15% in length of the distal section.
This invention has been described and specific examples of the invention have portrayed. The use of those specifics is not intended to limit the invention in any way. Additionally, to the extent that there are variations of the invention which are within the spirit of the disclosure and yet are equivalent to the inventions found in the claims, it is our intent that this patent cover those variations as well.
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This invention is a surgical device. In particular, it is a catheter suitable for accessing a tissue target within the body, typically a target which is accessible through the vascular system. Central to the invention is the use of a stiffener ribbon, typically metallic, wound within the catheter body in such a way as to create a catheter having controllable stiffness. The stiffener ribbon is adhesively bonded to a flexible outer tubing member so to produce a thin wall catheter section which is exceptionally flexible but highly kink resistant. The catheter sections made according to this invention may be used in conjunction with other catheter sections either using the concepts shown herein or made in other ways. Because of the effective strength and ability to retain a generally kink-free form, these catheters may be effectively used in sizes which are quite fine, e.g., 0.015" to 0.020" in diameter, and useable within typical vascular catheters.
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This application is a continuation of application Ser. No. 748,454, filed Jun. 25, 1985, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the preparation of hydroquinone monocarboxylates from hydroquinone dicarboxylates and, particularly, to the preparation of hydroquinone monoacetate from hydroquinone diacetate.
2. Description of the Prior Art
Hydroquinone monocarboxylates are valuable intermediates for the preparation of monohalohydroquinone (especially monochlorohydroquinone) dicarboxylates, which are themselves useful in the preparation of aromatic polyesters (cf. French Patent Application No. 79/24,135, published under No. 2,465,758 and U.S. Pat. No. 4,118,372). It has been found, in fact, that hydroquinone monocarboxylates may be selectively halogenated to monohalohydroquinone monocarboxylates, in contrast to hydroquinone which gives rise to appreciable amounts of dihalohydroquinone (cf. U.S. Pat. No. 2,743,173), which ultimately are determined as dihalohydroquinone dicarboxylates after acylation. It has also been found that hydroquinone monocarboxylates have the advantage of being capable of being halogenated in the presence of hydroquinone dicarboxylates, which themselves remain essentially inert during the halogenation. Such a property favors the halogenation of mixtures of hydroquinone monocarboxylates, hydroquinone dicarboxylates and minor amounts of hydroquinone, such as those obtained by partial acylation of hydroquinone.
No simple process is known which provides hydroquinone monocarboxylates in and of themselves. A selective route to these compounds from hydroquinone has been proposed, but its complexity deprives it of any industrial interest; in fact, this process consists of protecting one of the hydroxyl groups of hydroquinone as a functional group from which the hydroxyl moiety can readily be liberated, then acylating the other group and, finally, regenerating the first. Such a method has been applied by H. S. Olcott, J. Am. Chem. Soc., 59 392 (1937) to the preparation of hydroquinone monoacetate by reacting hydroquinone with benzyl chlorocarbonate to form the mixed benzyl and p-hydroxyphenyl carbonate which is then acetylated to mixed benzyl p-methylcarbonyloxyphenyl carbonate; in a third stage the latter is subjected to hydrogenolysis in the presence of palladium or platinum. The simplest means for providing hydroquinone monocarboxylates is the partial acylation of hydroquinone, which cannot be produced without simultaneous formation of hydroquinone dicarboxylates [cf. H. S. Olcott, Loc. cit. and D. Johnston, Chem. Ind. (London), page 1000 (1982)]. The use of such mixtures for the preparation of monohalohydroquinone monocarboxylates gives rise to an accumulation of hydroquinone dicarboxylates. The solution to the problem presented by selective production of monohalohydroquinone monocarboxylate and of corresponding dicarboxylates depends, therefore, on the development of a process for the recovery of hydroquinone dicarboxylates and the preparation of hydroquinone monocarboxylates. Cf. U.S. Pat. No. 2,588,978; published European Application, publication No. 0,060,092.
SUMMARY OF THE INVENTION
Accordingly, a major object of the present invention is the provision of an improved process for the preparation of hydroquinone monocarboxylates from hydroquinone dicarboxylates, which improved process features reacting an excess of a hydroquinone dicarboxylate with hydroquinone, optionally in the presence of a catalyst, and which improved process provides both desiderata heretofore conspicuously absent from the state of this art.
DETAILED DESCRIPTION OF THE INVENTION
More particularly according to the present invention, the reaction of hydroquinone dicarboxylates with hydroquinone, hereinafter designated as the "disproportionation reaction" or "disproportionation", may be represented by the following reaction mechanism: ##STR1##
It is an equilibrium reaction which results in the formation of a mixture of hydroquinone monocarboxylate, hydroquinone dicarboxylate and hydroquinone. Its composition depends upon the conditions of reaction. This mixture can be employed for the selective preparation of monohalohydroquinone monocarboxylates by halogenation of the hydroquinone monocarboxylate comprising same. In this case it is important that as little hydroquinone as possible remain in the mixture because, during subsequent halogenation, this compound gives rise to the production of undesirable dihalo derivates. This is the reason why the process is carried out in the presence of an excess of hydroquinone dicarboxylate which enables the reaction equilibrium to be shifted such as to promote the formation of hydroquinone monocarboxylate.
As a general rule, the excess of hydroquinone dicarboxylate is at least 0.5 mole vis-a-vis the stoichiometric amount resulting from the aforesaid reaction scheme (1). There is no critical upper limit on the excess of hydroquinone dicarboxylate; however, beyond a certain value, the advantage obtained in the conversion of hydroquinone is counterbalanced by the disadvantage of having to recycle large amounts of hydroquinone dicarboxylate. Consequently, it is unnecessary to employ an excess of hydroquinone dicarboxylate which is greater than 4 moles relative to the stoichiometric amount. In short, the amount of hydroquinone dicarboxylates, expressed in moles per mole of hydroquinone, is at least 1.5 and preferably in a range of from 1.5 to 5.
The disproportionation reaction may be carried out in bulk or in a solvent, at the temperature of reaction, for hydroquinone dicarboxylates, hydroquinone and hydroquinone monocarboxylates, which is inert under the conditions of the reaction. In the latter case, use is made more especially of:
(i) Carboxylic acids which are liquid under the conditions of the reaction and preferably at ambient temperature; representative are alkanoic acids containing from 1 to 8 carbon atoms, such as formic, acetic, propionic, butyric, isobutyric, 2-methylbutanoic, 2-ethylbutanoic, 2,2-dimethylbutanoic, pentanoic, 2-methylpentanoic, 5-methylpentanoic, 2-ethylhexanoic and hexanoic acids. Preferably used is the carboxylic acid from which the hydroquinone dicarboxylate is derived.
(ii) Aliphatic or heterocyclic ethers, such as ethyl, n-propyl and isopropyl ethers, tetrahydrofuran, and dioxane.
(iii) Saturated aliphatic, saturated alicyclic or aromatic hydrocarbons, such as n-hexane, cyclohexane, toluene or benzene.
(iv) Haloalkanes, such as chloroform, carbon tetrachloride or trichloroethylene.
(v) Haloaromatic hydrocarbons, such as chlorobenzene.
The temperature of the disproportionation reaction can vary over wide limits. In general, temperatures in the range of from 50 to 250° C., and preferably from 80 to 180° C., are suitable. The reaction may be carried out at normal pressure or under pressure; when the temperature selected is above the boiling point of some of the components of the mixture, it is possible to conduct the reaction under the autogenous pressure of the reactants.
When the disproportionation is carried out in a carboxylic acid it is possible to carry out the reaction either in the presence or in the absence of a catalyst. When a catalyst is indeed employed, strong inorganic or organic acids are used therefor, namely, acids which have a pK below 1 in water at 25° C. Preferably used are sulfuric acid and sulfonic acids, such as methanesulfonic, di- and trifluoromethane sulfonic, benzenesulfonic, toluenesulfonic, naphthalene sulfonic acids, or sulfonic resins.
The amount of strong acid, expressed in equivalents of protons per mole of hydroquinone, can also vary over wide limits. Typically it ranges from 0.0001 to 0.2 equivalent of proton per mole of hydroquinone.
When a solvent other than an acid, and in particular an ether, is employed, the operation may be carried out in the presence of a catalyst of the type of those which are used for transesterification reactions. For this purpose, organic nitrogenous bases are used, such as primary, secondary or tertiary amines and heterocyclic bases; representative are diethylamine, ethylamine, triethylamine, n-propylamine, diisopropylamine triethanolamine, pyridine and piperidine. It is also possible to use alkali metal carboxylates, such as K, Li or Na acetates and Lewis acids such as those noted in G. A. Olah, Friedel-Crafts Reaction, volume 1, pages 191 to 291. Preferably used are the zinc, titanium, manganese or cobalt salts or metal alkoxides. More preferred are the zinc halides, such as ZnCl 2; alkyl titanates, such as methyl, ethyl, n-propyl, isopropyl, n-butyl or isobutyl titanates; Mn and Co carboxylates, such as Mn and Co acetate, propionate and isobutyrate.
The amount of catalyst, expressed in moles per mole of hydroquinone, may range from 0.0001 to 0.2 mole per mole of hydroquinone.
Upon completion of the reaction, the components of the mixture may be separated by distillation and the hydroquinone dicarboxylate and hydroquinone recycled for the preparation of hydroquinone monocarboxylate. When the intention is to prepare monohalohydroquinone monocarboxylates, it is preferable to carry out the halogenation directly on the disproportionation mixture, if need be after having removed the solvent and the disproportionation catalyst. In the case where an alkanoic acid is used as a solvent, the halogenation can take place directly in the disproportionation mixture.
The hydroquinone dicarboxylates employed may be obtained by complete acylation of hydroquinone by means of the usual acylating agents such as acid anhydrides and chlorides.
The process of the invention is very particularly suitable for the preparation of hydroquinone monocarboxylates having the general formula: ##STR2## in which R is a straight or branched chain alkyl radical containing from 1 to 4 carbon atoms, from the corresponding hydroquinone dicarboxylates.
Methyl, ethyl, n-propyl, isopropyl, n-butyl and isobutyl radicals are representative of the radicals R.
In order to further illustrate the present invention and the advantages thereof, the following specific examples are given, it being understood that same are intended only as illustrative and in nowise limitative.
EXAMPLE 1
Into a 500 ml glass reactor, equipped with a stirrer and capable of withstanding pressure, were charged:
______________________________________(i) Hydroquinone 26.4 g (0.24 mole)(ii) Hydroquinone diacetate 139.68 g (0.72 moles)(iii)Diisopropyl ether 200 ml(iv) Triethylamine 1.2 g (0.012 mole)______________________________________
The temperature was raised to 150° C. for 3 hours at autogenous pressure. The solvent and the amine was then stripped off. A light beige solid residue was obtained which weighed 168.9 g. The following compounds were identified and determined by liquid phase chromatography analysis:
______________________________________ % by weight Reactants in the crude converted* product Moles or formed**______________________________________(1) Hydroquinone 56.2 0.489 0.231* diacetate(2) Hydroquinone mono- 39.2 0.435 0.435** acetate(3) Hydroquinone 1.7 0.026 0.214*______________________________________ Conversion of hydroquinone diacetate: 32.1% Conversion of hydroquinone: 89.2% Yield of hydroquinone monoacetate based on consumed hydroquinone and diester thereof: 100%
EXAMPLE 2
Into a 200 ml glass reactor, equipped with a stirring system, thermometer, vertical condenser and heating device, were charged:
______________________________________(i) Hydroquinone 9.8 g (0.0891 mole)(ii) Hydroquinone diacetate 51.8 g (0.267 mole)(iii) Acetic acid 246 ml(iv) p-Toluenesulfonic acid 0.64 g______________________________________
The homogeneous mixture was heated at reflux for 3 hours. Acetic acid was then removed by distillation under atmospheric pressure. After cooling a light solid residue was obtained which weighed 32.8 g.
Using liquid phase chromatography analysis, the following compounds were identified and determined:
______________________________________(1) Hydroquinone diacetate 32.8 g (0.169 mole)(2) Hydroquinone monoacetate 27.06 g (0.178 mole)(3) Hydroquinone 0.96 g (0.0087 mole)______________________________________
The yield of hydroquinone monoacetate was quantitative, based upon the hydroquinone diacetate and hydroquinone reactants which were converted.
EXAMPLE 3
Into a 500 ml glass reactor equipped as in Example 2 were charged:
______________________________________(i) Hydroquinone 8.92 g (0.081 mole)(ii) Hydroquinone diacetate 47.18 g (0.2432 mole)(iii) Acetic acid 224 ml(iv) p-Toluenesulfonic acid 0.58 g______________________________________
The mixture was heated to boiling for 3 hours. The products dissolved in the acetic solution were determined by liquid phase chromatography.
______________________________________ Determined, after Converted Charged reaction, or formed,Compounds mmoles mmoles mmoles______________________________________(1) Hydroquinone 243.2 163.6 79.6 diacetate(2) Hydroquinone mono- 152.5 152.5 acetate(3) Hydroquinone 81 7.9 73.1______________________________________ Conversion of hydroquinone: 90.2% Conversion of hydroquinone diacetate: 32.7% Yield of hydroquinone monoacetate based on converted hydroquinone and hydroquinone diacetate: 100%.
EXAMPLE 4
Into a 200 ml reactor, equipped with a stirrer and capable of withstanding pressure, were charged:
______________________________________(i) Hydroquinone 11 g (0.1 mole)(ii) Hydroquinone diacetate 58.2 g (0.3 mole)(iii) Acetic acid 100 ml(iv) p-Toluenesulfonic acid 0.5 g______________________________________
The mixture was raised to a temperature of 200° C. under autogenous pressure which was maintained for 2 hours.
The reaction mixture was cooled and diluted with diisopropyl ether. Determination by high pressure chromatography of the ether solution gave the following results:
______________________________________(1) Hydroquinone 1.31 g (0.012 mole)(2) Hydroquinone diacetate 39.3 g (0.203 mole)(3) Hydroquinone monoacetate 28 g (0.184 mole)______________________________________ Conversion of hydroquinone diacetate: 32% Yield of hydroquinone monoacetate based on converted hydroquinone diacetate and hydroquinone: 100%.
EXAMPLE 5
The operation was carried out as in Example 1 using carbon tetrachloride instead of diisopropyl ether. The reaction was carried out overnight at 150° C.
The conversion of hydroquinone was 89%.
The yield of monoester was quantitative based upon the converted diester and hydroquinone.
EXAMPLE 6
The operation was carried out as in Example 1 but the solvent was eliminated: the operation took place in the melt at 150° C. without a catalyst.
______________________________________(a) Charges:Hydroquinone 53 g (0.482 mole)Hydroquinone diacetate 291 g (1.5 mole)(b) Composition of the reaction mixture upon completion ofreaction (analysis by high pressure liquid chromatography):(1) Hydroquinone 4.78 g (0.043 mole)(2) Hydroquinone diacetate 207 g (1.07 mole)(3) Hydroquinone monoacetate 140 g (0.02 mole)______________________________________
While the invention has been described in terms of various preferred embodiments, the skilled artisan will appreciate that various modifications, substitutions, omissions, and changes may be made without departing from the spirit thereof. Accordingly, it is intended that the scope of the present invention be limited solely by the scope of the following claims, including equivalents thereof.
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A hydroquinone monocarboxylate, e.g., hydroquinone monoacetate, is facilely prepared by disproportionating/reacting a stoichiometric excess of a hydroquinone dicarboxylate, e.g., hydroquinone diacetate, with hydroquinone, optionally in the presence of a strong acid/transesterification catalyst.
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FIELD
[0001] The present specification relates generally to multifunction devices such as printers and copiers, and more particularly, to a technique for clearing jams using wireless handheld devices.
BACKGROUND
[0002] Multifunction devices such as copiers, printers, scanners etc provide a user interface that can be used to provide instructions to the user for troubleshooting common errors, such as a paper jam. Conventionally, such multifunction machines are designed such that troubleshooting instructions are displayed on a user interface located at the top of the machine. Often, however, due to the construction of such devices, problems must be addressed by opening the machine from the bottom or the front. For example, in case of a paper jam, the actual jam clearing process involves accessing the components inside the machine from either below or the front of the machine. This necessitates the user, who is trying to troubleshoot the problem, to look up and down again and again in order to be able to read the instructions and execute them and, further, to mentally map the troubleshooting directions, located on a simple interface, to the physical components, the relating of which may be very difficult.
[0003] Further, multifunction devices are being designed today to be increasingly compact and to occupy the least floor space or “footprint”. This makes access to internal components of the machine even more complicated for a user. Thus, for example, a compact paper path of a printer poses a greater challenge to a user for clearing jams of print media sheets, which may be stopped or jammed in various locations along the paper path. Likewise, tech representatives or other repair personnel have more restricted manual access to removal or repair of internal components that are more closely crowded together in compact printer designs.
[0004] Because of the problems encountered by general office workers in addressing such common errors, there is often a call for unplanned maintenance. This results in a cost to the product supplier as well as the user, causing unnecessary downtime.
[0005] There is therefore a need for a method and system that enables a frequent, non-technical user to easily clear jams and solve other common problems which may occur in the operation of a multi-functional device. Such a system should make the problem solving instructions more comprehensible to printer users and should also be able to provide clear views of the jammed machine.
SUMMARY
[0006] In one embodiment, the present specification discloses a computer readable medium storing a plurality of programmatic instructions adapted to be executed on a handheld device, wherein said plurality of programmatic instructions comprise routines for receiving data indicative of an error state in a multifunction device; routines for causing said handheld device to display an image representative of an area of the multifunction device which would need to be serviced to address said error state; routines for determining a plurality of instructions for addressing said error state, wherein said instructions comprise at least one of audio data, video data, text data, or graphical data; and routines for causing said handheld device to display said plurality of instructions in relation to said image representative of an area of the multifunction device.
[0007] In another embodiment, the present specification discloses a computer readable medium storing a plurality of programmatic instructions adapted to be executed on a handheld device, wherein said plurality of programmatic instructions comprise: routines for receiving data indicative of an error state in a multifunction device; routines for prompting a user to activate said handheld device to capture a first image representative of an area of the multifunction device which would need to be serviced to address said error state; routines for obtaining from a memory a second image representative of an area of the multifunction device which would need to be serviced to address said error state; routines for causing said handheld device to concurrently display said first image and said image; routines for determining a plurality of instructions for addressing said error state, wherein said instructions comprise at least one of audio data, video data, text data, or graphical data; and routines for causing said handheld device to display said plurality of instructions in relation to said first image and said second image.
[0008] Optionally, the routines for receiving data indicative of the error state comprise routines for causing said handheld device to wirelessly communicate with said multifunction device and to obtain said data indicative of the error state from said multifunction device. The memory is at least one of a memory local to said handheld device, a memory local to said multifunction device, or a memory remote from said handheld device and said multifunction device and accessible via a network communication. The data indicative of the error state comprises at least one of an error code, a type of multifunction device, or a type of error.
[0009] Optionally, the handheld device captures the first image using a camera integrated into the handheld device. The routines for causing said handheld device to display said plurality of instructions in relation to said first image and said second image cause said handheld device to overlay at least one of said text data or graphical data on said first and said second image. The routines for obtaining from a memory a second image representative of an area of the multifunction device which would need to be serviced to address said error state comprise routines for retrieving a graphical image of the area of multifunction device, which would need to be serviced to address said error state, wherein said graphical image is stored in a database.
[0010] Optionally, the graphical image is retrieved by analyzing the first image and identifying at least one graphical image in the database corresponding to said first image. The graphical image is retrieved by using said data indicative of the error state and querying the database for a graphical image associated with said error state. The routines for causing said handheld device to display said plurality of instructions in relation to said first image and said second image cause said handheld device to overlay at least one of said text data or graphical data on said graphical image.
[0011] Optionally, the computer readable medium further comprises routines for validating a completed instruction after a user confirms a completion of an instruction. The routines for validating a completed instruction prompt said user to capture a visual image of the area of the multifunction device being serviced using a camera integrated into the handheld device, obtain said visual image, analyze the visual image, and determine if said completed instruction was performed properly based upon said visual image.
[0012] Optionally, the error state is a sheet of paper being jammed within the multifunction device. The concurrent display comprises overlaying the first image atop the second image or overlaying the second image atop the first image.
[0013] In another embodiment, the present specification discloses a method of instructing a user to troubleshoot a malfunction in a multifunction device using a handheld device, wherein said handheld device executes a plurality of programmatic instructions, comprising: receiving data indicative of a malfunction in a multifunction device; prompting a user to capture a first image representative of an area of the multifunction device which would need to be serviced to address said malfunction; obtaining from a memory a second image representative of an area of the multifunction device which would need to be serviced to address said malfunction; causing said handheld device to concurrently display said first image and said image, wherein said concurrent display comprises at least one of overlaying the first image atop the second image or overlaying the second image atop the first image; determining a plurality of instructions for addressing said malfunction, wherein said instructions comprise at least one of audio data, video data, text data, or graphical data; and causing said handheld device to display said plurality of instructions in relation to said first image and said second image.
[0014] Optionally, receiving data indicative of the error state is performed by causing said handheld device to wirelessly communicate with said multifunction device and to obtain said data indicative of the malfunction from said multifunction device. The memory is at least one of a memory local to said handheld device, a memory local to said multifunction device, or a memory remote from said handheld device and said multifunction device and accessible via a network communication. The handheld device captures the first image using a camera integrated into the handheld device.
[0015] Optionally, the method further comprises overlaying at least one of said text data or graphical data on said first and second image. Obtaining from the memory the second image comprises retrieving a graphical image of the area of multifunction device, which would need to be serviced to address said malfunction, wherein said graphical image is stored in a database. The method further comprises retrieving the graphical image by analyzing the first image and identifying at least one graphical image in the database corresponding to said first image. The method further comprises retrieving the graphical image by using said data indicative of the malfunction and querying the database for a graphical image associated with said malfunction. The method further comprises overlaying at least one of said text data or graphical data on said graphical image.
[0016] Optionally, the method further comprises validating a completed instruction after a user confirms a completion of an instruction. The method further comprises prompting said user to capture a visual image of the area of the multifunction device using a camera integrated into the handheld device, analyzing the visual image, and determining if said completed instruction was performed properly based upon said visual image.
[0017] The aforementioned and other embodiments shall be described in greater depth in the drawings and detailed description provided below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] These and other features and advantages will be appreciated as they become better understood by reference to the following Detailed Description when considered in connection with the accompanying drawings, wherein:
[0019] FIG. 1 illustrates an exemplary paper path of a multifunction device;
[0020] FIG. 2 illustrates exemplary wireless communication between a multifunction device and handheld device;
[0021] FIG. 3 illustrates an exemplary flow chart for instructing a user to troubleshoot a multifunction device using a handheld device;
[0022] FIG. 4A is an exemplary embodiment of a first graphical user interface;
[0023] FIG. 4B is an exemplary embodiment of a second graphical user interface;
[0024] FIG. 4C is an exemplary embodiment of a third graphical user interface;
[0025] FIG. 4D is an exemplary embodiment of a fourth graphical user interface;
[0026] FIG. 4E is an exemplary embodiment of a fifth graphical user interface;
[0027] FIG. 4F is an exemplary embodiment of a sixth graphical user interface;
[0028] FIG. 4G is an exemplary embodiment of a seventh graphical user interface;
[0029] FIG. 4H is an exemplary embodiment of a eighth graphical user interface;
[0030] FIG. 4I is an exemplary embodiment of a ninth graphical user interface;
[0031] FIG. 5A illustrates a first exemplary display of a captured and graphical image;
[0032] FIG. 5B illustrates a second exemplary display of a captured and graphical image; and
[0033] FIG. 5C illustrates a third exemplary display of a captured and graphical image.
[0034] In the figures, the first digit of any three-digit number generally indicates the number of the figure in which the element first appears.
DETAILED DESCRIPTION
[0035] The present specification describes methods and systems that simplify the process of troubleshooting common errors in multifunction devices. In one embodiment, the method comprises capturing the image of the jammed device and its components using a camera built in a handheld smart device. The handheld device then overlays the captured image with computer generated images to provide instructions to the user to clear the jam. Since the instructions are accompanied by images of the actual jammed device, the user can easily visually relate to the instructions and solve the problem.
[0036] It should be appreciated that the methods and systems are being described with respect to specific embodiments, but are not limited thereto. The present specification is directed towards multiple embodiments. The following disclosure is provided in order to enable a person having ordinary skill in the art to practice the claimed embodiments. Language used in this specification should not be interpreted as a general disavowal of any one specific embodiment or used to limit the claims beyond the meaning of the terms used therein. The general principles defined herein may be applied to other embodiments and applications without departing from the spirit and scope of the claimed embodiments. Also, the terminology and phraseology used is for the purpose of describing exemplary embodiments and should not be considered limiting. Thus, the present specification is to be accorded the widest scope encompassing numerous alternatives, modifications and equivalents consistent with the principles and features disclosed. For purpose of clarity, details relating to technical material that are known in the technical fields related to the claims have not been described in detail so as not to unnecessarily obscure the claimed embodiments.
[0037] As used herein, the term ‘multifunction device’ or ‘device’ is defined as any machine that can operatively perform at least one of the following functions: printing, scanning, transmitting or receiving facsimiles, or copying. The term ‘handheld device’ includes any smart device having a processor and a memory, such as a mobile phone, smart phone, PDA, laptop, tablet PC or a dedicated handheld device. The term ‘error’, ‘error state’, or ‘malfunction’ includes any state of the device in which it no longer operates as intended and/or requires human intervention to address in order to return the device to a normal operating condition. It should be appreciated that the application being executed on the handheld, as described herein, comprises a plurality of instructions or routines stored on a computer readable medium in the handheld's memory and executed on the handheld processor. In another embodiment, the routines are stored on a computer readable medium associated with the multifunction device. In another embodiment, the routines are stored on a computer readable medium on a server or another computer in a network, with the handheld device and/or the multifunction device being in communication with the network.
[0038] Referring to FIG. 1 , the illustrated printer 10 is merely one example of many types of multifunction devices, having a paper path 12 . Print media sheets to be printed pass through and out of the printer 10 along the paper path 12 . For illustration of one example of the advantages of the subject modification of the printer 10 there is shown an exemplary sheet jam clearance baffle 14 , forming part of the exemplary paper path 12 . It is typical and well known for such baffles, or other movable or repositionable printer components, to define the normal paper path 12 during normal printing operation. An air duct 20 is located close to the baffle 14 so as to conserve internal machine space. This air duct 20 may be supplied with relatively low positive pressure air in a conventional manner by using an electric motor driven blower 30 , as schematically illustrated.
[0039] When certain printing machine failures occur, such as an unintended paper jam, the printer 10 is stopped or cycled down automatically through a machine stoppage signal from the controller 100 . The operator then typically opens exterior covers of the printer and reaches in to manually remove sheets from one or more locations along the paper path. This is illustrated in this example by the phantom open position of the baffle 14 . The location of sheet jam detectors (sensors) along a printer paper path is also well known in the art and need not be re-described herein.
[0040] From FIG. 1 , it would be apparent to one of ordinary skill in the art that a general office user, not technically qualified to handle such devices may not always be able to understand where the jam has occurred, and how to clear it. Further, jam clearance instructions if any provided by the device, are mostly provided on the top of device, whereas the user needs to open the machine from front or below. Therefore, in order to provide the user a clear view of the jammed area of machine, as well as to provide jam clearance instructions which are easier to understand, in one embodiment the present system uses a handheld device with imaging capability to capture the image of the jammed device or its components. The handheld device can be any device that has a camera, a display, a processor and memory with suitable software. The software is used to overlay computer generated images with the actual images of the jammed device captured by the camera, and to accordingly display appropriate troubleshooting instructions. The software also has the ability to interpret alarms, and to monitor a user's progress during troubleshooting.
[0041] FIG. 2 provides an exemplary illustration of one embodiment, wherein the handheld device 201 wirelessly communicates with the multifunction device 202 . The handheld device 201 may communicate using Bluetooth, infrared, radio frequency, WiFi, or any other wireless standard or medium known in the art. In one embodiment, device 202 is also equipped with a docking station (not shown) where the handheld device 201 is normally placed, and can be removed by the user for assistance when faced with a problem. In one embodiment, the handheld device 201 is a smart device customized for the purpose of providing troubleshooting assistance for a specific multifunction device. Further, in one embodiment the handheld device 201 is always in communication with the multifunction device 202 , and alerts the user in case of a problem.
[0042] In another embodiment, the handheld device is a mobile phone. One of ordinary skill in the art would appreciate that for the present purpose, the mobile phone comprises hardware and operating system suitable for the application and is preferably equipped with a camera. In this embodiment, software for overlaying images and displaying appropriate instructions, interpreting alarms and keeping track of user's progress is provided as an application that can be downloaded into the mobile phone. The software application is provided by the manufacturer of the multifunction device, and may be available for download, for example, from the manufacturer's website, a third party website, or the mobile phone provider's website. One of ordinary skill in the art would appreciate that in this case any user with a suitable mobile phone can download the application and use it for troubleshooting—that is, a dedicated device is not required for the purpose. When a user encounters an error in the multifunction device, he or she can activate the application on their mobile phone. The application communicates with the device to understand the error and instructs the user accordingly.
[0043] FIG. 3 illustrates an exemplary series of steps that, when performed, enable a user to troubleshoot a multifunction device using the handheld device when a problem is encountered with the multifunction device. FIGS. 4A-4I reflect the execution of those steps in the form of exemplary graphical user interfaces presented within a display of a handheld device.
[0044] The user interface on the machine informs 301 the user of the error and the nature of the problem. The user then takes the handheld, launches the troubleshooting application associated with the multifunction device, and establishes a connection 302 with the multifunction device. It may be noted that this step is not required if the handheld device is a dedicated one that docks with the multifunction device, as explained earlier. In this case the dedicated handheld is always in communication with the multifunction device.
[0045] If the handheld is a mobile phone, connection can be established with the multifunction device by launching the requisite application, which then establishes communication between the phone and the multifunction device. It may be noted that the application in the user's mobile phone can be configured to work with different multifunction devices. In one embodiment, after the user installs the application, the user can configure the application to assist in the troubleshooting of a device by a) placing the handheld application in communication with the device, such as via a discovery process using Bluetooth or other wireless protocol, and b) activating a configuration process in which the device communicates its identity, preferred methods of communication, alarm states, troubleshooting data, or other such configuration information. In another embodiment, the application allows the user to manually choose the device type from a list, generated from pinging all multifunction devices configured to communicate over the same wireless networks using a conventional wireless discovery process, such as Bluetooth, after which the application configures itself automatically.
[0046] Referring to FIG. 4A , the handheld device 400 is activated, using a keyboard or touch screen interface, to present on a display 405 a troubleshooting application that launches and displays a list of multifunction devices 410 A with which the handheld device is pre-configured to communicate. A user may select a specific multifunction device and initiate a connection therewith.
[0047] Once in data communication with the multifunction device, the handheld device receives 303 a signal containing data indicative of the problem detected by the multifunction device. It should be appreciated that a conventional multifunctional device is already configured to detect and determine an internal error occurring in the operation of the device. In one embodiment, the multifunction device is equipped with a transmitter which can wirelessly communicate a signal containing data indicative of the error or a transmitter which, via wired or wireless connection, communicate a signal containing data indicative of the error to a remotely located server or other computing device, which, in turn, can relay that signal, or another signal derived therefrom, to the handheld device.
[0048] Referring to FIG. 4B , the display 405 preferably shows the device to which the handheld 400 is communicating and/or for which the handheld 400 is attempting to assist in the troubleshooting. The device is denoted in a first area 410 B, along with the error code 415 B, a word description of the error code 420 B, and an option for receiving step-by-step visual instructions by pressing a button or icon 425 B. It should be appreciated that the error code 415 B and description of the detected error 420 B may be received from the device, as described above, in real time when the handheld is being used to troubleshoot the device or may be looked up in a database local to or remote from the handheld in response to the handheld receiving a signal indicative of the nature, type, scope, or defining characteristic of the error from the device. In one embodiment, the database is downloaded into the handheld device at the time the software application is installed. In one embodiment, the software application in the handheld is configured to provide assistance in service routines for the multifunction device, in addition to handling common errors.
[0049] It should also be appreciated that the handheld device may not communicate directly with the multifunction device. Rather, a user may launch the application on the handheld and, once launched, be prompted to capture, via a camera built into the handheld, an indicator displayed on the multifunction device which can be used by the application to access the nature and type of the device, as well as the nature and type of the error which has occurred. The multifunction device can display a bar code, a set of alphanumeric characters, or other images, that, once captured or otherwise input into the application, can be used to access a) the specific type of multifunction device, b) the specific error being experienced, and/or c) one or more graphics that, when displayed, can be used to explain how to troubleshoot the error by transmitting the data to a local database or a remote database via a network. Alternatively, the code can be inputted into the application via conventional handheld input mechanisms, such as a keyboard, touchscreen, or by voice recognition.
[0050] Referring back to FIG. 4B , assuming a user presses the icon for visual step-by-step instructions 425 B, the handheld device initiates 304 the process of instructing a user to address the detected error by displaying an instruction to open 305 the multifunction device cover and take a picture of the service area, namely the exposed portion of the device machinery, as further shown in display 428 C in FIG. 4C . The display 405 may instruct 306 a user to point the handheld, having a camera built in thereto, to a particular reference point within the device, such as physical marker. In one embodiment, one or more physical markers are placed on the internal components of the multifunction device. For example, components may be marked numerically as 1, 2, 3, 4, . . . 10, or alphabetically. The graphical user interface (GUI) on the display 405 can instruct the user to point the camera at physical marker 3 or 5 located within the multifunction device. In one embodiment, to assist the user in focusing correctly at the desired component, the GUI presents a square or a circle on the camera screen, and instructs the user to point the camera such that the marking of the component (3 or 5, etc.) is centered within the square or circle.
[0051] The user activates the handheld to capture 307 the multifunction device image according to the instructions. The application operating on the handheld 400 presents a user with an option, as shown in GUI 430 D in display 405 , to overlay step-by-step instructions on the captured picture of the service area or on a graphic of the service area, which may be retrieved based upon said captured picture. For example, the captured image may be used to determine a plurality of different characteristic features of the service area, using conventional image recognition processes, and then match those identified characteristic features to a database of graphical images. The corresponding graphical image may then be retrieved and transmitted or otherwise provided to the application. Alternatively, an actual image of the captured area may not be required to retrieve a graphic. Instead, a graphic may be retrieved from a database based upon the device type and the type of error that has occurred. Using the device type and error code, a corresponding graphic for the affected service area, which is stored in a flat table or relational database, may be retrieved.
[0052] In one embodiment, the retrieved graphical image of the area of the multifunction device to be serviced and the image captured by the user's activation of the handheld device are concurrently displayed in a side-by-side or overlaid configuration where the graphical image is overlaid on the captured image or the captured image is overlaid on the graphical image. Referring to FIGS. 5 a, 5 b, and 5 c, on receiving the error code or other information defining the malfunction, the system may prompt the user to open the multifunction device, or otherwise access the internal functional areas of the multifunction device, and take a picture of the area to be serviced using a camera built into the handheld. The picture, or captured image, 510 is then analyzed by the system and used to search a database for a relevant graphic, such as a diagram or illustration, 520 that can be displayed in conjunction with the captured image 510 . In one embodiment, shown in FIG. 5 a, the captured image 510 and graphical image 520 are displayed side-by-side. In another embodiment, shown in FIG. 5 b, the graphical image 520 is overlaid atop the captured image 510 . In another embodiment, shown in FIG. 5 c, the captured image 510 is overlaid atop the graphical image 520 .
[0053] Assuming the user clicks to approve the display, referring to FIGS. 3 and 4E , the application obtains 308 a diagram or graphic 440 E of the system, retrieved from a database or received from the device, based upon the captured image of the device (or the captured imaged itself) and further overlays an indicator of a first instruction step 445 E to be performed by a user or servicer of the device. It should be appreciated that the diagram or graphic of the system may incorporate the indicator, thereby not requiring the application to separately overlay an indicator. It should further be appreciated that application may retrieve a plurality of graphics, each associated with a different troubleshooting step, and each of which may already comprise an indicator that serves to visually direct a user to address a specific portion of the service area.
[0054] To the extent an overlay is used, the overlay may occur in a number of different ways, including a) overlaying an animation of what actions a user should take over the captured image or retrieved graphic, b) overlaying an outline of the affected area over the captured image or retrieved graphic, together with text instructions of how to repair the affected area, c) overlaying an outline of the affected area over the captured image or retrieved graphic, together with auditory instructions of how to repair the affected area, or d) any combination thereof In one embodiment, a user can select the first step, i.e. icon 445 E, or press a “continue” or “next button” to go to an auditory or written instruction 445 F, shown in FIG. 4F .
[0055] After confirming completion of the first step 445 F, the application may then display as second step 445 G, shown in FIGS. 4G and 4H , which provide a subsequent instruction 445 H to the user. It should be appreciated that this process can be repeated, to yield multiple instruction images, text instructions, and/or auditory instructions. After a user completes the instruction sequence, a final instruction may be displayed 4501 , instructing the user to close the device door and reset the multifunction device by, for example, pressing “OK”.
[0056] In another embodiment, the application executing on the handheld can concurrently monitor the user's progress toward troubleshooting the multifunction device error. Referring back to FIG. 3 , the application may periodically instruct a user to position the handheld in order to retake 309 camera images, as discussed above, after a user performs one or more of the instructed steps. By capturing images as the user progresses through the sequence of instructions, the application can confirm that the user is taking the appropriate actions.
[0057] For example, if a user responds to a first instruction 445 E, as shown in FIG. 4E , by moving the wrong component, a second captured image, which would be obtained by inserting a user instruction to position the handheld camera and activate an image capture process, could be used to provide corrective instructions by a) comparing the second captured image to the first captured image, b) determining a difference between the two images, c) equating the difference between the two images to a moved, modified, or otherwise changed component state by isolating the plurality of pixels representing the delta change between the images and identifying those isolated pixels within a device diagram obtained from the local or remote database, d) determining the identity of a device component equating to the isolated pixels, and e) referencing the most recent prior instruction given to the user, either from local cache or from the local or remote database, to determine if the modified component was the proper component to modify. Where the captured images are first used to identify corresponding graphics or diagrams, the second captured image may be used to retrieve a corresponding graphic or may be compared to the next expected graphic in a sequence of troubleshooting graphic images. If the second captured image does not match the expected graphic (namely the resulting image that should have been created had the prior instruction been properly executed), the application may conclude that the user has not taken the appropriate troubleshooting measures.
[0058] More specifically, if the verification process determines that the user has not taken the proper steps, the application will provide 311 corrective instructions to the user by a) determining what component was improperly modified, as described above, b) instructing the user to reverse his or her actions, thereby placing the improperly modified component into its prior state, and c) repeating its prior instruction with the target component highlighted and the improperly modified component “grayed out” or otherwise distinguished to assist the user in not making the same mistake again.
[0059] If the verification process, which may occur repeatedly in the course of a troubleshooting session, determines 310 that the user executed the prior instruction properly, it may proceed to a subsequent set of instructions or, if completed, instruct a user to close the device door. Upon closing the device door, the application on the handheld may query the multifunction device or may listen for a communication from the multifunction device for some indication that the error has cleared. Alternatively, the application may prompt the user for an input indicating whether the error has cleared, based on input received from the multifunction device. If the error has not cleared 312 , the application may repeat the process by requesting the user to open the device, capture 307 an image of the internal device, create 308 the overlayed set of instructions, and perform the verification steps 309 , 311 , 310 . It should be appreciated that the image capture verification process may be unnecessary if the multifunction device can communicate, in real-time, whether a user is modifying, correcting, or otherwise addressing the proper components to the handheld application executing on the handheld device.
[0060] In one embodiment, the application on the handheld logs all error data to a server, to assist maintenance or future troubleshooting. In one embodiment, the application software is configured to send the log data for all error states and actions taken directly to a help desk.
[0061] The present system allows a general office worker to fix common errors by themselves, without necessarily relying on technical personnel for every problem. Thus, in case of a jam for example, the system enables a user to correctly locate the problem area, move any components if required and removed the jammed sheets from the machine. One of ordinary skill in the art would appreciate that the system may also be used by technical personnel, in which case it would help them save time and effort in repair or service jobs.
[0062] Although described above in connection with particular embodiments disclosed herein, it should be understood the descriptions of the embodiments are illustrative and are not intended to be limiting. Various modifications and applications may occur to those skilled in the art without departing from the true spirit and scope of the specification as defined in the appended claims.
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The present specification discloses systems and methods for enabling users to troubleshoot multifunction devices using handheld devices, such as mobile phones. In one embodiment, software executing on the handheld device receives data indicative of an error state in a multifunction device, causes the handheld device to obtain and display an image representative of an area of the multifunction device which would need to be serviced to address the error state, determines instructions for addressing the error state, and causes the handheld device to display the instructions in relation to the image representative of an area of the multifunction device.
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FIELD OF THE INVENTION
The invention relates to a Trusted Service Manager being adapted to receive installation requests from Service Providers via a first communication channel, said installation requests comprising an application, a Service Provider identifier of the Service Provider and a unique identifier, e.g. a telephone number, of a target mobile communication device being equipped with a memory device to store the application; and to transmit the application contained in the installation request via a second communication channel, particularly an Over-the-Air Service of a Mobile Network Operator to the target mobile communication device.
BACKGROUND OF THE INVENTION
The MIFARE® classic family, developed by NXP Semiconductors is the pioneer and front runner in contactless smart card ICs operating in the 13.56 MHz frequency range with read/write capability. MIFARE® is a trademark of NXP Semiconductors. MIFARE complies with ISO14443 A, which is used in more than 80% of all contactless smart cards today. The technology is embodied in both cards and card reader devices. MIFARE cards are being used in an increasingly broad range of applications (including transport ticketing, access control, e-payment, road tolling, and loyalty applications). MIFARE Standard (or Classic) cards employ a proprietary high-level protocol with a proprietary security protocol for authentication and ciphering. MIFARE® technology has become a standard for memory devices with key-protected memory sectors. One example for a published product specification of MIFARE® technology is the data sheet “MIFARE® Standard Card IC MF1 IC S50—Functional Specification” (1998). MIFARE® technology is also discussed in: Klaus Finkenzeller, “RFID Handbuch”, HANSER, 3 rd edition (2002).
The MIFARE Classic cards are fundamentally just memory storage devices, where the memory is divided into sectors and blocks with simple security mechanisms for access control. Each device has a unique serial number. Anticollision is provided so that several cards in the field may be selected and operated in sequence.
The MIFARE Standard 1k offers about 768 bytes of data storage, split into 16 sectors with 4 blocks of 16 bytes each (one block consists of 16 byte); each sector is protected by two different keys, called A and B. They can be programmed for operations like reading, writing, increasing value blocks, etc. The last block of each sector is called “trailer”, which contains two secret keys (A and B) and programmable access conditions for each block in this sector. In order to support multi-application with key hierarchy an individual set of two keys (A and B) per sector (per application) is provided.
The memory organization of a MIFARE Standard 1k card is shown in FIG. 1 . The 1024×8 bit EEPROM memory is organized in 16 sectors with 4 blocks of 16 bytes each. The first data block (block 0 ) of the first sector (sector 0 ) is the manufacturer block. It contains the IC manufacturer data. Due to security and system requirements this block is write protected after having been programmed by the IC manufacturer at production. The manufacturer block is shown in detail in FIG. 2 .
Now referring again to FIG. 1 all sectors of the memory contain 3 blocks of 16 bytes for storing data (except sector 0 which contains only two data blocks and the read-only manufacturer block). These data blocks can be configured by the access bits as read/write blocks for e.g. contactless access control or value blocks for e.g. electronic purse applications, where additional commands like increment and decrement for direct control of the stored value are provided. The value blocks have a fixed data format which permits error detection and correction and a backup management. An authentication command has to be carried out before any memory operation in order to allow further commands.
Each sector of the memory further has it own sector trailer (see FIG. 3 ) containing the secret keys A and B (optional), which return logical “0”s when read and the access conditions for the four blocks of that sector, which are stored in bytes 6 . . . 9. The access bits also specify the type (read/write or value) of the data blocks. If key B is not needed, the last 6 bytes of block 3 can be used as data bytes.
MIFARE ICs are typically connected to a coil with a few turns and then embedded in plastic to form a passive contactless smart card. No battery is needed since the IC is supplied with energy from the field. When the card is positioned in the proximity of the reader antenna, the high speed RF communication interface allows to transmit data with 106 kBit/s. The typical operating distance of a MIFARE memory device is up to 100 mm (depending on antenna geometry). A typical ticketing transaction needs less than 100 ms (including backup management).
SmartMX (Memory eXtension) is a family of smart cards that have been designed by NXP Semiconductors for high-security smart card applications requiring highly reliable solutions, with or without multiple interface options. Key applications are e-government, banking/finance, mobile communications and advanced public transportation.
The ability to run the MIFARE protocol concurrently with other contactless transmission protocols implemented by the User Operating System enables the combination of new services and existing applications based on MIFARE (e.g. ticketing) on a single Dual Interface controller based smart card. SmartMX cards are able to emulate MIFARE Classic devices and thereby makes this interface compatible with any installed MIFARE Classic infrastructure. The contactless interface can be used to communicate via any protocol, particularly the MIFARE protocol and self defined contactless transmission protocols. SmartMX enables the easy implementation of state-of-the-art operating systems and open platform solutions including JCOP (the Java Card Operating System) and offers an optimized feature set together with the highest levels of security. SmartMX incorporates a range of security features to counter measure side channel attacks like DPA, SPA etc. A true anticollision method (acc. ISO/IEC 14443-3), enables multiple cards to be handled simultaneously.
It should be noted that the emulation of MIFARE Classic cards is not only restricted to SmartMX cards, but there may also exist other present or future smartcards being able to emulate MIFARE Classic cards.
It should further be noted that the invention is not restricted to MIFARE technology, but also applies to other memory devices, particularly those that comprise a plurality of memory sectors wherein the sectors are protected against unauthorized access by sector keys.
Recently, mobile communication devices have been developed which contain memory devices having unique memory device identifications, like MIFARE devices, either being configured as MIFARE Classic cards or as MIFARE emulation devices like SmartMX cards. These mobile communication devices comprise e.g. mobile phones with Near Field Communication (NFC) capabilities, but are not limited to mobile phones.
In February 2007 the GSM Assocation (GSMA) published a white paper outlining operator community guidance for the eco-system parties involved in the development of Mobile NFC (Near Field Communication) services. Mobile NFC is defined as the combination of contactless services with mobile telephony, based on NFC technology. The mobile phone with a hardware-based secure identity token (the UICC) can provide the ideal environment for NFC applications. The UICC can replace the physical card thus optimising costs for the Service Provider, and offering users a more convenient service.
Various different entities are involved in the Mobile NFC ecosystem. These are defined below:
Customer—uses the mobile device for mobile communications and Mobile NFC services. The customer subscribes to an MNO and uses Mobile NFC services. Mobile Network Operator (MNO)—provides the full range mobile services to the Customer, particularly provides UICC and NFC terminals plus Over The Air (OTA) transport services. Service Provider (SP)—provides contactless services to the Customer (SPs are e.g. banks, public transport companies, loyalty programs owners etc.). Retailer/Merchant—service dependent, e.g. operates a NFC capable Point of Sales (POS) terminal. Trusted Service Manager (TSM)—securely distributes and manages the Service Providers' services to the MNO customer base. Handset, NFC Chipset and UICC Manufacturer—produce Mobile NFC/Communication devices and the associated UICC hardware. Reader Manufacturer—produces NFC reader devices. Application developer—designs and develops the Mobile NFC applications. Standardisation Bodies and Industry Fora—develop a global standard for NFC, enabling interoperability, backward compatibility and future development of NFC applications and services.
One of the key findings in said white paper is that Mobile NFC will be successful provided that the Mobile NFC ecosystem is steady, providing value for all entities within it; and is efficient, by introducing a new role of the Trusted Service Manager.
The role of the Trusted Service Manager (TSM) is to:
Provide the single point of contact for the Service Providers to access their customer base through the MNOs. Manage the secure download and life-cycle management of the Mobile NFC application on behalf of the Service Providers.
The TSM does not participate in the transaction stage of the service, thus ensuring that the Service Providers' existing business models are not disrupted. Depending on the national market needs and situations, the TSM can be managed by one MNO, a consortium of MNOs, or by independent Trusted Third Parties. The number of operating TSMs in one market will depend on the national market needs and circumstances.
The present inventions applies to a Mobile NFC ecosystem with Trusted Service Manager (TSM) as disclosed in the above referenced GSMA white book. Particularly, it takes into account the specific role of the TSM which acts as the single point of contact for the Service Providers to access their customer base through the MNOs and manages the secure download and life-cycle management of the Mobile NFC application on behalf of the Service Provider. However, while the GSMA whitebook defines the role of the TSM in theory, for successful applications in practice there are still a couple of issues to be considered. For instance, when Service Providers intend to provide applications, particularly MIFARE applications (ticket issue, access control, coupon issue etc.) they prefer to transmit the application by SMS via the over-the-air (OTA) services of a Mobile Network Operator (MNO) to an NFC capable mobile phone being equipped with a memory device that comprises a plurality of key-protected memory sectors, particularly a MIFARE memory. In the NFC mobile phone the application has to be extracted from the SMS and has to be written either into (arbitrary) free memory sectors or into predefined sectors of a memory device that is specifically allocated to that particular application.
While the approach that the TSM is the only instance that controls the memory devices in mobile communication devices, particularly NFC mobile phones, brings about many advantages it has nevertheless also weak points. One of them is the fact that neither the Mobile Network Operator nor the Service Providers have full knowledge of what applications and services are installed in the mobile communication devices. When such a mobile communication device is reported as lost or stolen, the customer (who is the user and/or owner of this mobile communication device) wants to stop all applications and services (i.e. underground yearly pass, credit card and so on) installed in his device to hinder abuse of these services. In order to do this the customer has two choices: to contact his Mobile Network Operator and/or to contact all the Services Providers which have delivered the services and applications.
When being informed about a lost or stolen mobile communication device the Mobile Network Operator can discard the installed services on the mobile communication device but has no clue on how to stop the customer's registrations associated with the installed services.
When the customer intends to contact the Service Providers without having his mobile communication device at hand it could be difficult for him to remember what services have been installed and who are the Service Providers of these services.
OBJECT AND SUMMARY OF THE INVENTION
It is an object of the invention to provide a Trusted Service Manager of the type defined in the first paragraph in which the disadvantages defined above are avoided.
In order to achieve the object defined above, with a Trusted Service Manager according to the invention characteristic features are provided so that a Trusted Service Manager according to the invention can be characterized in the way defined below, that is:
A Trusted Service Manager being adapted/designed to:
receive installation requests from Service Providers via a first communication channel, said installation requests comprising an application, a Service Provider identifier of the Service Provider and a unique identifier, e.g. a telephone number, of a target mobile communication device being equipped with a memory device to store the application; transmit the application contained in the installation request via a second communication channel, particularly an Over-the-Air Service of a Mobile Network Operator to the target mobile communication device; keep a repository of information regarding the received applications, their associated service provider identifiers and their associated target mobile communication device identifiers; receive queries from a Mobile Network Operator via a third communication channel which queries ask for the Service Providers associated with a specific mobile communication device identifier and to process said queries by retrieving from the repository those Service Providers that are associated with the queried mobile communication device identifier.
The characteristic features according to the invention provide the advantage that by having a third party, i.e. the Trusted Service Manager, retrieved a full list of the Service Providers which have delivered services and applications to the mobile communication device the Service Providers and/or the customer can be informed accordingly so that appropriate measures can be taken to hinder abuse of the applications that are stored in his mobile communication device. It should be noted that the core aspect of the present invention is to provide information to the concerned parties about the applications and the Service Providers linked thereto, rather than describing disabling of the applications located in the mobile communication device. Another important aspect of the present invention is that the Service Providers only get information related to their applications, but do not get information about applications of other Service Providers which are also stored in the lost or stolen mobile communication device.
In one embodiment of the invention the Trusted Service Manager forwards a list of the retrieved Service Providers to the Mobile Network Operator which has sent the query. The advantage of this embodiment is that the customer only needs to inform the Mobile Network Operator about the loss of his mobile communication device and then the Mobile Network Operator will act as a “one stop shop” in order to carry out the necessary precautionary provisions.
In another embodiment of the invention the Trusted Service Manager itself sends a message containing the queried mobile phone identifier to all retrieved Service Providers. With this automatically generated messages the Service Providers are enabled to take the necessary decisions.
In yet another embodiment of the invention the Trusted Service Manager is adapted to forward a list of all retrieved Service Providers to the customer of the mobile phone. With this information the customer is enabled to consider which Service Providers have to be informed and which of them need not be informed.
The measures as claimed in claim 5 or claim 6 , respectively, provide the advantage that they rely on well-defined highly accessible network infrastructures and services.
The aspects defined above and further aspects of the invention are apparent from the exemplary embodiments to be described hereinafter and are explained with reference to these exemplary embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described in more detail hereinafter with reference to exemplary embodiments. However, the invention is not limited to them.
FIG. 1 shows the memory organization of a MIFARE Standard 1k EEPROM.
FIG. 2 shows the manufacturer block of a MIFARE memory.
FIG. 3 shows the sector trailer of a sector of a MIFARE memory.
FIG. 4 shows a mobile NFC ecosystem with Trusted Service Manager in which environment the present invention is embedded.
FIG. 5 shows a process flow in the mobile NFC ecosystem according to a first embodiment of the invention.
FIG. 6 shows a process flow in the mobile NFC ecosystem according to a second embodiment of the invention.
FIG. 7 shows a process flow in the mobile NFC ecosystem according to a third embodiment of the invention.
FIG. 8 shows a process flow in the mobile NFC ecosystem according to a fourth embodiment of the invention.
DESCRIPTION OF EMBODIMENTS
FIG. 4 schematically shows a Mobile NFC ecosystem as disclosed in the above referenced GSMA white book. The system comprises a Mobile Network Operator MNO, a couple of Service Providers SPx (wherein the lower case letter ‘x’ stands for a number), mobile communication devices MOx (wherein the lower case letter ‘x’ stands for a number) and a Trusted Service Manager TSM. Each mobile communication device MOx is assigned to a customer CU who has registered the mobile communication device MOx at the Mobile Network Operator MNO. The Mobile Network Operator MNO provides the full range mobile services to the customers CU, particularly provides UICC and NFC terminals plus Over The Air (OTA) transport services for their mobile communication devices MOx. The mobile communication devices MOx are equipped with memory devices MIF being adapted to securely store applications (sometimes also called services) APP1, APP2, APP3 or generally designated as APPx. The memory device MIF advantageously comprises a MIFARE memory card (e.g. a MIFARE Standard 1k memory card as shown in FIG. 1 ) or a SmartMX card. The mobile communication devices MOx equipped with said memory devices MIF are preferably configured as NFC mobile phones. The applications APPx being stored in the memory devices MIF are provided by the Service Providers SPx. Service Providers SPx are e.g. banks, public transport companies, loyalty programs owners etc.
The Trusted Service Manager TSM securely distributes and manages the Service Providers' SPx applications APPx to the Mobile Network Operator's MNO customer base as will be explained in more detail below.
When a Service Provider SPx wants to install a new application APPx (ticket, access control, coupon, etc.) in a memory device MIF of a mobile communication device MOx it sends an installation request INST via a first communication channel C 1 to the Trusted Service Manager TSM. The installation request INST comprises the application APPx to be installed, a Service Provider identifier SPx-ID of the Service Provider who sends the installation request INST and a unique identifier MOx-ID, e.g. an assigned telephone number, of a target mobile communication device MOx being equipped with a memory device MIF. The first communication channel C 1 is e.g. configured as a computer network such as the Internet. In the present example the preferred data transmission protocol between the Service Provider SPx and the Trusted Service Manager TSM is HTTPS. Usually, the Service Provider SPx has got the unique identifier MOx-ID of the mobile communication device MOx directly from the customer CU, e.g. when he orders a ticket via the website of the Service Provider SPx and in order to complete this order has to input the telephone number of his mobile communication device MOx into an online-form.
As the Trusted Service Manager TSM receives the installation request INST from the Service Provider SPx it extracts the application APPx and the mobile communication device identifier MOx-ID of the mobile communication device MOx and—provided that the memory device MIF of the mobile communication device MOx is a MIFARE memory—assigns under its own discretion one or more destination sectors and the associated sector key(s) (key A or B, see FIG. 1 ) of the memory device MIF. Next, the Trusted Service Manager TSM compiles the application APPx, the sector key(s) and the sector number(s) of the destination sectors into a setup-message SU. In order to improve security the Trusted Service Manager TSM may encrypt the setup-message SU. Then the Trusted Service Manager TSM sends the setup-message SU via a second communication channel C 2 , e.g. an over-the-air (OTA) service of the Mobile Network Operator MNO to the mobile communication device MOx. Presently, the preferred OTA service is SMS. In the mobile phone MOx there is a software application running being designed to extract all the data from the received setup-message SU, if necessary decrypting it first, and writing the extracted application APPx into the assigned destination sector(s) of the memory device MIF by using the extracted sector key(s).
According to the present invention, as the Trusted Service Manager TSM receives the installation request INST from the Service Provider SPx and extracts the application APPx and the mobile communication device identifier MOx-ID of the mobile communication device MOx it further writes (WRT) these data into a repository REP so that it can retrieve all Service Providers SPx that are associated with a specific mobile communication device identifier MOx-ID. The repository REP shown in FIG. 4 contains as a simplified example one application APP4 assigned to a NFC mobile phone (MO 1 ) which application APP4 has been delivered by a third Service Provider SP 3 , two applications APP1, APP2 which have been delivered by a first Service Provider SP 1 to the mobile communication device MOx and a third application APP3 which has been delivered by a second Service Provider SP 2 to the mobile communication device MOx. Further, another application APPx originating from another Service Provider SPx is also assigned to the mobile communication device MOx. The repository REP could for instance be configured as a data base, a file system or the like.
Now turning to FIG. 5 a first embodiment of the invention is explained. Provided that the customer CU has realized that his mobile communication device MOx has been lost or stolen he sends a report STL (by telephone, e-mail or whatsoever) of his loss to the Mobile Network Operator MNO. Since the customer CU has been registered with the Mobile Network Operator MNO it has all necessary information about the customer CU, his lost mobile communication device MOx and the assigned mobile communication device identifier MOx-ID in its customer base. Now the Mobile Network Operator MNO sends a query QU via a third communication channel C 3 to the Trusted Service Manager TSM including the identifier MOx-ID of the lost mobile communication device MOx in this query QU. The query QU asks the Trusted Service Manager TSM for all Service Providers SPx that have been associated with the lost mobile communication device MOx or in other words with its mobile communication device identifier MOx-ID. The Trusted Service Manager TSM processes this query QU by retrieving (RET) from its repository REP all Service Providers SPx that are associated with the queried mobile communication device identifier MOx-ID. Next, the Trusted Service Manager TSM replies to the query of the Mobile Network Operator MNO with a complete list LS of the retrieved Service Providers SPx. With this list LS the Mobile Network Operator MNO is in a position to send a message MSG to each of the Service Providers SPx contained in the list LS and to warn them about the lost/stolen mobile communication device MOx. If necessary each warned Service Provider SPx will contact (INF) the customer CU to carry out actions on the registration of the customer CU. Actions could be cancellation, report on another mobile telephone, freeze of the registration and so on.
FIG. 6 shows another embodiment of the invention that is closely related to the first embodiment that has been described above, with the main difference that the Trusted Service Manager TSM when having retrieved (RET) the Service Providers SPx associated with the mobile communication device MOx and its mobile communication device identifier MOx-ID, respectively, does not generate and return a list of them to the Mobile Network Operator MNO, but contacts (MSG) directly the concerned Service Providers SPx in order to warn them about the lost/stolen mobile communication device MOx.
FIG. 7 shows a third embodiment of the present invention. When the customer CU has realized that his mobile communication device MOx has been lost or stolen he sends a report STL (by telephone, e-mail or whatsoever) of his loss to the Mobile Network Operator MNO. The Mobile Network Operator MNO reacts to this report by sending a query QU via a third communication channel C 3 to the Trusted Service Manager TSM including in this query QU the identifier MOx-ID of the lost mobile communication device MOx. The query QU asks the Trusted Service Manager TSM for all Service Providers SPx that have been associated with the lost mobile communication device MOx and its mobile communication device identifier MOx-ID, respectively. The Trusted Service Manager TSM processes this query QU by retrieving (RET) from its repository REP all Service Providers SPx that are associated with the queried mobile communication device MOx and its mobile communication device identifier MOx-ID, respectively. Next, the Trusted Service Manager TSM replies to the query QU by sending a complete list LS of the retrieved Service Providers SPx to the Mobile Network Operator MNO. In the present embodiment of the invention the Mobile Network Operator MNO forwards this list LS of the retrieved Service Providers SPx to the customer CU. The customer CU is now in a position to decide whether he should contact (INF) the concerned Service Providers SPx to warn them about the lost/stolen mobile communication device MOx so that actions can be taken on the registration of the customer CU with the Service Providers SPx. Actions could be cancellation, report on an other mobile telephone, freeze of the registration and so on.
FIG. 8 shows another embodiment of the invention that is closely related to the third embodiment that has been described above, with the main difference that the Trusted Service Manager TSM when having retrieved the Service Providers SPx associated with the mobile communication device identifier MOx-ID generates a list LS of them and forwards this list LS directly to the customer CU of the mobile communication device MOx via a fourth communication channel C 4 , rather than returning the list to the Mobile Network Operator MNO. If necessary the Mobile Network Operator MNO when sending the query QU to the Trusted Service Manager TSM also sends details about the fourth communication channel C 4 to be used by the Trusted Service Manager TSM.
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A Trusted Service Manager (TSM) receives installation requests (INST) from Service Providers (SPx) comprising an application (APPx), a Service Provider identifier (SPx-ID) and an identifier (MOx-ID) of a target mobile communication device (MOx) that is equipped with a memory device (MIF) to store the application (APPx). The Trusted Service Manager (TSM) transmits the application (APPx) to the target mobile communication device (MOx) and keeps a repository (REP) of the received applications (APPx), their associated service provider identifiers (SPx-ID) and their associated target mobile communication device identifiers (MOx-ID). If the Trusted Service Manager (TSM) receives queries (QU) from a Mobile Network Operator (MNO) asking for the Service Providers associated with a specific mobile communication device identifier (MOx-ID) it retrieves from the repository (REP) those Service Providers (SPx) that are associated with the queried mobile communication device identifier (MOx-ID).
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BACKGROUND AND SUMMARY OF THE INVENTION
Conventional automotive disc brake systems comprise a hermetically sealed system employing a fluid for transmission of braking forces exerted by the vehicle operator on the brake pedal to the rotating wheels of the vehicle. Such systems generally include a master cylinder having a fluid reservoir and a piston responsive to actuation of the brake pedal, which causes the fluid to be forced through a distribution system running to each of the wheels. This pressurized fluid actuates another piston at each of the wheels. causing the brake shoes or pads to engage a rotating disc secured to each wheel.
In these disc brake systems, the fluid actuated pistons located at the individual wheels are housed in a caliper which also holds and restrains the brake pads thereby providing the braking force. As these forces are substantial, the housing must necessarily be a massive structure. Further, in that it is necessary to allow the brake pads to move axially with the piston while restraining both radial and circumferential movement of the brake pads, the pad supporting structure of the caliper must be accurately constructed. Also, the brake caliper will have provided in it a fluid chamber and fluid passageways communicating with a bleeder valve, the fluid chamber and provisions for external connection of a brake line. For these reasons, the caliper of a disc brake is necessarily an expensive component of the brake system when compared to the wheel cylinders of the older conventional brake systems, and, thus, it becomes highly desirable to avoid replacement of this component whenever possible.
It is extremely important to the operating efficiency of all fluid actuated braking systems to insure against the presence of any air being trapped within the system. As air is a compressible gas, the presence of air in any portion of the fluid system will absorb, rather than transmit, the pressure created by the master cylinder. Accordingly, bleeder valves are provided on the calipers which communicate with the fluid passageways to allow air to be expelled from the system. These bleeder valves are normally threaded into an aperture in the caliper housing and have a valve body which engages an accurately machined valve seat contained within the caliper. Occasionally, the threaded bleeder valve aperture may become damaged due to corrosion, lack of necessary care, or the like. Accordingly, the present invention provides a method and device by which this aperture may be repaired with a minimum of effort and expense, thus eliminating the necessity of replacing the caliper itself, as well as the associated expense and delay of repair in attempting to obtain a replacement caliper housing.
Other features and advantages of the present invention will become apparent from a review of the following detailed description of the preferred embodiment in which reference is made to the following drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a sectionalized view of a conventional disc brake caliper shown in operable relationship to a portion of a vehicle wheel suspension system shown in section;
FIG. 2 shows a sectionalized portion of the disc brake caliper of FIG. 1 having a damaged bleeder valve aperture about to be drilled in preparation for repair;
FIG. 3 is similar to FIG. 2 showing a sectionalized portion of the disc brake caliper with a bleeder valve aperture which has been drilled and is now about to be tapped;
FIG. 4 is similar to FIGS. 2 and 3 showing a sealing compound being applied to a repair sleeve device which is about to be installed in prepared bleeder valve aperture;
FIG. 5 shows a longitudinally sectionalized view of a repair sleeve device in accordance with the present invention; and
FIG. 6 shows a longitudinally sectionalized view of another embodiment of the repair sleeve device of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, there is shown a conventional disc brake caliper 10 having dual hydraulically actuated pistons 12 and 14 contained thereon. Pistons 12 and 14 are each moveable within a cylindrical bore 16 and each have an annular gasket 18 therearound which seals a fluid chamber 20 located behind each of pistons 12 and 14. Communicating with fluid chambers 20 are fluid passageways 22 and 24, one of which extends externally to means for connection of a brake line running from a master cylinder. The other fluid passageway 24 extends externally to a bleeder valve aperture 26. Bleeder valve aperture 26 has a threaded wall portion 28 extending into the caliper housing 10, an unthreaded portion 30 of approximately the same diameter as the threaded portion 28 extending an additional distance into the caliper housing and terminating at valve seat 32 which joins the bleeder valve aperture 26 with the internal fluid passageway 24 of the caliper 10. Fluid passageway 24 is centered in the bleeder valve aperture 26 and has a diameter substantially smaller than that of the bleeder valve aperture. Valve seat 32 comprises a tapered portion interconnecting the inner end of the bleeder valve aperture 26 and fluid passageway 24. A bleeder valve 34 is shown in FIG. 1 adjacent to bleeder valve aperture 26. Bleeder valve 34 is generally cylindrical in shape having a threaded portion 36 extending along its surface for engaging and retaining the valve in aperture 26. One end of bleeder valve 34 has a tapered conical shaped portion 38 complimentary to the valve seat 32 of the caliper, which cooperates with valve seat 32 to effectively seal the fluid passageway 24 when bleeder valve 34 is in a closed position. Bleeder valve 34 also has an unthreaded portion 39 located between threaded portion 36 and conical shaped portion 38 which is of a slightly smaller diameter than threaded portion 36. A small aperture 40 is disposed in unthreaded portion 39 and extends radially into bleeder valve 34 for a distance approximately half the diameter of unthreaded portion 39. A second aperture 41 extends longitudinally inward from the outer end of bleeder valve 34 terminating at the point of intersection with aperture 40. Threaded portion 36 of the bleeder valve terminates near its outer end at a hexagonal shape annular flange 42 which provides means by which a wrench may engage the bleeder valve 34 to loosen same during the bleeding of the brake lines.
Whenever it becomes necessary to bleed the brake lines of a vehicle, an individual will connect a rubber tube or the like over the bleeder valve 34, submerse the opposite end in a container having a small amount of brake fluid therein, then loosen the bleeder valve so as to allow fluid in the caliper passageways 24 and 22, fluid chambers 20, and brake lines to escape through the bleeder valve 34 expelling any air trapped within the hydraulic system as the brake pedal is alternately depressed and released. This bleeding operation is generally only performed at infrequent intervals, such as when disc brake pads are replaced or some other problem necessitating opening up of the otherwise hermetically sealed fluid system. As a result of this infrequent use, the bleeder valve may become frozen due to the corrosive conditions encountered at their location adjacent the vehicle wheels and the attempt to remove it resulting in the bleeder valve breaking off inside the aperture. Various other factors may also result in damage to the aperture, such as overtightening of the bleeder valve resulting in stripped threads or even rocks or other debris striking the valve. In order to effect a repair of a damaged bleeder valve aperture, it is first necessary to remove the disc brake caliper from its mountings, disconnect the brake line, and remove the pistons therefrom. Next, as shown in FIG. 2, the damaged aperture 26 is drilled out by means of a conventional twist drill 46 or the like. It is necessary that the drill have a diameter slightly larger than the diameter of the aperture 26 in order to allow for the wall thickness of the repair sleeve device, as described in greater detail below. Further, aperture 26 must be lengthened so as to allow the threads of the repair sleeve device to fully engage the caliper housing 10.
Next, as best seen in FIG. 3, the drilled aperture 44 is threaded by means of a conventional tap 48. As such taps are tapered so as to gradually form the peaks and valleys of the new threads, it will be necessary to cause the tap to enter the aperture a slightly greater distance than the length of the repair sleeve device so as to fully form the threads which the repair sleeve device will engage.
As is readily apparent, the operation of drilling and tapping will necessarily destroy the previously machined valve seat contained in the caliper housing. While it would be possible to machine a new valve seat in this aperture, such operations require specialized machinery and skill, neither of which is likely to be possessed by the mechanic attempting to repair the brake system. Accordingly, a repair sleeve device is provided which has a valve seat machined internally therein, as is described in greater detail below.
The aperture having thus been drilled and tapped as described above, the caliper housing is now carefully washed and cleaned so as to insure that all the metal particles resulting from the drilling and tapping thereof are removed. Should any such particles remain after the assembly of the caliper, they may result in the scoring of the piston walls, the plugging of the fluid passageways, or other like damage to the caliper and result in possible failure of the braking system itself.
Once the caliper has been drilled and tapped, as described above, the repair sleeve device 50 may be threaded into the aperture as shown in FIG. 4. In order to facilitate this operation, it is generally desirable to insert the bleeder valve 34 into the repair sleeve device 50 so as to provide an extension for engagement by wrench or the like, thus insuring the repair sleeve device is fully inserted into the aperture 44 and surface 51 is flush with the caliper housing. Additionally, it is necessary that a suitable sealant 52 be applied to the threads 54 of the repair sleeve device prior to its installation in the aperture so as to insure that when pressure is exerted on the fluid within the system, it will not leak around threads 54. There are many such sealants currently available on the market and one which has been found particularly well suited to this application is Lockite "Shaft and Bearing Mount". This sealant, when cured, also serves to retain the repair sleeve device 50 in the aperture 44.
The caliper may now be reassembled and installed on the vehicle and the balance of the brake repair completed in normal fashion.
Reference is now made to FIG. 5 in which there is shown in section a repair sleeve device 50 as previously mentioned. Repair sleeve device 50 is generally cylindrical in shape having external threads 56 disposed along the longitudinal walls thereof. Threads 56 will correspond and cooperate with threads 49 of the disc brake caliper bleeder valve aperture 44. An aperture 58 extends internally of the bleeder valve repair sleeve from one end thereof terminating a short distance from the opposite end and having threads 60 along a portion thereof, which are complimentary to those of a standard bleeder valve. Aperture 58 also has an unthreaded smooth wall portion 61 extending inward from the threaded portion 60. A second aperture 62 extends longitudinally into the sleeve 50 from the opposite end thereof. Second aperture 62 is concentric with aperture 58 and of a substantially smaller diameter. A valve seat portion 64, having inclined conical shaped walls, extends between and connects the two apertures 58 and 62. When installed in a disc brake caliper, this repair device having the internal valve seat 64 will provide the necessary sealing means for the bleeder valve assembly.
Referring now to FIG. 6, a second embodiment of the repair sleeve is shown therein at 66. Repair device 66 is identical to that described with reference to FIG. 5 having a large diameter threaded aperture 58 extending from one end thereof, a smaller unthreaded aperture 62 extending inward from the opposite end, and a valve seat portion 64 extending between the two aperture portions. This repair device, however, does not have a threaded external wall but, rather, has an accurately machined, smooth, longitudinal wall surface suitable for a press fit installation. When the repair device 66, as shown in FIG. 6, is used, the bleeder valve aperture of the disc brake caliper is first drilled as previously described. The drilled aperture is then accurately reamed to a proper diameter to allow for a press fit insertion of the repair sleeve device. A sealing composition, such as that previously described, is then applied to the external longitudinal wall surfaces of the repair sleeve, and the repair sleeve device is then pressed into the previously prepared aperture.
The disc brake caliper, having the repair sleeve device of the present invention installed thereon, is now ready for reassembly of the bleeder valve, pistons, and brake pads and installation on the vehicle, all of which is accomplished in a conventional manner.
There is thus disclosed herein a method by which a disc brake caliper may be easily repaired with minimal amount of time and effort, thereby minimizing the cost of such repairs to the owner of the vehicle. While this device has been described with reference to a disc brake caliper, the scope of the invention herein should not be so limited but may be practiced with application to other components of the brake system having bleeder valve assemblies; for example, the master cylinder. Additionally, in certain vehicles, a hydraulically actuated clutch may be employed, in which case, bleeder valves contained therein may be repaired in like manner, as described herein. It is thus apparent that various changes, modifications, and variations may be made without departing from the scope of the invention which should be limited only by the scope of the appended claims.
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There is disclosed herein a method for repairing a bleeder valve aperture on a disc brake caliper or the like and a device for use in practicing this method thereby eliminating the necessity of replacing the caliper housing. The repair method includes the drilling of the damaged aperture, tapping the enlarged aperture to create new threads thereon, and the insertion of a repair sleeve device having an externally threaded surface and a valve seat and threaded surface machined internally therein. This repair sleeve device is designed to cooperate with the bleeder valve and the caliper housing so as to allow the bleeder valve to function normally. Alternatively, a repair sleeve device having a smooth external surface and designed to be press fitted into an accurately reamed aperture is also contemplated.
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FIELD OF THE INVENTION
This invention relates to the process of controlling air flow to an internal combustion engines and, more particularly, a multi-stage process of air flow through an intake manifold using a selectively openable manifold tuning valve and short runner valves thereby providing several selective modes of air flow operation.
BACKGROUND OF THE INVENTION
U.S. Pat. No. 5,000,129 to Fukada et al, issued Mar. 19, 1991, for "Intake System For Internal Combustion Engine" discloses an air intake system for a V-block engine having a central surge tank disposed above the space between the left and right cylinder banks of the engine. This surge tank is operatively integrated with left and right side surge tanks extending above respective banks of cylinders. A communicating passage disposed between discrete side intake passages connects the central surge tank with the left and right surge tanks so that all of the tanks combine to serve as a single surge tank having a large volume for the suppression of intake air interference.
U.S. Pat. No. 5,133,308, issued Jul. 28, 1992, to Hitomi et al for "Intake System For Engine" discloses an intake system for a V-block internal combustion engine having a centralized junction chamber and a plurality of discrete intake passages connecting the junction chamber with respective cylinders of the engine. Rotary valves in the intake passages are operated by actuators responding to a controller that receives engine speed signals to close and open the valves for improving engine torque.
In contrast to the relatively complex structures and processes for regulating air flow found in the above citations and many prior constructions, the present invention provides a straight forward three plenum active intake manifold for an internal combustion engine operative in several alternate modes to produce an improved engine torque curve over the entire range of engine speeds while reducing induction noise and variances in pitch.
SUMMARY OF THE INVENTION
In this invention an air flow process is provided using a three plenum active engine air intake manifold with dual zip tubes and an acoustic balancing cross over passage to provide improved acoustic tuning and engine performance. This is accomplished by integrating long runner and short runner intake systems of the manifold with active electronic controlled valve devices to optimize plenum tuning over the entire range of engine operating speeds. This invention provides improved engine torque throughout the speed range of the engine while simultaneously reducing induction noises and pitch variability.
The engine performance over a relatively high speed range, such as a wide open throttle condition, is enhanced by direct air flow form the central plenum into the engine ports. This is accomplished by opening the short runner valves (SRVs) by means of an electronic signal to a valve actuator. The resultant air flows directly from the intermediate plenum, through the short runner passageways, and into the engine intake ports to the combustion chambers. The air flow restriction is minimized during this higher engine speed.
Over a relatively low engine speed range, engine performance is improved and noise levels are decreased, particularly at idle. The air flows from the two side plenums which are spaced outwardly from one another to either side of the central plenum. The side plenums are connected to the engine intake ports by narrow, long runner passages. The resultant air flow velocity is enhanced at these lower engine speeds. The spaced side plenums are linked together at one end of the manifold by a cross over passage which provides acoustic balance under some engine operating conditions. The side plenums are also connected at an opposite end of the manifold by passages provided by zip tubes. Each zip tube extends form a central air inlet opening outward to a side plenum.
Air flow through the cross over passage is controlled by a selectively openable manifold tuning valve (MTV). In the preferred embodiment of this manifold, the MTV is closed during idle and over a lower range of engine speeds. The closed valve causes acoustic pressure waves generated in each of the side plenums to return to the interior of that plenum and constructively act upon the pulsed air flow therein caused by opening and closing of the engine intake valves. Resultantly, the air flow through the long runners is enhanced which improves volumetric efficiency and engine torque.
This manifold may be used to improve engine torque output for a variety of different internal combustion engines by tailoring the plenum volumes corresponding to engine size and desired operating speed. Engine performance, namely torque, can be improved by selective application any one of three possible intake manifold combinations as follows: operation with the MTV closed and the SRVs closed; operation with the MTV opened and the SRVs closed; and operation with the MTV closed and the SRVs opened.
Noise reduction benefits are also provided by this manifold. At idle and operation in a low engine speed range, the short runner valves are selectively closed to restrict air to flow solely through the outwardly spaced side plenums and then through the long runner passages. During engine operation in a higher range of engine speeds, the short runner valves are opened to allow air to also flow through a more direct route into the combustion chambers in addition to the previous long runner route.
A reduction in externally received noise is also provided by this manifold. At engine idle and operation over a relatively low speed range, selective closure of the short runner valves force air to flow only from the side plenums and through the narrow, long runner passages. To improve engine breathing over a higher range of engine speeds, such as at wide open throttle, the short runner valves are opened which allows air to flow in a more direct path to the combustion chambers as well as through the more indirect long runner passages. Resultantly, the flow restriction is greatly decreased to the benefit of engine performance.
Noise attenuation is augmented by the intersection of each zip tube with a side plenum and with the central air inlet to the manifold which aids in pressure wave cancellation by setting up opposite self-destructive pressure waves. The subject manifold allows for any remaining audible waves or noise exiting the throttle body to be easily reduced or canceled using simple and conventional passive wave attenuation devices positioned externally from the manifold. Also, with the wave cancellation provided by this manifold, there is a significant reduction in the back pressure in the induction system. This improves peak engine performance.
Another advantage of this manifold design is the space efficient packaging for under-hood engine placement due to the relative planar configuration of the plenums and runners. The resultant tight packaging permits a lower and more streamlined hood line. The manifold further provides improved access to spark plugs and fuel injectors (neither shown) which would be located below the plane of the manifold. Serviceability would be enhanced with the present design. The design can be used for a wide range of engines, particularly, `V` type block engines, such as a 60 degree V-6 engine.
These and other objects, features, and advantages of the present invention will become more apparent from the following detailed description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a preferred embodiment of the three plenum intake manifold showing flow control valves and associated control mechanisms to operate the valves and with portions broken away to reveal air flow paths therein; and
FIG. 2 is an end elevational view from the front portion of an associated engine of the subject manifold with partial sectioning to reveal passages therein and various engine parts; and
FIG. 3 is top planar view of the subject manifold shown somewhat schematically and broken away to illustrate air flow paths therethrough when in one mode of operation; and
FIG. 4 is view similar to FIG. 3 but illustrating air flow paths through the subject manifold when in a second mode of operation; and
FIG. 5 is a graphical illustration which plots engine speed vs. engine torque for a particular engine having the subject manifold installed.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning now to FIGS. 1 and 2, a three plenum air distributing manifold 10 for a V type six cylinder internal combustion engine 12 is shown. The manifold is fully active to provide multiple tuning peaks which peaks are effective at different engine speed ranges to optimize engine torque.
The manifold 10 has a centralized axially extending plenum 14 into which a flow of air 16 is feed through a throttle body 18. Throttle body 18 houses a conventional throttle plate 20 shown diagrammatically separated from the throttle body 18 but in reality is operatively mounted therein in a manner allowing it to be pivoted so as to control air flow into the manifold.
In addition to the centralized plenum 14, the manifold has a pair of side plenums 22 and 24 which are fluidly connected to the center plenum 14 and the inlet through the throttle body 18. More particularly, side plenums 22 and 24 are connected to one another at one end of the manifold adjacent the throttle body by transversely extending zip tubes 28 and 30. The two side plenums 22 and 24 are also connected to one another at an opposite end of the manifold by laterally extending crossover passage 34.
As best shown FIG. 1, flow through the cross over passage 34 is regulated by a manifold tuning valve (MTV) 42 which is mounted at a mid-position in crossover passage 34. The MTV 42 has a valve plate 43 which is selectively pivoted between opened and closed positions by an actuator. The actuator may be a piston which is powered by fluid pressure. In the preferred embodiment shown in FIG. 1, the actuator is in the form of an electric motor 44 selectively controlled by an electronic control unit (ECU) 46 which is part of the onboard engine control system of the vehicle. ECU 46 receives input signals from sensors, such as an engine speed or rpm sensor 47, to control operation of motor 44 as well as other motors or actuators which will be described hereafter.
As shown in FIG. 1, the left side plenum 22 is connected to the three cylinders in the right hand cylinder bank of the engine 12 by long runners 50, 52 and 54. Referring now to FIG. 2, one of the runners 54 is shown extending between plenum 22 and an intake passage 56 which is formed in a cylinder head manifold 58. The intake passage 56 extends to an intake port 60 of the cylinder head 62 to permit air to flow into one of the engine's combustion chambers 75.
Referring back to FIGS. 1 and 3, the right side plenum 24 is connected to the three cylinders of the left hand bank by long runners 64, 66 and 68. Specifically, one of the long runner passages 66 from plenum 24 is shown in FIG. 2. Air passes from plenum 24, through passage 66 to connect with passage 70 in the cylinder head manifold 58 and then to intake port 71 of the left cylinder head 72 and into combustion chamber 77.
Looking to FIG. 2, both right and left banks (sides) of the engine are similar. More particularly, the respective right and left cylinder heads 62, 72 support conventional camshafts which operate intake valves which in turn control air flow into the combustion chambers. The camshaft 74 of cylinder head 62 is operably connected to intake valve 76 and another camshaft (not visible) associated with cylinder head 72 is operably connected to intake valve 78. Intake valves 76, 78 are opened to control flow of air and fuel into respective combustion chambers 75 and 77. By closing the valves 76, 78, the combustion chambers are sealed during the combustion event.
Additionally, the cylinder heads 62, 72 support exhaust valves associated with each combustion chamber. For example, an exhaust valve 73 is shown associated with combustion chamber 75. Exhaust camshafts (not visible) are supported by cylinder heads 62, 72 to operate the exhaust valves. The cylinder heads 62, 72 support valve covers 62', 72' which extend over the camshafts.
Referring now to FIGS. 3 and 4, central plenum 14 is shown with six short runners 80, 82, 84, 86, 88 and 90. Each short runner is directly connected to the passages in cylinder head manifold 58 as best seen in FIG. 2 with relation to runner 88 and passage 56. Accordingly, short runners 80, 82, 84, 86, 88, and 90 directly feed air to a corresponding passages in manifold 58 from central plenum 14. Specifically, in FIG. 2, the passage 91 of short runner 88 connects plenum 14 to passage 56 to flow air through intake port 60 and into combustion chamber 75.
The air flow through each of the short runners is controlled by a short runner valve (SRV) 96 as best seen in FIGS. 3, 4 (closed and opened respectively). In FIG. 2, one of the short runner valves 96 is shown operatively mounted in one of the short runner passages 88 positioned upstream of its intersection with the passage 56 in cylinder head manifold 58. Each of the valves 96 are butterfly-type plate valves attached to a common shaft 98. Shaft 98 is supported for rotation by the manifold 10 and extends through the central plenum 14 at the entrance to the short runners 80-90. The shaft 98 can be rotated so that the valves 96 are moved to closed positions as seen in solid line in FIG. 1 and also in FIG. 3. In the closed position, air flow through the short runners 80-90 is blocked. Resultantly, air flow to the combustion chambers is through the throttle body 18; zip tubes 28, 30; left and right plenums 22, 24; long runners 80-90; and connecting passages in the cylinder head manifold 58. This operative mode for the intake system is advantageous for idle and low speed operation of the engine.
As shown in FIG. 1, a crank arm 99 attached to the end of shaft 98 is engaged by a linkage 100 to operably connect the shaft 98 to a pneumatically powered motor 102. The pneumatic power to motor 102 is controlled by the ECU 46. Upon receiving an appropriate signal from a sensor or sensors, such as engine speed sensor 47, the ECU 46 directs power to the motor 102 for arranging the SRVs in their closed position for improved low speed operation and in their opened positions for improved high speed operation. More specifically, when the SRVs are closed, air flow into the short runner passages is blocked. This causes air to flow to the left side combustion chambers 77 through the long runners 64, 66, 68 from the right hand plenum 24. Similarly, air flow to the right side combustion chambers 75 is routed through the long runners 50, 52, 54 from the left side plenum 22. When high engine speeds are sensed by sensor 47, the signal to the ECU 46 activates motor 102 to open the SRVs. This improves air flow and increases engine performance by the addition of more direct flow paths to the combustion chambers.
Engine Performance with Subject Manifold
The subject manifold has been tested on a 3.2 L V-6 engine by Chrysler Corporation. In FIG. 5, engine performance (torque) is plotted according to engine speed. The curve P1 shows the performance with the MTV and SRVs closed. The curve P2 shows the performance with the MTV opened and the SRVs closed. The curve P3 shows the performance with the MTV closed and the SRVs opened. Under an engine idle condition represented by point I in FIG. 5, the ECU 46 directs motor 44 of the manifold tuning valve (MTV) 42 to position the MTV plate 43 to a fully closed position in the crossover passage 34 (see FIG. 1). Also, the ECU 46 controls actuation of motor 102 so as to maintain the SRVs in closed positions. Accordingly, cross over passage is blocked. With the MTV closed, pressure waves formed in the side plenums are not balanced acoustically by passage through the cross over. However, wave forms in the side plenums 22, 24 act independently to produce desirable enhanced air flows as more specifically described below.
During an engine idle condition, the valves of both the MTV and the SRV systems are closed as shown in FIGS. 1 and 3. Air for the engine enters the manifold through the throttle body and its flow volume is controlled by the positioning of the throttle valve plate 20 by the vehicle operator through the vehicle's accelerator pedal. Because the SRVs are closed, air flows from the throttle body to the combustion chambers through the zip tubes 28 and 30, into the two side plenums 22 and 24, and then through long runner passages 50, 52, 54 or 64, 66 and 68 to corresponding continuing passages in the air distribution manifold 58 to the intake ports formed in the two cylinder heads 62, 72 of the engine. When desired, small volumes of exhaust gas is added to the air flow (or recirculated) through intake ports 103 and 105 formed in the zip tubes 28 and 30. Whenever an engine intake valve is opened, air and any recirculated exhaust flows into an associated combustion chamber.
With the cross over passage 34 blocked by a closed valve plate 42 as shown in FIG. 1 and 3, pressure waves are generated in both side plenums 22, 24. These wave forms are normally of about the same frequency and amplitude in either plenum. The waves rebound from the closed cross over valve to cause increases in air density which enhance air flow into the long runners 50, 52, 54 and 64, 66, 68 at lower engine speeds of below 3600 rpm, for example. The air flow into the long runners is represented by flow arrows A in FIG. 3. As seen in FIG. 5, during an intermediate engine speed, the engine torque is significantly increased by maintaining the MTV and SRV systems closed as the air flow through the long runners is enhanced. This increase is represented by hatched area H in FIG. 5.
At higher intermediate engine speeds, for example of over about 3600 rpm, a torque benefit can be obtained by opening valve 43 of the MTV system while the SRVs 96 are maintained in closed positions. During a higher engine speed range, for example of over about 5000 rpm, the torque characteristics of the engine benefit by closing the MTV valve 43 and opening the SRVs 96. With SRVs 96 opened, air still can flow through the long runners but an additional and more direct path is opened extending from the central plenum 14 directly into the short runners as identified by flow arrows F in FIG. 4. By adding flow paths through the short runners, the total manifold tuning characteristic is changed resulting in a much greater air flow capacity. The resultant increase in air flow capacity generates increased torque over the higher speed range. In FIG. 5, the increased torque is represented by the hatched area H2.
While benefits of both the MTV and SRV systems are described and shown as occurring during certain engine speed ranges, there are other ranges and conditions which can benefit from differing intake manifold and valving configurations and combinations. Accordingly, for different internal combustion engine configurations and for different engine speed ranges, the subject intake manifold system can take different tuning characteristics to provide desired torque benefits derived from different SRV and MTV valving operations. Resultantly, by varying operation of the MTV and SRV systems, engine torque can be optimized for a number of different engines operating over a wide range of speeds.
In addition to the enhanced torque characteristics previously explained, a valuable contribution of this manifold with the MTV and SRV systems is an opportunity to decrease induction noise of the engine. It is particularly desirable to reduce noise during engine idle and during a lower speed range of engine operation. Under these conditions, the escape of pressure waves from the side plenums 22, 24 to the atmosphere through the throttle body is greatly inhibited by the geometry of the manifold. The multiple turns in the path between the interiors of plenums 22, 24 to the zip tubes 28, 30 and from the zip tubes into the throttle body air inlet passage help to decrease emission of noise through the throttle body and out to the atmosphere. The intersection of the zip tubes 28, 30 at a substantially right angle to the throttle body aids in cancellation of some pressure waves generated in the side plenums 22, 24. When pressure waves interact together at the point of intersection adjacent the throttle body, cancellation occurs. Resultantly, noise emission is decreased. Any small volumes of noise exiting the throttle body are easily canceled using simple conventionally passive devices. With the aforedescribed noise cancellation effects, back pressure of the induction system is reduced and engine performance and fuel economy are enhanced.
Also, with the subject manifold system, under hood packaging is improved so that additional hood streamlining is possible. Specifically, the subject manifold provides a compact and low profile engine package created because the basic configuration and size of each runner and each plenum is essentially in a common plane and is elongated in a generally horizontal plane. Note in FIG. 1 that this manifold has shallow openings 106 for receiving fasteners (not shown) to attach the manifold to the air distribution manifold 58. Also, access to fuel injectors (not shown) through the spaces between long runners 50-54 and 64-68 located outward from the central plenum 14.
While a preferred embodiment of the invention has been shown and described, other embodiments will now become apparent to those skilled in the art. Accordingly, this invention is not to be limited to that which is shown and described but by the following claims.
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A three plenum air distribution manifold for intake air to an internal combustion engine with long runners leading from first and second spaced side plenums for delivery of air and recirculating exhaust gases into corresponding combustion chambers of the engine. The side plenums are connected at their outer extremities by an acoustically balanced cross over passage selectively closed by a manifold tuning valve (MTV) for improving engine output torque during low engine speed. A third plenum intermediate the two side plenums communicates directly with the combustion chambers through short runner passages opened and closed by valves (SRVs) for optimizing the output of engine torque during a higher range of engine speeds. The air flow through the manifold is controlled by an onboard electronic controller responsive to operating signals from the engine to change the characteristics of the manifold with different engine speeds.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is
a divisional of U.S. patent application Ser. No. 12/541,496, filed on Aug. 14, 2009 (which application claims the priority, under 35 U.S.C. §119, of U.S. Provisional Patent Application No. 61/089,148, filed Aug. 15, 2008),
the entire disclosures of which are hereby incorporated herein by reference in their entireties.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0003] n/a
FIELD OF THE INVENTION
[0004] The present invention pertains to a method of delivering audio messages through a wireless connection to a vehicle. More particularly, the present invention pertains to a method of delivering audio messages that are triggered by criteria related to, for example, time, vehicle location, an event, a condition, mood-influencing intent, a tourist attraction, a user action, service reminders, and many more. The criteria-based messages are controlled by an automated voice-recognition system located at a remote data center and delivered through a wireless voice or data channel to the vehicle. The vehicle driver hears the audio message under various driving conditions. A voice user interface can be utilized by the vehicle driver to manage the audio messages.
BACKGROUND OF THE INVENTION
[0005] Constant changes in culture and technology provide an ever-increasing array of avenues for one to reach customers or potential customers. These include, for example, television, radio, magazines, direct mail, signage, the INTERNET, including standard and interactive social websites, and mobile devices, which are providing more and more connectivity to the previously mentioned channels of communication.
[0006] Not long ago, the advertising industry was limited to a substantially lesser number of media channels from which to choose. However, over time, advertisers have taken advantage of each new media channel option that has developed. These new channels are now quite numerous and advertising strategies have become more creative than ever. The growing number of media channels can be attributed mainly to the above-mentioned advances in communication technology, including, for instance, better and more abundant access to information deliverable over the INTERNET, such as 3G mobile devices.
[0007] In addition, with geographic location determining features, such as the global positioning systems (GPS), included in advanced mobile devices, the mobile device medium has the potential to provide marketers with the ability to target customers based on their geographic location and to also utilize imaging. Although, multimedia advertisements (i.e., including visual components) have become a dominant message format, such a format is usually not appropriate for a vehicle driver from a safety perspective.
[0008] Because the average person spends a substantial amount of time in their vehicle, the automobile is a highly desirable media channel for delivering advertising. However, there are challenges with the user interface under driving conditions, especially because images displayed in the vehicle can distract the driver. Before trying to push advertising messages to the vehicle, one must understand the task of driving and to know that safety is a high priority. Driving is so basic to modern life that drivers no longer think of it as a complex task. However, driving requires constant focus as well a vast amount of physical coordination and analytical skills. In addition, the cognitive load of driving has increased over time. Increasing traffic levels, complex mixes of road systems (often subject to construction or constriction), and a much higher flow of information and infotainment to the vehicle make ordinary driving a very demanding challenge. Physically, every part of the body is involved in driving. Even today's most advanced vehicles still require hands on the wheel and feet ready for the accelerator and brake pedal.
[0009] With technological advances, driving is still largely a silent activity when it comes to tools and controls. Speech is not always an easy interface to use, especially in an automotive environment when others in the car are talking. If a car has a speech input, it is usually an optional interface mode because there can be technical challenges when trying to automatically recognize a driver or passenger's speech in a hands-free automotive environment.
[0010] There are two main modes of communicating information to a vehicle driver: auditory and visual. Over a brief period of time (e.g., a few minutes), humans can perceive much more information through vision than through hearing. However, the driver of a vehicle must apply visual concentration on driving and driver distraction must be minimized.
[0011] Therefore, a need exists to overcome the problems with the prior art as discussed above.
SUMMARY OF THE INVENTION
[0012] The present invention is directed to a system, method, and process of delivering criteria-based audio messages from a remote data center database over a wireless link. The information delivered can be in the form of a short audio clip that is crafted carefully to give the desired effect on the vehicle driver. The messages are designed to be non-intrusive with a strong personality associated with the voices contained in the recordings. Such highly personified human recordings are triggered (initiated) based on one or a combination of different criteria including, but not limited to time, vehicle location, an event, a condition, a mood-influencing intent, a tourist attraction, or service reminders. An automated voice system located at the remote data center generates the audio messages.
[0013] A significant aspect of the invention disclosed here is that, in the audio domain, a service example can be more effective than a service description. After hearing a service example, people think of numerous other ways they could use the service. Analogous use cases are imagined in the driver's mind. The persona alone can influence mood. For example, imagine hearing a service demonstration portrayed by a combination of a male agent speaking to a female driver in a highly staged fashion. The service examples involve professional actors with voice characteristics that qualify them to be recording artists, which combines with the ability to speak quickly, clearly, and in a way that matches the goal of the scenario being acted out. The style of prompting used to describe a service is different from the style of prompting when acting out service example scenarios. For service examples, it is easier and more appropriate to exaggerate behavior, rather than remain somewhat monotonous, as is the case with service descriptions. Finally, the inventor's testing with human subjects clearly indicates that service examples, as described here, are far more effective than service descriptions in the context of influencing mood to buy while driving.
[0014] Flexibility is critical to delivering effective, up-to-date audio messages to vehicle drivers. All of the message recordings are conducted outside of the vehicle, typically at professional recording studios. The recordings are edited and concatenated in ways that enhance the affect on the driver and minimize driver distraction. For example, the messages should be short and to the point (less than 15 seconds, depending on the intent and scenario). In some cases, the driver requests to hear a service example (e.g., an acted out interaction between an agent and a driver) and, through a voice interface, the driver can elect to hear more or to stop the message at anytime.
[0015] It would be a significant advancement in the art to implement an automatic voice recognition system at a remote data center that would deliver audio messages from an off-board database over a wireless link to the vehicle driver in a hands-free environment. The primary advantages of the remote data center of the invention are flexibility and cost effectiveness. Because the platform is off-board, the application and message content can easily be modified without changing any in-vehicle hardware, or software. In terms of cost, server-based voice recognition resources can be shared across a large spectrum of different vehicles. For example, each channel of server-based voice-automation system could accommodate several vehicles simultaneously.
[0016] Locating the automated voice system at the remote data center provides substantial advantages over an embedded system inside the vehicle. The advantages include:
Increased operational flexibility and control from the call center; Increased efficiency, since content can be added or modified with centralized hardware and/or software; Improved scalability, since computer resources are shared across a large number of vehicles; Usability improvement, to the extent that calls from the vehicles can be monitored and improvements made at the centralized location, rather than in the vehicles; A “thin” client can be located in the vehicle using standard telematics control units, rather than a specialized on-board computer; and The ability to connect a vehicle driver to a human agent that is able to activate a new service specific to the vehicle.
[0023] Wireless delivery of audio messages can also help automobile manufacturers and dealerships promote a vehicle's value-added features that often go unnoticed and unused by its owner. Because of the off-board implementation, content can be modified to highlight features the automobile manufacturer would like to promote. For that matter, recall notification could be managed efficiently through criteria related to remote diagnostics of the vehicle provided through telematics.
[0024] With the foregoing and other objects in view, there is provided, in accordance with the invention, a method for delivering a criteria-based message to a vehicle occupant comprising the steps of transmitting a user initiated telematics request from a telematics unit integral with a vehicle to a data center remote from the vehicle, determining at the remote data center a response to the telematics request including both a descriptive response and an audio service demonstration, the user selecting one of the descriptive response and the audio service demonstration, dependent upon the selection by the user, communicating the response to the telematics request and the one of the descriptive response and the audio service demonstration from the remote data center to the telematics unit, and outputting the one of the descriptive response and the audio service demonstration to a user in the vehicle through a speaker within the vehicle.
[0025] With the objects of the invention in view, there is also provided a method for delivering a criteria-based message to a vehicle occupant, the method comprising the steps of determining a set of audio service demonstrations, associating at least one prerequisite with each of the audio service demonstrations, transmitting a user initiated telematics request, an identifier of the vehicle, and at least one criteria from a telematics unit integral with a vehicle to a data center remote from the vehicle, comparing at the remote data center at least one of the user initiated telematics request, the identifier of the vehicle, and the at least one criteria with the at least one prerequisite, determining at the remote data center a response to the telematics request including both a descriptive response and one of the audio service demonstrations dependent upon the comparison, communicating the response to the telematics request and the one of the descriptive response and the one audio service demonstration from the remote data center to the telematics unit, and outputting the one of the descriptive response and the one audio service demonstration to a user in the vehicle through a speaker within the vehicle.
[0026] In accordance with another mode of the invention, included with the user initiated telematics request at least one of an identifier of the vehicle and at least one criteria, the response determining step is carried out by determining at the remote data center a response to the telematics request that is dependent upon at least one of the vehicle identifier and the at least one criteria, and the communicating step is carried out by, dependent upon the selection by the user, communicating the one of the dependent descriptive response and the dependent audio service demonstration from the remote data center to the telematics unit.
[0027] In accordance with a further mode of the invention, the at least one criteria comprises at least one of a time of day, a time of year, and a season.
[0028] In accordance with an added mode of the invention, the at least one criteria comprises at least one of a task progress, a scheduled event, a geographic location of the vehicle, and a condition of the vehicle. The condition of the vehicle can be an indication that the vehicle is upside-down or an indication that the vehicle has been in an accident.
[0029] In accordance with an additional mode of the invention, an interrupt command is accepted from the telematics unit, the output of the audio service demonstration is halted in response to accepting the interrupt command, and a driver assist query is initiated.
[0030] In accordance with a concomitant mode of the invention, the audio service demonstration comprises an acted out service example that includes one or more of a description of a tourist attraction, a colloquy about purchasing an item, a colloquy about making a reservation, and a description of performing a service at a dealer of the vehicle.
[0031] Other features that are considered as characteristic for the invention are set forth in the appended claims.
[0032] Although the invention is illustrated and described herein as embodied in system, method, and process of delivering criteria-based audio messages from a remote data center database over a wireless link, 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.
[0033] 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
[0034] Advantages of embodiments of the present invention will be apparent from the following detailed description of the preferred embodiments thereof, which description should be considered in conjunction with the accompanying drawings in which:
[0035] FIG. 1 is a block diagram of a mobile communication system in accordance with the present invention;
[0036] FIG. 2 is a block diagram of a control center in accordance with the present invention; and
[0037] FIG. 3 is a flow diagram illustrating a process of utilizing the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0038] Aspects of the invention are disclosed in the following description and related drawings are directed to specific embodiments of the invention. Alternate embodiments may be devised without departing from the spirit or the scope of the invention. Additionally, well-known elements of exemplary embodiments of the invention will not be described in detail or will be omitted so as not to obscure the relevant details of the invention.
[0039] Before the present invention is disclosed and described, it is to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. It must be noted that, as used in the specification and the appended claims, the singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise.
[0040] While the specification concludes with claims defining the features of the invention that are regarded as novel, it is believed that the invention will be better understood from a consideration of the following description in conjunction with the drawing figures, in which like reference numerals are carried forward. The figures of the drawing are not drawn to scale.
[0041] The present invention provides a system and method for delivering information to a vehicle where the information is related, at least partially, to a particular criteria pertaining to the vehicle or driver. This criteria can include vehicle location, time of day, time of year, weather conditions, vehicle driver information, vehicle diagnostic information, vehicle-specific information (e.g., make, model, year, type, vehicle repair history and vehicle repair schedule), and many other pieces of information. Embodiments of the present invention provide a plurality of information types, such as sales and other commercial offers, and criteria used to determine which type will be transmitted and to whom, where, and at what time.
[0042] When one or more statistics associated with either the vehicle, the driver, or both, is known, the statistic(s) is compared to the criteria associated with each message and an advertisement message is transmitted to the vehicle for playback over the vehicle's audio system. In accordance with inventive aspects of the present invention, the driver could be given a choice of how the informational message is heard. This choice includes hearing a service description versus a service example. A service description is just that—details of the service are described to the driver in an effort to interest the driver and encourage the driver to purchase the service. A service example provides a dialogue, usually between two people, illustrating an example of how the service can be used. The voice application design of the present invention encourages the driver, or any other occupant within the vehicle, to listen to a service example, which can be randomly selected, instead of a service description. Research has shown that service examples are far more effective at selling than a less enjoyable service description. Embodiments of the present invention can feature multiple personas that add to the effectiveness of the up-selling technique.
[0043] Referring now to FIG. 1 , a block diagram of a representative system for delivering criteria-based messaging according to embodiments of the present invention is shown. A vehicle 100 , which includes any vehicle capable of movement, is operated by a driver 101 . The vehicle 100 , according to one embodiment, is provided with a telematics system 103 that includes a telematics control unit 102 , a wireless communication module 104 , an antenna 106 , a GPS receiver 107 , a microphone 108 , a speaker 110 , and a user input 112 , such as a button.
[0044] There are a number of exemplary uses for a telematics system 103 . One exemplary use is the most commonly found use of a telematics system—to summon roadside assistance. For the present example, the entity supplying the telematics system 103 has live operators at a remote facility, e.g., at a control center 200 , shown in FIG. 2 , for providing roadside assistance through a voice communication. Further, the user input 112 is operable to call the control center 200 upon a single actuation. For example, the telematics system 103 can have a red “emergency” button that, when pressed, opens a communications channel to the operator. Accordingly, when the vehicle occupant presses the button, the appropriate software is called up to enable a “live-operator-communication.”
[0045] If, as shown in FIG. 1 , the telematics system 103 has an embedded GPS system 106 , the data sent to the control center 200 can include current GPS location coordinates. In this way, the operator can be provided with the information pinpointing the vehicle's location before voice communication occurs between the operator and the occupant.
[0046] Roadside assistance is only one of the possible telematics functions that could be provided with the inventive telematics system 103 of the present invention. Another function that could be provided with the telematics system 103 is a door-unlock command. If the telematics system 103 is communicatively coupled with the device that unlocks a locked door of the vehicle, then the telematics system 103 can interface and actuate the door-unlocking device. If the telematics system 103 is similarly connected to the vehicle starting assembly, then the telematics system 103 can effect a remote engine start with little added difficulty. Likewise, if the telematics system 103 has access to the vehicle's diagnostics bus, then any available diagnostic status can be made accessible not only to the driver, but also to an operator at the control center 200 . In an emergency, where the driver/passenger(s) is not available, the telematics system 103 can be programmed to automatically send a diagnostics state(s) to the control center 200 .
[0047] It should be noted that at least part of the telematics system 103 is integrated with the vehicle. Here, integrated or integral means that part of the system 103 is at least semi-permanently attached to the vehicle or parts of the vehicle. That is, integral or integrated does not describe devices, such as cellular phones, which can easily be carried into and out of a vehicle. In some embodiments of the present invention, the telematics system 103 is not supplied by the original equipment manufacturer, but is, instead, an aftermarket device. However, once the aftermarket device is permanently or semi-permanently connected to the vehicle's wiring (i.e., diagnostic data wiring), the aftermarket telematics device becomes “integral” with the vehicle. In each case, the integrated telematics system 103 is embodied in at least one physical component of the system 103 (i.e., a telematics “device”) present at the vehicle that is physically accessible and/or visible to an occupant within the vehicle. The telematics device houses at least one component of the above-describe telematics system 103 and is in communication with the other components of the system 103 . For instance, at least the button 112 is physically accessible by an occupant of the vehicle and generally, one or more lights will be visible within the vehicle's interior. Pushing the button 112 will cause one or more of the other system components to operate.
[0048] FIG. 2 shows block diagram of an exemplary remote control center 200 . The control center 200 includes a data center 202 , an automated voice system 204 , studio recording prompts 206 , and a database 208 . The control center 200 receives communication signals from the vehicle 100 over a communication link 212 that is connected to a wireless network base station 210 .
[0049] In the context of the present invention, a data center 202 is substantially a highly automated call center that is aimed at providing telematics services. The data center 202 communicates with vehicles through voice and data channels and is capable of managing a variety of vehicle-centric functionality, including vehicle emergencies. Live agents and automated voice systems 204 are components of the data center. In one embodiment of the present invention, the type of data communicated to and from the vehicle includes, for instance, information related to vehicle location, diagnostic data, driver requests, and other vehicle-centric functionality. The voice-automated system 204 communicates with a vehicle driver much like a live agent would, although when emergencies are involved, calls are routed to live agents whenever possible. Voice automated systems 204 play audio prompts to the vehicle driver that are recorded at a studio, usually by professional talent (high quality voices). In many cases, text-to-speech engines generate the audio prompts and yield a lower quality of speech as heard by the driver. Text-to-speech can be used in place of studio prompts to save on cost, but human recordings are preferred for most applications.
[0050] The off-board automated voice system 204 and the other components shown in FIG. 2 are advantageous to the present invention. The intelligence behind the presently-inventive message criteria system is shared between the on-board and off-board components, but the major computing is performed at the control center 200 , where more computing power is available than on the vehicle. Updates can be performed to the off-board components much easier than identifying and accessing the many mobile units utilizing the inventive system.
[0051] For an outgoing message from the control center 200 to the vehicle, the criteria-based audio messages are managed and transmitted by the automated voice system 204 , then are passed through the data center 202 , through one of many available telecommunications networks 212 , through the wireless network base station 210 , over a wireless link 201 to the vehicle 100 , through the vehicle mounted wireless antenna 106 , through the vehicle mounted wireless communication module 104 , and finally broadcast on the vehicle's speaker(s) 110 in a hands-free environment.
[0052] When a vehicle driver 101 initiates a telematics connection, the vehicle driver's spoken commands pass through the vehicle microphone 108 , through the vehicle-mounted wireless communication module 104 , through the vehicle mounted wireless antenna 106 , over a wireless link 212 , through the wireless network's antenna 214 and wireless network base station 210 , through one of many available telecommunications networks 212 , and into the data center 202 , which is connected to the automated voice system 204 .
[0053] Once the command arrives, the automated voice system 204 interprets the spoken command(s). Depending on the nature of the telematics request from the vehicle driver 101 , the vehicle driver 101 can, for example, select a menu item, request to subscribe to a service, abort the session, command the system to perform any number of telematics tasks, or many other selectable options.
[0054] The telematics request can be accomplished automatically or by pressing the button 112 and speaking a command that is detected by the microphone 108 within the vehicle 100 . When a telematics connection is established between the vehicle 100 and control center 200 , information is exchanged between the vehicle 100 and the control center 200 . This information can include vehicle location, vehicle model information, vehicle driver information, diagnostic information, and other information, all referred to as “statistics” herein. Some information may be known prior to the driver 101 pushing the button 112 and some statistics are captured at the time or after the button 112 is pushed. It should be noted that pushing a button is only one exemplary way to cause the system to initiate a functional state and other methods, such as speaking a particular word, are contemplated by the present invention.
[0055] After communication between the vehicle 100 and control center 200 is established, the vehicle driver 101 hears audio prompts through the speaker 110 . The speaker 110 can be the vehicle's factor equipped speakers or can be aftermarket add-on speakers, preferably located in proximity to the vehicle driver 101 . Depending on conditions at the time of the telematics service request (i.e., the button push), the vehicle driver 101 may or may not hear an audio message.
[0056] As just one example of the present invention, a vehicle driver is exposed to an audio message when it is determined that the vehicle's location is within a specified radius surrounding the location of an upcoming event that is scheduled to occur. The intent of the message could be to promote the event to the driver with a short audio message that is played inside the vehicle using audio equipment located therein, such as speaker 110 . More specifically, if the event were, for instance, a sale at a car dealership, the car dealer would register the event with the control center 200 in advance and provide information relevant to the sale. The dealer could also select criteria prerequisites which the control center 200 would then use to filter potential message recipients based on their statistics within particular criteria categories. For instance, if the dealership was a particular dealership, one criteria could be whether or not a person is a current owner of a particular vehicle. A statistic would be the year or model of the particular. Therefore, as an example, a dealership could specify: 1) that the sale would be announced only to drivers of particular vehicles; 2) only to drivers of particular vehicles manufactured more than five years prior; and 3) only to drivers of particular vehicles manufactured more than five years prior that are currently within five miles of the dealership.
[0057] In some cases, the audio message will reference the event and provide directions and other information that will allow the user to attend the event either immediately or at a later date. In addition, the message may indicate that an email with details will be sent to the driver. This communication lets the driver know to expect the message, hopefully making the driver more willing to read it once he or she sees it in his or her inbox. In the email scenario, the driver is assumed to be a current service subscriber and the remote message center would have access to customer data, such as an email address.
[0058] Examples of telematics services are virtually unlimited, but include, from a remote center 200 to a driver 101 , provision of directions, location of nearby stores, restaurants, parks, highways, etc., placing reservations for the driver, directing emergency services to the vehicle's location, and the provision of many more services. In addition, the telematics system 103 is connected to multiple sensors throughout the car. Advantageously, the telematics system 103 is able detect a large number of attributes of the vehicle at any time. The attributes include the condition of the vehicle, such as the vehicle's diagnostic information (e.g., engine statistics), orientation of the vehicle (e.g. the car is upside down), whether airbags have deployed, whether the oil needs to be changed, if the car is mobile without a seatbelt connected, and many more. Each of these attributes can be transmitted to the remote data center and can be the subject of a criteria-based message.
[0059] In embodiments of the present invention where a telematics request is initiated by the button 112 , a criteria-based message could be delivered after the driver pushes the button 112 , but before the telematics request is delivered to the driver. In other words, the actual telematics request could be fulfilled after a short audio message is delivered to the driver. For example, if the vehicle driver 101 pushed the telematics button 112 for the purpose of getting driving directions from a call center agent, the criteria-based audio message would occur first. Embodiments of the present invention also provide for an interrupt feature where the driver 101 can halt the output of the message and jump to whatever driver assist query he or she was seeking.
[0060] Another example of criteria-based messaging involves service promotion, or up-selling. For example, a vehicle driver 101 may initiate a telematics request by pushing the button 112 inside the vehicle 100 . Although the button 112 is referred to herein in the singular, the button 112 can be multiple buttons. Examples of such buttons 112 include an SOS button, an information button, a concierge button, or a roadside button. Depending on conditions at the time of the telematics service request, the vehicle driver may or may not hear a criteria-based audio message. For illustration purposes, assume that the vehicle driver 101 pushes a concierge button, but the driver is not a subscriber to the concierge service. A dialogue would be initiated by the voice automation system 204 and prompting would occur with the intent of up-selling the vehicle's driver 101 by transforming the mood of the driver 101 into a buying mode.
[0061] As another example, a criteria-based message may be initiated by an upcoming or past expiration of a user's subscription to a service. In addition, a newly available subscription could be the subject the initiates a message being broadcast to a driver.
[0062] Criteria-based messaging can also be used to inform a driver that a new location-based service is available. A traffic report is just one example of a service that is only available and relevant in certain locations, such as metropolitan areas. Traffic reports are not available or considered as important in many regions where traffic is sparse. A vehicle driver may be in an area that has grown in population to the extent that traffic can be an issue. As new traffic services become available, criteria-based audio messaging can be used to inform drivers that traffic information is available in their immediate area, identified by the GPS component 107 , or an area that the GPS component 107 has identified that vehicle as traveling through at least once. Depending on a vehicle's location at the time of a telematics service request, the vehicle driver may hear a criteria-based audio message indicating that traffic service is now available.
[0063] Likewise, there may be a new facility or tourist attraction that could be advertised to a vehicle driver based on vehicle location. Again, a telematics request could be fulfilled after a short audio message is delivered to the driver.
[0064] As an additional example, criteria-based audio messages may be triggered based on seasonal changes. As just one example, many vehicles need special attention before winter begins, depending on their location of use. Upon pressing the button 112 , a message may be played that announces a particular business's products, e.g. snow tires, that are specific to a season (a first criteria) and the type of vehicle (a second criteria). Many other criteria can be utilized as well, such as the vehicle's normal driving area (determined via GPS 107 ), previous purchases or services performed on or to the vehicle, and many others.
[0065] As a further example of the advantageous features of the present invention, suppose a car salesperson is showing a vehicle to a potential buyer and wishes to demonstrate the advantageous feature of telematics system equipped on the vehicle. The salesperson can instruct the potential buyer to press the button 112 , which initiates a call to the control center 200 , which, in turn, determines whether the particular car is currently subscribed to the service (a criteria). If the unit is not identified as a currently subscribing vehicle, the control center 200 can initiate a demonstration service example in an effort to both educate the potential buyer, as well as entice the buyer to purchase the vehicle and to subscribe the inventive service. The following is an exemplary service example that can take place and educate as well as entertain the potential purchaser, or anyone else listening to the advertising message. Note that the following example dialogue between two people is an example of a prerecorded dialogue and that the potential purchaser or any other person at the vehicle side are listening to and are not participating in the dialogue.
Example
[0000]
Female voice: Telematics service center. How may we be of assistance?
Male voice: Today is my anniversary and I would like to have flowers delivered to my wife.
Female voice: Happy anniversary! I can certainly help you with that. What type of flowers were you looking for and where would you like them delivered.
Male voice: I was thinking of a dozen long stem roses. My wife's address at work is 3232 Main Street, Suite 123, so if they could be delivered before she leaves at 6:00, that would be great. Her name is Susie Smith.
Female voice: No problem Mr. Smith. I have located a flower shop near this address. When we finish this call, I will connect you directly with the shop. Is there anything else I can help you with?
Male voice: There is. I would like to take her to a nice dinner tonight. What are some good restaurants downtown?
Female voice: I have located quite a few highly rated restaurants in that area, what type of food are you looking for?
Male voice: A good steak restaurant sounds nice.
Female voice: I have located Restaurant X, which received five stars in our latest restaurant review. Would you like me to make reservations for you?
Male voice: Yes, please. I would like them for 7:00.
Female voice: Please hold for a second. Okay, your reservations have been made and are under your name. Would you like to have a bottle of Champagne on ice at the table when you arrive?
Male voice: Wow, that would be great!
Female voice: I will take care of that for you. Is there anything else I can help you with today?
Male voice: No, thank you so much.
Female voice: It was our pleasure. I will now connect you with the flower shop. Have a great evening!
[0081] The service example, such as the one above, is believed to be much more interesting to the listener than a simple prerecorded description of available features, which tend to be monotone and lack emotions. The above exemplary dialogue is not limited to potential purchases and can be played to owners of cars equipped with the present invention whether they are subscribers or not. In one embodiment, the invention can provide a system for tracking service examples or descriptions that have been demonstrated and ensures that these same advertising messages are not repeated to the same vehicle driver. The prerecorded service examples are an advantageous way to educate subscribers or non-subscribers of the types of services available. It allows dialogues to be played out without requiring live operators to speak to each person. However, the invention is in no way limited to pre-recorded messages and, in some cases, live operators can perform the service examples. It is envisioned that, prior to subscribing to the service, only pre-recorded messages will be available to the driver.
[0082] As previously stated, when delivering criteria-based messages, it is believed that service examples are more attractive to listeners and more effective at conveying a service's features. In addition, when considering potential audio prompts that a listener hears when using an automated voice applications, one goal has been to make the user's experience better by completing the caller's task in a time-efficient manner, making it less likely that a caller will request conversation with a human. Over time, automated applications have become more human-like with signs of reaching natural language. Callers can even relate to an automated “persona,” as speech vendors have been calling the implied personality of the automated system. There is an opportunity to involve the caller emotionally, even to entertain by humor, for example, and to make the call a pleasant experience. Even if a dialogue designer does not attempt to create human-like qualities, the caller will intuitively assign them to the automated persona. If used properly, this characteristic can make audio messages to the vehicle very effective.
[0083] FIG. 3 shows an exemplary process for performing the inventive method in accordance with embodiments of the present invention. The process starts at step 300 and moves directly to step 302 where at least one advertisement is established, the advertisement having at least one criteria requirement associated therewith. “Establishment” can mean the actual recording of the advertisement and the “criteria requirement” can indicate factors that determine who is to hear the recorded message and when they should hear it. The criteria requirement includes prerequisite statistics that are to be met before the advertisement should be transmitted to a particular vehicle. In step 304 , a driver 101 initiates a telematics feature within a vehicle 100 . For instance, the driver 101 can press the button 112 within the car. In step 306 , the in-car equipment initiates a communication session over a wireless link 212 to a remote control center 200 . Included in this communication of step 306 is at least one statistic pertaining to at least one criteria. This includes, for example, information pertaining to the vehicle to which the equipment is attached, the vehicle's location, whether the driver is a subscriber or not, and many others. In step 308 , the control center 200 compares the at least one criteria requirement to the at least one criteria. Based on this comparison, the control center returns a response to the vehicle 100 in step 310 . The response, in one embodiment, is an automatically determined advertising message based on one or more of the identified criteria and associated statistics. The message, for instance, is an advertising message attempting to persuade the listener to take an action. In step 312 , the advertisement message is broadcast to the driver. In step 314 , after the criteria-based message has finished playing in step 312 , the system allows the driver 101 to carry out his or her desired use of the telematics service. At any time during step 312 , the user can push a button (step 316 ) to interrupt the playing of the message and the process will immediately jump to step 314 .
[0084] A method and process of delivering criteria-based audio messages through a wireless connection to a vehicle has been described. The present invention pertains to a method and system for delivering audio messages that are stored off-board, and triggered by conditions related to criteria, such as time, vehicle location, an event, a condition, a mood-influencing intent, a tourist attraction, or service reminders. The criteria-based messages are controlled by an automated voice recognition system located at a remote data center and delivered via a wireless voice, or data channel to the vehicle. The vehicle driver and/or passengers hear the audio message under various driving conditions. A voice user interface is utilized by the vehicle driver to manage the audio messages. The invention further includes methodology for pushing audio messages to a vehicle in a highly controlled fashion and in a way that does not interfere with the task of driving. The present invention further includes techniques for designing audio messages that match the intent associated with the criteria required to trigger the deliverer of the audio message.
[0085] Although the foregoing specific details describe a preferred embodiment of this invention, persons reasonably skilled in the art of wireless data communication and/or voice recognition technology will recognize that various changes may be made in the details of the method and apparatus of this invention without departing from the spirit and scope of the invention as defined in the appended claims. Therefore, it should be understood that this invention is not to be limited to the specific details shown and described herein. The above-described embodiments should be regarded as illustrative rather than restrictive. Accordingly, it should be appreciated that variations to those embodiments can be made by those skilled in the art without departing from the scope of the invention as defined by the following claims.
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A method for delivering a criteria-based message to a vehicle occupant includes the steps of transmitting a user initiated telematics request from a telematics unit integral with a vehicle to a data center remote from the vehicle, determining at the remote data center a response to the telematics request including both a descriptive response and an audio service demonstration, the user selecting one of the descriptive response and the audio service demonstration, dependent upon the selection by the user, communicating the response to the telematics request and the one of the descriptive response and the audio service demonstration from the remote data center to the telematics unit, and outputting the one of the descriptive response and the audio service demonstration to a user in the vehicle through a speaker within the vehicle.
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Silanes are known as cross-linking agents which are useful in coatings and adhesives. One such type of coating is "clearcoats" for automobiles, which provide a clear protective layer over pigmented basecoats. Such coatings have been disclosed in U.S. Pat. Nos. 5,250,605, 5,162,426 and 5,244,959 to Hazan et al.; U.S. Pat. Nos. 4,499,150 and 4,499,151 to Dowbenko et al.; and PCT Publication No. WO 95/19982.
Some of this art teaches the utility of silane oligomers or interpolymers for such coatings. For example, U.S. Pat. Nos. 4,499,150 and 4,499,151 teach a copolymer of an ethylenically unsaturated alkoxysilane with another ethylenically unsaturated group made by free radical polymerization. Because of the formulation chemistry, these interpolymers are limited in structure and functionalities.
Moreover, U.S. Pat. No. 5,432,246 to Fenn et al. discloses a silane oligomer made from a 2° amino-alkoxy silane, a polyisocyanate and optionally a single isocyanate group. Such oligomers are based on the reaction of the amine with the isocyanate to form a substituted urea. In these oligomers all the isocyanate groups have reacted with the amine groups, so no such functionalities are present. Further, urea structures may increased viscosity to an unwanted degree.
It is desirable to have coatings which incorporate alkoxy silane functionalities because siloxane bonds provide good chemical resistance; however, appearance (gloss and DOI (distinctiveness of image)), mar resistance and lack of cracking all are other properties required for coatings, which properties are deficient in one respect or another in the known prior art.
SUMMARY OF THE INVENTION
The present invention teaches the formation and use of siloxane oligomers having a plurality of alkoxy groups, which oligomers have attached thereto, by other than an Si--O bond, further silyl functionalities. These oligomers may be of the formula
[R.sub.3 SiO.sub.1/2 ].sub.m [O.sub.1/2 Si(R.sub.2)O.sub.1/2 ].sub.n [SiO.sub.3/2 R].sub.o [SiO.sub.4/2 ].sub.p (I)
wherein
Each R is selected individually from the group consisting of B, R 1 ,--OR 1 and W;
wherein
B is a silyl functionality group bridged by other than an Si--O bond to the Si atom of the siloxane oligomer backbone;
each R 1 is individually a saturated or aromatic hydrocarbon group of 1 to 12 carbon atoms;
each W individually is a monovalent radical;
with the provisos that at least one R is a B and at least one quarter of all R groups are --OR 1 ;
m=2 to 20;
n=0 to 50;
o=0 to 20; and
p=to 5.
DETAILED DESCRIPTION OF THE INVENTION
Structure
In structure I above, B is a silyl functionality group which is attached to the siloxane oligomer by other than an Si--O bond. There must be at least one B per siloxane oligomer, which preferably is internal to the oligomer. More preferably there are at least two B groups per oligomer. Usually, if a B group is attached to a silicon atom of the siloxane backbone, the other R group(s) on that silicon atom is an alkoxy group.
The divalent linking group between the silicon atom of the silyl functionality group and the silicon atom of the siloxane oligomer may not contain an Si--O bond, but otherwise may include any heteroatoms, e.g., it may be alkylene, arylene, alkarylene, polyalkylene oxide, polyurethane, isocyanurate. The linking group may be branched and may be olefinically or aromatically unsaturated. Preferably the bridging group is an alkylene of 2 to 12 carbon atoms, e.g., cyclo aliphatic (e.g., 1,4 diethylene-cyclohexane or 1,3,5 triethylene cyclohexyl) or linear (e.g., butylene, propylene). The divalent linking group may be substituted with silyl or siloxy functions, as well as unsaturated groups. Indeed, the divalent linking group may form part of a backbone with relatively linear siloxane chains attached to either end of the group. An exemplary bridging group is 2,4 ethylene, 1-vinyl cyclohexane.
The silyl functionality at the end of the divalent bridging group may be an alkoxysilane, halo silane, a siloxane or may have further functionalities. Preferably, the silane is an alkoxy silane, more preferably a dialkoxy silane and most preferably a trialkoxy silane.
A preferred B group may be represented as --C f H 2f --SiR 2 g (X) 3-g wherein f=2 to 12, g=0 to 2, X is a halogen or --OR 2 , and each R 2 is selected from W and R 1 . More preferably f=2 to 6, g=3 and X is --OR 2 , and most preferably wherein R 2 R 1 , most preferably methyl. Preferable B's are --(CH 2 ) 2 Si(OCH 3 ) 3 ; --(CH 2 ) 2 Si(OC 2 H 5 ) 3 --(CH 2 ) 2 Si(OCH 3 ) 2 (CH 3 ); --(CH 2 .sub.) 2 Si(OCH 3 ) 2 Cl; --C 2 H 4 (C 6 H 9 )(C 2 H 4 Si(OCH 3 ) 3 ) 2 ; --C 2 H 4 (C 5 H 8 )C 2 H 4 Si(OC 2 H 5 ) 3 ; and --C 2 H 4 Si(OCH 3 ) 2 (OSi(OCH 3 ) 3 ).
W is a monovalent radical and may be an unsaturated non-aromatic hydrocarbon, hydroxy, an amine, an ester, a polyalkylene oxide, a thioester, an amide, a carbamate, an epoxy, cyano, polysulfide, or isocyanurate. Specific examples of W include gamma propyl amino, gamma propyl glycidoxy, acetoxy ethyl, propylene glycol, gamma propyl carbamate, dimethoxy phenyl propyl, n-octenyl, 2-ethyl, 3,4 epoxy cyclohexane, or cyano ethyl or an alkyl radical substituted with such groups. Usually if a W group is attached to a silicon atom, the other R group(s) on that silicon atom is a hydrocarboxy group (--OR 1 ),preferably an alkoxy.
R 1 is a saturated or aromatic hydrocarbon of 1 to 12 carbon atoms, e.g., alkyl (linear or branched) cycloalkyl, aryl or alkaryl. Exemplary R 1 are i-propyl, i-butyl, t-butyl, n-pentyl, cyclohexyl, phenyl, benzyl or napthyl. Specifically, methyl or ethyl are preferred for R 1 .
Preferably m+n+o+p<50, more preferably <30 and most preferably <15. Preferably m is 2 to 4, n is to 1 to 15, o is 0 to 2 and p is 0 to 1, though it is understood there may be distributions of the number of siloxy units within a given oligomer batch.
Preferably there are multiple alkoxy groups available on the oligomer so that upon curing these oligomers may cross-ink, i.e., form Si--O--Si bonds with each other or with a silylated polymer or inorganic material. Thus, R is --OR 1 , more preferably ethoxy or methoxy, in at least one quarter of the R groups, more preferably in at least half of the R groups, while the remainder of the R groups are B or W groups, more preferably, trialkoxysilylethyl groups, most preferably trimethoxysilylethyl. In such embodiments p=0, o=0, m=2 and n=2 to 20.
A preferred formula for the oligomer is
[R(R.sup.1 O).sub.2 SiO.sub.1/2 ].sub.m [O.sub.1/2 SiR(OR.sup.1)O.sub.1/2 ].sub.n [SiO.sub.3/2 R].sub.o
with R, R 1 , m, n and o as above and with R 1 preferably methyl, o=0, m=2 and n=0 to 15. Most preferably, all R's are either --OR 1 or B. Specific examples of the oligomer include ##STR1##
It is preferred that the oligomer has a viscosity of 0.5 to 500 csks or more preferably 0.5 to 200 csks (25° C.). As is clear to one of skill in the art, the viscosity of the oligomer may be adjusted by adjusting the number of siloxy groups in the oligomer. In most cases the viscosity will be adjusted for a specific application to ensure that the composition containing the oligomer will spread over a specific substrate or be sprayable.
Method of Manufacture
The oligomers of the present invention may be formed in a two step process or one step process. In the two step process a condensation reaction is followed by a hydrosilation reaction. Such a two step process is (1) a siloxane oligomer with olefinically (ethylenic or acetylenic) unsaturated groups is produced by condensation from an unsaturated alkoxy silane, and optionally, other alkoxy silanes; and (2) hydrosilylating the oligomer produced in step (1) with an alkoxy hydrido silane. Alternatively the two steps are, (1) a siloxane oligomer is formed by condensation from alkoxy hydrido silanes, and optionally, other alkoxy silanes, which (2) oligomer is hydrosilylated with an olefinically unsaturated alkoxy silane. In the one step process bis alkoxy silane(s), wherein the silicon atoms are attached by other than an Si--O bond are condensed, preferably with other alkoxy silanes, to form a siloxane oligomer.
The condensation may be performed according to either U.S. Pat. No. 4,950,779 or 5,210,168, which are incorporated herein by reference. In the two step process, the first starting material is either an olefinically unsaturated alkoxy silane or a hydrido alkoxy silane, which preferably are trialkoxysilanes. The alkoxy groups may be C 1 -C 12 , may be branched cyclic or include aryl groups, and may include heteroatoms. The preferred alkoxy groups are methoxy, ethoxy, isopropoxy, n-butoxy and cyclohexyloxy. Examples of the unsaturated group may be vinyl, acryl, methacryl, acrylate, acetylenyl, or any 1,2 unsaturated olefin. There may be different such unsaturated groups within one oligomer.
The starting material for the one step process is a bis alkoxy silane. Preferably a bis dialkoxy silane or bis trialkoxy silane is the starting material. Exemplary such silanes are 1, 4-bis(trimethoxysilylethyl)cyclohexane; 1,3,5tris(trimethoxysilylethyl)cyclohexane; and 1,4-bis(triethoxysilyl)butane. While such starting materials are more difficult to manufacture than the above starting materials, they offer two advantages, a one step process and the avoidance of the potential of unsaturated groups being left in the oligomer.
During condensation, other optional alkoxy silanes may be incorporated into the oligomer including, but not limited to, aryl silanes, alkyl silanes, amino silanes, epoxy silanes, amido silanes, carbamato silanes, cyano silanes, polyalkylene oxide silanes, ester silanes, or isocyanurate silanes. Said alkoxy silanes may be bis or tris alkoxy silanes. Specific examples of these silanes include: bis(trimethoxysilylethyl)benzene, tris(2-trimethoxysilylethyl)cyclohexane, 3-glycidoxypropyltrihethoxysilane, 3-aminopropyltriethoxysilane, 3-aminopropylmethyldiethoxysilane, and methyl N--(3-trimethoxysilylpropyl) carbamate. These silanes must have at least one alkoxy group (in which case they would be end units on the oligomer), but preferably are di- or tri- alkoxy silanes.
Moreover, in the condensation dialkoxy siloxy units may be inserted into the oligomer to affect the cross-linking, surface active and viscoelastic properties of the oligomer. Said may be done by using tetraalkoxy silanes, e.g., tetramethoxy or tetraethoxy silane.
The condensation of the alkoxy silane monomers is performed in the presence of a carboxylic acid (e.g., acetic or formic acid) or water. Additionally a strong condensation catalyst may be used, e.g., an ion exchange resin. The other reaction conditions of the condensation will depend on the monomeric silanes; however, temperature should be in the range of 20 to 60° C.
In the two step process the product of the condensation is a siloxane oligomer containing either (1) at least one unsaturated functionality which is attached to a silicon atom on the siloxane backbone by other than an Si--O bond or (2) at least one silanic hydride. The unsaturated or silanic hydride siloxane oligomer produced in Step 1 is reacted with either a hydrido silane or an olefinically unsaturated silane, respectively, in the presence of a catalyst by noble metal catalyst chemistry or by free radical chemistry. Such hydrosilation, for example, may be accomplished according to U.S. Pat. Nos. 5,530,452 and 5,527,936, which are incorporated herein by reference. It is preferred that the hydrido silane or olefinically unsaturated silane be trialkoxy to afford a great deal of cross-inking to the resulting oligomer. During reaction, the hydrogen on the hydrido silane is reactive with the unsaturation(s) groups and a bond is formed between the silicon atom and the unsaturated group (which, if ethylenic, is saturated in the process). In some cases there may be unsaturated sites left on the oligomer.
The resulting oligomer is of the structure above.
Utility
These oligomers are useful in coatings or adhesives, especially those where alkoxy silanes are a component. In one application oligomers may be used to moisture cure said adhesive or coating. The oligomers may be used as a reactive diluents, in that they have little volatility will not contribute to volatile organic compounds (VOCs) and have an adjustable viscosity to match an application, or to dilute another composition to make the entire composition spreadable or sprayable. Moreover, there is the benefit to the use of these oligomers in that the only VOC's which may be produced with the use of these oligomers may be the alcohols of the alkoxy groups.
Said oligomers may be used in masonry waterproofing, paints, corrosion protection systems, and on substrates such as cement, metal, polymers (PVC, PVS, EPDM, PE, PP, ABS, EPR, BR, silicone, polycarbonate, etc.), wood, a paint layer (as a primer) or rubber. Moreover, oligomers may be used in silicate hardcoats.
The oligomers may be used by themselves or with other monomers, cross-link epoxy silane with polyacid, and if the oligomer is unsaturated, copolymerized with other acetylenic unsaturated monomer. Specifically said oligomers are useful in the aforementioned clearcoats. Said clearcoats may be made per U.S. Pat. No. 5,244,696 to Hazan et al., which is incorporated herein by reference. Clearcoats made with the present oligomer have good mar resistance, good gloss (and gloss retention), chemical resistance, distinctiveness of image (DOI), and stain resistance.
Coating compositions incorporating the oligomer of this invention can include a number of ingredients to enhance preparation of the composition as well as to improve final properties of the coating composition and the finish. For example, it is often desirable to include about 20 to 90%, preferably 20 to 60%, by weight of the composition, of a film-forming reactive silane polymer. Such polymer typically has number average molecular weight of about 500 to 10,000.
The silane polymer is the polymerization product of about 30-95%, preferably 40-60%, by weight of ethylenically unsaturated nonsilane containing monomers and about 5-70%, preferably 10-60%, by weight of ethylenically unsaturated silane-containing monomers, based on the weight of the organosilane polymer. Suitable ethylenically unsaturated nonsilane containing monomers are alkyl acrylates, alkyl methacrylates and mixtures thereof, where the alkyl groups have 1-12 carbon atoms, preferably 3-8 carbon atoms.
The film-forming component of the coating composition is referred to as the "binder" and is dissolved, emulsified or otherwise dispersed in an organic solvent or liquid carrier. The binder generally includes all the components that contribute to the solid organic portion of the cured composition. Generally, pigments, and chemical additives such as stabilizers are not considered part of the binder. Non-binder solids other than pigments typically do not exceed about 5 % by weight of the composition. The term "binder" includes the oligomer of the present invention, the organosilane polymer, the dispersed polymer, and all other optional film-forming components. The coating composition contains about 50-100% by weight of the binder and about 0-50% by weight of the organic solvent carrier.
Suitable alkyl methacrylate monomers used to form the silane polymer are methyl methacrylate, ethyl methacrylate, propyl methacrylate, butyl methacrylate, isobutyl methacrylate, pentyl methacrylate, hexyl methacrylate, octyl methacrylate, nonyl methacrylate, lauryl methacrylate and the like. Suitable alkyl acrylate monomers include methyl acrylate, ethyl acrylate, propyl acrylate, butyl acrylate, isobutyl acrylate, pentyl acrylate, hexyl acrylate, octyl acrylate, nonyl acrylate, lauryl acrylate and the like. Cycloaliphatic methacrylates and acrylates also can be used, such as trimethylcyclohlexyl methacrylate, trimethylcyclohexyl acrylate, iso-butyl cyclohexyl methacrylate, t-butyl cyclohexyl acrylate, and t-butyl cyclohexyl methacrylate. Aryl acrylate and aryl methacrylate also can be used, such as benzyl acrylate and benzyl methacrylate. Mixtures of two or more of the above-mentioned monomers are also suitable.
In addition to alkyl acrylates and methacrylates, other polymerizable nonsilane-containing monomers, up to about 50% by weight of the polymer, can be used in the silane modified acrylic polymer for the purpose of achieving the desired properties such as hardness; appearance; mar, etch and scratch resistance, and the like. Exemplary of such other monomers are styrene, methyl styrene, acrylamide, acrylonitrile, methacrylonitrile, hydroxyethyl acrylate, methacrylic acid and the like.
EXAMPLES
Example 1--Preparing a Silane-Containing Acrylic Polymer
A silane-containing acrylic polymer is prepared similar to those listed in U.S. Pat. No. 4,499,150. A flask equipped with condenser, stirrer, and thermometer was charged with 218.4 g butyl acetate, 93.6 g VM&P naphtha and 62.4 g toluene and then heated to reflux. Three charges were simultaneously added over a two hour period, under a nitrogen blanket:
Charge I: 582.4 g methyl methacrylate, 291.2 g butyl acrylate, 364.0 g styrene and 218.4 g. gamma-methacryloxypropyltrlmethoxysilane.
Charge II: 125 g butyl acetate, and 72.8 g di-t-butyl peroxide
Charge III: 124.8 g butyl acetate and 72.8 g gamma-mercaptopropyltrimethoxysilane.
Upon the completion of these charges, additional peroxide (5.85 g ) was added and the mixture was allowed to reflux for 1.5 hours to assure the completeness of the polymerization. The final resin has a solid content of 69 percent, a Gardner-Holt viscosity of Z+.
Examples for Preparing the Hydrosilylated Vinyl Silane Oligomers
Example 2
To 444.6 g (3.0 moles) of vinyltrimethoxysilane in a 1 1. three-necked flask was quickly added 115.1 g (2.5 moles) 99% formic acid at room temperature. The flask was protected with nitrogen and over 3 hours a combination of methyl formate and methanol (a total of 241.7 g) were distilled from the reaction mixture, producing 310.9 g of partially hydrolyzed and condensed vinylmethoxysiliconate of 0.5 cstks viscosity.
The above reaction mixture was heated to 100° C. and 0.29 g of platinum-divinyltetramethyldisiloxane complex, containing 1.9% Pt, (Karstedt's catalyst; see U.S. Pat. No. 3,775,452) was added. From an addition funnel, 366.0 g (3.0 moles) of trimethoxysilane was added, maintaining the addition rate to sustain a reaction temperature of 110-120° C. After the addition was complete (4 hours), the flask was heated to 150° C., whereupon a small amount of black precipitate (platinum metal) formed. The product was cooled and filtered to produce a clear, colorless liquid of 32 cstks. viscosity.
Example 3
In a procedure similar to Example 2, 444.6 g of vinyltrimethoxysilane was allowed to react with 115.1 g 99% formic acid. During the distillation of volatile components, the flask was heated to 150° C. to distill unreacted vinyltrimethoxysilane. The flask was cooled to 85° C. and 0.29 g of Karstedt's catalyst was added and 366.0 g distilled triiethoxysilane was slowly added, maintaining the temperature of the exothermic reaction between 85-100° C. by the rate of addition of trimethoxysilane. After the reaction was complete, the flask was heated to 150° C., precipitating a small amount of Pt on the walls of the flask. The excess trimethoxysilane was distilled from the reaction mixture. Upon cooling and filtering, 390 g of clear colorless product of 41 cstks. viscosity was isolated. Analysis by 13 C NMR indicated 78% hydrosilation of the original vinyl groups present.
Example 4
Following Example 2, 48.9 g (0.33 mole) of vinyltrimethoxysilane and 29.8 g (0.17 mole) of 2-cyanoethyltrimethoxysilane were treated with 19.4 g (0.42 mole) of 99% formic acid. The flask contents were heated to 85° C. for 2 hours and the low boiling components were vacuum distilled. Hydrosilylation of the co-oligomeric reaction product with 40.3 g (0.33 mole) of trimethoxysilane and 0.04 g Karstedt's catalyst at 110-120° C., distilling the excess trimethoxysilane to 150° C. The residual catalyst was filtered, yielding a light yellow composition of 14 cstks. viscosity. Analysis by 13 C NMR indicated 75% hydrosilation of the original vinyl groups present.
Example 5
Following Example 2, 37.1 g (0.25 mole) of vinyltrimethoxysilane and 52.1 g (0.25 mole) of 2-acetoxyethyltrimethoxysilane were treated with a total of 22.1 g (0.48 mole) of 99% formic acid. In this example, the 2-acetoxyethyltrimethoxysilane was allowed to react with 9.7 g (0.21 mole) of formic acid before the addition of the vinyl silane. After distillation of the low boiling components, hydrosilylation of the co-oligomeric reaction product with 30.5 g (0.25 mole) of trimethoxysilane and 0.03 g Karstedt's catalyst at 110-120° C., distilling the excess trimethoxysilane to 150° C. The residual catalyst was filtered, yielding a colorless composition of 50 cstks. viscosity. Analysis by 13 C NMR indicated>90% hydrosilation of the original vinyl groups present.
Example 6
Following Example 2, 24.5 g (0.165 mole) of vinyltrimethoxysilane and 16.9 g (0.085 mole) of phenyltrimethoxysilane were treated with a total of 11.1 g (0.24 mole) of 99% formic acid. After distillation of the low boiling components, hydrosilylation of the co-oligomeric reaction product with 20.1 g (0.165 mole) of trimethoxysilane and 0.01 g Karstedt's catalyst at 110-120° C., distilling the excess trimethoxysilane to 150° C. The residual catalyst was filtered, yielding a colorless composition of 100 cstks. viscosity. Analysis by 13 C NMR indicated>80 % hydrosilation of the original vinyl groups present.
Example 7
Following Example 2, 18.5 g (0.125 mole) of vinyltrimethoxysilane and 29.1 g (0.125 mole) of 7-octenyltrimethoxysilane were treated with a total of 11.0 g (0.24 mole) of 99% formic acid. In this example, the 7-octenyltrimethoxysilane was allowed to react with 4.8 g of formic acid for 1 hour at 84-89° C. before the addition of the vinyl silane. The remaining 6.2 g of formic acid were added and the flask heated for 8 hours at 90-1 10C. After distillation of the low boiling components, complete hydrosilylation of both of the olefinic moieties of the co-oligomeric reaction product was attempted with 30.5 g (0.25 mole) of trimethoxysilane and 0.074 g Karstedt's catalyst at 100-120° C., distilling the excess trimethoxysilane to 150° C. The residual catalyst was filtered, yielding a yellow material of 85 cstks. viscosity.
Example 8
Following Example 2, 48.9 g (0.33 mole) of vinyltrimethoxysilane and 38.5 g (0.17 mole) of 2-phenethyltrimethoxysilane were treated with a total of 22.1 g (0.48 mole) of 99% formic acid. After distillation of the low boiling components, hydrosilylation of the co-oligomeric reaction product with 40.3 g (0.33 mole) of trimethoxysilane and 0.05 g Karstedt's catalyst at 120-130° C., distilling the excess trimethoxysilane to 150° C. The residual catalyst was filtered, yielding a straw colored composition of 50 cstks. viscosity.
Example 9
Following Example 2, 24.5 g (0.165 mole) of vinyltrimethoxysilane, 32.7 g (0.165 mole) of 2-phenyltrimethoxysilane, and 25.1 g (0.165 mole) of tetramethoxysilane were treated with a total of 19.3 g (0.42 mole) of 99% formic acid for 4 hours at 87-100° C. After distillation of the low boiling components, hydrosilylation of the co-oligomeric reaction product with 20.3 g (0.165 mole) of trirethoxysilane and 0.05 g Karstedt's catalyst at 102-145° C., distilling the excess trimethoxysilane to 150° C. The residual catalyst was filtered, yielding a clear, colorless product of 14 cstks. viscosity.
Example 10
To a solution containing 59.3 g (0.4 mole) vinyltrimethoxysilane, 54.8 g (0.4 mole) of methyltrimethoxysilane, and 60.9 g (0.4 mole) of tetramethoxysilane in a round bottomed flask was added 66 g (1.15 moles) of glacial acetic acid and 0.9 g (0.5 wt %) of PUROLITE C-175 acidic dry ion exchange resin (manufactured by Purolite Company, division of Bro Tech Corp.). The flask contents were heated to 90° C. for several hours, followed by distillation of 122 g methanol and methyl acetate. The vinyl containing oligomer in the flask then was hydrosilylated with 49 g (0.4 mole) of trimethoxysilane and 0.04 g Karstedt's catalyst at 115-145° C. The final product, after removal of the low boiling components and filtration to remove any solid materials, was 145 g and was 65 cstks. viscosity.
Example 11
In a reaction similar to example 10, solution containing 59.3 g (0.4 mole) vinyltrimethoxysilane, 54.8 g (0.4 mole) of methyltrimethoxysilane, and 60.9 g (0.4 mole) of tetramethoxysilane in a round bottomed flask was added 52.9 g (1.15 moles) of 99% formic acid and 0.9 g (0.5 wt %) of PUROLITE C-175 acidic dry ion exchange resin. The flask was heated to 85-100° C. to distill the produced methanol and methyl formate collecting a total of 99.1 g. The reaction mixture was then filtered, removing the ion exchange resin. The 110.8 g vinyl containing oligomer was then hydrosilylated with 49 g (0.4 mole) of trimethoxysilane and 0.04 g Karstedt's catalyst at 118-144° C. The final product, after removal of the low boiling components and filtration to remove any solid materials, was 153.6 g and was 27 cstks. viscosity.
Example 12
In a reaction similar to example 10, solution containing 59.3 g (0.4 mole) vinyltrimethoxysilane, 54.8 g (0.4 mole) of methyltrimethoxysilane, and 60.9 g (0.4 mole) of tetramethoxysilane in a round bottomed flask was added 20.7 g (1. 15 moles) of distilled water and 0.9 g (0.5 wt %) of PUROLITE C-175 acidic ion exchange resin. The reaction mixture was stirred at ambient temperature for one hourthen vacuum distilled, removing 71 g of low boiling components (mostly methanol). The reaction mixture was filtered, leaving 116 g of 5 vinyl oligomer. This component then was hydrosilylated with 49 g (0.4 mole) of triethoxysilane and 0.04 g Karstedt's catalyst at 110-146° C. The final product, after removal of the low boiling components and filtration to remove any solid materials, was 161 g and was 14 cstks viscosity.
Examples for Viscosity Reducing Properties
Example 13
The silane oligomers (20 g) of the examples above were blended with 100 g of the silane-containing acrylic polymer (Ex. 1). The Gardner-Holt viscosity and the solid contents of the resultant mixtures were measured and the results are shown:
______________________________________ % Solid Visc. 1 % Solid Sample Viscosity Silane w. Resin mixture______________________________________Resin Z+ 69% Z+ 69% Exp. 3 41 cstks 92% X - Y 73% Exp. 4 14 cstks 85% X+ 71% Exp. 5 50 cstks 92% Y - Z 73% Exp. 6 100 cstks 93% Y - Z 73% Exp. 7 85 cstks 94% Z- 73% Exp. 8 50 cstks 87% Y - Z 72% Exp. 9 14 cstks 76% X+ 70%______________________________________
The viscosity reducing properties of these compounds were evaluated in another way. The viscosities of these mixtures were measured using Ford Cup, #4. Since the resin (Ex. 1) was very viscous, the resin was diluted with a solvent mixture containing 75 % toluene and 25 % xylene. So to 85 g of the resin was added 15 g of the solvent mixture. The resultant resin mixture was found to have a solid content of 59% and the Ford Cup #4 viscosity of 147 seconds. To the above resin mixture was added 18.4 g of the silane oligomers or copolymers, the viscosities and the percent solid contents were measured:
______________________________________ Ford Cup % NVC #4 % NVC Sample Viscosity silane sec. mixture______________________________________Resin -- 59% 147 59% Example 3 41 cstks 92% 107 64% Example 4 14 cstks 85% 94 63% Example 5 50 cstks 92% 116 66% Example 6 100 cstks 93% -- -- Example 7 85 cstks 94% 126 65% Example 8 50 cstks 87% 109 64% Example 9 14 cstks 89% 104 62%______________________________________
Examples for Improved Physical Properties
The silane oligomers were formulated with the silane-containing acrylic polymer (Ex. 1) according to Table A and the resultant mixture was coated on the E-coated panel and cured at 130° C. for 30 minutes. The properties of these coatings were listed in Table B.
TABLE A______________________________________Coating Composition Percent by Weight Percent by Wt.______________________________________silane-containing acrylic polymer.sup.1 83.1% 92.8% Silane Oligomers 9.9% -- Dibutyltin dilaurate.sup.2 1.0% 0.9% Blocked acid.sup.3 1.5% 1.9% UV absorber.sup.4 0.9% 1.0% Polysiloxane.sup.5 1.7% 2.0% Triethylorthoformate 1.9% 1.5%______________________________________ .sup.1 To 100 grams of the acrylic silane polymer was added a solvent mixture consists of 8.6% butyl acetate, 11.9% acetone, 16.8% toluene, 56.4% xylene, 4% Cellosolve acetate (ethylene glycol monoethyl ether acetate), 2.3% butyl carbitol acetate (diethylene glycil monobutyl ether acetate). .sup.2 10 wt. % solution in xylene. .sup.3 NACURE 5925 amine blocked dodecyl benzene sulfonic acid from King Industries. .sup.4 TINUVIN 328 U.V. light absorber, product of CibaGeigy, Inc. .sup.5 DC 200 from Dow Corning Corp., dissolved in xylene to give a 0.54 wt. % solution.
TABLE B______________________________________ Gloss Gloss Pencil Sample 20°.sup.(1) 60°.sup.(1) DOI.sup.(2) Hardness.sup.(3 )______________________________________Resin 88 94 100 2B Example 3 84 92 100 2B Example 4 84 93 100 2B Example 5 84 91 100 2B Example 6 86 93 100 2B Example 7 81 91 100 2B Example 8 86 93 100 3B Example 9 86 92 100 2B______________________________________ .sup.(1) ASTM D523 .sup.(2) Distinctness of Image .sup.(3) ASTM D3363-74
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Alkoxy silane oligomers which have a non-hydrolyzable carbon bridged bond to another silane functionality are taught herein, as well as their manufacture and utility.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority under 35 U.S.C. § 119 of German Patent Application DE 10 2005 042 372.8 filed Sep. 7, 2005, the entire contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention pertains to medical devices, especially respirators (ventilators) and/or anesthesia apparatuses. The present invention also pertains to breathing masks.
BACKGROUND OF THE INVENTION
[0003] The components of a respirator, which are in contact with the fresh gas for the patient, are not subject to contamination with bacteria, fungi and viruses in case of proper handling. However, contamination cannot be ruled out in case of improper handling, and bacteria, fungi and viruses can spread rapidly under the conditions prevailing there. This problem is even more acute for components of an anesthesia apparatus with a breathing gas return. A humid and warm climate, which is ideal for the growth of bacteria and fungi, prevails within the respiration system and the flexible tubes leading to the patient. Regular cleaning and hygiene measures are correspondingly usually specified for these devices. The goal of performing the disinfection procedures performed is to reduce the germ count, e.g., by a certain factor of live microorganisms. However, experience has shown that these cleaning and hygienic measures are not always implemented reliably. Bacteria and/or fungi that are still present can spread again even if a medical device that was disinfected correctly in this respect is not being used.
[0004] Handling components of respirators and anesthesia apparatuses, such as breathing bags, alarm and control buttons, are not in contact with the gas being supplied for the patient. However, the surfaces may be contaminated by the operating personnel and contamination can thus be transmitted externally to the patient via this pathway. The same problems arise as in the case of the disinfection of breathing gas-carrying components.
[0005] Seals and filter materials of breathing masks become damp due to the close contact with the skin and likewise offer an ideal climate for the growth of bacteria and fungi. Regular cleaning and hygiene measures are usually provided for these devices as well, but there is no guarantee that they are always complied with.
[0006] Therefore, it can never be ruled out with certainty that infections can originate from the medical devices or breathing masks for the patient or user even if they are cleaned and disinfected according to the regulations.
[0007] An additional protection of medical devices or breathing masks against contamination with bacteria, fungi and/or viruses is therefore desirable.
[0008] WO 00/09173 discloses the use of stabilized silver ions as a surface coating of medical devices. The silver ions are stabilized by complexing with primary, secondary or tertiary amines, and are bound to hydrophilic polymers.
SUMMARY OF THE INVENTION
[0009] The object of the present invention is to provide improved protection for medical devices or breathing masks against contamination of the surfaces with bacteria, fungi and/or viruses.
[0010] According to the invention, a medical device or a breathing mask is provided having a surface made of a matrix material that contains silver particles with a size of 1 nm to 500 nm.
[0011] It was surprisingly found that improved protection of the medical devices or breathing masks against contamination with bacteria, fungi and/or viruses can be achieved by the use of silver particles in the nanosize range of 1 nm to 500 nm compared to the use of stabilized silver ions. It is suspected that silver ions (Ag + ), which are responsible for the antimicrobial action, are formed on the surface of the silver particles. If the silver particles are larger than 500 nm, the surface of the silver particles is too small to offer an effective antimicrobial protection. The smaller the silver particles are, the more they tend to agglomerate, which leads to a further decrease of the surface. The silver particles therefore preferably have a size of 5 nm to 100 nm and especially 10 nm to 80 nm.
[0012] The silver particles are present in the matrix material preferably at a concentration of 1 ppm to 1,000 ppm, more preferably 100 ppm to 800 ppm and especially 250 ppm to 750 ppm, and most preferably 500 pm to 700 ppm relative to the total weight of the matrix material.
[0013] The matrix material is preferably a polymer, preferably a hydrophilic polymer. It is suspected that hydrophilic polymers facilitate the formation of ions on the surface of the silver particles and the ion transport to the surface of the matrix material. Polyphenylene sulfide (PPS), polysulfone (PSU), polyphenylene sulfone (PPSU), cycloolefin copolymers (COC), silicones, polyoxyalkylenes, such as polyoxymethylene, and polyamides (PA), such as polyamide-12 (PA-12) or polyamide-6, which optionally contain up to 35 wt. % of glass fibers or glass beads, are most preferred. Polyphenylene sulfide most preferably contains up to 30 wt. % of glass fibers or glass beads. Polyamide most preferably contains up to 25 wt. % of glass fibers or glass beads.
[0014] The surface material may contain, furthermore, an inorganic filler, which further facilitates the formation of ions. This is especially advantageous if the matrix material is not sufficiently hydrophilic. The inorganic filler is preferably selected from among zeolites, silicon dioxide, titanium dioxide, aluminum oxide, zirconium oxide and mixtures thereof.
[0015] The medical device is preferably a respirator or anesthesia apparatus. The surface of the respirator or anesthesia apparatus is preferably that of a flexible breathing gas tube, a socket, bushing or seal in the respiration system of the respirator and/or anesthesia apparatus, that of a sensor housing and/or flexible tube for the internal measured gas return, that of a Y-piece for the breathing air tube, that of a control element for manual adjustment and/or that of a manual breathing bag, lime container, cable and/or tube duct, and other surfaces may also have the matrix material containing silver particles according to the present invention.
[0016] Silver particles with a mean particle size of 1 nm to 500 nm are commercially available, for example, from the firm of rent-a-scientist GmbH, Regensburg, under the name AgPURE Nanosilver®.
[0017] The silver particles can be introduced into the matrix material in the usual manner by mixing in a suitable mixer. However, a premix of the silver particles with a wax, which is subsequently mixed with the matrix material, is preferably prepared first. The premix may contain, for example, 1 wt. % to 10 wt. % of silver particles.
[0018] The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which preferred embodiments of the invention are illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] In the drawings:
[0020] FIG. 1 is a schematic side view showing an anesthetic evaporator according to the invention which can be connected to respirators or anesthesia apparatuses;
[0021] FIG. 2A is a schematic top view of a handwheel of the anesthetic evaporator of FIG. 1 ;
[0022] FIG. 2B is a schematic side view of a handwheel of the anesthetic evaporator of FIG. 1 ; and
[0023] FIG. 3 is schematic view of a respiration system of an anesthesia apparatus according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] Referring to the drawings in particular, FIG. 1 shows an anesthetic evaporator 1 , which can be connected to respirators or anesthesia apparatuses.
[0025] The anesthetic evaporator has a handwheel 2 for manually setting the quantity of anesthetic to be dispensed, a setting mark 3 for optically checking the state of opening of the anesthetic evaporator 1 , a filling device 4 and an inspection glass 5 .
[0026] FIGS. 2A and 2B show the handwheel 2 of the anesthetic evaporator 1 in a schematic top view and a schematic side view. The top view shows the profiling 8 as well as a switch 6 for locking and unlocking the handwheel 2 . The schematic side view shows, furthermore, setting marks 7 .
[0027] In the course of a usual anesthesia, the concentrations of the anesthetic in the breathing gas mixture are set differently. A high anesthetic concentration is usually selected during the initiation of the anesthesia, whereas a medium concentration of the anesthetic is set during the further course. The concentration of the anesthetic in the breathing air mixture is further reduced near the end of the anesthesia. To set the anesthetic gas concentration, the anesthesiologist must actuate the handwheel 2 of the anesthetic evaporator 1 . Besides, the anesthesiologist must be in contact with the patient. Transmission of germs from the handwheel to the patient and vice versa is now possible. Due to the coating of the handwheel with polyamide-6, which contained 25 wt. % of glass fibers and 680 ppm of silver particles with an average size of about 10 nm, reduced growth of bacteria and fungi, and death of contaminating germs applied previously was observed.
[0028] FIG. 3 shows a respiration system 19 of an anesthesia apparatus.
[0029] The respiration system 19 comprises connections 20 and sockets 21 for the flexible tubes 22 , with which the anesthetic gas 23 is transported to and from the patient. Furthermore, a breathing bag 24 is shown. The anesthetic gas 23 is sent from the respiration system 19 through the flexible tube 22 to the patient (not shown) and subsequently from the patient back into the respiration system 19 . A very humid climate, usually having a temperature of 30° C. to 35° C., prevails within the sockets 21 , which connect the respiration system 19 and the flexible tubes 22 . The coating of the inner surfaces of the sockets 21 and/or of the inner sides of the flexible breathing gas tubes 22 with polyphenylene sulfide (PPS), which contains 680 ppm of silver particles with an average size of about 10 nm, led to markedly reduced growth of bacteria or fungal populations.
[0030] While specific embodiments of the invention have been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.
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Silver particles with a size of 1 nm to 500 nm is provided in a matrix material that is used as a surface coating on medical devices or breathing masks for reducing the germ count on same.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is related to our copending application Ser. No. 806,988 filed June 16, 1977.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a heat stable fiber forming polyester and to a new and novel process for preparing it. More particularly, this invention relates to an improved linear high molecular weight heat stable polyester especially suitable for preparing fibers which have excellent resistance to degradation when utilized in commercial articles, such as tires, industrial belting, etc. wherein a high degree of heat is built up during use.
2. Description of the Prior Art
High molecular weight polyethylene terephthalate fiber forming polyesters are well known. They are prepared commercially either by the ester interchange reaction between dimethyl terephthalate and ethylene glycol or by the direct esterification process wherein terephthalic acid is reacted directly with ethylene glycol. These products and processes are well documented in U.S. patents, such as Nos. 2,465,310; 3,050,533; 3,051,212; 3,427,287 and 3,484,410 which cover not only the basic products and processes but many improvements thereon.
Polyethylene terephthalate fibers and cords are known to exhibit excellent dimensional stability, that is, low extension or growth during service, as well as to have a high resistance to thermal degradation; however, in pneumatic tires and industrial belts under high speed conditions under heavy load, loss of tensile strength is experienced due to high temperature conditions emanating under such conditions. Efforts to remedy this problem have all too often been ineffective. Most research in this field has been directed to producing a high molecular weight linear polyester having a low content of free carboxyl groups. The following patents are pertinent.
U.S. Pat. No. 3,051,212 to William W. Daniels relates to reinforced rubber articles and to textile cords and fibers for reinforcing such articles. This patent discloses that a linear terephthalate polyester having a concentration of free carboxyl groups of less than 15 equivalents per million grams may be prepared in a number of different ways. One effective procedure is to treat the filaments, after they have been formed, with a chemical reagent which reacts with and "caps" the free carboxyl group. One such agent is diazomethane.
U.S. Pat. No. 3,627,867 to Eckhard C. A. Schwarz discloses a process and apparatus for melt spinning high molecular weight polyethylene terephthalate into high-performance fibers under conditions which reduce the normally high viscosity of such polyester. Ethylene oxide or other low-boiling oxirane compound is injected under pressure into molten polyester before it is fed to the metering pump of the melt-spinning machine. The fibers are characterized by low free-carboxyl content and freedom from voids which might be expected from injection of the volatile material.
U.S. Pat. No. 3,657,191 to Rudolph Titzmann et al. is directed to a process for the manufacture of linear polyesters having an improved stability with respect to compounds with active hydrogen. Polyesters of this type are obtained by reacting polyesters with ethylene carbonates or monofunctional glycidyl ethers. The reaction is first carried out within a temperature range lying 10° to 60° C. below the softening point of the polyester and is then terminated during the melting and melt-spinning process.
U.S. Pat. No. 3,869,427 to Robert W. Meschke et al. discloses a process of preparing polyester filaments having low free-carboxyl-group contents which give superior performance in pneumatic tires and other reinforced rubber articles where heat-degradation is a problem. Reduction of free carboxyl groups is achieved by mixing with the molten polyester, prior to melt-spinning, 1,2-epoxy-3-phenoxypropane or 1,2-epoxy-3-n-hexyloxypropane.
U.S. Pat. No. 4,016,142 to William Alexander et al. discloses preparation of a fiber-forming polyester wherein the number of free carboxyl end groups present in the polymer may be reduced by adding to the polymerized polyester a glycidyl ether which reacts with the carboxyl end groups present to form free hydroxyl end groups.
Although the above-identified patents directed to stabilized polyesters are of major interest, certain of the proposed polyester modifiers are known to be highly toxic and/or hazardous to use on commercial scale. Moreover, we have found that the others are relatively less effective in terms of reducing the carboxyl end group concentration of the polyester. Accordingly, we have carried out considerable research in this field to solve or mitigate the long-standing problem of producing high molecular weight polyester stabilized against deterioration under high temperature operating conditions.
SUMMARY OF THE INVENTION
The present invention relates to an improved high molecular weight heat stable polyester and to a novel process for preparing it. The invention further provides polyester fibers which have excellent resistance to thermal degradation when utilized in commercial articles, such as tires, industrial belting, etc. wherein a high degree of heat is built up during use.
In accordance with the above objects, it has now been discovered that an improved heat stable fiber forming linear condensation polyester is obtained by incorporating therein a stabilizing amount of a stabilizer comprising an epoxy compound having 5 to 25 carbon atoms in the molecule and selected from the group having the formulae: ##STR2## where R represents the radical remaining after removal of the carboxyl group from a monocarboxylic acid, R 1 , R 2 , R 3 and R 4 represent hydrogen or hydrocarbon radicals, and n is an integer that can be 0 to 3. This novel polyester is obtained without undue difficulties in the processing thereof and the additive is compatible with other additives that may be desirable for specific uses. Preferably, the polyester in molten form is reacted with the epoxy compound, whereby the resulting thermally stabilized polyester has a free carboxyl concentration of less than 15 gram equivalents of carboxyl groups per 10 6 grams of polyester.
The epoxy compounds useful as stabilizers in the present invention are known compounds or are readily prepared by known procedure. In particular, amides of epoxyamines and carboxylic acids and the preparation thereof are described in U.S. Pat. No. 2,730,531 to George R. Payne et al., and U.S. Pat. No. 2,772,296 to Albert C. Mueller discloses a process for preparing epoxy esters, e.g., glycidyl benzoate is prepared by reacting benzoic acid with epichlorohydrin. The corresponding glycidyl thiobenzoate may be prepared from thiobenzoic acid.
The preparation of the improved polyester can be carried out by condensing an aromatic dicarboxylic acid, preferably terephthalic acid, and/or the lower alkyl ester thereof with a glycol containing 2 to about 10 carbon atoms per molecule under direct esterification and/or ester-interchange conditions. A stabilizing amount of the above-described stabilizer may be incorporated before, during or after polycondensation of the polyester. Preferably, the stabilizer is added to the molten polyester after the final polycondensation of the polymer.
The esterification of the aromatic dicarboxylic acid and/or the lower alkyl esters thereof and the glycol can start at a temperature as low as 200° C. and range up to 300° C. and at atmospheric and superatmospheric pressures ranging up to 500 psig. The reaction, either the direct esterification or ester-interchange is carried out in the absence of oxygen-containing gas. Preferably, the reaction temperature ranges from about 230° C. to about 280° C. and at a pressure ranging from about 50 to 250 psig. The reaction time will vary depending upon the reaction temperature and pressure. The glycol is reacted with the aromatic dicarboxylic acid and/or the lower alkyl ester thereof in an amount ranging from about 1 to about 3 mols of glycol per mol of acid. The amount of said epoxy compound added as stabilizer ranges generally from 5 to 70 gram mols of epoxy compound per 10 6 grams of the polyester. Preferably, 10 to 50 gram mols of epoxy compound is added per 10 6 grams of the polyester.
Other additives can be added to the polymer with complete compatibility therewith to control or tailor the reactions in order to obtain required characteristics of the final polymer for specific end uses. Many such additives are known and utilized to control dyeing, static, luster, flammability, light stability, brightness, etc.
The polycondensation of the esterification product obtained by the direct esterification or ester-interchange reaction between aromatic dicarboxylic acid or lower alkyl ester thereof with a glycol is usually carried out at a reduced pressure which can be as low as 0.1 torr and a temperature in the range of from about 260° C. to about 300° C. This part of the reaction is carried out under these conditions for periods of about 1.0 to about 10 hours and preferably from about 2 to about 6 hours until a polymerized polyester product of the required molecular weight as determined by viscosity or other convenient physical measures is obtained. The duration of such periods depends upon the various process polymerization conditions such as pressure and temperature profiles, ingredient mol ratios, surface generation conditions, catalyst type and concentration, any additives utilized, requisite viscosity, etc. Polycondensation is generally continued until the resultant polyester has an intrinsic viscosity in 60 percent phenol-40 percent tetrachloroethane mixture of about 0.6 to 1.0, preferably 0.8 to 0.95.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As previously mentioned, the present invention further provides polyester fibers which have excellent resistance to degradation when utilized in commercial articles, such as tires, industrial belting, etc. wherein a high degree of heat is built up during use. Accordingly, one preferred embodiment of this invention may be briefly stated as follows:
In the preparation of fibers particularly useful in reinforced rubber articles such as pneumatic tires and industrial belts, from high molecular weight linear terephthalate condensation polyester, the method of providing a reduction in the free carboxyl content of the polyester to a carboxyl concentration of less than 15 gram equivalents per 10 6 grams of polyester which comprises adding to the polyester after final polycondensation of the polyester a thermally stabilizing amount of a stabilizer comprising an epoxy compound selected from the group having the formulae: ##STR3## where R represents the radical remaining after removal of the carboxyl group from a monocarboxylic acid and n is an integer that can be zero or one, said epoxy compound having 5 to 20 carbon atoms in the molecule. Preferably, 10 to 50 gram mols of said epoxy compound are added to the polyester per 10 6 grams of the polyester.
The following examples are illustrative of embodiments of the present invention but are not to be construed as limiting the invention in any way. The ingredient parts are expressed as stated in the examples.
EXAMPLE 1
About 41.5 pounds per hour of terephthalic acid, 27.9 pounds per hour of ethylene glycol, 65 grams per hour of diisopropylamine and 16 grams per hour of antimony acetate are continuously fed to a paddle mixer where they are converted to a paste. The paste mixture is then pumped from the mixer by a feed pump to the inlet of a circulating pump. The paste mixture is pumped with 40 parts by weight per part of past mixture of recirculating mixture by the circulating pump through a multiple tube and shell heat exchanger where it is heated to 260°-270° C. After leaving the heat exchanger, the mixture enters an esterification reactor which is maintained at 260°-270° C. by conventional heating means, and 90 psig. pressure by means of an automatic vent valve. The recirculating mixture leaving this reactor is split, with part being returned to the inlet of the circulating pump where it is combined with fresh paste and part flowed to a series of three reactors where further esterification takes place at 270°-275° C. Total esterification time is about 3 hours. Following esterification the reaction mixture is fed into a polycondensation reactor operating at 275° C. and 30 torr pressure, with a residence time of 60 minutes. The resulting polyester polymer is fed to a polycondensation reactor operating at 275° C. and 2 torr pressure, with a residence time of 120 minutes. Then, the polyester polymer is processed in a final polycondensation at 278° C. and 0.5 torr pressure for 130 minutes. The polyester polymer melt at about 278° C. is pumped from the final polycondensation reactor by means of a screw pump and conducted to gear pumps for transfer to a spinning machine where polymer temperature is increased to about 300° C. Between the screw pump and the gear pump, 0.255 pound per hour of N-(2,3 epoxypropyl)-benzamide is added to the polyester polymer as stabilizer and intimately mixed with the polymer by means of a conventional stationary mixer. The polyester polymer is reacted with the N-(2,3 epoxypropyl)-benzamide for 3-20 minutes at about 278° to 300° C. until the polymer is spun at the rate of 48 pounds per hour through a 192 hole spinnerette. Yarn is continuously spun and drawn to form 1300 denier, 192 filament yarn. The undrawn yarn from the spinnerette has an intrinsic viscosity of 0.80 to 0.90 dl. per gram and about 12 gram equivalents of carboxyl end groups per 10 6 grams of polyester. The drawn yarn has 15.9 percent ultimate elongation and 8.5 grams per denier tensile strength. The drawn yarn retains 87 percent of its strength after exposure to pure ammonia gas for 3 hours at 150° C. This test shows that the yarn is very stable to both heat and ammonia, which is indicative of a good tire yarn. The drawn yarn is overfinished with a lubricating composition, twisted into 3 ply, 9 t.p.i. tire cord, woven into a fabric, dipped in a blocked diisocyanate-epoxide emulsion, stretched at 420° F., dipped in a resorcinol-formaldehyde-vinyl pyridine polymer emulsion, stretched at 440° F., and calendered with rubber to make rubberized fabric for tire building.. Tires made with this fabric are characterized by excellent durability when run on the wheel test stand.
Similar results are obtained when equivalent amounts of N-(2,3 epoxypropyl)-stearamide, N-(epoxyethyl)-benzamide, glycidyl benzoate or S-(glycidyl)-thiobenzoate are used in place of the N-(2,3 epoxypropyl)-benzamide.
EXAMPLE 2
This example demonstrates the use of 4-dimethylaminopyridine as a catalyst to accelerate the reaction of polyethylene terephthalate with an epoxy compound of the present invention.
About 48 pounds of polyethylene terephthalate chips having an intrinsic viscosity of 0.95 are mixed with 0.255 pound of N-(2,3 epoxypropyl)-benzamide and 0.01 pound of 4-dimethylaminopyridine by tumbling in a can. The mixture is then melted and spun at about 300° C. through a 1-inch extruder into 48 filament yarn which is plied and drawn at a draw ratio of 6.05 to 1 into 1300 denier, 192 filament yarn. The undrawn yarn from the spinnerette has an intrinsic viscosity of 0.84 and 9 equivalents of carboxyl end groups per 10 6 grams. The drawn yarn has 14.5 percent ultimate elongation and tensile strength of 8.4 grams per denier. The drawn yarn retains 90 percent of its strength after exposure to pure ammonia gas for 3 hours at 150° C. This yarn is converted into tire cord as in the first example. The cord is characterized as having excellent fatigue and durability properties.
EXAMPLE 3
Example 1 is repeated except that 0.51 pound per hour of N-(2,3 epoxypropyl)-benzamide is added to 48 pounds per hour of the polyester polymer. The undrawn yarn from the spinnerette has an intrinsic viscosity of 0.80 to 0.90 and about 5 equivalents of carboxyl end groups per 10 6 grams of polyester. The drawn yarn has 17.3 percent ultimate elongation and tensile strength of 8.1 grams per denier. The drawn yarn retains 96 percent of its strength after exposure to pure ammonia gas for 3 hours at 150° C.
EXAMPLE 4 (Comparative)
Example 1 is repeated except that no N-(2,3-epoxypropyl)-benzamide is added to the polyester polymer. The undrawn yarn from the spinnerette has an intrinsic viscosity of 0.80 to 0.90 and 30 equivalents of carboxyl end groups per 10 6 grams of polyester. The drawn yarn has 16.7 percent ultimate elongation and tensile strength of 8.2 grams per denier. The drawn yarn retains only 59 percent of its strength after exposure to pure ammonia gas for 3 hours at 150° C. These data in comparison with the data of Examples 1-3 demonstrate the beneficial effect respecting number of carboxyl end groups and strength retention of the polyester yarn of adding the stabilizer compound of the present invention.
EXAMPLE 5 (Comparative)
To demonstrate the criticalness of using the particular epoxy compounds of the present invention, Example 1 is repeated except that equivalent amounts of 4-methoxyphenyl-2,3-epoxypropyl ether, phenyl-2,3-epoxypropyl ether or C 8 + C 10 n-alkyl epoxypropyl ethers are used in place of the N-(2,3 epoxypropyl)-benzamide of Example 1. The undrawn yarn from the spinnerette has an intrinsic viscosity of 0.85 and 27-29 equivalents of carboxyl end groups per 10 6 grams of polyester. The drawn yarn is similar in properties to that produced in comparative Example 4.
Although we do not wish to be bound by any theory as to the mechanism of the present invention, we believe that the activity of the epoxy compounds of the present invention relates to the structure of the overall molecule and particularly to the position of the carbonyl oxygen with respect to the epoxy oxygen.
The proposed mechanism for the present invention is illustrated below with a typical epoxy compound of the invention, glycidyl benzoate. ##STR4##
We have found that optimum activity of the epoxy compounds of the present invention results when there are 3 to 4 atoms between the epoxy oxygen and the carbonyl oxygen. This corresponds to 6 or 7 atoms in the above-described cyclic intermediates.
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High molecular weight linear condensation polyesters are stabilized against deterioration by heat by reacting the polyester in molten form with an epoxy compound having 5 to 25 carbon atoms in the molecule and selected from the group consisting of ##STR1## where R represents the radical remaining after removal of the carboxyl group from a monocarboxylic acid, R 1 , R 2 , R 3 and R 4 represent hydrogen or hydrocarbon radicals, and n is an integer that can be 0 to 3.
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CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 60/636,644 filed Dec. 16, 2004.
STATEMENT REGARDING FEDERALLY-SPONSORED RESEARCH AND DEVELOPMENT
[0002] (Not Applicable)
REFERENCE TO AN APPENDIX
[0003] (Not Applicable)
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] This invention relates generally to accessory items useful for performing maintenance work in and around residential homes requiring the use of a ladder.
[0006] 2. Description of the Related Art
[0007] Maintenance in and about residences often require the use of a ladder of the extension type or the common stepladder. In many instances, particularly painting the inside or outside of homes, the use of a ladder is required. However, while many forms for providing means to hold a paint container have been used in the past, each has shown to have limitations which either are inconvenient in some circumstances or fail to possess characteristics or features which would solve other problems associated with such work.
[0008] Prior to the present invention, those of ordinary skill in the art have not satisfactorily produced a ladder accessory item which satisfactorily addresses such maintenance work to provide more convenience and efficiency to the user.
BRIEF SUMMARY OF THE INVENTION
[0009] The present invention is directed to accessory apparatus particularly useful with many conventional ladders of the type commonly used for painting and other maintenance work around buildings and particularly around residences.
[0010] It is one aspect of a preferred embodiment of the present invention to provide a container holder device which easily and simply may be removably mounted to a ladder wherein containers for paint or tools may be mounted in an easily reached and convenient position.
[0011] It is another aspect of the present invention to provide a pair of container holders adapted to be removably mounted in aligned relationship along the outside of and along the longitudinal extent of the legs of a ladder in a position convenient to the user.
[0012] It is another aspect of the present invention in a preferred embodiment to provide a pair of open basket-like container holders, each having an outwardly extending arm extendable through openings in the legs of the ladder toward one another to join in a removably fixed telescoping relationship.
[0013] It is another aspect of the present invention to provide a mounting means adopted to be removably mounted on a step of a conventional step ladder to removably receive the container holders particularly useful for conventional step ladders without providing openings along the legs of the step ladder.
[0014] It is therefore an object of the present invention to provide an accessory for use with ladders wherein paint and/or tool containers may be adjustably mounted to a ladder in an easy manner to facilitate maintenance work in an improved manner.
[0015] It is another object of the present invention to provide an apparatus of the type described for use in cooperation with a ladder which is simple and inexpensive to manufacture and therefore highly affordable to the potential users.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0016] FIG. 1 is a perspective view of an embodiment of the ladder accessory device constructed in accordance with the present invention;
[0017] FIG. 2 is a perspective view drawing each one of a pair of container holders shown in FIG. 1 , the view illustrating each one of the pair in a separated relationship prior to being mounted to a ladder;
[0018] FIG. 3 is a top plan view of the embodiment shown in FIG. 1 ;
[0019] FIG. 4 is a side elevational view of the embodiment shown in FIG. 1 ;
[0020] FIG. 5 is an end elevational embodiment shown in FIG. 1 ;
[0021] FIG. 6 is an exploded view of the embodiment shown in FIG. 1 in combination with one form of ladder;
[0022] FIG. 7 is a perspective view of an embodiment of the present invention showing the embodiment in an operational combination with one form of ladder.
[0023] FIGS. 8 and 9 are perspective views of a mounting means suitable for use on a conventional step ladder to provide another embodiment of the present invention;
[0024] FIG. 10 is a perspective view of the mounting means shown in FIGS. 8 and 9 in combination with the container holders as may be typically mounted on a conventional step ladder; and
[0025] FIG. 11 is a partial side sectional view of the combination of the mounting means and container holders illustrating their relationship in the mounted condition shown in FIG. 10 .
[0026] In describing the preferred embodiments of the invention which is illustrated in the drawings, specific terminology will be resorted to for the sake of clarity. However, it is not intended that the invention be limited to the specific term so selected and it is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar purpose. For example, the word connected or term similar thereto are often used.
DETAILED DESCRIPTION OF THE INVENTION
[0027] A ladder accessory device constructed in accordance with the present invention is shown in the form of one preferred embodiment in FIG. 1 and includes a pair of similar container holders indicated generally at 20 . Container holders 20 comprise an open type construction which herein means a form having side and bottom supports which do not form continuous enclosed sidewalls or a closed bottom wall. However, while preferred, continuously closed sidewalls and/or bottom wall may be employed without departing from the spirit of the present invention.
[0028] Each container holder 20 , as shown in FIG. 1 , includes a top opening surrounded by an upper rim formed by a hollow rod-like or tubular elements 22 . The ends of each element 22 may be joined to an adjacent element 22 by an elbow like joint such as at 24 which may be fixed in any conventional manner to the adjacent end of an adjoining element as 22 to form the closed upper rim as shown in the preferred embodiment. The joint formed at 24 may be fixed by soldering or welding, for example. The elbow joint may be a separate body or one or both ends of adjoining elements 22 may be bent to form the arcuate joint.
[0029] A bottom wall support is formed by two hollow rod-like elements 26 , generally similar to elements 22 , which are extended across one another at approximately a right angle and may be joined in their center to one another in any conventionally suitable manner. In FIG. 1 , bottom elements 26 are shown flattened in the center and fixed with a rivet 29 . However, other means such as soldering, welding or use of a suitable adhesive, for example, may be used as deemed suitable.
[0030] The outwardly extending ends of elements 26 may be fixed at 30 to the lower ends of four side support elements 28 . Elements 28 preferably are similar to the hollow rod elements 22 and 26 . The lower ends of side support elements 28 and the outward ends of elements 26 may be joined by an elbow shaped configuration such as employed at 24 , or in any other conventional well-known suitable manner to form an enclosure capable of holding a container which generally fits within the top opening of a holder 20 .
[0031] The upper ends of each side element 28 may be fixed in any suitable conventional manner to a respective one of elements 22 . One preferred form may comprise flattening an upper end portion of each element 28 and bending it into a generally U-shape which fits around the element 22 and fixing the joinder by soldering, welding or by other suitable fastening means.
[0032] It should be pointed out that while an open or frame-like construction is preferred to reduce manufacturing costs and the weight of the holder 20 , other forms having equivalent functionality may be employed without departing from the spirit of the present invention, including a holder having closed side and bottom walls and a top opening. Further, elements such as 24 , 26 and 29 may comprise metal or plastic tubing of sufficient strength to support the intended containers disposed in the holders 20 .
[0033] Each container holder 20 is provided with an outwardly extending arm, such as 32 and 34 . The inner ends of such arm 32 and 34 may be joined to one of rim elements 22 by butt welding, for example, and supported by diagonal members 36 , one of which is fixed to a respective arm 32 or 34 as seen in the Figures.
[0034] A similar flattening of the end portions of hollow rod-like elements 36 and bending to a generally U-shaped configuration may be usefully employed such as shown at 38 and 40 . The joinder at 38 and 40 may be similarly fixed by soldering, welding or other suitable conventional means.
[0035] Arms 32 and 34 preferably have a hollow tube configuration wherein the diameters permit one arm to be telescoped within the other arm for purposes as described below herein.
[0036] Now specifically referring to FIG. 6 and a portion of a conventional aluminum extension ladder, indicated generally at 44 , which comprises laterally spaced legs 46 and longitudinally spaced, fixed, rungs or steps 48 . In the ladder of well-known conventional construction, the rungs 48 are tubular, having an open passage extending to an open end 50 at opposing ends of each rung 48 .
[0037] Container holders 20 may be removably mounted to ladder 44 by inserting a respective one of arms 32 and 34 into the opposing open ends 50 of a rung 48 at a selected position along the length of ladder 44 usually dependent upon a user's position on ladder 44 relative to the work intended to be performed.
[0038] Either before or after mounting holders 20 as shown, a container, such as 52 and 54 , may be disposed within each one of open basket type holders 20 to securely support the containers 52 and 54 in a convenient and easy to reach position for the user.
[0039] For illustration purposes, container 52 represents a paint can or the like. Container 54 represents a suitable closed wall container, a plastic bucket for example, of a suitable size to fit within a container holder 20 . Container 54 may be used to store extra tools helpful for the particular maintenance work being performed, such as scrapers, brushes, wiping cloths, putty knives or the like, useful when doing a painting or other task. However, other tools may also be so stored in a ready-to-use position in container 54 as described and two containers such as 54 may be employed for maintenance work other than painting that require the use of a ladder, such as 44 .
[0040] As shown and described herein, it should be readily understood that the apparatus of the present invention represents a markedly convenient improvement aid to many maintenance chores, yet is simple and inexpensive to manufacture and significantly facilitates the work being done in a more efficient manner.
[0041] When the user needs to move up or down ladder 44 , each container holder 20 may be readily moved to a different rung 48 as needed. One merely needs to release the means for fixing arms 32 and 34 from within a given rung 48 and move each holder 20 accordingly to a different rung 48 .
[0042] In the preferred embodiment shown, a simple pin and hole arrangement in arms 32 and 34 may be employed to releasably fix arms 32 and 34 in their telescoped relationship. However, other suitable conventional methods and means well-known to those of ordinary skill may also be employed without departing from the spirit of the present invention to provide an equivalent function.
[0043] It should also be pointed out that the container holders 20 may also be employed with a conventional stepladder. However, with an extension ladder or a stepladder wherein the rungs or steps are solid or have no end open hollow construction, one merely has to provide suitable holes laterally aligned along the length of parallel extending legs of the ladder to provide openings capable of receiving arms 32 and 34 in essentially the same manner as described herein. Such holes may be drilled using readily available tools. In this configuration, the present invention is utilized in an equivalent manner to provide equivalent results of convenience and expediting a given maintenance chore.
[0044] Another embodiment of the present invention is shown in FIGS. 8-11 which is particularly useful for most conventional step ladders and does not require drilling openings in the legs of the step ladder to mount the container holders 20 .
[0045] A mounting means indicated generally at 56 preferably comprises a one piece construction of a metal or plastic material, for example, having a pair of openings, such as generally C-shaped ends 58 , spaced from one another and adapted to be received under and over a step portion 60 of a conventional step ladder, generally indicated at 62 in FIG. 10 . The longer leg 64 of the C-shaped ends 58 fits over the top of the step 60 and the shorter leg 66 slides under the step 60 to support the spaced loops or openings 70 and 72 formed at the opposite ends of mounting means 56 as best seen in FIGS. 10 and 11 . Mounting means 56 may be constructed from a single heavy gauge metal wire and bent into the shape shown or of any other suitable material molded, bent or otherwise constructed to a suitable functionally equivalent shape, or a combination of materials capable of constructing a similar functional shape using well-known manufacturing methods. The C-shaped shown wherein the C-shaped ends are formed at generally a right angle, may be formed with a more U-shape if deemed desirable and functionally suitable.
[0046] With specific reference to FIGS. 10 and 11 , a partial view of a conventional step ladder indicated generally at 62 with the container holders 20 and mounting means 56 operatively mounted on the ladder 62 with containers 52 and 54 positioned within holders 20 illustrate a typical functional position for use of the present invention.
[0047] Step ladder 62 typically includes spaced, parallel legs 61 and a plurality of steps 60 longitudinally spaced along the length of legs 61 .
[0048] To use the embodiment shown in FIGS. 8-11 , one merely mounts mounting means 56 to a step 60 by placing the C-shaped ends 58 under and over step 60 as shown in FIGS. 10 and 11 with the longer legs 64 resting on and engaging the upper surface 80 and the shorter legs 66 engaging an underside of step 60 . The opposing end of mounting means 56 with openings 70 and 72 are then removably fixed beyond the rear end of step 60 . Then the outwardly extending arms 32 and 34 may be extended through the openings 70 and 72 in a similarly functional manner as described earlier herein with respect to the embodiment shown in FIGS. 1-7 to mount container holders 20 in a stable position outside the width between legs 61 of step ladder 62 . Then suitable containers such as 52 and 54 may be removably mounted within container holders 20 .
[0049] While certain preferred embodiments of the present invention have been disclosed in detail, it is to be understood that various modifications may be adopted without departing from the spirit of the invention or scope of the following claims.
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A ladder accessory device useful in combination with a ladder to supportably hold one or two container holders in a convenient and easy to reach position for a person working on the ladder. A pair of container holders are removably mounted in laterally spaced, longitudinally aligned position along the length of the ladder. The container holders may include arms which pass through laterally spaced holes provided in aligned relationship to one another along the length of the legs of the ladder. Means are included to releasably fix the arm and the container holders in selected positions along the length of said legs.
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BACKGROUND OF THE INVENTION
The present invention relates to the handling of tools and particularly surgical instruments, which must be sterilized, counted and carried securely without contact with each other, into an operating room. More specifically, the invention relates to a carrying device for surgical instruments, which retains the instruments in selected positions and memorizes and indicates the total number of surgical instruments carried into an operating room, even though some or all of such instruments are removed from the device during a surgical procedure.
Instruments selected for use in a surgical procedure are usually placed in a sterilization tray in which they are immovably positioned in a manner such that the cutting edges do not come into contact with each other. The tray and instruments are next sterilized together and then presented to operating room personnel for their intended use. It is extremely important that an accurate count be made of the number of instruments so sterilized and presented, and that a count of the number of dirty instruments removed after the surgical procedure is completed be equal to the first count. Otherwise, there is a great risk that one or more instruments unknowingly may have been left inside of a patient after the surgical procedure has been completed, and the surgical incision closed. Although a member of the operating room personnel is usually designated to keep track of the counts, the mental alertness and memory of such person must be relied upon not to make a mistake in counts.
It is therefore an object of the present invention to provide a device for maintaining surgical instruments in an organized arrangement during and after sterilization, while memorizing the count of the number of instruments so maintained.
It is another object of the invention to provide a device for indicating at any time the number of surgical instruments carried by the device into a surgical operating room.
SUMMARY OF THE INVENTION
According to the preferred embodiment of the invention, the above objects are achieved by providing a carrier for surgical instruments which has a plurality of discrete instrument carrying boots arranged in juxtaposed relationship to each other. Each boot is adapted to receive and hold upright one of the rings of a ring handle instrument, or the handle of a flat handle instrument. The discrete boots are arranged on a common positioning bar and are adapted individually to rotate 180 degrees about the bar from an open, instrument handle receiving position to a closed, instrument handle rejecting position. By inserting the handles of selected instruments into corresponding open boots and rotating the unused boots to a closed position the count of the number of instruments selected is mechanically memorized. The count of the instruments initially loaded into the carrier of the invention, whether or not remaining therein at the end of the surgical procedure, is quickly determined by merely counting the total number of open boots. More simply, if the open boots are again filled with dirty instruments after the surgery has been completed, the operating room personnel are assured without having to make an actual count, that the number of instruments that come into an operating room also leave the operating room.
To insure that the memorized count cannot be changed inadvertently as by dropping the entire carrier, a pivotable locking bar is provided which is raised to allow setting of the boots into open and closed positions. The bar is then lowered into abutting relationship with the boots and held in place with a detent, to prevent any further movement of the set boots.
A rotatable cover in accordance with the invention includes a resilient pad which applies a gentle holding pressure against the instrument handles to secure them in their respective boots, when the cover is moved and locked into position overlaying the instrument handles inserted into their respective boots. The movable cover also supports a bar transversely disposed parallel to and overlaying the boots. The bar holds the inserted ring handle instruments in an open condition to facilitate cleaning and sterilization.
The invention is pointed out with particularity in the appended claims. The present invention is best understood by reference to the following detailed description thereof when taken in conjunction with the accompanying drawings in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a preferred embodiment of the instrument count memorizing device of the present invention;
FIG. 2 is a perspective view of an instrument retaining boot of the embodiment shown in FIG. 2;
FIG. 3 is a plan view of the embodiment of FIG. 1;
FIG. 4 is a side elevation of the embodiment of FIG. 1, illustrating the cover plate, instrument retaining boots and locking bar in different positions;
FIG. 5 is an end elevation of the embodiment shown in FIG. 1;
FIGS. 6a-g are diagrammatic views illustrating the operation of the instrument retaining boot of FIG. 2;
FIG. 7 is a side elevation of the embodiment of FIG. 1;
FIG. 8 is a perspective view of a modification of the present invention;
FIG. 9 is a view of the embodiment of FIG. 8, showing the operation of the cover plate;
FIG. 10 is a fragmented side view of a modification of the embodiment of FIG. 8;
FIG. 11 is a perspective view of another modification of the embodiment of FIG. 1, illustrating the carrying of flat handle instruments;
FIG. 12 is a perspective view showing one side of an instrument retaining boot of the modification shown in FIG. 11;
FIG. 13 is a perspective view showing another side of the instrument retaining boot shown in FIG. 12;
FIG. 14 is a plan view of a pair of the instrument retaining boots of FIG. 12 with a flat handle instrument inserted in one of the boots;
FIG. 15 is a fragmented perspective view of a modification of the instrument boot shown in FIG. 12.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIGS. 1, 3 the instrument count memorizer of the present invention comprises an instrument carrier including a metallic frame 10, preferably made of stainless steel and having a generally rectangular configuration with side members 12, 14 and end members 16, 18. Side members 12, 14 have inwardly extending flaps 20, 22 respectively to provide a support for a floor panel 24, perforated to freely admit and circulate steam for sterilization purposes. Flaps 20, 22 and floor panel 24 are rigidly assembled as by welding, into an open, box-like construction.
A bar 26, transversely positioned between side members 12, 14 and prevented from axial movement by push-on washers 25, 27 has a plurality of discrete, instrument carrying boots 28 mounted thereon in juxtaposed alignment and selectively spaced from each other by means of axially aligned spacing sleeves 30. As shown in more detail in FIG. 2, each boot 28 has a side wall 32, end walls 34, 36 of unequal length, and a floor 38 with perforations 40 to allow sterilizing steam to pass freely therethrough. A second side wall, opposite side wall 32, is not provided since, when in assembled relationship, the side wall 32 of each boot provides suitable side closure for the next adjacent boot. If desired, boot 28 may be integrally formed from a single piece of sheet material, with end walls 34, 36 and floor 38 bent into position and affixed to each other as by welding to form a rigid structure. Intermediate the top and bottom of side wall 32, and extending parallel to floor 38 and laterally for almost the entire length of side walls 32, is an elongated slot 42 which has enlarged ends 44, 46 respectively pointing in opposite directions from each other. Bar 26 passes through each slot 42 which has a width slightly greater than the diameter of the bar to allow boots 28 to slide laterally and rotate freely around bar 26.
With reference to FIGS. 6a-g, it will be seen that each boot 28 is free to slide laterally along floor panel 24 until one of the end enlargements 44, 46 of its associated slot 42 are reached. End enlargements 44, 46 of slot 42 allow boot 28 to be lifted slightly upward when rotation of the boot is desired so that the wall corners of the boot will freely clear floor panel 24 during rotation. In the illustrative example shown in FIG. 6, boot 28 is slid to the right until bar 26 engages enlargement 44 (FIGS. 6a-c). Boot 28 is then rotated 180 degrees about bar 26 in a counterclockwise direction (FIGS. 6d-f), whereupon it returns to its original but now inverted position with end wall 34 disposed closely adjacent to end member 18 of frame 10. Floor 38 now faces upwardly (FIG. 6g), thereby preventing insertion of a ring handle 50 of a hinged surgical instrument. Conversely, when end wall 36 of boot 28 is slidably positioned closely adjacent to end member 18 with enlargement 46 surrounding bar 26 (FIG. 6a), boot 28 cooperates with the side wall 32 of an adjacent boot to form a compartment presenting an opening 48 (FIG. 1) facing upwardly and adapted to receive a ring handle 50 of a surgical instrument.
The length of end wall 34 of boot 28 (FIG. 2) is suitably dimensioned, preferably slightly less than the vertical height of transversely disposed bar 26 above floor panel 24, in order to provide easy insertion of the ring handle 50 into a selected opening 48. Likewise, the corner 52 of sidewall 32 is rounded to facilitate further the insertion of ring handle 50.
The manner in which the instrument count memorizer is used will be apparent from the foregoing. After the number of instruments necessary for a particular surgical procedure has been determined, a like number of boots 28 are arranged by the method just described so that openings 48 face upwardly to receive a corresponding number of instrument ring handles 50. The remaining boots 28 are, of course, inverted with floors 38 facing upwardly to prevent insertion of instrument ring handles therein. It will therefore be seen that the number of openings 48 represents the count of the instruments carried by the present invention through the sterilizing process and into the operating room. Once the selected openings have been filled, the instruments remain stored therein through the sterilizing process and in the operating room until removed for use during the surgical procedure. Since the instrument count has been memorized as represented by openings 48 in boots 28, it will be evident that such openings must be filled with dirty instruments after the surgical procedure has been completed, to insure that all instruments used in the procedure have been retrieved and not left inside the body of a patient.
Referring again to FIGS. 1 and 3, a boot locking bar is provided to prevent further movement of boots 28, after the boots have been arranged into count memorizing positions. Locking bar 54 has a U-shaped configuration with outwardly extending fingers 56, 58 which extend through corresponding apertures in frame side members 12, 14 respectively. A detent button 60, fixedly positioned on frame side member 12 adjacent to the aperture for finger 58, is provided to hold locking bar 54 tightly against boots 28 after they have been arranged to memorize a desired count. When a count is to be memorized, locking bar 54 is pivoted upwardly past detent 60 into a vertical position (FIG. 4) so that boots 28 may be freely slid along floor panel 24 to their extended positions, rotated about bar 26, retracted and reset to form the desired count arrangement. Locking bar 54 is sufficiently resilient to allow fingers 56, 58 to move yieldably towards each other as bar 54 is pushed past detent 60.
After boots 28 have been arranged to reflect a selected instrument count and have been locked into position by downward rotation of locking bar 54, ring handles 50 of selected surgical instruments are each loaded into a corresponding opening 48 of boot 28. A hold down cover 62, pivotally mounted on frame side members 12, 14 is then rotated into locking engagement with ring handles 50.
As shown in FIGS. 1, 3, 4, 5 hold down cover 62, transversely disposed across frame 10 has a laterally extending cover plate 64 with downwardly extending arms 66, 68 attached thereto, which pivotally embrace frame side members 12, 14 respectively. Arms 66, 68 cooperate with cover plate 64 to form channels 70, 72 which receive and hold under compression a rectangular pad 74 formed from a resilient heat resistant material, such as silicone or other rubber-like compound. Also attached to each side of cover plate 64 are outwardly extending support arms 76, 78 which support an instrument handle spreader bar 80 transversely disposed across frame 10. Bar 80 may be attached to arms 76, 78 as by push-on retaining washers 82, 84 or by any other suitable means. As shown in FIGS. 4, 7 each of arms 66, 68 has a slot 86, 88 respectively angularly disposed in a downward direction away from cover plate 64, when the plate is seated adjacent to boots 28. Slots 86, 88 each have a scalloped edge 90, 92 respectively which engage with an associated pivot pin 94, 96 mounted on frame side members 14, 12.
With reference to FIGS. 1, 4, 7, after ring handles 50 have been inserted into selected openings 48 in boots 28, hold down cover 62 is rotated in an upward direction to a position immediately above ring handles 50. It is then pressed downwardly to cause pad 74 to deform and apply a firm holding pressure against the ring handles 50 nestled in openings 48. Hold down cover 62 will then be locked in position, securely holding ring handles 50 in place because of the upward pressure exerted against the cover by deformed pad 74, which causes a selected scallop of slot edges 90, 92 in arms 66, 68 to press against pivot pins 94, 96. An outwardly extending tab 98, integrally formed on cover plate 64 is provided to facilitate the manipulation of hold down cover 62. A plurality of scallops in edges 90, 92 are provided to allow adjustment of the pressure applied by pad 74, thus accomodating instruments with ring handles of different sizes. Support arms 76, 78 are angularly disposed with respect to cover plate 64 and lean forwardly towards frame end member 16 when hold down cover is in a locking position, thereby holding ring handles 51, which are arranged to rest on bar 80, in an open position to facilitate sterilization of the counted instruments.
A modification of the invention is shown in FIGS. 8, 9, wherein a ring handle spreader bar 100 and associated support arms, formed from a continuous length of rod stock material, are attached as by welding to a selected position on frame side members 12, 14, preferably adjacent to bar 26. Bar 100 is angularly disposed with respect to cover plate 64 in a manner similar to bar 80, to provide a selected amount of opening between ring handles 50, 51. In accordance with this modification of the invention, a convenient handle for transporting the count memorizer is provided by bar 100.
The locking arrangement provided by slots 86, 88 and pivot pins 94, 96 may also be modified to provide a more secure lock for hold down cover 62. As shown in FIGS. 8, 9, slots 86, 88 may be formed into a modified bayonet configuration 102 to provide stepped positions so that cover plate 62 may exert different amounts of pressure on instrument handles inserted in open boots 28. To further insure that cover plate 62 will not unlock during periods of rough handling of the count memorizer, the ends of slots 102 may be provided with enlargements 103 as shown in FIG. 10. Pivot pin 94, pressing against a selected enlargement 103 locks cover plate 62 in position in such a manner that it cannot be released until resilient pad 74 is further compressed by pressing cover plate 62 towards boots 28.
FIG. 11 illustrates a modification of the present invention to provide memorization of the count of other than ring handle instruments, such as thumb forceps, scalpels, leaf handle instruments or other flat handle instruments. In particular, instrument carrying boots 200 are provided which are similar to boots 28 but modified to receive the flat handles of instruments such as knife 202 and thumb forceps 204.
As shown in more detail in FIGS. 12, 13, 14 boot 200 has an upwardly extending end wall 206 and a notched out portion forming a slot-like configuration 208, which allows a flat handle instrument to be inserted into boot 200 and rest in a substantially horizontal position. Boot 200 has a side wall 210 in which a resilient finger 212 is formed as by lancing. Finger 212 has an inwardly protruding deformation 214 which, when boots 200 are assembled in a juxtaposed relationship as seen in FIG. 14, applies pressure against the flat side of the handle of an instrument such as knife 202, or thumb forceps 204. The flat handle is thereby urged against the wall 210 of the next adjacent boot 200, to hold it securely nestled in its associated boot 200.
Boot 216, disposed adjacent side frame member 14 has a side plate 218 (FIG. 15) laterally extending between end walls 36 and 220, and affixed thereto to provide an additional support wall when a flat handle instrument is inserted therein. Plate 218 prevents an instrument inserted into boot 216 from dislocating or falling out of the boot. A slot 222, formed in end plate 220 aids in properly positioning the handle on an instrument inserted in boot 216. The operation of the embodiment of FIG. 11 to store flat handle instruments and memorize an instrument count is the same as described for the embodiment of FIGS. 1-6.
While this invention has been shown and described in the best forms known, it will nevertheless be understood that this is purely exemplary and that modifications may be made without departing from the spirit of the invention.
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A device for storing sterile instruments and memorizing the count thereof. A main frame includes a plurality of juxtaposed boots, individually and selectively rotatable from open to closed positions. Each open boot stores the handle of an instrument and a rotatable cover plate is locked into position overlaying open and closed boots to apply holding contact pressure against instrument handles inserted in open boots. The number of open boots indicates the number of instruments selected to be stored by the device.
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BACKGROUND OF THE INVENTION
Decorative vinyl laminates have become a recognized alternative to natural woods in furniture manufacture and woodworking in general, due to their abrasion resistance, scratch resistance, water resistance, chemical resistance, barrier performance and flame spread resistance. In addition, adhesive technology has advanced to the extent that various epoxy, emulsion and solvent adhesives are available to bond the laminates to the substrate, depending upon the desired application. However, notwithstanding its adequate physical properties, vinyl has high elongation, resulting in a poor printed appearance compared to that of paper. Indeed, a typical vinyl product is 2 plys, a solid color base (color throughout) that is printed and a clear vinyl that is laminated over the print so as to protect if from abuse. The clear film is often coated with a scratch resistant coating to enhance its protective properties. Vinyl's poor appearance when printed stems from its high elongation; it stretches when in the printing press thereby "smearing" the image. Where paper is used instead, a pigmented paper can be used to eliminate the over-print step, resulting in superior print quality. Paper also handles better in lamination than does vinyl. Accordingly, it is desirable to use paper instead of vinyl. However, paper has lacked the physical strength necessary to perform as a machinable material. In particular, in miter-fold particle board applications, the paper must have sufficient strength to resist tearing and/or splitting when the miter-fold edge is formed. Heretofore, the superior printing quality of paper could not be exploited in such applications because of the severe stresses encountered during the miter-folding or "V-grooving" of the board.
SUMMARY OF THE INVENTION
The problems of the prior art have been overcome by the present invention, which provides a product that has the machinability of vinyl and the printability of paper, and a process for manufacturing such a product. Specifically, the product of the instant invention is a smooth, saturated only paper that is subjected to heavy calendering during processing in order to provide adequate smoothness as required by printers. The paper is saturated with an acrylic/PVC blend designed to give good "miter-fold" strength, good smoothness and adequate adhesive anchorage.
The particular saturant system used also allows the ink types used on vinyl films to adhere to the paper, and exhibits good stain resistance.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic view of the threading system for the stack calender used in accordance with the present invention; and
FIG. 2 is a comparison of important properties of paper and vinyl for particle board overlay applications.
DETAILED DESCRIPTION OF THE INVENTION
Suitable raw paper for use in the instant invention must be selected based upon good formation and good property potential, and must be saturable. The preferred raw paper meeting these requirements is Owensboro HP-8 75# available from W. R. Grace & Co. Conn. Such paper has a fiber composition of 85% (by weight) Northern Bleached Softwood Kraft and 15% (by weight) Hemlock Sulfite.
The saturant system must be able to withstand the actual physical abuse delivered to the sheet during the V-grooving operation. The physical properties that relate best to this operation are, in the order of importance, edge tear or tear initiation, internal tear (tear propagation), delamination resistance, and tensile strength/elongation. In addition, the saturant system must have the ability to be calendered to a high degree of smoothness, and must maintain that smoothness. An immediate smoothness less than about 100 Sheffield units is preferred. An acrylic system, being plastic in nature, has been found to calender to the required smoothness. Acrylics are also lightfast, which is a further advantage of the saturant. Preferably the major ingredient of the instant saturant is an acrylic latex, such as HYCAR 26104 available from The B. F. Goodrich Chemical Company. The acrylic latex can be used in an amount of from 55% to 96.75%, preferably 55-66%, most preferably about 56.75%, on a dry basis, depending upon the processing and smoothness retention. For maintaining smoothness, inorganic fillers in the saturant system such as clay or titanium dioxide tend to cause failures during miter-folding. Organic fillers such as unplasticized polyvinyl chloride, being less destructive to the cellulose fibers during folding because the particles are spherical as opposed to the platelet structure of the inorganics mentioned, are suitable. Preferably the filler is a polyvinyl chloride latex such as GEON 352 available from The B. F. Goodrich Chemical Company, used in an amount of from 0% to 40%, preferably 33-40%, most preferably about 40%, on a dry basis.
In order to increase the delamination resistance of the product, it is necessary to reduce the level of binder migration common during the drying of heavyweight papers. A thickener in the saturant system can be added for this purpose. Virtually any cellulosic thickener can be used, as can sodium polyacrylate and alkali reactive emulsions. However, cellulosics impart solvent resistance to the saturant (which can interfere with the printability), and brittleness. Sodium polyacrylate and the alkali reactive emulsions also exhibit these effects and can be water sensitive as well. Accordingly, the preferred thickener is sodium alginate. Kelgin MV, available from Kelco, Inc. has been found to be suitable, and is used in an amount of from 0.15% to 0.35%, dry basis, to limit migration at various saturator line speeds.
Another functional ingredient for the saturant system is a release agent, designed to migrate to the surface of the sheet during the calendering operation and provide release from the hot steel rolls. Emulsified waxes or waxy materials could be used for this purpose, although emulsified waxes tend to cause smoke generation during processing. Waxy materials such as stearylated melamine can impart other properties that may or may not be undesirable, such as water resistance after processing. Preferably the release agent is sorbitan tristearate, such as TWEEN 65, available from ICI Americas, Inc. The sorbitan tristearate has also been found to "fill" the sheet surface, thereby contributing to the smoothness. It is used in an amount of from 0% to 3%, dry basis, to provide release from the very hot calender rolls at various calender line speeds.
Other inert ingredients, such as pigments and defoamers can be added. Preferably the paper is saturated to a 40% add-on level.
Preferably the ingredients of the saturant system are used in the following amounts on a dry solids basis:
56.75% acrylic latex
40.00% polyvinyl chloride latex
0.25% sodium alginate
3.00% sorbitan tristearate
Since the pH of acrylic latexes is generally low, and the pH of PVC latexes is generally high, it is preferred that the pH of the acrylic latex be raised with dilute ammonium hydroxide and that the PVC latex be added thereto slowly. The order of addition of the remaining ingredients is not critical.
FIG. 1 illustrates the lacing procedure used to calender the saturated paper in accordance with the instant invention. The paper is unwound from roll 1, and passes by tension transducer roll 2 to heated steel calender roll 4. The paper then travels through a nip formed between roll 4 and fiber calender roll 5, past mt. hope spreader roll 6, tension rolls 3 and 3' (turned off and used as idler rolls), idler roll 7, and a second heated steel calender roll 8 where it is again heated. A second nip is formed between the second heated calendar roll 8 and fiber calendar roll 5. The sheet then passes over a steel idler roll 9, and is cooled by first and second cooling rolls 10 and 11. Adequate heat transfer between the paper web and these cooling rolls can be accomplished by cooling the rolls with ordinary tap water, which is typically at temperatures from 58° F. to 72° F., most typically 65° F. The sheet then passes over a large diameter mt. hope roll 12 and a large diameter idler roll 13, and is rewound on roll 14. The practical minimum diameter of any of the rolls is about 3 inches. The saturator squeeze rolls (not shown) and the calender steel rolls must be of a diameter and construction that will resist flexing during operation. As a practical matter, the minimum diameter of any of the rolls is 3 inches.
Temperature of the heated calender rolls, line speed and nip pressure are critical in order to achieve uniform caliper and smoothness of the sheet. Line speed and nip pressure have been found to effect the immediate Sheffield smoothness; higher speeds and higher pressures equate to lower immediate Sheffield smoothness. Line speed alone effects the Sheffield smoothness after 24 hours; lower line speeds produced material that had higher 24 hour Sheffield smoothness values. Temperature and pressure have a significant effect on the percent increase in smoothness after 24 hours, whereas line speed has only a slight effect. Higher temperature, higher pressure and lower line speeds lead to larger percent increases in smoothness after 24 hours. None of the variables were found to effect the machine direction (MD) or cross direction (CD) miter fold, or the CD internal tear. Line speed was found to effect MD internal tear; higher line speeds produced lower MD internal tear values. Higher line speeds also led to higher burst values. Based upon the foregoing, it is preferred that the line speed be 150 feet/minute, that the nip pressure be 1100 psig, and that the temperature of the heated steel calendar rolls 4 and 8 be 325° F. Significant deviations from these values result in a product that is unstable in terms of smoothness.
EXAMPLE 1
A comparison of some of the properties of paper and 8 mil vinyl sandwich film is shown in FIG. 2. The vinyl sandwich film compared therein was produced in accordance with the process outlines in PLASTIC FILMS, second edition, by John H. Briston, chapter 8, section 2, 1983, the disclosure of which is hereby incorporated by reference. In particular, the sandwich film is two films, one colored and printed and the other clear, that are laminated together. Both of the films of this sandwich were made by the process outlined in section 8.2.
The saturated paper of FIG. 2 was made in accordance with the instant invention. The untreated paper was saturated by forcing the paper to enter a large shallow pan that contained the saturant mixture. The paper was then directed through a pair of squeeze rolls similar to wringer rolls on old-style washing machines. This squeezing or wringing of the paper controls the add-on level. After squeezing, the paper was dried by a combination of forced hot-air, infrared and contact heat dryers. The paper was saturated to a 40% add-on level. Once dry, the paper was rerolled and subjected to the calendering process in accordance with the instant invention.
FIG. 2 shows the significant advantages realized when using paper instead of vinyl in terms of percent elongation and Elmendorf Tear (grams), without sacrificing tensile strength (lbs/inch of width). Preferably the saturated paper used in accordance with the instant invention has a caliper of 6-8 mils and a Sheffield smoothness of about 85.
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V-groovable gravure printable paper having the machinability of vinyl and the printability of paper, and a process for manufacturing such a product. A smooth, saturated only paper is subjected to heavy calendering during processing in order to provide adequate smoothness as required by printers. The paper is saturated with an acrylic/PVC blend designed to give good "miter-fold" strength, good smoothness and adequate adhesive anchorage. The saturant also allows the ink types used on vinyl films to adhere to the paper, and exhibits good stain resistance.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims priority to and the benefit of U.S. Provisional Patent Application No. 62/275,316, filed on Jan. 6, 2016, the entire contents of which are incorporated by reference herein.
FIELD
[0002] The present invention generally relates to a cosmetic brush with a tapered handle having three sides to facilitate precision brushing and/or other manipulation of a surface.
SUMMARY
[0003] Cosmetic brushes include a brush portion and a handle portion extending therefrom to facilitate engagement of the brush by a user or tool. Cosmetic brushes may be used in a variety of situations, for example, to manipulate, remove, and/or apply cosmetics to a user's skin or to another medium for viewing purposes.
[0004] Referring to FIG. 1 , many prior art cosmetic brushes incorporate handles that are cylindrical in shape. Due to the delicate nature of cosmetic application, removal, and/or manipulation, such a configuration of the brush handle may be cumbersome and yield imprecise results, for example, by leading to uneven distribution of cosmetics or due to lack of fine control over the brush by the user.
[0005] What is needed is a precision cosmetic brush to obtain more controlled application, removal, and/or distribution of cosmetics or other manipulation of a surface.
[0006] These and other objects, benefits, and advantages provided by the solutions enabled by embodiments of the present invention will be described in detail below with reference to the accompanying figures.
[0007] Applicant has discovered a solution to the need for precision control over a cosmetic brush by providing a uniquely-configured brush handle as described herein.
[0008] In an exemplary embodiment, a precision cosmetic brush is disclosed, and comprises a brush portion configured for engaging a surface and applying a cosmetic material to the surface, a ferrule supporting the brush portion, and a handle connected to the brush portion with the ferrule, the handle having a first end that is connected to the brush portion, a second end extending away from the brush portion, and an elongate body extending between the first and second ends of the handle. The handle is configured to facilitate control by a user of the precision cosmetic brush for applying the cosmetic material to the surface, and includes, along at least a segment of the handle, a triangular cross-section configured for the user to hold the precision cosmetic brush, and a taper in a direction extending away from the brush portion such that the triangular cross-section of the segment of the handle is larger toward the first end of the handle and tapers toward the second end of the handle.
[0009] In exemplary embodiments, the second end of the handle has a blunt configuration.
[0010] In exemplary embodiments, the segment of the handle has a taper that is within a range of 0.01 mm and 0.2 mm per unit mm along a length of the segment of the handle.
[0011] In exemplary embodiments, the handle is at least partially transparent.
[0012] In exemplary embodiments, the handle is configured to transmit between 75% and 95% of incident light therethrough.
[0013] In exemplary embodiments, the handle is at least partially opaque.
[0014] In exemplary embodiments, the brush portion includes one or more visual indicators.
[0015] In exemplary embodiments, the one or more visual indicators include at least one or more bands, marks or striations.
[0016] In exemplary embodiments, the brush portion includes a color gradient that includes a darker color toward the ferrule and a lighter color away from the ferrule.
[0017] In exemplary embodiments, the brush portion includes a color gradient from gray toward the ferrule to white away from the ferrule.
[0018] In exemplary embodiments, the ferrule is detachable such that the brush portion is removable from the ferrule.
[0019] In exemplary embodiments, the brush portion that is configured for engaging a surface is configured for engaging at least one of skin, hair or a display template.
[0020] In other exemplary embodiments, a precision cosmetic applicator is disclosed, and comprises an application portion configured for engaging a surface and applying a cosmetic material to the surface, and a handle connected to the application portion, the handle having a first end that is connected to the application portion, a second end extending away from the application portion, and an elongate body extending between the first and second ends of the handle. The handle is configured to facilitate control by a user of the precision cosmetic applicator for applying the cosmetic material to the surface, and includes, along at least a segment of the handle, a triangular cross-section configured for the user to hold the precision cosmetic applicator, and a taper in a direction extending away from the application portion such that the triangular cross-section of the segment of the handle is larger toward the first end of the handle and tapers toward the second end of the handle.
[0021] In exemplary embodiments, the application portion includes one of a brush, comb, wand, stylus, sponge, silicone or a doe foot.
[0022] In exemplary embodiments, the second end of the handle has a blunt configuration.
[0023] In exemplary embodiments, the segment of the handle has a taper that is within a range of 0.01 mm and 0.2 mm per unit mm along a length of the segment of the handle.
[0024] In exemplary embodiments, the handle is at least partially transparent.
[0025] In exemplary embodiments, the handle is configured to transmit between 75% and 95% of incident light therethrough.
[0026] In exemplary embodiments, the handle is at least partially opaque.
[0027] In exemplary embodiments, the application portion includes one or more visual indicators.
[0028] In exemplary embodiments, the one or more visual indicators include at least one or more bands, marks or striations.
[0029] In exemplary embodiments, the application portion includes a color gradient that includes a darker color toward the handle and a lighter color away from the handle.
[0030] In exemplary embodiments, the application portion includes a color gradient from gray toward the handle to white away from the handle.
[0031] In exemplary embodiments, the application portion that is configured for engaging a surface is configured for engaging at least one of skin, hair or a display template.
[0032] In other exemplary embodiments, a precision cosmetic brush is disclosed, and comprises a brush portion configured for engaging a surface and applying a cosmetic material to the surface, and a handle connected to the brush portion, the handle having a first end that is connected to the brush portion, a second end extending away from the brush portion, and an elongate body extending between the first and second ends of the handle. The handle is configured to facilitate control by a user of the precision cosmetic brush for applying the cosmetic material to the surface, and includes, along at least a segment of the handle, a triangular cross-section configured for the user to hold the precision cosmetic brush, and a taper in a direction extending from the second end of the handle toward the brush portion such that the triangular cross-section of the segment of the handle is larger toward the second end of the handle and tapers upward therefrom.
[0033] In exemplary embodiments, the second end of the handle has a blunt configuration.
[0034] In exemplary embodiments, the handle is at least partially transparent.
[0035] In exemplary embodiments, the handle is configured to transmit between 75% and 95% of incident light therethrough.
[0036] In exemplary embodiments, the handle is at least partially opaque.
[0037] In exemplary embodiments, the brush portion includes one or more visual indicators.
[0038] In exemplary embodiments, the one or more visual indicators include at least one or more bands, marks or striations.
[0039] In exemplary embodiments, the brush portion includes a color gradient that includes a darker color toward the handle and a lighter color away from the handle.
[0040] In exemplary embodiments, the brush portion includes a color gradient from gray toward the handle to white away from the handle.
[0041] In exemplary embodiments, the brush portion that is configured for engaging a surface is configured for engaging at least one of skin, hair or a display template.
BRIEF DESCRIPTION OF THE DRAWINGS
[0042] Various exemplary embodiments of this invention will be described in detail, with reference to the following figures, wherein:
[0043] FIG. 1 is a front view of a set of prior art cosmetic brushes with handles;
[0044] FIG. 2 is a perspective view of a cosmetic brush with handle according to an exemplary embodiment of the present invention;
[0045] FIG. 3 is a left side view of the cosmetic brush with handle of FIG. 2 ;
[0046] FIG. 4 is a right side view of the cosmetic brush with handle of FIG. 2 ;
[0047] FIG. 5 is a bottom plan view of the cosmetic brush with handle of FIG. 2 ;
[0048] FIG. 6 is a top plan view of the cosmetic brush with handle of FIG. 2 ;
[0049] FIG. 7 is a front side view of the cosmetic brush with handle of FIG. 2 ;
[0050] FIG. 8 is a rear side view of the cosmetic brush with handle of FIG. 2 ;
[0051] FIG. 9 is a perspective view of a cosmetic brush with handle according to an exemplary embodiment of the present invention;
[0052] FIG. 10 is a left side view of the cosmetic brush with handle of FIG. 9 ;
[0053] FIG. 11 is a right side view of the cosmetic brush with handle of FIG. 9 ;
[0054] FIG. 12 is a bottom plan view of the cosmetic brush with handle of FIG. 9 ;
[0055] FIG. 13 is a top plan view of the cosmetic brush with handle of FIG. 9 ;
[0056] FIG. 14 is a front side view of the cosmetic brush with handle of FIG. 9 ;
[0057] FIG. 15 is a rear side view of the cosmetic brush with handle of FIG. 9 ;
[0058] FIG. 16 is a perspective view of a cosmetic brush with handle according to an exemplary embodiment of the present invention;
[0059] FIG. 17 is a left side view of the cosmetic brush with handle of FIG. 16 ;
[0060] FIG. 18 is a right side view of the cosmetic brush with handle of FIG. 16 ;
[0061] FIG. 19 is a bottom plan view of the cosmetic brush with handle of FIG. 16 ;
[0062] FIG. 20 is a top plan view of the cosmetic brush with handle of FIG. 16 ;
[0063] FIG. 21 is a front side view of the cosmetic brush with handle of FIG. 16 ;
[0064] FIG. 22 is a rear side view of the cosmetic brush with handle of FIG. 16 ;
[0065] FIG. 23 is a front view of a set of cosmetic brushes with handles according to another exemplary embodiment of the present invention;
[0066] FIG. 24A is a front view of a cosmetic brush with handle according to another exemplary embodiment of the present invention;
[0067] FIG. 24B is a cross-sectional view of the cosmetic brush with handle of FIG. 24A ;
[0068] FIG. 25A is a front view of a cosmetic brush with handle according to another exemplary embodiment of the present invention;
[0069] FIG. 25B is a cross-sectional view of the cosmetic brush with handle of FIG. 25A ;
[0070] FIG. 26A is a front view of a cosmetic brush with handle according to another exemplary embodiment of the present invention;
[0071] FIG. 26B is a cross-sectional view of the cosmetic brush with handle of FIG. 26A ;
[0072] FIG. 27A is a front view of a cosmetic brush with handle according to another exemplary embodiment of the present invention;
[0073] FIG. 27B is a cross-sectional view of the cosmetic brush with handle of FIG. 27A ;
[0074] FIG. 28A is a front view of a cosmetic brush with handle according to another exemplary embodiment of the present invention;
[0075] FIG. 28B is a cross-sectional view of the cosmetic brush with handle of FIG. 28A ;
[0076] FIG. 29A is a front view of a cosmetic brush with handle according to another exemplary embodiment of the present invention;
[0077] FIG. 29B is a cross-sectional view of the cosmetic brush with handle of FIG. 29A ;
[0078] FIG. 30A is a front view of a cosmetic brush with handle according to another exemplary embodiment of the present invention;
[0079] FIG. 30B is a cross-sectional view of the cosmetic brush with handle of FIG. 30A ;
[0080] FIG. 31A is a front view of a cosmetic brush with handle according to another exemplary embodiment of the present invention;
[0081] FIG. 31B is a cross-sectional view of the cosmetic brush with handle of FIG. 31A ;
[0082] FIG. 31C is another cross-sectional view of the cosmetic brush with handle of FIG. 31A ;
[0083] FIG. 32A is a front view of a cosmetic brush with handle according to another exemplary embodiment of the present invention;
[0084] FIG. 32B is a cross-sectional view of the cosmetic brush with handle of FIG. 32A ;
[0085] FIG. 33A is a front view of a cosmetic brush with handle according to another exemplary embodiment of the present invention;
[0086] FIG. 33B is a cross-sectional view of the cosmetic brush with handle of FIG. 33A ;
[0087] FIG. 34A is a front view of a cosmetic brush with handle according to another exemplary embodiment of the present invention;
[0088] FIG. 34B is a side view of the cosmetic brush with handle of FIG. 34A ;
[0089] FIG. 34C is a cross-sectional view of the cosmetic brush with handle of FIG. 34A ;
[0090] FIG. 35A is a front view of a cosmetic brush with handle according to another exemplary embodiment of the present invention;
[0091] FIG. 35B is a cross-sectional view of the cosmetic brush with handle of FIG. 35A ;
[0092] FIG. 36A is a front view of a cosmetic brush with handle according to another exemplary embodiment of the present invention;
[0093] FIG. 36B is a cross-sectional view of the cosmetic brush with handle of FIG. 36A ;
[0094] FIG. 37A is a front view of a cosmetic brush with handle according to another exemplary embodiment of the present invention;
[0095] FIG. 37B is a cross-sectional view of the cosmetic brush with handle of FIG. 37A ;
[0096] FIG. 38A is a front view of a cosmetic brush with handle according to another exemplary embodiment of the present invention;
[0097] FIG. 38B is a cross-sectional view of the cosmetic brush with handle of FIG. 38A ;
[0098] FIG. 39A is a front view of a cosmetic brush with handle according to another exemplary embodiment of the present invention;
[0099] FIG. 39B is a cross-sectional view of the cosmetic brush with handle of FIG. 39A ;
[0100] FIG. 40A is a front view of a cosmetic brush with handle according to another exemplary embodiment of the present invention;
[0101] FIG. 40B is a cross-sectional view of the cosmetic brush with handle of FIG. 40A ;
[0102] FIG. 41A is a front view of a cosmetic brush with handle according to another exemplary embodiment of the present invention;
[0103] FIG. 41B is a cross-sectional view of the cosmetic brush with handle of FIG. 41A ;
[0104] FIG. 42A is a front view of a cosmetic brush with handle according to another exemplary embodiment of the present invention;
[0105] FIG. 42B is a cross-sectional view of the cosmetic brush with handle of FIG. 42A ;
[0106] FIG. 43A is a front view of a cosmetic brush with handle according to another exemplary embodiment of the present invention;
[0107] FIG. 43B is a cross-sectional view of the cosmetic brush with handle of FIG. 43A ;
[0108] FIG. 44A is a front view of a cosmetic brush with handle according to another exemplary embodiment of the present invention;
[0109] FIG. 44B is a cross-sectional view of the cosmetic brush with handle of FIG. 44A ;
[0110] FIG. 45A is a front view of a cosmetic brush with handle according to another exemplary embodiment of the present invention;
[0111] FIG. 45B is a cross-sectional view of the cosmetic brush with handle of FIG. 45A ;
[0112] FIG. 46A is a front view of a cosmetic brush with handle according to another exemplary embodiment of the present invention;
[0113] FIG. 46B is a side view of the cosmetic brush with handle of FIG. 46A ;
[0114] FIG. 46C is a cross-sectional view of the cosmetic brush with handle of FIG. 46A ;
[0115] FIG. 47A is a front view of a cosmetic brush with handle according to another exemplary embodiment of the present invention;
[0116] FIG. 47B is a cross-sectional view of the cosmetic brush with handle of FIG. 47A ;
[0117] FIG. 48A is a front view of a cosmetic brush with handle according to another exemplary embodiment of the present invention;
[0118] FIG. 48B is a side view of the cosmetic brush with handle of FIG. 48A ;
[0119] FIG. 48C is a cross-sectional view of the cosmetic brush with handle of FIG. 48A ;
[0120] FIG. 49A is a front view of a cosmetic brush with handle according to another exemplary embodiment of the present invention;
[0121] FIG. 49B is a cross-sectional view of the cosmetic brush with handle of FIG. 49A ;
[0122] FIG. 49C is a side view of the cosmetic brush with handle of FIG. 49A ;
[0123] FIG. 50A is a front view of a cosmetic brush with handle according to another exemplary embodiment of the present invention;
[0124] FIG. 50B is a cross-sectional view of the cosmetic brush with handle of FIG. 50A ;
[0125] FIG. 51A is a front view of a cosmetic brush with handle according to another exemplary embodiment of the present invention;
[0126] FIG. 51B is a cross-sectional view of the cosmetic brush with handle of FIG. 51A ;
[0127] FIG. 51C is a side view of the cosmetic brush with handle of FIG. 51A ;
[0128] FIG. 52A is a front view of a cosmetic brush with handle according to another exemplary embodiment of the present invention;
[0129] FIG. 52B is a cross-sectional view of the cosmetic brush with handle of FIG. 52A ;
[0130] FIG. 53A is a front view of a cosmetic brush with handle according to another exemplary embodiment of the present invention;
[0131] FIG. 53B is a cross-sectional view of the cosmetic brush with handle of FIG. 53A ;
[0132] FIG. 54A is a front view of a cosmetic brush with handle according to another exemplary embodiment of the present invention;
[0133] FIG. 54B is a cross-sectional view of the cosmetic brush with handle of FIG. 54A ;
[0134] FIG. 54C is a side view of the cosmetic brush with handle of FIG. 54A ;
[0135] FIG. 55A is a front view of a cosmetic brush with handle according to another exemplary embodiment of the present invention;
[0136] FIG. 55B is a cross-sectional view of the cosmetic brush with handle of FIG. 55A ;
[0137] FIG. 55C is a side view of the cosmetic brush with handle of FIG. 55A ;
[0138] FIG. 56A is a front view of a cosmetic brush with handle according to another exemplary embodiment of the present invention;
[0139] FIG. 56B is a cross-sectional view of the cosmetic brush with handle of FIG. 56A ;
[0140] FIG. 56C is a side view of the cosmetic brush with handle of FIG. 56A ;
[0141] FIG. 56D is a cross-sectional view of the cosmetic brush with handle of FIG. 56C ;
[0142] FIG. 57A is a front view of a cosmetic brush with handle according to another exemplary embodiment of the present invention;
[0143] FIG. 57B is a side view of the cosmetic brush with handle of FIG. 57A ;
[0144] FIG. 57C is a cross-sectional view of the cosmetic brush with handle of FIG. 57A ;
[0145] FIG. 57D is a top view of the cosmetic brush with handle of FIG. 57A ;
[0146] FIG. 57E is a front view of a cosmetic brush with handle according to another exemplary embodiment of the present invention;
[0147] FIG. 57F is a side view of the cosmetic brush with handle of FIG. 57E ;
[0148] FIG. 58A is a front view of a cosmetic brush with handle according to another exemplary embodiment of the present invention;
[0149] FIG. 58B is a cross-sectional view of the cosmetic brush with handle of FIG. 58A ;
[0150] FIG. 58C is a side view of the cosmetic brush with handle of FIG. 58A ;
[0151] FIG. 58D is a cross-sectional view of the cosmetic brush with handle of FIG. 58C ;
[0152] FIG. 59A is a front view of a cosmetic brush with handle according to another exemplary embodiment of the present invention;
[0153] FIG. 59B is a cross-sectional view of the cosmetic brush with handle of FIG. 59A ;
[0154] FIG. 59C is a side view of the cosmetic brush with handle of FIG. 59A ;
[0155] FIG. 60 is a top view of a cosmetic brush with handle according to another exemplary embodiment of the present invention;
[0156] FIG. 61 is a perspective view of cosmetic brush with handle according to another exemplary embodiment of the present invention;
[0157] FIG. 62 is another perspective view of the cosmetic brush with handle of FIG. 61 ;
[0158] FIG. 63 is another perspective view of the cosmetic brush with handle of FIG. 61 ;
[0159] FIG. 64 is another perspective view of the cosmetic brush with handle of FIG. 61 ;
[0160] FIG. 65 is a front view of the cosmetic brush with handle of FIG. 61 ;
[0161] FIG. 66 is a side view of the cosmetic brush with handle of FIG. 61 ;
[0162] FIG. 67 is a bottom plan view of the cosmetic brush with handle of FIG. 61 ;
[0163] FIG. 68 is a front view of a cosmetic brush with handle according to another exemplary embodiment of the present invention; and
[0164] FIG. 69 is a front view of a cosmetic brush with handle according to another exemplary embodiment of the present invention.
DETAILED DESCRIPTION
[0165] The present invention generally relates to a precision cosmetic brush or applicator with a tapered handle. In embodiments, the present invention is directed to a brush or applicator including an ergonomic handle to facilitate precision brushing of a surface and/or other manipulation of a surface with a brush portion/application portion. While exemplary embodiments are described herein with respect to a brush, it will be understood that the handle portion configurations described herein may be used with a different type of cosmetic applicators/implements, for example, a brush, comb, wand, stylus, sponge, silicone or a doe foot, to name a few.
[0166] It will be further understood that the handle portion configurations described herein may also be used with one or more of the brush and applicator types and configurations mentioned below or one or more of the following cosmetic applicators/implements for, for example, makeup mist, skincare mist, lipstick, lip crayon, lip gloss, lip liner, lip exfoliator, eyeliner pencil, liquid eyeliner, cream eyeliner, powder eyeliner, eye crayon, mascara, foundation cream, foundation serum, foundation powder, liquid foundation, eyeshadow powder, eyeshadow liquid, eyeshadow palette, eyeshadow cream, powder pressed, loose powder, blush cream, liquid blush, blush powder, bronzer cream, bronzer powder, liquid bronzer, highlighter cream, liquid highlighter, highlighter powder, shimmer powder, oil, primer, moisturizer, serum, lotion, cleanser, eyebrow pencil, eyebrow wax, eyebrow powder, eyebrow cream, eyebrow mascara, concealer pencil, liquid concealer, concealer cream, palette, or a compact, to name a few additional examples.
[0167] With reference to FIGS. 2-8 , a brush according to an exemplary embodiment of the present invention is illustrated and generally designated 100 . Brush 100 may include a brush portion 110 and a handle portion 120 , as shown.
[0168] Brush portion 110 may be an applicator member configured to engage a desired surface such as skin, hair (e.g., eyelashes or eyebrows), or a display template, for example, to by adding, removing, and/or manipulating a cosmetic material. In embodiments, brush portion 110 may include a polymeric material, e.g., synthetic fiber such as acrylic or plastic, that may have a desired rigidity and capacity for absorption of other materials, for example, bristles, fibers, cloth, pledgets, or foam, to name a few. In embodiments, brush portion 110 may be formed of a different type of fiber, such as natural or organic fibers, to name a few. Brush portion 110 may be configured in accordance with a desired type of surface engagement, for example, brush portion 110 may have a desired bristle count, length, density, or absorption capacity, to name a few. In embodiments, brush portion 110 may include a different type of material, such as a wand, comb, stylus, sponge, silicone or a doe foot. In embodiments, brush portion 110 may have an axial length of between and including 25 mm and 35 mm. In other exemplary embodiments, brush portion 110 may have a shorter or longer axial length, such as the lengths shown in Table 1 below.
[0169] In embodiments, brush portion 110 may be a solid color, such as black, white, pink, rose gold, brown, or a metallic color, such as gold, silver, rose gold, gun metal, or pearl, to name a few, or brush portion 110 may be multicolored. In embodiments, brush portion 110 may also include one or more visual indicators to facilitate use. For example, brush portion 110 may include a color gradient that shifts from a darker color closer to handle portion 120 to a lighter color further away from handle portion 120 . Such a visual configuration of brush portion 110 may aid a user in identifying the presence of cosmetic material on brush portion 110 during use of brush 100 . In embodiments, brush portion 110 may be visually configured to have a graduated configuration from a gray color closer to handle portion 120 (and ferrule 140 , when present) to a white color further away from handle portion 120 (and ferrule 140 , when present). In other exemplary embodiments, a color gradient of brush portion 110 may feature a graduated change of a different color or colors other than gray and/or white, such as a graduated change from a darker color closer to handle portion 120 to a lighter color further away from handle portion 120 . In embodiments, brush portion 110 may be visually configured, e.g., colored, to contrast against a cosmetic material being applied. In this regard, a user is afforded more precise control over brush 100 by being afforded a contrasting view of cosmetic material to be applied against a contrasting background. In embodiments, other types of visual indicia, for example, bands, marks, or striations, may be present on brush portion 110 to assist in fine control over engagement of brush 100 against a surface.
[0170] Handle portion 120 , as shown, may include a handle 130 and a ferrule 140 interconnecting the handle 130 and brush portion 110 . In embodiments, brush 100 may be devoid of a ferrule 140 , with brush portion 110 directly affixed to handle 130 .
[0171] Ferrule 140 supports brush portion 120 , and may be coupled to brush portion 120 by, for example, adhesion, crimping, clamping, interweaving, or friction fit, to name a few. In embodiments, the tightness of coupling of ferrule 140 to brush portion 110 is a function of the density of brush portion 110 . For example, a brush portion 110 having a greater number of bristles may require a greater crimp on ferrule 140 to maintain a secure engagement of brush portion 110 with ferrule 140 . In embodiments, brush portion 120 and ferrule 140 may be detachable from one another, e.g., so that replacement or alternative brush portions can be coupled with handle portion 120 . In embodiments, ferrule 140 may be detachable from handle portion 120 so that ferrule 140 and/or brush portion 110 may be replaced with respect to handle 130 .
[0172] In embodiments, ferrule 140 may be configured to support a variety of brush and applicator types and configurations, for example, a powder brush, a concealer brush, a contouring brush a bronzer brush, a foundation brush, a blush brush, a Kabuki brush, a blending brush, an eye brush, a crease brush, an eye liner brush, a face brush, a defining brush, a lip brush, an eye shadow brush, a stipple brush, a smudge sponge, a brow comb, an eyelash wand, or an eyebrow wand, or one of the cosmetic applicators/implements mentioned above, to name a few. Examples of brush types and configurations can be seen in FIGS. 9-69 . In embodiments, an applicator may have a cap (e.g., lipstick) that fits over the brush or other applicator.
[0173] Ferrule 140 may be formed of a suitable material configured to support brush portion 120 , for example, a polymeric material, a composite material, and/or a metallic material, to name a few. In embodiments, ferrule 140 may be formed at least partially of a metallic material with a smooth, e.g., brushed or polished, finish. In embodiments, ferrule 140 may be formed at least partially of a non-metallic finish (e.g., a black finish).
[0174] As shown, ferrule 140 may be a conic section, e.g., having a circular axial cross-section that tapers therealong, and which terminates at a point such that a side profile of the ferrule 140 is trapezoidal. In embodiments, ferrule 140 may taper such that a diameter of ferrule 140 reduces between and including a length of 26 mm and 1 mm in an axial direction. In embodiments, ferrule 140 may have an overall axial length of between and including 35 mm and 55 mm. Such a configuration may present a surface for engagement of the brush 100 by a user, for example, the thumb and index finger of a user, to facilitate fine manipulation of the brush portion 110 against a surface. In embodiments, ferrule 140 may have a different configuration, for example, a triangular, rectangular, or elliptical cross-section, and/or a different side profile, to name a few. The opening and diameter of ferrule 140 is affected by the volume of brush material of brush portion 110 to be held. In general, the greater the amount of brush material to be held, the wider the opening. Conversely, when a lesser amount of brush material is to be held, the opening of the ferrule may be tapered inwardly, as shown in FIGS. 16-22 .
[0175] Still referring to FIGS. 2-8 , handle 130 will be described in detail. Handle 130 , as shown, may be an elongate member with a triangular cross-section. In embodiments, the triangular cross-section may have a shape of an equilateral triangle, and may include vertices that are curved or beveled to avoid sharp corners. Accordingly, handle 130 presents three separate outer surfaces and edges for engagement by a user such that fine manual control of brush 100 is afforded to the user. In this regard, handle 130 may be formed of a material that is sufficiently rigid to be directionally manipulated by a user's fingers and/or hand. In embodiments, handle 130 may be formed of one or more of, for example, a polymeric material (such as glass or plastic), a composite material, or a metallic material, to name a few. In exemplary embodiments, handle 130 may be formed of an at least partially transparent material, including a fully transparent or a translucent material. Accordingly, handle 130 may be selected from a material having a high light transmissibility, e.g., configuration to transmit a percentage of incident light therethrough, such as between 75% and 95% of incident light. In embodiments, handle 130 may be formed of a polymeric material such as glass or plastic. Such transparency of handle 130 may reduce the occurrence of shadows cast by handle 130 on a target surface and/or may allow a user to at least partially view an environment through handle 130 . In embodiments, handle 130 may be opaque and display one or more colors, such as gold, silver, rose gold, gun metal, pearl, and/or other metallic colors, or a non-metallic color such as black, grey, white, pink, rose gold, brown, to name a few. In embodiments, handle 130 may be iridescent and/or may include glitter, pearls. or other decorative features, and may include printed text or graphics.
[0176] Handle 130 may have a length sufficient to afford a user with a desired grip of brush 100 . In embodiments, handle 130 may have a length between and including, for example, 90 mm and 100 mm. Such length of handle 130 may afford the user with dexterous control of brush 100 , for example, by allowing the user to tilt brush 100 using portions of handle 130 as a lever. A user is also afforded the option of grasping portions of handle 130 along its length that is most comfortable for his or her grip. In this regard, handle 130 is configured for use by a variety of users.
[0177] As shown, handle 130 (or a segment thereof) may be tapered, e.g., having a cross-sectional area that decreases therealong in a direction extending away from brush portion 110 . For example, handle 130 may decrease in cross-sectional diameter and area along a range between and including 8 mm and 5 mm. (As used herein, the cross-sectional diameter of a triangular cross-section is measured from one vertex of the triangle to a midpoint on the side of the triangle opposite that vertex. An example of a cross-sectional diameter is shown, for example, by dashed line 160 in FIG. 57C .) In embodiments, the cross-sectional diameter of handle 130 may taper at a rate of between and including 0.01 mm and 0.2 mm per unit mm (i.e., the taper is within a range of 0.01 mm and 0.2 mm per unit mm) along the length of handle 130 , or a segment thereof. In embodiments, the cross-sectional diameter of handle 130 may taper at a different rate per unit mm along the length of handle 130 . Such taper of handle 130 may provide the user with a comfortable grip of brush 100 , for example, by providing a relatively larger surface area for fine engagement, for example, by a user's fingers, and an increasingly narrower section of handle 130 that can rest comfortably on a user's wrist, palm, and/or thenar space without requiring the user to tense the muscles thereof to maintain a grip on handle 130 .
[0178] Handle 130 may also include an end 132 that is blunted, e.g., having a flattened or beveled surface. Such a configuration of end 132 may facilitate the free movement of end 132 by a user without worry as to possible scratching or poking of the user or a surface engaged by brush 100 . End 132 may also be configured to support brush 100 in a standing configuration on a flat surface. In embodiments, end 132 may be configured for engagement with, for example, a storage or display implement for brush 100 .
[0179] Referring to FIGS. 9-69 , various embodiments of cosmetic brushes with handles according to the present invention are illustrated. As shown, such embodiments according to the present invention may have a variety of configurations of overall lengths, brush portion lengths, ferrule lengths, handle lengths, and tapering handle cross-sectional diameters, with examples provided in Table 1 below at least for the embodiments of FIGS. 24A-59C .
[0000]
Tapering
Ferrule
Cross-Sectional
Corresponding
Overall
Brush Portion
length
Handle
Diameter
Figures
Length (mm)
Length (mm)
(mm)
Length (mm)
(mm)
24A and 24B
165-173
22-25
44-46
96-104
14-4
25A and 25B
164-170
28-32
34-36
97-105
19-5
26A and 26B
178-186
30-34
49-59
96-104
14-4
27A and 27B
162-170
9-13
39-41
107-115
8.5-3.5
28A and 28B
158-166
15-19
29-31
111-119
8.5-3
29A and 29B
161-169
8-12
39-41
111-119
8.5-3
30A and 30B
162-170
14-18
34-36
111-119
8.5-3
31A-31C
135-150 or
15.5-18.5 or
29-31
104-106 or
7-6
147-158
3-8
73-77
32A and 32B
171-179
17-23
38-42
111-119
10.5-3.5
33A and 33B
147-157
9-3
28-32
111-119
7-2.5
34A-34C
161-169
8-12
39-41
111-119
10.5-3.5
35A and 35B
148-158
6-10
29-31
111-119
7-2.5
36A and 36B
162-172
10-34
19-21
120-130
7-2.5
37A and 37B
149-157
7-9
29-31
111-119
7-2.5
38A and 38B
159-167
12-14
34-36
111-119
8.5-3
39A and 39B
162-170
9-13
39-41
111-119
10.5-3.5
40A and 40B
179-187
36-40
44-46
96-104
14-4
41A and 41B
171-177
39-41
34-36
96-104
16-5
42A and 42B
164-170
29-33
34-36
96-104
18-5
43A and 43B
169-177
16-30
44-46
96-104
14-4
44A and 44B
178-184
28-32
48-52
96-104
18-5
45A and 45B
168-176
30-34
38-42
106-114
18-5
46A-46C
157-163 or
12-16 or
44-46
96-104
18-5
156-164
12-17
47A and 47B
171-179
28-32
44-46
96-104
18-5
48A-48C
62-68
43-47
N/A
17-23
32-30
49A-49C
193-197
44-46
49-51
96-104
18-5
50A and 50B
188-194
38-42
49-51
96-104
18-5
51A-51C
188-196
40-44
49-51
96-104
18-5
52A and 52B
160-168
7-11
39-41
111-119
8.5-3
53A and 53B
158-167
5.5-9.5
39-41
111-119
6.5-2.5
54A-54C
182-200
49-53
44-96
96-104
23-7
55A-55C
171-179 or
34-36 or
39-41
96-104
23-7
165-179
29-36
56A-56D
172-182
40-42
34-36
96-104
29-11
57A-57D
85-93 or
18-28 or
N/A
67-75
21-19 or
100-110
29-34
20-25
57E-57F
100-110
29-34
N/A
67-75
20-25
58A-58D
166-174
28-32
39-42
96-104
14-4
59A-59C
167-175
29-33
39-41
96-104
14-4
[0180] FIGS. 9-15 depict an exemplary embodiment of a cosmetic brush with handle according to the present invention. In particular, FIGS. 9-15 illustrate, respectively, perspective, left side, right side, bottom plan, top plan, front side and rear side views of the cosmetic brush with handle in accordance with this respective embodiment.
[0181] FIGS. 16-22 depict an exemplary embodiment of a cosmetic brush with handle according to the present invention. In particular, FIGS. 16-22 illustrate, respectively, perspective, left side, right side, bottom plan, top plan, front side and rear side views of the cosmetic brush with handle in accordance with this respective embodiment.
[0182] FIG. 23 depicts a non-limiting example of a set of several different cosmetic brushes with handles in accordance with exemplary embodiments of the present invention.
[0183] Various embodiments of cosmetic brushes with handles according to the present invention are further illustrated in FIGS. 60-69 . For example, FIG. 60 is a top view of a cosmetic brush with handle according to another exemplary embodiment of the present invention. FIGS. 61-64 depict various perspective views of a cosmetic brush with handle according to another exemplary embodiment of the present invention. FIGS. 65-67 depict, respectively , front, side and bottom plan views of the cosmetic brush with handle of FIG. 61 . FIG. 68 is a front view of a cosmetic brush with handle according to another exemplary embodiment of the present invention. FIG. 69 is a front view of a cosmetic brush with handle according to another exemplary embodiment of the present invention.
[0184] FIGS. 57A to 57D depict another exemplary embodiment of a precision cosmetic brush 150 , such as a massager, that includes a brush portion 152 connected to a handle 154 . As depicted, in embodiments, only a lower segment 156 of brush 150 has a triangular cross-section and a taper for precision control of the brush, whereas an upper segment 158 of handle 154 need not be triangular in cross-section. Instead of tapering in a direction away from a brush, lower segment 150 of handle 154 tapers in a direction extending from a lower end toward an upper end of brush 150 such that the triangular cross-section of lower segment 156 of brush 150 is larger toward the lower end of the handle 154 (away from brush) and tapers upward therefrom toward the brush portion.
[0185] FIGS. 57E and 57F illustrate another exemplary embodiment of a precision cosmetic brush 150 ′, similar to brush 150 of FIGS. 57A to 57D , with a similar brush portion 152 ′ and a handle 154 ′ having a lower segment 156 ′ that is triangular in cross-section and an upper segment 158 ′ that need not have a triangular cross-section. Brushes 150 , 150 ′ are generally configured to be held by the respective lower segments 156 , 156 ′.
[0186] In other exemplary embodiments (not illustrated), a handle on a cosmetic brush or applicator or a cosmetic implement, such as on a lipstick or compact, may have a triangular cross-section to facilitate precision application of cosmetic material or manipulation of a surface, but may or may not be tapered or have a tapered segment. For example, the kabuki brush of FIG. 48 may include an alternative handle that is not tapered.
[0187] While this invention has been described in conjunction with the embodiments outlined above, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, the exemplary embodiments of the invention, as set forth above, are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the invention.
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A precision cosmetic brush is disclosed, and comprises a brush portion configured for engaging a surface, a ferrule supporting the brush portion, and a handle connected to the brush portion by the ferrule, the handle having an elongate body with a triangular cross-sectional profile, the handle tapered along its length. In embodiments, the brush portion is white or has visual indicators to facilitate the ability of a user to more precisely apply cosmetic material to a surface.
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BACKGROUND AND PRIOR ART
In recent years efficient automatic systems have been developed for welding girth joints in pipelines. One successful system involves a combination of operations, starting with an inside pass or "stringer bead" operation, where the pipe ends are held in mutual alignment by an internal clamp while an internal orbiting welder travels around inside the joint, as described and claimed in U.S. Pat. No. 3,564,264 and others. For most joints, several sequential welding steps or passes are required. This internal bead then serves not only to hold the pipe pieces together while unclamping and other operations are performed but serves also as a backing for the later passes, performed from the outside, to build the weld from the inside out. Means and methods for completing the operations from the outside are described in such patents as U.S. Pat. Nos. 3,718,798; 3,806,694 and others. A self-propelled carriage, guided in an orbital path around the joint, transports the welder which sets up and maintains an electric arc and operates to lay down molten metal and to fuse it into previous passes, in sequence, until the gap between the pipe ends is filled and capped. Normally, each pass is performed at a separate station, sequentially along the pipeline.
In cases where the pipes to be joined are of thin wall construction, say, below about 0.250 inches, the weld may be completed in only one or two outside passes, added to the internal stringer bead. In many cases the pipe wall is thicker than this and additional passes are required since there is a practical limit to the amount of molten weld metal that can be added and the amount of heat that can be put into the weld by the electric arc at a single pass, while still obtaining a weld of good quality. In any case, it is desirable to complete the welded joint in as few separate operations and stations as possible. As successive passes or steps are usually performed at separate and consecutive stations along the pipeline, each station must have a complete welder unit, i.e., at least a guide track, a carriage, and a welder device transported by the carriage. One or more operators are required at each station; hence, economy of manpower as well as of equipment dictates that the number of stations be held to a minimum, consistent with obtaining high quality in the weld at every step. Because of the hazards of leaks or breaks in the line, and the waste of valuable products which might occur if welds should fail, strict standards are required in pipeline construction. The industry, therefore, is interested in welding processes which will produce high joint quality. The costs of manual operations are very high; hence, there is a demand for a simple, automatic welding means and method that can complete work of high quality with a minimum of costly equipment, manpower and work stations.
On land, where space may not be a problem, it may be less important to reduce the number of stations that are needed to complete welding operations, although economy of operation is always important. At sea, or in any offshore situation where the pipeline is built on a barge and is lowered step by step to the ocean floor or other underwater surface as it is completed, the number of stations permissible becomes highly critical. To insure against possible pipeline breaks with consequent damage to the environment, and in view of the high costs of repair of underwater lines, as well as the value of oil, gas, and other products to be transported, the pipe used often has comparatively very thick walls. In many cases five, six or even more separate welding passes may be made to complete a weld in such pipe. By prior art methods, as many stations as passes are required, spaced consecutively along the line by a length of "joint" of pipe, commonly 40 feet per joint. With such work, using six stations, a line over 200 feet long is necessary, and longer if further stations are required. Aside from the welding, stations are usually required for stacking the pipe, bringing it to the line, etc., and, after the welding, for coating the welded joint, encasing it in concrete, etc., as is well known in the art. Space on any barge is limited and it is obviously desirable to complete the welding and all other operations in as few stations as possible. Even on land, where space is not so critical, it is desirable to keep the operation as compact as is convenient, for better communication, utilization of manpower, etc. An object of the present invention is to increase the portion of a welded joint that can be made at a single station. This saves equipment requirements as well as space.
Quite independent of the considerations mentioned above, there are desired physical and/or metallurgical effects on the weld that can be achieved by a dual weld technique. When welding passes are spaced apart by long time intervals, heat input must be higher to compensate for greater cooling, which can adversely affect the physical properties of the weld. Depending on the energy input of the arc and the heat absorbing and conducting properties of the metal, the cooling rates for the joint may be excessive. Among other things, high cooling rates may cause undesirable brittleness or high hardness and stresses in the welded joint. By making at least some in a series of plural passes close together, time-wise, some of these effects are avoided. In some cases, as in the prior art where single and separate welding passes are used, a special heat treatment may be required after the welded joint is completed, to normalize and/or to relieve stresses. Better heating and cooling rates may be obtained by multiple weld passes in close succession to eliminate the heat treating step and the extra station it requires. If six passes, for example, can be performed at three or four stations, while also eliminating the extra heat treating station, three or more stations can be dispensed with, greatly facilitating the operation, and reducing costs, especially on offshore barge operations.
Hence, another object is to better control heat input and cooling rates by combining or doubling up weld passes on a single apparatus. Preferably, multiple weld passes are performed at most stations, reducing station equipmment, and personnel requirements by as much as one-half. In theory, perhaps, more than two passes may be made with each piece of apparatus, but to obtain the desired metallurgical results, two passes are satisfactory. Experience has shown it to be very difficult for an operator to control more than two simultaneous passes or to restart more than two passes in case of a malfunction, unless conditions are unusually favorable.
It is known, of course, to use multiple arcs in tandem for welding, particularly in straightline operations. Such have been used in welding together the straight adjoining edges of metal plates. To apply this principle to pipeline girth joint welding, however is not so simple for several reasons. In the first place, pipes vary widely in diameter, that is the curvature that must be followed by the device may be greatly different from one job to another. This introduces one set of complications. The apparatus must travel in orbit, another limitation. Also, for deep gaps, as are to be welded in thick wall pipes, the width of fill needed may vary considerably, from bottom to top. There may be need, for this reason, to oscillate or move from side to side the welding head which is filling a wider part of the gap than its predecessor, whereas another head filling a narrower part of the gap should be oscillated at a narrower amplitude or perhaps not at all. To devise a simple apparatus that will accomplish such operations, without undue complications, is another object of this invention.
The success achieved in the past by the welding apparatus described in U.S. patents mentioned above, and others related thereto, has been based to a considerable extent on the fact that the devices are simple, rugged, but still highly precise and rapid in their operations. The devices are capable of fine adjustment so as to follow in the plane of the joint with high accuracy, and to stand off the optimum distance from the work, to oscillate or reciprocate with fine control from side to side of the joint in a path that will give optimum fill with effective side bonding of the joint, etc. To add another head to such an apparatus, thereby essentially doubling its capacity, without loss of high precision, is another and important object of the present invention. In thick wall pipe, it is often desirable to use a tapered gap or kerf, i.e., one that is wider at the top or outside, and an object here is to fill each layer of molten metal completely across the gap. Consecutive layers thus become progressively wider and an aspect of the present invention is the concept of increasing the oscillation amplitude as the consecutive passes are made, without using a separate oscillator.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a side view of a preferred welding device, according to the present invention, including a general showing of supporting carriage and guide track means which are not a part thereof but whose description seems desirable to properly explain the invention.
FIG. 2 is a fragmentary sectional view, taken substantially along the line 2--2 of FIG. 1, certain parts being omitted or broken away.
FIG. 3 is a fragmentary side view of a modification, showing somewhat different welding means and supporting elements therefor.
FIG. 4 is a fragmentary side view, with parts omitted or broken away, of still another modification, involving alternative welding apparatus and supporting means.
FIG. 5 is a top view, with parts in section or parts omitted, of the apparatus of FIG. 4.
DESCRIPTION OF PREFERRED EMBODIMENT
Referring first to FIGS. 1 and 2, there are shown in side view and in top or partly sectional view an improved welding apparatus having the usual conventional welding head 35 and a supplemental head 70. These terms are used for convenience, it being understood that in most cases neither head is more important than the other and that either of them may be modified in form, size, or purpose without departing from the spirit and purpose of the invention. The device can be run in either direction when the oscillation widths of the two weld passes are equal; normally, it is unidirectional in operation with the leading pass having the narrower oscillation.
In general, the apparatus shown in FIG. 1 includes a work piece or length of pipe 11 which is to be welded to another and similar piece not shown. A guide band or track 13 surrounds the pipe 11, being firmly locked in place parallel to the weld place by appropriate tightening or clamping means, not shown herein, but described and claimed in the Miller and Nelson U.S. Pat. No. 3,604,612 and shown in U.S. Pat. No. 3,806,694 to Nelson, Pollock and Randolph. Much of the mechanism illustrated in FIG. 1 is shown in the latter patent, which may be referred to for other details not of particular importance to the present invention. In either case, the supporting carriage 20 preferably is of self-propelled type, having its own drive motor and being guided in its orbital path around the pipe by grooved wheels such as is shown at 14. One or more of such wheels may be power driven, whereas the others may be merely guide rollers or idling retainers to keep the carriage on the track 13. The track 13 is spaced from the work surface 11 by foot elements or spacers 16. The particular carriage described in U.S. Pat. No. 3,604,612 is of rigid construction and is adapted to fit only pipes of similar diameters, or nearly similar. Where pipes of widely varying diameters are to be welded, it may be preferred to employ a carriage of the adjustable or so-called "flexible" type, as described in an application by Nelson, Randolph and Miller, Ser. No. 374,050, filed June 27, 1973, now U.S. Pat. No. 3,844,468. The latter has the advantage of versatility, being readily adaptable to many different diameters of pipe. As noted above, however, the carriage 20 itself is not part of the present invention, although a precision driven and precision guided carriage of some suitable kind is essential to satisfactory operation of the welding equipment of the present invention.
The welding apparatus of this invention comprises a main frame or side plate member 21 which is firm and rigid, attached pivotally to the carriage 20 at its lower right end, as seen in FIG. 1. A bolt or pin 23, or equivalent pivot device holds the carriage against any lateral motion or any movement other than pivotal, the purpose for the pivotal movement being to permit lifting the welder per se to a raised position, indicated partly in dotted lines, for inspection, replacement or repair of expendable parts around the arc, or for cleaning, etc. Normally, the carriage is locked down in welding position by a quick-release locking means not shown herein but described more particularly in U.S. Pat. No. 3,806,694, mentioned above. The lock-down means comprises a forked member 29, firmly secured to the carriage 20 by means not shown, and an upper arm 27 integral with side frame 21, extending to the left, FIG. 1, which can be quickly and precisely attached to fork member 29 by quick release and fine positioning means more fully described in the patent just mentioned. On being released, the welder may be swung clockwise, about pivot 23. When the locking parts are secured together, the whole welding device mounted on frame 21 is rigid and unitary with the carriage 20 and travels with it in fine alignment with the weld or the plane of the joint to be welded. A micrometer screw 31 is provided for accurate adjustment of the welder tip or nozzle 50 of head 35, the latter being set to guide consumable electrode wire W into the arc, in a manner now well known in the art. Reference character 35 refers to the first welding head as a whole, while reference character 50 refers to the tip or contact tube where the arc is formed. The latter is an expendable item, often being burned by the arc. Part 50 is quickly and easily replaceable when the carriage is raised, as described above and in U.S. Pat. No. 3,806,694. Screw 31 thus sets with high accuracy the so-called CTWD (contact tube to work distance) or spacing between tip 50 and pipe 11, which is one of the critical parameters for successful welding.
As further described in the same patent, the welding device includes a special means for oscillating the welding head, and particularly the contact tube 50, from side to side, with respect to the weld plane, as it is transported around the joint. The amplitude of this oscillation may vary from zero to a maximum, depending on the width of the gap to be filled, or the width of a capping pass to be made to cover the gap, as the weld is completed. The oscillation means, and the welder head itself, are mounted in a subframe 41 pivoted through ears 30 and 32 on a shaft 33 which is mounted in a bearing bracket 34 on the main frame or side plate 21. This subframe 41 is otherwise free to swing (but without play) about pin 33 in a more or less horizontal plane as viewed in FIG. 1, but is normally held in a predetermined position with respect to plate 21 by a micrometer screw 36. The purpose of this microadjustment means is to bring the welder contact tube 50 into precise alignment with the plane WP of the weld (see FIG. 2). If the head 35 is being oscillated from side to side, it is of course the center line of such oscillation that is brought into this alignment. When the apparatus is properly set, travel is started, an arc is struck, and molten electrode material is fed into and fused to the bottom and side walls of the gap to be filled, as is well known.
The reciprocating or oscillating means for moving the head 35 back and forth across the gap in the joint to be filled comprises an electric motor 39, mounted on a base 40 fixed to subframe member 41, having gear reduction means not shown herein, but described in the patent last mentioned above. Through these means, the motor derives an eccentric means 42 which has a variable throw, as already suggested, and which operates a rocker shaft 43 through a rocker arm 45. An improved form of this oscillating mechanism is described in an application by Nelson, Randolph and Pollock, Ser. No. 421,339, filed Dec. 3, 1973, and this preferably may be used here. Its details are not of importance in this invention.
Rocker shaft 43 bears near its left or forward end (as seen in FIG. 1) a rocker arm 47 which supports a rigid cantilever bar 48. The base 49 of the welding head 35 is secured to the bar 48 and means for bringing electric current for the arc and inert gas for shielding the arc are secured here also, as is conventional in the art. Water cooling means may be included, to hold equipment temperatures down around the arc, as is conventional and if desired. With this arrangement, as the rocker shaft 43 is rocked to a predetermined amplitude of movement, depending on the setting of variable throw eccentric 42; hence, the head will be oscillated and the tip or contact tube 50 will describe a more or less sinuous path centered along the weld plane, whose width depends on the setting of the variable eccentric. In FIG. 1, it may be considered that the arc will swing through the plane of the paper, towards and from the observer as the head is oscillated. In the present invention, oscillation of the head includes amplitudes between zero and a practical maximum.
A consumable electrode wire W is supplied from a spool or reel 53 mounted on a bracket 54 at the right end of the welder side frame 21. Wire feeding means, shown generally at 55, are similar to those described in some of the above mentioned patents, also in U.S. Pat. No. 3,632,959 to Nelson and Randolph. The feed means comprise feed rollers 56 and 57 and a wire guide tube 59 which is flexible but arranged to resist any tendency to impart a cast to the wire as it advanced through the contact tip 50 to the arc. Tube 59 preserves a fixed relationship between the feed roller and the head 35 which is not disturbed when the position or spacing of the nozzle 50 with respect to work piece 11 is adjusted by screw 31. The rollers 56 and 57, or one of them, are driven at a precisely controllable speed by a variable speed electric motor 58 through appropriate gearing as more fully described in several of the patents mentioned above, especially U.S. Pat. No. 3,632,959. Tube T insulates the wire coming from rear spool 53 where it passes by wire on spool 85.
As explained above, it is highly desirable, in many cases, to be able to make plural welding passes with a single carriage at a single station. The present invention includes means for making two or twin passes simultaneously in closely timed sequence. For convenience, the head 35 will be referred to as the conventional or normal or leading head, being essentially of the same form and arrangement as in the patents mentioned above, particularly U.S. Pat. No. 3,806,694. The other head 70 will be referred to as a second, secondary or follower head. It is to be understood, however, that this is not to imply that one head is superior to the other, as they will generally be of equal importance and utility.
The second or follower head 70, then, is supported on an outer arm 66 which is supported in turn on another or inner arm 68, FIG. 2. The latter is mounted for pivotal adjustment or movement up or down on a bolt 69 secured to an arm 71 fixed, in turn, to the plate 48, which carries and oscillates the conventional or leading head 35, as already explained. A nut 72 and a washer 73 on pivot bolt 69 may be loosened to permit the articulated arms 66, 68 to swing up or down with respect to the work surface 11. (It will be appreciated that the carriage may at times be below the pipe 11 and adjustment towards the pipe would be up and not down but these terms are used for convenience only.) This adjustment is needed for two reasons, viz., to accommodate pipes or other work pieces of different diameters: it is used also to adjust the CTWD of head 70 with respect to the work. Arm 66 is pivotally secured to arm 68 through a bolt 74 having a nut 75, which may be loosened to permit swinging arm 66 in a more or less horizontal plane, when in the position of FIG. 1, with respect to arm 68, e.g., for aligning the welder nozzle or contact tube with the plane WP of the weld. After adjustments in either case, nuts 72 or 75 may be retightened to hold the parts firmly in their adjusted positions.
As the welding nozzle 70 is cantilever supported at some distance from its main support bar 48, it is desirable to provide additional and stabilizing support for its outer end. For this purpose, a rigid bar 77, fixed to subframe 41, extends forward to the left, FIGS. 1 and 2. Also, the arm 71, which is rigidly affixed to bar 48, bears another curved arm 82 which also extends forwardly or to the left, FIGS. 1 and 2, in cantilever fashion for cooperation with bar 77. Like all the other parts mounted on subframe 41, the bar 77 and all its supports may be moved towards and away from the main frame or side plate 21 by turning screw 36, but its position in this respect is fixed accurately when this screw is set. Friction braking means are provided to hold both the screws 31 and 36 in their set positions, as will be mentioned below in connection with FIGS. 4 and 5, and as explained in U.S. Pat. No. 3,806,694 and in a more recent patent application, Ser. No. 456,626, filed Apr. 1, 1974, by Nelson, Randolph and Pollock. It will be noted that adjustment knobs 31 and 36 move both heads 70 and 35 in unison. These knobs may be used by the operator during the welding cycle.
At its front end, cantilever bar or arm 77 provides support for the front end of arm 82 through a pin 78, mounted in a bracket 79 on 77 and in line with the axis of the rocker shaft 43. A play-free antifriction bearing 84 mounted on arm 82 closely engages this pin and thus supports arm 82 and rigidifies the whole assembly, including both welding heads 35 and 70 and the entire oscillating mechanism. The alignment of the bearing 84 with shaft 43 provides for a smooth operating oscillation movement to both heads. However, since the radius of the nozzle or tip of head 70 may frequently be at a greater distance from the axis of oscillation (axis of rock shaft 43) it may be swung through a greater amplitude of motion than head 35, for a given angular movement of shaft 43. This arrangement will often be desirable, for example, when head 50 is leading and making a last filling pass and head 70 a capping pass, both heads moving clockwise, FIG. 1. An adjustable slide 301 on member 82 is provided to allow changes in the distance between the welding arcs at the two heads 35 and 70. Also, the rear plate 77 is slidably mounted at 303, FIG. 2, a slot 303 being provided to accommodate this adjustment. It will be understood that the carriage may run in either direction, at least in some cases, so that either head may lead, depending on the type of pass to be made. Referring to the left end of the unit as the "front", as above, is for convenience only. Head 70 may be disconnected from oscillating arm 48 or its extension and fixed to rear plate 77 to provide for a non-oscillating pass while head 35 is being oscillated.
For supplying consumable wire electrode material to the added head 70, a reel 85 is mounted on a bracket 86 and feeding means 87, essentially like means 55, drive the wire from reel 85 through a flexible guide tube 88 and through the nozzle of head 70 to the arc where welding is accomplished. The feeding means 87 is supported on a hollow rectangular column 89 fixed to the cantilever support bar 77 previously mentioned. A nozzle or tube 90 for supplying inert gas around the welder tip 70 is passed through this hollow column 89, being connected at its upper end to conventional gas supply conduit means, not shown. As noted below, the gas supply may surround head 70, if desired.
With the arrangment described, the two heads 35 and 70 travel together synchronously or in unison, one making a pass and the other adding to it as it comes along closely behind. The spacing between heads and the travel rate are adjusted for optimum heat control. If desired, the two heads 35 and 70 may each be vertically adjustable in its own mounting, so that the amplitude of oscillation imparted to each by a given angular oscillation of arm 47 may be adjusted as desired, within limits. That is, by turning screw 31 to bring the axis of rocker shaft 43 closer to or farther from the work, the effective amplitude of oscillation for either head may be set as desired; the other head then may be raised or lowered appropriately along its own axis and its amplitude of oscillation will depend on three factors (1) the throw of eccentric 42, (2) the setting of screw 31, and (3) the distance of the tip from axis 43.
A bolt 93 passing through an arcuate slot 94 in plate 77, centered on bolt 69, may be locked in place by a wing nut 95. This allows the wire feed 87 to move with the head 70 about the common pivot, bolt 69, and therefore maintains the same length of tube 88 between the wire feed means 87 and nozzle 70.
Referring now to FIG. 3, the apparatus arrangement there shown is quite similar to that of FIG. 1, except that the welding head 170, otherwise similar to head 70, is surrounded by the shroud of refractory material 172 so that the inert gas blanket may be held directly around the arc. Gas is supplied to a connection 174 and flows through a hollow arm 176 into a passage that connects with shroud 172. In some cases this arrangement is preferred; in others the arrangement of FIG. 1 is better, as where the directed force of the inert gas stream as it emerges from the nozzle or tube 90 is helpful to hold the pool of molten metal at the arc against running out of the joint. In other respects, FIG. 3 is similar to FIG. 1 and the identical parts are given the same reference numbers, which have been referred to above.
FIGS. 4 and 5 show another arrangement wherein the hinged joint at bolt 69, FIG. 1, is replaced by a separate vertical adjusting mechanism for the leading or outboard head 270. In some cases, the arrangement of FIG. 1 is difficult to set with high precision. Or difficulty may be encountered in locking the head in a precise position, requiring repeated trials or adjusting several times. In the arrangement of FIG. 4, a micrometer screw 110 is mounted in upper and lower precision bearings 112 and 114 secured to the flanged projections 116 and 118, respectively, of a bracket 120. The latter bears an arcuate slot 121 which rides on a pair of bolts 122 and 124 secured in a member 182 which is functionally equivalent to cantilever bar 82 which is shown to be fixed to the subframe 41 of FIG. 1. With this arrangement, bracket 120 may be raised or lowered with respect to the bolts 122 and 124 by loosening nuts (not shown) on these bolts, retightening them after an approximate adjustment has been made. The arcuate slot 121 approximates an arc centered on bolt 69, FIG. 3. Then the micrometer screw 110, which passes through a slight clearance hole in a bracket 130 that supports the welding head 270 may be turned to obtain a precise vertical adjustment.
Mention was made above of braking or friction means used to prevent the micrometer screws such as 31, 36, etc., from getting out of adjustment due to vibration and analogous causes. Such means are described in the above mentioned U.S. Pat. No. 3,806,694 and in application Ser. No. 456,626, above. They are shown here, diagrammatically only. For the vertical adjusting screw 110, FIGS. 4 and 5, they comprise a pair of opposed friction pads 142 and 144, of elastic material, FIG. 5, such as rubber or other plastic composition which is fairly hard and elastic, confined in a tubular zone and placed under compression by screws 146 and 148. These pads preferably are forced or molded into shape against the threaded parts of the screw 110, to provide a pronounced braking effect on this screw. The magnitude of braking effect can be adjusted by tightening or loosening the set screws 146 and 148.
For lateral adjustment, a transverse micrometer screw 140 is mounted in the bracket 130, being fixed in antifriction bearings 132 and 134 set in arms 136, 137 of bracket 130, and threaded through a clearance hole in an arm 138 by which the head 170 is supported. As best seen in FIG. 5, with this arrangement, the head 170 may be moved up or down forward or backward to align it with the weld plane WP. The bar 182, shown in FIG. 5 but not in FIG. 4, provides a cover for the arc.
Similarly, the transverse adjusting screw 140 is braked or held in a set position by a pair of pads 145 and 147, with adjustable set screws 149 and 151 behind them applying as much pressure as is desired to produce the needed braking effect.
To allow shielding gas to flow concentrically around the welding tip or nozzle, while electrode wire W is fed to the tube 50 through a spirally wound wire guide tube 88, which leads from the wire feeding means 87 to the contact tube 50, the following compact nozzle design is used.
The welding head as a whole is indicated at 270. Within it is fitted an externally threaded electrode retainer 251 in the form of a tube having a tapered bore, larger at the top than further down, to permit the electrode wire and its guide conduit 88 to swing from side to side, relatively speaking, as the head is oscillated. The relative position indicated at the right is designated W 1 , it being understood that the head rather than the wire W is oscillated from side to side. A holder 252, also tapered internally, sits on top of the retainer 251 and holds it in place, being threaded into the head 270. Also, a nut 254 which rests against an internal collar 253 within head 270, screws onto the lower end of retainer 251, locking it against the element 253.
A junction block 176, cast or otherwise formed as a part of head 270, has a threaded electrical connection 255 to which a power cable, not shown, may be attached to supply electrical current to the welding arc. A gas connection 174 in member 176 is adapted to receive gas from a conduit, not shown, and conducts this gas around the retainer 251, where it flows downwardly through a series of small orifices 257, arranged in a circle in collar element 253 to flow around the nozzle 50 and thus to shield the arc against atmospheric oxygen, nitrogen, etc. A nut 258 is threaded on the lower end of the spiral wire guide tube 88, to hold it in place, resting against an internal shoulder 259 within the guide tube retainer 251.
The arrangement of FIGS. 4 and 5 provides a somewhat more precise adjustment for spacing and aligning the head with respect to the joint or the weld plane than the arrangements of FIGS. 1 and 3. It will be obvious, however, that these mechanisms are essentially interchangeable and, for many purposes, are equivalent. Many other arrangements may be made and other modifications and alterations which do not depart from the spirit and purpose of the invention will suggest themselves to those skilled in the art.
In its method or process aspects, the invention includes a combination of steps which is believed to be novel. A plurality of welding instrumentalities are moved around the work in an orbital path and in unison, being arranged to accommodate various curvatures in said orbital path. These instrumentalities, which can be of various forms, are oscillated from side to side by a common means, preferably in such a manner that they may, if required, be oscillated to different amplitudes, to fill different widths of gap of space with molten metal. More specifically, the instruments are arranged so that each has its own gas supply and each head or instrument can be moved transversely for adjustment, or for oscillation, to the extent required, without interference with the other. The oscillation amplitude of one head can be set at zero or it may be up to maximum amplitudes. By adjusting the distance of each contact tube from the axis of oscillation, the plural heads thus may be used to fill a tapered gap smoothly and uniformly.
It is intended by the Claims below to cover all these apparatus arrangements and their obvious equivalents and variations as broadly as the state of the prior art properly permits
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Apparatus and method for welding girth joints in pipelines and similar structures, of the general type described and claimed in U.S. Pat. No. 3,806,694, is improved by adding to the normal or conventional head, on its frame, a second or supplemental welding head with its own independent wire electrode, electric power and shielding gas supply. The second head is mounted on an adjustable support for accommodating work pieces of different radius or for varying arc positions. Oscillating means for spreading the molten metal across the width of the joint, as normally provided for the single welding head in the patent mentioned, are adapted to operate the second head as well and to vary its amplitude of movement. Separate means are provided for adjusting the spacing between each head and the work and also for lateral adjustment to align the heads with the plane of the joint. By these means, the number of stations required for a multiple pass operation, on thick wall pipe, for example, may be reduced. By operating two welding heads on each of two or more carriages, welding equipment requirements may be cut nearly in half, with beneficial effects on the weld, due to improved thermal effects. Either head may precede the other; cantilever means provide stability for the head mounted most remotely from the frame.
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RELATED APPLICATIONS
This application claims priority to U.S. Provisional application Ser. No. 60/325,300 filed on Sep. 27, 2001.
BACKGROUND OF THE INVENTION
This invention relates to vehicle navigation systems and, more specifically, to map images appearing on a navigation system video screen of a display device.
Vehicle navigation systems typically include a display device with a video display that provides a graphical interface for the user. A main function of the video display is to depict the desired map area and route on which the user's vehicle is travelling. For convenience to the driver, several navigational modes may be provided. For example, an on-highway guidance mode may be provided in which directional arrows, highlighted routes, and/or voice instructions are given to the driver to guide the driver to a preselected destination.
An off-highway navigational mode has been provided to drivers hen traveling off of the road network provided by the storage device or other media. Once the vehicle is driven to a location without any nearby roads or other reference points it becomes more difficult to convey directions to the driver on how to get to the next destination. To this end, waypoints have been used, which represent a location such as latitude and longitude. The waypoints may be linked together to form a route by which the navigation system may direct the driver to follow. However, even with the use of waypoints and defined routes, providing direction to the driver may result in driver confusion. Therefore, what is needed is a navigation system that clearly conveys directions to a waypoint.
Depending upon the route, directing a driver from one waypoint directly to the next may be an inefficient manner in which to travel along a route. For example, a route which has sharp turn from one waypoint to the next will require the driver to arrive at the waypoint and then turn around and travel in a similar direction to reach the next waypoint. Therefore, what is needed is a navigation system that more efficiently guides a driver along a route.
SUMMARY OF THE INVENTION AND ADVANTAGES
The present invention provides a method of utilizing waypoints for a vehicle including the steps of adding a first waypoint relating to a first vehicle position and adding a second waypoint relating to a second vehicle position. The waypoints are saved as a route. Waypoint information relating to the waypoints and route information relating to the route may be manipulated. The method also includes displaying at least a portion of the route on a display screen and indicating a desired direction of vehicle travel from a current vehicle location to one of the waypoints. According to the present invention, the driver may be alerted when the vehicle has come within a particular distance of the waypoint or if the vehicle has veered from the route by a particular distance.
The present invention also includes an apparatus for a navigation system for providing waypoints. At least one position determining device provides a vehicle location signal. A database having a map includes a waypoint. A processor is interconnected to at least one positioning device and the database for determining the location of the vehicle relative to the map. A video display is connected to the processor for displaying a directional screen. A directional indicator indicates a desired direction of vehicle travel from the location of the vehicle to the waypoint with the processor displaying the indicator on the video display.
Accordingly, the above invention provides a navigation system that more efficiently guides a driver along a route.
BRIEF DESCRIPTION OF THE DRAWINGS
Other advantages of the present invention can be understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:
FIG. 1 is a schematic view of the vehicle navigation system of the present invention;
FIG. 2 is a front elevational view of the vehicle navigation system display unit having a video display;
FIG. 3 is a video display of the display unit depicting a configuration options menu;
FIG. 4 is a video display of the display unit depicting an off-road selection menu;
FIG. 5 is a video display of the display unit depicting marking a waypoint by the use of a cursor;
FIG. 6 is a video display of the display unit depicting a waypoint entry screen;
FIG. 7 is a video display of the display unit depicting a map area with waypoints;
FIG. 8 is a video display of the display unit depicting a first directional screen;
FIG. 9 is a video display of the display unit depicting a second directional screen;
FIG. 10 is a video display of the display unit depicting a third directional screen similar to the first directional screen;
FIG. 11 is a video display of the display unit depicting another second directional screen;
FIG. 12 is a video display of the display unit depicting a waypoint selection menu;
FIG. 13 is a video display of the display unit depicting an off-road options menu;
FIG. 14 is a video display of the display unit depicting an advanced off-road options menu;
FIG. 15 is a schematic representation of the laterally parallel waypoint proximity option; and
FIG. 16 is a schematic representation of the radial waypoint proximity option.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The navigation system 20 of the present invention is shown schematically in FIG. 1 . The navigation system 20 includes a unit 30 having a CPU 22 (Central Processing Unit) connected to a display device 24 and a directional input device 26 attached to the vehicle interior by a bracket 27 , or the like. The navigation system 20 further includes a database 28 connected to the CPU 22 . The database 28 is a mass media storage device, such as a CD-ROM, hard drive, DVD, RAM, ROM or the like which includes a map of the road system in the area to be traveled by the user. Each road in the database is divided into road segments, each having an associated set of cost values, which indicate the “cost” of traveling that road segment. For example, the cost values may include the length of the road segment, the estimated time to travel the road segment, and the type of road (i.e., highway, secondary road, toll road, one way, etc.). The road segment may be part of the vehicle route or may be a road segment outside the vehicle route.
The navigation system 20 can, but need not, be installed in a vehicle 21 . The navigation system can be used in conjunction with position determining devices, such as a GPS receiver 38 and a multi-axis accelerometer 40 . Navigation system 20 could alternatively or additionally include a gyroscope 42 , a compass 44 , and a wheel speed sensor 46 , all connected to the CPU 32 (connections not shown for simplicity). Preferably, a combination of these position determining devices is utilized to assure accurate location.
The display device 22 may include a speaker 29 . FIG. 2 is a perspective view of one disclosed embodiment of the display device 24 and directional input device 26 , preferably designed as an integral unit attached to the CPU by connection 25 . The display device 24 includes a video display 50 , or screen, such as a high resolution LCD or flat panel display. The directional input device 26 includes a multiple of input buttons 78 including preferably, an eight-way button shown generally at 80 and a selection key 86 such as an “Enter” key. Although an eight-way button is shown, it will be realized that other input devices, such as a joystick, mouse or roller ball can be employed. The eight-way button 80 is capable of moving in the direction of any one of the directional arrows 84 . Movement of the button 80 in the direction of one of the directional arrows 84 transmits a directional signal.
In on-road guidance mode, the vehicle route 52 is highlighted in a bright color, such as magenta, and arrows 54 overlay the route for easy identification by the user. On-road guidance mode is typically used when the user selects a particular destination. The navigation system then selects and highlights the route 52 based upon certain user selected parameters, such as shortest distance or shortest time. In on-road mode, the user has selected no particular destination. In this mode more detail may be desired than in on-road guidance mode because the user has not necessarily decided upon a particular route. In off-road mode, the navigation system has determined that the vehicle is no longer on any known road and that the vehicle is traveling off the road. To navigate, the driver may set waypoints that represent a precise location on a map. Waypoints may be linked to one another to form a complex route by which the driver may navigate from one destination to the next. Furthermore, waypoints may be used to represent such locations as telephone polls. This information may be used by utility companies to set a route from a location on-road to the location of the telephone poll off-road. Of course good waypoints may be applied to other such similar applications.
FIG. 3 is a video display of the display unit depicting a configuration options menu 64 . From this menu, the user may select an “Off-Road Navigation” menu by which the user may manipulate waypoint and route information. FIG. 4 depicts an off-road selection menu 66 having menu selection options “Mark by Position”, “Select Route/Waypoint”, “Next Waypoint”, and “Reverse Route ”Using the “Mark by Position” option, a map location may be saved as a waypoint by utilizing a cursor 68 , as shown in FIG. 5 . The user may pan, or move, the cursor 68 in a map area 69 to a desired location, which may be other than the present vehicle location (indicated by the vehicle icon 70 ). The latitude 72 and longitude 73 of the cursor 68 is displayed to the user. The distance of the cursor 68 to the vehicle 70 is indicated above the cursor 68 at 75 . The waypoint may be saved be pressing the “Enter” key 86 , after which a waypoint entry screen 74 , shown in FIG. 6, will be displayed prompting the user to enter information regarding the waypoint. Regardless of the mode of entry of a new waypoint, the user is prompted to enter descriptive information about the waypoint. As seen in FIG. 6, the latitude and longitude of the waypoint is displayed. A default label 77 of “Way001” is displayed unless the user enters a new 6-character alphanumeric description of the waypoint in the label field 77 . A default label of “Way002”, and so on, would be displayed for subsequent waypoints. The waypoint is represented by an icon in the map area once the waypoint has been saved. One default icon that may be used is a flag 90 . The default icon may be changed and selected from a group of icons to more meaningfully correspond the waypoint to the user.
FIG. 7 depicts a map area with first 92 and second 94 waypoints in a map area 69 . The waypoints 92 and 94 define a route depicted by path 96 , which is a straight line between the waypoints 92 and 94 . The direction and distance from the vehicle 70 to the next waypoint, which is first waypoint 92 , is indicated at 97 and 98 , respectively. The next waypoint, first waypoint 92 , is highlighted to stand out to the user. An option “More” 99 may be temporarily displayed to the user, to enable the user to readily manipulation waypoint and route information. As a simplified alternative to the map area 69 shown in FIG. 7, a first directional screen 100 may be used, as shown in FIG. 8. A simple horizon 102 is displayed with a three dimensional directional arrow 104 pointing the direction to next waypoint. The next waypoint, or waypoint to which the vehicle is traveling, is indicated at 103 .
The first directional screen 100 may include a lane indicia 106 to further assist the user in navigating to the next waypoint. A pointer 107 pointing at the center 108 of the lane indicia 106 corresponds to the vehicle following the route path. The ends 109 of the lane indicia 106 correspond to a user selected offset from the path. For example, the ends 109 may correspond to an offset of 500 feet from the path. Total time remaining and total remaining distance of the route may also be displayed. As long as the pointer 107 is on center 108 , the user is driving the vehicle along the path. As the vehicle wanders from the path, the pointer 107 will move along the lane indicia 106 to provide the user feed back of the degree to which the vehicle has strayed from the path.
A second direction screen 110 is shown in FIG. 9 in off-road guidance mode. A highlighted path 112 from the vehicle 70 to a waypoint (not shown) is displayed in the map area 69 . A two dimensional arrow 114 is overlaid on the path 112 . When the user selects a third directional screen 116 , shown in FIG. 10, the two dimensional arrow 114 is converted to a three dimensional arrow 118 on the simple horizon similar to the first directional screen 100 shown in FIG. 8 . If the vehicle 70 varies from the path 112 when in off-road mode, a new path 120 will be displayed from the present vehicle location to the next waypoint (not shown). The new path 120 may be a highlighted dashed line.
Waypoint and route information may be further manipulated by selecting “Select Route/Waypoints” from the off-road selection menu 66 . FIG. 12 depicts a waypoint selection menu 122 having “All Routes”, “Waypoints by Name”, “Waypoints by Distance”, and “Waypoints by Time” options. “All Routes” displays all of the routes alphabetically when selected. Similarly, “Waypoints by Name” displays all of the waypoints alphabetically. “Waypoints by Distance” displays all of the waypoints in order of closest to the present vehicle location to farthest from the present vehicle location. “Waypoints by Time” displays the waypoints in order of time of creation. In this manner, the waypoint and route information may be manipulated quickly in several different ways.
More advanced information relating the waypoints and routes may be manipulated using an off-road options menu 124 , shown in FIG. 13 . Routes and waypoints may be deleted using the “Clear” option. The offset from a path may be set by the user, as described above, using the “Advanced . . . ” option under the off-road options menu 124 , which will display the advanced off-road options menu 126 , shown in FIG. 14 . The offset from the path may set by the user by selecting the “XTE Alarm” option. As shown in FIG. 14, the offset is set at 0.2 miles. The offset sets the ends 109 of the lane indicia 106 . An audible alarm through speaker 26 may be used when the vehicle reaches one of the offsets from the path. The lane indicia 106 and how it relates with the waypoints 92 , 94 and path 96 is graphically illustrated in FIG. 15 . Each of the ends 109 correspond to an offset 130 , which is shown as dashed lines parallel to the path 96 . Preferably, the dashed lines are not displayed, but are only used to illustrate the operation of the offset. When the vehicle 70 reaches one of the offsets 130 , the arrow 107 will point at one of the ends 109 corresponding to the side of the offset, shown by dashed arrows 132 . An audible alarm may sound, or voice instructions may be activated, indicating to the driver that the vehicle has veered off the path by the selected offset distance.
An waypoint arrival option may also be set using the “Arrival Alarm” option under the advanced off-road menu 126 . FIG. 16 is a schematic representation of a radial waypoint proximity option. The radial waypoint proximity option may be used to simplify navigation along the route by directing the user to travel to the next waypoint once the vehicle is sufficiently proximate to the target waypoint. The route contains a path 96 a from a first waypoint (not shown) to a second waypoint 94 and a path 96 b from the second waypoint 94 to a third waypoint 134 . The arrival alarm may be set to any radial distance, such as 250 feet indicated at 136 and 500 feet indicated at 138 . Of course metric distances may be used. The dashed lines corresponding to the radial distance preferably is not displayed. If the radial distance is set to 500 feet, when the vehicle 70 reaches the radius 138 , the user will be directed to travel to the third waypoint 134 and a new path 140 will be generated. In this manner, the user may more efficiently travel along the route instead of needlessly traveling directing to each waypoint, which may add a significant distance to the distance traveled. An audible alarm, or voice instructions may be activated when the vehicle reaches the radial distance. For example, the voice instructions may direct the vehicle operator to “proceed 30 degrees left”.
The invention has been described in an illustrative manner, and it is to be understood that the terminology that has been used is intended to be in the nature of words of description rather than of limitation. Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims the invention may be practiced otherwise than as specifically described.
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A method and apparatus of utilizing waypoints for a vehicle is provided. A first waypoint relating to a first vehicle position is added to a second waypoint relating to a second vehicle position. The waypoints are saved as a route. Waypoint information relating to the waypoints and route information relating to the route may be manipulated. The method also includes displaying at least a portion of the route on a display screen and indicating a desired direction of vehicle travel from a current vehicle location to one of the waypoints. According to the present invention, the drive may be alerted when the vehicle has come within a particular distance of the waypoint or if the vehicle has veered from the route by a particular distance.
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This invention is a Continuation-In-Part of application Ser. No. 11/027,242 filed Dec. 31, 2004 now U.S. Pat. No. 7,210,910, which is a divisional application of Ser. No. 10/121,388 filed Apr. 12, 2002 now U.S. Pat. No. 6,884,034 which claims the benefit of priority to Provisional Application 60/342,564 filed Dec. 26, 2001, is a Continuation-In-Part of U.S. application Ser. No. 09/976,515 filed Oct. 12, 2001, now U.S. Pat. No. 6,659,721, which claims the benefit of Provisional Application 60/265,241 filed Jan. 31, 2001, and is a continuation-in-part of U.S. Ser. No. 09/711,599 filed Nov. 13, 2000, now U.S. Pat. No. 6,415,984, which is a divisional application of U.S. Ser. No. 09/415,883 filed Oct. 8, 1999 now U.S. Pat. No. 6,189,799, which is a divisional application of U.S. Ser. No. 09/067,236 filed Apr. 27, 1998 now U.S. Pat. No. 5,996,898 which is incorporated by reference, which is a continuation-in-part of U.S. Ser. No. 09/056,428 filed Apr. 7, 1998 now U.S. Pat. No. 6,039,541 all of which are incorporated by reference.
FIELD OF INVENTION
This invention relates to ceiling fans, and in particular to twisted leaf shaped blades formed from wood and/or plastic that run at reduced energy consumption with larger air movement volumes than traditional leaf shaped ceiling fan blades, and to methods of operating twisted leaf shaped ceiling fans.
BACKGROUND AND PRIOR ART
Circulating air by using aesthetically pleasing design fan blades has been done for many years. Leaf shaped flat type blades have become popular in recent years. See for example, U.S. patents: U.S. Pat. No. D387,156 to Johnson; U.S. Pat. No. D443,352 and U.S. Pat. No. D454,636 to Lantz; U.S. Pat. No. D485,345 and U.S. Pat. No. D510,992 to Bucher; U.S. Pat. No. D491,657 and U.S. Pat. No. 6,890,155 to Cartwright; and U.S. Pat. No. 6,923,624 to Tsai. Another popular blade style over the years is a flat planar rectangular blade that can have a slight tilt, as shown for example in U.S. patents: U.S. Pat. No. Des. 355,027 to Young and U.S. Pat. No. Des. 382,636 to Yang. These patents while moving air are not concerned with maximizing optimum downward airflow.
Furthermore, many of the flat ceiling fan blades have problems such as poor performance at high speeds, wobbling, and excessive noise that is noticeable to persons in the vicinity of the fan blades.
Also, the older design prior art leaf shaped ceiling fan blades are more prone to wobble and noise as the lift produced is non-uniform across the length of the blades.
Aircraft, marine and automobile engine propeller type blades have been altered over the years to shapes other than flat rectangular. See for example, U.S. Pat. No. 1,903,823 to Lougheed; U.S. Pat. No. 1,942,688 to Davis; U.S. Pat. No. 2,283,956 to Smith; U.S. Pat. No. 2,345,047 to Houghton; U.S. Pat. No. 2,450,440 to Mills; U.S. Pat. No. 4,197,057 to Hayashi; U.S. Pat. No. 4,325,675 to Gallot et al.; U.S. Pat. No. 4,411,598 to Okada; U.S. Pat. No. 4,416,434 to Thibert; U.S. Pat. No. 4,730,985 to Rothman et al. U.S. Pat. No. 4,794,633 to Hickey; U.S. Pat. No. 4,844,698 to Gornstein; U.S. Pat. No. 5,114,313 to Vorus; and U.S. Pat. No. 5,253,979 to Fradenburgh et al.; Australian Patent 19,987 to Eather. However, these patents are describing devices that are generally used for high speed water, aircraft, and automobile applications where the propellers are run at high revolutions per minute(rpm) generally in excess of 500 rpm. None of these propellers are designed for optimum airflow at low speeds of less than approximately 200 rpm which is the desired speeds used in overhead ceiling fan systems.
Some alternative blade shapes have been proposed for other types of fans. See for example, U.S. Pat. No. 1,506,937 to Miller; U.S. Pat. No. 2,682,925 to Wosik; U.S. Pat. No. 4,892,460 to Volk; U.S. Pat. No. 5,244,349 to Wang; Great Britain Patent 676,406 to Spencer; and PCT Application No. WO 92/07192.
Miller '937 requires that their blades have root “lips 26” FIG. 1 that overlap one another, and would not be practical or useable for three or more fan blade operation for a ceiling fan. Wosik '925 describes “fan blades . . . particularly adapted to fan blades on top of cooling towers such for example as are used in oil refineries and in other industries . . . ”, column 1, lines 1-5, and does not describe any use for ceiling fan applications. The Volk '460 patent by claiming to be “aerodynamically designed” requires one curved piece to be attached at one end to a conventional planar rectangular blade. Using two pieces for each blade adds extreme costs in both the manufacturing and assembly of the ceiling itself. Furthermore, the grooved connection point in the Volk devices would appear to be susceptible to separating and causing a hazard to anyone or any property beneath the ceiling fan itself. Such an added device also has necessarily less than optimal aerodynamic properties.
Tilted type design blades have also been proposed over the years. See for example, U.S. Pat. No. D451,997 to Schwartz.
However, none of the prior art modifies design shaped blades to optimize twist angles to optimize energy consumption and airflow, and reduce wobble and noise problems
Thus, the need exists for better performing leaf shaped ceiling fan blades over the prior art.
SUMMARY OF THE INVENTION
The first objective of the subject invention is to provide aesthetic ceiling fan blades having leaf shapes that are aerodynamically optimized to move up to approximately 40% or more air than traditional flat planar ceiling fan blades.
The second objective of the subject invention is to provide aesthetic ceiling fan blades having leaf shapes that are more quiet and provide greater comfort than traditional flat planar ceiling fan blades.
The third objective of the subject invention is to provide aesthetic ceiling fan blades having leaf shapes that are less prone to wobble than traditional flat planar ceiling fan blades.
The fourth objective of the subject invention is to provide aesthetic ceiling fan blades having leaf shapes that reduce electrical power consumption and are more energy efficient over traditional flat planar ceiling fan blades.
The fifth objective of the subject invention is to provide aesthetic ceiling fan blades having leaf shapes designed for superior airflow at up to approximately 240 revolutions and more per minute (rpm).
The sixth objective of the subject invention is to provide aesthetic ceiling fan blades having leaf shapes that are more aesthetically appealing than traditional flat planar ceiling fan blades.
The seventh objective of the subject invention is to provide aesthetic ceiling fan blades having leaf shapes capable of reduced low operational speeds for reverse operation to less than approximately 40 revolutions per minute.
The eighth objective of the subject invention is to provide aesthetic ceiling fan blades having leaf shapes with capable of reduced low operational forward speeds of less than approximately 75 revolutions per minute.
The ninth objective of the subject invention is to provide aesthetic ceiling fan blades having leaf shapes with reduced medium operational forward speeds of up to approximately 120 revolutions per minute, that can use less than approximately 9 Watts at low speeds.
The tenth objective of the subject invention is to provide aesthetic ceiling fan blades having leaf shapes that can have up to approximately 64 (sixty four) inch diameter (tip-to-tip fan diameter) or more for enhancing air moving efficiency at lower speeds than conventional fans.
The eleventh objective of the subject invention is to provide aesthetic ceiling fan blades having leaf shapes that can move air over large coverage areas compared to conventional blades.
The twelfth objective of the subjective invention is to provide aesthetic ceiling fan blades having leaf shapes where the altered twist and air foil design is as attractive or more attractive than standard existing planar leaf shaped blades.
A preferred embodiment can include a plurality of aerodynamically leaf shaped blades attached a ceiling fan motor. Each blade can have a twisted between the root end and the tip end and can move greater amounts of air then nonaerodynamically leaf shaped blades. Diameter sizes of the fans can include but not be limited to less than and up to approximately 48″, 52″, 54″, 56″, 60″, 64″, and greater. The blades can be made from wood, plastic, and the like.
Methods of operating the ceiling fan can include the steps of providing twisted leaf shaped blades attached to a ceiling fan motor, rotating the twisted leaf shaped blades relative to the motor, generating an airflow of at least approximately 1,250 cfm (cubic feet per minute) below the rotating blades, running the ceiling fan with the twisted leaf shaped blades with the motor at an efficiency of at least approximately 155 CFM per watt. The fan can be run at speeds up to approximately 250 RPM.
Another method of operating the ceiling fan can include the steps of providing twisted leaf shaped blades attached to a ceiling fan motor, rotating the twisted leaf shaped blades relative to the motor, generating an airflow of at least approximately 3,000 cfm (cubic feet per minute) below the rotating blades, and running the ceiling fan with the twisted leaf shaped blades with the motor at an efficiency of at least approximately 100 CFM per watt. The fan can be run at speeds up to approximately 250 RPM.
A still another method of operating a ceiling fan can include the steps of providing twisted leaf shaped blades attached to a ceiling fan motor, rotating the twisted leaf shaped blades relative to the motor, generating an airflow of at least approximately 5,000 cfm (cubic feet per minute) below the rotating blades, and running the ceiling fan with the twisted leaf shaped blades with the motor at an efficiency of at least approximately 75 CFM per watt. The fan can be run at speeds up to approximately 250 RPM.
A still another method of operating a ceiling fan can include the steps of providing aerodynamically leaf shaped blades attached to a ceiling fan motor, rotating the aerodynamically leaf shaped blades, generating air flow at least approximately 10% above nonaerodynamical leaf shaped blades, and increasing airflow efficiency at least approximately 10% above nonaerodynamical leaf shaped blades.
The generating air flow can also be at least approximately 19% above nonaerodynamical leaf shaped blades, and the increasing airflow efficiency can be at least approximately 19% above nonaerodynamical leaf shaped blades.
The generating air flow can also be at least approximately 50% above nonaerodynamical leaf shaped blades, and the increasing airflow efficiency can be at least at least approximately 50% above nonaerodynamical leaf shaped blades.
The generating air flow can also be at least approximately 55% above nonaerodynamical leaf shaped blades, and the increasing airflow efficiency can be at least approximately 55% above nonaerodynamical leaf shaped blades.
Twisted leaf shaped blades can be provided as the aerodynamically leaf shaped blades. The blades can have concave bends, convex bends and combinations of concave and convex bends that form general S cross-sectional shapes that together optimize airflow.
Further objects and advantages of this invention will be apparent from the following detailed descriptions of the presently preferred embodiments which are illustrated schematically in the accompanying drawings.
BRIEF DESCRIPTION OF THE FIGURES
First Embodiment Twisted Leaf Blades
FIG. 1A is a bottom perspective view of a first embodiment twisted leaf ceiling fan blade.
FIG. 1B is a bottom right root end perspective view of the twisted blade of FIG. 1A .
FIG. 1C is a bottom left root end perspective view of the twisted blade of FIG. 1A .
FIG. 1D is a top right tip end perspective view of the twisted blade of FIG. 1A .
FIG. 2A is a tip end side perspective view of the twisted blade of FIG. 1A along arrow 2 A.
FIG. 2B is a root end side perspective view of the twisted blade of FIG. 1A along arrow 2 B.
FIG. 3A is a left side perspective view of the twisted blade of FIG. 1A along arrow 3 A.
FIG. 3B is a right side perspective view of the twisted blade of FIG. 1A along arrow 3 B.
FIG. 4A is another bottom perspective view of the twisted blade of FIG. 1A with labeled cross-sections A, B, C, D, E, F.
FIG. 4B is another bottom right tip end perspective view of the twisted blade of FIG. 1A and 4A with labeled cross-sections A, B, C, D, E, F in perspective curve views.
FIG. 5 shows the cross-sections A, B, C, D, E, F of FIGS. 4A , 4 B superimposed over one another.
FIG. 5A shows the cross-section A of FIGS. 4A , 4 B, 5 .
FIG. 5B shows the cross-section B of FIGS. 4A , 4 B, 5 .
FIG. 5C shows the cross-section C of FIGS. 4A , 4 B, 5 .
FIG. 5D shows the cross-section D of FIGS. 4A , 4 B, 5 .
FIG. 5E shows the cross-section E of FIGS. 4A , 4 B, 5 .
FIG. 5F shows the cross-section F of FIGS. 4A , 4 B, 5 .
FIG. 6A is a perspective bottom view of a ceiling fan and twisted blades of FIGS. 1A-5F
FIG. 6B is a perspective top view of the ceiling fan and twisted blades of FIG. 6A .
FIG. 6C is a side perspective view of the ceiling fan and twisted blades of FIG. 6A .
FIG. 6D is a bottom view of the ceiling fan and twisted blades of FIG. 6A .
FIG. 6E is a top view of the ceiling fan and twisted blades of FIG. 6A .
Second Embodiment Twisted Leaf Blades
FIG. 7A is a bottom perspective view of a second embodiment twisted leaf ceiling fan blade.
FIG. 7B is a bottom right root end perspective view of the twisted blade of FIG. 7A .
FIG. 7C is a bottom left root end perspective view of the twisted blade of FIG. 7A .
FIG. 7D is a top right tip end perspective view of the twisted blade of FIG. 7A .
FIG. 8A is a tip end side perspective view of the twisted blade of FIG. 7A along arrow 8 A.
FIG. 8B is a root end side perspective view of the twisted blade of FIG. 7A along arrow 8 B.
FIG. 9A is a left side perspective view of the twisted blade of FIG. 7A along arrow 9 A.
FIG. 9B is a right side perspective view of the twisted blade of FIG. 7A along arrow 9 B.
FIG. 10A is another bottom perspective view of the twisted blade of FIG. 7A with labeled cross-sections A, B, C, D, E, F.
FIG. 10B is another bottom right tip end perspective view of the twisted blade of FIGS. 7A and 10A with labeled cross-sections A, B, C, D, E, F in perspective curve views.
FIG. 11 shows the cross-sections A, B, C, D, E, F of FIGS. 10A , 10 B superimposed over one another.
FIG. 11A shows the cross-section A of FIGS. 10A , 10 B, 11 .
FIG. 11B shows the cross-section B of FIGS. 10A , 10 B, 11 .
FIG. 11C shows the cross-section C of FIGS. 10A , 10 B, 11 .
FIG. 11D shows the cross-section D of FIGS. 10A , 10 B, 11 .
FIG. 11E shows the cross-section E of FIGS. 10A , 10 B, 11 .
FIG. 11F shows the cross-section F of FIGS. 10A , 10 B, 11 .
FIG. 12A is a perspective bottom view of a ceiling fan and twisted blades of FIGS. 7-11F
FIG. 12B is a perspective top view of the ceiling fan and twisted blades of FIG. 12A .
FIG. 12C is a side perspective view of the ceiling fan and twisted blades of FIG. 12A .
FIG. 12D is a bottom view of the ceiling fan and twisted blades of FIG. 12A .
FIG. 12E is a top view of the ceiling fan and twisted blades of FIG. 12A .
DESCRIPTION OF THE PREFERRED EMBODIMENT
Before explaining the disclosed embodiments of the present invention in detail it is to be understood that the invention is not limited in its application to the details of the particular arrangement shown since the invention is capable of other embodiments. Also, the terminology used herein is for the purpose of description and not of limitation.
Testing of novel ceiling fan blades were first described in detail to parent patent application to the subject invention, namely U.S. patent Ser. No. 09/056,428 filed Apr. 7, 1998, now U.S. Pat. No. 6,039,541, and incorporated by reference. The initial novel blades were tested between May and June, 1997 at the Florida Solar Energy Center® in Cocoa, Fla., and included three parameters of measurement data: airflow (meters per second (m/s), power (in watts) and speed (revolutions per minute (rpm)). Those novel ceiling fan blades far surpassed the operating parameters of various ceiling fans in operation, as do the subject fan blades of this invention.
This invention is a Continuation-In-Part of application Ser. No. 11/027,242 filed Dec. 31, 2004, which is a divisional application of Ser. No. 10/121,388 filed Apr. 12, 2002 now U.S. Pat. No. 6,884,034 which claims the benefit of priority to Provisional Application 60/342,564 filed Dec. 26, 2001, is a Continuation-In-Part of U.S. application Ser. No. 09/976,515 filed Oct. 12, 2001, now U.S. Pat. No. 6,659,721, which claims the benefit of Provisional Application 60/265,241 filed Jan. 31, 2001, and is a continuation-in-part of U.S. Ser. No. 09/711,599 filed Nov. 13, 2000, now U.S. Pat. No. 6,415,984, which is a divisional application of U.S. Ser. No. 09/415,883 filed Oct. 8, 1999 now U.S. Pat. No. 6,189,799, which is a divisional application of U.S. Ser. No. 09/067,236 filed Apr. 27, 1998 now U.S. Pat. No. 5,996,898 which is incorporated by reference, which is a continuation-in-part of U.S. Ser. No. 09/056,428 filed Apr. 7, 1998 now U.S. Pat. No. 6,039,541 all of which are incorporated by reference.
A prototype of the novel twisted leaf ceiling fan blades were tested in 2005. Existing ceiling fan leaf shaped blades such as those in U.S. Design Pat. D485,345 to Bucher which is incorporated by reference was modified to incorporate camber and twist in the decorative blade profile. A prototype was developed by taking one of the existing blades so that the lightweight wood of each fan blade was cut into five sections with four cuts. The cuts were each glued back together at a set angle. The two cuts closest to the leading edge of the blade were re-glued at an angle of approximately 10 degrees with the underside concave. The third cut was re-glued at a lesser angle of about 6 degrees. The fourth cut was re-glued with a reflex making the topside concave, at an angle of about 10 degrees. Each blade was glued in the same jig, so that all the blades were quite similar in shape. The reflex in the blade airfoil was to improve performance when the fan is running in reverse.
The leading edge of each blade was modified by adding some material to the bottom surface and removing some material from the top surface. This form of camber at the airfoil leading edge was also to improve performance. The blades were balanced with washers to make the static weight moments of all the blades the same. This was done by setting a fulcrum pivot for each blade at the motor shaft location. Weights were added to the blades until all the blade tips weighed the same, when weighed at the same radius.
The modified blade is intended to move more air than the flat paddle blade, with the same input power. The camber and twist allow the blade to work at lower RPM (revolutions per minute). To work effectively at lower RPM the blades can also be set at a higher pitch. The mounting brackets on the modified set of blades have been re-bent to a higher pitch setting.
The motor efficiency was expected to change with RPM. The modified aerodynamic blades were expected to work best in conjunction with a motor that has good efficiency at slower RPM.
To separate the effects of aerodynamics and electrical motor performance a dynamometer set up was used for the testing procedures. A dynamometer measures torque and RPM. A torque sensor can be used where the motor mounts to the ceiling. With no other torques on the motor, the torque on the mount is the same as the torque on the turning shaft. The mechanical power going from the motor to the fan is equal to the torque times the RPM times a constant factor.
In English units the torque in foot-lbs times the rotational speed in radians/second is the power in foot-lbs/second. In metric units the torque in newton-meters times the rotational speed in radians/second equals the power in watts. To convert RPM into radians/second, and rad/sec=2 PI×RPM/60.
Laboratory tests were conducted on a standard ceiling fan with leaf-like blades such as those shown and described in U.S. Design Pat. D485,345 to Bucher which is incorporated by reference against that for the improved “flying leaf” design. The Standard fan was a Hamptom Bay Model Antigua motor having blades with a diameter of approximately 56 inches across five blades, powered by a triple capacitor Powermax 188 mm by 155 mm motor.
The data yielded the following improvements in Table 1 at Low Speed of the existing standard leaf shaped blade having a low speed of approximately 70 RPM (revolutions per minute) and the novel twisted leaf shaped blades having a low speed of approximately 86 RPM.
Table 2 has data of Medium Speed for the existing standard leaf shaped blade having a medium speed of approximately 111 RPM, and the novel twisted leaf shaped blades having a medium speed of approximately 135 RPM.
Table 3 has data of High Speed for the existing standard leaf shaped blade having a high speed of approximately 134 RPM, and the novel twisted leaf shaped blades having a high speed of approximately 164 RPM.
Measurements were taken in an environmental chamber under controlled conditions using solid state measurement methods recommended by the United States Environmental Protection Agency in their Energy Star Ceiling Fan program which used a hot wire anemometer which required a temperature controlled room and a computer for testing data.
http://www.energystar.gov/ia/partners/prod_development/revisions/downloads/ceil_fans/final.pdf
In the tables below, air flow in CFM stands for cubic feet per minute, and power is measured in Watts (W).
TABLE 1
Low Speed
BLADE TYPE
Speed (RPM)
CFM
Power (Watts)
cfm/W
Standard Ceiling Fan
70
2330
17.4
134
with Leaf-like blades:
Same Ceiling Fan
86
2780
17.4
160
with Aerodynamic
Leaf-like blades:
As shown in Table 1 at low speed, absolute flow (CFM) (2780/2330) was increased by approximately 19.3% with efficiency (160/134) improved by a similar amount of approximately 19%.
TABLE 2
Medium Speed
BLADE TYPE
Speed (RPM)
CFM
Power (Watts)
cfm/W
Standard Ceiling Fan
111
3230
39.5
82
with Leaf-like blades:
Same Ceiling Fan
135
4840
39.1
124
with Aerodynamic
Leaf-like blades:
As shown in Table 2, at medium speed, absolute flow (CFM) (4840/3230) was increased by approximately 50% with efficiency (124/82) improved by approximately 51%.
TABLE 3
High Speed
BLADE TYPE
Speed (RPM)
CFM
Power (Watts)
cfm/W
Standard Ceiling Fan
134
4060
56.7
71
with Leaf-like blades:
Same Ceiling Fan
164
6304
56.6
111
with Aerodynamic
Leaf-like blades:
As shown in Table 3 at high speed, absolute flow (6304/4060) was increased by approximately 55% with efficiency (111/71) improved by approximately 56%.
Overall efficiency of the twisted leaf shaped aero dynamic blades were approximately 56% more efficiency at high speed than the standard Leaf-like blades.
The United States government has initiated a program entitled: Energy Star (www.energystar.gov) for helping businesses and individuals to protect the environment through superior energy efficiency by reducing energy consumption and which includes rating appliances such as ceiling fans that use less power than conventional fans and produce greater cfm output. As of Oct. 1, 2004, the Environmental Protection Agency (EPA) has been requiring specific air flow efficiency requirements for ceiling fan products to meet the Energy Star requirements which then allow those products to be labeled Energy Star rated. Table 4 below shows the current Energy Star Program requirements for residential ceiling fans with the manufacturer setting their own three basic speeds of Low, Medium and High.
TABLE 4
Air Flow Efficiency Requirements (Energy Star)
Fan Speed
Mininum Airflow
Efficiency Requirement
Low
1,250 CFM
155 CFM/Watt
Medium
3,000 CFM
100 CFM/Watt
High
5,000 CFM
75 CFM/Watt
Note, that Energy Star program does not require what the speed ranges for RPM are used for low, medium and high, but rather that the flow targets in Table 1 are met:
For Energy Star, residential ceiling fan airflow efficiency on a performance bases is measured as CFM of airflow per watt of power consumed by the motor and controls. This standard treats the motor, blades and controls as a system, and efficiency can be measured on each of three fan speeds (low, medium, high) using standard testing.
From Table 4, it is clear that the aerodynamic twisted leaf shape ceiling fan blades running at all speeds of low, medium and high meet and exceed the Energy Star Rating requirements. The subject invention is believed to be the only leaf shaped blades for use on ceiling fans that have been invented that can meet and exceed the Energy Star ratings.
First Embodiment Twisted Leaf Blades
FIG. 1A is a bottom perspective view of a first embodiment twisted leaf ceiling fan blade 1 showing root end 10 , tip end 20 , left side 30 and right side 40 . FIG. 1B is a bottom right root end 10 perspective view of the twisted blade 1 of FIG. 1A . FIG. 1C is a bottom left root end 10 perspective view of the twisted blade 1 of FIG. 1A . FIG. 1D is a top 4 right tip end 20 perspective view of the twisted blade 1 of FIG. 1A .
FIG. 2A is a tip end 20 side perspective view of the twisted blade 1 of FIG. 1A along arrow 2 A. FIG. 2B is a root end 10 side perspective view of the twisted blade 1 of FIG. 1A along arrow 2 B. FIG. 3A is a left side 30 perspective view of the twisted blade 1 of FIG. 1A along arrow 3 A. FIG. 3B is a right side 40 perspective view of the twisted blade 1 of FIG. 1A along arrow 3 B.
Referring to FIGS. 1A-3B , the bottom view side 2 can have a twisted leaf appearance configuration, with the side edges along right and left sides 30 , 40 being angled edges for enhanced airflow. Top side 4 of the twisted leaf blade 1 which faces up toward a ceiling can have a planar smooth surface. Sides 30 , 40 of the blade can have grooved cuts to add to the leaf appearance. Mounting holes 12 such as three being shown can pass through the blade adjacent to the root end 10 for attaching the blade to mounting arms (shown in FIGS. 6A-6E ) that are then attached to a ceiling fan motor housing (shown in FIGS. 6A-6E ).
FIG. 4A is another bottom perspective view of the twisted blade 1 of the preceding figures. The twisted blade 1 has an overall length between root end 10 and 20 being approximately 24″ long and 0.35″ thick with labeled cross-sections A having a width of approximately 2.85″, B having a width of approximately 7.47″, C having a width of approximately 10.72″, D having a width of approximately 12.20″, E having a width of approximately 9.15″, and F having a width of approximately 5.54″. Each of the cross-sections A-F being approximately 4.4″ apart from one another with cross-section A approximately 1″ in from root end 10 .
FIG. 4B is another bottom 2 right tip end 20 perspective view of the twisted blade 1 of FIG. 1A and 4A with labeled cross-sections A, B, C, D, E, F showing perspective curve views.
FIG. 5 shows the cross-sections A, B, C, D, E, F of FIGS. 4A , 4 B superimposed over one another across a center-line (CL).
FIG. 5A shows the cross-section A of FIGS. 4A , 4 B, 5 , having the leading edge ALE approximately 18 degrees below the horizontal plane HP and the trailing edge ATE adjacent to the horizontal plane HP. As can be seen the bottom surface 2 can have a leaf contoured surface with the top surface 4 being planar, and the leading edge ALE having a more blunt rounded edge than the trailing edge ATE.
FIG. 5B shows the cross-section B of FIGS. 4A , 4 B, 5 having a leading edge BLE slightly curved down approximately 13 degrees bend down below the horizontal plane HP. Cross-section B has the contoured leaf surface 2 with a concave bend configuration, and trailing edge BTE approximately 9 degrees below horizontal plane HP.
FIG. 5C shows the cross-section C of FIGS. 4A , 4 B, 5 having a leading edge CLE being approximately 10 degrees bent down from the horizontal plane HP. Cross-section C has a contoured leaf surface 2 with a concave bend, and a trailing edge CTE approximately 13 degrees below horizontal plane HP.
FIG. 5D shows the cross-section D of FIGS. 4A , 4 B, 5 having a leading edge DLE having a slight concave bend on bottom surface 2 , and a convex bend closer to trailing edge DTE. Cross-section D approaches a slight overall S curve shape with the leading edge DLE being approximately 5 degrees below the horizontal plane HP. The trailing edge DTE being approximately 7 degrees below horizontal plane HP.
FIG. 5E shows the cross-section E of FIGS. 4A , 4 B, 5 having a leading edge ELE having a concave bend on bottom surface 2 , and a convex bend closer to trailing edge ETE. Cross-section E has a more pronounced overall S curve shape with the leading edge ELE being approximately 4 degrees above the horizontal plane HP. The trailing edge ETE being approximately 1 degree below horizontal plane HP.
FIG. 5F shows the cross-section F of FIGS. 4A , 4 B, 5 having an overall convex bottom surface 2 with the leading edge FLE approximately 14 degrees above the horizontal plane.
FIG. 6A is a perspective bottom view of a ceiling fan 50 and twisted blades 1 of FIGS. 1A-5F attached to a ceiling fan motor 60 . FIG. 6B is a perspective top view of the ceiling fan 50 and twisted blades 1 of FIG. 6A . FIG. 6C is a side perspective view of the ceiling fan 50 and twisted blades 1 of FIG. 6A . FIG. 6D is a bottom view of the ceiling fan 50 and twisted blades 1 of FIG. 6A . FIG. 6E is a top view of the ceiling fan 50 and twisted blades 1 of FIG. 6A . Here, a preferred embodiment can use five (5) twisted leaf shaped blades 1 .
Other embodiments can use as few as two, three, four, and even six twisted leaf shaped blades. The blades can be formed from carved wood and/or injection molded plastic. The ceiling fan blades can have various diameters such as but not limited to approximately 42″, 46″, 48″, 52″, 54″, 56″, 60″ and even greater or less as needed.
Second Embodiment Twisted Leaf Blades
FIG. 7A is a bottom 102 perspective view of a second embodiment twisted leaf ceiling fan blade 100 showing root end 110 , tip end 120 , left side 130 and right side 140 . FIG. 7B is a bottom right root end 110 perspective view of the twisted blade 100 of FIG. 7A . FIG. 7C is a bottom left root end 110 perspective view of the twisted blade 100 of FIG. 7A . FIG. 7D is a top 104 right tip end 120 perspective view of the twisted blade 100 of FIG. 7A .
FIG. 8A is a tip end 120 side perspective view of the twisted blade 100 of FIG. 7A along arrow 8 A. FIG. 8B is a root end 140 side perspective view of the twisted blade 100 of FIG. 7A along arrow 8 B.
FIG. 9A is a left side 130 perspective view of the twisted blade 100 of FIG. 7A along arrow 9 A. FIG. 9B is a right side 140 perspective view of the twisted blade 100 of FIG. 7A along arrow 9 B.
FIG. 10A is another bottom perspective view of the twisted blade 100 of FIG. 7A with labeled cross-sections A, B, C, D, E, F.
The twisted blade 100 has an overall length between root end 110 and 120 being approximately 21″ long and 0.20″ thick with labeled cross-sections A having a width of approximately 3.02″, B having a width of approximately 7.18″, C having a width of approximately 9.05″, D having a width of approximately 10.90″, E having a width of approximately 9.00″, and F having a width of approximately 6.00″. Each of the cross-sections A-F being approximately 3.80″ apart from one another with cross-section A approximately 1″ in from root end 110 .
FIG. 10B is another bottom right tip end 120 perspective view of the twisted blade 100 of FIG. 7A and 10A with labeled cross-sections A, B, C, D, E, F in perspective curve views.
FIG. 11 shows the cross-sections A, B, C, D, E, F of FIGS. 10A , 10 B superimposed over one another.
FIG. 11A shows the cross-section A of FIGS. 10A , 10 B, 11 having the leading edge ALE approximately 12 degrees below the horizontal plane HP. As can be seen the bottom surface 102 can have a leaf contoured surface with the top surface 104 being planar, and the leading edge ATE having a more blunt rounded edge than the trailing edge ATE. The trailing edge ATE being approximately 7 degrees above the horizontal plane HP.
FIG. 11B shows the cross-section B of FIGS. 10A , 10 B, 11 having a leading edge BLE approximately 10 degrees bend down below the horizontal plane HP. Cross-section B has the contoured leaf surface 102 with a concave bend configuration, and trailing edge BTE approximately 3 degrees below horizontal plane HP.
FIG. 11C shows the cross-section C of FIGS. 10A , 10 B, 11 having a leading edge CLE bent being approximately 5 degrees bent down from the horizontal plane HP. Cross-section C has a contoured leaf surface 102 with a concave bend, and trailing edge CTE approximately 6 degrees below horizontal plane HP.
FIG. 11D shows the cross-section D of FIGS. 10A , 10 B, 11 having a leading edge DLE concave bend closer to the horizontal plane HP. Cross-section D approaches a slight overall S curve shape with the trailing edge DTE being approximately 2 degrees below horizontal plane HP.
FIG. 11E shows the cross-section E of FIGS. 10A , 10 B, 11 having a leading edge ELE having a concave bend on bottom surface 102 , and a convex bend closer to trailing edge ETE. Cross-section E has a more pronounced overall S curve shape with the leading edge ELE being approximately 4 degrees above the horizontal plane HP. The trailing edge ETE being approximately 1 degree below horizontal plane HP.
FIG. 11F shows the cross-section F of FIGS. 10A , 10 B, 11 having an overall convex bottom surface 102 with the trailing edge FTE approximately 5 degrees above the horizontal plane.
FIG. 12A is a perspective bottom view of a ceiling fan 150 and twisted blades 100 of FIGS. 7-11F attached to a ceiling fan motor 160 . FIG. 12B is a perspective top view of the ceiling fan 150 and twisted blades 100 FIG. 12A . FIG. 12C is a side perspective view of the ceiling fan 150 and twisted blades 100 of FIG. 12A . FIG. 12D is a bottom view of the ceiling fan 150 and twisted blades 100 of FIG. 12A . FIG. 12E is a top view of the ceiling fan 150 and twisted blades 100 of FIG. 12A .
The preferred embodiments can be used with blades that rotate clockwise or counter-clockwise, where the blades can be positioned to maximize airflow in either rotational directions.
While the preferred embodiment includes providing optimized twisted blades, the invention can be practiced with other aerodynamically shaped leaf shaped blades that can achieve enhanced airflow and efficiency results.
The blade mounting arms can also be optimized in shape to allow the blades to optimize pitch for optimal airflow with or without the aerodynamic leaf shaped blades.
Although the preferred embodiments show leaf shaped configurations on the bottom of the blades 1 , 100 , the blades can also have leaf shaped configurations on their top surface. Additionally, either or both the preferred embodiments can be made from wood and/or plastic, and the like.
While the invention has been described, disclosed, illustrated and shown in various terms of certain embodiments or modifications which it has presumed in practice, the scope of the invention is not intended to be, nor should it be deemed to be, limited thereby and such other modifications or embodiments as may be suggested by the teachings herein are particularly reserved especially as they fall within the breadth and scope of the claims here appended.
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Twisted leaf shaped ceiling fan blades for low, medium and high speed operation of less than approximately 250 rpm. The novel blades twisted blades can be configured for 52″, 54″, 56″, 60″ and 64″ diameter fans, and have less blades (3 for example) than conventional flat type bladed fans having 4, 5 blades and have greater air flow and less power draw results than the conventional flat 54 inch fans. Any of the novel twisted blades of 48″, 52″, 54″, 56″, 60″ and 64″ can be run at reduced speeds, drawing less Watts than conventional fans and still perform better with more air flow and less problems than conventional flat type conventional leaf shaped blades.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a hybrid-type power transmission in which an internal combustion engine and an electric rotating machine are used as a source of power for driving an output shaft through a change-speed mechanism.
2. Technical Background of the Invention
In the PCT application (PCT/JP2008/068678) filed on Oct. 15, 2008, one of the inventors has proposed a hybrid-type power transmission of this kind. As shown in FIGS. 1 and 2 , the hybrid-type power transmission comprises an input shaft 10 for drive connection with an internal combustion engine 14 , a change-speed mechanism 30 having a plurality of change-speed gear trains to be selectively established for transmitting a drive power from the input shaft 10 to an output shaft 11 at a selected speed ratio, a changeover mechanism 20 including a rotor-side rotary member 21 mounted on the input shaft for rotation with a rotor 13 a of an electric rotating machine 13 , an output-side rotary member 25 mounted on the input shaft 10 for rotation with a drive gear 16 in drive connection with the output shaft 11 , an input-side rotary member 24 mounted on the input shaft 10 for rotation therewith between the rotor-side rotary member 21 and the output-side rotary member 25 , and a sleeve 26 coupled with the rotor-side rotary member 21 for rotation therewith and shiftable in an axial direction to be selectively engaged with the output-side rotary member 25 or the input-side rotary member 24 , and a control device 18 for controlling each operation of the electric rotating machine 13 , the changeover mechanism 20 and the change-speed mechanism 30 . The electric rotating machine 13 is in the form of a motor-generator activated under control of the control device 18 to drive the input shaft 10 or the output shaft 11 or to be driven by the input shaft 10 or the output shaft 11 .
As shown in FIG. 1 , the change-speed mechanism 30 includes the plurality of change-speed gear trains G 1 ˜G 5 and a backward gear train GB arranged in parallel between the input and output shafts 10 and 11 , and a plurality of clutches C 1 ˜C 3 for changing over the gear trains G 1 ˜G 5 . The control device 18 is provided to selectively effect engagement of the clutches C 1 ˜C 3 through a shift actuator 19 and shift-forks F 1 ˜F 3 in response to instruction from a driver thereby to selectively establish a drive power train from the change-speed gear trains G 1 ˜G 5 and backward gear train GB for transmission of drive power between the input shaft 10 and the output shaft 11 . In a condition where a change-speed gear train was selected, the output shaft 11 is driven by the internal combustion engine 14 and/or the electric rotating machine 13 to drive left and right road wheels (not shown) through an output drive gear 31 , an output driven gear 32 , a differential 33 and drive shafts 34 a , 34 b.
As shown in FIGS. 1 and 2 , the changeover mechanism 20 for selectively effecting drive connection of the electric rotating machine 13 with the input shaft 10 or the output shaft 11 includes the rotor-side rotary member 21 coupled with the rotor 13 a of electric rotating machine 13 for rotation therewith, the input-side rotary member 24 mounted on the input shaft 10 for rotation therewith, the output-side rotary member 25 coupled with the drive gear 16 in drive connection with the output shaft 11 for rotation therewith, and the cylindrical sleeve 26 coupled with the rotor-side rotary member 21 for rotation therewith and shiftable in an axial direction to be engaged with the input-side rotary member 24 or the output-side rotary member 25 for transmission of the drive power.
As shown in detail in FIG. 2 , the input-side rotary member 24 is coaxially mounted at its hub portion on the input shaft 10 by means of spline connection and fixed in place by means of fastening rings. At opposite sides of the input-side rotary member 24 , the rotor 13 a of the electric rotating machine 13 and the drive gear 16 are rotatably supported at their hub portions on the input shaft 10 through a needle roller bearing, respectively. The drive gear 16 is in drive connection with the output shaft 11 through a driven gear 17 . The rotor-side rotary member 21 and output-side rotary member 25 are coaxially coupled at their hub portions with the rotor 13 a and drive gear 16 for rotation therewith respectively by means of serration press-fit. The rotary members 21 , 24 , 25 are formed with outer splines 21 a , 24 a , 25 a of the same cross-section, respectively. The input-side rotary member 24 is spaced from the output-side rotary member 25 in a distance. The cylindrical sleeve 26 is formed with axially spaced inner splines 26 a and 26 b . The first inner spline 26 a is slidably engaged with the outer spline 21 a of rotor-side rotary member 21 , while the second inner spline 26 b is selectively engaged with the outer spline 24 a of input-side rotary member 24 or the outer spline 25 a of output-side rotary member 25 in response to axial movement of the sleeve 26 .
A shift-fork 27 is engaged with an annular groove 26 c formed on the outer periphery of sleeve 26 to be operated by activation of the shift actuator 19 through a shift-rod 28 (see FIG. 1 ). When the sleeve 26 is placed at a center of its axial movement, the inner spline 26 b of sleeve 26 is positioned between the input-side rotary member 24 and output-side rotary member 25 . When the shift actuator 19 is activated under control of the control device 18 in response to an instruction of a driver, the sleeve 26 is shifted in an axial direction to be selectively engaged to the outer spline 24 a of input-side rotary member 24 or the outer spline 25 a of output-side rotary member 25 .
For smooth engagement of the splines in shift movement of the sleeve, it is required to synchronize the rotation speed of rotor-side rotary member 21 with the rotation speed of the input-side rotary member 24 or the output-side rotary member 25 . In the changeover mechanism 20 , the electric rotating machine 13 is operated under control of the control device 18 to synchronize the rotation speed of rotor-side rotary member 21 with the rotation speed of input-side rotary member 24 or the output-side rotary member 25 .
When a friction clutch 15 in the hybrid-type power transmission is engaged during operation of the internal combustion engine 14 in a condition where either one of the gear trains of the change-speed mechanism 30 was selected, the drive road wheels of the vehicle are driven by the engine 14 through the selected gear train. When the speed reduction ratio of the drive gear 16 and driven gear 17 is selected between the speed reduction ratios of the second change-speed gear train G 2 and the third change-speed gear train G 3 , the rotation speed of output-side rotary member 25 changes during lapse of a time as shown by a solid line No in FIG. 7 . In such an instance, the rotation speed of the input-side rotary member 24 changes in accordance with the change-speed ratio of the selected gear train as shown by solid lines Ni 1 ˜Ni 5 . In the graph of FIG. 7 , the rotation speed of input-side rotary member 24 is represented by the solid line Ni 1 when the first change-speed gear train 01 is selected and represented by the solid line Ni 2 when the second change-speed gear train G 2 is selected. In a condition where the change-speed gear trains were selected as described above, the changeover mechanism 20 is operated under control of the control device 18 in such a manner that the rotor-side rotary member 21 is brought into engagement with the input-side rotary member 24 or the output-side rotary member 25 in accordance with a depressed amount of an acceleration pedal, the selected change-speed gear train, the rotation speeds of the input and output shafts 10 , 11 , and acceleration of the vehicle.
Illustrated in FIG. 6 is a condition where the rotor-side rotary member 21 is selectively connected with the output-side rotary member 25 or the input-side rotary member 24 being rotated by the first change-speed gear train G 1 or the second change-speed gear train G 2 . When the rotor-side rotary member 21 is disconnected from the input-side rotary member 24 and connected with the output-side rotary member 25 , the shift actuator 19 is activated under control of the control device 18 to shift the sleeve 26 in such a manner as to disconnect the second inner spline 26 b of sleeve 26 from the outer spline 24 a of input-side rotary member 24 . In such an instance, the electric rotating machine 13 is activated under control of the control device 18 to synchronize the rotation speed of rotor-side rotary member 21 with the rotation speed of output-side rotary member 25 . To effect the synchronization, the rotation speed of the output-side rotary member 25 is defined as a target rotation speed No. Thus, the activation, of electric rotating machine 13 is controlled in such a manner that the rotation speed Nmc of rotor-side rotary member 21 approaches the target rotation speed No at a speed proportional to a difference with the target rotation speed No. With such control of the electric rotating machine 13 , the rotation speed Nine of rotor-side rotary member 21 decreases as shown in FIG. 6 and approaches to the target rotation speed No. After synchronized with the target rotation speed No, the rotation speed Nmc further decreases due to mechanical resistances in the electric rotating machine during lapse of a time after start of the shift operation of the sleeve 26 . After synchronization of the rotation speed Nmc with the target rotation speed No, the shift actuator 19 is activated again under control of the control device 18 to shift the sleeve 26 in such a manner as to bring the second inner spline 26 b into engagement with the outer spline 25 a of output-side rotary member 25 thereby to connect the rotor-side rotary member 21 to the output-side rotary member 25 .
Illustrated in FIG. 3( a 1 ) are the second inner spline 26 b of sleeve 26 and the outer spline 25 a of output-side rotary member 25 to be engaged with each other upon synchronization of the rotation speed Nmc with the target rotation speed No. As shown in the figure, the distal ends of splines 26 b and 25 a are spaced in a distance in an axial direction. The lapse of a time after start of the shift operation of sleeve 26 is caused by the distance between the distal ends of splines 28 b and 25 a and is affected by the shift speed of sleeve 26 and phase relationship between the splines 26 b and 25 a . The lapse of the time after synchronization of the rotation speed Nmc with the target rotation speed No will become a minimum value Tm 1 when the chamfer apex 26 b 1 of the second inner spline 26 b is engaged with the chamfer apex 25 a 1 of outer spline 25 a and will become a maximum value Tm 2 when the chamfer proximal end 26 b 2 of the second inner spline 26 is engaged with the chamfer proximal end 25 a 2 of the outer spline 25 a . (see imaginary lines b 2 in FIG. 3( b 1 )).
As described above, the rotation speed Nmc of sleeve 26 in slidable engagement with the rotor-side rotary member 21 is decreased after synchronized with the target rotation speed No as shown by the imaginary line Nmc 1 in FIG. 6 and is rapidly increased when the sleeve 26 is engaged with the output-side rotary member 25 between the minimum lapse of the time Tm 1 and the maximum lapse of the time Tm 2 .
When the rotor-side rotary member 21 is disconnected from the output-side rotary member 25 and connected to the input-side rotary member 24 , the shift actuator 19 is activated under control of the control device 18 to shift the sleeve 26 in such a manner as to disconnect the second inner spline 26 b from the outer spline 25 a of output-side rotary member 25 , while the electric rotating machine 13 is activated under control of the control device to synchronize the rotation speed of rotor-side rotary member 21 with the rotation speed of input-side rotary member 24 . After synchronization of the rotation speeds, the shift actuator 19 is sequentially activated under control of the control device 18 to shift the sleeve 26 in such a manner as to bring the second inner spline 26 b of sleeve 26 into engagement with the outer spline 24 a of input-side rotary member 24 . In such an instance, the rotation speed Nmd of sleeve 26 is increased by synchronization with the rotation speed of input-side rotary member 24 and is once decreased after synchronization with the rotation speed of input-side rotary member 24 as shown by an imaginary line Nmd 1 in FIG. 6 . Subsequently, the rotation speed Nmd 1 of sleeve 26 is rapidly increased to the rotation speed Ni of input-side rotary member 24 when the sleeve 26 is engaged with the input-side rotary member 24 between the minimum lapse of the time Tm 1 and the maximum lapse of the time Tm 2 .
As described above, the electric rotating machine is activated under control of the control device to synchronize the rotation speed of rotor-side rotary member 21 with the rotation speed of input-side rotary member 24 or output-side rotary member 25 in shifting operation of the sleeve 26 . In such an instance, the rotation speed of sleeve 26 is rapidly increased after once decreased when the sleeve is shifted to bring the rotor-side rotary member 21 into engagement with the output-side rotary member 25 or the input-side rotary member 24 . This causes impact noise in shifting operation of the sleeve 26 in the changeover mechanism 20 .
SUMMARY OF THE INVENTION
A primary object of the present invention is to provide a control device for the electric rotating machine in the hybrid-type power transmission capable of solving the problem discussed above.
According to the present invention, the object is accomplished by providing a hybrid-type power transmission comprising an input shaft for drive connection with an internal combustion engine, a change-speed mechanism having a plurality of change-speed gear trains to be selectively established for transmitting a drive power from the input shaft to an output shaft at a selected speed ratio, and a changeover mechanism for selectively effecting drive connection of an electric rotating machine with the input shaft or the output shaft. The changeover mechanism includes a rotor-side rotary member mounted on the input shaft for rotation with a rotor of the electric rotating machine, an output-side rotary member mounted on the input shaft for rotation with a drive gear in drive connection with the output shaft, an input-side rotary member mounted on the input shaft for rotation therewith between the rotor-side rotary member and the output-side rotary member, and a sleeve coupled with the rotor-side rotary member for rotation therewith and shiftable in an axial direction to be selectively engaged with the output-side rotary member or the input-side rotary member. A control device for the change-speed mechanism and the electric rotating machine is arranged to control the rotation speed of the electric rotating machine in such a manner that the rotation speed of the rotor-side rotary member synchronizes with a target speed higher in a predetermined difference than the rotation speed of the input-side or output-side rotary member in shifting operation of the sleeve.
In a practical embodiment of the present invention, the difference of the rotation speeds of the rotor-side rotary member and the input-side or output-side rotary member is determined in such a manner that the rotation speed of the rotor-side rotary member decreases less than that of the input-side or output-side rotary member at a time when the sleeve is brought into engagement with the input-side or output-side rotary member after synchronization of the rotation speed of the rotor-side rotary member with the target speed.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings,
FIG. 1 is a skeleton view illustrating components of a hybrid-type power transmission;
FIG. 2 is a partly enlarged sectional view of a changeover mechanism in the hybrid-type power transmission shown in FIG. 1 ,
FIGS. 3( a 1 ), 3 ( b 1 ) each illustrate a section circumferentially taken along 3 - 3 in FIG. 2 ,
FIGS. 3( a 2 ), 3 b 2 ) each illustrate the rotation speed of the rotor-side rotary member after synchronization with the rotation speed of the output-side rotary member,
FIGS. 4( a 1 ), 3 ( b 1 ) each illustrate a modification of each chamfer of the inner and output splines shown in FIGS. 3( a 1 ), 3 ( b 1 ),
FIGS. 4( a 2 ), 3 b 2 ) each illustrate the rotation speed of the rotor-side rotary member after synchronization with the rotation speed of the output-side rotary member,
FIG. 5 is a graph illustrating transition of the rotation speed of the rotor-side rotary member in shifting operation of the sleeve in the changeover mechanism,
FIG. 6 is a graph illustrating transition of the rotation speed of the rotor-side rotary member in shifting operation of the sleeve in the changeover mechanism, and
FIG. 7 is a graph illustrating change of the rotation speed of the input-side rotary member in the changeover mechanism.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, a preferred embodiment of the present invention adapted to the hybrid-type power transmission described above with reference to FIGS. 1 and 2 will be described with reference to FIG. 5 . Assuming that the sleeve 26 of the changeover mechanism 20 is shifted by operation of the shift actuator under control of the control device 18 to connect the rotor-side rotary member 21 to the output-side rotary member 25 in a condition where the rotation speed of input-side rotary member 24 is higher than the rotation-speed of output-side rotary member 25 as shown in FIG. 5 , the electric rotating machine 13 is activated under control of the control device 18 to synchronize the rotation speed of rotor-side rotary member 21 with the rotation speed of output-side rotary member 25 . In this embodiment, a rotation speed in a difference Δo higher than the rotation speed No of the output-side rotary member 25 is defined as a target rotation speed Ndo for synchronization. Thus, the electric rotating machine 13 is operated under control of the control device 19 in such a manner that the rotation speed Nma of rotor-side rotary member 21 decreases and synchronizes with the target rotation speed Ndo as shown in FIG. 5 . After synchronized with the target rotation speed Ndo, the rotation speed Nma of rotor-side rotary member 21 further decreases less than the target rotation speed Ndo due to mechanical resistances in the electric rotating machine 13 as shown by an imaginary line Nma 2 .
In this embodiment, the difference Δo is determined in such a manner that the imaginary line Nma 2 indicative of the rotation speed of rotor-side rotary member 21 crosses the solid line No indicative of the rotation speed of output-side rotary member 25 at a time between the minimum and maximum lapse of times Tm 1 and Tm 2 during which the apex of inner spline 26 b of sleeve 26 is brought into engagement with the apex of outer spline 25 a of output-side rotary member 25 . Practically, the difference Δo is determined on a basis of various factors such as a selected gear train, each rotation speed of the input and output shafts 10 , 11 , acceleration of the vehicle, a temperature affecting stir-resistance of lubricant, etc.
When the inner spline of sleeve 26 is engaged with the outer spline of output-side rotary member 25 at the time between the minimum and maximum lapse of times Tm 1 and Tm 2 , the rotation speed Nma of sleeve 26 is changed over to the rotation speed No of output-side rotary member 25 . In the case that the target rotation speed Ndo is determined as described above, the difference between the rotation speeds of sleeve 26 and output-side rotary member 25 becomes zero in a small extent between the minimum and maximum lapse of times Tm 1 and Tm 2 .
When the shift actuator 19 is activated under control of the control device 18 to shift the sleeve in such a manner as to disconnect the rotor-side rotary member 21 from the output-side rotary member 25 , the electric rotating machine 13 is activated under control of the control device 19 to synchronize the rotation speed of rotor-side rotary member 21 with the input-side rotary member 24 . In such an instance, a rotation speed in a difference Δi higher than the rotation speed Ni is defined as a target rotation speed Ndi in the same manner as described above. Thus, the electric rotating machine 13 is activated under control of the control device 18 in such a manner that the rotation speed Nmb of rotor-side rotary member 21 increases and synchronizes with the target rotation speed Ndi as shown in FIG. 5 . After synchronized with the target rotation speed Ndi, the rotation speed Nmb of rotor-side rotary member 21 decreases less than the target rotation speed Ndi due to mechanical resistance in the electric rotating machine 13 as shown by an imaginary line Nmb 2 .
As shown in FIG. 3( a 1 ), the inner spline 26 b of sleeve 26 is formed at its opposite ends with a chamfer of triangle in cross-section to be engaged with a chamfer of triangle in cross-section formed on each distal end of the outer splines 24 a , 25 a of input-side and output-side rotary members 24 , 25 . As the rotation speed Nma of sleeve 26 is higher than the rotation speed No of the output-side rotary member 25 after synchronization with the target rotation speed Ndi as described above, the inner spline 26 b of sleeve 26 tend to be moved toward the outer spline 25 a of output-side rotary member 25 in shifting operation of the sleeve 26 as shown by solid arrows in FIG. 3( a 1 ). If in such an instance, the chamfer of inner spline 26 b is brought into engagement at its front side with the back side of the chamfer of outer spline 25 a in a rotation direction, the difference between the rotation speeds of sleeve 26 and output-side rotary member 25 decreases as shown in FIG. 3( a 2 ). When the chamfer of sleeve 26 is moved back in a reverse rotation direction by engagement with the chamfer of output-side rotary member 25 , the difference of the rotation speeds becomes minus. When the proximal end 26 b 2 of the chamfer of inner spline 26 b displaces over the proximal end 25 a 2 of the chamfer of outer spline 25 a , the difference between the rotation speeds of sleeve 26 and output-side rotary member 25 becomes zero.
If as shown in FIG. 3( b 1 ), the chamfer of inner spline 26 b is brought into engagement at its back side with the front side of the chamfer of outer spline 25 a in a rotation direction, the difference between the rotation speeds of sleeve 26 and output-side rotary member 25 decreases as shown in FIG. 3( b 2 ). When the chamfer of sleeve 26 is engaged with the chamfer of outer spline 25 a as shown by an imaginary line b 1 , the sleeve 26 is moved in the rotation direction to increase the difference of the rotation speeds of sleeve 26 and output-side rotary member 25 . When the proximal end 26 b 2 of the chamfer of inner spline 26 a displaces over the proximal end 25 a 2 of the chamfer of outer spline 25 a , the difference between the rotation speeds of sleeve 26 and output-side rotary member 25 becomes zero.
As the difference between the rotation speeds of rotor-side rotary member 21 and input-side rotary member 24 or output-side rotary member 25 becomes extremely small in shifting operation of the changeover mechanism, the pushback force acting on the sleeve 26 becomes extremely small, and the occurrence of impact noise in shifting operation is extremely reduced. This is effective to bring the sleeve 26 into smooth engagement with the input-side rotary member 24 or output-side rotary member 25 .
Illustrated in FIGS. 4( a 1 ), 4 ( b 1 ) is a modification of each chamfer of the inner spline 26 b of sleeve 26 and outer splines 24 a , 25 a of rotary members 24 , 25 in the changeover mechanism. In this modification, each chamfer of the inner spline 26 b is formed at its backside with an inclined surface 26 b 5 , while each chamfer of the outer splines 24 a , 25 a of rotary members 24 , 25 is formed at its front side with an inclined surface 24 a 5 , 25 a 5 . When the sleeve 26 is shifted to the output-side rotary member 25 , the inner spline 26 b of sleeve 26 is displaced toward the outer spline 25 a of output-side rotary member 25 as shown by solid arrows and brought into engagement with the outer spline 25 a as shown in FIG. 4( a 1 ) or 4 ( b 1 ).
When the inner spline 26 b of sleeve 26 is brought into engagement with the outer spline 25 a of output-side rotary member 25 as shown in FIG. 4( a 1 ), the difference between the rotation speeds of sleeve 26 and output-side rotary member 25 decreases as shown by an imaginary line Nma 2 in FIG. 4( a 2 ). When the splines 26 b and 25 a are engaged with each other at their side surfaces as shown by an imaginary line c 1 , the difference between the rotation speeds of sleeve 26 and output-side rotary member 25 becomes zero without any increase as shown in FIG. 4( a 2 ). When the inner spline 26 b of sleeve 26 is brought into engagement with the outer spline 25 a of output-side rotary member 25 as shown in FIG. 4( b 1 ), the difference between the rotation speeds of sleeve 26 and output-side rotary member 25 decreases as shown by an imaginary line Nma 2 in FIG. 4( b 2 ). When the splines 26 b and 25 a are engaged with each other at their chamfers, the sleeve 26 is moved in the rotation direction to increase the difference between the rotation speeds as shown in FIG. 4( b 2 ). When the proximal end 26 b 4 of inner spline 26 b displaces over the proximal end 25 a 4 of outer spline 25 a as shown by an imaginary line d 2 in FIG. 4( b 1 ), the difference between the rotation speeds becomes zero as shown in FIG. 4( b 2 ).
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A hybrid-type power transmission in which an internal combustion engine and an electric rotating machine are used as a source of power for driving an output shaft through a change-speed mechanism. In the hybrid power transmission, the operation of the electric rotating machine is controlled in such a manner that the rotation speed of a rotor-side rotary member is synchronized with the rotation speed of an input-side or output-side rotary member when the rotation speed of the rotor-side rotary member becomes higher in a predetermined difference than the rotation speed of the input-side or output-side rotary member in shifting operation of a sleeve coupled with the rotor-side rotary member.
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BACKGROUND OF THE INVENTION
The present invention relates to a composition imparting an initial sensation similar to tingling upon first contact. More specifically, the present invention is a composition including a cooling sensate, a warming sensate and a tingling-type sensate, which when used in combination, imparts an immediate initial sensation. The initial sensation can best be described as a tingling or a stinging impression which also enhances the sensation of the other sensates used in the composition. In addition, the composition of the present invention also helps moderate the harsh and stimulative effects of the cooling agents. This moderation of the harsh effects of cooling agents is referred to herein as an emollient effect.
Various types of products incorporate ingredients which impart some kind of sensation to the mucous membranes, oral cavity, throat or skin. These ingredients may be used as flavors or fragrances in a wide range of products such as personal care products (perfumes deodorants, cosmetics, shampoos, skin creams, toothpastes and the like), pharmaceuticals (such as cough syrups, cough drops and the like) and foods (such as chewing gum, soda and the like).
For example, 1-menthol and 3-(1-menthoxy)propane-1,2-diol are used as active ingredients in products to impart a cooling sensation to the mouth or skin (U.S. Pat. No. 4,459,425). However, 1-menthol has the drawback of being very volatile as well as irritating to skin and mucous membranes. There is a limit to how much 1-menthol can be used in a product to produce a cooling sensation, because when used in greater amounts the 1-menthol becomes very harsh and irritating. Much research has been done to find alternatives to menthol as a cooling agent. In New Compounds with the Menthol Cooling Effect, J. Soc. Cosmet. Chem., 29: 185-200 (1978), by H. R. Watson et al., the physiological basis for the cooling effect of menthol is discussed. In addition, certain important molecular requirements were described that are believed to be necessary in order for a compound to have the desired effect. Several N-alkyl-carboxamide compounds were found to possess the cooling sensation of menthol while having the advantage of being less volatile. The pharmacology and toxicology of menthol use in various products and for various modes of administration has also been reported. See Menthol and Related Cooling Compounds, J. Pharm. Pharmacol., 46: 618-630 (1994), by R. Eccles. Another alternative to menthol is 1(2-hydroxyphenyl)-4-(3-nitrophyenyl)-1,2,3,5-tetrahydropyrimidine-2-one. This compound is discussed in A Chemical Which Produces Sensations of Cold, Environment, Drugs and Thermoregulation, 5 th International Symp. Pharmacol. Thermoregulation, Saint-Paul-de-Vence, 1982, pp. 183-186 (Karger, Basel, 1983) by E. T. Wei.
Other known physiological cooling agents including peppermint oil, N-substituted-p-menthane-3-carboxamides, acyclic tertiary and secondary carboxamides, 3-1-menthoxy propan-1,2-diol have also been reported (See PCT Published Application Number WO 97/06695).
Heating and/or warming sensates are also known. Vanillyl alcohol n-butyl ether (vanillyl butyl ether) is known as an active ingredient in products to impart a sharp, tangy bite or a heating/warming sensation (Japanese Laid-Open Application No. 54-67040). A formulation for cough drops has been reported which includes a physiological cooling agent and a physiological warming agent (PCT Published Application No. 1WO 97/06695). Physiological cooling agents disclosed therein include peppermint oil, N-substituted-p-menthane-3-carboxamides, acyclic tertiary and secondary carboxamides, 3-13menthoxy propan-1,2-diol. Physiological warming agents disclosed therein include vanillyl alcohol n-butyl ether, vanillyl alcohol n-propyl ether, vanillyl alcohol isopropyl ether, vanillyl alcohol isobutyl ether, vanillyl alcohol n-amino ether, vanillyl alcohol isoamyl ether, vanillyl alcohol n-hexyl ether, vanillyl alcohol methyl ether, vanillyl alcohol ethyl ether, gingerol, shogaol, paradol, zingerone, capsaicin, dihydrocapsaicin, nordihydrocapsaicin, homocapsaicin, homodihydrocapsaicin, ethanol, iso-propyl alcohol, iso-amylalcohol, benzyl alcohol, chloroform, eugenol, cinnamon oil, connamic aldehyde and phosphate derivatives of same.
A compound that possesses a hot, burning and tingling taste that is long lasting has been reported as 4-(1-methoxymethyl)-2-phenyl- 1,3-dioxolane or its derivatives represented by the following general formula (I):
wherein R 1 represents a hydrogen atom, a hydroxy group or a lower alkoxy group, R 2 and R 3 , which may be the same or different, each represent a hydrogen atom, a hydroxy group, a lower alkoxy group, or when taken together, R2 and R3 represent a methylene dioxy group. See U.S. Pat. No. 5,545,424 which is herein incorporated by reference. This warming sensate was also reported to prolong the sensations of certain cooling sensates, for example in combination with 1-menthol, 3-(-1-menthoxy)-1,2-propanediol (“TK-10” by Takasago International Corp., Tokyo, Japan) or isopulegol. The combination of the cooling and warming sensates signaled prolonged cooling effects to the user. Thus, the burning, tingling or bitter sensations associated with this warming sensate were able to convey to the user a better appreciation of the cooling sensate.
In addition, vanillyl alcohol n-butyl ether (vanillyl butyl ether) is known as an active ingredient in products to impart a sharp, tangy bite or a heating/warming sensation (Japanese Laid-Open Application No. 54-67040 and Examined Japanese Patent Application No. 61-9293).
Certain materials are known to cause a tingling, numbing and/or stinging sensation and are used in foods as popular spice and/or herb condiments. These include Jambu Oleoresin or para cress (Spilanthes sp.) the active ingredient being Spiranthol; Japanese pepper extract ( Zanthoxylum peperitum ) having the active ingredient(s) known as Saanshool-I, Saanshool-II and Sanshoamide, Black pepper extract ( Piper nigrum ) having the active ingredients Chavicine and Piperine.
It is also known to combine compounds known to possess flavor and/or sensate compounds to produce new active ingredients having altered properties. For example, PCT published application WO 98/47482 discloses formulations for cough drops which include a physiological cooling agent (such as menthol, peppermint oil, n-N-substituted-p-menthane-3-carboxamides, acyclic tertiary and secondary carboxamides, 3-1-menthoxy propan-1,2-diol) and a physiological warming agent (such as vanillyl alcohol n-butyl ether, vanillyl alcohol n-propyl ether, vanillyl alcohol isopropyl ether, vanillyl alcohol isobutyl ether, vanillyl alcolol n-amino ether, vanillyl alcohol isoamyl ether, vanillyl alcohol n-hexyl ether vanillyl alcohol methyl ether, vanillyl alcohol ethyl ether, gingerol, shogaol, paradol, zingerone, capsaicin, dihydrocapsaicin, nordihydrocapsaicin, homocapsaicin, homodihydrocapsaicin, ethanol, iso-propyl alcohol, iso-amylalcohol, benzyl alcohol, chloroform, eugenol, cinnamon oil, cinnamic aldehyde and phosphate derivatives of same.
Use of vanillyl butyl ether in combination with a cooling agent is disclosed in co-pending application entitled “COOL FEELING COMPOSITION” filed on or about Aug. 4, 1999 by one or more of the inventors of the present invention. The composition disclosed therein imparts a refreshing sensation in various consumer products.
The known cooling, warming and combination sensate compounds tend to have a lag time between first contact and when the sensate is first detected. It is often seconds before the sensation is actually perceived by the user. In addition, the cooling and warming sensate compounds, and combinations thereof that are known to date, do not last very long. It is often only a few seconds or minutes before the sensation wanes. It is desirable to have a cooling, warming or combination sensate compound that is perceived by the user immediately upon first contact with the user. It is also desirable for the perceived sensation to last for a greater duration of time than just the first few seconds or so.
OBJECTS AND SUMMARY OF THE INVENTION
It is an object of the present invention to provide a taste and touch sensate that overcomes the limitations of the prior art.
It is an object of the present invention to provide a sensate compound that provide a strong initial signal to the user.
It is a further object of the present invention to provide a sensate compound that provides a tingling and/or stinging impression upon contact.
It is a further object of the present invention to provide a sensate compound that provides lasting sensation beyond first contact.
It is a further object of the present invention to provide a sensate compound that provides an emollient effect on one or more stimulative co-ingredients.
After extensive research, the inventors of the present invention have discovered that combining cooling sensates with warming sensates and a tingling sensate (such as Jambu oleoresin or Spilanthol), results in enhancement of the flavor and/or sensation of the cooling and/or warming sensates. In addition, this combination has been shown to initiate perception of the flavor of the sensates in a shorter period of time than occurs when either the cooling sensate, the warming sensate, or a combination of the two are used without the tingling sensate.
Briefly stated, the present invention is a sensate composition including at least one cooling sensate, at least one warming sensate and at least one tingling sensate.
In an embodiment of the present invention, a method of using a sensate compositon as at least one of a fragrance and a flavor is provided, which includes forming a sensate composition having at least one cooling sensate, at least one warming sensate and at least one tingling sensate containing effective amounts of the sensates and admixing the sensate composition with a suitable carrier.
The above, and other objects, features and advantages of the present invention will become apparent from the following description. However, these examples are not to be construed to limit the scope of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As described above, 1-menthol, 3-(1-menthoxy)propane-1,2-diol and other compounds are known cooling agents. In addition, vanillyl butyl ether is known as a warming sensate. Jambu oleoresin is an extract used to impart tingling flavor in foods.
In the new sensate of the present invention, vanillyl butyl ether is combined with a cooling sensate and a warming sensate to impart an immediate sensation upon contact that also provides an emollient effect on the cooling sensate. The cooling sensate can be a single cooling sensate or a combination of different cooling sensates. The warming sensate can be a single such sensate or a combination thereof.
There are no specific limitations to the relative amounts of the compounds of the composition. However, it is preferred that vanillyl butyl ether is used in a relative amount with respect to the cooling agent so that no discernable warming effect occurs. Preferably, vanillyl butyl ether is used on a weight basis, from 1/1000 to 2 times as much as the cooling agent. More preferably, the vanillyl butyl ether is present in the composition from 1/200 to 1 times the amount of the cooling agent on a weight basis.
The new sensate composition of the present invention may further contain diluents (ethanol, purified water, etc.) which are safe for use in products used for consumption and/or topical use. The new sensate composition of the present invention can be used in various products to which the qualities of the sensate are desirable. Examples of suitable products include: cosmetics (such as lipstick, after shave lotions, foundation and the like), personal care products (such as skin creams, astringent lotions, cleansing lotions, deodorants, shampoos, conditioners, soaps, hair gels, hair tonics, hair growth stimulants, shaving foams, shaving creams, bubbling bath beads and the like) and pharmaceutical compositions (such as insect repellent sprays, hair tonics, analgesic preparations, lozenges and the like). These are set forth as examples, however the products in which the composition of the present invention may be used are not limited to these.
The amount of the sensate composition of the present invention in a product varies widely depending on the amount of the product used at one time and the manner in which it is used or applied. In general, the content of the sensate composition any be from 0.001 to 20% by weight, preferably from 0.01 to 10% by weight of the entire product composition. However, the sensate composition may be added to a product in any amount, as long as the effect of the composition is present. The sensate composition may be made first, then added to a product. Alternatively, the cooling agent, warming agent and tingling agent may be added separately to the product.
The present invention will be described in greater detail by reference to the following Embodiments and Comparative Examples, however, it should be noted the invention is not limited to these examples.
Embodiment 1
Embodiment 1 was prepared by mixing N-ethyl-2-isopropyl-5-methylcyclohexane carboxamide as a cooling agent, vanillyl butyl ether as a warming agent and Jambu Oleoresin as a tingling agent with other ingredients according to the following formulation to produce a mouthwash. These ingredients are prepared according to methods that are known in the art.
Percentage
Ingredient
(%) in flavors
ethyl alcohol
55.0
propylene glycol
28.0
N-ethyl-2-isopropyl-5-methylcyclohexane carboxamide
3.0
isopulegole
8.0
Jambu Oleoresin
2.5
vanillyl butyl ether
3.0
mouthwash herbal flavor base
0.5
A sensory evaluation was performed on the mouthwash of Embodiment 1. Eight members of a panel trained as Flavorists evaluated the products. They found that the blend produced a unique flavor and taste profile. Members of the panel reported a tingling sensation upon first contact with the mouthwash. No delay in perceived sensation was reported.
COMPARATIVE EXAMPLE 1
Comparative Example 1 was made in the same manner as Embodiment 1, except that Jambu Oleoresin was omitted.
A taste panel was convened to evaluate any perceived differences in character between the mouthwash of Embodiment 1 and Comparative Example 1. Panelists were asked to compare the flavor sensation of the two products and comment on any differences.
The majority of the panelists noted that there was a distinct difference in warming sensation perception and onset. The coded sample containing the Jambu Oleoresin was described as having a fuller warming, tingling effect as compared to the Jambu free system which was less complex and less stimulating with an almost retarded onset of the cooling perception. There was a noted synergistic effect between the ingredients. The profiles were described as a significant tingling and an enhancement of the cooling and warming perception of the product. The study showed that all three components, cooling, heating and tingling are necessary to produce the observed unique effect.
Embodiment 2
Embodiment 2 was prepared by mixing 3-(-1-menthoxy)-1,2 propanediol (“TK-10” from Takasago, Takasago International Corp., Tokyo, Japan) as a cooling agent, capiscum oleoresin as a warming agent and Jambu Oleoresin as a tingling agent with other ingredients according to the following formulation to make a toothpaste according to methods that are known in the art.
Ingredient
Percentage
ethanol
48.0
Benzyl alcohol
34.0
Jambu Oleoresin
10.0
Ginger Oleoresin
2.0
Capsicum Oleoresin
0.5
3-(-1-menthoxy)-1,2-propanediol (“TK-10”)
2.0
COMPARATIVE EXAMPLE 2
Comparative Example 2 was prepared in the same manner as Embodiment 2, except Jambu Oleoresin was omitted.
A select taste panel evaluated the perceived differences in character between the toothpaste preparation of Embodiment 2 and Comparative Example 2. Panelists were asked to compare the flavor sensation of the two products and comment on any differences. Evaluations were performed blind.
The majority of the panelists noted that the sample containing the tingling sensate material had quicker tingling sensation onset and an enhanced, prolonged cool, tingling, pleasant aftertaste. Panelists for the most part perceived Comparative Example 2 to be pleasant but lacking in the robustness and impact of Embodiment 2.
Embodiment 3
Embodiment 3 was prepared by mixing 4-(1-menthoxy-methyl)-2,3′-methoxy-4′-hydroxyphenyl)-1,3-dioxolane, ginger oleoresin, vanillyl butyl ether and Jambu Oleoresin with other ingredients according to the following candy formulation which was prepared in accord with methods well known in the art.
Ingredient
Percentage
medium chain triglycerides
82.0
vanillyl butyl ether
7.5
ginger oleoresin
3.1
capsicum oleoresin
0.1
4-(1-menthoxy-methyl)-2,3′-methoxy-4′-
4.0
hydroxyphenyl)-1,3-dioxolane
menthol
1.0
Jambu Oleoresin
3.0
COMPARATIVE EXAMPLE 3
Comparative Example 3 was prepared in the same manner as Embodiment 3, except no Jambu Oleoresin was used.
A panel group was convened to evaluate Embodiment 3 and Comparative Example 3 in random blind fashion and comment on any noted differences. Eight members of a panel trained as Flavorists evaluated the product. Members of the panel reported a tingling sensation upon first contact with the candy. No delay in perceived sensation was reported. Analysis of panelists comments showed a marked enhancement of the warming sensation was realized in Embodiment 3 as compared to Comparative Example 3. The onset of the flavor was more pronounced in Embodiment 3 than in Comparative Example 3. Panelists observed Comparative Example 3 seemed to be less bright and slower to exhibit any unique sensations.
Embodiment 4 (E4)
Embodiment 4 was prepared by mixing menthol, 3-(1,2-menthoxy) propane-1,2-diol, vanillyl butyl ether and Jambu Oleoresin with other ingredients according to the following formulation. A cosmetic cologne or other similar product may be prepared from this formulation by admixture with known ingredients in accord with formulations well known in the art.
COMPARATIVE EXAMPLE 4 (CE4)
Comparative Example 4 was made in the same fashion as Embodiment 4, except that Jambu Oleoresin was omitted.
COMPARATIVE EXAMPLE 5 (CE5)
Comparative Example 5 was made in the same fashion as Embodiment 4, except that vanillyl butyl ether was omitted.
Amount (% by weight)
Ingredient
E 1
CE 1
CE 2
menthol
0.50
0.50
0.50
3-(1,2-menthoxy) propane-1,2-diol
0.50
0.50
0.50
Vanillyl butyl ether
0.05
0.05
—
Jambu extract (10% solution)
0.50
—
0.50
Ethanol (50% solution)
98.45
98.50
98.45
A formal panel evaluated Embodiment 4 and Comparative Examples 4 and 5 according to the following protocol. 0.1 ml of the composition was placed on a patch cloth and applied to the forearm of each of the panelists. The sensate compositions were evaluated for their relative performance in the following categories: cooling sensate, stimulation, emollient and comfort/preference. The results are reported in Table 1.
TABLE 1
Panelist (A-C)
and Time
Comfort/
Course
Cooling Sensate
Stimulation
Emollient
Preference
0 minutes
A
CE4 > E5 > CE5
CE4 > E5 > CE5
CE5 > E5 > CE4
E5 > CE5 = CE4
B
E5 = CE4 > CE5
CE4 > E5 > CE5
CE5 = E5 > CE4
E5 > CE5 > CE4
C
E5 = CE4 > CE5
CE4 > E5 > CE5
CE5 > E5 > CE4
E5 > CE4 > CE5
5 minutes
A
CE4 > E5 > CE5
CE4 > E5 > CE5
CE5 > E5 > CE4
E5 ≧ CE4 > CE5
B
E5 = CE4 > CE5
CE4 > E5 > CE5
CE5 = E5 > CE4
E5 > CE5 > CE4
C
E5 = CE4 > CE5
CE4 > E5 > CE5
CE5 > E5 > CE4
E5 > CE4 > CE5
10 minutes
A
CE4 > E5 > CE5
CE4 > E5 > CE5
CE5 > E5 > CE4
E5 > CE5 = CE4
B
CE4 > E5 > CE5
CE4 > E5 > CE5
CE5 = E5 > CE4
E5 > CE4 > CE5
C
E5 > CE4 = CE5
CE4 > E5 > CE5
CE5 = E5 > CE4
E5 > CE4 = CE5
The results showed that the addition of Jambu Oleoresin increased the emollient effect on menthol and vanillyl butyl ether without losing cooling effect. Almost all panelists preferred Embodiment 4 over Comparative Examples 4 and 5.
Having described preferred embodiments of the invention with reference to the accompanying drawings, it is to be understood that the invention is not limited to those precise embodiments, and that various changes and modifications may be effected therein by one skilled in the art without departing from the scope or spirit of the invention as defined in the appended claims.
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The present invention is directed to a sensate composition including at least one cooling sensate, warming sensate and tingling sensate. The tingling sensate is at least one of Jambu Oleoresin and Spilanthol. The present invention is further directed to a method of using the sensate composition in a food, pharmaceutical or personal care product.
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STATEMENT AS TO FEDERALLY SPONSORED RESEARCH
This invention was made with support from the National Institute of Health (Grant No. R01-CA39237). Accordingly, the U.S. government may have certain rights in the invention.
FIELD OF THE INVENTION
The present invention relates generally to the manipulation of genetic materials, and, more particularly, to recombinant DNA procedures which make possible the identification of novel DNA sequences and polypeptides encoded thereby.
BACKGROUND OF THE INVENTION
Bombesin, a tetradecapeptide amide first isolated from the skin of the frog Bombina bombina, is a potent mitogen for mouse Swiss 3T3 fibroblast cells. It also stimulates secretion for guinea pig pancreatic acini. Bombesin-like peptides are produced and secreted by human small cell lung cancer cells and exogenously added bombesin-like peptides can stimulate the growth of human SCLC cells in vitro. Two examples of bombesin-like peptides are gastrin releasing peptide (GRP) and neuromedin B (NMB).
GRP is a 27 amino acid peptide amide and was first isolated from the porcine gut. The C-terminal amino acid sequence of GRP is almost identical to that of bombesin. NMB, on the other hand, is a decapeptide amide, the structure of which is almost identical to the last ten amino acids in the C-terminal region of GRP. Both GRP and NMB share high amino acid sequence homology with bombesin and indeed possess bombesin-like properties. Other bombesin-like peptides include litorin and neuromedin C (NMC).
Recent structure-function and DNA cloning studies demonstrate that at least two classes of receptors mediate the action of bombesin-like peptides. One class, the GRP preferring subtype (GRP receptor), has a high affinity for GRP and a low affinity for NMB, whereas the other class, the NMB-preferring subtype (NMB receptor), has a high affinity for NMB and lower affinity for GRP. Both classes of receptors are widely present both in the central nervous system and in the gastrointestinal tract. A third receptor class, the BRS-3 receptor, has recently been found in both rat testes and pregnant uteruses. Unlike the GRP and NMB receptors, none of the presently known bombesin-like peptide binds with high affinity (K d <25 nM) to the BRS-3 receptor.
SUMMARY OF THE INVENTION
We have discovered novel genes which code for receptors capable of binding to bombesin-like peptides. The term "bombesin-like peptide" used here and below refers to a peptide capable of binding with a K d less than 1 μM to either the GRP receptor, the NMB receptor, the BRS-3 receptor, or to any other bombesin receptor subtypes such as the BB4 and BB5 receptors described below. Examples of bombesin-like peptides include, but are not limited to, bombesin, GRP, NMB, NMC, BB4 and BB5.
Accordingly, in one aspect, the invention features a pure nucleic acid (for example, genomic DNA, cDNA, or RNA) encoding a receptor for a bombesin-like peptide, the receptor including SEQ ID NO: 2, SEQ ID NO: 4, or SEQ ID NO: 6 (e.g., either as the entirety of the receptor or as a fragment thereof). In other words, a pure nucleic acid which encodes a receptor for a bobmesin-like peptide and includes SEQ ID NO: 1, SEQ ID NO: 3, or SEQ ID NO: 5; or a degenerate variant thereof embodies an aspect of this invention.
The invention also features a pure nucleic acid which (i) is capable of hybridizing to SEQ ID NO: 1, SEQ ID 5 NO: 3, or SEQ ID NO: 5 under a high- or a low-stringency hybridization condition; and (ii) encodes a receptor protein for a bombesin-like peptide. By "low-stringency hybridization condition" is meant: prehybridization in 25% formamide, 5× SSC, 25 mM potassium phosphate buffer (pH 7.4), 5× Denhardt's, and 50 μg/ml denatured salmon sperm DNA for 4-12 hours at 37° C. which is followed by hybridization for 12-24 hours at 37° C. and washing in 2× SSC containing 0.1% SDS, at 42° C.; or an equivalent thereof. By "high-stringency hybridization condition" is meant: prehybridization in 50% formamide, 5× SSC, 25 mM potassium phosphate buffer (pH 7.4), 5× Denhardt's, and 50 μg/ml denatured salmon sperm DNA for 4-12 hours at 37° C., which is followed by hybridization for 12-24 hours at 37° C. and washing in 2× SSC containing 0.1% SDS, at 55° C.; or an equivalent thereof. E.g., see Sambrook, et al. Molecular Cloning, A Laboratory Manual, 2nd Ed. Cold Spring Harbor Laboratory Press, New York (1989), hereby incorporated by reference.
In related aspects, a cell containing one of the nucleic acids mentioned above, and a vector which includes such a nucleic acid and is capable of directing expression of the peptide encoded by that nucleic acid in a vector-containing cell are also within the scope of this invention.
Other embodiments include a pure receptor protein encoded by a nucleic acid of this invention which is capable of binding to a bombesin-like peptide, and a pure antibody which is specific for such a receptor protein.
In another aspect, this invention features a method of screening for a compound capable of interacting with a receptor protein for a bombesin-like peptide, the method comprising the steps of: (i) providing a cell which expresses a receptor protein of this invention (e.g., a native cell expressing the receptor obtained from the brain tissue, a frog egg into which mRNA encoding the receptor is introduced, or a host cells into which DNA encoding the receptor protein is introduced for expression); (ii) contacting the compound with the receptor protein expressed by the cell; and (iii) detecting an interaction, if any, between the compound and the receptor protein (e.g., binding or any biochemical response as a result of the binding).
By "pure nucleic acid" is meant a nucleic acid that is free or substantially free (i.e., at least 60% by weight free) of the DNA or RNA sequences which, in the naturally-occurring genome of the organism from which the nucleic acid of the invention is derived, flank it. The term therefore includes, for example, a recombinant DNA which is incorporated into a vector, into an autonomously replicating plasmid or virus, or into the genomic DNA of a prokaryote or eukaryote; or which exists as a separate molecule (e.g., a cDNA or a genomic or cDNA fragment produced by PCR or restriction endonuclease digestion) independent of other sequences. It also includes a recombinant DNA which is part of a hybrid gene encoding additional polypeptide sequence. Chemically synthesized nucleic acids are also encompassed.
By "protein" is meant any chain of amino acids, regardless of length or post-translational modification (e.g., glycosylation or phosphorylation).
By "pure receptor protein" or "pure antibody" is meant a receptor protein or antibody which has been substantially separated from components which naturally accompany it, i.e., it is at least 60%, by weight, free from the proteins and naturally-occurring organic molecules with which it is naturally associated. A pure protein (i.e., a receptor protein or an antibody of this invention) may be obtained, for example, by extraction from a natural source, by expression of a recombinant nucleic acid, or by chemical synthesis. Purity can be measured by any appropriate method, e.g., those described in column chromatography, polyacrylamide gel electrophoresis, or by HPLC analysis.
Other features and advantages of the invention will be apparent from the following description and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings are first briefly described.
FIG. 1 is a nucleotide sequence (SEQ ID NO:1) encoding the frog BB4 receptor; the encoded amino acid sequence (SEQ ID NO:2) is also shown.
FIG. 2 is a graph showing the responses to exogenous bombesin of Xenopus oocytes injected respectively with RNA's encoding the human GRP receptor and the frog BB4 receptor.
DETAILED DESCRIPTION OF THE INVENTION
Insertion of a DNA sequence of this invention into a vector, introduction of the recombinant vector thus obtained into a host cell, and subsequent expression of a receptor protein encoded by the inserted DNA sequence can be performed to produce that receptor protein. Such techniques are well known to a person of ordinary skill in the art, and in any event can be found in the literature, e.g., Sambrook, et al. Molecular Cloning, A Laboratory Manual, 2nd Ed. Cold Spring Harbor Laboratory Press, New York (1989), hereby incorporated by reference. Note that all nucleic acid sequences of this invention can be readily prepared by a person of ordinary skill in the art employing one or more the DNA sequences disclosed herein.
A receptor of this invention or its fragment (produced recombinantly, synthetically, or by conventional purification methods) can be used to generate an antibody (monoclonal or polyclonal) to be used as a diagnostic tool for detecting that receptor on cells from a given tissue, since the presence or expression level of that receptor may be related to cancer or other disorders. Of course, such an antibody can also be generated using a peptide fragment (e.g., a fragment of that receptor) which has at least one antigenic determinant that is immunologically reactive with an antigenic determinant of that receptor. Methods of generating and collecting such an antibody are well known in the art. For example, see Harlow et al., Antibodies--Laboratory Manual (1988, Cold Spring Harbor Laboratory), which is hereby incorporated by reference.
Conversely, any positively identified cells can be used to screen for compounds (e.g., a synthetic compound or the native ligand of that receptor) which interact with that receptor in various ways. As an example, bombesin-like peptides are produced and secreted by human small cell lung cancer cells (see BACKGROUND OF THE INVENTION above). Thus, some of the positively identified compounds (agonists or antagonists) can be used in the diagnosis or treatment of small cell lung cancer.
One way of detecting an interaction between a compound and the receptor of this invention is to monitor changes in intracellular calcium, as demonstrated in an actual example shown below. Alternatively, binding assays can be performed in screening for compounds which interact with the receptor. For experimental details, see von Schrenck T., et al. Am. J. Physiol. 1989; 256:G747-G758; and Moody T. W., et al., Methods Enzymol. 1989; 168:481-493, both of which are hereby incorporated by reference.
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. The following specific embodiments are, therefore, to be construed as merely illustrative, and not limitative of the remainder of the disclosure in any way whatsoever.
Identification of novel receptors for bombesin-like peptides
The rat, mouse, and human GRP receptors and the human and rat NMB receptors were aligned in a manner described in Spindel, et al., Recent. Prog. Horm. Res. 1993; 48:365, 380-81, which is hereby incorporated by reference. This multiple alignment indicated certain conserved regions, based on which PCR primers and probes were prepared as tools used to look for novel receptors for bombesin-like peptides. More specifically, the following primers/probes were prepared: AT(ACT) CA(AG) CTI ACI TCI GTI GGI GTI TCI GT (SEQ ID NO: 7); (GA)TA IAG IGC (GA)AA IGG (AG)TT IAC (GA)CA IGA (GA)TT (SEQ ID NO: 8); (AC)G(ACGT) AA(AG) (AC)G(ACGT) (CT)T(ACGT) GC(ACGT) AA (SEQ ID NO: 9); and CC(ACGT) AC(GA) AA(ACGT) AC(ACGT) A(GA)(ACGT) AC (SEQ ID NO: 10). All primers/probes are written 5' to 3' mixed residues are shown in parentheses, and the symbol "I" denotes deoxyinosine.
Total RNA was then prepared by homogenization of frog brain (Bombina orientalis) in guanidine thiocyanate followed by centrifugation through CsCl. 5 μg total RNA was reverse transcribed with 25 pmole oligo(dT 18 ), 200 units of M-MLV reverse transcriptase (GIBCO-BRL, Gaithersburg, Md.), 5× buffer (250 mM Tris-HCl, pH 8.3; 375 mM KCl, 15 mM MgCl 2 , 50 mM DTT, 2.5 mM dNTP's) in 20 μl total volume at 37° C. for 1 hour. The entire reverse transcription was used in a 100 μl PCR reaction using 100 pmoles of SEQ ID NO: 7 and 100 pmoles of SEQ ID NO: 8. PCR conditions consisted of one cycle at 92° C.×2 min, 55° C.×2 min, 72° C.×3 min for second strand synthesis, followed by 35 cycles of 92° C.×40 sec, 55° C.×1 min, 72° C.×2 min. A 20 μl-aliquot of this reaction was separated on a 1% agarose gel, transferred to a Nylon membrane and hybridized to two 32 P-end labelled internal oligonucleotide probes (SEQ ID NO: 9 and SEQ ID NO: 10). The hybridizing product was subcloned into PGEM-T vector (Promega, Madison, Wis.) and sequenced as described in Nagalla, et al., J. Biol. Chem. 1992; 267:6916-22, which is hereby incorporated by reference.
Sequence analysis of multiple clones revealed a nucleotide sequence corresponding to position 585-position 1178 of SEQ ID NO: 1, which encoded amino acid sequence corresponding to position 132-position 329 of SEQ ID NO: 2. Both SEQ ID NO: 1 and 2 are shown in FIG. 1. The homology of the encoded amino acid sequence with the GRP, NMB and BRS-3 receptors was analyzed. The encoded amino acid sequence showed a 70.7% homology with the BRS-3 receptor, a 61.1% homology with the GRP receptor, and a 51.1% homology with the NMB receptor. These results suggested that this newly discovered encoded amino acid sequence represented a new receptor subtype, which is designated as frog BB4 receptor. To prove that this receptor was not the GRP or NMB receptor, other clones were isolated from frog stomach, brain and skin mRNA that had higher (>80% homology) with their mammalian counterparts.
A cDNA library was next constructed from B. orientalis brain in the vector λZAP II (Stratagene, Inc., La Jolla, Calif.) using reagents and protocols provided by the supplier. To screen the cDNA library, a 32 P-labeled cRNA probe was prepared from the nucleotide sequence which corresponds to position 585-position 1178 of SEQ ID NO: 1 using the T7 promoter in the PGEM-T vector. A hybridizing clone was isolated and found to encode the full coding sequence of the Bombina orientalis BB4 receptor. See SEQ ID NO: 1 and 2 in FIG. 1. As will be set forth below, functional studies showed that frog BB4 receptor potently responded to bombesin, suggesting that this new receptor represents the prototype receptor for the bombesin/ranatensin branch of the bombesin-like peptides and is different from the BRS-3 receptor which does not respond to bombesin.
The cDNA encoding the frog BB4 receptor was then used to screen a monkey brain cDNA library (purchased from Clontech, Inc., Palo Alto, Calif.) at low stringency (25% formamide, 5× SSC, 37° C. with washing at 50° C. in 2× SSC). Multiple hybridizing clones were isolated. Sequence analysis of the clones revealed two subtypes with partial sequences: monkey BB4 (SEQ ID NO: 3) and monkey BB5 (SEQ ID NO: 5), which encode SEQ ID NO: 4 and SEQ ID NO: 6, respectively. Monkey BB4 appears highly homologous to frog BB4, i.e., an 88.1% homology in the 84 amino acid overlap. SEQ ID NO: 3, 4, 5 and 6 are shown below:
CAGACATCTG ACGCGGTGTT GAAGACGTGC GGCAAAGCTG TTTGTGTTTG GATTATCTCC ATGCTACTTG CTGCCCCTGA GGCAGTGTTT TCGGATTTGT ATGAATTCAC CAGCCCTGAC AAGAATATGT CCTTCAAAAC ATGTGCCCCT TATCCTGTTT CTGAAAAGCT ACTGCAAGAG ACACATTCGC TGATGTGCTT CTTAGTGTTC TATATTATTC CCTTGTCTAT TATCTCCGCC TACTACTTCC TC SEQ ID NO: 3
Gln Thr Ser Asp Ala Val Leu Lys Thr Cys Gly Lys Ala Val Cys Val Trp Ile Ile Ser Met Leu Leu Ala Ala Pro Glu Ala Val Phe Ser Asp Leu Tyr Glu Phe Thr Ser Pro Asp Lys Asn Met Ser Phe Lys Thr Cys Ala Pro Tyr Pro Val Ser Glu Lys Leu Leu Gln Glu Thr His Ser Leu Met Cys Phe Leu Val Phe Tyr Ile Ile Pro Leu Ser Ile Ile Ser Ala Tyr Tyr Phe Leu SEQ ID NO: 4
CAGACCTCAG ATGCTGTGCT GAAGACCTGT GCCAAAGCTG GTGGCATCTG GATCATGGCT ATGATATTTG CTCTGCCAGA GGCTATATTC TCAAATGTAT ACACTTTCCA AGGTCCTAAC AGAAACGTAA CATTTGAATC CTGTAACTCC TACCCTATCT CTGAGAGGCT TTTGCAGGAA ATACATTCTC TGTTGTGTTT CTTGGTGTTC TACATTATCC CGCTCTCGAT TATCTCCGCC TATTACTTCC SEQ ID NO: 5
Gln Thr Ser Asp Ala Val Leu Lys Thr Cys Ala Lys Ala Gly Gly Ile Trp Ile Met Ala Met Ile Phe Ala Leu Pro Glu Ala Ile Phe Ser Asn Val Tyr Thr Phe Gln Gly Pro Asn Arg Asn Val Thr Phe Glu Ser Cys Asn Set Tyr Pro Ile Ser GluArg Leu Leu Gln Glu Ile His Ser Leu Leu Cys Phe Leu Val Phe Tyr Ile Ile Pro Leu Ser Ile Ile Ser Ala Tyr Tyr Phe SEQ ID NO: 6
Function studies (changes in intracellular calcium)
To prepare the receptor RNA for injection into Xenopus oocytes, the linearized cDNA encoding frog BB4 receptor, was phenol extracted, ethanol precipitated, and then transcribed with T7 or T3 RNA polymerase. Transcription reactions were carried out in a 50-100 μl volume containing 5-20 μg DNA template, 40 mM Tris (pH 7.9), 7 mM MgCl 2 , 10 mM DTT, 2 mM spermidine, 10 mM NaCl, 25 μg/ml BSA, 0.5 mM ATP, 0.5 mM UTP, 0.5 mM CTP, 0.2 mM GTP, 1 mM 7-Me GpppG (Pharmacia, Piscataway, N.J.), 50-100 units RNA polymerase and 125-250 units RNasin (Promega, Madison, Wis.). The reactions were incubated at 40° C. for 90 minutes, treated with FPLC purified DNase (Pharmacia, Piscataway, N.J.), phenol extracted twice, ethanol precipitated twice, and then resuspended in 5-10 μl H 2 O. See Julius, et al. Science 1988; 241:558-564, which is hereby incorporated by reference.
To measure bombesin-induced changes in intracellular calcium, the procedure described in Sandberg, et al. FEBS Lett 1988; 241:177-180 (hereby incorporated by reference) was followed with some modifications (see Spindel, et al., Mol. Endocrinol. 1990; 4:1956-1963; and Giladi, et al., Biotechniques 1991; 10:744-747) to determine, both of which are hereby incorproated by reference). More specifically, oocytes were removed from an albino Xenopus, treated with collagenase, defollicated, and then injected in the presence of OR-2 (a buffer solution suitable for frog oocytes) without calcium. The injection needles were rinsed with 1 mM EDTA before each use. For injection, the transcribed RNA (typically, 1-2 μl) was dried down and then suspended in an equal volume of an aequorin solution. The aequorin solution was prepared at a concentration of 1 mg/ml in 1 mM EDTA and stored in aliquots at -85° C. Aequorin was obtained from Friday Harbor Photoproteins, Friday Harbor, Wash.
To record the bombesin-induced response, oocytes were placed in 500 μl OR-2 in 12×55 mm disposable polystyrene tubes in a luminometer. Light output from the oocyte as recorded by the luminometer is a function of ligand-induced increases in intracellular calcium. The baseline response to OR-2 was first recorded, followed by the recording of the response to bombesin.
As a positive control, Xenopus oocytes containing exogenous human GRP receptor were also prepared and assayed in analogous manners.
FIG. 2 demonstrates the respective responses of GRP and BB4 receptors to 1 nM (in the OR-2 buffer) of bombesin. It is clear that the BB4 receptor, unlike the BRS-3 receptor, potently responded to bombesin.
OTHER EMBODIMENTS
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 claims.
For example, contemplated equivalents of this invention include nucleic acid or peptide sequences which are substantially identical to those clearly described above and explicitly claimed below. By "substantially identical" is meant a nucleic acid or peptide exhibiting at least 50%, preferably 85%, more preferably 90%, and most preferably 95% homology to a reference amino acid or nucleic acid sequence. For peptides, the length of comparison sequences will generally be at least 16 amino acids, preferably at least 20 amino acids, more preferably at least 25 amino acids, and most preferably 35 amino acids. For nucleic acids, the length of comparison sequences will generally be at least 50 nucleotides, preferably at least 60 nucleotides, more preferably at least 75 nucleotides, and most preferably 110 nucleotides.
Sequence identity is typically measured using sequence analysis software (e.g., Sequence Analysis Software Package of the Genetics Computer Group, University of Wisconsin Biotechnology Center, 1710 University Avenue, Madison, Wis. 53705). Such software matches similar sequences by assigning degrees of homology to various substitutions, deletions, substitutions, and other modifications. Conservative substitutions typically include substitutions within the following groups: (i) glycine, alanine; (ii) valine, isoleucine, leucine; (iii) aspartic acid, glutamic acid, asparagine, glutamine; (iv) serine, threonine; (v) lysine, arginine; and (vi) phenylalanine, tyrosine.
Furthermore, nucleic acide and peptides which are allelic variations, natural mutants, and induced mutants are also within the scope of this invention.
Still other contemplated equivalents of this invention include peptides which are shorter than a receptor of this invention (e.g., a fragment thereof) which has at least one antigenic determinant that is immunologically reactive with an antigenic determinant of that receptor.
Other embodiments are also within the claims set forth below.
__________________________________________________________________________SEQUENCE LISTING(1) GENERAL INFORMATION:(iii) NUMBER OF SEQUENCES: 10(2) INFORMATION FOR SEQ ID NO: 1:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 1563(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(xi) SEQUENCE DESCRIPTION: SEQ ID NO: 1:CACGAGTGCAAGCACTAAACCACCCTAGTGCTGATGAGAGCTGTGATTTCTGGAGATACC60GAGTTTGTGGACATCAATTAGGTTTCATTTGTGGAACTTTAATTGAGGTCACTTGTGTGC120TGCAATTCATGAACTTGAAACTGCTGAAGAAGAAATTTGGAACAACTGAATTTTATTTAG180ATTAAAAAAAAATGCCTGAAGGTTTTCAGTCACTTAACCAGACATTGCCA230MetProGluGlyPheGlnSerLeuAsnGlnThrLeuPro1510TCTGCTATAAGTAGCATAGCTCATTTGGAATCCCTTAATGACAGTTTC278SerAlaIleSerSerIleAlaHisLeuGluSerLeuAsnAspSerPhe152025ATTTTAGGTGCAAAGCAAAGTGAAGATGTATCCCCTGGGTTAGAAATA326IleLeuGlyAlaLysGlnSerGluAspValSerProGlyLeuGluIle30354045CTGGCTCTAATTTCTGTCACATATGCTGTTATTATTTCTGTCGGTATC374LeuAlaLeuIleSerValThrTyrAlaValIleIleSerValGlyIle505560CTTGGAAACACAATACTTATAAAAGTATTTTTTAAAATCAAGTCAATG422LeuGlyAsnThrIleLeuIleLysValPhePheLysIleLysSerMet657075CAGACTGTTCCTAATATTTTCATCACCAGCCTGGCTTTTGGAGATCTT470GlnThrValProAsnIlePheIleThrSerLeuAlaPheGlyAspLeu808590CTTCTACTGCTGACCTGCGTGCCAGTGGACGCATCTCGGTATATTGTG518LeuLeuLeuLeuThrCysValProValAspAlaSerArgTyrIleVal95100105GACACGTGGATGTTTGGAAGAGCTGGCTGTAAGATAATTTCCTTCATA566AspThrTrpMetPheGlyArgAlaGlyCysLysIleIleSerPheIle110115120125CAGCTTACCTCTGTCGGAGTGTCGGTGTTTACTTTAACTGTCCTCAGT614GlnLeuThrSerValGlyValSerValPheThrLeuThrValLeuSer130135140ACTGACAGGTACAGAGCCATTGTGAAACCCTTGCAATTGCAGACCTCA662ThrAspArgTyrArgAlaIleValLysProLeuGlnLeuGlnThrSer145150155GATGCCGTTTTGAAGACATGTGGCAAAGCTGTTTGTGTTTGGATCATT710AspAlaValLeuLysThrCysGlyLysAlaValCysValTrpIleIle160165170TCCATGCTCCTCGCTGCTCCAGAAGCTGTGTTCTCAGATTTGTATGAA758SerMetLeuLeuAlaAlaProGluAlaValPheSerAspLeuTyrGlu175180185TTTGGCAGCTCGGAAAAAAATACCACTTTTGAAGCCTGTGCTCCATAT806PheGlySerSerGluLysAsnThrThrPheGluAlaCysAlaProTyr190195200205CCAGTCTCTGAAAAGATTCTGCAAGAGACACATTCCCTAATATGCTTC854ProValSerGluLysIleLeuGlnGluThrHisSerLeuIleCysPhe210215220CTGGTATTCTACATTGTTCCCCTGTCAATCATTTCTGCATATTACTTC902LeuValPheTyrIleValProLeuSerIleIleSerAlaTyrTyrPhe225230235CTTATTGCAAAAACCCTGTACAAAAGTACTTTCAACATGCCTGCTGAA950LeuIleAlaLysThrLeuTyrLysSerThrPheAsnMetProAlaGlu240245250GAGCACACTCACGCCCGAAAACAGATAGAATCGCGCAAACGAGTGGCA998GluHisThrHisAlaArgLysGlnIleGluSerArgLysArgValAla255260265AAAACTGTGTTGGTGTTGGTGGCATTGTTCGCAGTGTGCTGGTTGCCA1046LysThrValLeuValLeuValAlaLeuPheAlaValCysTrpLeuPro270275280285AACCACATGCTCTACTTGTATCGATCCTTCACATATCACTCCGCAGTG1094AsnHisMetLeuTyrLeuTyrArgSerPheThrTyrHisSerAlaVal290295300AATTCCTCTGCGTTTCACCTGTCAGCCACAATCTTTGCGCGAGTACTG1142AsnSerSerAlaPheHisLeuSerAlaThrIlePheAlaArgValLeu305310315GCTTTGCGCAATTCCTGCGTCAACCCCTTCGCCCTCTATTGGCTAAGC1190AlaLeuArgAsnSerCysValAsnProPheAlaLeuTyrTrpLeuSer320325330AAGAGCTTTAGGCAGCATTTTAAAAAGCAAGTGTATTGTTGTAAGACT1238ArgSerPheArgGlnHisPheLysLysGlnValTyrCysCysLysThr335340345GAACCTCTGCATCCAACAAAGTCCGACCCACAGCAGTACCATAACTGG1286GluProLeuHisProThrLysSerAspProGlnGlnTyrHisAsnTrp350355360365AATTACCGCTGTGAAAGGCAACATCCAGATGTCTGAAATTAGC1329AsnTyrArgCysGluArgGlnHisProAspVal370375ATTACATTATTAAGTGCTTACGATGTAAAGAAAGAGTGACAGTGTCGCCAAATAAGTTAT1389AAAAAGTTTATAAAACTTACTGTAAACAAAAGATGGATAAAGTTTTTGTTGCTGCATATT1449GACGTCTGTTTATTAAAAATCCAGAGTATAAAGTTTTATTACTACAAACAAAAAAATATA1509CCTCAACATTCTAACCACAATTGAATTATTCATATATTACCCTTATTTATTCAG1563(2) INFORMATION FOR SEQ ID NO: 2:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 376(B) TYPE: amino acid(C) STRANDEDNESS: single(D) TOPOLOGY: Not Relevant(xi) SEQUENCE DESCRIPTION: SEQ ID NO: 2:MetProGluGlyPheGlnSerLeuAsnGlnThrLeuProSerAlaIle151015SerSerIleAlaHisLeuGluSerLeuAsnAspSerPheIleLeuGly202530AlaLysGlnSerGluAspValSerProGlyLeuGluIleLeuAlaLeu354045IleSerValThrTyrAlaValIleIleSerValGlyIleLeuGlyAsn505560ThrIleLeuIleLysValPhePheLysIleLysSerMetGlnThrVal65707580ProAsnIlePheIleThrSerLeuAlaPheGlyAspLeuLeuLeuLeu859095LeuThrCysValProValAspAlaSerArgTyrIleValAspThrTrp100105110MetPheGlyArgAlaGlyCysLysIleIleSerPheIleGlnLeuThr115120125SerValGlyValSerValPheThrLeuThrValLeuSerThrAspArg130135140TyrArgAlaIleValLysProLeuGlnLeuGlnThrSerAspAlaVal145150155160LeuLysThrCysGlyLysAlaValCysValTrpIleIleSerMetLeu165170175LeuAlaAlaProGluAlaValPheSerAspLeuTyrGluPheGlySer180185190SerGluLysAsnThrThrPheGluAlaCysAlaProTyrProValSer195200205GluLysIleLeuGlnGluThrHisSerLeuIleCysPheLeuValPhe210215220TyrIleValProLeuSerIleIleSerAlaTyrTyrPheLeuIleAla225230235240LysThrLeuTyrLysSerThrPheAsnMetProAlaGluGluHisThr245250255HisAlaArgLysGlnIleGluSerArgLysArgValAlaLysThrVal260265270LeuValLeuValAlaLeuPheAlaValCysTrpLeuProAsnHisMet275280285LeuTyrLeuTyrArgSerPheThrTyrHisSerAlaValAsnSerSer290295300AlaPheHisLeuSerAlaThrIlePheAlaArgValLeuAlaLeuArg305310315320AsnSerCysValAsnProPheAlaLeuTyrTrpLeuSerArgSerPhe325330335ArgGlnHisPheLysLysGlnValTyrCysCysLysThrGluProLeu340345350HisProThrLysSerAspProGlnGlnTyrHisAsnTrpAsnTyrArg355360365CysGluArgGlnHisProAspVal370375(2) INFORMATION FOR SEQ ID NO: 3:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 252(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(xi) SEQUENCE DESCRIPTION: SEQ ID NO: 3:CAGACATCTGACGCGGTGTTGAAGACGTGCGGCAAAGCTGTTTGTGTT48GlnThrSerAspAlaValLeuLysThrCysGlyLysAlaValCysVal151015TGGATTATCTCCATGCTACTTGCTGCCCCTGAGGCAGTGTTTTCGGAT96TrpIleIleSerMetLeuLeuAlaAlaProGluAlaValPheSerAsp202530TTGTATGAATTCACCAGCCCTGACAAGAATATGTCCTTCAAAACATGT144LeuTyrGluPheThrSerProAspLysAsnMetSerPheLysThrCys354045GCCCCTTATCCTGTTTCTGAAAAGCTACTGCAAGAGACACATTCGCTG192AlaProTyrProValSerGluLysLeuLeuGlnGluThrHisSerLeu505560ATGTGCTTCTTAGTGTTCTATATTATTCCCTTGTCTATTATCTCCGCC240MetCysPheLeuValPheTyrIleIleProLeuSerIleIleSerAla65707580TACTACTTCCTC252TyrTyrPheLeu84(2) INFORMATION FOR SEQ ID NO: 4:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 84(B) TYPE: amino acid(C) STRANDEDNESS: Not Relevant(D) TOPOLOGY: Not Relevant(xi) SEQUENCE DESCRIPTION: SEQ ID NO: 4:GlnThrSerAspAlaValLeuLysThrCysGlyLysAlaValCysVal151015TrpIleIleSerMetLeuLeuAlaAlaProGluAlaValPheSerAsp202530LeuTyrGluPheThrSerProAspLysAsnMetSerPheLysThrCys354045AlaProTyrProValSerGluLysLeuLeuGlnGluThrHisSerLeu505560MetCysPheLeuValPheTyrIleIleProLeuSerIleIleSerAla65707580TyrTyrPheLeu84(2) INFORMATION FOR SEQ ID NO: 5:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 250(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(xi) SEQUENCE DESCRIPTION: SEQ ID NO: 5:CAGACCTCAGATGCTGTGCTGAAGACCTGTGCCAAAGCTGGTGGCATC48GlnThrSerAspAlaValLeuLysThrCysAlaLysAlaGlyGlyIle151015TGGATCATGGCTATGATATTTGCTCTGCCAGAGGCTATATTCTCAAAT96TrpIleMetAlaMetIlePheAlaLeuProGluAlaIlePheSerAsn202530GTATACACTTTCCAAGGTCCTAACAGAAACGTAACATTTGAATCCTGT144ValTyrThrPheGlnGlyProAsnArgAsnValThrPheGluSerCys354045AACTCCTACCCTATCTCTGAGAGGCTTTTGCAGGAAATACATTCTCTG192AsnSerTyrProIleSerGluArgLeuLeuGlnGluIleHisSerLeu505560TTGTGTTTCTTGGTGTTCTACATTATCCCGCTCTCGATTATCTCCGCC240LeuCysPheLeuValPheTyrIleIleProLeuSerIleIleSerAla65707580TATTACTTCC250TyrTyrPhe83(2) INFORMATION FOR SEQ ID NO: 6:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 83(B) TYPE: amino acid(C) STRANDEDNESS: Not Relevant(D) TOPOLOGY: Not Relevant(xi) SEQUENCE DESCRIPTION: SEQ ID NO: 6:GlnThrSerAspAlaValLeuLysThrCysAlaLysAlaGlyGlyIle151015TrpIleMetAlaMetIlePheAlaLeuProGluAlaIlePheSerAsn202530ValTyrThrPheGlnGlyProAsnArgAsnValThrPheGluSerCys354045AsnSerTyrProIleSerGluArgLeuLeuGlnGluIleHisSerLeu505560LeuCysPheLeuValPheTyrIleIleProLeuSerIleIleSerAla65707580TyrTyrPhe83(2) INFORMATION FOR SEQ ID NO: 7:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 29(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ix) FEATURE:(D) OTHER INFORMATION: N at each of positions 9, 12, 15,18, 21, 24 and 27 is deoxyinosine(xi) SEQUENCE DESCRIPTION: SEQ ID NO: 7:ATHCARCTNACNTCNGTNGGNGTNTCNGT29(2) INFORMATION FOR SEQ ID NO: 8:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 30(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ix) FEATURE:(D) OTHER INFORMATION: N at each of positions 4, 7, 13, 19and 25 is deoxyinosine(xi) SEQUENCE DESCRIPTION: SEQ ID NO: 8:RTANAGNGCRAANGGRTTNACRCANGARTT30(2) INFORMATION FOR SEQ ID NO: 9:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 17(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ix) FEATURE:(D) OTHER INFORMATION: N at each of positions 3, 9, 12 and15 is A, C, G or T(xi) SEQUENCE DESCRIPTION: SEQ ID NO: 9:MGNAARMGNYTNGCNAA17(2) INFORMATION FOR SEQ ID NO: 10:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 17(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ix) FEATURE:(D) OTHER INFORMATION: N at each of positions 3, 9, 12 and15 is A, C, G or T(xi) SEQUENCE DESCRIPTION: SEQ ID NO: 10:CCNACRAANACNARNAC17__________________________________________________________________________
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Pure nucleic acids encoding novel receptors for bombesin-like peptides, the novel receptors themselves, and their antibodies. Also disclosed is a method of screening for a compound capable of interacting with any of these novel receptors.
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BACKGROUND OF THE INVENTION
The present invention relates generally to printed circuit boards (PCB), and more particularly to printed circuit boards laminated without fiber reinforced binders.
Current market trends in the electronic industry are to decrease size while increasing device speed, capability and interconnection density. A high interconnection density requires multilayer printed circuit boards having two or more layers of interconnections. Typically, there are four to eight layers, as specified, for example, by the Personal Computer Memory Card International Association (PCMCIA) manufacturing guidelines and tending to steadily rise.
Increased signal speed creates a greater need for component and circuitry impedance matching. Current technological developments require less distortion in signal propagation and a need for controlled impedance for impedance matching. High signal propagation speed requires a lower insulator dielectric constant. Reduced cross-talk requires reduced dielectric thickness, and cost and waste must be minimized.
Current state of the art multilayer printed circuit boards consist of two or more layers of patterned conductive sheets separated by an insulating material consisting of a glass fiber reinforced resin. Interconnections between different layers are provided using via holes through the insulating material plated with metal. Via holes may be through holes, blind vias or buried vias. Through holes pass through the entire thickness of the printed circuit board. Blind vias and buried vias pass through only part of the board, with the blind vias having an end exposed, and the buried vias having neither one of the ends exposed.
Multilayer PC boards are produced by laminating cores, prepreg and optionally carrier-mounted copper foil. Prepregs are sheets of glass fiber reinforced resin which is dried but not cured. This material is called "B" stage. Cores are fully cured ("C" stage) fiber reinforced resin (core material) covered with copper foil, usually on both sides. "A" stage is the resin compound in a liquid form with its solvent carrier.
After patterning the copper on the "inner layers" and subjecting them to an oxide process as known in the art, the cores are stacked with prepreg inserted between them. The outermost components of the stack are cores (core cap) or carrier-mounted copper foil (foil cap). The stack is laminated using heat and pressure such that the resin in the prepreg is fully cured. Plated via holes may be provided for interlayer contact by mechanically, laser or plasma drilling through the laminated structure followed by copper plating. Blind vias may be provided by laser or plasma drilling partly through the structure followed by plating, or by laminating a subassembly, providing through-holes and then laminating an additional layer on one side followed by plating. Buried vias may be provided by producing a blind via and laminating additional layers on the exposed end of the hole or by providing a through hole and laminating additional layers on both sides. Between drilling and the additional laminating, the following steps are carried out. The through holes are electroless plated with copper, the exposed copper is patterned, and then additional copper is electroplated onto the traces.
Blind vias may be provided by laser/plasma drilling because the hole stops when reaching a copper layer. The laser/plasma drilling is uneven if the material is inhomogeneous. Blind vias cannot be produced directly by mechanical drilling.
Heat sinks may be attached to printed circuit boards by using an adhesive sheet with openings cut in the areas where components will be assembled.
Conventional PCB fabrication methods require 8 to 28 mils (thousandths of an inch) core material thickness to build 4 to 10 layers into a circuit board; 5 mil core material is employed for applications requiring more than 10 layers. Standard glass reinforced prepreg has a dielectric constant of 4.3-4.6 at 1 MHz and a glass transition temperature (Tg) of approximately 130 C. Prepreg has a dielectric constant of 4.2 to 4.8 due to the combination of fiberglass dielectric constant of 6.3 and resin dielectric constant of 3.8. As discussed above, a reduced dielectric constant leads to an increased signal propagation velocity. For example, a 19% reduction in the dielectric constant results in a 11% rise of the signal propagation velocity.
To achieve a greater layer count in a multilayer board, the thickness of the prepreg material must be decreased to less than 5 mils. The minimum processing thickness of prepreg in production volumes is 3 to 5 mils. Thinner prepreg is more likely to provide insufficient resin during lamination. Processing material with a core thickness of less than 5 mils exceeds most current process and equipment designs and capabilities.
PCMCIA manufacturing guidelines specify a finished thickness of 30 mil maximum. Current conventional processes require 2 to 3 mil core material to achieve 6 to 8 layers with a thickness of less than 30 mil. Processing core material of less than 5 mil exceeds standard process capabilities in handling and transfer systems for conveyor driven processes. Upgrading to accommodate thinner material processing requires high capital investments.
Thinner PCB's require a single ply of prepreg (single fiberglass weave) for bonding inner layers. Suitable prepreg exceeds 2 mils thickness in a single ply and has a loose fiber weave. The result is overall mechanical weakness, poor dimensional stability and resin starvation.
Current restraints of laser and plasma drilling technology are the dissimilar resin and fiberglass properties (i.e. melting points). The complex process of material removal (vaporization) is uneven due to the dissimilar melting points.
A major factor inhibiting fine line technology is surface smoothness. Smoother surfaces permit straighter traces. On a flat surface, a higher trace resolution is achieved. Weave texture protrusion through Cu foil limits the achievement of finer traces.
Currently, patterned adhesive sheets are needed for heat sink attachment.
A recently developed technique for PCB fabrication is the Surface Laminar Circuit (SLC) technique. This technique produces a surface laminar layer built up on a copper-clad glass fiber reinforced epoxy sheet. The surface laminar layer is made of photosensitive epoxy dielectric layers and plated copper wiring layers. Interconnections between the wiring layers are provided by photo processed via holes made in the dielectric layer.
SUMMARY OF THE INVENTION
Accordingly, an object of the present invention is to provide printed circuit boards of reduced overall thickness and increased layer count without excessive reduction in the thickness of core material.
Another object of the present invention is to provide printed circuit boards with increased control of laser or plasma drilling.
A further object of the present invention is to provide a method for printed circuit board fabrication with reduced use of prepreg for cost reduction.
Yet another object of the present invention is to provide printed circuit boards with increased signal velocity.
Still another object of the present invention is to provide printed circuit boards with straighter traces and higher trace resolution.
The present invention is directed to a printed circuit board having a first component with a first flat surface and a second component with a second flat surface. An unreinforced, thermosetting, non-photosensitive resin layer is interposed between the first and second surfaces. If the first and second components are printed circuit board cores, the resin need not be non-photosensitive but use of non-photosensitive resin is still possible.
The method of the present invention includes providing at least a first component having a first surface and a second component having a second surface. The first surface is coated with a first layer of unreinforced thermosetting resin and the first layer is cured. A second layer is applied to either the first coated surface or to the second surface and dried. The components are then stacked such that the first and second layers are interposed between the first and second surfaces. Heat and pressure are then applied whereby the second layer is cured and binds the stacked components.
Additional objects and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of the specification, schematically illustrate a preferred embodiment of the invention and, together with the general description given above and the detailed description of the preferred embodiment given below, serve to explain the principles of the invention.
FIG. 1 is a cross-sectional view of a printed circuit board according to the present invention.
FIG. 2 is a cross-sectional view illustrating the binding of a copper foil to a core.
FIG. 3 is a cross-sectional view of the structure resulting from the step of FIG. 2.
FIG. 4 is a cross-sectional view illustrating an alternate method for the binding of a copper foil to a core.
FIG. 5 is a cross-sectional view illustrating the binding of a core to the structure of FIG. 3.
FIG. 6 is a cross-sectional view of the structure resulting from the step of FIG. 5.
FIG. 7 is a cross-sectional view of the structure of FIG. 6 after the drilling of a through hole.
FIG. 8 is a cross-sectional view of the structure of FIG. 7 after the plating of the through hole.
FIG. 9 is a cross-sectional view illustrating the binding of a foil cap to the structure of FIG. 8.
FIG. 10 is a cross-sectional view of the structure resulting from the step of FIG. 9.
FIG. 11 is a cross-sectional view illustrating the binding of a heat sink to the structure of FIG. 10 to obtain the structure of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention will be described in terms of the preferred embodiment. The preferred embodiment is a printed circuit board laminated without reinforced binder and method for its fabrication. Such a structure is shown in FIG. 1.
The structure of FIG. 1 includes unreinforced thermosetting resin layers 34, 48, 50, 66 and 74 which do not have to be photosensitive. The resin may have a glass transition temperature of about 120° to 270° C. and a dielectric constant of about 3.8 at 1 MHz. Layer 34 is interposed between copper foil 30 plated with copper layer 56 and fiber reinforced core material 20 carrying traces 22 and 24. Layer 48 is interposed between core material 20 and fiber reinforced core material 40 carrying traces 38 and 42. Layer 50 is interposed between core material 40 and the upper plane of plated copper layer 56. Layer 66 is interposed between upper plane of plated copper layer 56 and copper foil 62. Between a heat sink 68 and copper foil 62 is unreinforced resin layer 74.
The upper plane of plated copper layer 56 is connected to trace 38 through a buried via 52 in unreinforced resin layer 50. It is also connected to copper foil 30 through blind via 54. The thickness of the unreinforced resin layers may be between about 0.7 mils and 2.5 mils, more preferably between about 1.0 mil and 2.0 mils, and most preferably about 1.5 mils.
The fabrication of the board of FIG. 1 may begin, as shown in FIG. 2, with core 21 including core material 20 carrying patterned copper traces 22 and 24. Core 21 may be 5 mil core material, 1/2 oz. low profile Cu foil, HTE or non-HTE. Core 21 is coated with a layer of epoxy resin 26 which is fully cured (to C stage). Possible resin formulations will be given below. The coating may be done by screen printing as described below. The curing may be carried out for about 15 minutes at about 177° C. A second coating of resin 28 is then applied and dried but not cured to attain B stage. The drying may be carried out for about 5 minutes at a temperature of about 177° C. The coated core is then stacked onto copper foil 30 on carrier 32. Copper foil 30 may be 1/2 oz. foil.
The assembly is then laminated at a pressure of 50-100 psi, vacuum of 60 inches and a temperature of 181° C. with a heat rate of rise of 10°-12° C. As a result, layer 28 bonds to foil 30 and cures to C stage. The resulting structure after removal of the carrier is shown in FIG. 3, where layers 26 and 28, now indistinguishable, are shown as layer 34. In this process, layer 26 served to prevent short circuits between trace 24 and foil 30, and layer 28 served to bind the core and the foil.
As shown in FIG. 4, foil 30 could have been coated with a fully cured resin layer 36 before the lamination. Foil 30 may be patterned (not shown) with straighter traces and higher trace resolution because it is smoother than the copper foils cladding fiber-reinforced resin cores.
A second core 40 carrying traces 38 and 42 may be laminated onto the resulting structure as shown in FIGS. 5 and 6 (or stacked before the lamination step described above and laminated in one step). As described above, a layer of resin 44 is applied onto core 40 and fully cured to C stage. Next, another layer of resin 46 is applied and dried but not cured to attain B stage. After lamination, layers 44 and 46 become indistinguishable and are shown as layer 48 in FIG. 6.
A resin layer 50 is then applied to the exposed surface of core 40 and trace 38, and fully cured. A through hole 54 is drilled using mechanical drilling, and a blind via hole 52 is drilled using laser or plasma drilling. For laser drilling, an RF control sealed CO 2 laser may be used, with a pulse duration of 90-110 milliseconds and power of 120-150 watts. The resulting structure is shown in FIG. 7.
In FIG. 8, the structure of FIG. 7 has been copper plated and the top surface of the copper plating 56 has been patterned using photolithography and etching as known in the art. The laser or plasma etched blind via 52 may be distinguished from mechanically drilled via 54 because it is closed by trace 38 and plated layer 56.
FIGS. 9 and 10 illustrate the attachment of a foil cap 62 to the structure of FIG. 8. Copper foil 62 is carried by carrier 64 and coated with fully cured C stage resin layer 60 and dried B stage resin layer 58 (FIG. 9). After lamination, layers 58 and 60 become indistinguishable and are represented as layer 66 in FIG. 10. Foil 62 may be patterned (not shown) with straighter traces and higher trace resolution because it is smoother than the copper foils cladding fiber-reinforced resin cores.
FIGS. 11 and 1 illustrate the attachment of a heat sink 68 to the structure of FIG. 10. Heat sink 68 is coated with fully cured C stage resin layer 70 and dried B stage resin layer 72 (FIG. 11). After lamination, layers 70 and 72 become indistinguishable and are represented as layer 74 in FIG. 1.
Two possible resin compositions that can be used to practice the present invention are given below. The first composition consists of 50-70% Shell™ compound 1206R-55 and the remainder Shell™ compound 183. The first compound is mixed into the second slowly, with vigorous mixing to ensure uniformity. Heating the mixture between 35°-40° C. taking care not to exceed 90° C. will help dissolve the resin. The viscosity of the mixture is about 28,000±5000 cps. The mixture must be kept covered and used within 24 hours. Pot life is approximately 2.5 days before viscosity starts to change.
The second composition consists of 20-30% Shell™ compound 1206R-55 and the remainder Shell™ compound 1151. The first compound is mixed into the second slowly, with vigorous mixing to ensure uniformity. The viscosity of the mixture is about 7000 to 8000 cps. The mixture must be kept covered and used within 24 hours. Pot life is approximately 3 days before viscosity starts to change.
Screen printing of the resin layers may be done using a mesh of 91-110T monofilament polyester. The stencil material may be Red TI or Indirect films available from Ulano™. For hand printing, screen tension may be about 23-27 N/cm 2 , with an optimum of about 25 N/cm 2 , squeegee hardness may be about 70 durometer and off contact may be about 3/16". For automatic printing, the screen tension may be about 25 N/cm 2 ±2N/cm 2 , squeegee hardness may be about 70 durometer, off contact may be 1/2" and pressure may be 90 psi on the front side and 100 psi on the rear side.
In summary, a printed circuit board laminated without reinforced binder and a method for its fabrication have been described.
The present invention has been described in terms of a preferred embodiment. The invention, however, is not limited to the embodiment depicted and described. Rather, the scope of the invention is defined by the appended claims.
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A printed circuit board laminated without reinforced binder. The invention makes possible reduced board thickness and increased layer count without excessive reduction in the thickness of core material. Laser or plasma drilling can be performed with increased control. Straighter traces, higher trace resolution and higher signal velocity with reduced distortion are made possible.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority under 35 U.S.C. §119 to Korean Patent Application No. 10-2012-0023964 filed on Mar. 8, 2012, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to triphenylamine derivatives and a method for preparing the derivatives. More specifically, the present invention relates to triphenylamine derivatives with low band gaps and high efficiency organic photovoltaic cells using the derivatives.
2. Description of the Related Art
The supply of fossil fuels as representative energy sources is finite and the emission of carbon dioxide from the combustion of fossil fuels brings about environmental problems, such as greenhouse effect. Under these circumstances, there is a growing demand for environmentally friendly alternative energy sources. In efforts to overcome the problems of fossil fuels, various energy sources, such as water power and wind power, are being investigated, and the sunlight is also investigated as a new renewable energy source due to its unlimited availability. Solar powered photovoltaic cells can be broadly classified into two groups: photovoltaic cells using inorganic materials, such as silicon, and photovoltaic cells using organic materials. In comparison with silicon-based inorganic photovoltaic cells, organic thin-film photovoltaic cells have the advantages of low fabrication costs and the possibility of manufacturing freely bendable, flexible, large-area devices. Due to these advantages, a great deal of research has been conducted on organic thin-film photovoltaic cells. Most studies on materials for organic thin-film photovoltaic cells have focused on polymeric materials (G. Li, V. Shrotriya, J. S. Huang, Y. Yao, T. Moriarty, K. Emery and Y. Yang, Nat. Mater., 2005, 4, 864-868, W. L. Ma, C. Y. Yang, X. Gong, K. Lee and A. J. Heeger, Adv. Fund'. Mater., 2005, 15, 1617-1622, H.-Y. Chen, J. Hou, S. Zhang, Y. Hang, G. Yang, G. Yang, Y. Yang, L. Yu, Y. Wu, G. Li, Nat. Photon., 2009, 3, 649). However, the control over the molecular weight of polymeric materials and the removal of catalysts are difficult. The efficiency of photovoltaic cell devices may vary depending on the arrangement of polymeric materials, resulting in poor reproducibility of performance. To overcome such drawbacks, there arises a need to develop a novel monomolecular compound that has a low band gap over a broad light-absorbing range, a high hole mobility and an appropriate molecular level, thus being suitable for use in the fabrication of a high efficiency organic photovoltaic cell.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide triphenylamine derivatives with low band gaps suitable for use in organic photovoltaic cells, and a method for preparing the derivatives.
It is another object of the present invention to provide high efficiency organic photovoltaic cells including the triphenylamine derivatives with low band gaps.
According to an aspect of the present invention, there is provided a triphenylamine derivative represented by Formula (I):
wherein the R 1 groups, which may be the same or different, each independently represent a straight or branched, saturated or unsaturated C 1 -C 20 alkyl group, and the Ar moieties, which may be the same or different, each independently represent a linking group selected from
wherein the R 2 groups, which may be the same or different, each independently represent a straight or branched, saturated or unsaturated C 1 -C 20 alkyl group.
In one embodiment of the present invention, the triphenylamine derivative may be a compound represented by Formula (Ia) or (Ib):
According to another aspect of the present invention, there is provided a method for preparing a triphenylamine derivative represented by Formula (I), as depicted in Reaction (I):
wherein each R is a 2-ethylhexyl or 2-butyloctyl group. The reaction is preferably carried out in the presence of bis(triphenylphosphine)palladium (II) dichloride (PdCl 2 (PPh 3 ) 2 ) as a catalyst.
According to yet another aspect of the present invention, there is provided an organic photovoltaic cell including a photoactive layer using the triphenylamine derivative represented by Formula (1). The photoactive layer may further include a fullerene derivative.
The triphenylamine derivative of the present invention has a low band gap over a broad light-absorbing range, a high hole mobility and an appropriate molecular level. In addition, the organic photovoltaic cell including a photoactive layer using the triphenylamine derivative has very high efficiency.
BRIEF DESCRIPTION OF THE DRAWINGS
These and/or other aspects and advantages of the invention will become apparent and more readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings of which:
FIG. 1 shows absorbance curves for a solution and a film of TDPP(EH) prepared in Synthesis Example 7 of the present invention;
FIG. 2 shows absorbance curves for a solution and a film of TDPP(BO) prepared in Synthesis Example 8 of the present invention;
FIG. 3 is a curve showing the current density-voltage (J-V) characteristics of TDPP(EH) prepared in Synthesis Example 7 of the present invention; and
FIG. 4 is a curve showing the current density-voltage (J-V) characteristics of TDPP(BO) prepared in Synthesis Example 8 of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention will now be described in more detail.
The present inventors have succeeded in synthesizing novel compounds with low band gaps from thiophene monomers and diketopyrrolopyrrole monomers, which were reported to have high hole mobilities and high absorbance values, and triphenylamine core structures with high hole conductivities, and in acquiring high photovoltaic efficiency of organic thin-film photovoltaic cells using the novel compounds.
The present invention provides a triphenylamine derivative represented by Formula (I):
wherein the R 1 groups, which may be the same or different, each independently represent a straight or branched, saturated or unsaturated C 1 -C 20 alkyl group, and the Ar moieties, which may be the same or different, each independently represent a linking group selected from
wherein the R 2 groups, which may be the same or different, each independently represent a straight or branched, saturated or unsaturated C 1 -C 20 alkyl group.
The present invention will be explained in more detail with reference to the following examples. However, these examples are given to assist in a further understanding of the invention and are not to be construed as limiting the scope of the invention.
Compounds (1), (3), (7), (8) and (12) shown in the reaction schemes were purchased from Aldrich or Lumtec.
Synthesis Example 1
Synthesis of 5-(iodomethyl)undecane (Formula 2)
2-Butyl-1-octanol (Formula 1) (6.4 ml, 28.6 mmol), triphenylamine (15.0 g, 57.2 mmol) and imidazole (3.89 g, 57.2 mmol) were placed in dichloromethane (210 ml) as a solvent in a 500 ml flask furnished with a magnetic stirring bar. The mixture was cooled to 0° C. After slow addition of iodine (14.52 g, 57.2 mmol) and slow heating to room temperature, the resulting mixture was allowed to react about 2 hr. After completion of the reaction, a saturated aqueous solution of sodium sulfite was added until no precipitate was observed. The reaction mixture was extracted with water and chloroform. The chloroform layer was dried over magnesium sulfate and the solvents were removed using a rotary evaporator. The residue was purified by column chromatography (eluent=hexane) to afford 8.0 g (yield=95%) of 5-(iodomethyl)undecane (Formula 2).
1 H-NMR (CDCl 3 , δ ppm) 0.88 (t, 6H), 1.23 (m, 17H), 3.24 (d, 2H)
Synthesis Example 2
Synthesis of 3,6-di(thiophen-2-yl)pyrrolo[3,4-c]pyrrole-1,4(2H,5H)-dione (Formula 4)
t-amyl alcohol (250 ml) was placed in a 500 ml flask equipped with a magnetic stirring bar and a condenser. After heating to 60° C., sodium pieces were slowly added. The reaction was allowed to proceed at 120° C. for about 12 hr. Thereafter, 2-thiophenecarbonitrile (Formula 3) (10.0 ml, 107.4 mmol) and di-n-butylsuccinate (12.6 ml, 53.69 mmol) were slowly added. The mixture was allowed to react at 120° C. for about 12 hr. The reaction mixture was cooled, and acetic acid (11.2 ml, 195.7 mmol) and methanol (7.7 ml, 134.2 mmol) were added thereto. After reaction at room temperature for about 30 min, the reaction mixture was left to stand at room temperature for about 30 min to give a precipitate. The precipitate was filtered and dried under vacuum to afford 8.2 g (yield=51%) of 6-di(thiophen-2-yl)pyrrolo[3,4-c]pyrrole-1,4(2H,5H)-dione (Formula 4).
1 H-NMR (DMSO, δ ppm) 4.85 (dd, 2H), 5.51 (d, 2H, aromatic proton), 5.76 (d, 2H, aromatic proton), 8.79 (s, 2H, —NH—)
Synthesis Example 3
Synthesis of 2,5-bis(2-butyloctyl)-3,6-di(thiophen-2-yl)pyrrolo[3,4-c]pyrrole-1,4(2H,5H)-dione (Formula 5)
6-Di(thiophen-2-yl)pyrrolo[3,4-c]pyrrole-1,4(2H,5H)-dione (Formula 4) (0.59 g, 1.96 mmol) prepared in Synthesis Example 2 and 5-(iodomethyl)undecane (Formula 2) (1.75 g, 5.89 mmol) prepared in Synthesis Example 1 were placed in a 500 ml flask equipped with a magnetic stirring bar and a condenser. The mixture was dissolved in dimethylformamide (30 ml) as a solvent. The reaction was allowed to proceed at 140° C. for about 12 hr. After completion of the reaction, the reaction solution was slowly cooled to room temperature to obtain a precipitate. The precipitate was collected by filtration to remove the solvent, followed by extraction with ether and water. Purification by column chromatography (eluent=chloroform/hexane (1:1)) afforded 0.6 g (yield=45%) of 2,5-bis(2-butyloctyl)-3,6-di(thiophen-2-yl)pyrrolo[3,4-c]pyrrole-1,4(2H,5H)-dione (Formula 5).
1 H-NMR (CDCl 3 , δ ppm) 0.84 (t, 6H), 1.24 (m, 64H), 1.90 (m, 2H), 4.02 (d, 4H), 7.26 (dd, 2H, aromatic proton), 7.62 (d, 2H, aromatic proton), 8.85 (d, 2H, aromatic proton)
Synthesis Example 4
Synthesis of 3-(5-bromothiophen-2-yl)-2,5-bis(2-butyloctyl)-6-(thiophen-2-yl)pyrrolo[3,4-c]pyrrole-1,4(2H,5H)-dione (Formula 6)
2,5-Bis(2-butyloctyl)-3,6-di(thiophen-2-yl)pyrrolo[3,4-c]pyrrole-1,4(2H,5H)-dione (Formula 5) (1.17 g, 1.84 mmol) was dissolved in chloroform (40 ml) as a solvent in a 100 ml flask furnished with a magnetic stirring bar. The solution was cooled to 0° C. Thereafter, a solution of N-bromosuccinimide (0.34 g, 1.93 mmol) in chloroform (20 ml) as a solvent was slowly added dropwise to the flask through a dropping funnel. The reaction was allowed to proceed for about 2 hr. The reaction mixture was extracted with chloroform and water. The chloroform layer was collected and the solvent was removed using a rotary evaporator. The residue was purified by column chromatography (eluent=dichloromethane/hexane (1:1)) to afford 0.6 g (yield=45%) of 3-(5-bromothiophen-2-yl)-2,5-bis(2-butyloctyl)-6-(thiophen-2-yl)pyrrolo[3,4-c]pyrrole-1,4(2H,5H)-dione (Formula 6).
1 H-NMR (CDCl 3 , δ ppm) 0.84 (t, 6H), 1.24 (m, 64H), 1.90 (m, 2H), 4.02 (d, 4H), 7.22 (d, 1H, aromatic proton), 7.26 (dd, 1H, aromatic proton), 7.62 (d, 1H, aromatic proton), 8.59 (d, 1H, aromatic proton), 8.85 (d, 1H, aromatic proton)
Synthesis Example 5
Synthesis of tris(4-(thiophen-2-yl)phenyl)amine (Formula 9)
Anhydrous toluene (20 ml) as a solvent was placed in a 100 ml flask equipped with a magnetic stirring bar and a condenser, and then tris(4-bromophenyl)amine (1.0 g, 2.1 mmol) (Formula 7), 4,4,5,5-tetramethyl-2-(thiophen-2-yl)-1,3,2-dioxaborolane (1.7 g, 7.88 mmol) (Formula 8), dipalladiumtris(dibenzylacetone) (Pd 2 (dba) 3 ) (0.1 g, 0.11 mmol), tri-o-tolyl phosphate (P(o-tolyl) 3 ) (0.2 g, 0.4 mmol), potassium carbonate (K 2 CO 3 ) (1.1 g, 8.3 mmol) and trioctylmethylammonium chloride (Aliquat 336) (1 drop) were added thereto. After oxygen was removed from the flask by vacuum-nitrogen cycling, the mixture was stirred at reflux under a nitrogen atmosphere at 85° C. for 48 hr. The stirring was stopped, and the toluene layer was collected, filtered through a short column (eluent=chloroform), and dried. The residue was purified by column chromatography (eluent=dichloromethane/hexane (1:1)) to afford 0.88 g (yield=86%) of tris(4-(thiophen-2-yl)phenyl)amine (Formula 9).
1 H-NMR (CDCl 3 , δ ppm) 7.07 (dd, 3H, aromatic proton), 7.13 (d, 6H, aromatic proton), 7.24 (m, 6H, aromatic proton), 7.52 (d, 6H, aromatic proton)
Synthesis Example 6
Synthesis of tris(4-(5-trimethylstannyl yl)phenyl)amine (Formula 11)
Tris(4-(thiophen-2-yl)phenyl)amine (Formula 9) (0.1 g, 0.203 mmol) was placed in a 25 ml flask furnished with a magnetic stirring bar. Flame drying was conducted to remove moisture from the flask, followed by vacuum-nitrogen cycling to create a nitrogen atmosphere in the flask. Anhydrous tetrahydrofuran (THF) (5 ml) as a solvent was added to the flask. The mixture was cooled to −78° C., and then n-butyllithium (0.05 g, 0.8 mmol) and tetramethylethylenediamine (0.1 mg, 0.8 mmol) were slowly added thereto. After slow heating to room temperature, the reaction was continued for 2 hr. The reaction mixture was cooled to −78° C., and then trimethyltin chloride (SnMe 3 Cl) (0.2 g, 0.8 mmol) was added thereto. The temperature was allowed to rise to room temperature. The resulting mixture was allowed to react for 8 hr. The reaction mixture was extracted with water and ether. The ether layer was collected and the solvents were removed using a rotary evaporator. The residue was reprecipitated in chloroform and methanol, and dried in vacuo to afford 70 mg (yield=35%) of tris(4-(5-trimethylstannyl)thiophen-2-yl)phenyl)amine (Formula 11).
1 H-NMR (CDCl 3 , δ ppm) 7.12 (d, 6H, aromatic proton), 7.15 (d, 3H, aromatic proton), 7.34 (d, 3H, aromatic proton), 7.52 (d, 611, aromatic proton)
Synthesis Example 7
Synthesis of triphenyl derivative TDPP(EH) (Formula Ia)
3-(5-Bromothiophen-2-yl)-2,5-bis(2-ethylhexyl)-6-(thiophen-2-yl)pyrrolo[3,4-c]pyrrole-1,4(2H,5H)-dione (Formula 12) (1044.8 mg, 1.35 mmol) and tris(4-(5-trimethylstannyl)thiophen-2-yl)phenyl)amine (Formula 11) (487.2 mg, 0.41 mmol) were placed in a 25 ml flask furnished with a magnetic stirring bar, and then toluene (40 ml) and dimethylformamide (10 ml) as solvents were added thereto. Oxygen was removed from the flask by degassing. Bis(triphenylphosphine)palladium(II)dichloride (PdCl 2 (PPh 3 ) 2 ) (15.1 mg 0.016 mmol) as a catalyst was added, followed by heating to 80° C. The mixture was allowed to react for about 4 hr. The reaction mixture was cooled to room temperature, reprecipitated in methanol (150 ml), and filtered to obtain a dark brown solid. The solid was dissolved in chloroform and purified by column chromatography (eluent=dichloromethane/hexane (2:1)) to afford 650 mg (yield=77%) TDPP(EH) (Formula Ia) as the final product in the form of a black powder.
1 H-NMR (CDCl 3 , 6 ppm) 0.88 (m, 36H), 1.25 (m, 48H), 4.04 (d, 12H), 7.18 (d, 6H, aromatic proton), 7.24 (dd, 3H, aromatic proton), 7.27 (d, 3H, aromatic proton), 7.31 (d, 3H, aromatic proton), 7.33 (d, 3H, aromatic proton), 7.55 (d, 6H, aromatic proton), 7.62 (d, 3H, aromatic proton), 8.85 (d, 3H, aromatic proton), 8.94 (d, 3H, aromatic proton)
Synthesis Example 8
Synthesis of triphenyl TDPP(BO) (Formula Ib)
3-(5-Bromothiophen-2-yl)-2,5-bis(2-butyloctyl)-6-(thiophen-2-yl)pyrrolo[3,4-c]pyrrole-1,4(2H,5H)-dione (Formula 6) (288.0 mg, 0.40 mmol) and tris(4-(5-trimethylstannyl)thiophen-2-yl)phenyl)amine (Formula 11) (119.5 mg, 0.12 mmol) were placed in a 25 ml flask furnished with a magnetic stirring bar, and then toluene (8 ml) and dimethylformamide (2 ml) as solvents were added thereto. Oxygen was removed from the flask by degassing. Bis(triphenylphosphine)palladium(II)dichloride(PdCl 2 (PPh 3 ) 2 ) (3.4 mg, 0.005 mmol) as a catalyst was added, followed by heating to 80° C. The mixture was allowed to react for about 4 hr. The reaction mixture was cooled to room temperature, reprecipitated in methanol (150 ml), and filtered to obtain a dark brown solid. The solid was dissolved in chloroform and purified by column chromatography (eluent=dichloromethane/hexane (2:1)) to afford 201 mg (yield=68%) of TDPP(BO) (Formula Ib) as the final product in the form of a black powder.
1 H-NMR (CDCl 3 , δ ppm) 0.88 (m, 36H), 1.25 (m, 90H), 4.04 (d, 12H), 7.18 (d, 6H, aromatic proton), 7.24 (dd, 3H, aromatic proton), 7.27 (d, 3H, aromatic proton), 7.31 (d, 3H, aromatic proton), 7.33 (d, 3H, aromatic proton), 7.55 (d, 6H, aromatic proton), 7.62 (d, 3H, aromatic proton), 8.85 (d, 3H, aromatic proton), 8.94 (d, 3H, aromatic proton)
Example 1
Fabrication of Photovoltaic Cells Using Triphenylamine Derivatives
Each of the triphenylamine derivative TDPP(EH) (Formula Ia) prepared in Synthesis Example 7 and the triphenylamine derivative TDPP(BO) (Formula Ib) prepared in Synthesis Example 8 was used to fabricate a photovoltaic cell having a structure of ITO/PEDOT:PSS/triphenylamine derivative:PC 70 BM (1:3.5)/Al in accordance with the following procedure. First, an ITO substrate was sequentially washed with isopropyl alcohol for 10 min, acetone for 10 min and isopropyl alcohol for 10 min, and dried before use. A solution of PEDOT:PSS in a ratio of 1:1 was diluted in methanol, spin coated at a rate of 4,000 rpm on the ITO substrate, and dried at 110° C. for 10 min. The triphenylamine derivative and PC 70 BM were dissolved in a ratio of 1:3.5 in chloroform to prepare a solution having a concentration of 15 mg/ml. The solution was spin coated at a rate of 2,500 rpm on the substrate, and an aluminum electrode was deposited to a thickness of 100 nm thereon.
Evaluation Example 1
Characterization of Photovoltaic Cells
FIGS. 1 and 2 are absorbance curves for solutions and films of TDPP(EH) (Formula Ia) prepared in Synthesis Example 7 and TDPP(BO) (Formula Ib) prepared in Synthesis Example 8, respectively. The maximum absorbance values and optical band gaps of the solutions and the films were determined from the absorbance data, and the results are shown in Table 1. From these results, it can be seen that the triphenylamine derivatives having low band gaps are suitable for use in the fabrication of high efficiency organic photovoltaic cells.
TABLE 1
Solution
Solution
Film
Optical band gap
(λ max , nm)
(λ onset , nm)
(λ onset , nm)
(E g,opt , eV)
TDPP(EH)
596
665
700
1.77
TDPP(BO)
593
665
700
1.77
The characteristics of the photovoltaic cells were measured, and the results are shown in FIGS. 3 and 4 . Main parameters indicating the performance of the photovoltaic cells for the curves of FIGS. 3 and 4 are described in Table 2.
TABLE 2
V oc (V)
J sc (mA/cm 2 )
FF
PCE (%)
TDPP(EH)
0.78
7.90
0.36
2.2
TDPP(BO)
0.85
3.50
0.35
1.1
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Disclose is a triphenylamine derivative with a low band gap. The triphenylamine derivative is represented by Formula (I):
wherein R 1 and Ar are as defined in the specification. Further disclosed is a high efficiency organic photovoltaic cell using the derivative.
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TECHNICAL FIELD
[0001] The invention relates to the field of automatically configuring a client application at a device in a communications network.
BACKGROUND
[0002] Mobile devices can subscribe to services and content via a communication network. For example, a user of a device may wish to subscribe to a news feed, and any relevant news content will be automatically sent to the mobile device. Similarly, a mobile device may subscribe to an anti-virus service, and virus database updates are sent to the mobile device.
[0003] The Short Message Service (SMS) uses standard communications protocols to allow the exchange of short text messages between mobile devices, or between a mobile device and another node in a communication network such as a server. SMS based services are commonly used by mobile devices to subscribe to content or services. SMS services can be used to activate, subscribe to, update, and charge for content and services. SMS messages are delivered via a Short Message Service Centre (SMSC), which effectively provides a store-and-forward operation. When a user sends an SMS message to another user, the message is stored at the SMSC and delivered to the recipient when the recipient is next available which delivers it to the destination user when they are available.
[0004] The mobile device market is very fragmented, with many different types of device available to the user, and many different operators providing access networks for the device to attach to a communications network. The increasing number of options in terms of the mobile device and operator networks brings complexity in the system, as each operator introduces its own SMSC configuration and client to support the operation of a gateway. Any client application at the mobile device must be provided with operator-specific network settings to support an SMS based subscription. Each client application that is developed must be modified and given operator-specific settings. This means that separate operator variants are required for each application. The variants must be separately built, tested, signed, and published. The same problems are encountered when an update to the client application is published; updates must be provided in variants for different network operators.
[0005] A similar problem occurs because users have different devices. An application is configured for one type of device may not be optimally configured to work on another type of device. For example, different device firmware versions contain functional deviations, and client applications need to be able to adapt component functionality based on the firmware version.
SUMMARY
[0006] It is an object of the invention to overcome problems associated with configuring a client application depending on the operator network in which the device is being used, or the type of device that is being used.
[0007] According to a first aspect of the invention, there is provided a method of configuring an application at a device in a communications network. A server receives a request message from the device. The request message includes information that identifies the application, and further information relating to either or both of the device type or a network operator associated with the device. The further information is used by the server to obtain specific configuration information relating to the application. A response is sent to the device, the response including the obtained specific configuration. The specific configuration information can subsequently be used by the device to configure the application. In this way, only one application need be published, and settings specific to particular operators or devices can be provided to the device.
[0008] In one embodiment of the invention, the further information relates to the network operator, and includes a Mobile Country Code (MCC) and a Mobile Network Code (MNC). In this case, the configuration information includes operator-specific information that the device uses to configure the application according to network operator requirements.
[0009] In an alternative embodiment of the invention, the further information relates to the network operator and includes an International Mobile Subscriber Identity (IMSI). In this case, the configuration information comprises operator-specific information that the device can use to configure the application according to network operator requirements. In a further alternative embodiment of the invention, the further information relates to the network operator and includes the IP address being used by the device. In this embodiment, the configuration information comprises operator-specific information that can be used by the device to configure the application according to network operator requirements.
[0010] In another alternative embodiment, the further information relates to the device type. In this case, it may include an International Mobile Equipment Identity (IMEI) specific to the device. The configuration information comprises information that can be used by the device to configure the application according to the device type. Other device identifiers may also be used, such as manufacturer names and model numbers, serial numbers and so on.
[0011] As an option, the information identifying the application and the further information are sent from the device in an activation message to activate the application. However, this is not strictly necessary. For example, the invention may be implemented when the application receives a message that an update is available.
[0012] Either of the request message and the response message may be sent using Short Message Service (SMS) protocols, although it will be apparent that any suitable messaging protocol may be used.
[0013] In an embodiment of the invention, the request message comprises a Uniform Resource Locator (URL). The URL is made up of segments, including a segment identifying a domain from which the specific configuration information can be obtained, a segment identifying the application and a segment, identifying the network operator associated with the device. The combined segments of the URL describe a path via which the specific configuration information can be obtained.
[0014] According to a second aspect of the invention, there is provided a server for use in a communications network. The server is provided with a communications device for receiving a request message from a remote device, the request message identifying an application at the device and further information relating to any of a network operator associated with the device and a device type. A processor is provided for using the further information to obtain configuration information relating to the application. The communications device is further arranged to send a response message to the device, the response message comprising the obtained configuration information, which can be used by the device to configure the application.
[0015] In one embodiment, the server is provided with a database. The database stores information identifying a plurality of network operators and, for each network operator, information identifying the application and operator-specific information relating to the application. In an alternative embodiment of the invention, the database stores information identifying a plurality of device types and, for each device type, information identifying the application and device-specific information relating to the application.
[0016] Where the further information relates to the network operator associated with the device, it may be any of a MCC and MNC, an IP address being used by the device, and an IMSI. Where the further information relates to the device type, it may be an IMEI, although any type of device type identifier can be used.
[0017] In an embodiment of the invention, the request message may be sent as an activation message to activate the application, although there are circumstances described above in which the request message may be sent to, for example, request an update for the application.
[0018] According to a third aspect of the invention, there is provided a device for use in a communications network. The device is provided with a processor for generating a request message. The request message includes information that identifies an application at the device, and further information that identifies either or both of a network operator associated with the device and a device type. A transmitter is provided for sending the request message to a remote server. A receiver is also provided for receiving from the remote server a response message. The response message includes configuration information relating to the application. The processor is arranged to configure the application using the configuration information received in the response message.
[0019] In the case where the further information relates to the network operator associated with the device, it may include any of a MCC and a MNC, an IP address being used by the device, and an IMSI. In the case where the further information relates to the device type, it may include an IMEI specific to the device, although any device type identifier may be used, for example a manufacturer and model name.
[0020] In an embodiment of the invention, the request message may be sent as an activation message to activate the application, although there are circumstances described above in which the request message may be sent to, for example, request an update for the application.
[0021] According to a fourth aspect of the invention, there is provided a computer program that comprises computer readable code which, when run on a server, causes the server to behave as a server as described above in the second aspect of the invention. There is also provided a computer readable medium on which the computer program is stored.
[0022] According to a fifth aspect of the invention, there is provided a computer program comprising computer readable code which, when run on a computer device, causes the computer device to behave as a device as described above in the third aspect of the invention. There is also provided a computer readable medium on which the computer program is stored.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 illustrates schematically in a block diagram a client and a server according to a first embodiment of the invention;
[0024] FIG. 2 is a signalling diagram illustrating signalling between a client and a server when the client starts a new application where the operator is identified using the MCC and MNC;
[0025] FIG. 3 is a signalling diagram illustrating signalling between a client and a server when the client starts a new application where the operator is identified using an IP address;
[0026] FIG. 4 illustrates schematically in a block diagram a client and a server according to a third embodiment of the invention; and
[0027] FIG. 5 is a signalling diagram illustrating signalling between a client and a server when the client starts a new application and the device is to be identified using the IMEI code of the device.
DETAILED DESCRIPTION
[0028] According to a first specific embodiment of the invention, and referring to FIG. 1 , there is illustrated a device 1 and a server 2 . The device 1 has a processor 3 configured to run an application 4 . A communications device 5 is provided to allow the device 1 to communicate with other nodes in a communications network. The device 1 may also be provided with a Subscriber Identity Module (SIM) 6 card. The SIM card 6 stores information including the following:
a unique serial number that identifies the SIM card; an International Mobile Subscriber Identity (IMSI) that identifies the subscriber; temporary information related to the local network, which may include a temporary id that has been issued to the user; a list of the services accessible by the user; security authentication and ciphering information.
[0034] The invention supports automatic configuration of the client application 4 at the device 1 by identifying the user's operator. The user's operator may be any type of network operator, examples of which include a Mobile Network Operator (MO), a Virtual Mobile Network Operators (MVNO), an Internet Service Provider (ISP), and a local fixed line network owner. Automatic configuration allows the client application 4 to automatically adapt its functionality, look-and-feel, and settings to match local operator preferences. This dramatically shortens delivery time and maintenance efforts needed with mobile operator partners. Examples of settings that may be configured include customizing the client application components, user interface look-and-feel (for example co-branding, which may involve any of the name of the application, the name of the application provider, the name of network operator, and any relevant logos), and application settings (including network operator related settings).
[0035] In an embodiment of the invention, identification of the operator is performed using the IMSI. An IMSI is typically 15 digits long. The first three digits of the IMSI denote the Mobile Country Code (MCC), and the next two (in European standards) or three (in North American standards) digits denote the Mobile Network Code (MNC). The remaining digits denote the mobile station identification number (MSIN) within the identified network.
[0036] The client application obtains the MCC and the MNC from the SIM 6 , and sends this in an activation message to the server 2 when the application is first activated. The server 2 receives the message at its communications device 7 . The message is handled by a processor 8 , which uses the MCC and the MNC to identify the network operator for the device 1 . A database 9 is queried using the MCC and the MNC to obtain service settings for the client application 4 that are specific to the network operator. For example, operator A may require service settings A, operator B may require service settings B and so on. Note that FIG. 1 illustrates the database located at the server 2 , although it could in an alternative embodiment be at a remote location from the server.
[0037] Once the service settings have been obtained, they are communicated to the device 1 . The client application uses the operator-specific service settings to configure itself to ensure that it is operating in accordance with the requirements of the operator.
[0038] The above description assumes that the client application 4 is configured when it is first activated, although in an alternative embodiment this may occur at any time when the application 4 is run. This allows the client application 4 to change its configuration “on the fly” and take account of any changes to the operator-specific service settings.
[0039] An example signalling diagram is illustrated in FIG. 2 , with the following numbering corresponding to that of the figure:
[0040] S 1 . A user of the device starts the application 4 .
[0041] S 2 . The device 1 sends an activation request to the server. The activation request includes the IMSI, or at least the MCC and MNC from the IMSI.
[0042] S 3 . The server uses the MCC and MNC to identify the user's operator.
[0043] S 4 . The identified operator is used to query a database in order to obtain operator-specific settings for the application. Of course, the database may simply be queried using the received MCC and MNC, in which case steps S 3 and S 4 are combined.
[0044] S 5 . The operator-specific settings are sent from the server 2 to the device 1 .
[0045] S 6 . The application 4 at the device customises its behaviour on the basis of the received operator-specific settings.
[0046] The first specific embodiment of the invention can be applied to mobile devices and laptop PCs that have mobile networking capabilities (SIM card slot or a wireless DSL dongle). On such devices, applications can utilize the invention to customise their behaviour according to network operator-specific settings when they are run.
[0047] The invention may be implemented using hardware, as described above. Alternatively, the device may be provided with a memory 10 in which software 11 is stored to ensure that the device 1 can operate the invention. Similarly, the backend server 2 may also have a memory 12 storing software that, when run, causes the backend server 2 to behave as described above.
[0048] The MCC and MNC may be sent as part of a URL that links directly to the operator-specific settings obtainable by the server 2 . For example, once the MCC and MNC have been obtained, a URL is sent in order to activate the application. The URL includes information identifying the application as well as the MCC and MNC. For example, when a user starts up an mobile security application, as described in S 1 above, the URL http://mobile.f-secure.com/partners/234/15/mobile-security-os9x.sisx is generated and sent (according to S 2 above) to the server. The URL breaks down as follows:
http://mobile.f-secure.com/partners defines the domain via the operator-specific configuration information is obtainable. 234 is the MCC (in this example, the country code for the UK) 15 defines the MNC (in this example, the Vodafone® network). Mobile-security-os9x.sisx defines the application.
[0053] The URL therefore describes a path to the required operator-specific settings that can be used by the server to obtain the settings before forwarding them to the user.
[0054] In some instances, the MNC and/or MCC may not be obtainable by the device, or may not have a corresponding entry in the database. In this case, the server redirects the query and provides generic or “safe” settings to the application.
[0055] According to a second specific embodiment of the invention, the network operator is identified using the device's IP address rather than the MCC and the MNC. This allows the application 4 to be configured for other types of device in real time by identifying the country of access and the service provider. Each mobile operator or Internet service provider is allocated IP address space. This is used to identify the operator, as with the first specific embodiment of the invention, and to allow operator-specific settings to be sent to the device for configuring the application. The procedure is much that that described above, with reference to FIG. 2 . FIG. 3 shows the procedure according to the second specific embodiment, with the following numbering corresponding to the numbering of FIG. 3 :
[0056] S 7 . A user of the device starts the application 4 .
[0057] S 8 . The device 1 sends an activation request to the server. The activation request includes the IP address currently being used by the device 1 .
[0058] S 9 . The server uses the IP address to identify the user's operator.
[0059] S 10 . The identified operator is used to query a database in order to obtain operator-specific settings for the application. Of course, the database may simply be queried using the IP address, in which case steps S 9 and S 10 are combined.
[0060] S 11 . The operator-specific settings are sent from the server 2 to the device 1 .
[0061] S 12 . The application 4 at the device customises its behaviour on the basis of the received operator-specific settings.
[0062] The second specific embodiment of the invention allows the application to be customised depending on operator settings even where a particular device does not have an IMSI.
[0063] Examples of customisation of operator settings include operator branding, functionality specific to the operator and so on.
[0064] According to a third specific embodiment, the client application is configured on the basis of the type of device that is being used. Each mobile device is preconfigured with an International Mobile Equipment Identity (IMEI). The IMEI is unique to every mobile device and is normally used in GSM networks to identify the device and compare the identity of the device with a blacklist of stolen devices.
[0065] An IMEI comprises 14 digits and a checksum. The first eight digits of the IMEI identify the manufacturer and model of the device being used. The database 9 accessed by the server, instead of or in addition to storing operator-specific settings, stores device-specific settings.
[0066] Referring to FIG. 4 , there is illustrated a device 14 and a server 15 . The device 14 has a processor 16 configured to run an application 17 . A communications device 18 is provided to allow the device 14 to communicate with other nodes in a communications network. The device also includes a memory 19 . The memory 19 may store software 20 that allows the device to run. The device is provisioned with an IMEI which is maintained in a memory.
[0067] The invention supports automatic configuration of the client application 4 at the device 1 by identifying the manufacturer and the model of the device 14 . This allows the client application 4 to automatically adapt its functionality, look-and-feel, and settings to match the requirements and capabilities of the device. This shortens delivery and upgrade time for the application 17 .
[0068] The client application obtains the IMEI from the device 14 , and sends this in an activation message to the server 15 when the application is first activated. The server 15 receives the message at its communications device 21 . The message is handled by a processor 22 , which uses the IMEI to identify the manufacturer and model of the device 14 . A database 23 is queried using the IMEI to obtain service settings for the client application 4 that are specific to the device type. For example, device type A may require service settings A, device type B may require service settings B and so on.
[0069] Note that FIG. 4 illustrates the database 23 located at the server 15 , although it could in an alternative embodiment be at a remote location from the server. Note also that much of the functionality of the server may be implemented using software, in which case a program 24 stored in a memory 25 is used to control the behaviour of the server 15 .
[0070] Once the device-specific service settings have been obtained, they are communicated to the device 14 . The client application 17 uses the device-specific service settings to configure itself to ensure that it is operating in accordance with the requirements and capabilities of the device.
[0071] The above description assumes that the client application 17 is configured when it is first activated, although in an alternative embodiment this may occur at any time when the application 17 is run. This allows the client application 17 to change its configuration “on the fly” and take account of any changes to the capabilities of the device (such as an upgrade to the device memory or firmware)
[0072] An example signalling diagram is illustrated in FIG. 5 , with the following numbering corresponding to that of the figure:
[0073] S 13 . A user of the device starts the application 4 .
[0074] S 14 . The device 1 sends an activation request to the server. The activation request includes the IMEI.
[0075] S 15 . The server uses the IMEI to identify the device type.
[0076] S 16 . The device type is used to query a database 23 in order to obtain device-specific settings for the application. Of course, the database may simply be queried using the received IMEI, in which case steps S 15 and S 16 are combined.
[0077] S 17 . The device-specific settings are sent from the server 15 to the device 14 .
[0078] S 18 . The application 17 at the device 14 customises its behaviour on the basis of the received device-specific settings.
[0079] Note that whilst the first, second and third embodiments are all described separately, the invention could be implemented using any combination of the embodiments. For example, a server that implemented both the first and third specific embodiments would have a database that had both operator-specific settings and device-specific settings, meaning that an application could be configured by network operator and by device type in a single signalling operation.
[0080] The invention allows applications to be customised on activation, which removes the need to publish specific application variants for each network operator. This enables faster operator deliveries, and reduces the number of client application variants by utilizing the same binary for different operators and device types. The invention also allows changes to settings and business logic without updating the actual client application, and allows easier and cost efficient maintenance when an update to the application is published, as it is sufficient to only publish one update and operator-specific changes or device-specific changes.
[0081] It will be appreciated by the person of skill in the art that various modifications may be made to the above-described embodiments without departing from the scope of the invention. For example, the above description describes identifying the network operator using the MCC and MNC, but it will be apparent that any type of identifier may be used. For example, a MSISDN number may be used to identify the network operator.
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A method and apparatus for configuring an application at a device in a communications network. A server receives a request message from the device. The request message includes information that identifies the application, and further information relating to either or both of the device type or a network operator associated with the device. The further information is sued by the server to obtain specific configuration information relating to the application. A response is sent to the device, the response including the obtained specific configuration. The specific configuration information is subsequently be used by the device to configure the application.
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This is a Continuation of application Ser. No. 08/214,064, filed Mar. 15, 1994 now abandoned, which is a Continuation of application Ser. No. 08/032,235, filed Mar. 17, 1993, now abandoned.
FIELD OF THE INVENTION
The present invention relates to plants having reduced susceptibility to infection from tospoviruses, genetic material capable of generating tolerance to tospoviruses, probes suitable for isolating and diagnosing, and processes for obtaining such plants and genetic material and probes.
BACKGROUND OF THE INVENTION
Viral infections in plants are frequently responsible for detrimental effects in growth, undesirable morphological changes, decreased yield and the like. Such infections often result in a higher susceptibility to infection in infected plants to other plant pathogens and plant pests. Transmission of plant viruses generally occurs via insect or fungal carriers or may occur through mechanical means.
Plant breeders continuously look to develop varieties of crop plant species tolerant to or resistant to specific virus strains. In the past, virus resistance conferring genes have been transferred from wild types related to commercial plants into commercial varieties through breeding. The transfer of an existing resistance in the wild from the wild type gene pool to a cultivar is a tedious process in which the resistance conferring gene(s) must first be identified in a source (donor) plant species and then combined into the gene pool of a commercial variety. Resistance or tolerance generated in this way is typically active only against one or at best a few strains of the virus in question. One disadvantage of breeding cultivars for resistance to a particular virus species is that there is often a lack of a gene source suitable for conferring disease resistance within the crop species.
Other approaches to limit the effect of virus induced disease on plants include the use of chemicals such as insecticides, fungicides and the like which act against virus carriers, and/or rely on the employment of preventative methods such as efficient phytosanitary working conditions. However, the use of chemicals to combat virus disease by killing the carrier is subject to increasingly tougher governmental regulations which present growers with a decreasing scala of permitted chemical plant-protectants.
In an alternative, a system referred to as "cross-protection" may be employed. Cross-protection is a phenomenon in which infection of a plant with one strain of a virus protects that plant against superinfection with a second related virus strain. The cross-protection method preferentially involves the use of avirulent virus strains to infect plants, which act to inhibit a secondary infection with a virulent strain of the same virus. However, the use of a natural cross-protection system can have several disadvantages. The method is very labour intensive because it requires inoculation of every plant crop, and carries the risk that an avirulent strain may mutate to a virulent strain, thus becoming a causal agent for crop disease in itself. A further possible hazard is that an avirulent virus strain in one plant species can act as a virulent strain in another plant species.
Several studies have indicated that the viral coat protein of the protecting virus plays an important role in cross-protection and that protection occurs when the resident virus and the challenging virus have the same or closely related coat protein structures.
Recent developments in gene manipulation and plant transformation techniques have given rise to new methods for generating virus resistance in plants. Genetically engineered cross-protection is a form of virus resistance which phenotypically resembles natural cross-protection, but is achieved through the expression of genetic information of a viral coat protein from the genome of a genetically manipulated plant. Generation of virus resistance via genetic engineering has been described in for instance, EP 223 452 and reported by Abel et al (1986) Science 232:738-743!. It was shown that expression of the tobacco mosaic virus strain U1 (TMV-U1) coat protein gene from the genome of a transgenic plant resulted in a delay of symptom development after infection with any TMV strain. Similar results with respect to coat protein-mediated protection have also been obtained for alfalfa mosaic virus (AMV), potato virus X (PVX) and cucumber mosaic virus (CMV).
Although TMV, CMV, AMV and PVX belong to different virus groups, they share a common architecture: in all such viruses the viral RNA is a positive strand RNA encapsidated by a viral coat consisting of many individual but identical viral coat proteins.
However, tospoviruses are essentially different from the plant viruses mentioned above. The genus tospovirus belongs to the family Bunyaviridae. All tospoviruses are transmitted by thrips. The virus particles are spherical in shape (80-120 nm in diameter) and contain internal nucleocapsids surrounded by a lipid envelope studded with glycoprotein surface projections. The multipartite genome consists of linear single stranded RNA molecules of negative or ambisense polarity. The terminal nucleotides of these RNA molecules are characterised by a consensus sequence as follows: 5' AGAGCAAUX....................GAUUGCUCU 3', wherein X is C or U. Members of the tospovirus group include tomato spotted wilt virus (TSWV), Impatiens necrotic spot virus (INSV), and tomato chlorotic spot virus (TCSV), also known as tomato mottled spot virus (TMSV) or TSWV-like isolate BR-O3. A general description of a tospovirus, using TSWV as a representative of the genus tospoviruses can be found in our co-pending application EP 426 195 herein incorporated by reference.
The tospovirus particle contains at least 4 distinct structural proteins: an internal nucleocapsid protein N of 29 kd and two membrane glycoproteins: G1, approximately 78 kd, and G2 approximately 58 kd. In addition, minor amounts of a large protein, L, approximately 260 kd have been detected in virus particles. Tospoviral genomes consist of three linear single stranded RNA molecules of about 2900 nucleotides (nt) (S RNA), about 5000 nt, (M RNA) and about 8900 nt (L RNA), each tightly associated with nucleocapsid proteins and a few copies of the L protein to form circular nucleocapsids. A schematic structure outlining most properties of an INSV is given in FIG. 1. Based on the above and other properties, INSV (like TSWV) has been classified as a member of the tospovirus genus.
Circumstantial evidence has been presented which suggests that an M RNA encoded gene is directly or indirectly involved in the synthesis of the G1 membrane glycoprotein Verkleij and Peters, (1983) J. Gen. Virol. 64:677-686!.
As mentioned above, tospoviruses such as TSWV, INSV and the like are transmitted by certain species of thrips. These tospovirus carriers belong to the family Tripidae and include tobacco thrips (Frankliniella fusca (Hinds.)), western flower thrips (F. occidentalis (Pergande)), common blossom thrips (F. Schultzei (Trybom)), chilli thrips (Scirtothrips dorsalis (Hood)), Thrips setosus (Moulton), onion thrips (T. tabaci (Lindeman)), F. intonsa and melon thrips (T. palmi (Karny)). The tospovirus is acquired by thrips only during their larval stages. Larvae can transmit the virus before they pupate but adults more commonly transmit the virus. Adult thrips can remain infective throughout their lives.
Tospoviruses are widespread in temperate, subtropical and tropical climate zones throughout the world. The current distribution of tospoviruses covers all continents and makes them one of the most widely distributed of groups of plant viruses. At least 370 plant species representing 50 plant families, both monocotyledons and dicotyledons, are naturally infected by tospoviruses of the Bunyaviridae. Tospoviruses seriously affect the production of food and ornamental crops. Symptoms of tospovirus infection in plants include stunting, ringspots, dark purple-brown sunken spots, stem browning, flower breaking, necrotic and pigmental lesions and patterns, yellows and non-necrotic mottle, mosaic in greens or even total plant death. Most plant hosts display only a few of these symptoms, however, the wide range of symptoms produced by tospovirus infection has complicated diagnosis of the disease and has led to individual diseases being given several different names. A further complication is that tospovirus symptoms within the same plant species may vary depending on the age of the plant, time of infection during the life-cycle of the plant, nutritional levels, environmental conditions, such as temperature, and the like.
Although TSWV has been known for many years, is widely distributed, and is the causal agent of a disease which leads to significant loss in yield in crops and ornamentals, limited progress has been made in identifying sources of genes capable of conferring resistance to TSWV or other tospoviruses. A monogenic TSWV tolerance has been identified in Lycopersicon peruvianum, but this trait has not been transferred to cultivated tomatoes so far, nor has a resistance source been identified for other crop species. The use of natural cross-protection systems to decrease the invasive effects by tospovirus strains capable of causing damage is not well documented. Limited positive results have been reported for tomato and lettuce.
The introduction of genetic information capable of conferring resistance or tolerance to tospoviruses into plant gene pools by means of genetic manipulation provides the breeder and grower alike with a new method for combatting tospovirus induced disease. In particular, it has been found that genetic manipulation techniques may be employed to confer resistance to INSV related disease in plants.
SUMMARY OF THE INVENTION
According to the present invention there is provided a recombinant INSV DNA construct comprising a DNA sequence coding for transcription into
a) an RNA sequence of an INSV or an RNA sequence homologous thereto;
b) an RNA sequence of an INSV or an RNA sequence homologous thereto capable of encoding for an INSV protein or a part thereof, in which one or more codons have been replaced by synonyms, or an RNA sequence homologous thereto; or
c) an RNA sequence complementary to an RNA sequence according to a) or b),
which INSV DNA is under expression control of a promoter capable of functioning in plants and includes a terminator capable of functioning in plants.
The DNA sequences defined under a), b) and c) above, for the purposes of the present invention will be referred to as "INSV Related DNA Sequences" hereinafter. An INSV Related DNA Sequence according to the invention may be modified as appropriate to create mutants or modified sequences homologous to such INSV Related DNA Sequences from which they are derived, using methods known to those skilled in the art such as site-directed mutagenesis and the like. Such mutants or modified coding sequences are embraced within the spirit and scope of the invention.
The term "RNA sequence of an INSV" may refer to a sequence of the S, M or L RNA strand, preferably an S or M RNA strand, more preferably to an S RNA strand of an INSV.
The term "RNA sequence homologous to an RNA sequence of an INSV" refers to an RNA sequence of an INSV wherein a number of nucleotides have been deleted and/or added but which is still capable of hybridization to a nucleotide sequence complementary to an RNA sequence of an INSV under appropriate hybridization conditions. For the purposes of the present invention appropriate hybridization conditions may include but are not limited to, for example, an incubation for about 16 hours at 42° C., in a buffer system comprising 5×standard saline citrate (SSC), 0.5% sodium dodecylsulphate (SDS), 5×Denhardt's solution, 50% formamide and 100 μg/ml carrier DNA (hereinafter the buffer system), followed by washing 3× in buffer comprising 1×SSC and 0.1% SDS at 65° C. for approximately an hour each time
Preferably, hybridization conditions employed in the present invention may involve incubation in a buffer system for about 16 hours at 49° C. and washing 3× in a buffer comprising 0.1×SSC and 0.1% SDS at 55° C. for about an hour each time. More preferably, hybridization conditions may involve incubation in a buffer system for about 16 hours at 55° C. and washing 3× in a buffer comprising 0.1×SSC and 0.1% SDS at 65° C. for approximately an hour each time.
The length of the INSV Related DNA Sequence will i.a. depend on the particular strategy to be followed, as will become apparent from the description hereinafter. In general, the INSV Related DNA Sequence may comprise at least 20, and suitably 50 or more nucleotides.
The term "promoter" refers to the nucleotide sequence upstream from the transcriptional start site and which contains all the regulatory regions required for transcription, including the region coding for the leader sequence of mRNA (which leader sequence comprises the ribosomal binding site and initiates translation at the AUG start codon).
Examples of promoters suitable for use in DNA constructs of the present invention include viral, fungal, bacterial, animal and plant derived promoters capable of functioning in plant cells. The promoter may express the DNA constitutively or differentially. Suitable examples of promoters differentially regulating DNA expression are promoters inducible by disease carriers, such as thrips, e.g. so-called wound-inducible promoters. It will be appreciated that the promoter employed should give rise to the expression of an INSV Related DNA Sequence at a rate sufficient to produce the amount of RNA necessary to decrease INSV susceptibility in a transformed plant. The required amount of RNA to be transcribed may vary with the type of plant. Particularly preferred promoters include the cauliflower mosaic virus 35S (CaMV 35S) promoter, derivatives thereof, and a promoter inducible after wounding by a disease carrier such as thrips, e.g. a wound inducible promoter. Examples of further suitable promoters include nopaline synthase, octopine synthase and the like.
The term "terminator" refers to a DNA sequence at the end of a transcriptional unit which signals termination of transcription. Terminators are DNA 3'-non-translated sequences that contain a polyadenylation signal, that causes the addition of polyadenylate sequences to the 3'-end of a primary transcript. Terminators active in plant cells are known and described in the literature. They may be isolated from bacteria, fungi, viruses, animals and/or plants. Examples of terminators particularly suitable for use in the DNA constructs of the invention include the nopaline synthase terminator of A. tumefaciens, the 35S terminator of CaMV and the zein terminator from Zea mays.
In accordance with the present invention, an RNA sequence is complementary to another RNA sequence if it is able to form a hydrogen-bonded complex therewith, according to rules of base pairing under appropriate hybridization conditions (as described hereinabove).
The present invention also provides a vector capable of introducing the DNA construct of the invention into plants and methods of producing such vectors.
The term "vector" as employed herein refers to a vehicle with which DNA constructs of INSV or fragments thereof may be incorporated into the cells of a host organism.
The term "plants" refers to differentiated plants as well as undifferentiated plant material such as protoplasts, plant cells, including cybrids and hybrids, seeds, plantlets and the like which under appropriate conditions can develop into mature plants, progeny thereof and parts thereof such as cuttings, fruits of such plants and the like.
The invention further provides plants comprising in their genome a DNA construct of the invention, and methods of producing such plants. Such methods include plant breeding, plantlets derived from protoplast fusion and the like.
The plants according to the invention have reduced susceptibility to diseases induced by INSV or diseases related to INSV infection and suffer from substantially fewer or none of the disadvantages and limitations of plants obtained by classical methods as mentioned hereinabove.
Many types of plants are susceptible to INSV infection however only in some types is INSV infection known to give rise to a disease state directly attributable to the virus. Such types of plants include the ornamental or flowering plants. Examples of such plants include but are not limited to Ageratum, Amaranthus, Anthirrhinum, Aquilegia, Begonia, Chrysanthemum, Cineraria, clover, Cosmos, cowpea, Cyclamen, Dahlia, Datura, Delphinium, Gerbera, Gladiolus, Gloxinia, Hippeastrum, Impatiens, Mesembryanthemum, petunia, Primula, Saint Paulia, Salpiglossis, Tagetes, Verbena, Viola, Vinca, Zinnia, Pelargonium and the like.
Other types of plants may be susceptible to INSV infection but these plants may not present disease symptoms directly associated with INSV infection, however such plants may present symptoms of a disease as a result of a secondary infection by a different organism made possible as a result of an initial infection by INSV. Such plants may therefore be viewed as being the subject of an INSV infection related disease and may include plants selected from a wider group of plant types. Further examples of this group of plant types may include vegetable and other crops. Such crop types include alfalfa, aubergine, beet, broad bean, broccoli, brussels sprouts, cabbage, cauliflower, celery, chicory, cow pea, cucumber, endive, gourd, groundnut, lettuce, melon, onion, papaya, pea, peanut, pepper, pineapple, potato, safflower, snap bean, soybean, spinach, squash, sugarbeet, sunflower, tobacco, tomato, water melon and the like.
The invention relates in particular to ornamental plants and preferably to those listed ornamental plants comprising in their plant genome a DNA construct of the invention.
The particular features of tospoviruses including those of INSV are illustrated hereinafter.
The S, M and L RNA are single stranded RNA molecules. The S RNA of INSV is about 3000 nucleotides long(SEQ. ID No.1; SEQ ID No. 2) and comprises two genes, one (SEQ ID No.3) encoding a non-structural protein (NSs) in viral sense, the other one (SEQ ID No.11) encoding the nucleocapsid protein (N) in viral complementary sense. The intergenic region between the NSs- and N-gene can be folded into a secondary structure (Seq ID No. 7 and SEQ ID No.8). The 5'- and 3'-terminal sequences of the S RNA are capable of hybridizing to each other such that the first nucleotide is opposite (and complementary) to the last nucleotide of said S RNA strand. For the purposes of the description the double-stranded structure obtained by hybridizing both RNA termini will be referred to as a "pan-handle" (SEQ ID No.5 and SEQ ID NO. 6) hereinafter.
The M RNA strand of INSV comprises about 5000 nucleotides (SEQ ID No. 14). It contains at least two open reading frames, one encoding a non-structural protein (NSm) in viral sense (SEQ ID No.15), and another open reading frame (SEQ ID No.21) in viral complementary sense. This open reading frame is translated on polysomes located on the endoplasmic reticulum where the nascent polypeptide chain is cleaved co-translationally to form the spike proteins G1 and G2 respectively. As with S RNA, the termini of the M RNA strand are complementary to each other and may likewise hybridize to form a "pan-handle" (SEQ ID No.18 and SEQ ID No.19).
The L RNA strand of INSV comprises about 8900 nucleotides. It contains complementary 3' and 5' ends for a length of from about 50 to about 80 nucleotides. The RNA has a negative polarity, with one open reading frame (ORF) located as the viral complementary strand. This ORF corresponds to a primary translation product of about 2875 amino acids in length with an anticipated Mw of between about 300,000 to about 350,000. Comparison with the polymerase proteins of other negative strand viruses indicates that this protein probably represents a viral polymerase. In some mutant strains, shortened L RNA molecules have been found in addition to the wild type, full length L RNA. These shortened L RNAs however are observed to possess the characteristic terminal nucleotide sequences and thus are capable of forming "pan handle" structures. They are also encapsidated with nucleocapsid protein and are included in virus particles. Their presence suppresses symptom development resulting in less severe detrimental effect. Thus, these shortened L RNA molecules can be regarded as defective interfering (DI) RNAs. A defective interfering RNA is one which is capable of interfering in replication by competing with other genomic RNAs for polymerases and therefore is capable of being replicated, and by so doing inhibits the replication and/or expression of other genomic RNA's with which it is competing. Thus, a DI RNA may comprise any RNA sequence which is capable of being replicated and may be an L, S, or M RNA within the context of the present invention. Such DI RNA sequences may comprise RNA sequences which have had nucleotides either deleted from or added thereto provided that they are capable of competing for polymerases and of replicating.
A preferred embodiment of the invention relates to DNA constructs of the invention coding for transcription into INSV RNA sequences of a "pan-handle" (SEQ ID No.5, SEQ ID No.6; SEQ ID No.18, SEQ ID No.19), or into INSV RNA sequences homologous thereto.
Another preferred embodiment of the invention relates to DNA constructs of the invention coding for transcription into INSV-RNA sequences of an open reading frame in viral complementary sense i.e. having negative polarity, or into corresponding RNA sequences in which one or more codons have been replaced by their synonyms, or into RNA sequences homologous thereto.
A further preferred embodiment of the invention relates to DNA constructs of the invention coding for transcription into INSV-RNA sequences of a hairpin (SEQ ID No.7, SEQ ID No.8; SEQ ID No.13, SEQ ID No.16) or into RNA sequences homologous thereto.
Preferably, the INSV-RNA sequence referred to hereinabove has at least 20 nucleotides. Preferably, the INSV-RNA sequence has at least 50 nucleotides.
Examples of DNA constructs suitable for use according to the invention include INSV-Related DNA Sequences coding for transcription into (reference is made to the sequence listing);
i) the viral S RNA nucleotide sequence from 1 to 3017 (SEQ. ID No.1)
ii) the viral S RNA nucleotide sequence from position 25 to 3017 (SEQ. ID No.2);
iii) the viral S RNA nucleotide sequence from 87 to 1436 (SEQ. ID No.3);
iv) the viral S RNA nucleotide sequence from 2080 to 2868 (SEQ. ID No.4);
v) the viral S RNA "pan-handle" structure comprising:
a) a first nucleotide sequence of from about 30 to about 36 nucleotides in length from the 5' end of the viral S RNA
and
b) a second nucleotide sequence of from about 30 to about 36 nucleotides in length from the 3' end of the viral S RNA
vi) the viral S RNA nucleotide sequence from 1437 to 2079; (SEQ ID No. 7)
vii) the viral S RNA nucleotide sequence from 1440 to 2041; (SEQ ID No.8)
viii) the viral complementary S RNA nucleotide sequence from 1 to about 3017; (SEQ ID No.9)
ix) the viral complementary S RNA nucleotide sequence from 1 to 2993; (SEQ ID No.10)
x) the viral complementary S RNA nucleotide sequence from 150 to 938; (SEQ ID No.11)
xi) the S RNA nucleotide sequence from 1581 to 2930 of the viral complementary S RNA strand; (SEQ ID No.12);
xii) the viral complementary S RNA secondary structure having a nucleotide sequence of 642 nucleotides from 939 to 1580; (SEQ ID No.13)
xiii) S RNA nucleotide sequence from 87 to 1436 in which one or more codons have been replaced by their synonyms;
xiv) S RNA nucleotide sequence from 2080 to 2868 in which one or more codons have been replaced by their synonyms;
xv) the M RNA nucleotide sequence from 1 to 4970 (SEQ ID No.14);
xvi) the M RNA sequence from 86 to 997 (SEQ ID No.15);
xvii) the M RNA sequence of the intergenic region from 998 to 1470 (SEQ ID No.16);
xviii) the M RNA sequence from 1471 to 4884; (SEQ ID No. 17)
xix) the M RNA "pan-handle" structure comprising: a) a first nucleotide sequence of from about 30 to about 36 nucleotides in length from the 5' end of the viral M RNA
and
b) a second nucleotide sequence of from about 30 to about 36 nucleotides in length from the 3' end of the viral M RNA
xx) the complementary viral M RNA sequence from 1 to 4970; (SEQ ID No.20)
xxi) the complementary viral M RNA sequence from position 87 to position 3500 of the complementary viral M RNA sequence; (SEQ ID No.21)
xxii) the complementary viral M RNA sequence from position 3974 to 4885 (SEQ ID No.22)
xxiii) RNA sequences homologous to the nucleotide sequences defined under i) to xii) and xv) to xxii) hereinabove.
xxiv) fragments of sequences defined under i) to xxii) hereinabove.
Preferred INSV-Related DNA Sequences code for transcription into the RNA sequences according to sequences iv) to xii) and xv) to xxii) as defined above, or into RNA sequences homologous thereto, or into fragments thereof comprising at least 15 nucleotides, more preferably at least 20 nucleotides, and most preferably at least 50 nucleotides.
According to another preferred embodiment of the invention the DNA constructs of the invention comprise INSV Related DNA Sequences coding for transcription into a combination of the 5' and 3' terminal sequences (ie "pan-handles) of viral S, M or L RNA respectively, more preferably of S or M RNA, and most preferably of S RNA. Examples of S RNA and M RNA terminal sequences include
i) a first nucleotide sequence 36 nucleotides in length from the 5' end of the viral S RNA:
5' AGAGCAATNN NNNNNNNNNN NNNNGAACAAC CCAAGC 3'
(SEQ ID No.5 i.e. nucleotides from position 1 to 36 of SEQ ID No.1, where N stands for A,T,G, or C)
and
a second nucleotide sequence 36 nucleotides in length from the 3' end of the viral S RNA:
5' GATTATATG ATGTTATATT CGTGACACAA TTGCTCT 3'
(SEQ ID No.6 ie nucleotides from position 2981 to 3017 of SEQ ID No.1)
ii) a first nucleotide sequence of 36 nucleotides in length from the 5' end of the viral M RNA:
5' AGAGCAATCA GTGCATCAAA ATTATATCTA GCCGAA 3'
(SEQ ID No.18 ie nucleotides from position 1 to 36 of SEQ ID No.13)
and
b) a second nucleotide sequence 36 nucleotides in length from the 3' end of the viral M RNA
5' TGTTGTATGT AGAGATTTTG TTTGCACTGA TTGCTC T 3'
(SEQ ID No.19 ie nucleotides from position 4941 to 4970 of SEQ ID No. 13)
In the case of the terminus at the 5' end of the S RNA it is not known whether or not there are sixteen or seventeen nucleotides in the unknown region demarked by a series of "N" s, however the exact number of nucleotides in this region is not considered to be critical to the formation of "pan-handle" structures so long as the 5' end of the S RNA is capable of complementing the 3' end of the S RNA thus enabling the formation of a "pan-handle" structure.
The invention further provides probes suitable for use as diagnostic tools for the diagnosis of disease in plants suspected of being infected with INSV tospoviruses. Such probes comprise a labeled oligonucleotide (RNA or DNA) sequence complementary to an RNA sequence of an INSV tospovirus. The desired length of the sequence and appropriate method for diagnostic use of probes are known by those skilled in the art. A suitable probe may comprise a nucleotide sequence of at least 12 to about 800 nucleotides, preferably at least 15, more preferably more than 30 nucleotides, and most preferably from about 400 to 600 nucleotides complementary to an RNA sequence of an INSV tospovirus.
Probes according to the invention are helpful in identifying INSV tospovirus RNA or parts thereof in infected plant material i.a. for diagnostic purposes prior to full presentation of disease symptoms in plants.
The invention accordingly also provides a diagnostic method of determining INSV tospovirus infection in plants which comprises detecting INSV tospovirus replicative forms employing the probes of the invention in dot-blot type assays.
Probes according to the invention are useful in the construction of and use of chimeric genes comprising a DNA sequence corresponding to an RNA sequence of an INSV tospovirus.
The DNA constructs of the invention may be obtained by insertion of an INSV Related DNA Sequence in an appropriate expression vector, such that the sequence is brought under expression control of a promoter capable of functioning in plants and its transcription is terminated by a terminator capable of functioning in plants.
The term "appropriate expression vector" as used herein refers to a vector containing a promoter region and a terminator region which are capable of functioning in plant cells.
The insertion of an INSV Related DNA Sequence into an appropriate expression vector may be carried out in a manner known per se. Suitable procedures are illustrated in the examples hereinafter.
Likewise the construction of an appropriate expression vector may be carried out in a manner known per se.
Plants according to the invention may be obtained by
a) inserting into the genome of a plant cell a DNA construct as hereinbefore defined;
b) obtaining transformed cells; and
c) regenerating from the transformed cells genetically transformed plants.
DNA vectors of the present invention may be inserted into the plant genome of plants susceptible to INSV infection. Such plant transformation may be carried out employing techniques known per se for the transformation of plants, such as plant transformation techniques involving Ti plasmids derived from Agrobacterium tumefaciens, A. rhizogenes or modifications thereof, naked DNA transformation or electroporation of isolated plant cells or organized plant structures, the use of micro-projectiles to deliver DNA, the use of laser systems, liposomes, or viruses or pollen as transformation vectors and the like.
Plants of the invention may be monitored for expression of an INSV-Related DNA Sequence by methods known in the art, including Northern analysis, Southern analysis, PCR techniques and/or immunological techniques and the like. The plants of the invention show decreased susceptibility to INSV infection as demonstrated by tests whereby the plants are exposed to INSV preferentially at a concentration in the range at which the rate of disease symptoms correlates linearly with INSV concentration in the inoculum.
Methods suitable for INSV inoculation are known in the art and include mechanical inoculation, and in particular, the use of appropriate vectors.
Plants of the invention may also be obtained by the crossing of a plant obtained according to the methods of the invention with another plant to produce plants having in their plant genome a DNA construct of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is illustrated by the following non-limiting examples and accompanying figures.
FIG. 1: Schematic representation of an INSV particle.
FIG. 2: Sequence strategy for INSV viral S RNA.
FIG. 3: Open reading frame analysis of the INSV S RNA, full bars represent translational stop codons (TAA, TAG, TGA), half size bars indicate start codons (ATG).
FIG. 4: Schematic review of the construction of a suitable expression vector (pZU-B).
FIG. 5: Schematic review of the construction of a suitable plasmid comprising the INSV N protein-coding sequence.
FIG. 6: Schematic review of the construction of a suitable plasmid comprising the INSV NSs protein-coding sequence.
FIG. 7: Schematic review of the construction of a suitable plasmid comprising the INSV NSm protein-coding sequence.
FIG. 8: Schematic review of the construction of a suitable plasmid comprising the INSV G1/G2 glycoprotein precursor-coding sequence.
FIG. 9: Schematic review of the construction of a INSV N gene-containing plant transformation vector.
FIG. 10: Schematic review of the construction of a INSV NSs gene-containing plant transformation vector.
FIG. 11: Schematic review of the construction of a INSV G1/G2 glycoprotein precursor gene-containing plant transformation vector.
FIG. 12: Schematic review of the construction of a INSV NSm gene-containing plant transformation vector.
FIG. 13: The secondary structure located at the intergenic region of INSV S RNA.
Suitable examples of preferred INSV Related DNA Sequences coding for transcription into a sequence of the secondary structure of the intergenic region of S RNA or of RNA sequences homologous thereto are sequences coding for the 1437 to 2079 nucleotide sequence of S RNA or for a sequence homologous to such sequences.
Other advantageous features of the present invention will be apparent from the following examples.
MATERIAL AND METHODS
All INSV RNA-derived sequences presented here are depicted as DNA sequences for the sole purpose of uniformity. It will be appreciated that this is done for convenience.
Cultivars of Nicotiana tabacum and Petunia hybrida, used in plant transformation studies, are grown under standard greenhouse conditions. Axenic explant material is grown on standard MS media Murashige and Skoog, (1962) Physiol Plant 15:473-497! containing appropriate phytohormones and sucrose concentrations.
E. coli bacteria are grown on rotary shakers at 37° C. in standard LB-medium. Agrobacterium tumefaciens strains are grown at 28° C. in MinA medium supplemented with 0.1% glucose Ausubel et al., (1987) Current Protocols in Molecular Biology, Green Publishing Associates and Wiley Intersciences, New York, Chichester, Brisbane, Toronto, and Singapore!.
In all cloning procedures the E. coli strain JM83, (F - , Δ(lac-pro), ara, rpsL, .O slashed.80, dlacZM15) is used as a recipient for recombinant plasmids.
Binary vectors are conjugated to Agrobacterium tumefaciens strain LBA 4404, a strain containing the Ti-plasmid vir region, Hoekema et al., (1983) Nature 303:179-180! in standard triparental matings using the E. coli HB101, containing the plasmid pRK2013 as a helper strain. Figurski and Helinski, (1979) Proc. Natl. Acad. Sci.USA 76:1648-1652! Appropriate Agrobacterium tumefaciens recipients are selected on media containing rifampicin (50 μg/ml) and kanamycine (50 μg/ml).
Cloning of fragments in the vectors pUC19 Yanish-Perron et al. (1985) Gene 33:103-119!, pBluescript (Stratagene), pBIN19 Bevan et al., (1984) Nucl Acids Res. 12:8711-8721! or derivatives, restriction enzyme analysis of DNA, transformation to E. coli recipient strains, isolation of plasmid DNA on small as well as large scale, nick-translation, in vitro transcription, DNA sequencing, Southern blotting and DNA gel electrophoresis are performed according to standard procedures Maniatis et al., (1982) Molecular Cloning, a Laboratory Manual. Cold Spring Harbor Laboratory, New York; Ausubel et al. supra, (1987)!.
DNA amplification using the polymerase chain reaction (PCR) were performed as recommended by the supplier of the Taq polymerase (Perkin Elmer Cetus).
Amplifications of RNA by reverse transcription of the target RNA followed by standard DNA amplification were performed using the Gene Amp RNA PCR Kit as recommended by the supplier (Perkin Elmer Cetus).
DESCRIPTION OF THE PREFERRED EMBODIMENTS
EXAMPLES
Example 1
Isolation of INSV particles and genetic material therein
INSV isolate NL-07, an isolate from Impatiens, is maintained on Impatiens by grafting. Virus is purified from systemically infected Nicotiana rustica leaves, after mechanical inoculation essentially as described by Tas et al. (1977) J. Gen. Virol. 36:81-91!. All material used in the isolation procedure should be maintained at a temperature of 4° C. Twelve days after inoculation 100 grams of infected leaves are harvested and ground for 5-10 seconds at a low speed setting in 5 volumes extraction buffer (0.1M NaH 2 PO 4 , 0.01M Na 2 SO 3 , pH 7) in a Waring blender. The suspension is filtered through cheesecloth and the filtrate is centrifuged for 10 minutes at 16,000×g. The resulting pellet is resuspended in three volumes resuspension buffer (0.01M NaH 2 PO 4 , 0.01M Na 2 SO 3 , pH 7). The pellet is dissolved by stirring carefully at 4° C. After centrifuging for 10 minutes at 12,500×g the pellet is discarded and the supernatant centrifuged again for 20 minutes at 50,000×g. The pellet is resuspended in 0.2 volume of resuspension buffer (0.01M NaH 2 PO 4 , 0.01M Na 2 SO 3 , pH 7) and kept on ice for 30 minutes. Anti-serum raised in rabbits against material from non-infected Nicotiana rustica is added to the solution and carefully stirred for 1 hour. Non-viral complexes are pelleted after 10 minutes centrifuging at 16,000×g. The cleared supernatant is loaded on a linear 5%-40% sucrose gradient in resuspension buffer(0.01M NaH 2 PO 4 , 0.01M Na 2 SO 3 , pH 7), and spun for 45 minutes at 95,000×g. The opalescent band containing INSV particles is carefully collected with a syringe and diluted 4 times with resuspension buffer. Washed viruses are pelleted by centrifugation for 1.5 hours at 21,000×g and resuspended in one volume of resuspension buffer. Generally, 100 grams of leaf material yields approximately 0,5 mg of INSV viruses. INSV RNA is recovered preferentially from purified virus preparations by SDS-phenol extractions followed by ethanol precipitation. From 1 mg INSV, 1-5 μg of RNA is extracted. The isolated RNA molecules are analysed for intactness by electrophoresis on an agarose gel. Three distinct RNA molecules are identified with apparent sizes of about 3000 nucleotides (S RNA), about 4900 nucleotides (M RNA) and about 8900 nucleotides (L RNA) respectively.
Example 2
Sequence determination of the 3'-termini of the INSV viral RNAs
In order to perform direct RNA sequencing, INSV RNA is extracted from purified nucleocapsids essentially according to Verkleij et al. (1983) supra. Twelve days after inoculation 100 grams of infected leaves are harvested and ground for 5-10 seconds at a low speed setting in four volumes of TAS-E buffer (0.01M EDTA, 0.01M Na 2 SO 3 , 0.1% cysteine, 0.1M TRIS pH 8.0) in a Waring blender. The suspension is filtered through cheesecloth and centrifuged for 10 minutes at 1,100×g. Nucleocapsids are recovered from the supernatant after 30 minutes of centrifuging at 66,000×g. The pellet is carefully resuspended in one volume of TAS-R buffer (1% Nonidet NP-40, 0.01M EDTA, 0.01M Na 2 SO 3 , 0.1% cysteine, 0.01M glycine, 0.01M TRIS, pH 7.9). The pellet is dissolved by stirring carefully for 30 minutes at 4° C. The supernatant is cleared by centrifuging for 10 minutes at 16,000×g. Crude nucleocapsids are collected from the cleared supernatant by sedimentation through a 30% sucrose cushion for 1 hour at 105,000×g. The nucleocapsid pellet is resuspended in 400 μl 0.01M Na-citrate pH 6.5, layered on a 20-40% sucrose (in 0.01M Na-citrate pH 6.5) and spun for 2 hours at 280,000×g. The three different opalescent bands, respectively L, M and S nucleocapsid, are collected separately. INSV RNA is recovered preferentially from purified nucleocapsid preparations by SDS-phenol extractions followed by ethanol precipitation. Generally, 100 μg of RNA are obtained from 100 grams of infected leaves. The 3'-ends of the separate INSV RNAs are labeled using RNA ligase and 5'- 32 P!pCp. The end-labeled RNA molecules are separated on a low gelling temperature agarose gel Wieslander, (1979) Anal Biochem 98:305-309!. The enzymatic approach described by Clerx-Van Haaster and Bishop (1980) Virology 105:564-574! and Clerx-Van Haaster et al. (1982) J Gen Virol 61:289-292! is used to determine the 30 terminal nucleotides of the 3'- and 5'-ends of both S and M RNA.
Synthetic oligonucleotides complementary to the 3'-termini are synthesized using a commercially available system (Applied Biosystems) and used for dideoxy-sequencing with reverse transcriptase.
Example 3
cDNA cloning of INSV genetic material
Oligonucleotides complementary to the 3'-end of the S RNA are used for priming first strand cDNA synthesis. With these primers, double stranded DNA to INSV RNA is synthesized according to Gubler and Hoffman (1983) Gene 25:263-269!.
Two different approaches are used to generate cDNA clones to the INSV viral RNAs. A first series of clones is obtained by random priming of the INSV RNA using fragmented single stranded calf thymus DNA, followed by first and second strand cDNA synthesis. cDNA is made blunt-ended using T4-DNA polymerase and ligated with T4 ligase into the SmaI site of pUC19.
A second series of INSV cDNA clones is obtained by priming first strand DNA synthesis with the oligonucleotides complementary to the 20 terminal nucleotides at the 3'-ends of the INSV RNAs. Blunt ended cDNA fragments are cloned into the Sma I site of pUC19.
cDNA clones from both series containing viral inserts are selected via colony hybridization, essentially according to the method of Grunstein and Hogness (1975) Proc. Natl. Acad. Sci. USA 72:3961-3965! using 32 !P-labeled, randomly primed first strand cDNA as a probe. Sets of overlapping cDNA clones are selected by Southern analysis followed by plasmid walking, in order to construct a restriction map, based on cDNA derived sequences of the S RNA (FIG. 2).
Example 4
Sequence determination of the INSV S RNA
In order to determine the sequence of the S RNA 5 selected cDNA clones are subcloned into pBluescript, resulting in the plasmids pINSV-S2, pINSV-S15, pINSV-S61, pINSV-S60 and pINSV-S39, (FIG. 2). The clones are sequenced in both directions using the protocol of zhang et al. (1988) Nucl. Acids. Res. 16:1220!. The nucleotide sequence of the 3'-end of the S RNA is determined by primer extension of the synthetic oligonucleotide INSV-S60 (5' d(AGAGCAATTGTGTCA) which is complementary to the 15 nucleotides of the 3'-terminus. Sequence data from the INSV S RNA (3017 nt) is summarized in the sequence listing (SEQ ID No.1 to SEQ ID No.12).
Computer simulated translation of the 6 different reading frames on the viral strand and viral complementary strand reveals the presence of two putative open reading frames (FIG. 3). On the viral strand an open reading frame is found starting at position 87 and terminating at a UAA stopcodon at position 1436 encoding a protein of 449 amino acids with a predicted molecular mass of about 51.2 kd. This protein is a non-structural protein, tentatively designated NSs (FIG. 3/SEQ ID No.26). The other open reading frame is located on the viral complementary strand from position 2080 to 2868 (SEQ ID No. 11), encoding a 262 amino acid long polypeptide with a predicted molecular mass of about 28.7 kd. This open reading frame encodes the viral nucleocapsid protein N (FIG. 3/SEQ ID No 25). Thus FIG. 3 shows the coding capacities of the viral and the viral complementary strand of INSV S RNA, indicating the NSs and N protein genes are expressed from subgenomic mRNAs (SEQ ID No.3, SEQ ID No.11 respectively). Thus, the situation occurs that a plant virus RNA has an ambisense gene arrangement. Other important features of this S RNA sequence is the existence of complementary terminal repeats capable of forming so-called "pan-handle" structures. These structures play an important role in replication and transcription of viral RNA. Another putative regulatory element is the secondary structure in the intergenic region of the S RNA, which most likely contains the transcription termination signals for both subgenomic mRNAs, encoding respectively the N and NSs-protein.
The nucleotide sequence of the INSV M and L RNA is elucidated employing similar strategies and methods as used to determine the nucleotide sequence of the S RNA.
Example 5
Construction of an expression vector pZU-B
The recombinant plasmid pZO347 is a derivative of pBluescript carrying a 496 bp BamHI-SmaI fragment containing a 426 bp 35S promoter fragment (HincII fragment) of CaMV strain Cabb-S, linked to a 67 bp fragment of the non-translated leader region, the so-called Ω-region, of the tobacco mosaic virus. This results in a chimeric promoter with a complete transcriptional fusion between the promoter of CaMV to the untranslated leader of TMV. By using in vitro mutagenesis the original position of the TMV ATG startcodon is mutated to a SmaI site.
The plasmid pZO008 carries the nopaline synthase (NOS) terminator as a 260 bp PstI-HindIII fragment. This PstI-HindIII fragment is excised from pZO008 and ligated using T4 ligase into PstI-HindIII linearized pZO347. The resulting recombinant plasmid pZU-B is another plant expression vector. The sequence of this 35S-Ω promoter as used in the plant expression vector pZU-B is shown as SEQ ID No.23. The resulting recombinant plasmid pZU-B contains the 35S HincII-TMV Ω fusion (35S-Ω), unique SmaI and PstI sites and the NOS terminator (FIG. 4). This expression vector is preferentially used in constructing translational fusions of the gene for expression downstream of the chimaeric promoter 35S-Ω.
Example 6
Subcloning of the INSV N protein gene
The INSV N protein coding sequence is obtained by fusion of the cDNA clones pINSV-S60 and pINSV-S39 (FIG. 5). The cDNA clone pINSV-S60 is subjected to SpeI digestion and the fragment containing the 3'-end of the INSV N protein gene is separated electrophoretically and purified from the gel using a DEAE membrane (NA-45, Schleicher and Schull) and cloned in the largest SpeI fragment of pINSV-S39 linearized resulting in the recombinant plasmid pINSV-N. Primers are designed homologous to the translational start and stop codon. Primer INSV-066 d(GCAGATATCATGAACAAAGC) creates an EcoRV site just proximal to the start codon.
Primer INSV-070 d(GCAACCTGCAGCTCAAATCTCTT) creates a PstI site just distal to the stop codon. These primers are used in standard PCR experiments in which pINSV-N is used as the template. The resulting PCR fragment is isolated from the gel using a DEAE membrane (NA-45, Schleicher and Schull) and cloned in the SmaI linearized pBluescript to generate plasmid pINSV-N2. The added restriction sites, EcoRV and PstI, facilitate the construction of further plasmids. (Alternatively, one may choose to add the sites in different ways such as but not limited to site-directed mutagenesis or by ligation of other synthetic oligonucleotide linkers. Such methods are all known to a person skilled in the art.)
Example 7
Subcloning of the INSV non-structural protein genes (NSs gene) of INSV S RNA
The sequence of the gene corresponding to the non-structural protein NSs is isolated using RNA based PCR on isolated INSV S RNA. Two primers are designed which are homologous to regions spanning either the translational start codon or stop codon. The start codon primer contains an EcoRV site proximal to the ATG codon, the stop codon primer has a PstI site just distal thereto. Purified INSV S RNA is subjected to the Gene AMP RNA PCR. The resulting PCR fragment is isolated from the gel and cloned into SmaI linearized pBluescript yielding the recombinant plasmid pINSV-NSs (FIG. 6).
Example 8
Subcloning of the INSV non-structural protein gene (NSm gene) of the INSV M RNA
The sequence of the gene corresponding to the non-structural protein NSm is isolated using RNA based PCR on isolated INSV M RNA. Two primers are designed which are homologous to regions spanning either the translational start codon or stop codon. The start codon primer contains an EcoRV site proximal to the ATG codon, the stop codon primer has a PstI site just distal thereto. Purified INSV S RNA is subjected to the Gene AMP RNA PCR. The resulting PCR fragment is isolated from the gel and cloned into SmaI linearized pBluescript yielding the recombinant plasmid pINSV-NSm (FIG. 7).
Example 9
Subcloning of the INSV G1/G2 glycoprotein gene (G1/G2 gene) of the INSV M RNA
The sequence of the gene corresponding to the G1/G2 glycoprotein precursor is isolated using RNA based PCR on isolated INSV M RNA. Two primers are designed homologous to regions spanning either the translational start codon or stop codon. The start codon primer contains an EcoRV site proximal to the ATG codon, the stop codon primer has a PstI site just distal thereto. Purified INSV M RNA is subjected to the Gene AMP RNA PCR. The resulting PCR fragment is isolated from the gel and cloned into SmaI linearized pBluescript yielding the recombinant plasmid pINSV-G1/G2 (FIG. 8).
Example 10
Construction of plant transformation vectors containing INSV sequences
Example 10A
N protein constructions in pZU-B
In order to make a fusion in which the ATG start codon from the N protein gene is fused directly to the 3'-end of the TMV untranslated leader of the 35S-Ω promoter the start codon of the N gene has to be mutated using the PCR approach as hereinbefore described. The N protein gene is excised from the plasmid pINSV-N2 via an EcoRV-PstI digestion. The fragment is isolated and inserted into the SmaI-PstI linearised pZU-B, resulting in recombinant plasmid pINSV-NB. The chimeric cassette containing the 35S-Ω promoter, the N gene and the NOS terminator is excised from the plasmid pINSV-NB via a BamHI/XbaI digestion. The isolated chimaeric gene cassette is then inserted into the BamHI/XbaI linearized pBIN19 to create the binary transformation vector pINSV-NBB. The resulting plasmid pINSV-NBB (FIG. 9) is used in plant transformation experiments using methods well known to a person skilled in the art.
Example 10B
NSs protein gene constructions in pZU-B
In order to create a fusion in which the ATG start codon from the NSs protein is fused directly to the 3'-end of the TMV leader of the 35S-Ω promoter the start codon of the NSs gene is mutated, using the PCR approach. The plasmid PINSV-Ns is digested with EcoRV and PstI and the NSs containing fragment is isolated from the gel and inserted into SmaI/PstI linearized pZU-B resulting in the recombinant plasmid pINSV-NSsB. The chimaeric cassette containing the 35S-Ω promoter, the mutated NSs protein gene and the NOS terminator is excised from the plasmid pINSV-NSsB via a BamHI/XbaI digestion. The isolated chimeric gene cassette is then inserted into the BamHI/XbaI linearized pBIN19 to create the binary transformation vector pINSV-NSsBB. The resulting plasmid pINSV-NSsBB (FIG. 10) is used in plant transformation experiments using methods well known to a person skilled in the art.
Example 10C
G1/G2 glycoprotein gene constructions in pZU-B
In order to create a fusion in which the ATG start codon from the G1/G2 glycoproteinprecursor is fused directly to the 3'-end of the TMV leader of the 35S-Ω promoter the start codon of the G1/G2 gene is mutated, using the PCR approach. The plasmid pINSV-G1/G2 is digested with EcoRV and PstI and the G1/G2 containing fragment is isolated from the gel and inserted into SmaI/PstI linearized pZU-B resulting in the recombinant plasmid pINSV-G1/G2B. The chimeric cassette containing the 35S-Ω promoter, the mutated G1/G2 glycoprotein gene and the NOS terminator is excised from the plasmid pINSV-G1/G2B via a BamHI/XbaI digestion. The isolated chimeric gene cassette is then inserted into the BamHI/XbaI linearized pBIN19 to create the binary transformation vector pINSV-G1/G2BB. The resulting plasmid pINSV-G1/G2BB (FIG. 11) is used in plant transformation experiments using methods well known to a person skilled in the art.
Example 10D
NSm protein gene constructions in pZU-B
In order to create a fusion in which the ATG start codon from the NSm protein is fused directly to the 3'-end of the TMV leader of the 35S-Ω promoter the startcodon of the NSm gene is mutated, using the PCR approach. The plasmid pINSV-NSm is digested with EcoRV and PstI and the NSm-containing fragment is isolated from the gel and inserted into SmaI/PstI linearized pZU-B resulting in the recombinant plasmid pINSV-NSmB. The chimeric cassette containing the 35S-Ω promoter, the mutated NSm protein gene and the NOS terminator is excised from the plasmid pINSV-NSmB via a BamHI/XbaI digestion. The isolated chimeric gene cassette is then inserted into the BamHI/XbaI linearized pBIN19 to create the binary transformation vector pINSV-NSmBB. The resulting plasmid pINSV-NSmBB (FIG. 12) is used in plant transformation experiments using methods well known to a person skilled in the art.
Example 10E
5'- and 3'-termini "pan-handle" constructions in pZU-B
A DNA analysis programme is used to locate the "pan-handle" element of the loop in the viral INSV S RNA. The strongest "pan-handle" structure that is detected includes about the first 24-25 nucleotides at the 5'-end (1 to 24 or 25) of the viral S RNA and about the last 36 nucleotides at the 3'-end of the viral S RNA (SEQ ID Nos 5 and 6 respectively). The length of the pan-handle element of the loop is about 36 nucleotides long.
These regions are synthesized on a commercial DNA synthesizer and appropriate linker sequences are added. Construction of the "pan-handle" vectors of S and M RNA results in respectively: pINSV-termS and pINSV-termM. Using appropriate restriction enzyme combination these fragments are inserted between the 35S-Ω promoter and the NOS terminator of pZU-B yielding the chimeric cassettes: pINSV-termSA, pINSV-termMA, pINSV-termSB and pINSV-termMB. These cassettes are then transferred into the binary transformation vector pBIN19 using appropriate enzyme combinations yielding the following plasmids: pINSV-termSAB, pINSV-termMAB, pINSV-termSBB and pINSV-termMBB. Alternatively, it is possible to design "pan-handle" constructs including the 3'- and 5'-end termini that are larger than indicated above, or separated by any other DNA sequence in order to enhance the stability of the transcripts produced from these recombinant genes in plants. All "pan-handle" constructs resemble shortened tospovirus RNA molecules, specifically INSV RNA molecules and therefore can be regarded as defective interfering RNAs.
Example 10F
Construction containing INSV S RNA secondary structure region in pZU-B
A DNA analysis programme is used to locate a secondary structure in the viral INSV S RNA. The strongest secondary structure detectable starts at nucleotide 1440 and ends at nucleotide 2041 of SEQ ID No.1, (SEQ ID No 8).
The DNA fragment carrying the secondary structure region is isolated from pINSV-S61 using a PCR approach similar to that described earlier. The two primers used contain the sequences 1440-1460 and 2021-2041 of SEQ ID No.1. The PCR fragment is excised from an agarose gel and subsequently treated with T4 polymerase to create blunt ends and is subsequently cloned into the SmaI site of the expression vector pZU-B, resulting in the recombinant plasmid PINSV-HpSB. The plasmid pINSV-HpSB is digested with HindIII and the fragment containing the chimeric gene is excised from an agarose gel and ligated into XbaI linearized pBIN19, resulting in the transformation vector pINSV-HpSBB.
(It is clear to a person skilled in the art that other fragments can be isolated from the cDNA clones of the INSV S RNA containing the hairpin region as described above without interference to function. Also, a fragment containing the hairpin region may be synthesized using a DNA-synthesizer.)
Example 11
Transformation of binary vectors to tobacco plant material
Methods to transfer binary vectors to plant material are well established and known to a person skilled in the art. Variations in procedures exist due to for instance differences in used Agrobacterium strains, different sources of explant material, differences in regeneration systems depending on as well the cultivar as the plant species used.
The binary plant transformation vectors as described above are used in plant transformation experiments according to the following procedures. The constructed binary vector is transferred by tri-parental mating to an acceptor Agrobacterium tumefaciens strain, followed by southern analysis of the ex-conjugants for verification of proper transfer of the construct to the acceptor strain, inoculation and cocultivation of axenic explant material with the Agrobacterium tumefaciens strain of choice, selective killing of the Agrobacterium tumefaciens strain used with appropriate antibiotics, selection of transformed cells by growing on selective media containing kanamycine, transfer of tissue to shoot-inducing media, transfer of selected shoots to root inducing media, transfer of plantlets to soil, assaying for intactness of the construct by southern analyses of isolated total DNA from the transgenic plant, assaying for proper function of the inserted chimeric gene by northern analysis and/or enzyme assays and western blot analysis of proteins.
Example 12
Expression of INSV S RNA sequences in tobacco plant cells
RNA is extracted from leaves of regenerated plants using the following protocol. Grind 200 mg leaf material to a fine powder in liquid nitrogen. Add 800 μl RNA extraction buffer (100 mM Tris-HCl (pH 8,0), 500 mM NaCl, 2 mM EDTA, 200 mM β-Mercapto-ethanol, 0,4% SDS) and extract the homogenate with phenol, collect the nucleic acids by alcohol precipitation. Resuspend the nucleic acids in 0,5 ml 10 mM Tris-HCl (pH 8,0), 1 mM EDTA, add LiCl to a final concentration of 2M, leave on ice for maximal 4 hours and collect the RNA by centrifugation. Resuspend in 400 μl 10 mM Tris-HCl (pH 8,0), 1 mM EDTA and precipitate with alcohol, finally resuspend in 50 μl 10 mM Tris-HCl (pH 8,0), 1 mM EDTA. RNAs are separated on glyoxal/agarose gels and blotted to Genescreen as described by van Grinsven et al. (1986) Theor Appl Gen 73:94-101!. INSV S RNA sequences are detected using DNA or RNA probes labeled with 32 P!, 35 S! or by using non-radioactive labeling techniques. Based on northern analysis, it is determined to what extent the regenerated plants express chimaeric INSV S RNA sequences.
Plants transformed with chimaeric constructs containing an INSV N protein-encoding sequence are also subjected to western blot analysis. Proteins are extracted from leaves of transformed plants by grinding in sample buffer according to the method of Laemmli (1970) Nature 244:29-30!. A 50 μg portion of protein is subjected to electrophoresis in a 12,5% SDS-polyacrylamide gel essentially as described by Laemmli (1970) supra. Separated proteins are transferred to nitrocellulose electrophoretically as described by Towbin et al. (1979) Proc. Natl. Acad. Sci. USA 76:4350-4354!. Transferred proteins are reacted with antiserum raised against purified INSV structural or non-structural proteins (Towbin et al. (1979) supra. Based on the results of the western analysis, it is determined that transformed plants do contain INSV N proteins encoded by the inserted chimaeric sequences.
Example 13
Resistance of plants against INSV infection
Transformed plants are grown in the greenhouse under standard quarantine conditions in order to prevent any infections by pathogens. The transformants are self-pollinated and the seeds harvested. Progeny plants are analyzed for segregation of the inserted gene and subsequently infected with INSV by mechanical inoculation. Tissue from plants systemically infected with INSV is ground in 5 volumes of ice-cold inoculation buffer (10 mM phosphate buffer supplemented with 1% Na 2 SO 3 ) and rubbed in the presence of carborundum powder on the first two fully extended leafs of approximately 5 weeks old seedlings. Inoculated plants are monitored for symptom development during 3 weeks after inoculation.
Plants containing INSV Related DNA Sequences show reduced susceptibility to INSV infection as exemplified by a delay in symptom development, whereas untransformed control plants show severe systemic INSV symptoms within 7 days after inoculation.
Example 14
Use of synthetic oligonucleotides for diagnostic purposes
RNA is extracted from leaves of suspected plants using the following protocol: grind 1 gram of leaf material, preferentially showing disease symptoms, in 3 ml 100 mM Tris-HCl, 50 mM EDTA, 1.5M NaCl and 2% CTAB (pH 8.0). After grinding, 1 ml of the homogenate is subjected to chloroform extraction and incubated at 65° C. for 10 minutes. The inorganic phase is then collected and extracted with phenol/chloroform (1:1), followed by a last extraction with chloroform. The ribonucleic acids are isolated from the inorganic phase, containing the total nucleic acids, by adding LiCl to a final concentration of 2M. The preparation is incubated at 4° C. for 1 hour, after which the ribonucleic acids are collected by centrifugation. The ribonucleic acid pellet is resuspended in 25 μl 10 mM Tris-HCl, 1 mM EDTA (pH 8.0). The ribonucleic acids are recovered by standard alcohol precipitation. The ribonucleic acid pellet is resuspended in 25 μl 10 mM Tris-HCl, 1 mM EDTA (pH 8.0).
1 μl of the purified ribonucleic acids is spotted on a nylon blotting membrane (e.g. Hybond-N, Amersham UK). The presence of INSV in the plant is detected by standard hybridization, using any part or parts of the sequence isolated from virions or preferentially by designing synthetic oligomers on the basis of disclosed sequence information as a probe. (Alternatively, in vitro transcripts of regions of the INSV genome are used to detect INSV Related RNA Sequences in diseased plants.) A diseased plant is diagnosed by the occurrence of hybridization at the dot containing RNA material from the diseased plant.
__________________________________________________________________________SEQUENCE LISTING(1) GENERAL INFORMATION:(iii) NUMBER OF SEQUENCES: 27(2) INFORMATION FOR SEQ ID NO:1:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 3001 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(xi) SEQUENCE DESCRIPTION: SEQ ID NO:1:AGAGCAATGAACAACCAAGCTACAACAAATCTTACAATATTGTCAATTACATTACTACTT60CCATTTTAACATGTCTAGTGCAATGTATGAAACAATTATCAAATCGAAGTCCTCAATCTG120GGGAACAACATCTTCGGGTAAAGCAGTAGTAGATAGTTATTGGATTCATGATCAATCTTC180CGGAAAGAAGTTGGTCGAAGCTCAACTCTATTCTGACTCCAGGAGCAAGACCAGTTTCTG240TTACACTGGTAAAGTTGGCTTTCTCCCAACAGAAGAAAAAGAAATTATAGTGAGATGTTT300TGTGCCTATTTTTGATGACATTGATCTGAATTTCTCCTTTTCAGGGAATGTTGTCGAAAT360TCTGGTCAGATCTAACACAACAAACACAAACGGTGTTAAACATCAAGGTCATCTCAAAGT420GTTATCCTCTCAGTTGCTCAGAATGCTTGAAGAGCAAATAGCAGTGCCTGAAATTACTTC480AAGATTCGGTCTGAAAGAATCTGACATCTTCCCTCCAAATAATTTCATTGAAGCTGCAAA540TAAAGGATCATTGTCTTGTGTCAAAGAAGTCCTTTTTGATGTCAAGTATTCAAACAACCA600ATCCATGGGCAAAGTCAGTGTTCTTTCTCCTACCAGAAGTGTTCATGAATGGCTGTACAC660ACTTAAGCCTGTTTTTAACCAATCCCAGACCAACAACAGGACAGTAAACACTTTGGCTGT720AAAATCACTGGCAATGTCTGCAACTTCTGATTTAATGTCAGATACTCATTCGTTTGTCAG780GCTCAATAATAACAAGCCTTTTAAAATCAGCCTTTGGATGCGCATCCCTAAAATAATGAA840ATCAAACACATACAGCCGGTTCTTCACCCTGTCTGATGAATCTTCTCCTAAAGAGTATTA900TATAAGCATTCAATGTCTTCCGAATCACAACAATGTTGAAACAGTCATTGAATATAACTT960TGATCAGTCAAACCTCTTCTTGAATCAACTCCTTCTAGCAGTGATTCATAAAATTGAGAT1020GAATTTTTCTGATCTAAAAGAACCTTACAATGTTATCCATGATATGTCGTATCCTCAAAG1080AATTGTTCATTCACTTCTTGAAATCCACACAGAACTTGCTCAAACTGTCTGTGACAGTGT1140TCAGCAAGACATGATTGTCTTCACTATAAATGAGCCAGATCTAAAGCCAAAAAAGTTTGA1200GCTAGGGAAAAAGACTTTAAATTATTCAGAAGATGGTTATGGGAGAAAATATTTCCTTTC1260TCAGACCTTGAAAAGTCTTCCGAGAAACTCACAAACAATGTCTTATTTGGATAGCATCCA1320GATGCCCGATTGGAAATTTGACTATGCTGCAGGTGAAATAAAAATTTCTCCTAGATCAGA1380GGATGTTTTGAAAGCTATTTCTAAATTAGATTTAAATTAACCTTGGTTAAACTTGTCCCT1440AAGTAAAGTTTGTTTACATGCATTTAGATCAGATTAAACAAATCTAATAACAGATAAACC1500AAAAACAATCATATGAAATAAATAAATAAACATAAAATATATAAAAAATACAAAAAAAAT1560CATAAAATAAATAAAAACCAAAAAAGGATGGCCTTCGGGCACAATTTGGTTGCTTTAATA1620ATGCTTTAAAATGAATGTATTAGTAAATTATAAACTTTAAATCCAATCTACTCACAAATT1680GGCCAAAAATTTGTATTTGTTTTTGTTTTTGTTTTTTGTTTTTTGTTTTTGTTTTGTTTT1740ATTTGTTTTTTATTTTGTTTTTTGTTTTTTGTTTTTTATTTTATTTATATATATATATAT1800ATATATTTTGTAGTGGTTTTTATTGTTTTTATTATTTTTTGTAGCTTTTTTACTTGTTTA1860TTTCACACGCAAACACACTTTCAAGTTTATATATTAAAACACACATTAAACTTATTTCAA1920ATAATTTATAAAAGCACACTTAATACACTCAAACAATAATTAATTATTTTATTTTTTATT1980TTATTTTTTATTTTTATTATTTTTATTTTTATTTATTTAAATGCATTTAACACAACACAA2040AGCAAACCAAGCTCAAATCTCTTTTAAATAGAATCATTTTTCCCAAAATCAATAGTAGCA2100TTAAACATGCTGTAAATGGATGTAAGCCCTTCTTTGTAGTGGTCCATTGCAGCAAGTCCT2160TTAGCTTTCGGACTACAAGCCTTTAGTATATCTGCATATTGTTTAGCCTTGCCAATTTCA2220ACAGAGTTCATGCTATATCCTTTGCTTTTTAGAACTGTGCACACTTTCCCAACTGCCTCT2280TTAGTGCTAAACTTAGACATGTCAATTCCAAGCTCAACATGTTTAGCATCTTGATAAATA2340GCCGGAACTAGTGCAGCTATTTCAAAATTCAGTACAGATGCTATCAGAGGAAGACTTCCT2400CCTAAGAGAACACCCAAGACACAGGATTTCAAATCTGTGGTTGCAAGACCATATGAGGCA2460ATCAGAGGGTGACTTGGAAGGCTATTTATAGCTTCAGTCAGAGCAGATCCATTGTCCTTT2520ATCATTCCAACAAGATGAACTCTCACCATTGCATCAAGTCTTCGGAAAGTCATATCATTG2580ACCCCAACTCTTTCTGAATTGTTTCTAGTTTTCTTAATTGTGACTGATCCAAAAGTGAAG2640TCAGCACTCTTAATGACTCTCATTATAGATTGCCTATTCTTGAGGAAGGATAGGCAGGAT2700GCAGTAGTCATGTTCTGAATCTTTTCACGGTTGTTGGTAAAGAAGTCAGTGAAATTGAAA2760GACCCTTCATTTTGAGTTTCCTCAAATTCTAAGGAATCAGATTGAGTCAAAAGCTTGACT2820ATGTTCTCCTTGGTAATCTTTGCTTTGTTCATCTTGATCTGCTGACTTTACTAACTTTAA2880AGCTTAAAGTGTTCAAATTACTAAATAGTACTTGCGGTTAAAGTAGTATTTGGTAAAATT2940TGTAATTTTTCAGTTTCTAGCTTTGGATTATATGATGTTATATTCGTGACACAATTGCTC3000T3001(2) INFORMATION FOR SEQ ID NO:2:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 2993 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(xi) SEQUENCE DESCRIPTION: SEQ ID NO:2:GAACAACCAAGCTACAACAAATCTTACAATATTGTCAATTACATTACTACTTCCATTTTA60ACATGTCTAGTGCAATGTATGAAACAATTATCAAATCGAAGTCCTCAATCTGGGGAACAA120CATCTTCGGGTAAAGCAGTAGTAGATAGTTATTGGATTCATGATCAATCTTCCGGAAAGA180AGTTGGTCGAAGCTCAACTCTATTCTGACTCCAGGAGCAAGACCAGTTTCTGTTACACTG240GTAAAGTTGGCTTTCTCCCAACAGAAGAAAAAGAAATTATAGTGAGATGTTTTGTGCCTA300TTTTTGATGACATTGATCTGAATTTCTCCTTTTCAGGGAATGTTGTCGAAATTCTGGTCA360GATCTAACACAACAAACACAAACGGTGTTAAACATCAAGGTCATCTCAAAGTGTTATCCT420CTCAGTTGCTCAGAATGCTTGAAGAGCAAATAGCAGTGCCTGAAATTACTTCAAGATTCG480GTCTGAAAGAATCTGACATCTTCCCTCCAAATAATTTCATTGAAGCTGCAAATAAAGGAT540CATTGTCTTGTGTCAAAGAAGTCCTTTTTGATGTCAAGTATTCAAACAACCAATCCATGG600GCAAAGTCAGTGTTCTTTCTCCTACCAGAAGTGTTCATGAATGGCTGTACACACTTAAGC660CTGTTTTTAACCAATCCCAGACCAACAACAGGACAGTAAACACTTTGGCTGTAAAATCAC720TGGCAATGTCTGCAACTTCTGATTTAATGTCAGATACTCATTCGTTTGTCAGGCTCAATA780ATAACAAGCCTTTTAAAATCAGCCTTTGGATGCGCATCCCTAAAATAATGAAATCAAACA840CATACAGCCGGTTCTTCACCCTGTCTGATGAATCTTCTCCTAAAGAGTATTATATAAGCA900TTCAATGTCTTCCGAATCACAACAATGTTGAAACAGTCATTGAATATAACTTTGATCAGT960CAAACCTCTTCTTGAATCAACTCCTTCTAGCAGTGATTCATAAAATTGAGATGAATTTTT1020CTGATCTAAAAGAACCTTACAATGTTATCCATGATATGTCGTATCCTCAAAGAATTGTTC1080ATTCACTTCTTGAAATCCACACAGAACTTGCTCAAACTGTCTGTGACAGTGTTCAGCAAG1140ACATGATTGTCTTCACTATAAATGAGCCAGATCTAAAGCCAAAAAAGTTTGAGCTAGGGA1200AAAAGACTTTAAATTATTCAGAAGATGGTTATGGGAGAAAATATTTCCTTTCTCAGACCT1260TGAAAAGTCTTCCGAGAAACTCACAAACAATGTCTTATTTGGATAGCATCCAGATGCCCG1320ATTGGAAATTTGACTATGCTGCAGGTGAAATAAAAATTTCTCCTAGATCAGAGGATGTTT1380TGAAAGCTATTTCTAAATTAGATTTAAATTAACCTTGGTTAAACTTGTCCCTAAGTAAAG1440TTTGTTTACATGCATTTAGATCAGATTAAACAAATCTAATAACAGATAAACCAAAAACAA1500TCATATGAAATAAATAAATAAACATAAAATATATAAAAAATACAAAAAAAATCATAAAAT1560AAATAAAAACCAAAAAAGGATGGCCTTCGGGCACAATTTGGTTGCTTTAATAATGCTTTA1620AAATGAATGTATTAGTAAATTATAAACTTTAAATCCAATCTACTCACAAATTGGCCAAAA1680ATTTGTATTTGTTTTTGTTTTTGTTTTTTGTTTTTTGTTTTTGTTTTGTTTTATTTGTTT1740TTTATTTTGTTTTTTGTTTTTTGTTTTTTATTTTATTTATATATATATATATATATATTT1800TGTAGTGGTTTTTATTGTTTTTATTATTTTTTGTAGCTTTTTTACTTGTTTATTTCACAC1860GCAAACACACTTTCAAGTTTATATATTAAAACACACATTAAACTTATTTCAAATAATTTA1920TAAAAGCACACTTAATACACTCAAACAATAATTAATTATTTTATTTTTTATTTTATTTTT1980TATTTTTATTATTTTTATTTTTATTTATTTAAATGCATTTAACACAACACAAAGCAAACC2040AAGCTCAAATCTCTTTTAAATAGAATCATTTTTCCCAAAATCAATAGTAGCATTAAACAT2100GCTGTAAATGGATGTAAGCCCTTCTTTGTAGTGGTCCATTGCAGCAAGTCCTTTAGCTTT2160CGGACTACAAGCCTTTAGTATATCTGCATATTGTTTAGCCTTGCCAATTTCAACAGAGTT2220CATGCTATATCCTTTGCTTTTTAGAACTGTGCACACTTTCCCAACTGCCTCTTTAGTGCT2280AAACTTAGACATGTCAATTCCAAGCTCAACATGTTTAGCATCTTGATAAATAGCCGGAAC2340TAGTGCAGCTATTTCAAAATTCAGTACAGATGCTATCAGAGGAAGACTTCCTCCTAAGAG2400AACACCCAAGACACAGGATTTCAAATCTGTGGTTGCAAGACCATATGAGGCAATCAGAGG2460GTGACTTGGAAGGCTATTTATAGCTTCAGTCAGAGCAGATCCATTGTCCTTTATCATTCC2520AACAAGATGAACTCTCACCATTGCATCAAGTCTTCGGAAAGTCATATCATTGACCCCAAC2580TCTTTCTGAATTGTTTCTAGTTTTCTTAATTGTGACTGATCCAAAAGTGAAGTCAGCACT2640CTTAATGACTCTCATTATAGATTGCCTATTCTTGAGGAAGGATAGGCAGGATGCAGTAGT2700CATGTTCTGAATCTTTTCACGGTTGTTGGTAAAGAAGTCAGTGAAATTGAAAGACCCTTC2760ATTTTGAGTTTCCTCAAATTCTAAGGAATCAGATTGAGTCAAAAGCTTGACTATGTTCTC2820CTTGGTAATCTTTGCTTTGTTCATCTTGATCTGCTGACTTTACTAACTTTAAAGCTTAAA2880GTGTTCAAATTACTAAATAGTACTTGCGGTTAAAGTAGTATTTGGTAAAATTTGTAATTT2940TTCAGTTTCTAGCTTTGGATTATATGATGTTATATTCGTGACACAATTGCTCT2993(2) INFORMATION FOR SEQ ID NO:3:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 1350 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(xi) SEQUENCE DESCRIPTION: SEQ ID NO:3:ATGTCTAGTGCAATGTATGAAACAATTATCAAATCGAAGTCCTCAATCTGGGGAACAACA60TCTTCGGGTAAAGCAGTAGTAGATAGTTATTGGATTCATGATCAATCTTCCGGAAAGAAG120TTGGTCGAAGCTCAACTCTATTCTGACTCCAGGAGCAAGACCAGTTTCTGTTACACTGGT180AAAGTTGGCTTTCTCCCAACAGAAGAAAAAGAAATTATAGTGAGATGTTTTGTGCCTATT240TTTGATGACATTGATCTGAATTTCTCCTTTTCAGGGAATGTTGTCGAAATTCTGGTCAGA300TCTAACACAACAAACACAAACGGTGTTAAACATCAAGGTCATCTCAAAGTGTTATCCTCT360CAGTTGCTCAGAATGCTTGAAGAGCAAATAGCAGTGCCTGAAATTACTTCAAGATTCGGT420CTGAAAGAATCTGACATCTTCCCTCCAAATAATTTCATTGAAGCTGCAAATAAAGGATCA480TTGTCTTGTGTCAAAGAAGTCCTTTTTGATGTCAAGTATTCAAACAACCAATCCATGGGC540AAAGTCAGTGTTCTTTCTCCTACCAGAAGTGTTCATGAATGGCTGTACACACTTAAGCCT600GTTTTTAACCAATCCCAGACCAACAACAGGACAGTAAACACTTTGGCTGTAAAATCACTG660GCAATGTCTGCAACTTCTGATTTAATGTCAGATACTCATTCGTTTGTCAGGCTCAATAAT720AACAAGCCTTTTAAAATCAGCCTTTGGATGCGCATCCCTAAAATAATGAAATCAAACACA780TACAGCCGGTTCTTCACCCTGTCTGATGAATCTTCTCCTAAAGAGTATTATATAAGCATT840CAATGTCTTCCGAATCACAACAATGTTGAAACAGTCATTGAATATAACTTTGATCAGTCA900AACCTCTTCTTGAATCAACTCCTTCTAGCAGTGATTCATAAAATTGAGATGAATTTTTCT960GATCTAAAAGAACCTTACAATGTTATCCATGATATGTCGTATCCTCAAAGAATTGTTCAT1020TCACTTCTTGAAATCCACACAGAACTTGCTCAAACTGTCTGTGACAGTGTTCAGCAAGAC1080ATGATTGTCTTCACTATAAATGAGCCAGATCTAAAGCCAAAAAAGTTTGAGCTAGGGAAA1140AAGACTTTAAATTATTCAGAAGATGGTTATGGGAGAAAATATTTCCTTTCTCAGACCTTG1200AAAAGTCTTCCGAGAAACTCACAAACAATGTCTTATTTGGATAGCATCCAGATGCCCGAT1260TGGAAATTTGACTATGCTGCAGGTGAAATAAAAATTTCTCCTAGATCAGAGGATGTTTTG1320AAAGCTATTTCTAAATTAGATTTAAATTAA1350(2) INFORMATION FOR SEQ ID NO:4:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 789 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(xi) SEQUENCE DESCRIPTION: SEQ ID NO:4:TTAAATAGAATCATTTTTCCCAAAATCAATAGTAGCATTAAACATGCTGTAAATGGATGT60AAGCCCTTCTTTGTAGTGGTCCATTGCAGCAAGTCCTTTAGCTTTCGGACTACAAGCCTT120TAGTATATCTGCATATTGTTTAGCCTTGCCAATTTCAACAGAGTTCATGCTATATCCTTT180GCTTTTTAGAACTGTGCACACTTTCCCAACTGCCTCTTTAGTGCTAAACTTAGACATGTC240AATTCCAAGCTCAACATGTTTAGCATCTTGATAAATAGCCGGAACTAGTGCAGCTATTTC300AAAATTCAGTACAGATGCTATCAGAGGAAGACTTCCTCCTAAGAGAACACCCAAGACACA360GGATTTCAAATCTGTGGTTGCAAGACCATATGAGGCAATCAGAGGGTGACTTGGAAGGCT420ATTTATAGCTTCAGTCAGAGCAGATCCATTGTCCTTTATCATTCCAACAAGATGAACTCT480CACCATTGCATCAAGTCTTCGGAAAGTCATATCATTGACCCCAACTCTTTCTGAATTGTT540TCTAGTTTTCTTAATTGTGACTGATCCAAAAGTGAAGTCAGCACTCTTAATGACTCTCAT600TATAGATTGCCTATTCTTGAGGAAGGATAGGCAGGATGCAGTAGTCATGTTCTGAATCTT660TTCACGGTTGTTGGTAAAGAAGTCAGTGAAATTGAAAGACCCTTCATTTTGAGTTTCCTC720AAATTCTAAGGAATCAGATTGAGTCAAAAGCTTGACTATGTTCTCCTTGGTAATCTTTGC780TTTGTTCAT789(2) INFORMATION FOR SEQ ID NO:5:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 21 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(xi) SEQUENCE DESCRIPTION: SEQ ID NO:5:AGAGCAATGAACAACCCAAGC21(2) INFORMATION FOR SEQ ID NO:6:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 36 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(xi) SEQUENCE DESCRIPTION: SEQ ID NO:6:GATTATATGATGTTATATTCGTGACACAATTGCTCT36(2) INFORMATION FOR SEQ ID NO:7:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 643 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(xi) SEQUENCE DESCRIPTION: SEQ ID NO:7:CCTTGGTTAAACTTGTCCCTAAGTAAAGTTTGTTTACATGCATTTAGATCAGATTAAACA60AATCTAATAACAGATAAACCAAAAACAATCATATGAAATAAATAAATAAACATAAAATAT120ATAAAAAATACAAAAAAAATCATAAAATAAATAAAAACCAAAAAAGGATGGCCTTCGGGC180ACAATTTGGTTGCTTTAATAATGCTTTAAAATGAATGTATTAGTAAATTATAAACTTTAA240ATCCAATCTACTCACAAATTGGCCAAAAATTTGTATTTGTTTTTGTTTTTGTTTTTTGTT300TTTTGTTTTTGTTTTGTTTTATTTGTTTTTTATTTTGTTTTTTGTTTTTTGTTTTTTATT360TTATTTATATATATATATATATATATTTTGTAGTGGTTTTTATTGTTTTTATTATTTTTT420GTAGCTTTTTTACTTGTTTATTTCACACGCAAACACACTTTCAAGTTTATATATTAAAAC480ACACATTAAACTTATTTCAAATAATTTATAAAAGCACACTTAATACACTCAAACAATAAT540TAATTATTTTATTTTTTATTTTATTTTTTATTTTTATTATTTTTATTTTTATTTATTTAA600ATGCATTTAACACAACACAAAGCAAACCAAGCTCAAATCTCTT643(2) INFORMATION FOR SEQ ID NO:8:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 602 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(xi) SEQUENCE DESCRIPTION: SEQ ID NO:8:TGGTTAAACTTGTCCCTAAGTAAAGTTTGTTTACATGCATTTAGATCAGATTAAACAAAT60CTAATAACAGATAAACCAAAAACAATCATATGAAATAAATAAATAAACATAAAATATATA120AAAAATACAAAAAAAATCATAAAATAAATAAAAACCAAAAAAGGATGGCCTTCGGGCACA180ATTTGGTTGCTTTAATAATGCTTTAAAATGAATGTATTAGTAAATTATAAACTTTAAATC240CAATCTACTCACAAATTGGCCAAAAATTTGTATTTGTTTTTGTTTTTGTTTTTTGTTTTT300TGTTTTTGTTTTGTTTTATTTGTTTTTTATTTTGTTTTTTGTTTTTTGTTTTTTATTTTA360TTTATATATATATATATATATATTTTGTAGTGGTTTTTATTGTTTTTATTATTTTTTGTA420GCTTTTTTACTTGTTTATTTCACACGCAAACACACTTTCAAGTTTATATATTAAAACACA480CATTAAACTTATTTCAAATAATTTATAAAAGCACACTTAATACACTCAAACAATAATTAA540TTATTTTATTTTTTATTTTATTTTTTATTTTTATTATTTTTATTTTTATTTATTTAAATG600CA602(2) INFORMATION FOR SEQ ID NO:9:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 3000 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(xi) SEQUENCE DESCRIPTION: SEQ ID NO:9:AGAGCAATTGTGTCACGAATATAACATCATATAATCCAAAGCTAGAAACTGAAAAATTAC60AAATTTTACCAAATACTACTTTAACCGCAAGTACTATTTAGTAATTTGAACACTTTAAGC120TTTAAAGTTAGTAAAGTCAGCAGATCAAGATGAACAAAGCAAAGATTACCAAGGAGAACA180TAGTCAAGCTTTTGACTCAATCTGATTCCTTAGAATTTGAGGAAACTCAAAATGAAGGGT240CTTTCAATTTCACTGACTTCTTTACCAACAACCGTGAAAAGATTCAGAACATGACTACTG300CATCCTGCCTATCCTTCCTCAAGAATAGGCAATCTATAATGAGAGTCATTAAGAGTGCTG360ACTTCACTTTTGGATCAGTCACAATTAAGAAAACTAGAAACAATTCAGAAAGAGTTGGGG420TCAATGATATGACTTTCCGAAGACTTGATGCAATGGTGAGAGTTCATCTTGTTGGAATGA480TAAAGGACAATGGATCTGCTCTGACTGAAGCTATAAATAGCCTTCCAAGTCACCCTCTGA540TTGCCTCATATGGTCTTGCAACCACAGATTTGAAATCCTGTGTCTTGGGTGTTCTCTTAG600GAGGAAGTCTTCCTCTGATAGCATCTGTACTGAATTTTGAAATAGCTGCACTAGTTCCGG660CTATTTATCAAGATGCTAAACATGTTGAGCTTGGAATTGACATGTCTAAGTTTAGCACTA720AAGAGGCAGTTGGGAAAGTGTGCACAGTTCTAAAAAGCAAAGGATATAGCATGAACTCTG780TTGAAATTGGCAAGGCTAAACAATATGCAGATATACTAAAGGCTTGTAGTCCGAAAGCTA840AAGGACTTGCTGCAATGGACCACTACAAAGAAGGGCTTACATCCATTTACAGCATGTTTA900ATGCTACTATTGATTTTGGGAAAAATGATTCTATTTAAAAGAGATTTGAGCTTGGTTTGC960TTTGTGTTGTGTTAAATGCATTTAAATAAATAAAAATAAAAATAATAAAAATAAAAAATA1020AAATAAAAAATAAAATAATTAATTATTGTTTGAGTGTATTAAGTGTGCTTTTATAAATTA1080TTTGAAATAAGTTTAATGTGTGTTTTAATATATAAACTTGAAAGTGTGTTTGCGTGTGAA1140ATAAACAAGTAAAAAAGCTACAAAAAATAATAAAAACAATAAAAACCACTACAAAATATA1200TATATATATATATATAAATAAAATAAAAAACAAAAAACAAAAAACAAAATAAAAAACAAA1260TAAAACAAAACAAAAACAAAAAACAAAAAACAAAAACAAAAACAAATACAAATTTTTGGC1320CAATTTGTGAGTAGATTGGATTTAAAGTTTATAATTTACTAATACATTCTTTTAAAGCAT1380TATTAAAGCAACCAAATTGTGCCCGAAGGCCATCCTTTTTTGGTTTTTATTTATTTTATG1440ATTTTTTTTGTATTTTTTATATATTTTATGTTTATTTATTTATTTCATATGATTGTTTTT1500GGTTTATCTGTTATTAGATTTGTTTAATCTGATCTAAATGCATGTAAACAAACTTTACTT1560AGGGACAAGTTTAACCAAGGTTAATTTAAATCTAATTTAGAAATAGCTTTCAAAACATCC1620TCTGATCTAGGAGAAATTTTTATTTCACCTGCAGCATAGTCAAATTTCCAATCGGGCATC1680TGGATGCTATCCAAATAAGACATTGTTTGTGAGTTTCTCGGAAGACTTTTCAAGGTCTGA1740GAAAGGAAATATTTTCTCCCATAACCATCTTCTGAATAATTTAAAGTCTTTTTCCCTAGC1800TCAAACTTTTTTGGCTTTAGATCTGGCTCATTTATAGTGAAGACAATCATGTCTTGCTGA1860ACACTGTCACAGACAGTTTGAGCAAGTTCTGTGTGGATTTCAAGAAGTGAATGAACAATT1920CTTTGAGGATACGACATATCATGGATAACATTGTAAGGTTCTTTTAGATCAGAAAAATTC1980ATCTCAATTTTATGAATCACTGCTAGAAGGAGTTGATTCAAGAAGAGGTTTGACTGATCA2040AAGTTATATTCAATGACTGTTTCAACATTGTTGTGATTCGGAAGACATTGAATGCTTATA2100TAATACTCTTTAGGAGAAGATTCATCAGACAGGGTGAAGAACCGGCTGTATGTGTTTGAT2160TTCATTATTTTAGGGATGCGCATCCAAAGGCTGATTTTAAAAGGCTTGTTATTATTGAGC2220CTGACAAACGAATGAGTATCTGACATTAAATCAGAAGTTGCAGACATTGCCAGTGATTTT2280ACAGCCAAAGTGTTTACTGTCCTGTTGTTGGTCTGGGATTGGTTAAAAACAGGCTTAAGT2340GTGTACAGCCATTCATGAACACTTCTGGTAGGAGAAAGAACACTGACTTTGCCCATGGAT2400TGGTTGTTTGAATACTTGACATCAAAAAGGACTTCTTTGACACAAGACAATGATCCTTTA2460TTTGCAGCTTCAATGAAATTATTTGGAGGGAAGATGTCAGATTCTTTCAGACCGAATCTT2520GAAGTAATTTCAGGCACTGCTATTTGCTCTTCAAGCATTCTGAGCAACTGAGAGGATAAC2580ACTTTGAGATGACCTTGATGTTTAACACCGTTTGTGTTTGTTGTGTTAGATCTGACCAGA2640ATTTCGACAACATTCCCTGAAAAGGAGAAATTCAGATCAATGTCATCAAAAATAGGCACA2700AAACATCTCACTATAATTTCTTTTTCTTCTGTTGGGAGAAAGCCAACTTTACCAGTGTAA2760CAGAAACTGGTCTTGCTCCTGGAGTCAGAATAGAGTTGAGCTTCGACCAACTTCTTTCCG2820GAAGATTGATCATGAATCCAATAACTATCTACTACTGCTTTACCCGAAGATGTTGTTCCC2880CAGATTGAGGACTTCGATTTGATAATTGTTTCATACATTGCACTAGACATGTTAAAATGG2940AAGTAGTAATGTAATTGACAATATTGTAAGATTTGTTGTAGCTTGGTTGTTCATTGCTCT3000(2) INFORMATION FOR SEQ ID NO:10:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 2993 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(xi) SEQUENCE DESCRIPTION: SEQ ID NO:10:AGAGCAATTGTGTCACGAATATAACATCATATAATCCAAAGCTAGAAACTGAAAAATTAC60AAATTTTACCAAATACTACTTTAACCGCAAGTACTATTTAGTAATTTGAACACTTTAAGC120TTTAAAGTTAGTAAAGTCAGCAGATCAAGATGAACAAAGCAAAGATTACCAAGGAGAACA180TAGTCAAGCTTTTGACTCAATCTGATTCCTTAGAATTTGAGGAAACTCAAAATGAAGGGT240CTTTCAATTTCACTGACTTCTTTACCAACAACCGTGAAAAGATTCAGAACATGACTACTG300CATCCTGCCTATCCTTCCTCAAGAATAGGCAATCTATAATGAGAGTCATTAAGAGTGCTG360ACTTCACTTTTGGATCAGTCACAATTAAGAAAACTAGAAACAATTCAGAAAGAGTTGGGG420TCAATGATATGACTTTCCGAAGACTTGATGCAATGGTGAGAGTTCATCTTGTTGGAATGA480TAAAGGACAATGGATCTGCTCTGACTGAAGCTATAAATAGCCTTCCAAGTCACCCTCTGA540TTGCCTCATATGGTCTTGCAACCACAGATTTGAAATCCTGTGTCTTGGGTGTTCTCTTAG600GAGGAAGTCTTCCTCTGATAGCATCTGTACTGAATTTTGAAATAGCTGCACTAGTTCCGG660CTATTTATCAAGATGCTAAACATGTTGAGCTTGGAATTGACATGTCTAAGTTTAGCACTA720AAGAGGCAGTTGGGAAAGTGTGCACAGTTCTAAAAAGCAAAGGATATAGCATGAACTCTG780TTGAAATTGGCAAGGCTAAACAATATGCAGATATACTAAAGGCTTGTAGTCCGAAAGCTA840AAGGACTTGCTGCAATGGACCACTACAAAGAAGGGCTTACATCCATTTACAGCATGTTTA900ATGCTACTATTGATTTTGGGAAAAATGATTCTATTTAAAAGAGATTTGAGCTTGGTTTGC960TTTGTGTTGTGTTAAATGCATTTAAATAAATAAAAATAAAAATAATAAAAATAAAAAATA1020AAATAAAAAATAAAATAATTAATTATTGTTTGAGTGTATTAAGTGTGCTTTTATAAATTA1080TTTGAAATAAGTTTAATGTGTGTTTTAATATATAAACTTGAAAGTGTGTTTGCGTGTGAA1140ATAAACAAGTAAAAAAGCTACAAAAAATAATAAAAACAATAAAAACCACTACAAAATATA1200TATATATATATATATAAATAAAATAAAAAACAAAAAACAAAAAACAAAATAAAAAACAAA1260TAAAACAAAACAAAAACAAAAAACAAAAAACAAAAACAAAAACAAATACAAATTTTTGGC1320CAATTTGTGAGTAGATTGGATTTAAAGTTTATAATTTACTAATACATTCATTTTAAAGCA1380TTATTAAAGCAACCAAATTGTGCCCGAAGGCCATCCTTTTTTGGTTTTTATTTATTTTAT1440GATTTTTTTTGTATTTTTTATATATTTTATGTTTATTTATTTATTTCATATGATTGTTTT1500TGGTTTATCTGTTATTAGATTTGTTTAATCTGATCTAAATGCATGTAAACAAACTTTACT1560TAGGGACAAGTTTAACCAAGGTTAATTTAAATCTAATTTAGAAATAGCTTTCAAAACATC1620CTCTGATCTAGGAGAAATTTTTATTTCACCTGCAGCATAGTCAAATTTCCAATCGGGCAT1680CTGGATGCTATCCAAATAAGACATTGTTTGTGAGTTTCTCGGAAGACTTTTCAAGGTCTG1740AGAAAGGAAATATTTTCTCCCATAACCATCTTCTGAATAATTTAAAGTCTTTTTCCCTAG1800CTCAAACTTTTTTGGCTTTAGATCTGGCTCATTTATAGTGAAGACAATCATGTCTTGCTG1860AACACTGTCACAGACAGTTTGAGCAAGTTCTGTGTGGATTTCAAGAAGTGAATGAACAAT1920TCTTTGAGGATACGACATATCATGGATAACATTGTAAGGTTCTTTTAGATCAGAAAAATT1980CATCTCAATTTTATGAATCACTGCTAGAAGGAGTTGATTCAAGAAGAGGTTTGACTGATC2040AAAGTTATATTCAATGACTGTTTCAACATTGTTGTGATTCGGAAGACATTGAATGCTTAT2100ATAATACTCTTTAGGAGAAGATTCATCAGACAGGGTGAAGAACCGGCTGTATGTGTTTGA2160TTTCATTATTTTAGGGATGCGCATCCAAAGGCTGATTTTAAAAGGCTTGTTATTATTGAG2220CCTGACAAACGAATGAGTATCTGACATTAAATCAGAAGTTGCAGACATTGCCAGTGATTT2280TACAGCCAAAGTGTTTACTGTCCTGTTGTTGGTCTGGGATTGGTTAAAAACAGGCTTAAG2340TGTGTACAGCCATTCATGAACACTTCTGGTAGGAGAAAGAACACTGACTTTGCCCATGGA2400TTGGTTGTTTGAATACTTGACATCAAAAAGGACTTCTTTGACACAAGACAATGATCCTTT2460ATTTGCAGCTTCAATGAAATTATTTGGAGGGAAGATGTCAGATTCTTTCAGACCGAATCT2520TGAAGTAATTTCAGGCACTGCTATTTGCTCTTCAAGCATTCTGAGCAACTGAGAGGATAA2580CACTTTGAGATGACCTTGATGTTTAACACCGTTTGTGTTTGTTGTGTTAGATCTGACCAG2640AATTTCGACAACATTCCCTGAAAAGGAGAAATTCAGATCAATGTCATCAAAAATAGGCAC2700AAAACATCTCACTATAATTTCTTTTTCTTCTGTTGGGAGAAAGCCAACTTTACCAGTGTA2760ACAGAAACTGGTCTTGCTCCTGGAGTCAGAATAGAGTTGAGCTTCGACCAACTTCTTTCC2820GGAAGATTGATCATGAATCCAATAACTATCTACTACTGCTTTACCCGAAGATGTTGTTCC2880CCAGATTGAGGACTTCGATTTGATAATTGTTTCATACATTGCACTAGACATGTTAAAATG2940GAAGTAGTAATGTAATTGACAATATTGTAAGATTTGTTGTAGCTTGGTTGTTC2993(2) INFORMATION FOR SEQ ID NO:11:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 789 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(xi) SEQUENCE DESCRIPTION: SEQ ID NO:11:ATGAACAAAGCAAAGATTACCAAGGAGAACATAGTCAAGCTTTTGACTCAATCTGATTCC60TTAGAATTTGAGGAAACTCAAAATGAAGGGTCTTTCAATTTCACTGACTTCTTTACCAAC120AACCGTGAAAAGATTCAGAACATGACTACTGCATCCTGCCTATCCTTCCTCAAGAATAGG180CAATCTATAATGAGAGTCATTAAGAGTGCTGACTTCACTTTTGGATCAGTCACAATTAAG240AAAACTAGAAACAATTCAGAAAGAGTTGGGGTCAATGATATGACTTTCCGAAGACTTGAT300GCAATGGTGAGAGTTCATCTTGTTGGAATGATAAAGGACAATGGATCTGCTCTGACTGAA360GCTATAAATAGCCTTCCAAGTCACCCTCTGATTGCCTCATATGGTCTTGCAACCACAGAT420TTGAAATCCTGTGTCTTGGGTGTTCTCTTAGGAGGAAGTCTTCCTCTGATAGCATCTGTA480CTGAATTTTGAAATAGCTGCACTAGTTCCGGCTATTTATCAAGATGCTAAACATGTTGAG540CTTGGAATTGACATGTCTAAGTTTAGCACTAAAGAGGCAGTTGGGAAAGTGTGCACAGTT600CTAAAAAGCAAAGGATATAGCATGAACTCTGTTGAAATTGGCAAGGCTAAACAATATGCA660GATATACTAAAGGCTTGTAGTCCGAAAGCTAAAGGACTTGCTGCAATGGACCACTACAAA720GAAGGGCTTACATCCATTTACAGCATGTTTAATGCTACTATTGATTTTGGGAAAAATGAT780TCTATTTAA789(2) INFORMATION FOR SEQ ID NO:12:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 1350 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(xi) SEQUENCE DESCRIPTION: SEQ ID NO:12:TTAATTTAAATCTAATTTAGAAATAGCTTTCAAAACATCCTCTGATCTAGGAGAAATTTT60TATTTCACCTGCAGCATAGTCAAATTTCCAATCGGGCATCTGGATGCTATCCAAATAAGA120CATTGTTTGTGAGTTTCTCGGAAGACTTTTCAAGGTCTGAGAAAGGAAATATTTTCTCCC180ATAACCATCTTCTGAATAATTTAAAGTCTTTTTCCCTAGCTCAAACTTTTTTGGCTTTAG240ATCTGGCTCATTTATAGTGAAGACAATCATGTCTTGCTGAACACTGTCACAGACAGTTTG300AGCAAGTTCTGTGTGGATTTCAAGAAGTGAATGAACAATTCTTTGAGGATACGACATATC360ATGGATAACATTGTAAGGTTCTTTTAGATCAGAAAAATTCATCTCAATTTTATGAATCAC420TGCTAGAAGGAGTTGATTCAAGAAGAGGTTTGACTGATCAAAGTTATATTCAATGACTGT480TTCAACATTGTTGTGATTCGGAAGACATTGAATGCTTATATAATACTCTTTAGGAGAAGA540TTCATCAGACAGGGTGAAGAACCGGCTGTATGTGTTTGATTTCATTATTTTAGGGATGCG600CATCCAAAGGCTGATTTTAAAAGGCTTGTTATTATTGAGCCTGACAAACGAATGAGTATC660TGACATTAAATCAGAAGTTGCAGACATTGCCAGTGATTTTACAGCCAAAGTGTTTACTGT720CCTGTTGTTGGTCTGGGATTGGTTAAAAACAGGCTTAAGTGTGTACAGCCATTCATGAAC780ACTTCTGGTAGGAGAAAGAACACTGACTTTGCCCATGGATTGGTTGTTTGAATACTTGAC840ATCAAAAAGGACTTCTTTGACACAAGACAATGATCCTTTATTTGCAGCTTCAATGAAATT900ATTTGGAGGGAAGATGTCAGATTCTTTCAGACCGAATCTTGAAGTAATTTCAGGCACTGC960TATTTGCTCTTCAAGCATTCTGAGCAACTGAGAGGATAACACTTTGAGATGACCTTGATG1020TTTAACACCGTTTGTGTTTGTTGTGTTAGATCTGACCAGAATTTCGACAACATTCCCTGA1080AAAGGAGAAATTCAGATCAATGTCATCAAAAATAGGCACAAAACATCTCACTATAATTTC1140TTTTTCTTCTGTTGGGAGAAAGCCAACTTTACCAGTGTAACAGAAACTGGTCTTGCTCCT1200GGAGTCAGAATAGAGTTGAGCTTCGACCAACTTCTTTCCGGAAGATTGATCATGAATCCA1260ATAACTATCTACTACTGCTTTACCCGAAGATGTTGTTCCCCAGATTGAGGACTTCGATTT1320GATAATTGTTTCATACATTGCACTAGACAT1350(2) INFORMATION FOR SEQ ID NO:13:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 642 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(xi) SEQUENCE DESCRIPTION: SEQ ID NO:13:AAGAGATTTGAGCTTGGTTTGCTTTGTGTTGTGTTAAATGCATTTAAATAAATAAAAATA60AAAATAATAAAAATAAAAAATAAAATAAAAAATAAAATAATTAATTATTGTTTGAGTGTA120TTAAGTGTGCTTTTATAAATTATTTGAAATAAGTTTAATGTGTGTTTTAATATATAAACT180TGAAAGTGTGTTTGCGTGTGAAATAAACAAGTAAAAAAGCTACAAAAAATAATAAAAACA240ATAAAAACCACTACAAAATATATATATATATATATATAAATAAAATAAAAAACAAAAAAC300AAAAAACAAAATAAAAAACAAATAAAACAAAACAAAAACAAAAAACAAAAAACAAAAACA360AAAACAAATACAAATTTTTGGCCAATTTGTGAGTAGATTGGATTTAAAGTTTATAATTTA420CTAATACATTCTTTTAAAGCATTATTAAAGCAACCAAATTGTGCCCGAAGGCCATCCTTT480TTTGGTTTTTATTTATTTTATGATTTTTTTTGTATTTTTTATATATTTTATGTTTATTTA540TTTATTTCATATGATTGTTTTTGGTTTATCTGTTATTAGATTTGTTTAATCTGATCTAAA600TGCATGTAAACAAACTTTACTTAGGGACAAGTTTAACCAAGG642(2) INFORMATION FOR SEQ ID NO:14:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 4970 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(xi) SEQUENCE DESCRIPTION: SEQ ID NO:14:AGAGCAATCAGTGCATCAAAATTATATCTAGCCGAATTCAATCATTATCTTCTCAATATT60TTAATTCTTAATCTACCGTCCAGAGATGAATAGTTTTTTCAAATCACTCAGATCATCTAG120CAGCAGGGAGCTAGATCACCCTAGGGTTACAACTACCCTCTCTAAACAAGGAGCAGACAT180TGTTGTACACAATCCTTCTGCTAATCACAACAACAAGGAAGTTCTCCAAAGAGCCATGGA240TAGCTCTAAAGGGAAGATTTTGATGAACAATACAGGCACCTCATCACTAGGCACATATGA300GTCTGACCAGATATCTGAATCAGAGTCTTATGATCTTTCTGCTAGAATGATTGTTGATAC360AAATCATCATATCTCCAGCTGGAAAAATGATCTTTTTGTAGGTAATGGTGATAAAGCTGC420AACCAAGATAATTAAGATACATCCAACCTGGGATAGCAGAAAACAATACATGATGATCTC480AAGGATAGTTATCTGGATATGCCCTACTATAGCTGATCCTGATGGGAAATTGGCTGTAGC540TTTAATTGATCCTAACAAGAGTGTTAATGCCAGAACTGTTTTGAAAGGGCAAGGAAGCAT600TAAAGATCCTATATGTTTTGTTTTTTATCTAAATTGGTCCATTCCAAAAGTTAACAACAC660TTCAGAGAATTGTGTTCAGCTTCATTTATTATGTGATCAAGTTTACAAGAAAGATGTTTC720TTTTGCTAGTGTCATGTATTCTTGGACAAAAGAATTCTGTGATTCACCAAGAGCAGATCT780GGATAAAAGCTGCATGATAATACCCATCAATAGGGCTATTAGAGCCAAATCGCAAGCCTT840CATTGAAGCCTGCAAGTTAATCATACCTAAAGGCAATTCTGAAAAGCAAATTAGAAGACA900ACTTGCAGAGCTAAGTGCTAATTTAGAGAAATCTGTTGAAGAAGAGGAGAATGTTACTGA960TAACAAGATAGAGATATCATTTGATAATGAAATCTAAATATGTTTTCATTTAATAATAAA1020TAATATATATTGTTCATAATATTTTGAATGTTTAAGTAAAAAATAAAGCAAGATAAAAAA1080CTATATATATATATATATATAGAAGTATAAAATATATATGTATTTGTGTTTAAAAACAAA1140TCAAAAACCAAAAAAGAAAAAAGAAAAAATAAACAAAAAACAAAAACAAAAACAAAAACA1200AACAAAAAGCAAAAAATAGAAAAAAGTTGAAAAAAACCAAAAAAATTTTTTTTGTAAATA1260AATAAGGCTCCGGCCAGATTTGGTCTAAGACCTTTTTATTTGTTTTTATACATTTTATTT1320GTTTTTGTTGATTTTTATTTTTATTATTTTTATATTTTTTATATAGTTTGCTTATTTAAC1380ACTTATTTAGACAAATTAAATTTATTTGATTACAATCATTCTGCCTTATTTAATTTAAAA1440CACATTTGGTGTATATTCCAATGAATTTAATCATATACCGCTGAAGTCTAGAGGAGGTCT1500TCTTCTAGTGATGGTGTCTTTACCAGAAGACGTGGAAACCAAAGAATAATCATTAGTGTC1560TTCAATATATTTTGTCTTGTAAGACTTGTTTCTAACATAGCCTCTACACATTGTGGCAAC1620AATAGAGCAGAGGTAAGCAAGAGCAAATACAAAGAGTATGAGCAATACTACTCTGACTGT1680ATCAAAGAAGGATCCAAAGTGGCTTGCTATAAAGTTAAAAGGGCTTTTAACATAGTCCCA1740AAAGCTCCAAACTGATGTGTCAGAATTATATTGCTGTTCCTCGTGTGCATGTTGGTCATT1800TTGATCAATTATGTTTTCTGGTTCCAGCACAGCAACAGAATCTACAAGTGCCTCAACTGA1860GTATGATTTGTCTCCTTCTGGTTCTATAATCATTTTTTGTTTTTCTGGGTTAGAAGTGCA1920GAACATTGTCAAGTTATACTTATTAGCACCTTTCTTTACTGCTATCTGGTATGTTGACAA1980TGAACATTGTTTCATGGTTAACCTTGCAGAAAAAGTTATGTCTGATATAAATGAGGCAGC2040ACACCTCAGCCCTTGGCTACATAAGAAACATCCCTTACAGCTTAAAGAGACAGAACTCAA2100TATAGGCTTTTTTGGTACAGTTTTAAACAATTCAGAAGGTAGATCCAAAACAATTTTAAG2160CTTACCTAGACTAAAGATCTTTTCCATATAAAAACTATTCTGGTCAGTAAACTGAACTGG2220AATGTCCGATATTTGGTTCAAACCTGTTTTAAATCTGTATGTGTCATAACCACATGATTT2280TATCGTAATTGTTTTTTTACCAATTGCTGAACAATCCCAGGACAGATCGTTTGTATCTAA2340TGTTTTCTTAGAGAAAATGGGATCACCTTGGTGTGAAAGTTGAGGATGACCAAACATTTT2400TGATGGATTATTTAATCTAGCTATGTTTCCCGCATATACGTGACTATCAGGTCCATGAGC2460TATCAGCTGGCCTATTGTTAAGCCATCATTATGGAAATCCGCTAATATATCAGCCTGGAA2520ATATCCTGATTCAGATGGGACTTCCTCAGATACAGTGAAACACTTTGCTCCCACAAATCC2580AGATATACATACTTCAGACTTGATTGTTGATTTAATAACAGAATAAATCCTGAAAGATTG2640ATCCATATCATACACATTTCTACAAAACCCACAAGTGGCTCCTTCATTGATAGCCAAACA2700CCAAACCTCTTCACAACCCCAGTAAGATGTTGGTGTTATGCAGAAATCTTGATACCCAGT2760TATCGGTTGTTCTTTTCTGCAATCTGAGCATTTACCTGTGCATGTTGAAAAGAAATCAGT2820GTGGGTGCTTTGTATAGGAGCTGTAGTGTATTGTTCAGAAACATCATACTGTATTCTAAC2880TTTTTTAATATAAACAACAAACTTCTGAGCAGTGCTAGAACTTTTGTCATTAAGAGAGAA2940AACTGTGCCCCCACCTGATAATAAAGATTCTTCTATCATGTATCTATATTTTCCATCTAT3000CACCGAGTCAAATATGAGAGATTTTCTTGGAAAAATGCTTTCAGGTATGTCTGATTCATT3060AGATTTAAGTGCATCTCCAGAAATGTATCCATATTTTTCAGTTTTATTGTAGAAATCAAT3120TATACCATTCCTAAGCCTTTTCATGAAGTGTAGATTCACAGCATTCAATCCCAATGTGTC3180ACCAGAATATTCTAAGAACCCATTATCTAAAGGCTTGCTTTGGAAAATAGAGGCATACTC3240ACAACCAAATCTGCATTTGACAAAAGTTACTAAAGCATTTTCAGTTATCCTGCCTTTGCA3300TTCTTGATAAGGTATACAATCCATAGGACCTTCTGTCACAACATTGGTTAGAAAGTTAGA3360TTCTACAATAGAATTTTCTTTAATAGCACAGAAGCATTGGTCTTTTTCAGGACATTTGTC3420ATATCTGTTTGTAACAAAGCGGTCACAACCAGGGACATAATAACAGCTATCCAAACACTG3480AGCAGTTTGAGCCATAGACATAGGCATCTGTGACAAAATCAGAAATCCTATCAAAGTTTC3540TGTGACTGCTTTTAGGAAAGAGAGGCCTATTTTTGTATTAACTATCAAATGGAACCATTC3600AATGCTAGCCCAGTTGTATTTTTTATTCTTCTCTGCTGTTCTAGTTATTATAGGACATTC3660TTCTGAGTGTTCTTCAGAGGCTTTGTTTTTGTTACAAATGCATAATTTTGAGCATTCATG3720GGTTACCAAACATAAATTTCCACAGACCTTACATTTCAAGGGAAAATAAGACCATAAATA3780ATTTATCAGTAGTAGTATAGGATACGTTATCAATCCCAGAAGATCATACCCATAGAACAG3840TGTTTTAGATGTTTTGTTTACCAAGTACCTTATAGGGAAATAGACAATCAGAGCAATCAT3900GATCAATCTAAACCATGAGAAGTTGATGCAAGCAGTTTGTTTGTAAATATTTTTGGAGTA3960CTTTATAATACAATCTCTAACTCTTTTGTCCACTAAAGGAACTTTAGAAGACTTGTCACC4020GCACAATAGGTTATGCTTACCATCCATATTTTCTTCTGTGAAAGTCAAACTAACTGAGCC4080AGAGAAGCTTATTATGGAATGGCTCATGTCACTTCCTTCTCTTTTGACGACGTAACCCAT4140GATTTTCTCAGGTGTAGTTAATGAAACTGTATAAGAATTAACTATGTTTGTTTTTGATAT4200TTTACAATCACCTGAGAATTTCACACTCTGGAGAGAGACTGTGCCATTAGTTGGTCTAGA4260ATTGTACATGATTGGATAATTGTAATTCTCCAAACTTTCAATTATATAGAATTTAGTTCC4320TATAGATAATTTCCTTTTGTTATCGATTTTTGTTATTGGTACAACTGGAACAGTTTCAAA4380GCTTCTTGGCAATTCAGAAGATCCTTCACAGTTTCCCAATTTAGTTATAGTGTCACTGAT4440ACATGAATATATAACACCATTGCTTTCTACTTGGTAATAAACATTGAATGTTGAAACTCC4500TTTAATGCTACAAGTCAAACTTGAAGCATTTAGGCATGGATTTGGTAAATCCATAACTGA4560TATAGTTGTTGGTGTAGAAGACAATCCACTTGGAGATTGAGGTACCTCATTATTGGCAAG4620AACAGTTTGAGTATCTCGTGTTGGTCTAAGGGTTTTACCTGTTGCATTCTGGAGCATTTC4680AGCCAAAGTATCTAGAATTTCATTTTTATGATCTACAGAACGGTCATAATAAGCTTCATC4740ATAAATTTCTGGATGATCGCCCCTTTCAACATGAATCTTTGCATCTGTCTCCTTTAATGC4800CATAAAGGATAAGATAACAGAAGTAACAACTAGTGTACATACACTAATTTTAACAAGTAA4860CTCGCACATCTTTAGAATTTTCATTCTAAAAAGTCGAATAACACTAGTTCTAAAATTGCT4920TTATGAGTTTGATCTGTTGTATGTAGAGTTTTGTTTGCACTGATTGCTCT4970(2) INFORMATION FOR SEQ ID NO:15:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 912 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(xi) SEQUENCE DESCRIPTION: SEQ ID NO:15:ATGAATAGTTTTTTCAAATCACTCAGATCATCTAGCAGCAGGGAGCTAGATCACCCTAGG60GTTACAACTACCCTCTCTAAACAAGGAGCAGACATTGTTGTACACAATCCTTCTGCTAAT120CACAACAACAAGGAAGTTCTCCAAAGAGCCATGGATAGCTCTAAAGGGAAGATTTTGATG180AACAATACAGGCACCTCATCACTAGGCACATATGAGTCTGACCAGATATCTGAATCAGAG240TCTTATGATCTTTCTGCTAGAATGATTGTTGATACAAATCATCATATCTCCAGCTGGAAA300AATGATCTTTTTGTAGGTAATGGTGATAAAGCTGCAACCAAGATAATTAAGATACATCCA360ACCTGGGATAGCAGAAAACAATACATGATGATCTCAAGGATAGTTATCTGGATATGCCCT420ACTATAGCTGATCCTGATGGGAAATTGGCTGTAGCTTTAATTGATCCTAACAAGAGTGTT480AATGCCAGAACTGTTTTGAAAGGGCAAGGAAGCATTAAAGATCCTATATGTTTTGTTTTT540TATCTAAATTGGTCCATTCCAAAAGTTAACAACACTTCAGAGAATTGTGTTCAGCTTCAT600TTATTATGTGATCAAGTTTACAAGAAAGATGTTTCTTTTGCTAGTGTCATGTATTCTTGG660ACAAAAGAATTCTGTGATTCACCAAGAGCAGATCTGGATAAAAGCTGCATGATAATACCC720ATCAATAGGGCTATTAGAGCCAAATCGCAAGCCTTCATTGAAGCCTGCAAGTTAATCATA780CCTAAAGGCAATTCTGAAAAGCAAATTAGAAGACAACTTGCAGAGCTAAGTGCTAATTTA840GAGAAATCTGTTGAAGAAGAGGAGAATGTTACTGATAACAAGATAGAGATATCATTTGAT900AATGAAATCTAA912(2) INFORMATION FOR SEQ ID NO:16:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 473 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(xi) SEQUENCE DESCRIPTION: SEQ ID NO:16:ATATGTTTTCATTTAATAATAAATAATATATATTGTTCATAATATTTTGAATGTTTAAGT60AAAAAATAAAGCAAGATAAAAAACTATATATATATATATATATAGAAGTATAAAATATAT120ATGTATTTGTGTTTAAAAACAAATCAAAAACCAAAAAAGAAAAAAGAAAAAATAAACAAA180AAACAAAAACAAAAACAAAAACAAACAAAAAGCAAAAAATAGAAAAAAGTTGAAAAAAAC240CAAAAAAATTTTTTTTGTAAATAAATAAGGCTCCGGCCAGATTTGGTCTAAGACCTTTTT300ATTTGTTTTTATACATTTTATTTGTTTTTGTTGATTTTTATTTTTATTATTTTTATATTT360TTTATATAGTTTGCTTATTTAACACTTATTTAGACAAATTAAATTTATTTGATTACAATC420ATTCTGCCTTATTTAATTTAAAACACATTTGGTGTATATTCCAATGAATTTAA473(2) INFORMATION FOR SEQ ID NO:17:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 3414 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(xi) SEQUENCE DESCRIPTION: SEQ ID NO:17:TCATATACCGCTGAAGTCTAGAGGAGGTCTTCTTCTAGTGATGGTGTCTTTACCAGAAGA60CGTGGAAACCAAAGAATAATCATTAGTGTCTTCAATATATTTTGTCTTGTAAGACTTGTT120TCTAACATAGCCTCTACACATTGTGGCAACAATAGAGCAGAGGTAAGCAAGAGCAAATAC180AAAGAGTATGAGCAATACTACTCTGACTGTATCAAAGAAGGATCCAAAGTGGCTTGCTAT240AAAGTTAAAAGGGCTTTTAACATAGTCCCAAAAGCTCCAAACTGATGTGTCAGAATTATA300TTGCTGTTCCTCGTGTGCATGTTGGTCATTTTGATCAATTATGTTTTCTGGTTCCAGCAC360AGCAACAGAATCTACAAGTGCCTCAACTGAGTATGATTTGTCTCCTTCTGGTTCTATAAT420CATTTTTTGTTTTTCTGGGTTAGAAGTGCAGAACATTGTCAAGTTATACTTATTAGCACC480TTTCTTTACTGCTATCTGGTATGTTGACAATGAACATTGTTTCATGGTTAACCTTGCAGA540AAAAGTTATGTCTGATATAAATGAGGCAGCACACCTCAGCCCTTGGCTACATAAGAAACA600TCCCTTACAGCTTAAAGAGACAGAACTCAATATAGGCTTTTTTGGTACAGTTTTAAACAA660TTCAGAAGGTAGATCCAAAACAATTTTAAGCTTACCTAGACTAAAGATCTTTTCCATATA720AAAACTATTCTGGTCAGTAAACTGAACTGGAATGTCCGATATTTGGTTCAAACCTGTTTT780AAATCTGTATGTGTCATAACCACATGATTTTATCGTAATTGTTTTTTTACCAATTGCTGA840ACAATCCCAGGACAGATCGTTTGTATCTAATGTTTTCTTAGAGAAAATGGGATCACCTTG900GTGTGAAAGTTGAGGATGACCAAACATTTTTGATGGATTATTTAATCTAGCTATGTTTCC960CGCATATACGTGACTATCAGGTCCATGAGCTATCAGCTGGCCTATTGTTAAGCCATCATT1020ATGGAAATCCGCTAATATATCAGCCTGGAAATATCCTGATTCAGATGGGACTTCCTCAGA1080TACAGTGAAACACTTTGCTCCCACAAATCCAGATATACATACTTCAGACTTGATTGTTGA1140TTTAATAACAGAATAAATCCTGAAAGATTGATCCATATCATACACATTTCTACAAAACCC1200ACAAGTGGCTCCTTCATTGATAGCCAAACACCAAACCTCTTCACAACCCCAGTAAGATGT1260TGGTGTTATGCAGAAATCTTGATACCCAGTTATCGGTTGTTCTTTTCTGCAATCTGAGCA1320TTTACCTGTGCATGTTGAAAAGAAATCAGTGTGGGTGCTTTGTATAGGAGCTGTAGTGTA1380TTGTTCAGAAACATCATACTGTATTCTAACTTTTTTAATATAAACAACAAACTTCTGAGC1440AGTGCTAGAACTTTTGTCATTAAGAGAGAAAACTGTGCCCCCACCTGATAATAAAGATTC1500TTCTATCATGTATCTATATTTTCCATCTATCACCGAGTCAAATATGAGAGATTTTCTTGG1560AAAAATGCTTTCAGGTATGTCTGATTCATTAGATTTAAGTGCATCTCCAGAAATGTATCC1620ATATTTTTCAGTTTTATTGTAGAAATCAATTATACCATTCCTAAGCCTTTTCATGAAGTG1680TAGATTCACAGCATTCAATCCCAATGTGTCACCAGAATATTCTAAGAACCCATTATCTAA1740AGGCTTGCTTTGGAAAATAGAGGCATACTCACAACCAAATCTGCATTTGACAAAAGTTAC1800TAAAGCATTTTCAGTTATCCTGCCTTTGCATTCTTGATAAGGTATACAATCCATAGGACC1860TTCTGTCACAACATTGGTTAGAAAGTTAGATTCTACAATAGAATTTTCTTTAATAGCACA1920GAAGCATTGGTCTTTTTCAGGACATTTGTCATATCTGTTTGTAACAAAGCGGTCACAACC1980AGGGACATAATAACAGCTATCCAAACACTGAGCAGTTTGAGCCATAGACATAGGCATCTG2040TGACAAAATCAGAAATCCTATCAAAGTTTCTGTGACTGCTTTTAGGAAAGAGAGGCCTAT2100TTTTGTATTAACTATCAAATGGAACCATTCAATGCTAGCCCAGTTGTATTTTTTATTCTT2160CTCTGCTGTTCTAGTTATTATAGGACATTCTTCTGAGTGTTCTTCAGAGGCTTTGTTTTT2220GTTACAAATGCATAATTTTGAGCATTCATGGGTTACCAAACATAAATTTCCACAGACCTT2280ACATTTCAAGGGAAAATAAGACCATAAATAATTTATCAGTAGTAGTATAGGATACGTTAT2340CAATCCCAGAAGATCATACCCATAGAACAGTGTTTTAGATGTTTTGTTTACCAAGTACCT2400TATAGGGAAATAGACAATCAGAGCAATCATGATCAATCTAAACCATGAGAAGTTGATGCA2460AGCAGTTTGTTTGTAAATATTTTTGGAGTACTTTATAATACAATCTCTAACTCTTTTGTC2520CACTAAAGGAACTTTAGAAGACTTGTCACCGCACAATAGGTTATGCTTACCATCCATATT2580TTCTTCTGTGAAAGTCAAACTAACTGAGCCAGAGAAGCTTATTATGGAATGGCTCATGTC2640ACTTCCTTCTCTTTTGACGACGTAACCCATGATTTTCTCAGGTGTAGTTAATGAAACTGT2700ATAAGAATTAACTATGTTTGTTTTTGATATTTTACAATCACCTGAGAATTTCACACTCTG2760GAGAGAGACTGTGCCATTAGTTGGTCTAGAATTGTACATGATTGGATAATTGTAATTCTC2820CAAACTTTCAATTATATAGAATTTAGTTCCTATAGATAATTTCCTTTTGTTATCGATTTT2880TGTTATTGGTACAACTGGAACAGTTTCAAAGCTTCTTGGCAATTCAGAAGATCCTTCACA2940GTTTCCCAATTTAGTTATAGTGTCACTGATACATGAATATATAACACCATTGCTTTCTAC3000TTGGTAATAAACATTGAATGTTGAAACTCCTTTAATGCTACAAGTCAAACTTGAAGCATT3060TAGGCATGGATTTGGTAAATCCATAACTGATATAGTTGTTGGTGTAGAAGACAATCCACT3120TGGAGATTGAGGTACCTCATTATTGGCAAGAACAGTTTGAGTATCTCGTGTTGGTCTAAG3180GGTTTTACCTGTTGCATTCTGGAGCATTTCAGCCAAAGTATCTAGAATTTCATTTTTATG3240ATCTACAGAACGGTCATAATAAGCTTCATCATAAATTTCTGGATGATCGCCCCTTTCAAC3300ATGAATCTTTGCATCTGTCTCCTTTAATGCCATAAAGGATAAGATAACAGAAGTAACAAC3360TAGTGTACATACACTAATTTTAACAAGTAACTCGCACATCTTTAGAATTTTCAT3414(2) INFORMATION FOR SEQ ID NO:18:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 36 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(xi) SEQUENCE DESCRIPTION: SEQ ID NO:18:AGAGCAATCAGTGCATCAAAATTATATCTAGCCGAA36(2) INFORMATION FOR SEQ ID NO:19:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 36 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(xi) SEQUENCE DESCRIPTION: SEQ ID NO:19:CTGTTGTATGTAGAGTTTTGTTTGCACTGATTGCTC36(2) INFORMATION FOR SEQ ID NO:20:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 4970 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(xi) SEQUENCE DESCRIPTION: SEQ ID NO:20:AGAGCAATCAGTGCAAACAAAACTCTACATACAACAGATCAAACTCATAAAGCAATTTTA60GAACTAGTGTTATTCGACTTTTTAGAATGAAAATTCTAAAGATGTGCGAGTTACTTGTTA120AAATTAGTGTATGTACACTAGTTGTTACTTCTGTTATCTTATCCTTTATGGCATTAAAGG180AGACAGATGCAAAGATTCATGTTGAAAGGGGCGATCATCCAGAAATTTATGATGAAGCTT240ATTATGACCGTTCTGTAGATCATAAAAATGAAATTCTAGATACTTTGGCTGAAATGCTCC300AGAATGCAACAGGTAAAACCCTTAGACCAACACGAGATACTCAAACTGTTCTTGCCAATA360ATGAGGTACCTCAATCTCCAAGTGGATTGTCTTCTACACCAACAACTATATCAGTTATGG420ATTTACCAAATCCATGCCTAAATGCTTCAAGTTTGACTTGTAGCATTAAAGGAGTTTCAA480CATTCAATGTTTATTACCAAGTAGAAAGCAATGGTGTTATATATTCATGTATCAGTGACA540CTATAACTAAATTGGGAAACTGTGAAGGATCTTCTGAATTGCCAAGAAGCTTTGAAACTG600TTCCAGTTGTACCAATAACAAAAATCGATAACAAAAGGAAATTATCTATAGGAACTAAAT660TCTATATAATTGAAAGTTTGGAGAATTACAATTATCCAATCATGTACAATTCTAGACCAA720CTAATGGCACAGTCTCTCTCCAGAGTGTGAAATTCTCAGGTGATTGTAAAATATCAAAAA780CAAACATAGTTAATTCTTATACAGTTTCATTAACTACACCTGAGAAAATCATGGGTTACG840TCGTCAAAAGAGAAGGAAGTGACATGAGCCATTCCATAATAAGCTTCTCTGGCTCAGTTA900GTTTGACTTTCACAGAAGAAAATATGGATGGTAAGCATAACCTATTGTGCGGTGACAAGT960CTTCTAAAGTTCCTTTAGTGGACAAAAGAGTTAGAGATTGTATTATAAAGTACTCCAAAA1020ATATTTACAAACAAACTGCTTGCATCAACTTCTCATGGTTTAGATTGATCATGATTGCTC1080TGATTGTCTATTTCCCTATAAGGTACTTGGTAAACAAAACATCTAAAACACTGTTCTATG1140GGTATGATCTTCTGGGATTGATAACGTATCCTATACTACTACTGATAAATTATTTATGGT1200CTTATTTTCCCTTGAAATGTAAGGTCTGTGGAAATTTATGTTTGGTAACCCATGAATGCT1260CAAAATTATGCATTTGTAACAAAAACAAAGCCTCTGAAGAACACTCAGAAGAATGTCCTA1320TAATAACTAGAACAGCAGAGAAGAATAAAAAATACAACTGGGCTAGCATTGAATGGTTCC1380ATTTGATAGTTAATACAAAAATAGGCCTCTCTTTCCTAAAAGCAGTCACAGAAACTTTGA1440TAGGATTTCTGATTTTGTCACAGATGCCTATGTCTATGGCTCAAACTGCTCAGTGTTTGG1500ATAGCTGTTATTATGTCCCTGGTTGTGACCGCTTTGTTACAAACAGATATGACAAATGTC1560CTGAAAAAGACCAATGCTTCTGTGCTATTAAAGAAAATTCTATTGTAGAATCTAACTTTC1620TAACCAATGTTGTGACAGAAGGTCCTATGGATTGTATACCTTATCAAGAATGCAAAGGCA1680GGATAACTGAAAATGCTTTAGTAACTTTTGTCAAATGCAGATTTGGTTGTGAGTATGCCT1740CTATTTTCCAAAGCAAGCCTTTAGATAATGGGTTCTTAGAATATTCTGGTGACACATTGG1800GATTGAATGCTGTGAATCTACACTTCATGAAAAGGCTTAGGAATGGTATAATTGATTTCT1860ACAATAAAACTGAAAAATATGGATACATTTCTGGAGATGCACTTAAATCTAATGAATCAG1920ACATACCTGAAAGCATTTTTCCAAGAAAATCTCTCATATTTGACTCGGTGATAGATGGAA1980AATATAGATACATGATAGAAGAATCTTTATTATCAGGTGGGGGCACAGTTTTCTCTCTTA2040ATGACAAAAGTTCTAGCACTGCTCAGAAGTTTGTTGTTTATATTAAAAAAGTTAGAATAC2100AGTATGATGTTTCTGAACAATACACTACAGCTCCTATACAAAGCACCCACACTGATTTCT2160TTTCAACATGCACAGGTAAATGCTCAGATTGCAGAAAAGAACAACCGATAACTGGGTATC2220AAGATTTCTGCATAACACCAACATCTTACTGGGGTTGTGAAGAGGTTTGGTGTTTGGCTA2280TCAATGAAGGAGCCACTTGTGGGTTTTGTAGAAATGTGTATGATATGGATCAATCTTTCA2340GGATTTATTCTGTTATTAAATCAACAATCAAGTCTGAAGTATGTATATCTGGATTTGTGG2400GAGCAAAGTGTTTCACTGTATCTGAGGAAGTCCCATCTGAATCAGGATATTTCCAGGCTG2460ATATATTAGCGGATTTCCATAATGATGGCTTAACAATAGGCCAGCTGATAGCTCATGGAC2520CTGATAGTCACGTATATGCGGGAAACATAGCTAGATTAAATAATCCATCAAAAATGTTTG2580GTCATCCTCAACTTTCACACCAAGGTGATCCCATTTTCTCTAAGAAAACATTAGATACAA2640ACGATCTGTCCTGGGATTGTTCAGCAATTGGTAAAAAAACAATTACGATAAAATCATGTG2700GTTATGACACATACAGATTTAAAACAGGTTTGAACCAAATATCGGACATTCCAGTTCAGT2760TTACTGACCAGAATAGTTTTTATATGGAAAAGATCTTTAGTCTAGGTAAGCTTAAAATTG2820TTTTGGATCTACCTTCTGAATTGTTTAAAACTGTACCAAAAAAGCCTATATTGAGTTCTG2880TCTCTTTAAGCTGTAAGGGATGTTTCTTATGTAGCCAAGGGCTGAGGTGTGCTGCCTCAT2940TTATATCAGACATAACTTTTTCTGCAAGGTTAACCATGAAACAATGTTCATTGTCAACAT3000ACCAGATAGCAGTAAAGAAAGGTGCTAATAAGTATAACTTGACAATGTTCTGCACTTCTA3060ACCCAGAAAAACAAAAAATGATTATAGAACCAGAAGGAGACAAATCATACTCAGTTGAGG3120CACTTGTAGATTCTGTTGCTGTGCTGGAACCAGAAAACATAATTGATCAAAATGACCAAC3180ATGCACACGAGGAACAGCAATATAATTCTGACACATCAGTTTGGAGCTTTTGGGACTATG3240TTAAAAGCCCTTTTAACTTTATAGCAAGCCACTTTGGATCCTTCTTTGATACAGTCAGAG3300TAGTATTGCTCATACTCTTTGTATTTGCTCTTGCTTACCTCTGCTCTATTGTTGCCACAA3360TGTGTAGAGGCTATGTTAGAAACAAGTCTTACAAGACAAAATATATTGAAGACACTAATG3420ATTATTCTTTGGTTTCCACGTCTTCTGGTAAAGACACCATCACTAGAAGAAGACCTCCTC3480TAGACTTCAGCGGTATATGATTAAATTCATTGGAATATACACCAAATGTGTTTTAAATTA3540AATAAGGCAGAATGATTGTAATCAAATAAATTTAATTTGTCTAAATAAGTGTTAAATAAG3600CAAACTATATAAAAAATATAAAAATAATAAAAATAAAAATCAACAAAAACAAATAAAATG3660TATAAAAACAAATAAAAAGGTCTTAGACCAAATCTGGCCGGAGCCTTATTTATTTACAAA3720AAAAATTTTTTTGGTTTTTTTCAACTTTTTTCTATTTTTTGCTTTTTGTTTGTTTTTGTT3780TTTGTTTTTGTTTTTTGTTTATTTTTTCTTTTTTCTTTTTTGGTTTTTGATTTGTTTTTA3840AACACAAATACATATATATTTTATACTTCTATATATATATATATATATAGTTTTTTATCT3900TGCTTTATTTTTTACTTAAACATTCAAAATATTATGAACAATATATATTATTTATTATTA3960AATGAAAACATATTTAGATTTCATTATCAAATGATATCTCTATCTTGTTATCAGTAACAT4020TCTCCTCTTCTTCAACAGATTTCTCTAAATTAGCACTTAGCTCTGCAAGTTGTCTTCTAA4080TTTGCTTTTCAGAATTGCCTTTAGGTATGATTAACTTGCAGGCTTCAATGAAGGCTTGCG4140ATTTGGCTCTAATAGCCCTATTGATGGGTATTATCATGCAGCTTTTATCCAGATCTGCTC4200TTGGTGAATCACAGAATTCTTTTGTCCAAGAATACATGACACTAGCAAAAGAAACATCTT4260TCTTGTAAACTTGATCACATAATAAATGAAGCTGAACACAATTCTCTGAAGTGTTGTTAA4320CTTTTGGAATGGACCAATTTAGATAAAAAACAAAACATATAGGATCTTTAATGCTTCCTT4380GCCCTTTCAAAACAGTTCTGGCATTAACACTCTTGTTAGGATCAATTAAAGCTACAGCCA4440ATTTCCCATCAGGATCAGCTATAGTAGGGCATATCCAGATAACTATCCTTGAGATCATCA4500TGTATTGTTTTCTGCTATCCCAGGTTGGATGTATCTTAATTATCTTGGTTGCAGCTTTAT4560CACCATTACCTACAAAAAGATCATTTTTCCAGCTGGAGATATGATGATTTGTATCAACAA4620TCATTCTAGCAGAAAGATCATAAGACTCTGATTCAGATATCTGGTCAGACTCATATGTGC4680CTAGTGATGAGGTGCCTGTATTGTTCATCAAAATCTTCCCTTTAGAGCTATCCATGGCTC4740TTTGGAGAACTTCCTTGTTGTTGTGATTAGCAGAAGGATTGTGTACAACAATGTCTGCTC4800CTTGTTTAGAGAGGGTAGTTGTAACCCTAGGGTGATCTAGCTCCCTGCTGCTAGATGATC4860TGAGTGATTTGAAAAAACTATTCATCTCTGGACGGTAGATTAAGAATTAAAATATTGAGA4920AGATAATGATTGAATTCGGCTAGATATAATTTTGATGCACTGATTGCTCT4970(2) INFORMATION FOR SEQ ID NO:21:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 3414 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(xi) SEQUENCE DESCRIPTION: SEQ ID NO:21:ATGAAAATTCTAAAGATGTGCGAGTTACTTGTTAAAATTAGTGTATGTACACTAGTTGTT60ACTTCTGTTATCTTATCCTTTATGGCATTAAAGGAGACAGATGCAAAGATTCATGTTGAA120AGGGGCGATCATCCAGAAATTTATGATGAAGCTTATTATGACCGTTCTGTAGATCATAAA180AATGAAATTCTAGATACTTTGGCTGAAATGCTCCAGAATGCAACAGGTAAAACCCTTAGA240CCAACACGAGATACTCAAACTGTTCTTGCCAATAATGAGGTACCTCAATCTCCAAGTGGA300TTGTCTTCTACACCAACAACTATATCAGTTATGGATTTACCAAATCCATGCCTAAATGCT360TCAAGTTTGACTTGTAGCATTAAAGGAGTTTCAACATTCAATGTTTATTACCAAGTAGAA420AGCAATGGTGTTATATATTCATGTATCAGTGACACTATAACTAAATTGGGAAACTGTGAA480GGATCTTCTGAATTGCCAAGAAGCTTTGAAACTGTTCCAGTTGTACCAATAACAAAAATC540GATAACAAAAGGAAATTATCTATAGGAACTAAATTCTATATAATTGAAAGTTTGGAGAAT600TACAATTATCCAATCATGTACAATTCTAGACCAACTAATGGCACAGTCTCTCTCCAGAGT660GTGAAATTCTCAGGTGATTGTAAAATATCAAAAACAAACATAGTTAATTCTTATACAGTT720TCATTAACTACACCTGAGAAAATCATGGGTTACGTCGTCAAAAGAGAAGGAAGTGACATG780AGCCATTCCATAATAAGCTTCTCTGGCTCAGTTAGTTTGACTTTCACAGAAGAAAATATG840GATGGTAAGCATAACCTATTGTGCGGTGACAAGTCTTCTAAAGTTCCTTTAGTGGACAAA900AGAGTTAGAGATTGTATTATAAAGTACTCCAAAAATATTTACAAACAAACTGCTTGCATC960AACTTCTCATGGTTTAGATTGATCATGATTGCTCTGATTGTCTATTTCCCTATAAGGTAC1020TTGGTAAACAAAACATCTAAAACACTGTTCTATGGGTATGATCTTCTGGGATTGATAACG1080TATCCTATACTACTACTGATAAATTATTTATGGTCTTATTTTCCCTTGAAATGTAAGGTC1140TGTGGAAATTTATGTTTGGTAACCCATGAATGCTCAAAATTATGCATTTGTAACAAAAAC1200AAAGCCTCTGAAGAACACTCAGAAGAATGTCCTATAATAACTAGAACAGCAGAGAAGAAT1260AAAAAATACAACTGGGCTAGCATTGAATGGTTCCATTTGATAGTTAATACAAAAATAGGC1320CTCTCTTTCCTAAAAGCAGTCACAGAAACTTTGATAGGATTTCTGATTTTGTCACAGATG1380CCTATGTCTATGGCTCAAACTGCTCAGTGTTTGGATAGCTGTTATTATGTCCCTGGTTGT1440GACCGCTTTGTTACAAACAGATATGACAAATGTCCTGAAAAAGACCAATGCTTCTGTGCT1500ATTAAAGAAAATTCTATTGTAGAATCTAACTTTCTAACCAATGTTGTGACAGAAGGTCCT1560ATGGATTGTATACCTTATCAAGAATGCAAAGGCAGGATAACTGAAAATGCTTTAGTAACT1620TTTGTCAAATGCAGATTTGGTTGTGAGTATGCCTCTATTTTCCAAAGCAAGCCTTTAGAT1680AATGGGTTCTTAGAATATTCTGGTGACACATTGGGATTGAATGCTGTGAATCTACACTTC1740ATGAAAAGGCTTAGGAATGGTATAATTGATTTCTACAATAAAACTGAAAAATATGGATAC1800ATTTCTGGAGATGCACTTAAATCTAATGAATCAGACATACCTGAAAGCATTTTTCCAAGA1860AAATCTCTCATATTTGACTCGGTGATAGATGGAAAATATAGATACATGATAGAAGAATCT1920TTATTATCAGGTGGGGGCACAGTTTTCTCTCTTAATGACAAAAGTTCTAGCACTGCTCAG1980AAGTTTGTTGTTTATATTAAAAAAGTTAGAATACAGTATGATGTTTCTGAACAATACACT2040ACAGCTCCTATACAAAGCACCCACACTGATTTCTTTTCAACATGCACAGGTAAATGCTCA2100GATTGCAGAAAAGAACAACCGATAACTGGGTATCAAGATTTCTGCATAACACCAACATCT2160TACTGGGGTTGTGAAGAGGTTTGGTGTTTGGCTATCAATGAAGGAGCCACTTGTGGGTTT2220TGTAGAAATGTGTATGATATGGATCAATCTTTCAGGATTTATTCTGTTATTAAATCAACA2280ATCAAGTCTGAAGTATGTATATCTGGATTTGTGGGAGCAAAGTGTTTCACTGTATCTGAG2340GAAGTCCCATCTGAATCAGGATATTTCCAGGCTGATATATTAGCGGATTTCCATAATGAT2400GGCTTAACAATAGGCCAGCTGATAGCTCATGGACCTGATAGTCACGTATATGCGGGAAAC2460ATAGCTAGATTAAATAATCCATCAAAAATGTTTGGTCATCCTCAACTTTCACACCAAGGT2520GATCCCATTTTCTCTAAGAAAACATTAGATACAAACGATCTGTCCTGGGATTGTTCAGCA2580ATTGGTAAAAAAACAATTACGATAAAATCATGTGGTTATGACACATACAGATTTAAAACA2640GGTTTGAACCAAATATCGGACATTCCAGTTCAGTTTACTGACCAGAATAGTTTTTATATG2700GAAAAGATCTTTAGTCTAGGTAAGCTTAAAATTGTTTTGGATCTACCTTCTGAATTGTTT2760AAAACTGTACCAAAAAAGCCTATATTGAGTTCTGTCTCTTTAAGCTGTAAGGGATGTTTC2820TTATGTAGCCAAGGGCTGAGGTGTGCTGCCTCATTTATATCAGACATAACTTTTTCTGCA2880AGGTTAACCATGAAACAATGTTCATTGTCAACATACCAGATAGCAGTAAAGAAAGGTGCT2940AATAAGTATAACTTGACAATGTTCTGCACTTCTAACCCAGAAAAACAAAAAATGATTATA3000GAACCAGAAGGAGACAAATCATACTCAGTTGAGGCACTTGTAGATTCTGTTGCTGTGCTG3060GAACCAGAAAACATAATTGATCAAAATGACCAACATGCACACGAGGAACAGCAATATAAT3120TCTGACACATCAGTTTGGAGCTTTTGGGACTATGTTAAAAGCCCTTTTAACTTTATAGCA3180AGCCACTTTGGATCCTTCTTTGATACAGTCAGAGTAGTATTGCTCATACTCTTTGTATTT3240GCTCTTGCTTACCTCTGCTCTATTGTTGCCACAATGTGTAGAGGCTATGTTAGAAACAAG3300TCTTACAAGACAAAATATATTGAAGACACTAATGATTATTCTTTGGTTTCCACGTCTTCT3360GGTAAAGACACCATCACTAGAAGAAGACCTCCTCTAGACTTCAGCGGTATATGA3414(2) INFORMATION FOR SEQ ID NO:22:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 912 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(xi) SEQUENCE DESCRIPTION: SEQ ID NO:22:TTAGATTTCATTATCAAATGATATCTCTATCTTGTTATCAGTAACATTCTCCTCTTCTTC60AACAGATTTCTCTAAATTAGCACTTAGCTCTGCAAGTTGTCTTCTAATTTGCTTTTCAGA120ATTGCCTTTAGGTATGATTAACTTGCAGGCTTCAATGAAGGCTTGCGATTTGGCTCTAAT180AGCCCTATTGATGGGTATTATCATGCAGCTTTTATCCAGATCTGCTCTTGGTGAATCACA240GAATTCTTTTGTCCAAGAATACATGACACTAGCAAAAGAAACATCTTTCTTGTAAACTTG300ATCACATAATAAATGAAGCTGAACACAATTCTCTGAAGTGTTGTTAACTTTTGGAATGGA360CCAATTTAGATAAAAAACAAAACATATAGGATCTTTAATGCTTCCTTGCCCTTTCAAAAC420AGTTCTGGCATTAACACTCTTGTTAGGATCAATTAAAGCTACAGCCAATTTCCCATCAGG480ATCAGCTATAGTAGGGCATATCCAGATAACTATCCTTGAGATCATCATGTATTGTTTTCT540GCTATCCCAGGTTGGATGTATCTTAATTATCTTGGTTGCAGCTTTATCACCATTACCTAC600AAAAAGATCATTTTTCCAGCTGGAGATATGATGATTTGTATCAACAATCATTCTAGCAGA660AAGATCATAAGACTCTGATTCAGATATCTGGTCAGACTCATATGTGCCTAGTGATGAGGT720GCCTGTATTGTTCATCAAAATCTTCCCTTTAGAGCTATCCATGGCTCTTTGGAGAACTTC780CTTGTTGTTGTGATTAGCAGAAGGATTGTGTACAACAATGTCTGCTCCTTGTTTAGAGAG840GGTAGTTGTAACCCTAGGGTGATCTAGCTCCCTGCTGCTAGATGATCTGAGTGATTTGAA900AAAACTATTCAT912(2) INFORMATION FOR SEQ ID NO:23:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 446 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(xi) SEQUENCE DESCRIPTION: SEQ ID NO:23:GGATCCGGAACATGGTGGAGCACGACACGCTTGTCTACTCCAAAAATATCAAAGATACAG60TCTCAGAAGACCAAAGGGCAATTGAGACTTTTCAACAAAGTTATTGTGAAGATAGTGGAA120AAGGAAGGTGGCTCCTACAAATGCCATCATTGCGATAAAGGAAAGGCCATCGTTGAAGAT180GCCTCTGCCGACAGTGGTCCCAAAGATGGACCCCCACCCACGAGGAGCATCGTGGAAAAA240GAAGACGTTCCAACCACGTCTTCAAAGCAAGTGGATTGATGTGATATCTCCACTGACGTA300AGGGATGACGCACAATCCCACTATCCTTCGCAAGACCCTTCCTCTATATAAGGAAGTTCA360TTTCATTTGGAGAGGACTTTTTACAACAATTACCAACAACAACAAACAACAAACAACATT420ACAATTACTATTTACAATTACCCGGG446(2) INFORMATION FOR SEQ ID NO:24:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 861 amino acids(B) TYPE: amino acid(C) STRANDEDNESS: unknown(D) TOPOLOGY: unknown(ii) MOLECULE TYPE: protein(xi) SEQUENCE DESCRIPTION: SEQ ID NO:24:MetGluThrAlaSerAsnSerGluArgProHisGluProHisGluLeu151015TyrSerSerGluArgLeuGluAlaArgGlySerGluArgSerGluArg202530SerGluArgSerGluArgAlaArgGlyGlyLeuLeuGluAlaSerPro354045HisIleSerProArgAlaArgGlyValAlaLeuThrHisArgThrHis505560ArgThrHisArgLeuGluSerGluArgLeuTyrSerGlyLeuAsnGly65707580LeuTyrAlaLeuAlaAlaSerProIleLeuGluValAlaLeuValAla859095LeuHisIleSerAlaSerAsnProArgSerGluArgAlaLeuAlaAla100105110SerAsnHisIleSerAlaSerAsnAlaSerAsnLeuTyrSerGlyLeu115120125ValAlaLeuLeuGluGlyLeuAsnAlaArgGlyAlaLeuAlaMetGlu130135140ThrAlaSerProSerGluArgSerGluArgLeuTyrSerGlyLeuTyr145150155160LeuTyrSerIleLeuGluLeuGluMetGluThrAlaSerAsnAlaSer165170175AsnThrHisArgGlyLeuTyrThrHisArgSerGluArgSerGluArg180185190LeuGluGlyLeuTyrThrHisArgThrTyrArgGlyLeuSerGluArg195200205AlaSerProGlyLeuAsnIleLeuGluSerGluArgGlyLeuSerGlu210215220ArgGlyLeuSerGluArgThrTyrArgAlaSerProLeuGluSerGlu225230235240ArgAlaLeuAlaAlaArgGlyMetGluThrIleLeuGluValAlaLeu245250255AlaSerProThrHisArgAlaSerAsnHisIleSerHisIleSerIle260265270LeuGluSerGluArgSerGluArgThrArgProLeuTyrSerAlaSer275280285AsnAlaSerProLeuGluProHisGluValAlaLeuGlyLeuTyrAla290295300SerAsnGlyLeuTyrAlaSerProLeuTyrSerAlaLeuAlaAlaLeu305310315320AlaThrHisArgLeuTyrSerIleLeuGluIleLeuGluLeuTyrSer325330335IleLeuGluHisIleSerProArgThrHisArgThrArgProAlaSer340345350ProSerGluArgAlaArgGlyLeuTyrSerGlyLeuAsnThrTyrArg355360365MetGluThrMetGluThrIleLeuGluSerGluArgAlaArgGlyIle370375380LeuGluValAlaLeuIleLeuGluThrArgProIleLeuGluCysTyr385390395400SerProArgThrHisArgIleLeuGluAlaLeuAlaAlaSerProPro405410415ArgAlaSerProGlyLeuTyrLeuTyrSerLeuGluAlaLeuAlaVal420425430AlaLeuAlaLeuAlaLeuGluIleLeuGluAlaSerProProArgAla435440445SerAsnLeuTyrSerSerGluArgValAlaLeuAlaSerAsnAlaLeu450455460AlaAlaArgGlyThrHisArgValAlaLeuLeuGluLeuTyrSerGly465470475480LeuTyrGlyLeuAsnGlyLeuTyrSerGluArgIleLeuGluLeuTyr485490495SerAlaSerProProArgIleLeuGluCysTyrSerProHisGluVal500505510AlaLeuProHisGluThrTyrArgLeuGluAlaSerAsnThrArgPro515520525SerGluArgIleLeuGluProArgLeuTyrSerValAlaLeuAlaSer530535540AsnAlaSerAsnThrHisArgSerGluArgGlyLeuAlaSerAsnCys545550555560TyrSerValAlaLeuGlyLeuAsnLeuGluHisIleSerLeuGluLeu565570575GluCysTyrSerAlaSerProGlyLeuAsnValAlaLeuThrTyrArg580585590LeuTyrSerLeuTyrSerAlaSerProValAlaLeuSerGluArgPro595600605HisGluAlaLeuAlaSerGluArgValAlaLeuMetGluThrThrTyr610615620ArgSerGluArgThrArgProThrHisArgLeuTyrSerGlyLeuPro625630635640HisGluCysTyrSerAlaSerProSerGluArgProArgAlaArgGly645650655AlaLeuAlaAlaSerProLeuGluAlaSerProLeuTyrSerSerGlu660665670ArgCysTyrSerMetGluThrIleLeuGluIleLeuGluProArgIle675680685LeuGluAlaSerAsnAlaArgGlyAlaLeuAlaIleLeuGluAlaArg690695700GlyAlaLeuAlaLeuTyrSerSerGluArgGlyLeuAsnAlaLeuAla705710715720ProHisGluIleLeuGluGlyLeuAlaLeuAlaCysTyrSerLeuTyr725730735SerLeuGluIleLeuGluIleLeuGluProArgLeuTyrSerGlyLeu740745750TyrAlaSerAsnSerGluArgGlyLeuLeuTyrSerGlyLeuAsnIle755760765LeuGluAlaArgGlyAlaArgGlyGlyLeuAsnLeuGluAlaLeuAla770775780GlyLeuLeuGluSerGluArgAlaLeuAlaAlaSerAsnLeuGluGly785790795800LeuLeuTyrSerSerGluArgValAlaLeuGlyLeuGlyLeuGlyLeu805810815GlyLeuAlaSerAsnValAlaLeuThrHisArgAlaSerProAlaSer820825830AsnLeuTyrSerIleLeuGluGlyLeuIleLeuGluSerGluArgPro835840845HisGluAlaSerProAlaSerAsnGlyLeuIleLeuGlu850855860(2) INFORMATION FOR SEQ ID NO:25:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 744 amino acids(B) TYPE: amino acid(C) STRANDEDNESS: unknown(D) TOPOLOGY: unknown(ii) MOLECULE TYPE: protein(xi) SEQUENCE DESCRIPTION: SEQ ID NO:25:MetGluThrAlaSerAsnLeuTyrSerAlaLeuAlaLeuTyrSerIle151015LeuGluThrHisArgLeuTyrSerGlyLeuAlaSerAsnIleLeuGlu202530ValAlaLeuLeuTyrSerLeuGluLeuGluThrHisArgGlyLeuAsn354045SerGluArgAlaSerProSerGluArgLeuGluGlyLeuProHisGlu505560GlyLeuGlyLeuThrHisArgGlyLeuAsnAlaSerAsnGlyLeuGly65707580LeuTyrSerGluArgProHisGluAlaSerAsnProHisGluThrHis859095ArgAlaSerProProHisGluProHisGluThrHisArgAlaSerAsn100105110AlaSerAsnAlaArgGlyGlyLeuLeuTyrSerIleLeuGluGlyLeu115120125AsnAlaSerAsnMetGluThrThrHisArgThrHisArgAlaLeuAla130135140SerGluArgCysTyrSerLeuGluSerGluArgProHisGluLeuGlu145150155160LeuTyrSerAlaSerAsnAlaArgGlyGlyLeuAsnSerGluArgIle165170175LeuGluMetGluThrAlaArgGlyValAlaLeuIleLeuGluLeuTyr180185190SerSerGluArgAlaLeuAlaAlaSerProProHisGluThrHisArg195200205ProHisGluGlyLeuTyrSerGluArgValAlaLeuThrHisArgIle210215220LeuGluLeuTyrSerLeuTyrSerThrHisArgAlaArgGlyAlaSer225230235240AsnAlaSerAsnSerGluArgGlyLeuAlaArgGlyValAlaLeuGly245250255LeuTyrValAlaLeuAlaSerAsnAlaSerProMetGluThrThrHis260265270ArgProHisGluAlaArgGlyAlaArgGlyLeuGluAlaSerProAla275280285LeuAlaMetGluThrValAlaLeuAlaArgGlyValAlaLeuHisIle290295300SerLeuGluValAlaLeuGlyLeuTyrMetGluThrIleLeuGluLeu305310315320TyrSerAlaSerProAlaSerAsnGlyLeuTyrSerGluArgAlaLeu325330335AlaLeuGluThrHisArgGlyLeuAlaLeuAlaIleLeuGluAlaSer340345350AsnSerGluArgLeuGluProArgSerGluArgHisIleSerProArg355360365LeuGluIleLeuGluAlaLeuAlaSerGluArgThrTyrArgGlyLeu370375380TyrLeuGluAlaLeuAlaThrHisArgThrHisArgAlaSerProLeu385390395400GluLeuTyrSerSerGluArgCysTyrSerValAlaLeuLeuGluGly405410415LeuTyrValAlaLeuLeuGluLeuGluGlyLeuTyrGlyLeuTyrSer420425430GluArgLeuGluProArgLeuGluIleLeuGluAlaLeuAlaSerGlu435440445ArgValAlaLeuLeuGluAlaSerAsnProHisGluGlyLeuIleLeu450455460GluAlaLeuAlaAlaLeuAlaLeuGluValAlaLeuProArgAlaLeu465470475480AlaIleLeuGluThrTyrArgGlyLeuAsnAlaSerProAlaLeuAla485490495LeuTyrSerHisIleSerValAlaLeuGlyLeuLeuGluGlyLeuTyr500505510IleLeuGluAlaSerProMetGluThrSerGluArgLeuTyrSerPro515520525HisGluSerGluArgThrHisArgLeuTyrSerGlyLeuAlaLeuAla530535540ValAlaLeuGlyLeuTyrLeuTyrSerValAlaLeuCysTyrSerThr545550555560HisArgValAlaLeuLeuGluLeuTyrSerSerGluArgLeuTyrSer565570575GlyLeuTyrThrTyrArgSerGluArgMetGluThrAlaSerAsnSer580585590GluArgValAlaLeuGlyLeuIleLeuGluGlyLeuTyrLeuTyrSer595600605AlaLeuAlaLeuTyrSerGlyLeuAsnThrTyrArgAlaLeuAlaAla610615620SerProIleLeuGluLeuGluLeuTyrSerAlaLeuAlaCysTyrSer625630635640SerGluArgProArgLeuTyrSerAlaLeuAlaLeuTyrSerGlyLeu645650655TyrLeuGluAlaLeuAlaAlaLeuAlaMetGluThrAlaSerProHis660665670IleSerThrTyrArgLeuTyrSerGlyLeuGlyLeuTyrLeuGluThr675680685HisArgSerGluArgIleLeuGluThrTyrArgSerGluArgMetGlu690695700ThrProHisGluAlaSerAsnAlaLeuAlaThrHisArgIleLeuGlu705710715720AlaSerProProHisGluGlyLeuTyrLeuTyrSerAlaSerAsnAla725730735SerProSerGluArgIleLeuGlu740(2) INFORMATION FOR SEQ ID NO:26:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 1261 amino acids(B) TYPE: amino acid(C) STRANDEDNESS: unknown(D) TOPOLOGY: unknown(ii) MOLECULE TYPE: protein(xi) SEQUENCE DESCRIPTION: SEQ ID NO:26:MetGluThrSerGluArgSerGluArgAlaLeuAlaMetGluThrThr151015TyrArgGlyLeuThrHisArgIleLeuGluIleLeuGluLeuTyrSer202530SerGluArgLeuTyrSerSerGluArgSerGluArgIleLeuGluThr354045ArgProGlyLeuTyrThrHisArgThrHisArgSerGluArgSerGlu505560ArgGlyLeuTyrLeuTyrSerAlaLeuAlaValAlaLeuValAlaLeu65707580AlaSerProSerGluArgThrTyrArgThrArgProIleLeuGluHis859095IleSerAlaSerProGlyLeuAsnSerGluArgSerGluArgGlyLeu100105110TyrLeuTyrSerLeuTyrSerLeuGluValAlaLeuGlyLeuAlaLeu115120125AlaGlyLeuAsnLeuGluThrTyrArgSerGluArgAlaSerProSer130135140GluArgAlaArgGlySerGluArgLeuTyrSerThrHisArgSerGlu145150155160ArgProHisGluCysTyrSerThrTyrArgThrHisArgGlyLeuTyr165170175LeuTyrSerValAlaLeuGlyLeuTyrProHisGluLeuGluProArg180185190ThrHisArgGlyLeuGlyLeuLeuTyrSerGlyLeuIleLeuGluIle195200205LeuGluValAlaLeuAlaArgGlyCysTyrSerProHisGluValAla210215220LeuProArgIleLeuGluProHisGluAlaSerProAlaSerProIle225230235240LeuGluAlaSerProLeuGluAlaSerAsnProHisGluSerGluArg245250255ProHisGluSerGluArgGlyLeuTyrAlaSerAsnValAlaLeuVal260265270AlaLeuGlyLeuIleLeuGluLeuGluValAlaLeuAlaArgGlySer275280285GluArgAlaSerAsnThrHisArgThrHisArgAlaSerAsnThrHis290295300ArgAlaSerAsnGlyLeuTyrValAlaLeuLeuTyrSerHisIleSer305310315320GlyLeuAsnGlyLeuTyrHisIleSerLeuGluLeuTyrSerValAla325330335LeuLeuGluSerGluArgSerGluArgGlyLeuAsnLeuGluLeuGlu340345350AlaArgGlyMetGluThrLeuGluGlyLeuGlyLeuGlyLeuAsnIle355360365LeuGluAlaLeuAlaValAlaLeuProArgGlyLeuIleLeuGluThr370375380HisArgSerGluArgAlaArgGlyProHisGluGlyLeuTyrLeuGlu385390395400LeuTyrSerGlyLeuSerGluArgAlaSerProIleLeuGluProHis405410415GluProArgProArgAlaSerAsnAlaSerAsnProHisGluIleLeu420425430GluGlyLeuAlaLeuAlaAlaLeuAlaAlaSerAsnLeuTyrSerGly435440445LeuTyrSerGluArgLeuGluSerGluArgCysTyrSerValAlaLeu450455460LeuTyrSerGlyLeuValAlaLeuLeuGluProHisGluAlaSerPro465470475480ValAlaLeuLeuTyrSerThrTyrArgSerGluArgAlaSerAsnAla485490495SerAsnGlyLeuAsnSerGluArgMetGluThrGlyLeuTyrLeuTyr500505510SerValAlaLeuSerGluArgValAlaLeuLeuGluSerGluArgPro515520525ArgThrHisArgAlaArgGlySerGluArgValAlaLeuHisIleSer530535540GlyLeuThrArgProLeuGluThrTyrArgThrHisArgLeuGluLeu545550555560TyrSerProArgValAlaLeuProHisGluAlaSerAsnGlyLeuAsn565570575SerGluArgGlyLeuAsnThrHisArgAlaSerAsnAlaSerAsnAla580585590ArgGlyThrHisArgValAlaLeuAlaSerAsnThrHisArgLeuGlu595600605AlaLeuAlaValAlaLeuLeuTyrSerSerGluArgLeuGluAlaLeu610615620AlaMetGluThrSerGluArgAlaLeuAlaThrHisArgSerGluArg625630635640AlaSerProLeuGluMetGluThrSerGluArgAlaSerProThrHis645650655ArgHisIleSerSerGluArgProHisGluValAlaLeuAlaArgGly660665670LeuGluAlaSerAsnAlaSerAsnAlaSerAsnLeuTyrSerProArg675680685ProHisGluLeuTyrSerIleLeuGluSerGluArgLeuGluThrArg690695700ProMetGluThrAlaArgGlyIleLeuGluProArgLeuTyrSerIle705710715720LeuGluMetGluThrLeuTyrSerSerGluArgAlaSerAsnThrHis725730735ArgThrTyrArgSerGluArgAlaArgGlyProHisGluProHisGlu740745750ThrHisArgLeuGluSerGluArgAlaSerProGlyLeuSerGluArg755760765SerGluArgProArgLeuTyrSerGlyLeuThrTyrArgThrTyrArg770775780IleLeuGluSerGluArgIleLeuGluGlyLeuAsnCysTyrSerLeu785790795800GluProArgAlaSerAsnHisIleSerAlaSerAsnAlaSerAsnVal805810815AlaLeuGlyLeuThrHisArgValAlaLeuIleLeuGluGlyLeuThr820825830TyrArgAlaSerAsnProHisGluAlaSerProGlyLeuAsnSerGlu835840845ArgAlaSerAsnLeuGluProHisGluLeuGluAlaSerAsnGlyLeu850855860AsnLeuGluLeuGluLeuGluAlaLeuAlaValAlaLeuIleLeuGlu865870875880HisIleSerLeuTyrSerIleLeuGluGlyLeuMetGluThrAlaSer885890895AsnProHisGluSerGluArgAlaSerProLeuGluLeuTyrSerGly900905910LeuProArgThrTyrArgAlaSerAsnValAlaLeuIleLeuGluHis915920925IleSerAlaSerProMetGluThrSerGluArgThrTyrArgProArg930935940GlyLeuAsnAlaArgGlyIleLeuGluValAlaLeuHisIleSerSer945950955960GluArgLeuGluLeuGluGlyLeuIleLeuGluHisIleSerThrHis965970975ArgGlyLeuLeuGluAlaLeuAlaGlyLeuAsnThrHisArgValAla980985990LeuCysTyrSerAlaSerProSerGluArgValAlaLeuGlyLeuAsn99510001005GlyLeuAsnAlaSerProMetGluThrIleLeuGluValAlaLeuPro101010151020HisGluThrHisArgIleLeuGluAlaSerAsnGlyLeuProArgAla1025103010351040SerProLeuGluLeuTyrSerProArgLeuTyrSerLeuTyrSerPro104510501055HisGluGlyLeuLeuGluGlyLeuTyrLeuTyrSerLeuTyrSerThr106010651070HisArgLeuGluAlaSerAsnThrTyrArgSerGluArgGlyLeuAla107510801085SerProGlyLeuTyrThrTyrArgGlyLeuTyrAlaArgGlyLeuTyr109010951100SerThrTyrArgProHisGluLeuGluSerGluArgGlyLeuAsnThr1105111011151120HisArgLeuGluLeuTyrSerSerGluArgLeuGluProArgAlaArg112511301135GlyAlaSerAsnSerGluArgGlyLeuAsnThrHisArgMetGluThr114011451150SerGluArgThrTyrArgLeuGluAlaSerProSerGluArgIleLeu115511601165GluGlyLeuAsnMetGluThrProArgAlaSerProThrArgProLeu117011751180TyrSerProHisGluAlaSerProThrTyrArgAlaLeuAlaAlaLeu1185119011951200AlaGlyLeuTyrGlyLeuIleLeuGluLeuTyrSerIleLeuGluSer120512101215GluArgProArgAlaArgGlySerGluArgGlyLeuAlaSerProVal122012251230AlaLeuLeuGluLeuTyrSerAlaLeuAlaIleLeuGluSerGluArg123512401245LeuTyrSerLeuGluAlaSerProLeuGluAlaSerAsn125012551260(2) INFORMATION FOR SEQ ID NO:27:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 3218 amino acids(B) TYPE: amino acid(C) STRANDEDNESS: unknown(D) TOPOLOGY: unknown(ii) MOLECULE TYPE: protein(xi) SEQUENCE DESCRIPTION: SEQ ID NO:27:MetGluThrLeuTyrSerIleLeuGluLeuGluLeuTyrSerMetGlu151015ThrCysTyrSerGlyLeuLeuGluLeuGluValAlaLeuLeuTyrSer202530IleLeuGluSerGluArgValAlaLeuCysTyrSerThrHisArgLeu354045GluValAlaLeuValAlaLeuThrHisArgSerGluArgValAlaLeu505560IleLeuGluLeuGluSerGluArgProHisGluMetGluThrAlaLeu65707580AlaLeuGluLeuTyrSerGlyLeuThrHisArgAlaSerProAlaLeu859095AlaLeuTyrSerIleLeuGluHisIleSerValAlaLeuGlyLeuAla100105110ArgGlyGlyLeuTyrAlaSerProHisIleSerProArgGlyLeuIle115120125LeuGluThrTyrArgAlaSerProGlyLeuAlaLeuAlaThrTyrArg130135140ThrTyrArgAlaSerProAlaArgGlySerGluArgValAlaLeuAla145150155160SerProHisIleSerLeuTyrSerAlaSerAsnGlyLeuIleLeuGlu165170175LeuGluAlaSerProThrHisArgLeuGluAlaLeuAlaGlyLeuMet180185190GluThrLeuGluGlyLeuAsnAlaSerAsnAlaLeuAlaThrHisArg195200205GlyLeuTyrLeuTyrSerThrHisArgLeuGluAlaArgGlyProArg210215220ThrHisArgAlaArgGlyAlaSerProThrHisArgGlyLeuAsnThr225230235240HisArgValAlaLeuLeuGluAlaLeuAlaAlaSerAsnAlaSerAsn245250255GlyLeuValAlaLeuProArgGlyLeuAsnSerGluArgProArgSer260265270GluArgGlyLeuTyrLeuGluSerGluArgSerGluArgThrHisArg275280285ProArgThrHisArgThrHisArgIleLeuGluSerGluArgValAla290295300LeuMetGluThrAlaSerProLeuGluProArgAlaSerAsnProArg305310315320CysTyrSerLeuGluAlaSerAsnAlaLeuAlaSerGluArgSerGlu325330335ArgLeuGluThrHisArgCysTyrSerSerGluArgIleLeuGluLeu340345350TyrSerGlyLeuTyrValAlaLeuSerGluArgThrHisArgProHis355360365GluAlaSerAsnValAlaLeuThrTyrArgThrTyrArgGlyLeuAsn370375380ValAlaLeuGlyLeuSerGluArgAlaSerAsnGlyLeuTyrValAla385390395400LeuIleLeuGluThrTyrArgSerGluArgCysTyrSerIleLeuGlu405410415SerGluArgAlaSerProThrHisArgIleLeuGluThrHisArgLeu420425430TyrSerLeuGluGlyLeuTyrAlaSerAsnCysTyrSerGlyLeuGly435440445LeuTyrSerGluArgSerGluArgGlyLeuLeuGluProArgAlaArg450455460GlySerGluArgProHisGluGlyLeuThrHisArgValAlaLeuPro465470475480ArgValAlaLeuValAlaLeuProArgIleLeuGluThrHisArgLeu485490495TyrSerIleLeuGluAlaSerProAlaSerAsnLeuTyrSerAlaArg500505510GlyLeuTyrSerLeuGluSerGluArgIleLeuGluGlyLeuTyrThr515520525HisArgLeuTyrSerProHisGluThrTyrArgIleLeuGluIleLeu530535540GluGlyLeuSerGluArgLeuGluGlyLeuAlaSerAsnThrTyrArg545550555560AlaSerAsnThrTyrArgProArgIleLeuGluMetGluThrThrTyr565570575ArgAlaSerAsnSerGluArgAlaArgGlyProArgThrHisArgAla580585590SerAsnGlyLeuTyrThrHisArgValAlaLeuSerGluArgLeuGlu595600605GlyLeuAsnSerGluArgValAlaLeuLeuTyrSerProHisGluSer610615620GluArgGlyLeuTyrAlaSerProCysTyrSerLeuTyrSerIleLeu625630635640GluSerGluArgLeuTyrSerThrHisArgAlaSerAsnIleLeuGlu645650655ValAlaLeuAlaSerAsnSerGluArgThrTyrArgThrHisArgVal660665670AlaLeuSerGluArgLeuGluThrHisArgThrHisArgProArgGly675680685LeuLeuTyrSerIleLeuGluMetGluThrGlyLeuTyrThrTyrArg690695700ValAlaLeuValAlaLeuLeuTyrSerAlaArgGlyGlyLeuGlyLeu705710715720TyrSerGluArgAlaSerProMetGluThrSerGluArgHisIleSer725730735SerGluArgIleLeuGluIleLeuGluSerGluArgProHisGluSer740745750GluArgGlyLeuTyrSerGluArgValAlaLeuSerGluArgLeuGlu755760765ThrHisArgProHisGluThrHisArgGlyLeuGlyLeuAlaSerAsn770775780MetGluThrAlaSerProGlyLeuTyrLeuTyrSerHisIleSerAla785790795800SerAsnLeuGluLeuGluCysTyrSerGlyLeuTyrAlaSerProLeu805810815TyrSerSerGluArgSerGluArgLeuTyrSerValAlaLeuProArg820825830LeuGluValAlaLeuAlaSerProLeuTyrSerAlaArgGlyValAla835840845LeuAlaArgGlyAlaSerProCysTyrSerIleLeuGluIleLeuGlu850855860LeuTyrSerThrTyrArgSerGluArgLeuTyrSerAlaSerAsnIle865870875880LeuGluThrTyrArgLeuTyrSerGlyLeuAsnThrHisArgAlaLeu885890895AlaCysTyrSerIleLeuGluAlaSerAsnProHisGluSerGluArg900905910ThrArgProProHisGluAlaArgGlyLeuGluIleLeuGluMetGlu915920925ThrIleLeuGluAlaLeuAlaLeuGluIleLeuGluValAlaLeuThr930935940TyrArgProHisGluProArgIleLeuGluAlaArgGlyThrTyrArg945950955960LeuGluValAlaLeuAlaSerAsnLeuTyrSerThrHisArgSerGlu965970975ArgLeuTyrSerThrHisArgLeuGluProHisGluThrTyrArgGly980985990LeuTyrThrTyrArgAlaSerProLeuGluLeuGluGlyLeuTyrLeu99510001005GluIleLeuGluThrHisArgThrTyrArgProArgIleLeuGluLeu101010151020GluLeuGluLeuGluIleLeuGluAlaSerAsnThrTyrArgLeuGlu1025103010351040ThrArgProSerGluArgThrTyrArgProHisGluProArgLeuGlu104510501055LeuTyrSerCysTyrSerLeuTyrSerValAlaLeuCysTyrSerGly106010651070LeuTyrAlaSerAsnLeuGluCysTyrSerLeuGluValAlaLeuThr107510801085HisArgHisIleSerGlyLeuCysTyrSerSerGluArgLeuTyrSer109010951100LeuGluCysTyrSerIleLeuGluCysTyrSerAlaSerAsnLeuTyr1105111011151120SerAlaSerAsnLeuTyrSerAlaLeuAlaSerGluArgGlyLeuGly112511301135LeuHisIleSerSerGluArgGlyLeuGlyLeuCysTyrSerProArg114011451150IleLeuGluIleLeuGluThrHisArgAlaArgGlyThrHisArgAla115511601165LeuAlaGlyLeuLeuTyrSerAlaSerAsnLeuTyrSerLeuTyrSer117011751180ThrTyrArgAlaSerAsnThrArgProAlaLeuAlaSerGluArgIle1185119011951200LeuGluGlyLeuThrArgProProHisGluHisIleSerLeuGluIle120512101215LeuGluValAlaLeuAlaSerAsnThrHisArgLeuTyrSerIleLeu122012251230GluGlyLeuTyrLeuGluSerGluArgProHisGluLeuGluLeuTyr123512401245SerAlaLeuAlaValAlaLeuThrHisArgGlyLeuThrHisArgLeu125012551260GluIleLeuGluGlyLeuTyrProHisGluLeuGluIleLeuGluLeu1265127012751280GluSerGluArgGlyLeuAsnMetGluThrProArgMetGluThrSer128512901295GluArgMetGluThrAlaLeuAlaGlyLeuAsnThrHisArgAlaLeu130013051310AlaGlyLeuAsnCysTyrSerLeuGluAlaSerProSerGluArgCys131513201325TyrSerThrTyrArgThrTyrArgValAlaLeuProArgGlyLeuTyr133013351340CysTyrSerAlaSerProAlaArgGlyProHisGluValAlaLeuThr1345135013551360HisArgAlaSerAsnAlaArgGlyThrTyrArgAlaSerProLeuTyr136513701375SerCysTyrSerProArgGlyLeuLeuTyrSerAlaSerProGlyLeu138013851390AsnCysTyrSerProHisGluCysTyrSerAlaLeuAlaIleLeuGlu139514001405LeuTyrSerGlyLeuAlaSerAsnSerGluArgIleLeuGluValAla141014151420LeuGlyLeuSerGluArgAlaSerAsnProHisGluLeuGluThrHis1425143014351440ArgAlaSerAsnValAlaLeuValAlaLeuThrHisArgGlyLeuGly144514501455LeuTyrProArgMetGluThrAlaSerProCysTyrSerIleLeuGlu146014651470ProArgThrTyrArgGlyLeuAsnGlyLeuCysTyrSerLeuTyrSer147514801485GlyLeuTyrAlaArgGlyIleLeuGluThrHisArgGlyLeuAlaSer149014951500AsnAlaLeuAlaLeuGluValAlaLeuThrHisArgProHisGluVal1505151015151520AlaLeuLeuTyrSerCysTyrSerAlaArgGlyProHisGluGlyLeu152515301535TyrCysTyrSerGlyLeuThrTyrArgAlaLeuAlaSerGluArgIle154015451550LeuGluProHisGluGlyLeuAsnSerGluArgLeuTyrSerProArg155515601565LeuGluAlaSerProAlaSerAsnGlyLeuTyrProHisGluLeuGlu157015751580GlyLeuThrTyrArgSerGluArgGlyLeuTyrAlaSerProThrHis1585159015951600ArgLeuGluGlyLeuTyrLeuGluAlaSerAsnAlaLeuAlaValAla160516101615LeuAlaSerAsnLeuGluHisIleSerProHisGluMetGluThrLeu162016251630TyrSerAlaArgGlyLeuGluAlaArgGlyAlaSerAsnGlyLeuTyr163516401645IleLeuGluIleLeuGluAlaSerProProHisGluThrTyrArgAla165016551660SerAsnLeuTyrSerThrHisArgGlyLeuLeuTyrSerThrTyrArg1665167016751680GlyLeuTyrThrTyrArgIleLeuGluSerGluArgGlyLeuTyrAla168516901695SerProAlaLeuAlaLeuGluLeuTyrSerSerGluArgAlaSerAsn170017051710GlyLeuSerGluArgAlaSerProIleLeuGluProArgGlyLeuSer171517201725GluArgIleLeuGluProHisGluProArgAlaArgGlyLeuTyrSer173017351740SerGluArgLeuGluIleLeuGluProHisGluAlaSerProSerGlu1745175017551760ArgValAlaLeuIleLeuGluAlaSerProGlyLeuTyrLeuTyrSer176517701775ThrTyrArgAlaArgGlyThrTyrArgMetGluThrIleLeuGluGly178017851790LeuGlyLeuSerGluArgLeuGluLeuGluSerGluArgGlyLeuTyr179518001805GlyLeuTyrGlyLeuTyrThrHisArgValAlaLeuProHisGluSer181018151820GluArgLeuGluAlaSerAsnAlaSerProLeuTyrSerSerGluArg1825183018351840SerGluArgSerGluArgThrHisArgAlaLeuAlaGlyLeuAsnLeu184518501855TyrSerProHisGluValAlaLeuValAlaLeuThrTyrArgIleLeu186018651870GluLeuTyrSerLeuTyrSerValAlaLeuAlaArgGlyIleLeuGlu187518801885GlyLeuAsnThrTyrArgAlaSerProValAlaLeuSerGluArgGly189018951900LeuGlyLeuAsnThrTyrArgThrHisArgThrHisArgAlaLeuAla1905191019151920ProArgIleLeuGluGlyLeuAsnSerGluArgThrHisArgHisIle192519301935SerThrHisArgAlaSerProProHisGluProHisGluSerGluArg194019451950ThrHisArgCysTyrSerThrHisArgGlyLeuTyrLeuTyrSerCys195519601965TyrSerSerGluArgAlaSerProCysTyrSerAlaArgGlyLeuTyr197019751980SerGlyLeuGlyLeuAsnProArgIleLeuGluThrHisArgGlyLeu1985199019952000TyrThrTyrArgGlyLeuAsnAlaSerProProHisGluCysTyrSer200520102015IleLeuGluThrHisArgProArgThrHisArgSerGluArgThrTyr202020252030ArgThrArgProGlyLeuTyrCysTyrSerGlyLeuGlyLeuValAla203520402045LeuThrArgProCysTyrSerLeuGluAlaLeuAlaIleLeuGluAla205020552060SerAsnGlyLeuGlyLeuTyrAlaLeuAlaThrHisArgCysTyrSer2065207020752080GlyLeuTyrProHisGluCysTyrSerAlaArgGlyAlaSerAsnVal208520902095AlaLeuThrTyrArgAlaSerProMetGluThrAlaSerProGlyLeu210021052110AsnSerGluArgProHisGluAlaArgGlyIleLeuGluThrTyrArg211521202125SerGluArgValAlaLeuIleLeuGluLeuTyrSerSerGluArgThr213021352140HisArgIleLeuGluLeuTyrSerSerGluArgGlyLeuValAlaLeu2145215021552160CysTyrSerIleLeuGluSerGluArgGlyLeuTyrProHisGluVal216521702175AlaLeuGlyLeuTyrAlaLeuAlaLeuTyrSerCysTyrSerProHis218021852190GluThrHisArgValAlaLeuSerGluArgGlyLeuGlyLeuValAla219522002205LeuProArgSerGluArgGlyLeuSerGluArgGlyLeuTyrThrTyr221022152220ArgProHisGluGlyLeuAsnAlaLeuAlaAlaSerProIleLeuGlu2225223022352240LeuGluAlaLeuAlaAlaSerProProHisGluHisIleSerAlaSer224522502255AsnAlaSerProGlyLeuTyrLeuGluThrHisArgIleLeuGluGly226022652270LeuTyrGlyLeuAsnLeuGluIleLeuGluAlaLeuAlaHisIleSer227522802285GlyLeuTyrProArgAlaSerProSerGluArgHisIleSerValAla229022952300LeuThrTyrArgAlaLeuAlaGlyLeuTyrAlaSerAsnIleLeuGlu2305231023152320AlaLeuAlaAlaArgGlyLeuGluAlaSerAsnAlaSerAsnProArg232523302335SerGluArgLeuTyrSerMetGluThrProHisGluGlyLeuTyrHis234023452350IleSerProArgGlyLeuAsnLeuGluSerGluArgHisIleSerGly235523602365LeuAsnGlyLeuTyrAlaSerProProArgIleLeuGluProHisGlu237023752380SerGluArgLeuTyrSerLeuTyrSerThrHisArgLeuGluAlaSer2385239023952400ProThrHisArgAlaSerAsnAlaSerProLeuGluSerGluArgThr240524102415ArgProAlaSerProCysTyrSerSerGluArgAlaLeuAlaIleLeu242024252430GluGlyLeuTyrLeuTyrSerLeuTyrSerThrHisArgIleLeuGlu243524402445ThrHisArgIleLeuGluLeuTyrSerSerGluArgCysTyrSerGly245024552460LeuTyrThrTyrArgAlaSerProThrHisArgThrTyrArgAlaArg2465247024752480GlyProHisGluLeuTyrSerThrHisArgGlyLeuTyrLeuGluAla248524902495SerAsnGlyLeuAsnIleLeuGluSerGluArgAlaSerProIleLeu250025052510GluProArgValAlaLeuGlyLeuAsnProHisGluThrHisArgAla251525202525SerProGlyLeuAsnAlaSerAsnSerGluArgProHisGluThrTyr253025352540ArgMetGluThrGlyLeuLeuTyrSerIleLeuGluProHisGluSer2545255025552560GluArgLeuGluGlyLeuTyrLeuTyrSerLeuGluLeuTyrSerIle256525702575LeuGluValAlaLeuLeuGluAlaSerProLeuGluProArgSerGlu258025852590ArgGlyLeuLeuGluProHisGluLeuTyrSerThrHisArgValAla259526002605LeuProArgLeuTyrSerLeuTyrSerProArgIleLeuGluLeuGlu261026152620SerGluArgSerGluArgValAlaLeuSerGluArgLeuGluSerGlu2625263026352640ArgCysTyrSerLeuTyrSerGlyLeuTyrCysTyrSerProHisGlu264526502655LeuGluCysTyrSerSerGluArgGlyLeuAsnGlyLeuTyrLeuGlu266026652670AlaArgGlyCysTyrSerAlaLeuAlaAlaLeuAlaSerGluArgPro267526802685HisGluIleLeuGluSerGluArgAlaSerProIleLeuGluThrHis269026952700ArgProHisGluSerGluArgAlaLeuAlaAlaArgGlyLeuGluThr2705271027152720HisArgMetGluThrLeuTyrSerGlyLeuAsnCysTyrSerSerGlu272527302735ArgLeuGluSerGluArgThrHisArgThrTyrArgGlyLeuAsnIle274027452750LeuGluAlaLeuAlaValAlaLeuLeuTyrSerLeuTyrSerGlyLeu275527602765TyrAlaLeuAlaAlaSerAsnLeuTyrSerThrTyrArgAlaSerAsn277027752780LeuGluThrHisArgMetGluThrProHisGluCysTyrSerThrHis2785279027952800ArgSerGluArgAlaSerAsnProArgGlyLeuLeuTyrSerGlyLeu280528102815AsnLeuTyrSerMetGluThrIleLeuGluIleLeuGluGlyLeuPro282028252830ArgGlyLeuGlyLeuTyrAlaSerProLeuTyrSerSerGluArgThr283528402845TyrArgSerGluArgValAlaLeuGlyLeuAlaLeuAlaLeuGluVal285028552860AlaLeuAlaSerProSerGluArgValAlaLeuAlaLeuAlaValAla2865287028752880LeuLeuGluGlyLeuProArgGlyLeuAlaSerAsnIleLeuGluIle288528902895LeuGluAlaSerProGlyLeuAsnAlaSerAsnAlaSerProGlyLeu290029052910AsnHisIleSerAlaLeuAlaHisIleSerGlyLeuGlyLeuGlyLeu291529202925AsnGlyLeuAsnThrTyrArgAlaSerAsnSerGluArgAlaSerPro293029352940ThrHisArgSerGluArgValAlaLeuThrArgProSerGluArgPro2945295029552960HisGluThrArgProAlaSerProThrTyrArgValAlaLeuLeuTyr296529702975SerSerGluArgProArgProHisGluAlaSerAsnProHisGluIle298029852990LeuGluAlaLeuAlaSerGluArgHisIleSerProHisGluGlyLeu299530003005TyrSerGluArgProHisGluProHisGluAlaSerProThrHisArg301030153020ValAlaLeuAlaArgGlyValAlaLeuValAlaLeuLeuGluLeuGlu3025303030353040IleLeuGluLeuGluProHisGluValAlaLeuProHisGluAlaLeu304530503055AlaLeuGluAlaLeuAlaThrTyrArgLeuGluCysTyrSerSerGlu306030653070ArgIleLeuGluValAlaLeuAlaLeuAlaThrHisArgMetGluThr307530803085CysTyrSerAlaArgGlyGlyLeuTyrThrTyrArgValAlaLeuAla309030953100ArgGlyAlaSerAsnLeuTyrSerSerGluArgThrTyrArgLeuTyr3105311031153120SerThrHisArgLeuTyrSerThrTyrArgIleLeuGluGlyLeuAla312531303135SerProThrHisArgAlaSerAsnAlaSerProThrTyrArgSerGlu314031453150ArgLeuGluValAlaLeuSerGluArgThrHisArgSerGluArgSer315531603165GluArgGlyLeuTyrLeuTyrSerAlaSerProThrHisArgIleLeu317031753180GluThrHisArgAlaArgGlyAlaArgGlyAlaArgGlyProArgPro3185319031953200ArgLeuGluAlaSerProProHisGluSerGluArgGlyLeuTyrIle320532103215LeuGlu__________________________________________________________________________
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Recombinant Impatiens Necrotic Spot Virus (INSV) DNA constructs comprising an INSV DNA coding for transcription into INSV RNA sequences or into RNA sequences related thereto, the use of such DNA constructs to transform plants having reduced susceptibility to INSV infection and probes for the isolation of INSV or diagnosis of plant INSV related diseases.
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BACKGROUND
[0001] The present invention concerns a safety device for the railroad industry.
[0002] With the signing of the Rail Safety Improvement Act, in October 2008, the railroad industry will need to be “Positive Train Control” compliant throughout the United States by 2015.
[0003] The term “Positive Train Control” (PTC) means that a system must be designed to prevent: train to train collisions; over speed derailments; incursions into established work zone limits; and movement of a train through a switch left in the improper position.
[0004] To satisfy these requirements, a number of new types of devices are needed to provide complete PTC systems.
[0005] In particular, there is a need for a device to capable report to an on-board locomotive subsystem the status of a wayside signal supplied to a wayside signal lamp. The wayside signal allows the determination whether the locomotive movement is in agreement with the condition of the railroad. The report of the status of this wayside signal is necessary to satisfy the fundamental requirements of any PTC solution.
SUMMARY OF THE INVENTION
[0006] An object of the present invention is to provide a response to this need.
[0007] The present invention provides a current sensor for monitoring the current flowing in a wire of a circuit, the current sensor includes a variable inductance contactless current detector to sense the current flowing in said wire, serially connected to an internal power source and a resistor to form a voltage divider circuit and a voltage detector to monitor the voltage level across the resistor, and generate an output signal.
[0008] The variable inductance contactless current detector according to the invention, called VCS for “Vital Current Sensor” throughout this document, is a stand-alone device used to monitor, in an “overlay” configuration, the status of the wayside signal of an associated wayside signal lamp.
[0009] This may be accomplished by measuring the current drawn by the wayside signal lamp, which corresponds to the wayside signal.
[0010] The output signal of the VCS represents the status of the wayside signal.
[0011] The output signal of the VCS is intended to drive an input of a wayside interface unit (WIU), which converts the analog output signal of the VCS into a communication message, which is eventually delivered to an onboard locomotive subsystem. The details of the operation of the WIU are outside the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] A preferred embodiment of the present invention will be elucidated with reference to the drawings, in which:
[0013] FIG. 1 represents a Vital Current Sensor according to a preferred embodiment of the invention;
[0014] FIG. 2 shows graphs illustrating the various types of current waveforms the VCS will respond to (both AC and DC, steady state and modulated);
[0015] FIG. 3 is a circuit illustrating the major components of the output circuit responsible for generating the DC output voltage;
[0016] FIG. 4 is a graph representing the output signal of the VCS of FIG. 1 relative to the current flowing in the monitored wayside lamp;
[0017] FIG. 5 is a graph illustrating the general relationship of DC current on the control winding of the sensing inductor to its inductance value;
[0018] FIG. 6 is a graph illustrating the Current Sensor's transfer function of input sensed current to output voltage; and
[0019] FIG. 7 is a graph illustrating the general relationship of AC current on the control winding of the sensing inductor to its inductance value.
DETAILED DESCRIPTION
[0020] As shown in FIG. 1 , the VCS 1 comprises a housing 3 , for example made of plastic, which is provided with:
[0021] power input connectors 5 and 7 , to be connected to an external power source 8 , for supplying a nominal 12V DC to the VCS ; signal output connectors 9 and 11 , to be connected with corresponding input connectors of a WIU 12 , for the exchange of an output signal S generated by VCS 1 ; and, a wire passage 15 .
[0022] The passage 15 extents between two through holes 17 and 19 , provided on two opposite walls of the housing 3 . The passage 15 is realized by a tubular sheath 21 , made for example of Garolite (a paper-based material that is lighter than metal but denser and stronger), whose ends are maintained in said through holes 17 and 19 and which connects one external face 23 of the housing 3 to the opposite external face 25 .
[0023] Inside the housing, the VCS 1 comprises:
[0024] a voltage source 31 ;
[0025] a magnetic core 33 ;
[0026] a fixed resistor 35 , whose resistance is R1; and,
[0027] an output circuit 37 .
[0028] The voltage source 31 is a quadrupole, whose first and second input terminals, 45 and 47 , are respectively connected to the power input connectors 5 and 7 . The voltage source 31 has first and second onput terminals 46 and 48 .
[0029] The magnetic core 33 surrounds the sheath 21 of the passage 15 , so that the passage goes through the magnetic core center.
[0030] A primary winding 53 of the magnetic core 33 has a first terminal 56 connected to the second output terminal 48 of the voltage source 31 and a second terminal 58 connected to a first terminal 66 of the fixed resistor 35 .
[0031] The second terminal 68 of the fixed resistor 35 is connected to the first output terminal 46 of the voltage source 31 .
[0032] The output circuit 37 is a quadrupole. Its first and second input terminals, 76 and 78 , are connected respectively to the first and second terminals 66 and 68 of the fixed resistor 35 . Its first and second output terminals, 77 and 79 , are connected respectively to the output connectors 9 and 11 .
[0033] In a typical application, the VCS 1 is used in combination with a WIU 12 . Consequently, the output connectors 9 an 11 provided on the housing 3 are connected to input connectors provided on the WIU 12 . The output signal S generated by the VCS 1 is thus transmitted to the WIU 12 .
[0034] The VCS 1 is able to sense the current I flowing through a wire 80 of a wayside circuit 82 connecting a lamp driving unit 84 to a wayside signal lamp 85 . In the typical setup the wayside signal lamp 85 is an 18W or a 25W lamp.
[0035] The lamp driving unit 84 may drive the wayside signal lamp with either a Direct Current or an Alternating Current. Both currents can be controlled either to be ON steady, or modulated ON and OFF to produce a flashing indication, typically at a 1 Hz rate.
[0036] FIG. 2 depicts the various types of current the VCS 1 can detect.
[0037] The first graph G 1 of FIG. 2 depicts a DC current transitioning from the OFF state to the ON state.
[0038] The second graph G 2 of FIG. 2 depicts an AC current transitioning from the OFF state to the ON state.
[0039] The third graph G 3 of FIG. 2 depicts a modulated DC current cycling between the OFF state and the ON state.
[0040] The fourth graph G 4 of FIG. 2 depicts a modulated AC current cycling between the OFF state and the ON state.
[0041] The wire 80 is threaded through the VCS 1 , in the passage 15 .
[0042] For the installation, the wire 80 is disconnected from at least one of the connection points in the wayside circuit 82 , inserted through the passage 15 of the VCS 1 , and then reconnected to an original connection point.
[0043] The core 33 is used as a variable impedance component, whose impedance L 1 is controlled by a secondary “winding”. This secondary winding is realized by the wire 80 being passed through the magnetic core center.
[0044] Thus inductor L 1 and fixed resistor R1, connected in series, compose a voltage divider circuit supplied by voltage source 31 .
[0045] The output circuit 37 monitors the voltage V developed across the fixed resistor 35 , and generates an output signal S when the monitored voltage V exceeds a preset threshold V 0 , corresponding to a preset threshold I 0 for the current I in wire 80 . This threshold V 0 is defined by the passive components selected to make the output circuit 37 .
[0046] An illustrative example of a preferred embodiment of output circuit 37 is shown in FIG. 3 . Output circuit 37 consists of a driver stage 130 , configured as a bridge driver, a series resonant L-C tuned circuit, made of a capacitor 140 and a transformer 150 , and an output block made of a rectified DC output 160 , sufficient to energize an input circuit of the WIU.
[0047] The AC voltage V developed across the fixed resistor 35 is applied to the input 78 of the driver stage 130 , resulting in both sides of the transformer 150 primary and series capacitor 140 being driven between +V_DRIVE and COMMON. The voltage produced across the transformer 150 secondary is the product of twice the input voltage and the amplification factor of the series resonant L-C tuned circuit at resonance divided by the turns ratio of transformer 150 . If the input frequency departs from the resonant frequency of the series resonant L-C tuned circuit, the amplification factor rapidly decreases and the output voltage reduces accordingly, de-energizing the WIU input circuit.
[0048] In the preferred embodiment, the output signal S generated by the output circuit 37 is a DC output voltage: when the current I is above the threshold I 0 , the output of circuit 37 is driven to an ON (permissive) state. In this state, the output circuit 37 provides a nominal output signal S of 12V DC; on the contrary, when the current I falls below the threshold I 0 , the output is driven to an OFF (non-permissive) state. In this state, the output circuit 37 provides a nominal output signal S of 0V DC.
[0049] During operation, when the current I flowing in the wire 80 is null (i.e. the lamp 85 is de-energized), the impedance L 1 of the magnetic core 33 is relatively high with respect to the fixed resistance R 1 . The majority of the signal amplitude from the voltage source 31 is divided primarily across L 1 (i.e. the core). The output circuit 37 monitors the voltage across the fixed resistor R 1 , and since this voltage is below the voltage threshold V 0 there is no output from the VCS 1 .
[0050] As the current level increases in the wire 80 , the magnetic core 33 saturates and its impedance L 1 decreases. This in turn increases the voltage level across the fixed resistor 35 . Once this voltage V is of a sufficient level, the output circuit 37 activates and generates an output signal S.
[0051] FIG. 4 shows schematically the operational structure of the magnetic core 33 , with the field lamp wire 80 represented as a control winding on the left, and a inductance winding 82 on the right.
[0052] As DC current I in the control winding increases, the inductance L 1 of the inductance winding remains relatively stable until the magnetic core enters into saturation. Once in saturation, the inductance L 1 of the inductance winding, and hence its corresponding impedance, drops dramatically as illustrated in FIG. 5 .
[0053] When applied in the VCS, the signal lamp current I is used as the control winding current. As the lamp current I increase, the inductance L 1 decrease once the core goes into saturation and the VCS output is enabled as described in the preceding paragraphs above.
[0054] In order to optimize the effect, the magnetic core 33 is designed to switch from a non-saturate state to a saturate state when the monitored current I moves above the predefined threshold I 0 .
[0055] FIG. 6 graphically shows the relationship between the current I in the wayside signal lamp 85 and the voltage of the output signal S generated by the VCS 1 .
[0056] During operation, when the current I is in the range from 0 to 0.5A, the output signal S voltage must not exceed 3.4V (i.e. the OFF-state) (zone 100 in FIG. 2 ).
[0057] When the lamp current I exceeds 1.3A, the output signal S voltage can be any value between 9V DC and 16.5V DC (i.e. the ON-state) (zone 110 in FIG. 2 ).
[0058] In the range of the current I between 500 mA and 1.3A, the output signal S is indeterminate and can be anywhere between 0V and 16.5V DC (zone 120 in FIG. 2 ).
[0059] With this behavior, the VCS 1 complies with the safety requirements for a device intended to be integrated in a PTC system, and, as such is considered as a “fail-safe” device. Indeed, under no circumstances the output signal S exceeds 3.4V DC when the current being monitored is below 0.5A DC or 0.5Arms; under no circumstances the output signals “flashes” (i.e. oscillates between the ON state and the OFF state) when the current being monitored is either constantly below or constantly above the detection threshold (this requirement originating from the fact that, in North American signal applications, a flashing signal aspect is considered to be more permissive than a steady, i.e. non-flashing, signal aspect); a failure of the VCS 1 which generates an output signal when the monitored current is above the preset threshold is considered to be an acceptable failure (i.e. safe side).
[0060] Any current I that causes the saturable inductor made of the magnetic core to change its impedance will cause the VCS output circuit to energize.
[0061] When the VCS senses an AC current I in the wire 80 , the AC current waveform travels from 0 current, to the positive peak current, back to zero current, then to peak negative current, finally returning to 0 current. This sequence is repeated for as long as the AC current is present. At both the positive and negative peaks, the saturable inductor is in the saturation state. During the transition time, the saturable inductor is in various states of intermediary saturation, including not saturated at all. At this time, the VCS output circuit turns off.
[0062] The relationship between the inductance L 1 and AC current I is shown in FIG. 7 . The rate at which the core goes in and out of saturation is directly proportional to the frequency of the AC current I.
[0063] However, this is sufficient filtering in order the output block of the output circuit to maintain a value of the output voltage during this time. The end result is that the final output voltage from the VCS appears to be on steady when detecting AC current.
[0064] Unlike the condition when the lamp is driven with an AC current, when the lamp current is DC, the sense core is driven into a continuous state of saturation.
[0065] This allows the VCS to be used to detect the state of any signal lamp, to be either steady ON, FLASHING, or OFF. In the case where a railroad system uses flashing aspects, signals will typically flash at a rate of 1 Hz with a nominal duty cycle of 50.
[0066] In combination with a WIU, a single VCS is used for each wayside signal lamp to be monitored.
[0067] The VCS is a unique device suitable for use in “fail-safe” railways applications. In addition, any failure of the VCS will have no impact on the operation or performance of the wayside signal lamp being monitored. The isolation between the monitored system and the VCS is extremely high.
[0068] The VCS is a contactless monitoring component, able to detect current on a wire without the need of a physical connection. The installation of the VCS does not require any electrical connection to the circuit to be monitored. So, it is very easy to put in place.
[0069] Compared to the prior art, the design of the present sensor is simpler and only uses analog components. There is no dedicated active means, such as a processor, for the checking of the threshold.
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A sensor for monitoring the current flowing in a wire of a circuit is provided. The sensor includes a variable inductance contactless current detector to sense the current flowing in the wire, serially connected to an internal power source and a resistor to form a voltage divider circuit. The sensor also includes a voltage detector to monitor the voltage level across the resistor and generate an output signal. A system is also provided.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the field of infrared sensing, and more particularly to a method and apparatus for calibrating an imaging sensor.
2. Description of the Related Art
Elemental infrared detectors are often used in conjunction with missiles and night vision systems to sense the presence of electromagnetic radiation having wavelengths of 1-15 μm. To detect infrared radiation, these elemental detectors often use temperature sensitive pyroelectric crystals such as triglicine sulfate and lanthanum doped lead zirconate titanate. Such crystals exhibit spontaneous electrical polarization in response to incident infrared radiation which creates a potential drop across the electrodes of the detector. Elemental detectors may also be fabricated from materials which rely on photoconductive or photoemission properties to detect infrared radiation.
Arrays of such elemental detectors may be used to form thermal imaging systems. In real time thermal imaging systems such as forward looking infrared ("FLIR") imaging sensors, oscillating prism mirrors are used to scan radiation emitted by a source across a one-dimensional array of elemental detectors. When the elemental detectors are used in this manner, the temporal outputs of the detectors may be used to generate a two-dimensional representation of the image. In two-dimensional detector array imaging systems images such as those using staring detector arrays, the elemental detectors are used to produce free charge carriers which are then injected into a change coupled device ("CCD"). The output from the CCD is then processed by using time delay integration and parallel-to-serial scan conversion techniques.
Because each detector channel (i.e., the detector together with its coupling and amplifying electronics) in an imaging sensor often produces a different response to a given intensity of infrared radiation, it is often necessary to calibrate the detector channels so that a given infrared signal would produce approximately the same output at each channel. To provide for such calibration, it was often necessary to use an extended source emitting a uniform level of infrared radiation. When such an extended source was used, all the detectors would focus on the source during the calibration cycle while their outputs were measured. The outputs from the detector channels would then be compared so that the processing electronics could compensate for the differences in the electrical characteristics of the channels. As an alternative technique for calibrating a detector array, each of the elemental detectors were sequentially exposed to a constant intensity point source such as a scanned laser or star. After the outputs of each of the detector channels were measured, the processing electronics would determine the relative output variation of the detector channels so as to enable array calibration.
While the methods for calibrating the detector channels described above were somewhat effective, they often had several disadvantages. The alternative methods which used extended sources had to have a uniform distribution of intensity, a condition difficult to achieve in practice. Further, using constant intensity point sources for calibration was often inefficient in terms of calibration time as each individual detector element had to scan the same point source before the processing electronics could provide the necessary signal adjustment.
SUMMARY OF THE INVENTION
According to the preferred embodiment of the present invention, an image sensor for scanning a thermal image is disclosed. The imaging sensor comprises a first set of elemental detectors operable to receive a thermal image during a first portion of the calibration cycle. A second set of elemental detectors is provided which are operable to receive the image during a second portion of the calibration cycle. Means are provided for calibrating the first and second sets of elemental detectors by comparing the output of the first set of elemental detectors during the first portion of the calibration cycle with the outputs of the second set of elemental detectors during the second portion of the calibration cycle.
BRIEF DESCRIPTION OF THE DRAWINGS
The various advantages of the present invention will become apparent to one skilled in the art upon reading the following specification and by reference to the drawings in which:
FIG. 1 is a diagrammatic side illustration of the operation of an imaging sensor;
FIG. 2 illustrates the sequence by which an image shifts on a detector array during the initial portions of the calibration cycle according to the present invention; and
FIG. 3 illustrates the sequence by which an image shifts on a 17×17 element detector array during the calibrating cycle according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a detector array 10 is provided to detect a thermal image in the field-of-view of the array 10. The thermal image may be generated by different intensities of infrared radiation emitted by a source 12. The detector array 10 comprises a plurality of elemental detectors each able to receive a portion of the thermal energy emitted from the source 12 which lies within its field-of-view.
To position the thermal image on the elemental detectors, a detector mount 14 is provided. The detector mount 14 includes a horizontal positioner 16 and a vertical positioner 18. The horizontal positioner 16 allows the image to be horizontally located on a particular element in the detector array 10, while the vertical positioner 18 allows vertical positioning of the image on the detector array 10. By suitable adjustment of the horizontal and vertical positioners 16, 18, a predetermined portion of the image can be focused on selected elemental detectors of the detector array 10 so that the elemental detectors can be calibrated as described subsequently.
To deliver the thermal image to the array 10, a re-imaging mirror 20 is provided. The re-imaging mirror 20 as shown in FIG. 1 is used to symbolize the collecting telescope optics of a thermal imaging system and may be similar to that described in Hudson, Infrared Systems Engineering, John Wiley & Sons, 1969 at FIGS. 5-20, which is hereby incorporated by reference. The re-imaging mirror 20 receives the thermal image from the source 12 through a diffuser 22 and directs the image to the detector array 10. The diffuser 22 is used to optically increase the uniformity of the thermal image delivered to the re-imaging mirror 20. While the diffuser may be fabricated from a ground dielectric transmission material, other suitable materials may be used.
To process the signals received from the source 12, the output of each elemental detector element of the array 10 is connected to an A.C.-coupling circuit. For purposes of illustration, the A.C.-coupling circuit for only a particular elemental detector is shown and includes a coupling capacitor 24 and a resistor 26. The capacitor 24 and the resistor 26 are used to remove the D.C. bias potential supplied to the detectors which form the array 10. The output of the capacitor 24 is coupled to an amplifier 28 which in turn is coupled to a signal processor 30. The output from the processor 30 is used to evaluate the thermal image received by the array 10.
To compensate for differences in the electrical characteristics of the elemental detectors and their respective coupling and amplifying electronics, the horizontal positioner 16 and the vertical positioner 18 locate the center of a predetermined portion of the image at image position P 1 during the first portion of the calibration cycle. The predetermined portion of the image may be selected to correspond to the brightest portion image so as to obtain desirable signal-to-noise characteristics. However, it is to be understood that another portion of the image may be selected. The thermal radiation comprising the image should remain substantially constant during the calibration cycle to insure that output variation between selected detector channels corresponds to the variation in the electrical characteristics of channels. Nevertheless, the magnitude of the thermal radiation distribution may be nonuniform during the calibration cycle.
When the center of the predetermined portion of the image is located at image position P 1 , the center of the predetermined portion is focused on the detector D 1 ,1. The output from the detector channel including the detector D 1 ,1 is then measured and stored. For purposes of illustration, the first digit in the subscript of the detector designation "D" refers to the relative horizontal position of the elemental detector in the array 10, while the second digit refers to its relative vertical position in the array 10. Accordingly, the elemental detector D 1 ,2 refers to the elemental detector which is in the first column and second row of the detector array shown in FIGS. 2 and 3. Further, while reference is made to the output of a particular detector, it is to be understood that the output is that of the detector channel which includes that particular detector.
During the second portion of the calibration cycle, the horizontal positioner 16 and vertical positioner 18 shift the location of the array such that the center of the predetermined portion of the image is located at image position P 2 . The horizontal positioner 16 and the vertical positioner 18 may typically provide a displacement of 0.0002 inch. It is to be understood, however, that the magnitude of the displacement will vary according to the center-to-center separation of adjacent detectors. When the image is moved by the positioners 16, 18 in this manner, the center of the predetermined portion of the image is focused on the detector D 2 ,1. The output of the detector D 2 ,1 is then measured and compared with the output of the detector D 1 ,1 during the first portion of the calibration cycle. Because the same portion of the image that was focused on the detector D 2 ,1 during the second portion of the calibration cycle was focused on detector D 1 ,1 during the first portion of the calibration cycle, the differences in their outputs correspond to the variation in the electrical characteristics of their respective detector channels. The relative response of the detector D 2 ,1 in terms of the detector D 1 ,1 can therefore be mathematically related as follows: ##EQU1## where Δ 2 ,1 is a relative response of the detector D 2 ,1 with respect to the detector D 1 ,1 ;
ξ 2 ,1 (2) is the output of the detector D 2 ,1 while the predetermined portion of the image is located at image position P 2 ; and
ξ 1 ,1 (1) is the output of the detector D 1 ,1 while the predetermined portion of the image is located at image position P 1 .
Therefore, the output of the detector D 2 ,1 may be adjusted to reflect the variation between the electrical characteristics of detectors D 2 ,1 and D 1 ,1 by dividing the output of the detector D 2 ,1 by its relative response Δ 2 ,1.
During the third portion of the calibration cycle, the array is displaced by the horizontal positioner 16 and the vertical positioner 18 such that the predetermined portion of the image is centered at image position P 3 . Because the image remains substantially constant between image position P 2 and image position P 3 , the infrared radiation delivered to the detector D 2 ,2 during the third portion of the calibration cycle will be substantially the same as the thermal radiation delivered to detector D 2 ,1 during the second portion of the calibration cycle. Similarly, the thermal radiation delivered to the detector D 1 ,2 during the third portion of the calibration cycle will be substantially the same as the thermal radiation delivered to detector D 1 ,1 during the second portion of the calibration cycle. To calibrate the outputs of the detectors D 2 ,2 and D 1 ,2 in terms of the output of the detector D 1 ,1, the relative responses for the detectors D 2 ,2 and D 1 ,2 may be determined as follows: ##EQU2## and ##EQU3## where: Δ 2 ,2 is the relative response of the detector D 2 ,2 in terms of the detector D 1 ,1 ;
Δ 1 ,2 is the relative response of th detector D 1 ,2 in terms of the detector D 1 ,1 ;
ξ 2 ,2 (3) is the output of the detector D 2 ,2 during the third portion of the calibration cycle;
ξ 2 ,1 (2) is the output the detector D 2 ,1 during the second portion of the calibration cycle;
ξ 1 ,1 (1) is the output of he detector D 1 ,1 during the first portion of the calibration cycle;
ξ 1 ,2 (3) is the output of the detector D 1 ,2 during the third portion of the calibration cycle; and
ξ 1 ,1 (2) is the output of the detector D 1 ,1 during the second portion of the calibration cycle.
Accordingly, the output of the detector D 2 ,2 may be adjusted to reflect the variation between the electrical characteristics of the detector 9D 2 ,2 and the detector D 1 ,1 by dividing the output of the detector D 2 ,2 by its relative response Δ 2 ,2. Similarly, the output of the detector D 1 ,2 may also be adjusted to compensate for electrical variation between the detector D 1 ,2 and the detector D 1 ,1 by dividing the output of the detector D 1 ,2 by its relative response Δ 1 ,2. It should be noted however that other data reduction algorithms may be used. Since the same thermal radiation received by the detector D 2 ,1 during the second portion of the calibration cycle is received by the detector D 1 ,1 during the first portion of the calibration cycle, the relative response Δ 2 ,2 may be written as follows: ##EQU4##
During the fourth portion of the calibration cycle, the center of the predetermined portion of the image is shifted to image position P 4 . The output of the detectors D 2 ,3 and D 1 ,3 are then measured and their relative responses calculated according to the following equations: ##EQU5## Accordingly, the set of detectors including detectors D 2 ,3 and D 1 ,3 may be calibrated by measuring their outputs during the fourth portion of the calibration cycle, and comparing their outputs to the outputs of the set of detectors comprising D 2 ,2, D 2 ,1, D 1 ,2 and D 1 ,1 during the first, second and third portions of the calibration cycle as described above.
The relative responses of the remaining detectors in the array can be determined by sequentially locating the predetermined portion of the image at image positions P 5 through P 11 and making the appropriate measurements and calculations similar to those described above. By making these measurements and calculations, the variation in the electrical characteristics between detector channels such as those due to differing responsivities and gain characteristics can be reduced. It should be understood, however, that the movement of the predetermined portion of the image across the array does not necessarily have to follow the sequence described above. Rather, any suitable path may be used so long as substantially the same thermal image which is delivered to one set of elemental detectors in a particular portion of a calibration cycle is also delivered to another set of elemental detectors in an earlier portion of the calibration cycle. Further, two or more calibration cycles may be used to achieve greater accuracy in calculating the relative responses of the elemental detectors.
It should be understood that the invention was described in connection with a particular example thereof. While FIG. 3 shows the movement of a predetermined portion of the image with respect to a 17×17 array of elemental detectors, it will be understood that arrays of different sizes may also be used. Other modifications will become apparent to those skilled in the art after a study of the specification, drawings and following claims.
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An imaging sensor for scanning a thermal image is disclosed. The imaging sensor comprises a first set of elemental detectors operable to receive a thermal image during a first portion of the calibration cycle. A second set of elemental detector is provided which are operable to receive the image during a second portion of the calibration cycle. Means are provided for calibrating the first and second sets of elemental detectors by comparing the output of the first set of elemental detectors during the first portion of the calibration cycle with the outputs of the second set of elemental detectors during the second portion of the calibration cycle.
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This is a continuation of application Ser. No. 119,913, filed Feb. 8, 1980 (now abandoned).
FIELD OF THE INVENTION
The invention is in the field of apparatus for drawing single crystal ingots from a melt and more particularly relates to a pulling head for a Czochralski crystal growth apparatus.
The government has rights in this invention pursuant to Contract No. JPL 954884 awarded by the U.S. Department of Energy.
BACKGROUND OF THE INVENTION
Apparatus for the growth of single crystal ingots by the Czochralski method includes a crucible to contain a melt and a mechanism for concurrently drawing a crystal from the melt along a vertical axis at a steady rate while providing relative rotation about this axis for the growing crystal with respect to the melt. Vertical lift of the crystal ingot is effectuated from the "pulling head" portion of the apparatus which must maintain mechanical alignment of the axis of rotation with the vertical pulling axis while providing case of access for maintainence and rapid turnaround time in a production context. Moreover, in one class of apparatus it is desirable to carry out the process in a vacuum tight housing in order to obtain improved freedom from contamination.
It is known in the prior art to employ a ball chain and takeup drum for vertically lifting the crystal as it is drawn from the melt. In the known apparatus the alignment of the pulling axis, gravitationally defined by the ball chain, with the rotation axis is maintained by causing the takeup drum to travel along a lead screw, transverse to the crystal pulling rotation axis.
The known drum translation apparatus employes a keyed or splined mechanism, or linear ball bushing to constrain the drum translation to its rotational axis during rotation of the drum. A fixed nut and lead screw on the axis of the drum have such a thread pitch to translate the drum by an amount equal to the width of the chain. Thus, the chain is maintained tangent with the drum circumference and in constant alignment with the desired crystal rotation axis. The lubrication requirements for the lead screw and spline of the known chain pulling mechanism is clearly ill-suited to contain a contamination-free environment desired for crystal growth with the present invention.
The transverse travel requirement for the drum of the prior art mechanism further enlarges the volume of the pulling head and affects the balance of the mechanism which controls rotation about the vertical axis. The winding of the chain on the drum is a source of uneven lift as the chain increments relax against the drum surface while under tension. Such relaxation occurs in an uncontrolled fashion and small irregularities in vertical pulling are introduced thereby.
Crystal pulling apparatus of the form above described utilizes a chain taking the form of a linkage of spherical beads. This arrangement has a number of advantageous properties but the chain must be replaced at moderately frequent intervals of use. In the prior art one end of the chain is secured to the drum directly via mechanical fastener. Consequently the entire chain must be replaced as a routine preventative maintenance measure requiring that the pulling head chamber be opened for access.
BRIEF DESCRIPTION OF THE INVENTION
An object of the present invention is the provision, in a crystal growing furnace of the Czochralski type, for a pulling head whih is compact while effectuating long pull lengths.
Another object of the present invention is the provision of a pulling head for a Czochralski type crystal growth apparatus which exhibits superior properties of stability and control for maintaining uniform rotational and vertical motions of the growing crystal ingot.
In one feature of the invention, the growing crystal is suspended by beaded chain and pulling is accomplished with a sprocket adapted to such chain, said sprocket discharging chain into a bin.
In another feature of the invention the lateral surfaces of the sprocket are adapted to conform to the shape of the chain beads by the formation of pockets in such lateral surface.
In yet another feature of the invention, excess chain is accommodated which permits routine discard of a portion of thermally exposed chain in preparation for new crystal growth.
These objects and features are realized by separating the vertical actuation of the chain and chain take-up through provision of a sprocket for the vertical pulling function and a simple container for the storage of untensioned chain. The sprocket engaging the chain is characterized by concave pockets forming the sprocket teeth, such pockets conforming to the spherical shaped beads of the ball chain. As a result of this configuration, the pulling function is executed more smoothly.
Chain takeup is accomplished by discharge of the free end of the chain from the sprocket into a container thereby eliminating the need for a traveling alignment mechanism synchronized with a rotating takeup means.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 shows schematically a crystal pulling system incorporating the present invention.
FIG. 2 is a partially schematic view of the pulling head of the present invention.
FIG. 3 is another view of a part of the mechanism of FIG. 2.
DETAILED DESCRIPTION OF THE INVENTION
A crystal growing system incorporating the present invention is outlined briefly in FIG. 1. A furnace 1 heats a crucible 2 of refractory material (ordinarily quartz) to maintain a melt 3 of the feedstock of the desired crystal material. A crystal 4 is pulled from the melt 3 by pulling head 5 through linkage 6. A housing 7 surrounds the entire apparatus to maintain freedom from contaminants and in some instances to provide hermetic envelope to support a vacuum or inert atmosphere within. Motors 8 and 9 provide relative rotational and pulling motions of the ingot with respect to the melt.
The invention is best described with the aid of FIG. 2 which shows the salient components of the pulling head. A housing 10, preferably formed of a transparent material, is closed on both ends by top plate 12 and bottom plate 14 to form the pulling head enclosure. The bottom plate 14 communicates with the vertical column 16 of the full crystal growing system. A growing crystal 18 drawn from a melt, not shown, is supported from a seed holder 20 supported by the beaded chain or ball chain 22. Ball chain 22 may be formed of a plurality of hollow spherical members, loosely linked to adjacent like members by rod or tubular dumbell shaped segments. The ball chain 22 engages sprocket 24 and the untensioned or free end of ball chain 22 is discharged from sprocket 24 to collect in container 26. Sprocket 24 is formed from a cylindrical section, the curved surface of which has pockets formed in such surface to accommodate the links of the ball chain 22. In order to assure enough wrap around sprocket 24 to support the weight of the growing crystal, an idler pulley 28 constrains the free end of ball chain 22 to sprocket 24. Switch actuator 29 senses an end-of-chain condition. This assures the desired feeding of the free end of ball chain 22 to feed the seed into the melt. It is apparent that a portion of the interior volume of the pulling head chamber may serve as a collecting volume in lieu of container 26.
The entire pulling head is adapted for rotation about vertical axis 30 through bearing assembly 32. Fixed motor 34 drives the entire pulling head through motor pulleys 35, belts 36 and head pulleys 37.
Vertical pulling power is provided by motor 38 through a transmission train schematically illustrated in FIG. 3. This transmission is conventional and provides a reduction appropriate to turn sprocket shaft 40 at rotational speeds in the range of 0.1 to 1.5 revolutions per hour. Further adjustment of pulling rate is obtained by choice diameter for sprocket 24. This has been selected to produce a circumference of 10 inches; the reduction ratios in cooperation with such sprocket diameter yields vertical pull rates in the range 1-15 inches per hour. Accordingly, rotational power is provided to shaft 42 on vertical transmission axis 42' through intermediate reduction gearing 44. Vertical shaft 42 is built in two portions with coupling 45 provided to permit simple removal of top plate 12 for access to the mechanism. Right angle drive 46, for example, a worm and worm-wheel set, provides further reduction gearing and transmits power to the sprocket shaft 40.
Whereas traveling drum pulling heads of the prior art employ a fixed length chain, the present apparatus uses variable length chain. the excess chain stored in container 26 permits frequent removal of a portion of chain proximate the seed holder. Because the strength of the chain is degraded by continuous exposure to high temperatures in this region, the likelihood of chain failure is minimized by routine removal of a portion of chain so exposed before initiating new crystal growth. The excess chain permits this routine practice. Chain failure, it will be noted, is a disasterous occurrence resulting in loss of an ingot grown at great expense, likely damage to the crucible and hot zone components considerable amount of time to restore the condition of the apparatus. This excess chain feature in unavailable on known traveling drum pulling heads because the upper end of the chain in such apparatus is secured to the drum to sustain a correlation between the rotation of the drum pulling axis and ingot altitude on such axis. Another simple embodiment of the principle here described would utilize a drum or other spooling means in lieu of the sprocket with sufficient wraps of suspending medium to obtain a frictional stabilization of the load. The untensioned length of suspending medium, whether chain or cable, would be discharged into a portion of the apparatus envelope.
Since many changes could be made in the described construction and many apparently widely different embodiments of this invention could be made without departing from the scope thereof, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
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A pulling head for a Czochralski type crystal growing furnance includes a ball linked chain for suspending the growing crystal ingot, a sprocket for engaging such chain to pull the ingot from a melt, motor means for driving the sprocket and a chain storage means to receive untensioned chain discharged from the sprocket.
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BACKGROUND
[0001] This invention relates to football goals for use in domestic gardens and more particularly to collapsible football goals and netting to prevent loss of a game ball into neighbouring areas.
[0002] One of the biggest frustrations of playing football in the garden, playground or any confined space is that if you kick the ball at the goal and miss, the ball may fly over the fence into an area belonging to a third party, break a window, or damage property.
[0003] In addition, if the goals used (whether a formal plastic or metal structure, or simply two jumpers on the ground) have no mesh or netting, then even a successfully scored goal can leave the football some way away or cause damage.
[0004] Therefore there is a need for a football goal that helps prevent the ball from escaping from the end or ends of the pitch.
[0005] Solutions exist in the form of low cost plastics frames supporting netting that may be tethered to the grass by means of pegs or hooks. These are considered undesirable as when not in use they damage the grass and are unsightly. They also only capture the ball when a goal is scored and provide no means of preventing escape of the ball onto other people's land.
[0006] It would therefore be advantageous to provide a football goal that could be quickly and easily collapsed when not in use.
[0007] According to a first aspect of the present invention, there is provided a football goal and backstop in the form of a curtain as set forth in claim 1 of the appended claims.
[0008] The present invention provides an all-in-one football goal curtain that acts as both a football goal and backstop to prevent the ball from escaping, without requiring the use of structural poles, that collapses and can be drawn away like a curtain.
[0009] According to a second aspect of the present invention, there is further provided a method of creating a collapsible football goal as set forth in claim 16 of the appended claims.
[0010] Of course the invention is not limited to use on a football pitch, but may be applicable to any game involving a projectile and a goal, such as hockey.
[0011] The prior art discloses a number of Patents and Applications such as WO 2009/149402 A1; U.S. 2007/0158913 A1; U.S. 2009/0209372 A1; U.S. Pat. No. 6,849,009 B1). As is shown, conventional solutions for providing a backstop system involve attachment to an existing goal, and/or include a goal portion made of rigid poles. The present invention seeks to improve on this by providing an integral goal and backstop curtain having no rigid members to provide the structure of the goal. This makes it very easily erectable and collapsible. As erection of the goal and the backstop is provided entirely by tensioning either the net or the rope, in the absence of any rigid members such as those shown in the prior art, removal of the tension enables the entire goal and backstop to be collapsed or retracted, and if desired folded for storage.
[0012] One exception to the above is provided by U.S. Pat. No. 5 , 277 , 430 . This patent discloses an all in one backstop and goal portion formed from a one piece net or curtain. In the embodiment disclosed it is intended to be attached over the mouth of an open garage. One limitation of the disclosure is the requirement to insert a rigid goal mouth to help define its shape. This inclusion prevents the goal and backstop from being quickly and easily retracted and makes the collapsed apparatus significantly heavier and bulkier than the solution proposed by the present invention.
DESCRIPTION
[0013] The invention will now be described further by way of example with reference to the accompanying drawings in which FIGS. 1-4 successively illustrate the stages of assembly of the collapsible football goal according to the present invention, from a collapsed stage ( FIG. 1 ) to a fully erected stage ( FIG. 4 .).
[0014] A cable 1 is suspended above a desired goal-line from a solid location at opposing sides 2 of an intended play area. The solid location could be a tree, a post, a fence, a wall, a designed pole, or any other suitable tethering point, the term solid merely indicating its capacity to support the weight of the cable 1 and subsequent curtain mesh supported thereby. The cable 1 may be permanently attached, or with hooks, allowing it to be selectively removed or retracted to one end, much like a retractable washing line.
[0015] A substantial area of curtain 3 , including within it, a goal mouth, is supported so that it hangs from the overhead cable. It is free to slide along the cable, so that it opens and closes like a conventional window curtain. It may be attached by curtain hooks or loops, or the cable may be threaded through the netting or a sleeve attached to the top of the netting. The curtain may be made from any suitable material, mesh or otherwise, but is typically a nylon material.
[0016] The hanging curtain 3 is larger than the goal mouth within it, ideally as wide and high as possible, so as to cover as much of the width and height of the goal line as possible to prevent the ball from escaping.
[0017] The hanging curtain 3 and/or goal portion may be tensioned widthways by at least one tether, or for example a tethering rope 9 . In the preferred embodiment, the tethering rope 9 is secured such that it is unable to slide relative to the cross bar of the goal mouth. By securing the distal ends of the tethering rope 9 to similar fixed supports, the additional tension provided aids in clearly defining the goal mouth.
[0018] In practice, it is preferable to secure the distal ends of the tethering rope 9 above the desired height of the cross bar. As stated, the tension in the rope 9 is what most effectively defines the shape and position of the cross bar of the goal. The cross bar may then be pulled downwards by additional vertical ropes and anchored to the ground. As a result of having to pull the cross bar down to its desired height, a vertical component of the tension in the tethering rope 9 , serves to tension the vertical ropes therein clearly defining the goal posts.
[0019] Vertical tension in the remainder of the curtain may be provided by additional tethers at ground level. This may be achieved by the use of tent pegs or the like. Alternatively weights may be used to hold the base of the curtain at ground level. These also help the goal form a structured goal mouth shape without the need for rigid posts and help to prevent a ball rolling under the curtain.
[0020] The preferred embodiment is therefore capable of performing all the required functions of a back stop and a goal without the need for rigid posts to be inserted as a framework into the back stop, goal mouth or goal in order to provide structure. It may still be desirable to provide such a frame work in order to provide a more rigid post or crossbar. The framework may consist of interlocking plastic or metal tubes or may be inflatable. The framework is typically inserted into sleeves within the curtain provided at the edges of the goal mouth. This enables players of the game to determine without ambiguity if a ball has ‘hit the post’ such as may occur when playing with a permanent goal structure. What is essential is that the goal back stop and goal mouth may be erected and clearly defined without the need for such support members, and their use should be deemed as optional.
[0021] In the goal area 4 of the curtain 3 , the mesh may be modified with extra side panels 5 of netting inserted to allow it to retain the ball when the flap (goal) is pulled out of the plane of the curtain into the shape of a football goal. The mouth of the goal may be co-planar with the curtain, or alternatively, the curtain may form the back panel of the goal, with additional portions protruding out of the curtain 3 to provide the goal mouth. This latter embodiment is less preferable since it is more likely to require additional tensioning of some sort to provide structure to the goal mouth.
[0022] The preferred embodiment, shown in the figures, has the goal mouth ‘cut-out’ from the curtain 3 , with a protruding flap 6 , forming the back and optionally the sides 5 of the goal. When the flap is pulled into position, the resulting back and optional side panels of the goal may then be attached to the ground either by pegs 7 in key locations, weights, or any other suitable method. This is both to establish the shape of the goal and to prevent ball from escaping under the net.
[0023] The remainder 8 of the width of the main curtain 3 may be attached to the ground in the same way as above.
[0024] It may be that the vertices of the goal mouth are marked or have some form of material attached so as to give the appearance of goalposts and crossbar.
[0025] Alternatively the goal mouth or entire goal may be coloured differently to make it more easily distinguished from the remainder 8 of the curtain 3 .
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A flexible collapsible curtain for hanging up as a football pitch backstop characterised by a flap protruding from the plane of the curtain to define a goal having a goal mouth in the plane of the curtain, wherein, in use, the edges of the goal mouth are defined by tension in the curtain.
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BACKGROUND OF THE INVENTION
The invention relates to a pressure-fluid-operated percussion device comprising a frame allowing a tool to be arranged therein movably in its longitudinal direction, means for feeding pressure liquid to the percussion device and for returning pressure liquid to a pressure liquid tank, and means for producing a stress pulse in the tool by utilizing pressure of the pressure liquid, wherein the percussion device comprises a working pressure chamber filled with pressure liquid and, between the working pressure chamber and the tool, a transmission piston which is movably arranged in the longitudinal direction of the frame and which is in contact with the tool either directly or indirectly at least during stress pulse generation, and a charging pressure chamber on the side of the transmission piston facing the tool so that the transmission piston is provided with a pressure surface facing the working pressure chamber and on the side of the charging pressure chamber a pressure surface facing the tool.
In the prior art, in a percussion device a stress pulse in a tool is produced by using a reciprocating percussion piston which, at the end of its stroke movement, hits an end of a tool or a shank connected thereto, thus producing in the tool a stress pulse propagating towards the material to be processed. The reciprocating stroke movement of a percussion piston is typically produced by means of a pressure medium whose pressure makes the percussion piston move in at least one direction, today typically in both directions. In order to enhance the stroke movement, a pressure accumulator or a spring or the like may be utilized to store energy during a return movement.
Due to the reciprocating movement of a percussion piston, acceleration forces in opposite directions are alternately produced in percussion devices equipped with a percussion piston which subject the mechanism to stress and impede control of the percussion device. In addition, due to such forces, boom structures and feeding apparatuses usually employed for supporting a percussion device have to be more robust than would otherwise be necessary. Furthermore, in order to make a stress pulse to be transferred from the tool to the material to be processed, such as rock to be broken, efficiently enough, the percussion device, and hence the tool, have to be pushed against the material with a sufficient force. Due to dynamic acceleration forces, the feed force and structures, accordingly, have to be dimensioned to be robust enough so that the pressing force on the tool which remains as a difference of acceleration caused by the feed force and the movement of the percussion piston would still be sufficiently large. Furthermore, percussion devices equipped with a percussion piston operating by a reciprocating stroke movement are only able to provide low stroke frequencies since to accelerate the percussion piston in its direction of movement always requires an amount of power proportional to the mass of the percussion piston, and high frequencies would require high acceleration and thus extremely high powers. This, in turn, is not feasible in practice, since all the rest in the percussion device and the support structure thereof would have to be dimensioned accordingly. When at the same time this would result in a considerable decrease in efficiency, the stroke frequency of existing percussion devices is only a few dozens of Hz at its best.
BRIEF DESCRIPTION OF THE INVENTION
An object of the present invention is to provide a percussion device to enable dynamic forces generated therein and drawbacks caused thereby to become significantly smaller. A further object is to provide a percussion device which has a good efficiency and which enables stress pulse frequencies significantly higher than existing ones to be provided.
The percussion device of the invention is characterized in that the means for producing a stress pulse comprise a pressure liquid source connected with the working pressure chamber in order to maintain pressure in the working pressure chamber, and means for intermittently feeding, to the charging pressure chamber, pressure liquid whose pressure enables the transmission piston to be pushed towards the working pressure chamber, against the pressure of the pressure liquid in the working pressure chamber and into a predetermined backward position of the transmission piston such that pressure liquid is discharged from the working pressure chamber, and for alternately allowing pressure liquid to be discharged rapidly from the charging pressure chamber so that a force produced by the pressure of the pressurized pressure liquid in the working pressure chamber and flowing thereto from the pressure liquid source pushes the transmission piston in the direction of the tool, compressing the tool in its longitudinal direction and thus generating a stress pulse in the tool.
A basic idea underlying the invention is that the transmission piston is continuously subjected to a pressure acting towards the tool, the pressure being derived from a pressure fluid source connected to the working pressure chamber.
A further basic idea underlying the invention is that pressurized pressure fluid is fed to a charging pressure chamber residing on another side of the transmission piston to move the transmission piston to a particular predetermined position, i.e. to a position wherefrom the transmission piston is allowed, by means of a force produced by the pressure in the working chamber, to abruptly compress the tool towards the material to be processed, thus producing a stress pulse in the tool.
Still another basic idea underlying the invention is that when the transmission piston is in said position and substantially in contact with the tool or shank, the charging pressure chamber is connected with a “tank pressure” so that the pressure acting on the opposite side of the transmission piston produces a sudden compression on the tool or the like, thus producing a stress pulse which propagates through the tool to the material to be processed.
An advantage of the invention is that this solution enables a good efficiency to be achieved since moving the transmission piston to a stress pulse initiating position, i.e. to a releasing position, takes place substantially against a constant pressure. A further advantage of the invention is that this enables the compressive stress energy of a stress wave being reflected from the material being processed via the tool and the transmission piston to the working pressure chamber to be recovered. A still further advantage is that the stress pulse generation frequency can be made considerably higher than that of the known percussion devices since there is no large-mass, and thus slow, percussion piston which is to be made to reciprocate. Still another advantage of the invention is that the solution is simple to implement and the operation is easy to control.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described in closer detail in the accompanying drawings, wherein
FIGS. 1 a and 1 b show principles of an embodiment of a percussion device according to the invention during charging and during stress pulse generation, respectively, and
FIGS. 2 a and 2 b show theoretical energy graphs related to charging and stress pulse generation, respectively.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 a schematically shows principles of an embodiment of a percussion device according to the invention in a situation wherein the percussion device is being “charged” in order to produce a stress pulse. The figure shows a percussion device 1 comprising a frame 2 . For pressure liquid, the frame comprises a working pressure chamber 3 which, on one side, is defined by a transmission piston 4 . The working pressure chamber 3 is connected via a channel 5 to a pressure source, such as a pressure liquid pump 6 , which feeds pressurized pressure liquid to the space 3 at a pressure P 1 . On the other side of the transmission piston 4 , opposite to the pressure chamber 3 , a charging pressure chamber 7 is provided which, in turn, is connected via a channel 8 and a valve 9 to a pressure liquid source, such as a pressure liquid pump 10 , which feeds pressurized liquid whose pressure is P 2 . From the valve 9 , a pressure liquid return channel 11 is further provided to a pressure liquid tank 12 .
A tool 13 , which may be a drill rod or, typically, a shank connected to the drill rod, is further connected to the percussion device 1 . At the opposite end of the tool, there is provided a drill bit, such as a rock bit or the like, not shown, which during operation is in contact with the material to be processed. It may further comprise a pressure accumulator 14 connected with the working pressure chamber 3 in order to dampen pressure pulses.
In the situation shown in FIG. 1 a , “charging” is implemented wherein pressure liquid, controlled by the valve 9 , is fed to the charging pressure chamber 7 such that the transmission piston 4 moves in the direction of arrow A until it has settled, in the position according to FIG. 1 a , in its uppermost, i.e. backward, position. At the same time pressure liquid is discharged from the working pressure chamber. The backward position of the transmission piston 4 is determined by the mechanical solutions in the percussion device 1 , such as various shoulders or stops; in the embodiment according to FIGS. 1 a and 1 b , a shoulder 2 a and the rear surface of a flange 4 a of the transmission piston. During operation of the percussion device, the percussion device 1 is pushed towards the material to be processed at force F, i.e. a “feed force”, which keeps the transmission piston 4 in contact with the tool 13 and the tip thereof, i.e. a drill bit or the like, in contact with the material to be processed. When the transmission piston 4 has moved in the direction of arrow A as far as possible, the valve 9 is moved into the position shown in FIG. 1 b so that pressure liquid from the charging pressure chamber 7 is allowed to abruptly discharge into the pressure liquid tank 12 . The transmission piston is then allowed to move forward in the direction of the tool 13 due to the pressure of the pressure liquid in the working pressure chamber 3 and further flowing thereto from the pressure liquid pump 6 . Pressure P 1 acting on the transmission piston 4 in the working pressure chamber 3 produces a force which pushes the transmission piston 4 in the direction of arrow B towards the tool 13 , compressing the tool 13 . As a result, a sudden compressive stress is generated in the tool 13 through the transmission piston 4 , this sudden compressive stress thus producing a stress pulse through the tool 13 all the way to the material to be processed. A “reflection pulse” being reflected from the material being processed, in turn, returns through the tool 13 , pushing the transmission piston 4 again in the direction of arrow A in FIG. 1 a so that the energy of the stress pulse is transferred to the pressure liquid in the working pressure chamber. At the same time, the valve 9 is again switched to the position shown in FIG. 1 a , and pressure liquid is again fed to the charging chamber 7 to push the transmission piston 4 to its predetermined backward position.
Pressure surface areas of the transmission piston 4 , i.e. a surface area A 1 facing the working pressure chamber 3 and a surface area A 2 facing the charging chamber 7 , respectively, can be chosen in many different ways. The simplest way of implementation is the embodiment shown in FIGS. 1 a and 1 b wherein the surface areas differ in size. In such a case, choosing the surface areas appropriately enables pressures of equal amount to be used on both sides of the transmission piston 4 , i.e. pressures P 1 and P 2 may be equal in amount. Therefore, pressure liquid may enter both spaces from the same pressure liquid source. This simplifies the implementation of the percussion device. This, in turn, results in a further advantage that the transmission piston 4 may readily be provided with a shoulder-like flange 4 a and the frame may readily be provided with a shoulder 2 a , respectively, so that the shoulder 2 a of the frame 2 defines the backward position of the transmission piston 4 ; in the figure the uppermost position, i.e. position where stress pulse generation always starts. The surface areas may also be equal in size, in which case pressure P 2 has to be higher than pressure P 1 .
FIGS. 2 a and 2 b describe theoretical energy graphs related to charging and stress pulse generation, respectively, in a percussion device according to the invention.
When the transmission piston is moved according to FIG. 2 a against pressure P 1 acting in the working pressure chamber, at the end the amount of charged energy is P 1 ×V 1 , i.e. the product of pressure and volume replaced by a pressure area A 1 , which is depicted by rectangle A. If the value of the pressure acting in the working pressure chamber would initially be 0, the amount of charged energy would be P 1 ×V 1 /2, i.e. half the energy mentioned above, which is depicted by triangle B. Similarly, the amount of energy fed into the percussion device is depicted by rectangle C shown in broken line, which is the product of pressure P 2 (substantially constant) and an increase in volume V 2 that has occurred as a result of a transition of a pressure surface A 2 . This surface area of rectangle C, i.e. the fed energy, is equal in size to the surface area of rectangle A.
When the transmission piston is according to FIG. 2 b allowed to press the tool, the amount of energy transferred to a stress pulse is P 1 ×V 1 , i.e. the product of pressure and said volume, which is depicted by rectangle D. If the value of the pressure acting in the working chamber would be 0 at the end, the amount of energy transferred to a stress pulse would be P 1 ×V 1 /2, i.e. half the energy mentioned above, which is depicted by triangle E.
Although this theoretical examination does not accurately depict real operational processes and pressure levels in practice, it nevertheless provides a clear description as to how the percussion device of the invention, by employing the same pressure values of pressure liquid to be fed, enables power higher than that produced by devices wherein the pressure varies between zero and a maximum pressure to be achieved.
Using short travels in the direction of a tool, the percussion device according to the invention enables stress pulses to be produced at a high frequency since the necessary amounts of pressure liquid to be fed are relatively small while they at the same time enable a large force to be produced. Furthermore, since the mass of the transmission piston 4 is small, no significant dynamic forces are generated. Similarly, moving the transmission piston 4 into its backward position, i.e. starting position, only requires a short movement, thus enabling pulses and a high stress pulse frequency to be achieved, which results in a high frequency of stress pulses between the tool and the material to be processed, usually also called a stroke frequency in connection with known percussion devices. The drawings and the related description are only intended to illustrate the idea of the invention. The details of the invention may vary within the scope of the claims.
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A pressure-fluid-operated percussion device includes a frame allowing a tool to be arranged movably in its longitudinal direction. Pressure liquid is fed to the percussion device and returned to a pressure liquid tank. A stress pulse is produced in the tool utilizing pressure of the pressure liquid. A pressure liquid source maintains pressure in the working pressure chamber. Pressure liquid is intermittently fed to the percussion device such that the pressure liquid pushes a transmission piston into a predetermined backward position. Pressure liquid is alternately discharged rapidly from the percussion device so that the pressure of the pressure liquid in the working pressure chamber and the pressure liquid flowing from the pressure liquid source pushes the transmission piston towards the tool, generating a stress pulse in the tool.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to firearm supports, and more particularly to an adjustable firearm support that attaches to a firearm stock and is manually operated to adjust firing elevation.
2. Description of the Prior Art
Fire arm and firearm supports of various designs have existed almost as long as firearms have existed. These supports have been used to provide a stable platform from which a mounted weapon may be fired with greater accuracy. One of these prior art supports, described in U.S. Pat. No. 5,345,706 issued to Brown, employs a clasp mechanism for latching to a firearm stock sling stud and a telescoping member to provide a highly portable, one leg firearm support for use by a firearm marksman in the standing position.
In order to shoot with great accuracy, a firearm marksman will shoot from the sitting position at a shooting bench or the prone position. When shooting from the sitting position at a shooting bench or the prone position, the firearm marksman, must precisely adjust the elevation of his firearm. When attempting to shoot from the sitting position at a shooting bench or the prone position with very great accuracy, a firearm marksman will often place a sand bag under the butt end of the firearm stock and manipulate that sand bag to obtain elevation. Sand bags, however are heavy and cumbersome and are an imprecise means of adjusting elevation. Further, marksman, in some situations, must carry their firearms and other equipment over significant distances. They need a compact device that can be easily attached to and carried with their firearm. What is needed then is a lightweight, compact and portable device that can be easily attached to a firearm and which can be used to precisely adjust elevation.
SUMMARY OF THE INVENTION
The adjustable firearm support of the present invention satisfies the aforementioned need by providing a very lightweight, compact and portable device which provides a means for precisely adjusting the elevation of a firearm.
The adjustable firearm support of the present invention works in combination with a firearm stock having a sling stud mounted to its underside adjacent to its butt end. The sling stud has a central hole for receiving hooks, clasps and the like. The adjustable firearm support includes four basic parts; namely, a support rod, a base member, a position sleeve, and a support leg. The support rod is externally threaded and has a clasp at one end for engaging the sling stud. The base member has a top cradle surface with sloped or curved sides that can conform to the surface of the firearm stock near the sling stud. The base member also has an axially symmetric lower surface and a central opening extending from the top cradle surface to the lower surface which allows it to fit over the support rod when the support rod is attached to the sling stud. The position sleeve has an axial bore which is threaded to accept the support rod and an axially symmetric upper surface shaped to rotate against the axially symmetric lower surface of the base member. The top end of the support leg is bored with a threaded bore for receiving the support rod and the bottom end of the support leg is fashioned for concentric rotation on a stable, horizontal surface.
The adjustable firearm support of the present invention is assembled as follows: The support leg is threaded on to the support rod. The position sleeve is then threaded onto the support rod. The base member is placed upon the support rod and then finally, the clasp is attached to the support rod. To use the adjustable firearm support, the clasp is attached to the sling stud near the butt end of the firearm stock. Then the position sleeve is tightened up against the base member. This pushes the base member firmly against the firearm stock to firmly mount the adjustable fire support to the firearm stock. Once the support leg is positioned on a stable, horizontal surface, it can be rotated about the support rod to precisely adjust the vertical position of the other parts of the adjustable firearm support and more importantly adjust the vertical position of the firearm stock to which they are attached.
The adjustable firearm support of the present invention also includes features that allow the support leg and support rod to be retracted up against the firearm stock for easy transport. These features include a pivot joint between the clasp and the remainder of the support rod and a slot in the lower end of the base member to provide clearance for the support rod as it rotates about the pivot joint into a retracted position. When in the retracted position, the position sleeve is tightened against the base member to lock the support rod, position sleeve and support leg into the retracted position. The base member has a second axial surface that receives the top surface of the position sleeve when, in the retracted position, it is tightened against the base member.
In addition to the above features for allowing the support rod, position sleeve and support leg to fold into a retracted position, a sling lug is also added to the base member. The base member sling lug is adapted to accept a sling strap end ring so that a sling strap can be attached to the firearm for easy transport.
Accordingly, the adjustable firearm support of the present invention attaches easily to a firearm and provides precise elevation adjustment. It is so compact that it goes almost unnoticed. Yet, when used with a sighting scope, a firearm marksman can aim and fire his firearm with extreme accuracy.
Other features and advantages of the present invention will be more readily apparent by reference to the following detailed description in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may be best understood by those having ordinary skill in the art by reference to the following detailed description when considered in conjunction with the accompanying drawings in which:
FIG. 1 is a side view of the adjustable firearm support of the present invention mounted to a firearm stock shown in reference.
FIG. 2 is an exploded front view of the adjustable firearm support of the present invention.
FIG. 3 is a section view taken from plane 3--3 of FIG. 2.
FIG. 4 is a top view taken from plane 4--4 of FIG. 2.
FIG. 5 is a section view taken form plane 5--5 of FIG. 4.
FIG. 6 is a side view of a first alternative embodiment of the adjustable firearm support of the present invention.
FIG. 7 is a side view of a second alternative embodiment of the adjustable firearm support of the present invention.
FIG. 8 is a cross section view of an alternative embodiment of the support leg of the adjustable firearm support of the present invention.
FIG. 9 is a top view of an alternative embodiment of the support leg of the adjustable firearm support of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Throughout the following detailed description, the same reference numerals refer to the same elements in all figures.
FIG. 1 is a side view of the adjustable firearm support 10 of the present invention shown in relation to a sling 12 and a firearm stock 14 which includes a sling stud 16 having a sling stud hole 17. As can be seen in FIG. 1, the adjustable firearm support 10, comprises a clasp 20, a support rod 50, a position sleeve 60, a support leg 70 and a base member 120.
FIG. 2, an exploded view of adjustable firearm support 10 of the present invention, shows clasp 20, support rod 50, position sleeve 60, support leg 70 and base member 120. In FIG. 2, clasp 20 is shown in relation to sling stud 16. Clasp 20 includes a clasp body 22, a stationary prong 24, a clasp pin 26, a slide pin 28, an external knob 32, a latch plate 34, a clevis 36 and a clevis pin 40. Stationary prong 24 projects upwardly from clasp body 22 and carries clasp pin 26. Slide pin 28 slides within clasp body 22 and is spring biased by an internal spring (not shown). Latch plate 34 is fixed at one end to slide pin 28 and has a hole (not shown) at its other end for receiving clasp pin 26. Knob 32 is attached at the other end of slide pin 28 and is used to manually adjust slide pin 28 and latch plate 34 which is attached to slide pin 28. The internal spring which biases slide pin 28 urges slide pin 28 so that latch plate 34 engages clasp pin 26 and so that knob 32 is pushed away from clasp body 22. Clasp pin 26 is adapted to engage sling stud hole 17 of sling stud 16 so that clasp 20 can be attached to sling stud 16. Clevis 36 depends from clasp body 22 and includes two co-axial clevis pin holes 38 adapted for receiving clevis pin 40. The components of clasp 20 should be fabricated from high strength steel capable of withstanding significant stresses.
As can be seen in FIG. 2, support rod 50 includes a lug portion 52, a threaded shaft 56 and a bolt head 58. Lug portion 52 has a hole 53 for receiving clevis pin 40 of clasp 20 so that clasp 20 can be attached to support rod 50. Threaded shaft 56 extends from lug portion 52 to bolt head 58. Support rod 50 can be fabricated from steel or brass or any material suitable for holding threaded surfaces. Support rod 50 could be easily fabricated from a simple carriage type bolt by machining a lug such as lug 52 into the end opposite the bolt head.
As can also be seen in FIG. 2, Position sleeve 60 includes a shoulder portion 63 and a knurled portion 65. Shoulder portion 63 defines an axially symmetric upper surface for position sleeve 60. Position sleeve 60 has an axial bore (not shown) which is threaded to receive the threaded shaft 56 of support rod 50. Position sleeve 60 can be fabricated from steel or brass or any material suitable for holding knurled and threaded surfaces.
Support leg 70 is also shown in FIG. 2. It includes a large handle body 72, a top surface 73, a threaded axial bore 74 and a rotation member 76. The large handle body 72 is designed to be easily manipulated by an operator. Threaded axial bore 74 is in normal relation to top surface 73 and is adapted to receive threaded portion 56 of support rod 50. Counter bore 75 extends from the bottom end of handle body 72 and meets threaded axial bore 74 near the center of handle body 72. Rotation member 76 closes off counter bore 75 and is adapted to turn on a stable surface. Support leg 70 can be made from a hard plastic capable of accepting internal threads or may have a metal insert for providing threaded axial bore 74. In the preferred embodiment, support rod 50 is threaded into support leg 70 before rotation member 76 is permanently fixed in place by an adhesive thereby creating a permanent assembly.
FIG. 9 is a top view of an alternative support leg 670 having a slotted bore 672. The slotted bore 672 has a threaded semi-cylindrical wall 674 at one end and a bias means 675 comprising a smooth bearing member 676 and spring 678 at the other end. Support rod 50 is urged by bias means 675 against threaded semi-cylindrical wall 674. When opposite manual pressure is applied to support leg 670, support rod 50 is released from threaded semi-cylindrical wall 674 so that support leg 670 can be freely moved relative to support rod 50. It should be readily apparent to the skilled reader that a spring biased insert could be disposed within a support leg having a smooth bore. The insert would have a slotted bore with one threaded wall. The insert could be manipulated by external manual pressure to release the threaded wall from a support rod so that the support leg could be easily translated relative to the support rod.
Base member 120 is shown in FIG. 2 and is shown in more detail in FIGS. 3, 4 and 5. FIG. 2 shows a front view of base member 120. As can be seen in FIG. 2, base member 120 has a cylindrical outer surface 122, a side slot 128, a clearance face 136, side spot face surface 138, a sling lug 139 and an upper cradle surface 140 and a lower surface 130. FIG. 3 is a section view of base member 120 taken from plane 3--3 of FIG. 2. FIG. 4 is a top view of base member 120 and FIG. 5 is a section view taken from plane 5--5 of FIG. 4. Together, these views show that base member 120 has a central bore 124, a clasp slot 126, and a lower spot face surface 132. Side spot face surface 138 is disposed in outer surface 122, while lower spot face surface 132 is defined within lower surface 130. As is best seen in FIG. 3, side slot 128 communicates with side spot face surface 138 clearance face 136 and lower spot face surface 132 and is adapted to allow support rod 50 to swing up into a retracted, horizontal position as it pivots about clevis pin 40. As is also shown in FIG. 3, central bore 124 runs the length of base member 120 from cradle surface 140 to lower spot face surface 132 and is sized to accept support rod 50 and sling stud 16. FIG. 5 shows that clasp slot 126 begins in cradle surface 140 and extends only part of the distance from cradle surface 140 to lower spot face surface 132 and is sized to allow clasp 20 to retract down into base member 120. As can be seen in FIG. 3 and FIG. 4, clasp slot 126 only extends across part of the width of base member 120. As is shown in FIG. 5, lower spot face surface 132 provides a recess for receiving shoulder portion 63 of position sleeve 60. Lower spot face surface 132 and side spot face surface 138 can define any axially symmetric surface definition as long as that definition corresponds to the axially symmetric upper surface defined by shoulder portion 63 of position sleeve 60. Sling lug 139 can either be recessed or projecting as shown in FIG. 3 and is adapted to receive a second clasp substantially identical to clasp 20 so that a sling strap can be attached to base member 120.
The skilled reader should easily appreciate that base member 120 could have a simple, flat lower surface while position sleeve 60 could have a corresponding, simple, flat upper surface. Such simple flat surfaces would fall within the general category of axially symmetric surfaces from which compatible surfaces could be selected. Likewise, base member 120 could also have a simple flat side surface disposed about side slot 128. Still further, while clearance face 136 is helpful to the operation of firearm support 10, it could be omitted because it is not necessary to the function of firearm support 10. It should also be readily apparent to the skilled reader that sling lug 139 could be moved to locations on outer surface 122 of base member 120 other than the location shown in FIGS. 2, 3, and 4.
The adjustable firearm support 10 can be assembled as follows: First, support rod 50 is threaded into support leg 70 so that bolt head 58 of support rod 50 is closely adjacent to top end of counter bore 75 of support leg 70. Second, rotation member 76 is glued into the bottom end of support leg 70. Third, position sleeve 60 is threaded down onto support rod 50 until it is closely adjacent to top surface 73 of support leg 70. Fourth, base member 120 is placed down upon support rod 50 until lug portion 52 of support rod 50 emerges above cradle surface 140 of base member 120. Fifth and finally, clasp 20 is attached to clevis portion 53 of support rod 50 by inserting clevis pin 40 through co-axial clevis pin holes 38 of clasp 20 and hole 53 of support rod 50.
The assembled adjustable firearm support 10 can be used with a firearm having firearm stock 14 and a sling stud 16 in the following manner: Clasp 20 is attached to sling stud 16 by disengaging latch plate 34 from clasp pin 26, inserting clasp pin 26 into sling stud hole 17 and then re-engaging latch plate 34 with clasp pin 26. Position sleeve 60 is rotated about support rod 50 until it pushes up against spot face surface 132 of base member 120 so that cradle surface 140 of base member 120 firmly engages firearm stock 14. Rotation member 76 of support leg 70 is then placed on a stable surface and support leg 70 is then rotated about support rod 50 to finely adjust the vertical position of firearm stock 14.
Shown in FIG. 8 is an alternate means for adjusting the vertical position of a support rod 550 in relation to a support leg 570. FIG. 7 shows a support rod 550 that is smooth and carries a rack 552. FIG. 7 also shows a leg 570 having a smooth bore 572 for receiving support rod 550, a slot 574 for clearing rack 552 and a rotatably mounted gear axle and knob assembly 576 adapted for engaging rack 552 thereby providing an alternative vertical adjustment means for adjusting the vertical position of support leg 570 in relation to support rod 550. Support rod 550 of FIG. 7 still includes a threaded upper portion (not shown) for receiving a position sleeve such as the position sleeve 60 shown in FIG. 2. The skilled reader will readily appreciate that any one of several different vertical adjustment means could be employed to accomplish the vertical adjustment of a support leg relative to a support rod and the remainder a firearm support.
The adjustable firearm support 10 of the present invention can be placed in a retracted position by loosening position sleeve 60 so that shoulder portion 63 of position sleeve 60 is disengaged from lower spot face 132. Support rod 50 together with position sleeve 60 and support leg 70 can be rotated about clevis pin 40 and through side slot 128 of base member 120 while shoulder portion 63 of position sleeve 60 just misses clearance face 136 of base member 120. After the support rod 50, position sleeve 60 and support leg 70 have been thus rotated from a vertical position to a horizontal position, position sleeve 60 can be tightened until shoulder portion 63 of position sleeve 60 firmly engages side spot face surface 138 of base member 120 thereby locking support rod 50, position sleeve 60 and support leg 70 into a folded position.
As is evident from the above description, clasp 20, support rod 50, position sleeve 60 and base member 120 cooperate with sling stud 16 to provide a clamping means for clamping the adjustable firearm support 10 to firearm stock 14. It will be evident to those skilled in the art that this preferred embodiment as well as other embodiments described herein could employ other means of clamping an adjustable firearm support to a firearm stock. Such other means could include a flexible strap that can be tightened to pull a base member or base member similar to base member 120 tightly against a firearm stock such as firearm stock 14. Such a strap could also include a leveraged buckle for tightly securing a base member or base member such as base member 120 to a firearm stock such as firearm stock 14. Such other means could include a threaded tap recessed into stock 14 in combination with a threaded bolt member for securing a base member similar to base member 120 to stock 14. Numerous other mechanical means could be imagined for securing a base member or base member such as base member 120 to stock 14. Once a base member such as base member 120 is firmly fixed to a firearm stock, a support leg in combination with a support rod attached to such a base member can be used to provide a means for vertical adjustment.
As shown in FIG. 6, a second embodiment of the adjustable firearm support 10A is shown in relation to firearm stock 14 and sling stud 16 having sling stud hole 17. Adjustable firearm support 10A includes a support rod 150, a hook member 160 and a modified base member 220. Support rod 150 includes an upper lug portion 152 a lower threaded portion 154. Hook member 160 includes a hook 162 having a horizontal pin 164 for engaging sling stud hole 17. Hook member 160 also has a clevis 166 for attaching to upper lug portion 152 of support rod 150. Clevis 166 of hook member 160 is pinned by joint pin 168 to a corresponding upper lug portion 152 of support rod 150. Once lower lug portion 152 of support rod 150 is pinned to clevis 166 of hook member 160, support rod 150 can rotate around the joint between clevis 166 and lug portion 152. The remainder of support rod 150 is substantially identical to support rod 50 described above. Modified base member 220 is identical to base member 120 of FIG. 2, except that it does not have a feature corresponding to clasp slot 126 of base member 120. Central bore 224 of base member 220 is also adapted to closely fit around support rod 150. A position sleeve (not shown) substantially identical to position sleeve 60 of FIG. 2 is employed as described above to bias base member 220 against the firearm stock. As described above, support rod 150 receives a support leg (not shown) which is substantially identical to support leg 70 shown in FIG. 2. In this embodiment, support rod 150 would have to made from a high strength material capable of withstanding significant stresses.
Illustrated in FIG. 7, is a third alternative embodiment of adjustable firearm support 10B of the present invention shown in relation to adjustable firearm stock 14 and sling stud 16 having sling stud hole 17. Adjustable adjustable firearm support 10B includes a base member 320, a first support rod 350, a position sleeve 360 and a second support rod 380. In this embodiment, first support rod 350 includes an upper portion 352 and a lower portion 356. Upper portion 352 of first support rod 350 has a stationary hook 354 adapted for engaging sling stud 16 and lower portion 356 of first support rod 350 is threaded to receive internally threaded position sleeve 360. Base member 320 has a lower spot face surface 324 for receiving position sleeve 360. Base member 320 also has a central bore 322 for receiving sling stud 16 and support rod 350. Position sleeve 360 threads onto first support rod 350 and has an axially symmetric upper surface 362 adapted for smoothly engaging lower spot face surface 324 of base member 320. Base member 320 also has a means for attaching second support rod 380. Second support rod 380 can be rigidly fixed to base member 320 or can be pivotably mounted to base member 320. FIG. 4 shows second support rod 380 having an upper clevis portion 382 that engages a lug 328 fixed to base member 320. A bolt 384 and a wing nut 386 clamp upper clevis portion 382 of second support rod 380 to lug 328 of base member 320. With the addition of a locking means such as corresponding serrated surfaces (not shown) or a lock washer (not shown), the joint between upper clevis portion 382 of second support rod 380 and lug 328 of base member 320 can be locked in either a vertical or retracted horizontal position. As with the above described embodiments, second support rod 380 receives a support leg (not shown) which is substantially identical to support leg 70 shown in FIG. 2. and that support leg can be rotated about second support rod 380 to provide fine vertical adjustment.
The skilled reader, in view of this specification may envision numerous modifications and variations of the above disclosed preferred embodiment.
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The adjustable firearm support of present invention works in combination with a firearm stock having a sling stud mounted to its underside near its butt end. This firearm support includes four basic parts; namely, a support rod, a base member, a position sleeve and a support leg. The support rod has a pivotally mounted clasp for engaging the sling stud and a threaded outer surface for receiving the position sleeve and the support leg which both have threaded central bores. The base member has an upper cradle surface for fitting up against the firearm stock, a central bore for receiving the support rod and a side slot for allowing the support rod to pivot in relation to its clasp into a horizontal folded position. An assembled adjustable firearm support can be attached to a firearm stock by engaging the clasp with the sling stud and tightening the position sleeve up against base member. When the support leg of the attached adjustable firearm support is placed on a stable horizontal surface, the support leg can be rotated about its threads to move it up and down in relation to the support rod to finely adjust the elevation of the firearm.
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BACKGROUND OF THE INVENTION
The present invention relates to a four-wheel drive vehicle and more particularly to a system for indicating slipping of each driving wheel of the vehicle.
The four-wheel drive vehicle is useful to travel on slippery roads such as snowy and icy roads. However, if any one of the four wheels slips on such a slippery road, it is difficult to start the vehicle. The driver must get out of the vehicle when slipping occurs and inspect which wheel slips. The slipping of a wheel may be stopped by changing the position of the passengers or the load on the vehicle.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a slip indicating system for a four-wheel drive vehicle which detects the revolution speed of each wheel and indicates automatically which wheel is slipping by a difference between wheel speeds.
According to the present invention, there is provided a slip indicating system for a four-wheel drive vehicle comprising a speed detector for detecting the speed of each wheel individually, means for comparing the speeds detected by the speed detectors and for producing outputs in accordance with the difference between the speeds, switch units adapted to be closed by said outputs, and indicators adapted to be operated by closing of the switch units.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a plan view showing a four-wheel driving system provided with a system of the present invention;
FIG. 2 is a sectional view showing a wheel speed detector;
FIG. 3 is a block diagram showing an indicating system; and
FIG. 4 is an electric circuit used in the system of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a vehicle has a body 1, front wheels 2 and 3 and rear wheels 4 and 5. An engine 6 is mounted on the body 1 at a front portion thereof. Power of the engine is transmitted to the front wheels through a transmission 7 and respectively to both of the front and rear wheels by engaging a clutch provided in the transmission 7. Gear change of the transmission is performed by operating a change speed lever 8. The clutch in the transmission 7 is engaged by operating a select lever 9 for transmitting the power also to the rear wheels 4, 5. The output of the transmission 7 is transmitted to the front wheels 2, 3 through a shaft 13, a front differential 14 and front axles 15. The power transmission to the rear wheels 4, 5 comprises a propeller shaft 10 extending from the transmission 7, a rear differential 11 and rear axles 12.
In order to detect the rotational speed of the front and rear wheels 2, 3, front-wheel speed detectors 16, 17 are provided adjacent to axles 15 and rear wheels speed detectors 18, 19 are provided adjacent to axles 12. The output of each speed detector is connected to a judging circuit 20, the output of which is connected to an indicator 22 such as lamps on an instrument panel 21 (FIG. 1) for individually indicating slipping of respective any one of the four wheels.
Referring to FIG. 2 showing one of the speed detectors 16 to 19, a plurality of permanent magnets 23 are circumferentially arranged on the axle 12 (or on the axle 15) and secured thereto. The magnets 23 are separated from each other by synthetic resin 24 or other insulation secured on the axle. The magnets 23 are arranged to alternate North and South poles. A reed switch 26 is provided on a support 25 formed on the body 1 and positioned in the vicinity of the magnets 23 with a slight gap therefrom.
FIG. 3 shows the indicating system according to the present embodiment.
Output signals from the speed detectors for the wheels are applied to the judging circuit 20. A four-wheel drive switch 27 is also connected with the judging circuit 20. The four-wheel drive switch 27 is actuated by the select lever 9 of the above-mentioned clutch and turned on during the four-wheel drive operation. The indicator 22 contains a slip indicating lamp 28, and four individual slipping wheel indicating lamps 29, 30, 31, 32 corresponding to the individual wheels 2, 4, 5, 3, respectively. The lamps 28 to 32 are connected in series with respective switch elements 33, 34, 35, 36, 37 which are connected to the control output of the judging circuit 20.
FIG. 4 is a detailed electric circuit of the indicating system shown in FIG. 3.
Positive electric voltage is applied through a resistor 39 to the reed switch 26 in the speed detector 16. The reed switch 26 is connected to an integrating circuit consisting of a resistor 40 and a capacitor 41, and the resistor 40 is connected to a voltage divider consisting of resistors 42 and 43. The divided voltage is applied to non-inverting inputs of comparators 44, 45, 46 and outputs of the comparators 44 to 46 are connected to the base of a transistor 47 which corresponds to the switch element 34 in FIG. 3. The emitter of the transistor 47 is grounded and the collector is connected to the slipping wheel indicating lamp 29. These parts constitute a first unit of a slip indicating circuit for the front wheel 2. There are three other units for the other wheels with similar constitution: namely, a second unit actuated by a reed switch 48 in the speed detector 18; a third unit actuated by a reed switch 58 in the speed detector 19; and a fourth unit actuated by a reed switch 68 in the speed detector 17. Voltage at the resistor 40 of the first unit is applied to comparators 54, 65, 75 of each of the other units; similarly the voltage at a resistor 50 of the second unit is applied to comparators 44, 64, 74 of the other units; the voltage at a resistor 60 of the third unit is applied to comparators 45, 55, 76 of the other units; and the voltage at a resistor 70 of the fourth unit is applied to comparators 46, 56, 66 of the other units. Outputs of the comparators 44-46, 54-56, 64-66 and 74-76 are applied through diodes 78-81 respectively to the base of a transistor 82 which corresponds to the switch element 33, the emitter of which is grounded, and the collector of which is connected to the slip indication lamp 28.
The function of the present invention will be explained.
When the four-wheel drive is selected by operating the select lever 9, engine power is transmitted to the front and rear wheels 2, 3, 4, 5 through the shaft 13, propeller shaft 10 and axles 12, 15 to achieve four-wheel drive. When the wheels 2-5 begin to rotate, the magnets 23 of each speed detector rotates together with the respective axle. Because of the rotation of the magnets 23, the reed switch 26 (48, 58, 68) of each speed detector is turned on and off to cause a voltage variation at the output of each integrating circuit in dependency on the number occurrences of on-off of the switch. A voltage depending on the wheel speed of each wheel is applied to each of the comparators 44-46, 54-56, 64-66 and 74-76. As long as all wheels rotate at the same speed, the voltages at the capacitors 41, 51, 61, 71 are substantially equal to each other. Thus, each comparator of each unit is applied at the non-inverting input with a voltage lower than the voltage at the inverting input, so that the output of the each comparator is negative. Thus, transistors 47, 57, 67, 77 (as the switches 34, 35, 36, 37) remain off, and therefore, none of the slipping wheel indicating lamps 29-32 and slip indicating lamp 28 are turned on.
If for example the front wheel 2 slips, its wheel speed increases rapidly. Thus, the terminal voltage of the capacitor 41 of the integrating circuit becomes higher; and consequently the voltage applied to the non-inverting inputs of the comparators 44-46 becomes higher than the inverting terminal voltages applied from the other capacitors 51, 61, 71. Accordingly, the comparators 44-46 produce a positive voltage to turn on the transistor 47, so that the slipping wheel indicating lamp 29 is turned on. Thus, slipping of the front wheel 2 is indicated. Similarly, the output from comparators 44-46 turns on the transistor 82 through a diode 78 to turn on the slip indicating lamp 28 indicating that one of the wheels is slipping. This operation is performed similarly on each of other wheels 3-5. Accordingly, the driver readily knows which wheel is slipping. The slipping of the wheel may be stopped by changing the position of the passengers or the loads on the vehicle.
According to the present invention, the driver finds out which wheel is slipping so that the vehicle can be easily moved on slippery roads, such as snowy or muddy roads.
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Speed detectors are provided for detecting speeds of each of the four wheels of a vehicle. An electric circuit is provided to compare the speeds of all wheels and to turn on at least one lamp when a difference between individual wheel speeds is detected, whereby slipping of wheels is indicated.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This is a continuation of U.S. Application Ser. No. ______ of the same title filed Feb. 23, 2006, and claims priority to and benefit of that application and, through it, U.S. Provisional application No. 60/656,155, filed Feb. 23, 2005. Both applications are incorporated herein by reference.
BACKGROUND
[0002] The use of glass and other delicate material for fruit ripening displays as disclosed in copending U.S. patent application Ser. No. 10/920,044, filed on Aug. 16, 2004, and incorporated herein by reference, creates difficulty when the ripening displays use metal and other hard materials in their other parts. In particular, the use of vents, more particularly metal vents, as disclosed in that application, creates a hard interface with the glass material. Since 1) the glass in the disclosed fruit ripening displays may be relatively thin to permit clear viewing of the fruit, 2) the vent may be elevated relative to the fruit support surface so that the fruit resting on the fruit support surface will be biased not to cover the vent holes and 3) the vent may be made of stainless steel, carbon steel, or other hard substance to ensure durability and lack of chemical interaction with fruit acids, there is now a need for a buffer interface between these fruit ripening display vents and the display parts. Further, the buffer interface may beneficially streamline air flow between the ripening chamber and the outer atmosphere by, for example, sealing off any spaces that may interfere with proper circulation through the fruit ripener display vent.
SUMMARY
[0003] Applicants provide various methods and apparatuses that permit beneficial venting of fruit ripening displays. In one aspect, a fruit ripening display comprises one or more display parts, one or more vents, and a butter interface between at least one part and at least one vent that comprises an air flow channeler. In another aspect, a fruit ripening display comprises one or more display parts, one or more vents, and a buffer interface that is grooved to accept at least one of said one or more fruit ripening display parts. In another aspect, the fruit ripening display vent comprises one or more protrusions that comprise a buffer interface locator. Each of these aspects may be used in permutation and combination with one another. Further embodiments as well as modifications, variations and enhancements are also described herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1 is a perspective view of a vent-buffer interface assembly.
[0005] FIG. 2 is an exploded perspective view of the vent-buffer interface assembly of FIG. 1
[0006] FIG. 3 is a cross-section of the vent-buffer interface assembly of FIG. 1 taken vertically through its center line.
[0007] FIG. 4 is a perspective view of a vent-buffer interface assembly.
[0008] FIG. 5 is an exploded perspective view of the vent-buffer interface assembly of FIG. 4 .
[0009] FIG. 6 is a cross-section of the vent-buffer interface assembly of FIG. 5 taken vertically through its center line.
[0010] FIG. 7 is a bottom view of a vent having an inward hole slope.
[0011] FIG. 8 is a cross-section of the vent of FIG. 7 taken vertically through its center line.
[0012] FIG. 9 is a perspective view of a fruit ripening display employing a buffer interface.
[0013] FIG. 10 is a side elevation view of the fruit ripening display of FIG. 9 .
[0014] FIG. 11 is a perspective view of a fruit ripening display employing a buffer interface.
[0015] FIG. 12 is a side elevation view of the fruit ripening display of FIG. 11 .
[0016] FIG. 13 is a side elevation view of a fruit ripening display employing an alternate vent-display part connector.
[0017] FIG. 14 is a side elevation view of a fruit ripening display employing a vent that consists or comprises the interface material.
[0018] FIG. 15 is a side elevation view of a cross-section of a buffer interface with groove and lock.
[0019] FIG. 16 is a see-through top view of the buffer interface of FIG. 15 .
[0020] FIG. 17 is a side elevation view of a cross-section of a buffer interface with groove and lock.
[0021] FIG. 18 is a see-through top view of the buffer interface of FIG. 17 .
DETAILED DESCRIPTION
[0022] FIG. 1 shows a perspective view of a fruit ripening display vent 100 having four holes. FIG. 2 shows a perspective exploded view of the vent of FIG. 1 with a buffer interface 102 . The buffer interface has a substantially reciprocal contour relative to the underside of the vent 100 . Indeed, they may fit flush against one another. They may be connected together by a connector such as glue or rivet or simply pressure fit together. FIG. 3 shows a cross-section of vent 100 comprising buffer interface 102 . Preferably, buffer interface 102 contains director portions that create directed gas flow between the inside and outside of the ripening display chamber. For example, the buffer interface 102 may comprise flow channeler 104 . In a preferred embodiment, the buffer interface 102 also comprises a tapered section 106 that may rest in an opening of the display. In this way, the vent may fit the display opening despite variations in hole size due to manufacturing tolerances. In the preferred embodiment, the tapered section acts like a stopper and has a diameter that tapers from a size larger than the display opening to a size smaller than the display opening. FIGS. 4-6 show the same views, structures and concepts for a three-hole vent design.
[0023] The buffer interface may be made of thermoplastic rubber or any other material that can beneficially absorb forces between the display part and the vent. In addition, the buffer interface preferably has good gripping properties so that the vent is not easily disconnected from the display. Preferably, it is also made of a dishwasher and food safe material.
[0024] FIGS. 7 and 8 show a vent 700 that has an inward hole slope 702 that leads to the perimeter of its vent holes. Although vent 700 with inward hole slope 702 shows a four-hole variation, it may be used with the three-hole variation as shown in FIGS. 4-6 , with a two-hole variation, or with some other hole variation. This inward hole slope 702 is in contrast to the right angle cut of the vent hole perimeter shown in FIGS. 1 through 6 . More preferably, the inward hole slope 702 continues past the plane of the vent underside so as to form one or more protruding inlets 710 on the underside of the vent.
[0025] In a preferred embodiment, the protruding inlet comprises a buffer interface locator. According to this aspect, the buffer interface preferably has the substantially reciprocal shape of a vent having one or more protruding inlets. In that way, the protruding inlet can help locate the buffer interface on the underside of the vent when connecting the vent and buffer interface together since it forces a limited number of connecting positions. This is very useful when the buffer interface is manually glued to the underside of the vent. It helps reduce the chance the buffer interface will be attached in a way that covers part of a vent hole.
[0026] FIGS. 9 and 10 show a fruit ripening display in which the vent 100 and buffer interface 102 may be used. Alternately, the vent 700 with inward hole slope 702 leading to the perimeter of its vent holes may be used, preferably along with a substantially reciprocally contoured buffer interface. More preferably the buffer interface also further comprises a tapered section. The fruit support surface 900 may be glass or other material and has a hole (not shown) that permits gas exchange between the fruit ripener display chamber and the outer atmosphere through vent 100 or 700 . The tapered section 106 of the buffer interface 102 is visible in FIG. 10 . FIGS. 11 and 12 show the same views and concepts as FIGS. 11 and 12 for a three-hole vent design. Other vents, vent hole configurations and vent hole shapes may be used.
[0027] In another aspect, interfaces may be attached to other parts of the fruit ripener display. For example, an interface, preferably one made of thermoplastic rubber, may interface between display part 910 and the display support portion of base part 920 of FIGS. 9 and 10 . Likewise, feet 930 may have an interface, preferably one made of thermoplastic rubber, between them and the table top. This also applies to the embodiment of FIGS. 11 and 12 .
[0028] As shown in FIG. 13 , various vent connectors may be made of a preferred interface material, such as thermoplastic rubber, that absorbs force between the vent and the fruit support surface. For example, items 1616 , 1625 , and the underside of 1617 may be made all or in part of an interface material, such as thermoplastic rubber. The vent could be pressure fit, glued or otherwise connected to the fruit support surface via some or all of these interfaces.
[0029] As shown in FIG. 14 , the vent 2715 may itself comprise or consist of an interface material, such as thermoplastic rubber, that helps absorb forces between the vent and fruit support surface. The vent 2715 preferably comprises an integral tapered section 2717 made of an interface material.
[0030] As shown in FIGS. 15 and 16 , the buffer interface 3000 may comprise a groove 3002 and lock 3004 . In this embodiment, the lock forms an entire perimeter of the buffer interface, thereby giving the lock a ring shape. Although this locking ring may be circular (as shown) it may have other shapes. To attach the vent-buffer interface assembly to the fruit ripening display part, the locking ring is placed through an opening in the fruit ripening display part whose own perimeter is preferably equal to or less than the locking ring perimeter at their points of contact. The groove, whose height should accommodate the thickness of the display part, then receives the display part's edge. The display part is thus bounded by the upper portion of lock 3004 .
[0031] The buffer interface of this embodiment may also comprise an air flow channeler 3006 , which itself may comprise a surface of the locking ring. Although the flow channeler as shown vertically channels air flow through the vent and away from the vent's outer perimeter, it may be of other thicknesses, orientations and locations such that it channels air passing through the vent away from the vent's natural contour. The buffer interface of this embodiment may also have a substantially reciprocal contour relative to at least one of said one or more said fruit ripening display vents at its point of contact. Further, the buffer interface of this embodiment may be located on a vent (not shown) by one or more vent protrusions that comprise a buffer interface locator.
[0032] In a most preferred embodiment, shown in FIGS. 17 and 18 , the buffer interface 3100 may comprise one or more partial grooves 3102 , with the lock comprised of one or more locking tabs 3104 . Although the locking tabs may be orientated along the perimeter of a circle (as shown), they may be provided in a different orientation. To attach the vent-buffer interface assembly to the fruit ripening display part, the locking tabs are placed through an opening in the fruit ripening display part whose own perimeter is preferably as narrow or narrower than the distance between the locking tabs at the points of contact. The groove, whose height should accommodate the thickness of the display part, then receives the display parts edge. The display part is thus bounded by the upper portion of one or more locking tabs 3104 .
[0033] The buffer interface of this embodiment may also comprise an air flow channeler 3106 , which may itself comprise a locking tab surface. Although the flow channeler as shown vertically channels air flow through the vent and away from the vent's outer perimeter, it may be of other thickness, orientations and locations such that it channels air passing through the vent away from the vent's natural contour. The buffer interface of this embodiment may also have a substantially reciprocal contour relative to at least one of said one or more said fruit ripening display vents at its point of contact. Further, the buffer interface of this embodiment may be located on a vent (not shown) by one or more vent protrusions that comprise a buffer interface locator. In the case of these and other embodiments disclosed herein, the vent and the buffer interface can be made of a uniform material and form an integral unit having the foregoing configurations.
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Apparatuses and methods for interfacing the vents and display parts of a fruit ripening display are provided. In one aspect, a fruit ripening display comprises one or more display parts, one or more vents, and a butter interface that comprises an air flow channeler. In another aspect, a fruit ripening display comprises one or more display parts, one or more vents, and a buffer interface that is grooved to accept at least one of said one or more fruit ripening display parts.
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BACKGROUND OF THE INVENTION
This invention relates to insulated gate field effect transistors (IGFET) and more particularly to such a transistor exhibiting a small PN junction capacitance between the substrate of one type conductivity and the source and/or drain of the other conductivity type.
In general, the limitations on operating speed of IGFETs are imposed mainly by device gain and capacitances including those of the PN junctions of the device itself that are in the load circuit.
Since the highly conductive source and drain regions have a much higher dopant concentration than does the substrate, junction capacitance of source and drain can be reduced by using a higher resistivity substrate. However, the minimum practical impurity concentration in the substrate of an integrated circuit is that for which the junction depletion width is not the limiting factor to packing density.
A known solution to this problem is to implant impurities of opposite conductivity to that of the substrate to the specific depth of the source/drain-substrate junctions to create a thin intrinsic region just under the source and drain. However, this process entails a subsequent annealing step that further drives all previously incorporated impurities. That annealing is preferably avoided as being additionally complicating and degrading of integrated circuit performance.
A widely used approach for making IGFET's includes a blanket ion implantation of impurities through an oxide layer into an entire device area to adjust the threshold of the IGFET device. Then a blanket polysilicon layer is deposited, a photoresist mask is formed thereover and through the mask the polysilicon is etched away leaving only a polysilicon gate. Source and drain regions are then formed using the gate as a mask. An example of such a self-aligned gate method is found in the patent to Owens et al, U.S. Pat. No. 4,598,460 issued July 8, 1986 and assigned to the same assignee as is the present invention. However, if high concentration channel doping is included throughout the device area, the junction capacitances of source and drain increases as a direct result of that blanket channel-adjust and device speed is thereby diminished.
To overcome this problem it has been proposed that the channel-adjust implantation be accomplished selectively at the gate area only through both the oxide layer and an overlying thin layer of polysilicon. The polysilicon is sputter deposited. It is impossible to use the more efficient chemical vapor deposition method because it must be executed at temperatures no lower than about 400° C. which would destroy the underlying photoresist. Then using the same mask a high-melting-metal and silicon are cosputtered. The mask and unwanted metal are removed by a lift off process and the metal and silicon are sintered at about 900° C. to form a compound self-aligned gate consisting of a first layer of polysilicon and a second layer of metal silicide.
This process retains the advantage of self-aligned gates but is complex, expensive and critical to control due at least to the use of the critical mask lift off steps, the metal silicde deposition steps, and the high temperature anneal step. The lift off process is particularly critical because if, at any point in an aperture of the photoresist mask the photoresist wall is not almost absolutely vertical, the silicide at that point will not be discontinuous and the mask will not lift off.
It is therefore an object of this invention to overcome the shortcomings in the prior art and to provide a relatively simple and reliable method for making a FET having a small PN junction capacitance between the substrate and the source and/or drain.
SUMMARY OF THE INVENTION
A method for making an insulated gate field effect transistor (IGFET) includes the steps of selectively doping at a FET gate site a region of a semiconductor substrate of one conductivity type with impurities of the one type for adjusting the channel threshold voltage of the FET. This doping is effected through a mask that shields the drain site and/or the source site from the dopant. The first mask is removed and a second mask is formed covering the gate site and having openings over the source and drain sites. The exposed polysilicon is etched away to define the polysilicon gate. Subsequently, the source and drain are formed by doping the substrate through the openings of the second mask with N-type impurities.
This invention stems from the recognition that in substantially all IGFET devices of the prior art the standard practice of providing a blanket implantation of channel adjusting impurities contributes alien impurities to the dominant impurities of opposite type that form the source and drain. After all of the heating steps to which these alien impurities are subjected during device manufacture, a significant diffusion of them ensues driving them below the source and drain that add to the like impurities of the substrate. Thus the junction capacitance of source-to-substrate or drain-to-substrate is enhanced and the maximum speed at which the IGFET operates is reduced.
In some circuit positions, the speed of an IGFET is limited by the drain-to-substrate and not the source-to-substrate capacitance, e.g. the pull down transistor in a CMOS stage. There are also circuit roles for an IGFET wherein speed of transistor operation is limited by the source-to-substrate capacitance and not the drain-to-substrate capacitance, e.g. the pull up transistor in a CMOS circuit. In these two cases, respectively, it is only necessary to mask off the drain or the source during the channel doping.
In other cases, such as in a programmable logic array, the role of a memory IGFET (e.g. an EPROM device) may change from one wherein the source is at signal ground to one wherein the drain is at signal ground. In this case, low drain-to-substrate and source-to-substrate capacitance is desirable for high speed operation and both source and drain will be masked off during the channel adjust doping step.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1-6 illustrate a preferred process of this invention for fabricating an integrated CMOS EPROM.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Employing the process of this invention for making an integrated circuit electrically programmable read only memory (EPROM) with CMOS peripheral circuits, certain early steps are executed that provide an intermediate structure illustrated in FIG. 1. These early steps are described and illustrated in detail in the above-mentioned patent U.S. Pat. No. 4,598,460 and this application is incorporated by reference herein. Those early steps are as follows.
A P-type substrate surface upon which a self-aligned EPROM and both P-channel and N-channel transistors are to be formed is completely covered with a thin silicon dioxide layer 14 that is formed by exposing substrate 12 to a high temperature in the presence of steam. After this initial oxidation, a conventional photoresist etch is performed. In this etching step, a photoresist mask is used to selectively etch and create an aperture in the oxide layer.
This is followed by an N-well ion implant wherein N-type ions such as phosphorous ions in the order of 10 12 ions/cm 2 bombard the entire substrate surface. However, only the region of substrate 12 beneath the oxide aperture receives these N-type ions causing a predetermined concentration of impurities in region 18.
Following the N-type implant, the photoresist layer is stripped, and an N-well diffusion is performed. In this step, the substrate is raised to a high temperature, approximately 1200°. This high temperature heating drives the N-type dopant impurities that diffuse and form an N-well 18 in FIG. 1. Before the diffusion, well 18 had a depth of only a few thousand angstroms. After the diffusion, it has a depth of approximately 30,000 angstroms, and ultimately, after all of the subsequent heating steps, the N-type impurities concentration at a depth of 0.2 micron becomes about 1×10.sup.≠ atoms/cm 2 . The P-channel transistor is to be built in this N-well 18.
Silicon nitride is then deposited on the surface of oxide layer 14 forming a nitride layer that is then selectively etched away through a photoresist masking layer. The masking layer msks all the regions where a device is to be built, whether the device is an EPROM device, a P-channel transistor, or an N-channel transistor. This etching removes the regions of the silicon nitride layer not covered by the photoresist "device" mask.
Following the nitride etch, P+ guard rings 26 are formed by a blanket boron implant that is masked off in the device regions by the remaining patches of nitride and photoresist.
After the formation of guard rings 26, the photoresist masking layer is removed and a new photoresist masking layer is provided which is used with the remaining patches of the nitride layer as masks to a phosphorous ion implant to create N+ guard ring 28 within N-well 18.
The photoresist layer is then removed and a field oxidation is performed during which the substrate is subjected to a high temperature for a long period of time to cause oxide layer 14 to become greatly enlarged as shown in FIG. 1. The regions of oxide layer 14 beneath the remaining patches of the nitride layer are not affected except for regions right at the edges of the nitride layer. The remaining patches of the nitride layer are then removed.
The removal of the nitride layer is followed by forming over oxide layer 14 a photoresist mask 30 with openings that expose the source, drain and channel regions, i.e. the entire device region, at the site of the P-channel transistor, and only the channel regions at the site of the N-channel transistor and EPROM device. Now an implantation of 1.8×10 12 boron ions/cm 2 at 60 KEV is effected through the mask 30 to adjust the thresholds of the N-channel devices as well as the P-channel transistor. The mask 30 prevents implanting boron ions at the sites of the sources and drains of the N-channel EPROM device and of the N-channel transistor. Mask 30 is then removed. This ultimately results, after all of the heating steps, in a peak boron concentration in the channel regions 36 and 38 of 3×10 16 atoms/cm 2 .
Region 36, which is the channel region of the P-channel transistor, also receives P-type implants during this step. The region 36 was doped independently with N-type impurities in an earlier step to form the N-well 18. During that independent doping of well regions 18, the boron implant shown was considered in advance and compensated for to realize the desired threshold voltage. The mask 30 having an aperture over the entire device region of the P-channel transistor advantageously enables the further channel-adjusting boron atoms to be implanted in the source gate and drain sites of this device. This leads to an overall reduction of dominant N-type impurities at the source/drain to well PN junctions.
At this point in the process, the thin portions 40 of the silicon dioxide layer 14 that cover the channel region 32 of the EPROM, the channel region 36 of the P-channel transistor and the channel region 38 of the N-channel transistor have a thickness that is the result of several heating steps and is thus not well controlled. It is here that the oxide thickness will also determine the threshold of the EPROM and the N-channel and P-channel devices. Region 40 is therefore etched and channel regions 32, 36 and 38 are exposed.
FIG. 2 shows an oxide layer 42 in the same location from which the thin portions of oxide layer 14 was removed. Oxide layer 42 is grown at these locations in a channels-oxidation step at 950° C. in 10% steam under very precise control.
The oxidation to form layer 42 is followed by deposition of a blanket layer of polysilicon (44 not shown altogether). This layer is produced by a standard chemical vapor deposition (CVD) step including placing the substrate in a vacuum hot-wall furnace, drawing a vacuum, raising the temperature to 625° C. and admitting silane (SiH 4 ) gas to a subatmospheric pressure. When the polysilicon thickness has reached about 4000 angstroms, the deposition is terminated.
The polysilicon is preferably rendered more conductive by ion implantation. Alternative doping may be accomplished by a standard phosphorous diffusion step, known as POCI 3 doping, to impart conductivity amounting to about 15 ohms per square. The polysilicon blanket layer covering the whole surface of the substrate provides an efficient mask for preventing penetration of the doping impurities anywhere into or adjacent the underlying substrate.
Thinner polysilicon layers may be used, preferably down to no less than about 2000 to 2500 angstroms below which its masking efficiency and conductivity tend to become inadequate.
A photoresist masking layer 48 is formed over the area of the entire EPROM device, and in the direction of drain to source just over a central area of each of the P-channel and N-channel devices to define the gates of the P-channel and N-channel devices. This is followed by a silicon etch to selectively remove portions of polysilicon layer (44). Thus, remaining portions 44a and the polysilicon gates 44b and 44c of the P-channel and N-channel devices are at this point in the process as shown in FIG. 2.
The photoresist layer 48 is then stripped away and polysilicon gate regions 44a, 44b and 44c are oxidized to form the silicon dioxide layers 46a, 46b and 46c as shown in FIG. 3.
A second blanket layer of polycrystalline silicon (52 not shown) is deposited upon the substrate. This polycrystalline layer (52) is doped with an N-type dopant. A photoresist layer portion 54b covers the P-channel transistor and the N-channel transistor. Photoresist portion 54a covers a central part of the EPROM device site and overlies the second polysilicon layer (52) and first layer (44) of N+ polysilicon layer 52a above the EPROM channel.
A first etch is an N+ polysilicon etch which removes N+ polysilicon layer (52) except for the portion below photoresist layer 54a. A second etch is a buffered-hydrofluoric polycrystalline-oxide etch which removes polycrystalline oxide layer 46 except for the portion below photoresist layer 54a. The final etch is a polysilicon etch which removes polysilicon layer 44a except for the portion 44a' below photoresist layer 54a.
The structures below photoresist layer 54a are EPROM control gate 52a which is formed from N+ polysilicon layer (52), interpoly oxide layer 46a which is formed from polysilicon oxide layer (46), and floating gate 44a' which is formed from polysilicon layer 44.
Following the series of etches to form the EPROM gate structures, photoresist layers 54a and 54b are stripped and another photoresist layer (56 not shown) is formed to cover the EPROM device site, leaving open the polysilicon layer 44b above P-channel 36 and leaving open the polysilicon layer 44c above the N-channel region 38.
A polysilicon etch is then performed removing polysilicon layer portion 52b over the N-channel and P-channel regions, and not the portion 52a below photoresist layer (56). The photoresist layer (56) is then removed and a polysilicon oxidation step is performed. This oxidation step results in the formation of the polysilicon oxide layer 62 on the EPROM gate structure shown in FIG. 7, and also adds thickness to the oxide layer 46 that covers P-channel gate 44b and N-channel gate 44c.
Referring to FIG. 4, photoresist masking layer 64 is deposited and an aperture is formed in layer 64 above the site in N-well 18 where the P-channel transistor is to be formed. A P-type ion implant is performed with masking layer 64 preventing ions from being implanted in the N-channel transistor channel region 38 and in the EPROM device channel region 32. P-channel gate 44b, along with its oxide layer 46b, prevent P-type ions from entering channel region 36 underneath. The enlarged regions of oxide layer 14 prevent the P-type ions from being implanted in N+ guard rings 28. The result is the formation of P+ regions 66. P+ regions are the source 66s and drain 66d regions of the P-channel transistor.
Referring now to FIG. 5, the source and drain regions of the EPROM and the N-channel transistor are formed. Photoresist layer 64 is stripped and a new photoresist mask layer 68 is formed. Photoresist layer 68 has aperture 70 above the region where the N-channel transistor is to be formed and aperture 72 above the region where the EPROM device is to be formed. Following the formation of apertures 70 and 72 in layer 68, N-type arsenic ions are implanted. N-channel transistor gate 44c and its oxide layer 46 protect a portion of N-channel region 38 from receiving the ion implants. This results in the formation of N+ source regions 74s and 76s and drain regions 74d and 76d which define gate-aligned channels 32 and 38.
Of course, it is generally necessary to insure that the doping of the channel region to adjust the transistor threshold voltage completely spans the distance source to drain. At first consideration this suggests that it will be difficult in the process of this invention to realize the registration accuracy necessary to attain that objective. However, that is not the case because in the mask (30) for selectively exposing the channels to threshold adjusting impurities, the doped channel regions become wider than the mask aperture dimensions due to lateral diffusions of the impurities; and because in the subsequent mask (48) for selectively etching polysilicon and defining the gates there are mask islands corresponding to the gates and the underlying polysilicon is undercut by the etchant so that the dimensions of the resulting gates are less than those of the mask islands. Thus as a practical matter the dimensions of the apertures of the first mask are preferably made equal to the dimensions of the islands of the second mask greatly simplifying design and without the need for different masks dimensions to compensate for worse case misregistration of sequentially employed masks and/or without making the costly effort to achieve extraordinarily tight mask registration.
This practice of using equal dimensions of the successive masks, at least in the direction of from source to drain, causes a small overlap of the channel adjusted regions and the source and drain. However, this small overlap increases the junction capacitances insubstantially.
Referring now to FIG. 6, the substrate is subjected to heating at about 900° C. to drive the source and drain impurities further into the substrate. This results in a depth of 0.3 micron for sources and drains 76d, 76s, 66d, 66s, 74d and 74s, whereas the threshold-adjusting boron in the channels is driven deeper also. The P/P-junction defining regions 32 and 38 become 0.8 micron deep and the N-/N junction defining region 36 becomes about 0.5 micron deep.
Again referring to FIG. 6, a contact etching step is performed. In this step, glass is deposited on the surface and heated until it reflows slightly, thereby forming reflow glass layer 78. A photoresist mask is then deposited and contact holes are cut to all source, drain and gate regions. The photoresist is then removed.
A metal alloy is then deposited. This metal alloy comes in contact with the areas beneath the apertures which have been etched in glass layer 78, thereby forming metal contacts 80. This is followed by a metal photoresist masking and a metal etch which leaves metal above the regions to which contact is required. A passivation layer 82 is then deposited and etched, resulting in the final structure as shown in FIG. 6.
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An integrated circuit including CMOS transistors and an EPROM device by a method including selectively implanting threshold adjusting atoms of P-type in the channel regions of the N-type transistors while exposing the whole device area of the P-channel transistor. Subsequently, the sources and drains of the N-channel transistors are selectively implanted using the gates as a self-aligning mask portion. The PN-junction capacitance of the sources and drains of the N-channel transistors are thereby kept low and not subject to the degrading effects of the threshold adjusting implant. The P-channel is also affected and source drain capacitances there are reduced so that the speed of all three types of transistors are enhanced. Only high-yield process steps are included.
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BACKGROUND OF THE INVENTION
[0001] This invention relates to a flavoring system and method, particularly for use in snack food production in which a flavoring such as salt or a spice is applied onto potato chips or the like after they are taken out of a frying machine.
[0002] Apparatus for adding flavoring to snack food items such as potato- or corn-based items have been described, for example, in Japanese Patent Publications Tokko 4-35132 and 2689139 and U.S. Pat. Nos. 5,090,593 and 5,846,324. In these prior are apparatus, food items such as potato chips taken out of a frying machine are introduced into a rotary drum and a flavoring material is added at a specified ratio to mix them together. Whenever a different kind of flavoring material is to be used, it is necessary to wash all components downstream of the flavoring apparatus. This typically includes a weighing machine for dividing received items into batches of a specified weight to be made into individual packaged products.
[0003] It now goes without saying that washing all these devices on the downstream side is both cumbersome and time-consuming. Moreover, since all these devices must be stopped during such a washing operation, it has a significantly adverse effect on the productivity of the system.
[0004] When devices on a production line are to be washed, the one on the upstream side is stopped first but those on the downstream side are allowed to continue operating until the products being processed thereby are all discharged. Since the operator cannot exactly control the number of finally outputted products before the system is completely stopped, there may be left a container which is only incompletely filled with finished products.
[0005] In view of such problems with prior art systems, it may be proposed to provide as many flavoring systems as there are different kinds of flavoring materials to be used, each system being used for applying only one kind of flavoring material. This, however, will affect the equipment cost adversely. Moreover, one cannot do away with the washing if the consumers' taste changes and a new kind of flavoring must be introduced.
[0006] Another problem with prior art flavoring apparatus is that food items of different sizes remain inside the apparatus for different periods of time. As a result, the rate of application on individual food items cannot be made uniform even if the quantity of added flavoring material is adjusted according to the flow rate of items.
[0007] Still another problem is that a material such as stainless steel must be used for devices on the downstream side because flavoring materials often contain salt. Since the parts that come into contact with food items must be easily detachable, the device becomes accordingly more complicated and expensive to produce.
[0008] An apparatus is known for packaging quantities of a frozen product in which a sauce is supplied into the same packaging following portioning of the product. However, this is not suitable for handling flavoring for snack food items.
SUMMARY OF THE INVENTION
[0009] It is therefore an object of this invention, in view of the problems of the prior art technology described above, to provide an improved flavoring system which does not require washing operations although they were necessary with conventional systems when a different kind of flavoring material was to be used.
[0010] It is another object of this invention to provide such a flavoring system with which differently flavored products can be produced according to a preliminarily planned schedule and a change in the kind of flavoring material to be applied can be effected quickly, or even automatically.
[0011] It is still another object of this invention to provide a method of flavoring food items to be packaged without the necessity of washing many components of the system used for the method whenever a different kind of flavoring material is to be used.
[0012] A flavoring system according to this invention may be characterized as comprising a portioning device for receiving items and sequentially supplying batches of a specified quantity of these items, a flavoring dispenser for dispensing measured quantities of a flavoring material, an applying device downstream of the portioning device for individually applying the measured quantities of flavoring material to the batches of items, a packaging device downstream of the applying device for packaging the batch of items in a bag, a sensor for monitoring discharge of flavoring material and a sorting device for discarding a packaged product packaged by the packaging device if the sensor detects an abnormality in the discharge of the flavoring material.
[0013] A control unit may be further included for operating the portioning device, the dispenser and the flavoring device in a mutually correlated manner. If the portioning device discharges a defective batch which is not of the specified quantity of the items, the control unit may control such that the flavoring material is not applied to the defective batch discharged from the portioning device. The applying device may be adapted to apply the flavoring material at a set ratio to each of the batches of the specified quantity. The applying device and the dispenser may be exchangeably attached to the flavoring system. The applying device may include a charging device for electrically charging particles of the flavoring material and an ejecting device for ejecting the electrically charged particles of the flavoring material towards the items of the batch. The applying device may further include a mixing device for mixing together the flavoring material and each of the batches of items.
[0014] The portioning device may comprise a weighing device which serves to supply the items to a plurality of weigh hoppers, to measure the individual weights of the items in these weigh hoppers, to select a combination of the weigh hoppers with a specified weight on the basis of the measured weights and to thereby supply one of the batches. The applying device may be simply one of a plurality of applying devices adapted to receive the items from a common supplying device, each of the plurality of applying devices applying a different flavoring material. The control unit may operate the packaging device in a mutually correlated manner with the other components of the flavoring system. The applying device may serve to coat the items with the flavoring material.
[0015] The packaging device may be a vertical pillow packaging machine of a known kind, serving to form an elongated film into a tubular form to produce a bag while filling the bag with the batch of items, to seal the film between this bag and another bag being subsequently formed, and to cut the film to separate them one bag from the other.
[0016] A method of flavoring items according to this invention may be characterized as comprising the steps of sequentially providing batches of items of a specified quantity, dispensing measured quantities of a flavoring material, applying each of the measured quantities of flavoring material to a respective one of the batches of items, and packaging the flavored items. The quantity of flavoring material may be determined in accordance with the number, the weight or the volume of items in the batch.
[0017] Throughout herein, the items may be food items and the flavoring material may be in the form of particulate, powder or liquid.
[0018] It is to be noted in particular, in contrast to the prior art, that an applying device is incorporated downstream to the portioning device such that the flavoring material is applied to the items, rather than during a subsequent cooking step. In addition, the system according to this invention overcomes the washing problems mentioned above. Thus, since the flavoring material is applied after the items are portioned into batches of a specified quantity by means of a weighting machine or the like, the flavoring material being applied does not come into contact with the weighing device and it becomes unnecessary to wash the weighing machine each time a new flavoring material is selected. Thus, the system need not be stopped for a washing operation and hence the productivity improves dramatically. Since the flavoring operations are carried out for each of the batches, the flavoring material can be supplied according to the content of each batch and hence the quality of taste can be made uniform among the products. Moreover, since the weighing device need not be washed, it need not be detachably structured. Thus, such a system can be provided more inexpensively.
[0019] The invention allows differently flavored products to be produced according to a preliminarily planned schedule and a change in the kind of flavoring material to be applied can be effected quickly, or even automatically. An important aspect of the invention is that the items can be coated, preferably uniformly, with the flavoring material. The invention enables the flavoring material to be changed instantly such that differently flavored products can be produced on a single production line. Moreover, this invention provides a flavoring system that is inexpensive and durable. Flavoring materials typically includes seasoning such as salt and spices but may also include other particulate, powder or liquid that may typically require to be applied reasonably uniformly. Flavoring materials according to this invention may also include chemical flavors commonly referred by “E numbers” such as cheese and onion flavors. The items are typically snack food products such as potato chips but could include other foodstuffs such as cereals, nuts, biscuits, confectionery, etc. The items are typically unseasoned and unflavored prior to the portioning operation but can already be partly seasoned.
[0020] The portioning device is typically a weigher but the portioning may be effected also by number, volume or even by type of item.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] Some examples of systems and methods according to the present invention will now be described with reference to the accompanying drawing, in which:
[0022] [0022]FIG. 1 is a schematic block diagram for showing the basic structure of a flavoring system embodying this invention;
[0023] [0023]FIG. 2 is a schematic block diagram for showing the basic structure of a seasoning device such as shown in FIG. 1;
[0024] [0024]FIG. 3 is a schematic diagonal view of a mixing device such as shown in FIGS. 1 and 2;
[0025] [0025]FIG. 4A is a plan view of a mixing device and FIG. 4B is a side view of a portion of a mechanism for rotating the drum;
[0026] [0026]FIGS. 5A, 5B and 5 C are schematic sectional views for showing how food items and a flavoring material are mixed together;
[0027] [0027]FIG. 6 shows how data may be stored in a memory;
[0028] [0028]FIG. 7 is a schematic block diagram of another flavoring device;
[0029] [0029]FIG. 8 is a sectional view taken along line 8 - 8 in FIG. 7;
[0030] [0030]FIG. 9 is a partially sectional view of the flavoring dispenser; and
[0031] [0031]FIG. 10 is a block diagram of a control system.
DETAILED DESCRIPTION OF THE INVENTION
[0032] The invention is described next by way of an example. FIG. 1 shows the basic structure of a flavoring system embodying this invention including a transporting device 100 for transporting unseasoned or unflavored food items, a weighing device 200 for portioning or partitioning the food items transported by the transporting device 100 into batches of a specified quantity for filling one bag, a flavoring device 300 for applying a flavoring material to each batch of the food items, a packaging device 400 for packaging the flavored food items, a sorting device 500 for eliminating from the production line defective products caused by an error in weighing or application of flavoring material, a packing device 600 for packing packaged products in a box, and a control unit 700 for not only controlling each of the devices 100 , 200 , 300 , 400 , 500 and 600 but also coordinating their operations.
[0033] The transporting device 100 is for receiving food items from a frying machine (not shown) and transporting them to the weighing device 200 . A vibrating feeder 110 is provided at its downstream end for supporting thereon the transported food items. When a supply-requesting signal S 1 is received from the weighing device 200 , the vibrating feeder 110 vibrates for a specified length of time to deliver the food items thereon to the weighing device 200 .
[0034] The weighing device 200 is for receiving the food items delivered by the vibrating feeder 110 and producing batches of the food items each for filling one bag as a finished product. It has a dispersion feeder 210 at the top, and when the amount of the food items thereon becomes too small, it transmits the aforementioned supply-requesting signal S 1 to the vibration feeder 110 .
[0035] When a discharge-requesting signal S 2 is received from the flavoring device 300 , the weighing device 200 opens its timing hopper 220 to discharge the food items m of a specified amount which have been held therein. Thereafter, the weighing device 200 starts its weighing operations to portion another batch with a specified quantity and discharges this new batch into the timing hopper 220 which has just been emptied and is waiting for the next discharge-requesting signal S 2 .
[0036] The purpose of this weighing device 220 is to portion the food items and to discharge these portioned batches. The portioning need not be in terms of weight but may be in terms of volume. In the case of a snack food of the type having individually different sizes, it is convenient to use a combinational weigher such as described in U.S. Pat. No. 5,757,866 issued May 19, 1998, adapted to use a dispersion feeder 210 to distribute food items supplied at the top center among a plurality of weigh hoppers, to measure the individual weights of the items in these weigh hoppers, and to select a combination of the weigh hoppers such that the total of the weights of the items in the selected combination of the weigh hoppers will be of a specified magnitude. With a weigher of this type, even irregularly shaped items can be portioned accurately.
[0037] If an error is committed in the weighing, the weighing device 200 transmits an error signal S 3 to the control unit 700 . Upon receiving an error signal S 3 , the control unit 700 transmits a stop signal S 4 to the flavoring device 300 to stop its operation. Thus, if a batch with an incorrect quantity is discharged, this batch is not flavored and may be collected to be used for producing a differently flavored product or be recycled for use with the same flavor.
[0038] As shown in FIG. 2, the seasoning device 300 includes a supplying device or a dispenser 310 for discharging a flavoring material, a mixing device 320 constituting an applying device for mixing the discharged flavoring material and the batch of food items m discharged from the timing hopper 220 , and a control device 330 for controlling the supplying device 310 and the mixing device 320 .
[0039] The supplying device 310 includes a charge hopper 311 for storing the flavoring material, a vibratory feeder 312 for transporting the flavoring material inside the charge hopper 311 to its front end little by little, a weigh hopper 313 for receiving the flavoring material S from the vibratory feeder 312 and weighing the received flavoring material and a weight sensor 314 for measuring the weight of the weigh hopper 313 .
[0040] The control device 330 drives the feeder 312 while monitoring the value measured by the weight sensor 314 . When a specified quantity of the flavoring material has been received by the weigh hopper 313 , the feeder 312 is stopped. If the flow rate of the flavoring material from the charge hopper 311 or the amount of the flavoring material therein is insufficient and the specified quantity of the flavoring material fails to be received by the weigh hopper 313 within a specified length of time, the control device 330 concludes that an abnormal condition has occurred and outputs a discharge abnormality signal S 5 to the control unit 700 . Upon receiving the discharge abnormality signal S 5 , the control unit 700 outputs signals S 9 and S 10 to the packaging device 400 and the sorting device 500 to eliminate defective products which have not been flavored properly.
[0041] The structure of the supply device 310 depends on the form of the flavoring material. If the flavoring material is in a liquid form, an air spray device may be appropriate. If the flavoring material is in the form of a paste, a screw conveyor capable of controlling the supply according to its angle of rotation may be used. If the flavoring material is in a granular or powder form, a device capable of controlling the supply according to the volume may be preferred. In other words, although a screw conveyor is schematically shown in FIG. 5A, this is not intended to limit the scope of this invention.
[0042] Although FIG. 2 shows an embodiment whereby an abnormality in the supply rate of the seasoning material is detected by the weight measured by the weigh hopper 313 , neither is this intended to limit the scope of the invention. The method of detecting an abnormal situation varies, depending on the mechanism for supplying the flavoring material. If the flavoring material is a liquid, for example, an abnormal condition may be detected by means of a flow rate sensor. Whatever the form of the flavoring material, an abnormal supply condition may be detected by means of a weight sensor to monitor the rate of its decrease. In summary, a system according to this invention is capable of dependably preventing improperly flavored products from being shipped.
[0043] The mixing device 320 is for mixing and applying the flavoring material on only one batch at a time of the flavoring material. Thus, it may be much smaller than the conventional mixers such as disclosed in U.S. Pat. Nos. 5,090,593 and 5,846,324.
[0044] [0044]FIG. 3 shows an example of the mixing device 320 , structured such that a plurality of small drums T 1 -T m will rotate around a vertical axis of rotation 0 while each of them rotates around itself. Explained more in detail with reference to FIG. 4A, the drums T 1 -T m are attached to the tips of arms 321 extending radially from the axis of rotation 0 such that as the central rotary shaft along the axis of rotation is rotated, the drums T 1 -T m rotate horizontally together with the arms 321 , as indicated by arcuate arrows. Each arm 321 carries on its end distal from the axis of rotation O a rotary member 321 b adapted to rotate around its direction of extension. As shown in FIG. 4B, the rotary member 321 b is connected to a fixed annular rack 323 and a pinion 322 such that, as the arms 321 rotate horizontally around the axis of rotation O, the pinion 322 engaging with the fixed rack 323 rotates along the rack 323 . As a result, the rotary member 321 b which is integrally formed with the pinion 322 , as well as the associated one of the drums T 1 -T m , will rotate around the axis of rotation of the arm 321 .
[0045] Each of the drums T 1 -T m has an opening 325 , provided with a sliding gate 324 biased by a spring (not shown) in the direction of closing it. When one of the drums T 1 -T m reaches the receiving position for receiving unseasoned or unflavored food items (the position of drum T 1 in FIG. 3), its opening 325 is at an upwardly facing position, as shown in FIG. 5A, and the sliding gate 324 is opened. At the same time, another of the drums (T m in the example of FIG. 3) which is at the discharge position has its sliding gate 324 opened with its opening 325 facing in the vertically downward direction, as shown in FIG. 5C. At other positions, the drums T 1 -T m have their sliding gates 324 closed, as shown in FIG. 5B, sealing inside both a batch of food items m and a flavoring material S.
[0046] As shown in FIG. 5, there are protrusions 326 inside the drums T 1 -T m serving to stir and mix the food items and the seasoning material S together as the drums T 1 -T m rotate. This results in the food items being uniformly coated with the flavoring material. Numeral 223 in FIG. 3 indicates the gate of the timing hopper 220 and numeral 327 in FIG. 4B indicates a frame for supporting tip parts of the arms 321 .
[0047] When a discharge requesting signal S 6 is outputted from the packaging device 400 , the control device 330 stops drum T m directly above a chute 410 of the packaging device 400 . At the same time, drum T 1 stops at a position directly below the timing hopper 220 . Thereafter, the control device 330 opens the slide gates 324 of these two drums T 1 and T m and outputs a discharge end signal S 7 to the packaging device 400 and a discharge requesting signal S 2 to the weighing device 200 .
[0048] As the discharge requesting signal S 2 is received, the weighing device 200 opens the timing hopper 220 and transmits a discharge end signal S 8 to the control device 330 . Thereupon, the control device 330 controls the supplying device 310 to cause an appropriate amount of the seasoning material S according to the weight of the food items m to be discharged, closes the gates 324 and rotates the drums T 1 -T m .
[0049] Thus, each of the drums T 1 -T m is stopped whenever it comes to the position directly above the packaging device 400 and discharges the seasoned food items down to the packaging device 400 . At the same time, the emptied drum receives a new batch of food items from the timing hopper 220 and a specified amount of the flavoring material S is added from the supplying device 310 . Thereafter, the control device 330 rotates the drums T 1 -T m such that the food items m and the flavoring material S are stirred together.
[0050] Examples of the packaging device 400 includes those adapted to open a bag and filling items in the opened bag and the so-called vertical pillow type adapted to form an elongated film into a tubular shape while filling it with items, to seal simultaneously the top of the filled bag and the bottom of a next bag to be filled and to cut the film in between. With such a vertical pillow type packaging device, bags which are not sealed or cut can be produced temporarily by changing its mode of operation. Thus, when the control unit has received an error signal S 3 from the weighing device 200 or a discharge abnormality signal S 5 from the seasoning device 300 , a mode changing signal S 9 may be outputted to the packaging device 400 to change the mode of its operation such that properly produced products and defective products can be easily distinguished from the ways they are packaged.
[0051] The aforementioned sorting device 500 is for the purpose of eliminating defective ones of the bags B from the production line described above in response to a signal S 10 from the control unit 700 . If it is disposed on the downstream side of the packaging device 400 , as is the case according to the embodiment being described, it may appropriately comprise a sorting conveyor. If it is disposed between the flavoring device 300 and the packaging device 400 , it may comprise a switching chute adapted to change the direction of discharge in response to a command signal. Thus, although an error may be committed in the flavoring process, defective products can be dependably prevented from being shipped.
[0052] The packing device 600 is for packing the completed bags B in cardboard boxes for shipment and also serves to count the number of bags B which have been handled. The counted number is transmitted to the control unit 700 to be used in production management.
[0053] The control unit 700 is for controlling the devices 200 , 300 , 400 , 500 and 600 in proper coordination and includes an input/output device 710 for communicating with these devices to control them individually and a memory 720 for storing production data on products for each kind, for example, as shown in FIG. 6. The memory 720 stores data for each kind of product such as the kind of flavoring material to be applied, the rate of its application, the speed of operation of the packaging device (say, in bpm=bags per minute), the weight of each bag to be produced and the planned number of bags to be produced. If the user operates on the input/output device 710 to input a product (code) number, various data on the corresponding kind of product are retrieved and transmitted to the individual ones of the corresponding devices. For example, the data on the kind and rate of application of the flavoring material are transmitted to the flavoring device 300 , the speed of operation is transmitted to the packaging device 400 and the weight of each bag is transmitted to the weighing device 200 . The planned number of products is set in a microcomputer 730 .
[0054] When the user operates a start key displayed on the input/output device 710 , the control unit 700 starts to control the devices from the upstream side, recording the numbers of processed batches (or bags) individually by the devices 200 , 300 , 400 , 500 and 600 . From these data, the microcomputer 730 calculates the number of batches (or bags) yet to be processed. If this value becomes zero for any of these devices, a stop command is delivered to the corresponding device to stop its operations.
[0055] In the case of an error where defective products have been produced and eliminated, the deficiency caused thereby is added to the planned number of products for the devices on the upstream side such that a desired number of finished products will be produced. In this manner, a desired planned number of products can be obtained without producing a waste.
[0056] Since the flavoring device is adapted to flavor only one batch of food items at a time, it need not be as big as the conventional devices. Thus, a plurality of flavoring devices each for applying a different kind of flavoring material may be provided such that differently flavored food products can be produced easily by appropriately exchanging them.
[0057] Alternatively, a plurality of supplying devices 310 for different kinds of flavoring materials may be provided such that their outlets are all adjacent to the opening 325 of the mixing device 320 and the kind of flavoring material can be selected. In such an application, each drum of the mixing device 320 may be selectively used for a flavoring material. For example, one kind of flavoring material may be added to even-numbered drums and another kind of flavoring material may be added to odd-numbered drums. Since none of these drums is going to have different kinds of flavoring materials, there is no need to wash the mixing device 320 .
[0058] It is also possible, as another application, to produce one bag at a time of differently flavored food items in a sequential manner such that a series of differently flavored packages can be produced, as could not be done by the prior art technology.
[0059] The invention has been described above by way of a system with one production line to carry out weighing, flavoring, packaging and packing but a distributing device such as disclosed in Japanese Patent Publication Tokko 4-35132 may be used if a plurality of such production lines are used on the upstream side of the transporting device 100 for each of the production lines such that food items can be distributed among the production lines uniformly. If each production is associated with a specified kind of seasoning material in such a system, products of different kinds can be produced simultaneously immediately before they are packaged and items which are left over can be returned and recycled to another production line.
[0060] The seasoning device 300 described above is convenient when flavoring materials of different types are used because a plurality of rotary drums are used. FIG. 7 shows another kind of flavoring device 30 suited for flavoring materials in a powder form.
[0061] As shown in FIG. 7, there is a charging device 20 directly below the timing hopper 220 for electrically charging the unflavored food items as they are dropped from the timing hopper 220 . This charging device 20 is composed of a grounded electrode 22 b and another electrode 22 a connected to a high-voltage source 21 . As the dropped food items fall between these electrodes 22 a and 22 b , they are charged in a specified polarity. Such a charging device 20 , however, may be dispensed with if the weighing device 200 and the timing hopper 220 are made of a dielectric material because the food items that are dropped are kept at the ground level.
[0062] Below the charging device 20 are a receiving chute 31 and a flavoring chute 32 provided with a pair of electrostatic guns 33 . These electrostatic guns 33 are for spraying the flavoring material in the powder form after charging it in a specified polarity, installed opposite each other on the wall surfaces of the seasoning chute 32 . The tips of the nozzles of the guns 33 are connected through branch pipes 35 a and 35 b to a pipe 35 leading to a compressor 34 . A screw-type supplying device 36 is connected to another branch pipe 35 c on the upstream side on the pipe 35 for supplying the flavoring material from a storage tank 37 . The nozzles at the tips of the electrostatic guns 33 are each provided with a trumpet-shaped deflector 33 a , as shown in FIG. 8, such that the flavoring material in the powder form will be dispersed as shown by arrows A.
[0063] As shown in FIG. 9, the supplying device 36 is provided with a screw 36 b attached to the main shaft 36 a ′ of a driver motor 36 a and a cylinder 36 c which contains them. The cylinder 36 c has a hole 36 c ′ at its tip, opening to the interior of a tank 37 for the flavoring material. As the driver motor 36 a is switched on to rotate the screw 36 b , the flavoring material inside the tank 37 is taken into the cylinder 36 c and discharged into the pipe 35 , as indicated by arrow B. An air inlet 36 d is provided on the other side of the screw 36 b , being connected to the branch pipe 35 c serving as a path for compressed air and led to the tips of the nozzles of the electrostatic guns 33 , as indicated by arrow C. The pipe 35 also includes a switch valve 38 for adjusting the flow rate of the flavoring material in the powder form containing air.
[0064] As shown in FIG. 7, there is a collecting device 40 for the flavoring material, having a discharge chute 41 which covers the bottom portion of the seasoning chute 32 and leading to the packaging device 400 . A pair of suction openings 41 a is provided at an elevated portion of the discharge chute 41 for connecting to a cyclone 42 for removing the excess seasoning material through a pipe 43 . The cyclone 42 is connected with a vacuum pump 42 a for exhausting air. A switch valve 44 is provided in the pipe 43 for controlling the collection of the seasoning material in the powder form.
[0065] Next, the operation of the flavoring device 30 of FIG. 7 will be explained. As a batch of food items is discharged from the timing hopper 220 , their passage is detected by sensors 17 a and 17 b . As their detection signals are received, the control device 39 (FIG. 10) for the flavoring device 30 activates the electrostatic guns 33 .
[0066] The food items which have passed through the charging device 20 are charged in a specified polarity and are dropped from the receiving chute 31 to the flavoring chute 32 . At the same time, the flavoring material in the powder form is taken out of the tank 37 through the supplying device 36 at a specified rate. As it is led into the pipe 35 through the branch pipe 35 c , it is sprayed by compressed air into the flavoring chute 32 through the nozzles of the electrostatic guns 33 . Since the flavoring material and the food items are charged oppositely in polarity, the flavoring material in the powder form floating in the travel path of the food items is electrostatically attracted by the falling food items and becomes attached thereto. Thus, the floating flavoring material is dependably and instantly attached to the food items.
[0067] The rate of supply of the flavoring material can be adjusted by controlling the speed of rotation of the screw 36 b through the control device 39 . The time of air supply and the flow rate can be controlled by adjusting the switch valve 38 . The rate of spray of the flavoring material can thus be controlled at will. The deflectors 33 a at the tips of the nozzles of the electrostatic guns 33 serve to have the flavoring material sprayed in directions not perpendicular to the direction of fall of the food items. Thus, the flavoring material being ejected does not inhibit the free fall of the food items and has no adverse effect on the high-speed flavoring process. The control unit 700 may be programmed to change the rate of spray according to the weight of the batch of food items being dropped.
[0068] Parts of the flavoring material that were sprayed into the seasoning chute 32 but failed to attach to a food item are collected by the cyclone 42 through the discharge chute 41 , as indicated by arrow D in FIG. 7, as the switch 44 is opened. Thus, the waste of the flavoring material can be avoided. Moreover, this prevents the defective sealing by the packaging device 400 disposed below the discharge chute 41 due to the presence of excess powder particles of the flavoring material. The collected flavoring material can be recycled and used again.
[0069] The examples described above are intended to be illustrative, not as limiting the scope of the invention. Many modifications and variations are possible within the scope of the invention. For example, more than two electrostatic guns may be used for more evenly attaching the flavoring material onto the falling food items. Although sensors 17 a and 17 b were used for detecting the passage of food items being dropped, these sensors may be dispensed with by using the opening signal of the timing hopper 220 as a substitute. It also goes without saying that the packaging device to be used in a system embodying this invention need not be of a vertical pillow type. Any device adapted to fill a bag with the flavored food items may be incorporated into a system of this invention.
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A flavoring system has a portioning device such as a weigher for receiving unflavored food items and sequentially supplying batches of a specified quantity of them, dispenses measured quantities of a flavoring material with a dispenser, applies these measured quantities of flavoring material to the supplied batches and packages the flavored batches of items in a bag. A sensor monitors the discharge of the flavoring material and a sorting device discards packaged products if the sensor detects an abnormality in the discharge of the flavoring material. A plurality of dispensers may be provided for dispensing measured quantities of different flavoring materials.
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FIELD OF THE INVENTION
[0001] The field of the invention is subterranean safety valves of the flapper type and more particularly vortex control features that allow the flapper to close in high velocity fluid flow applications.
BACKGROUND OF THE INVENTION
[0002] Subsurface safety valves generally have a flapper that is closed by a torsion spring that is mounted on a pivot pin for the flapper. A hydraulic control system actuates a piston to move a flow tube in the valve passage against the flapper to hold it open. If pressure in the hydraulic system is removed or lost, the closure spring acts on the flow tube to lift it away from the flapper that until that time had been behind the flow tube in a recess in the housing. Once the flow tube moves up the torsion spring in the flapper pivot shaft would do the work of starting rotational movement of the flapper toward its conforming seat. When the flapper contacted the seat the pressure of the fluid below kept the flapper in that closed position sealed against the flapper seat. Pressurizing the control system again brought the flow tube against the closed flapper and made it pivot off the seat back to the open position.
[0003] As safety valves were made with larger flow bores and dealt with higher velocities particularly in gas service transient vortexes were formed of high pressure zones that changed location depending on the velocity. At certain flow passage dimensions and flow velocities these high pressure zones occurred in front of an open flapper to create a sufficient hold open force that the torsion spring was unable to move the flapper to the closed position even after the flow tube was raised to allow such flapper movement.
[0004] In the past, in addressing the larger sized flapper safety valves and the limitations of the torsion spring to move an ever heavier flapper, designs were developed along the lines of providing an assist to the torsion spring to start the flapper moving toward the closed position when the flow tube was raised up. U.S. Pat. No. 6,227,299 used a leaf spring 122 located behind the flapper 86 to add a closing force. US Publication 2009/0151924 uses a shape memory alloy closure spring to get a boost in the flapper closing force. Going in the opposite direction, U.S. Pat. No. 7,703,532 holds the flapper open with movably mounted magnets and U.S. Pat. No. 7,270,191 provides a mechanism to open the flapper when it will not go from the closed to the open position with the hydraulic system. US Publication 2009/0032238 uses repelling magnets in the housing and the flapper to give an assist to a torsion spring on the flapper pivot pin. U.S. Pat. No. 7,448,219 is a hingeless flapper design that shapes the flapper to be aerodynamic so that it can operate responsive to the flow passing by in an automotive application. U.S. Pat. No. 7,644,732 uses a bypass technique for dealing with pressure surges in a lubrication system when the circulating oil is still cold.
[0005] The various solutions discussed above have in common a focus on adding a closing force when it is time for the flapper to go to the closed position. The present invention addresses the configuration of the flow passage to reduce or eliminate the effect of flow induced pressure transients that can overcome the ability of the flapper torsion spring to close it in high velocity fluid flow situations in the order of 300 feet per second or higher. Rather than adding to the mechanical closing force applied to the flapper, the present invention focuses on dissipation of flow induced moving pressure gradients that can act on the flapper at the time it needs to close and reducing their affects by shaping the profile of the flow passage in the vicinity of the flapper or the flapper itself so that the localized pressure differentials are not large enough to overcome the torsion spring trying to close the flapper. Those and other aspects of the present invention will become more apparent to those skilled in the art from a review of the description of the preferred embodiment and the associated drawings while recognizing that the full scope of the invention is provided by the appended claims.
SUMMARY OF THE INVENTION
[0006] The problem of flappers that will not close due to high velocity gas rushing past and creating a vortex that has zones of high pressure pressing the flapper against the force of the torsion spring is reduced or overcome with modifications in the passage through a subsurface safety valve so as to reduce the intensity of the vortex to allow the torsion spring to pivot the flapper to closed position. Various shapes are inserted adjacent the flapper base to create turbulence to minimize or prevent the vortex and the associated pressure increases that would otherwise prevent flapper closure with the flow tube retracted. Inserts that create turbulence are placed in a recess that in part holds the flapper when it is rotated to the open position. Additionally and alternatively the flapper itself can be machined so as to create a larger annular space behind the flapper when it is open so that some part of the generated vortex can be used to push the flapper to the closed position and to offset the high pressure zones created on the other side of the open flapper.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a prior art view of a flapper in the open position even after the flow tube moves uphole and flow passing through the passage that holds the flapper open due to a vortex causing high pressure;
[0008] FIG. 2A schematically shows the vortex against the flapper to hold it open;
[0009] FIG. 2B illustrates the vortex shown in FIG. 2A and the high velocity flow passing straight through as the flapper is held open;
[0010] FIG. 3 shows one form of a device to reduce the pressure in the vortex using a partial sleeve that comes to a point directed at the incoming flow and has opposed sides sloping away from the leading point;
[0011] FIG. 4 puts an insert in the groove where the flapper is located when it is open showing a series of transverse ridges; and
[0012] FIG. 5 shows an insert member in the groove where the flapper is located in the open position where the insert has an internal open space.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0013] As an introduction to the issue addressed by the invention FIG. 1 illustrates a tubular string 10 that has a safety valve housing 12 secured to the string 10 at opposite ends 14 and 16 . In the position of FIG. 1 the flow tube (not shown) has already been raised by a control system (not shown). Normally, the raising of the flow tube allows a torsion spring 20 about a pivot shaft 18 to apply its stored potential energy force and rotate the flapper 22 toward a schematically illustrated seat 24 . All the components of the housing 12 are not shown to add clarity to the identification of the issue using FIG. 1 . Arrow 26 represents the incoming high velocity stream that is most likely to be gaseous and in the order of about 300 feet per second or higher to cause the problem. Flow lines 28 graphically illustrate how most of the flow goes straight through the housing 12 in a direction toward the surface. However, depending on the velocity and the composition of the passing fluid some of the flow begins to ebb into the recess 30 and create a vortex 32 generally that begins away from the location of the flapper 22 and works its way around the housing 12 in the recess 30 . The vortex creates a high pressure concentration that is shiftable with the velocity that passes through the housing 12 . In the beginning as the velocity picks up the vortex 32 is located near the lower end 34 of the flapper 22 . At that location, the vortex 32 can actually be an aid to closure of the flapper 22 as it can pass through the gap 36 between the inside of the recess 30 and the housing 12 . Once reaching the small annular space 38 defined by the tapered surface 40 on flapper 22 and the housing 12 , the presence of the higher pressure at location 38 helps push the flapper away from wall 42 . However as the velocity increases and the center of the higher pressure vortex 32 moves closer to the surface and toward the pivot shaft 18 the moment balance shifts and there is an ever greater moment acting on the top side 44 of the flapper that can be easily in excess of the closing moment applied by the torsion spring 20 as aided by what remaining portions of the vortex 32 still in the vicinity of the gap 36 .
[0014] FIG. 2A adds to the schematic representation of how the vortex 32 works its way circumferentially to the top surface 44 of the flapper 22 . FIG. 2B is the same illustration as FIG. 2A but showing a different viewing angle for more of a perspective view. Should the velocity at the time the flow tube is raised in an effort to have the torsion spring 20 rotate the flapper 22 to a closed position against its seat 24 , the result can be that there is no flapper 22 movement at all. This can defeat the operation of the safety valve and can cause a blowout that would otherwise be prevented by the proper operation of the safety valve.
[0015] There are several ways that this situation can be addressed and three variations are illustrated in FIGS. 3-5 as preferred without any intent on limiting the variety of the approaches that look to reconfigure the internal passage in the housing 12 or the relation of the passage 44 to the flapper 22 or/and shaping of the flapper so that the vortex 32 is minimized in its intensity to the point where the torsion spring 20 can close the flapper 22 ′ as needed or in the ideal case prevent the vortex 32 from forming at all. In FIG. 3 the shoulder 46 and the flapper base 48 define the recess 30 ′ between them. Since the view in FIG. 3 is in section, only one half of the insert 50 is illustrated. The balance of the insert 50 that is not shown is preferably the mirror image of what is depicted. As a result the shape forms a downhole oriented point that can be sharp or blunt 52 from which opposed sides 54 extend and diverge in a direction toward the surface. The flow direction is given by arrow 56 . The thickness of the insert 50 as well as its shape can be optimized using Computational Flow Dynamics software that can create a three dimensional model of the flow regime through the passage 44 . Thus the height of the insert 50 can be varied to be taller, shorter or about the same height as the shoulder 46 that defines the recess 30 ′.
[0016] In a variation of the FIG. 3 design the insert 50 can be shaped to be a cylindrical member that fills partially to totally that portion of the recess 30 ′ that continues beyond the sides of the flapper 22 ′ so that in essence the circumferential extent of the recess 30 ′ is somewhat wider that the width of the flapper 22 ′ and that is it. Alternatively the flapper base 48 can be extended to accomplish the same result in a one piece rather than a two piece construction.
[0017] Another option is shown in FIG. 4 where the insert 58 is similarly positioned as in FIG. 3 and this time has a series of ridges such as 60 and 62 that are transverse to the direction of flow 64 that would otherwise cause the vortex 32 to form. The number and height and orientation of the ridges can also be optimized for the expected flow velocities. There can be ridge combinations that are transverse as shown in FIG. 4 combined with some ridges that are closer to parallel to the flow direction. A surface roughening on the face of the insert that faces the passage 44 is another alternative to control the vortex 32 ′.
[0018] Another approach is seen in FIG. 5 where the insert 65 has a void 66 that in the FIG. 5 is illustrated as square. Here again as in FIGS. 3 and 4 what is shown is a part of the insert 64 without the mirror image of it that is not in the illustration. Here again the void shape can be varied and optimized by mathematical modeling. There are other options for vortex control that can be implemented. For one the width of the gap 36 can be varied. Another approach is to increase the volume of the space behind the flapper and the surrounding housing. One example is to machine grooves on the back side of the flapper that faces the wall 42 ′ such as schematically illustrated by the dashed line 68 . There is a limit to the extent that the grooves on the back of the flapper can be used especially in the larger sizes as the flapper has to take large pressure differentials when closed and adding grooves can promote flapper distortion under maximum working pressure differentials to the point where leakage can occur. The idea on the back of the flapper is to create empty space behind the flapper to enable the vortex 32 to get into that space and add a closing moment that can help the torsion spring close the flapper.
[0019] It should also be noted that as the velocity increases the vortex 32 moves closer to the pivot shaft 18 and has a much smaller moment arm in the high pressure zone that it creates. That is one reason that the various inserts of FIGS. 3-5 end at the flapper base 48 . Optionally there can be a gap between the insert of any of the illustrated configurations or others that can be developed with mathematical modeling and the flapper base.
[0020] Another option to get an assist to the flapper 22 ′ is illustrated in FIG. 3 . A passage or passages 70 can start at passage 44 at a location 72 that is above the shoulder 76 where the flow tube 77 lands when the valve is in the open position. When the vortex 32 is centered on the flapper 22 ′, the tubing pressure in the passage 44 can be communicated to the zone behind the flapper 22 ′ at 74 . The passage 70 can be run as shown in FIG. 3 or it can use an external jumper if the passage from location 72 is run to the exterior face 79 and then jumpered to the outer face and into a lateral bore of the housing 81 in behind the flapper 22 ′.
[0021] While the illustrated valve is shown as operated with a flow tube 77 other designs using flappers that operate without a flow tube are also contemplated. Such devices can be powered by magnetic or other force fields to move the flapper between the open and closed positions.
[0022] The above description is illustrative of the preferred embodiment and various alternatives and is not intended to embody the broadest scope of the invention, which is determined from the claims appended below, and properly given their full scope literally and equivalently.
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The problem of flappers that will not close due to high velocity gas rushing past and creating a vortex that has zones of high pressure pressing the flapper against the force of the torsion spring is reduced or overcome with modifications in the passage through a subsurface safety valve so as to reduce the intensity of the vortex to allow the torsion spring to pivot the flapper to closed position. Various shapes are inserted adjacent the flapper base to create turbulence to minimize or prevent the vortex and the associated pressure increases that would otherwise prevent flapper closure with the flow tube retracted. Inserts that create turbulence are placed in a recess that in part holds the flapper when it is rotated to the open position.
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TECHNICAL FIELD
[0001] This invention relates to engine valve trains and, more particularly, to valve trains with ball and socket-type joints.
BACKGROUND OF THE INVENTION
[0002] It is known in the art relating to engine valve trains to provide actuating members, such as rocker arms and push rods or other components, having ball and socket-type joint connections. In some embodiments, more than one rocker arm and/or push rod or other actuator may be utilized in a train to actuate a single valve or multiple valves. Assembly of such valve trains can require excessive time in alignment of the components. For example, connecting a push rod between a pair of rocker arms at ball and socket joints in order to insert the ball ends into the sockets may require simultaneously depressing the valve actuating rocker against the valve spring. Also, insertion of a single push rod into a rocker arm socket may prove difficult in alignment of the components.
SUMMARY OF THE INVENTION
[0003] The present invention facilitates the assembly of valve trains with ball and socket-type joints by providing, where appropriate, assembly guides to aid in inserting and aligning an actuating member, such as a push rod, with one or more sockets on a mating actuating member or members. In an exemplary embodiment, a primary push rod engages and actuates a primary rocker arm which is connected with a secondary push rod engaging and actuating a second rocker arm that directly actuates a valve. The primary push rod has a spherical or ball end which is received in a socket of the primary rocker arm to aid alignment and insertion of the push rod with the rocker arm socket. The invention provides a conical guide surrounding the socket which slopes inwardly toward the socket and, upon assembly, guides the end of the push rod into position in the socket with a minimum of manual guidance.
[0004] The secondary push rod must be aligned with and inserted into sockets on both the primary and the secondary rocker arms. To assist this process, the invention provides guides, each having at least one guide surface which, in a preferred embodiment, comprises a partial cone surface extending out from the lower side of each of the rocker arm sockets. In assembly, the valve actuating rocker arm is rotated in a valve opening direction and the push rod is laid upon the part-conical guide surfaces. The valve actuating rocker arm is then released and returned by the valve spring to the actuating position, causing the ends of the push rod to ride up the assembly guides and slide into the sockets on the rocker arms in its operating position.
[0005] These and other features and advantages of the invention will be more fully understood from the following description of certain specific embodiments of the invention taken together with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] [0006]FIG. 1 is a plan view in fragmentary cross section of a nearly assembled exemplary valve train arrangement including assembly guides in accordance with the invention;
[0007] [0007]FIG. 2 is a side view in fragmentary cross section of the valve train arrangement of FIG. 1;
[0008] [0008]FIG. 3 is a pictorial view of the arrangement of FIGS. 1 and 2 showing a push rod in a nearly installed position; and
[0009] [0009]FIG. 4 is a pictorial view of an alternative rocker arm having multiple assembly guide projections adjacent to a ball socket.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0010] Referring now to the drawings in detail, numeral 10 generally indicates an exemplary valve train arrangement including ball and socket-type joints provided with assembly guides in accordance with the invention.
[0011] Valve train 10 includes a primary push rod 12 connected at a ball and socket joint 14 with a primary rocker arm 16 . Rocker arm 16 pivots on an axis 18 and includes a second socket 20 in which a ball end 22 of a secondary push rod 24 is received. A second ball end 26 of push rod 24 is received in a socket 28 of a secondary rocker arm 30 which is pivotable about a secondary axis 32 . The secondary rocker arm 30 further engages a valve stem 34 for actuating a valve which is closed by a valve spring 36 .
[0012] Assembly of the valve train as described, without assembly guides according to the invention, may be accomplished in any desired manner. However one possible assembly process could involve:
[0013] Installation of the primary push rod 12 into a cam follower, not shown;
[0014] Alignment of the primary push rod 12 with a socket 38 of the joint 14 and rotation of the rocker arm 16 to engage push rod 12 ;
[0015] Rotation of the secondary rocker arm 30 against the valve stem 34 and spring 36 to provide clearance for insertion of the secondary push rod 24 ;
[0016] Alignment of the secondary push rod ball ends 22 , 26 with sockets 20 , 28 of the primary and secondary rocker arms; and
[0017] Rotation of the secondary rocker arm 30 by the spring 36 back to the valve closed position to engage the ball ends of push rod 24 with their respective sockets in rocker arms 16 , 30 .
[0018] The process as described requires care in aligning and maintaining alignment of the components while they are being installed in their respective ball and socket joint connections, which may lead to increased assembly time or misalignment leading to repeated attempts to complete the assembly process.
[0019] To facilitate assembly, sockets 20 , 28 of rocker arms 16 , 30 are each provided with an assembly guide 40 in the form of a protruding lip having a part conical guide surface 42 which slopes inward toward its respective socket 20 or 28 . If desired, the continuous lip of assembly guide 40 could be replaced by a plurality of rods or other individual projections, each providing a sloping surface angled toward its respective socket 22 or 28 . As shown, the assembly guides 40 are preferably cast in place as part of the rocker arms 16 , 30 . However, they could alternatively be formed as separate components subsequently attached to their respective rocker arms in any suitable fashion. For example, they could be made of plastic and snapped into suitable projection pegs surrounding the rocker arm sockets.
[0020] The ball and socket joint 14 between push rod 12 and rocker arm 16 provides an example of the alternative proposal mentioned above. The rocker arm 16 includes an assembly guide 44 made as a separate component of any suitable metal or plastic material. The guide 44 is provided with an internal conical guide surface 46 and is configured with a connecting end 48 which snaps over a machined portion of the rocker arm 16 surrounding socket 38 of the joint 14 . The assembly guide 44 may, if desired, be made of lightweight plastic material in order to minimize the inertia of the valve train during actuation of the valve.
[0021] Assembly of the valve train described may be accomplished with the same steps previously described. However, the assembly process is made easier by the assembly guides 40 , 44 provided. For example, the initial insertion of the push rod 12 into the socket 38 of joint 14 is made easier by the conical assembly guide surface 46 which requires less accurate alignment of the components and guides the end of the push rod 12 into position in the socket 38 as the rocker arm 16 is rotated to connect with the push rod. Likewise, installation of the secondary push rod 24 is made easier. When the rocker arm 30 is rotated against the valve spring 36 , the push rod 24 is merely placed in position with its ball ends 22 , 26 on the guide surfaces 42 of the assembly guides 40 . The rocker arm 30 is then allowed to return to the assembled position, and the push rod ball ends are guided by the conical guide surfaces 42 up into their respective sockets 20 , 28 of the associated rocker arms 16 , 30 .
[0022] Thus, it is seen that the provision of assembly guides adjacent to the sockets of the associated ball and socket joints considerably simplifies assembly of the components of a valve train by reducing or avoiding the necessity of aligning the parts carefully and instead providing guidance of the ball components as they are inserted into their respective sockets.
[0023] [0023]FIG. 4 illustrates an alternative valve actuating rocker arm 50 including a ball socket 52 for receiving a ball end push rod (such as rod 24 ) or another actuating member. An assembly guide 54 is provided below the socket 52 and is formed by a pair of protrusions 56 having guide surfaces 58 angled upwardly toward the socket 52 . The assembly guide 54 is used as described earlier to support a ball end of a push rod and guide the ball end up into the socket 52 as the rocker arm 50 is pivoted toward engagement of the socket 52 with the push rod. A rocker arm may have any suitable configuration as called for by the valve train application. In this case, a valve actuating arm 60 and a socket carrying connecting arm 62 are supported by spaced bearing portions 64 for pivotally mounting the rocker arm 50 on a shaft or other supporting pivot.
[0024] The terms “ball” and “ball end” are used herein to indicate a socket engaging connecting portion and should be broadly interpreted to include various suitable bearing connections for engaging a socket. Such connections may, without limitation, include ring-shaped or part spherical bearings having continuous or interrupted bearing surfaces as may be appropriate.
[0025] While the invention has been described by reference to certain preferred embodiments, it should be understood that numerous changes could be made within the spirit and scope of the inventive concepts described. Accordingly, it is intended that the invention not be limited to the disclosed embodiments, but that it have the full scope permitted by the language of the following claims.
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A valve train with components connected by ball and socket joints is provided with projecting assembly guides adjacent the sockets of selected joints. The assembly guides include guide surfaces angling toward the sockets to guide the ball end of a push rod or other actuator into the socket of an associated rocker arm or other component. The guide surfaces may be generally conical or comprised of multiple spaced surfaces. The assembly guides facilitate assembly of valve trains, especially where components with multiple ball and socket joints are involved.
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The present application is a continuation-in-part application of application Ser. No. 272,680 filed Nov. 7, 1988 and now U.S. Pat. No. 4,988,223, issued on Jan. 29, 1991.
BACKGROUND OF THE INVENTION
The invention concerns an electromagnetic drive mechanism for the pin in a matrix printing head that has a magnet with an articulated armature, whereby the free end of the armature acts on the pin and can be returned to its disengaged position by a recovery mechanism.
German as 1 817 848 discloses a printing-pin magnet with electromagnetic attraction and repulsion. This device, however, requires two complete separate magnet systems, each with its own armature.
The combined mass of the two armatures decelerates operation. Also necessary is a spring to establish the armature's disengaged position, and the spring must also be activated during attraction, using up additional energy during the period and decelerating the attraction.
A system of articulated-armature magnets for a line printer with an electromagnetic recuperating magnet is known from German GM 1 923 036. Its armature is in the form of a bent lever, one arm of which has a hammer mounted on it and the other arm of which constitutes the actual armature. The end of the armature is wider, and the pole surfaces of the magnets, which are positioned on each side, are at an angle to each other, which makes the mechanism complicated to assemble. Since the armature is several times larger than any of its magnetically active regions, it operates much more slowly than a simple magnet.
German 3 139 502 C2 discloses a rapid-excitation circuit for printing magnet along with circuitry for intercepting the turn-off current with a buffer capacitor, whereby the temporarily stored capacitor charge flows later, once the magnet has been completely drained of current, through the same coil in the opposite direction, resulting in combination with a permanent magnet in the armature circuit in a recovery action. This design depends in its function on many components and their tolerances.
A matrix printing head with an armature that is turned and milled from a ferromagnetic blank is known from German 2 201 049 B2. Although the ends of the armature are in the same plane, they can be aligned in that plane only by turning and not by lapping because of the presence of an elevated edge with a groove for securing the armature that does not allow further processing. Since the armature rests against the yoke in the center, the width of the interferric gap is dictated by the distance between a cover-support surface and the face of the armature, by the thickness of the stop, and by the thickness of the armature, and accordingly depends on, among other factors, the mutual tolerance to which the face and the supporting surface can be turned.
The object of the invention is a simple and relatively small articulated-armature magnet system for a matrix printing head that will operate rapidly.
SUMMARY OF THE INVENTION
This object is attained in that the recovery mechanism is another articulated-armature magnet with an armature identical with that of the first but with its yoke mounted on the side of the armature that faces away from the first magnet's yoke. Advantageous embodiments are disclosed herein.
To simplify the design and ensure an interferric gap with a narrow tolerance, the spacer is made out of three stamped and sandwiched blanks of sheet metal. Wider cutouts are preferably stamped into the inner blank of the sandwich to accommodate a pivot on the armature. The articulated armature magnets are mounted in a practical way on a base plate with recesses, and the windings are then slid over them and soldered in place. The light-metal structures are drilled out to accommodate the coils and the base plate. The casting compound is introduced after the magnets have been installed, and the faces and pole surfaces are jointly ground to provide a defined reference surface for assembling the spacers. The spacers can easily be stamped out of blanks of sheet metal with narrow tolerances. Since all the armatures in one head are jigged together into one set and ground before the pivots are inserted, there is only one grinding process, specifically the one that relates to all the interferric-gap widths that dictate the thickness of the armature, which accordingly exhibit practically no difference.
When all the armatures are ground in the same process, it is an advantage to radially taper the pole surfaces of the armatures in relation to the pivots to ensure flat surface-to-surface contact not only at the pole surfaces but also at the surfaces of the stops in order to increase the attenuation and minimize the residual gap. Since the face of the stop that faces the armature is also ground, the interferric gap and hence the stroke traveled by the armature will be dictated by the thickness of the spacer or by the overall thickness of the blanks that comprise it minus the thickness of the armature. This ensures that the flights traveled by the armatures until the pins strike the paper will all be of equal duration, which results in characters that will be precisely up to standard because the site of pin impact will be subject to practically no displacement on the paper in relation to the position that they should occupy with respect to the direction that the head moves in at normal printing speed. The importance of this chronological printing precision increases with the speed of character sequence and to allow a printing-head advance rate of 200 characters per second in a rapid-writing head, which corresponds to an advance of 50 cm/sec. The precise flight of the pins over time and the resulting satisfactory printing quality at a high character speed entails the advantage of high-resolution characters with 24 or 36 pins for example at near letter quality and high speed with a corresponding number of armatures and pins. It is also possible and to advantage to position an additional spring at the recuperation end of the armature to supplement recuperation and braking.
The high-speed printout attainable with the narrow interferric-gap tolerances and with the armature being recuperated with a spring can be accelerated by associating an armature-return mechanism in the form of an electromagnet instead of a spring with each attraction magnet in an articulated armature. The operating magnet must be able to move only the armature and the pin when no current is flowing through the armature-return magnet and to apply sufficient impact energy dot printing. Since the armature-return magnet does not need to be tensioned, an approximately 30% higher printing speed can be attained with the same size components and the same operating conditions.
The armature-return magnets are preferably positioned mirror-inverted in relation to the attraction magnets and they are correspondingly simple to manufacture. When they are inactivated, the pole surfaces of the armature-return magnets act as a stop for the armature. Since less power is needed for return of the armatures because the impact energy of the pins that is not consumed during the printing process causes the pins to rebound, the armature-return magnet can have shorter legs and smaller coils. Since, because the residual gap is very narrow, only a relatively slight number of ampere turns, approximately 2% of the number of turns around the armature-attraction magnets, is necessary to retain the returned armature, the losses that occur in the windings during retention and that are known to depend on the square of the number of ampere turns, will be only about 0.5 per mil.
It is also possible and to advantage to associate a spring or a permanent magnet with the driving or return end of the armature in order to augment activation or return and retention. The non-linear pole-force characteristic of an armature-return magnet can be completely exploited without special expenditure if the pole surfaces of the permanent magnet are processed along with those of the electromagnet during the grinding process, ensuring flat surface contact on the part of the armature. Powerful shearing on the part of the force of the permanent magnet as a result of a wide interferric gap left at the rear in relation to the reflux yoke and created by the armature-return magnet, prevents any noticeable effects on the magnetic force due to fluctuations in temperature.
The armature can be advantageously mounted practically without tension or torsion in relation to the poles of the magnet and to the pins if the pins and/or pivots are welded to the armature in situ, preferably with a laser beam or electron beam. To center the armature precisely in the magnetic field, the electromagnets are advantageously excited with a pulsed current before welding and subjected to a continuous current during welding.
The drawings illustrate advantageous embodiments, wherein:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a magnified section through a matrix head with armature-return magnets,
FIG. 2 illustrates a circuit for controlling an attraction magnet and a return magnet,
FIG. 3 is a section of a spacer and bearing block,
FIG. 4 is a section of a spacer made out of sheet metal, and
FIG. 5 is a top view of an armature at the same scale as FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a section, magnified approximately five times and extending radially out from a midline M, through a matrix printing head with a light-metal structure 1 into which is cast an attraction-magnet yoke 3, on which is mounted a winding 4. Attraction-magnet yoke 3 is accommodated in a recess in a base plate 2. Base plate 2, which accommodates all the attraction magnets along with their windings 4 and electric connections, is secured in a bore 12 in the center of light-metal structure 1. Segmental recesses 42 in light-metal structure 1 are filled with casting compound that dissipates the heat from magnet windings 4. Satisfactory heat dissipation is promoted by cooling fins 17 on the outer surface of light-metal structure 1, and the webs between the magnets also dissipate heat. A casting compound with high heat conductivity is employed, with particles of metal as a filler for example. The face S1 of light-metal structure 1 and the pole surfaces S2 of attraction-magnet yokes 3 are ground in common. Mounted on face S1 is a spacer, including spacers 70, 71 and 71A, in which is articulated an armature 5 surrounded by a lubricant. Secured to the end of armature 5 that extends toward the center of the head is a matrix pin 51. Pins 51 slide back and forth toward an unillustrated printing die in web-shaped channels 61. Pin channels 61 are accommodated in a known way in a housing 6 that is secured by means of screws 62 in cylindrical grooves 18 in light-metal structure 1.
The swing of armature 5 is limited by its impact surfaces, which are ground even with the supporting surface S1A of the armature stop of spacer 71A, 70 and 71. An interferric gap SP for the articulated-armature magnets accordingly derives from the difference between the overall thickness D of the spacer and the thickness of the armature.
An armature-returning mechanism in the form of a return electromagnet 3A and 4A engages armature 5. A compression spring 15 and/or a permanent magnet 15M can also be accommodated in cylindrical openings in metal structure 1 and 1A. Armature-return electromagnets 3A and 4A are positioned symmetrical with respect to armature 5 and mirror-inverted with respect to armature-attraction magnets 3 and 4 and are also secured in a base plate 2A and cast into a light-metal structure IA. The pole surfaces of armature-return magnets 3A constitute armature-stop surfaces S2A. Base plates 2 and 2A are sealed off on the outside by cover plates 41 and 41A.
FIG. 2 illustrates circuitry for controlling the windings of an armature-attraction magnet 4 and of an armature-return magnet 4A. Operating voltage U is supplied to a variable source IQ of current I that in a practical way contains pulse-pause controls PP and an idling circuit FD. Its output terminal can be switched back and forth by way of controllable switches RS and AS to the winding 4A of the armature-returning mechanism or the winding 4 of the activating magnet. Central printing controls ZS emit an activating signal A to switch AS for a prescribed activating time for each point printed, depending on the desired impact strength and on the particular type of paper being printed. Printing controls ZS simultaneously dictate the current intensity of source IQ with a current-intensity control signal or signals IS. An appropriate poled signal R simultaneously opens switch RS and drains the current from armature-return and retention magnet 4A. At the expiration of the activation period, more or less when the pin strikes the paper, control signal A is turned off and signal R turns on the current to the armature-return magnet. It is of advantage for the current to be more or less as intense during the armature-return period as it is during the propulsion period in order to generate more or less the same initial magnetic-field strength in the interferric gap and rapidly reverse the direction that the armature travels in. The result is an essentially lower current intensity due to a change in current-intensity control signals IS, so that, when the armature reaches the stop, it will not rebound but will remain in position and the pin can be activated again either immediately or at any prescribed time with no waiting period.
In one advantageous embodiment of the circuit, the energy from a coil 4 or 4A that has just been disengaged is transferred to the coil that has just been activated at the same instant and that activates the same armature, essentially accelerating the buildup and breakdown of current. The current is allowed to travel from one winding 4 to the other 4A by means of transfer diodes D3 and D4 that constitute a series circuit at alternating ends of the windings, with blocking diodes D1 and D2 disengaging them at opposite ends.
To activate the armature as rapidly as possible and to ensure extensive independence from the saturation property of the magnetic material and especially from its temperature dependence, it is recommended that the ampere turn correspond to approximately 70% of the saturation magnetization of the armature during the attraction phase. Limiting the saturation will also maintain crosstalk from one magnet to another within acceptable limits. In one energy-saving embodiment the ampere turn during the armature-return phase is in a practical way 1/3 of what it is during the attraction phase. The ampere turn is accordingly decreased to a maintenance ampere turn of approximately 2% of the attraction-phase ampere turn.
An especially rapid resetting of the armature between the two magnets that act on it alternately can be attained when the magnetic fields of both magnets extend rectified through the armature as the result of appropriate polarization of the windings. No switchover-turbulence losses or field-establishment delays will accordingly occur in the armature.
An advantageously energy-saving way of supplying current to armature-return magnets 3A and 4A can be attained by exploiting the rebound energy of matrix pins 51 and armature 5 in that, once the attraction-phase current has been discontinued, which occurs more or less when the pin impacts, there will be a delay during which no current is supplied that lasts until the armature is completely reversed, 10 to 20 microseconds for example, only subsequent to which is current supplied to armature-return magnets 3A and 4A at 1/3 to 1/10 the attraction-phase ampere turn until armature 5 arrives at the stop and releases its rebound energy in that position, which in that position, which requires approximately 2/3 to all of the attraction-phase period. The current intensity is then reduced to the maintenance current intensity of approximately 2% of the attraction-phase current intensity. The aforesaid operating ranges relate to the printing of up to five exploitations and of more than five exploitations. Prescription of the appropriate values independent of application is assumed. It is preferable to vary the prescribed values in such a way that they can be switched between two operating situations. When there are more than five exploitations, the maximum attraction-phase ampere turn is employed and, when there are less than five exploitations, the attraction-phase ampere turn is decreased to 3/4 of the maximum.
One advantageous embodiment of a spacer is illustrated in FIG. 3 and 4. FIG. 3 illustrates part of a blank stamped out of thin metal that acts in the capacity of an inner sheet-metal mounting blank 70 and has inwardly segmental cutouts 75 for accommodating the armatures. Segmental cutouts 75 have laterally wider bearing chambers 76 that accommodate the pivots 52 illustrated in FIG. 5. Positioning noses 77 on each side of the vicinity of bearing chambers 76 guide the armatures laterally. Orientation holes 74 make it possible to bolt this component to the other blanks of sheet metal and to the light-metal structure.
FIG. 4 illustrates part of the other sheet-metal spacers 71 that demarcate the position of the pivots on each side of the inner sheet-metal blank, creating extensively closed bearing chambers that are in a practical way filled with permanent lubricant. Segments 72 that allow the armatures to move freely are stamped out of the sheet metal, which also has holes 73 for orienting and bolting.
FIG. 5 is a top view of an armature 5 sandwiched together from stamped-out blanks 53 and 53M of sheet metal. Inner blank 53M extends to whatever pin-attachment length is most practical, and a matrix pin 51 is welded to its face. Welded into a groove 54 at the opposite end is a pivot 52 in groove 54 in section. The thickness of pivot 52 equals that of the inner blank of sheet metal to close tolerance.
A wedge-shaped armature that tapers in accordance with the angle at which it pivots can also be employed to optimal effect instead of an armature that is uniformly thick in the vicinity of the poles.
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An electromagnetic drive mechanism for a pin in a matrix printing head has a first magnet with an articulated armature, wherein a free end of the armature acts on the pin and can be returned to a disengaaged position by a recovery mechanism. The recovery mechanism comprises another articulated-armature magnet with an armature identical with that of the first magnet but with a yoke mounted on a side of the armature that faces away from a yoke of the first magnet.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to communications systems for use in oilfield applications and more particularly to an apparatus and method for transmitting acoustic signals between a surface location and a downhole location in a well.
2. Description of the Related Art
The control of oil and gas production wells constitutes an on-going concern of the petroleum industry due, in part, to the enormous monetary expense involved as well as the risks associated with environmental and safety issues.
One type of conventional production system utilizes electrical submersible pumps (ESP) for pumping fluids from downhole. In addition, there are two other general types of productions systems for oil and gas wells, namely plunger lift and gas lift. Plunger lift production systems include the use of a small cylindrical plunger which travels through tubing extending from a location adjacent the producing formation down in the borehole to surface equipment located at the open end of the borehole. In general, fluids that collect in the borehole and inhibit the flow of fluids out of the formation and into the well borehole are collected in the tubing. Periodically, the end of the tubing is opened at the surface and the accumulated reservoir pressure is sufficient to force the plunger up the tubing. The plunger carries with it to the surface a load of accumulated fluids that are ejected out the top of the well thereby allowing gas to flow more freely from the formation into the borehole to be delivered to a distribution system at the surface. After the flow of gas has again become restricted due to the further accumulation of fluids downhole, a valve in the tubing at the surface of the well is closed so that the plunger then falls back down the tubing and is ready to lift another load of fluids to the surface upon the reopening of the valve.
A gas lift production system includes a valve system for controlling the injection of pressurized gas from a source external to the well, such as another gas well or a compressor, into the borehole. The increased pressure from the injected gas forces accumulated formation fluids up a central tubing extending along the borehole to remove the fluids and restore the free flow of gas and/or oil from the formation into the well. In wells where liquid fall back is a problem during gas lift, plunger lift may be combined with gas lift to improve efficiency.
In both plunger lift and gas lift production systems, there is a requirement for the periodic operation of a motor valve at the surface of the wellhead to control either the flow of fluids from the well or the flow of injection gas into the well to assist in the production of gas and liquids from the well. These motor valves are conventionally controlled by timing mechanisms and are programmed in accordance with principles of reservoir engineering which determine the length of time that a well should be either “shut in” and restricted from the flowing of gas or liquids to the surface and the time the well should be “opened” to freely produce. Generally, the criterion used for operation of the motor valve is strictly one of the elapse of a preselected time period. In most cases, measured well parameters, such as pressure, temperature, etc. are used only to override the timing cycle in special conditions.
It will be appreciated that relatively simple, timed intermittent operation of motor valves and the like is often not adequate to control either outflow from the well or gas injection to the well so as to enhance well production. As a consequence, sophisticated computerized controllers have been positioned at the surface of production wells for control of downhole devices such as the motor valves.
In addition, such computerized controllers have been used to control other downhole devices such as hydro-mechanical safety valves. These typically microprocessor based controllers are also used for zone control within a well and, for example, can be used to actuate sliding sleeves or packers by the transmission of a surface command to downhole microprocessor controllers and/or electromechanical control devices.
In recent years, production well control systems have evolved to include complex communication requirements for controlling downhole tools such as various pumps and valves. Many control systems utilize information gathered by downhole sensors and transmitted uphole for determining proper valve and pump control settings. The control settings are transmitted then downhole to control the downhole devices.
Telemetry between the surface controllers and downhole sensors and devices is accomplished using a two-way telemetry system. A two-way system is generally required so that information from the sensors such as pressure, temperature and flow can be sent to the surface for use by the controllers. This data is then processed at the surface by the computerized control system. Electrically submersible pumps use pressure and temperature readings received at the surface from downhole sensors to change the speed of the pump in the borehole.
A signal transmitted to the surface from deep within the well requires sufficient power to ensure a signal-to-noise (S/N) ratio capable or providing useful decoding at the surface. The conventional two-way telemetry system suffers in that sufficient power supplies generally require a relatively large volume. Thus requiring complex and/or expensive downhole power supply designs. Therefore a need exists for a two-way telemetry system that provides good S/N ratio and relatively low downhole power requirements.
SUMMARY OF THE INVENTION
The present invention addresses one or more of the above-identified problems found in conventional well communications systems by providing a semi-passive two way communications apparatus and method sending an acoustic signal using controlled reflected acoustic energy.
One aspect of the invention is an apparatus for transmitting an acoustic signal between a well borehole first location and a second location comprising a signal generator located at the first location for generating an acoustic source signal. A transmitting medium is operatively associated with the signal generator for carrying the acoustic source signal to the second location. A controllable signal reflector disposed at the second location is used to reflect at least a portion of the source signal, the reflected signal being indicative of a parameter of interest. And a receiver is disposed at the first location for receiving the reflected signal.
The transmitting medium may be fluid in a pipe, fluid between the pipe and borehole wall, the pipe itself or even the earth. A signal generator and receiver are selected according to the desired transmitting medium.
The signal generator might be a fluid pump adapted to transmit acoustic energy into the fluid, or the generator might be a device for transmitting acoustic energy into the pipe or the earth.
The receiver might include a hydrophone, a geophone or an accelerometer depending upon the transmitting medium selected.
The reflected signal may be a bi-level echo signal representing a string of binary states or the reflected signal may be a multi-level echo signal.
Another aspect of the present invention is a method for transmitting an acoustic signal between a well borehole first location and a second location comprising generating a source signal from the first location using signal generator. The method includes carrying the source signal to the second location along a transmitting medium operatively associated with the signal generator and reflecting at least a portion of the source signal with a controllable signal reflector disposed at the second location, the reflected signal being indicative of a parameter of interest. The method also includes detecting the reflected signal at the first location with a receiver disposed at the first location for receiving the reflected signal.
BRIEF DESCRIPTION OF THE DRAWINGS
For detailed understanding of the present invention, references should be made to the following detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings, in which like elements have been given like numerals and wherein:
FIG. 1 is an elevation view of a production well system having a communication apparatus according to the present invention;
FIG. 2 is a schematic representation of a communications method according to the present invention;
FIGS. 3A-C are plots showing characteristics of various reflection signals;
FIGS. 4A-B are alternative embodiments of controllable acoustic reflectors according to the present invention;
FIG. 5 is a partial elevation view of the system of FIG. 1 showing alternative placements of surface elements of the present invention; and
FIG. 6 is and alternative MWD embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
An embodiment of a production well telemetry system according to the present invention is shown in FIG. 1 . The production well system 100 includes a production pipe 102 disposed in a well borehole 104 . At the surface a conventional wellhead 106 directs produced fluids through a flow line 108 . A control valve 110 and a regulator 112 coupled to the flow line 108 are used to control fluid flow to a separator 114 . The separator 114 separates the produced fluid into its component parts of gas 116 and oil 118 .
Various downhole controllable devices such as hydro-mechanical safety valves 122 , and sliding sleeves or packers 124 are used for zone control within the well. These devices are preferably operated by downhole microprocessor based controllers 126 or directly controlled by a surface controller 128 . The surface controller 128 is used to transmit, for example, a command to the downhole microprocessor controllers 126 and/or the various electromechanical control devices 122 and 124 .
The surface controller 128 includes a source signal generator 130 to generate an acoustic source signal comprising a series of acoustic energy pulses. The source signal is transmitted to the downhole devices via the fluid in the annulus between the production pipe and borehole wall or via a fluid line 132 the fluid within the production pipe 102 .
A low power signal reflector device 134 such as a controllable diaphragm or a variable volume Helmholz resonator is used to reflect a portion of the source signal as an encoded message containing the parameters measured downhole and/or commands from the downhole microprocessor 126 .
The measured parameters originate at downhole sensors 120 coupled to the production pipe 102 to sense parameters such as pressure, temperature, and flow rate, etc. for use in determining automatically control settings for the downhole controllable devices 122 and 124 .
An acoustic sensor 136 is located at a selected location, preferably at the surface near or on the wellhead 106 . In a preferred embodiment, the sensor 136 is a hydrophone receiver coupled to the wellhead 106 and adapted to detect acoustic energy in the production pipe fluid or annulus fluid. Those skilled in the art would appreciate, however, that other sensors would be useful in detecting acoustic energy as well. For example, accelerometer-type sensors and geophones may also be used as a surface receiver, when the transmission medium is the production pipe or the earth as will be discussed later.
The hydrophone 136 will produce an output indicative of the echo signal sensed. The output of the hydrophone is thus coupled to the surface controller such that the sensed signal is decoded and used by the surface controller to determine and set well control settings. The hydrophone is preferably coupled to the controller via an electrically conductive wire, but the coupling may be any suitable known method of data coupling, such as radio frequency (RF) or inductive coupling.
FIG. 2 is a schematic representation of a signal transmitting method 200 used in the system of FIG. 1 . Shown is a source signal 202 transmitted to a downhole location via the fluid 204 in a production pipe 206 . A downhole control unit 210 controls a downhole controllable reflector 208 to reflect a portion of the source signal 202 as an encoded message intended for transmission to the surface as an echo signal 212 . The echo signal 212 is sensed at the surface with a suitable receiver 214 and then decoded using the surface controller described above and shown in FIG. 1 .
FIG. 3A is an experimentally derived plot 300 of reflected signal amplitude 302 with respect to time 304 . Tests have shown that a reflected signal is adequately distinguishable over background noise in a production well environment over several reflection cycles. A series of reflection pulses 306 a-d are generated by reflecting a source signal as described above and shown in FIG. 2 . Although each successive reflection pulse exhibits a loss in amplitude, tests have shown as many as eight distinguishable reflection signals resulting from a single source signal pulse reflected at a depth of 8000 feet. This characteristic us used according to the present invention to transmit bi-level or multi-level acoustic signals as will now be described.
FIG. 3B is an exemplary plot 320 showing bi-level signal transmission. A bi-level signal comprises approximately two amplitude states 322 a-b of predetermined duration representing binary states of 0 and 1. This transmission method is easily conducted using a two-position diaphragm reflector or a Helmholz volume including a two-position internal volume control device such as a controllable plate or flapper valve. Using either of the diaphragm or controllable volume Helmholz resonator, one position or volume provides a large reflected portion of the source signal, while the second position or volume provides relatively little reflection of the source signal. These two distinct reflections represent binary states of “1” and “0”, respectively. Message signals can thus be sent in serial fashion by simply controlling the position of the signal reflector.
As discussed above with respect to FIG. 2, the source signal is a series of pulses at a predetermined frequency. Consequently, any reflected signal will likewise be a multi-pulse signal at the predetermined frequency. The reflected signal, however, might be phase shifted.
Referring back to FIG. 1, the surface receiver 136 detects the reflected signal and transmits the signal to the surface controller 128 . The received signal is decoded using a counter (not separately shown) in the controller to count reflected signal pulses or by determining the time during which a reflection remains at one of the two states. For example, a binary string such as 1010 will be encoded by the downhole reflector such that a series of large echo pulses are alternated with a series of lower amplitude echo pulses as shown in FIG. 2 .
FIG. 3C is a plot 330 illustrating multi-level transmitting. Multi-level transmitting is conducted by using a downhole reflector according to the present invention for reflecting the source signal to provide a reflected signal comprising multiple amplitude states 332 -e. For example, a reflector controllably positioned to one of five different states may transmit signal states of 0 , 1 , 2 , 3 , and 4 . These several states may be used to transmit multiple messages thereby increasing channel capability e.g. the number of sensor output data handling capability. This provides increased capacity for data telemetry. One skilled in the art would appreciate the fact that controlling signal duration 334 at any particular level as shown in FIG. 3 or at any particular state as shown in FIG. 3B is accomplished by control of the reflector position.
FIGS. 4A and 4B are alternative embodiments for the downhole reflector of FIGS. 1 and 2. FIG. 4A is a controllable diaphragm 400 , which as shown, may utilize independently controlled pistons 402 , 404 . Each piston is controllable to assume a number of positions. In one embodiment, the pistons 402 and 404 each include a corresponding diaphragm element 406 and 408 . Each diaphragm element 406 and 408 is a hydraulic-controlled fin-shaped member coupled to the piston and operated by a source pump (not shown) via hydraulic lines 410 and 412 . The hydraulic lines 410 and 412 are preferably integral to the tool body 414 . The fins 406 and 408 are thus controllable to one of two or more positions to effect the desired reflection characteristic. The source signal will be reflected, and at each fin position, the reflected signal will have distinguishable characteristics such as the amplitude of the signal. The length of time the fin is maintained in a particular position will determine the duration of a reflected signal.
FIG. 4B is an alternative embodiment of a reflector 420 according to the present invention. The downhole reflector 420 includes a tool body 422 having an integral resonator 424 . The resonator 424 is, for example, a Helmholz resonator by which reflected signal amplitude and duration are controlled by controlling the volume of the resonator 424 .
FIG. 4B shown one embodiment of such a resonator having a two-position flap 426 . The flap 426 is mounted to the body 422 on a controllable pivot 428 that allows the flap 426 to be controlled to at least two positions 426 a and 426 b . A downhole controller and a stepper motor or solenoid (not shown) are used to control position of the flap 426 . The controller moves the flap 426 to a desired position in response to a downhole sensor output.
One position 426 a of the flap 426 results in little or no reflection of a source signal. A second position 426 b of the flap 426 results in a substantial reflection of the source signal. Thus a binary string message is easily created that is passively transmitted to the surface as an echo signal by control of the flapper 426 .
FIG. 5 shows alternative embodiments of the present invention with several locations for the surface receiver 136 a-b and source signal generator 130 a-b described above. As discussed above, the fluid in the annulus 502 may used as the transmission medium in these several embodiments of the present invention. The source generator 130 a may be positioned at the surface to transmit the source signal or the source generator 130 b may be position within the borehole 504 .
In one embodiment the receiver 136 a is located at a suitable surface location to detect a reflected signal from the main well borehole 504 . In another embodiment the receiver 136 b is located at a surface location to sense a reflected signal using a sensing borehole 506 . The sensing borehole 506 is a small borehole drilled to meet the main borehole 504 at a suitable point downhole of all surface equipment associated with the main well operations. In this manner, noise typically generated by such surface equipment is substantially removed from the received echo signal at the sensor 136 b.
The signal-transmitting medium in an alternative embodiment is not necessarily limited to using the fluid as described above. For example, the transmitting medium might be the production pipe or the earth itself. Well know techniques of inducing an acoustic signal into a pipe include the use of magnetostrictive devices, ceramics and mechanical actuators such as solenoids. Well known techniques using acoustic energy sources such as vibrator trucks, explosives and air guns may be used to induce an acoustic source signal in the earth.
In either case, i.e. using the pipe or earth as the transmission medium, a hydrophone is not used as a receiver. Alternative receivers for these applications include geophones and accelerometers.
Downhole signal reflectors for these alternative embodiments include any suitable controllable device for interrupting the source signal path. One possible technique is to control fluid in a fluid reservoir in the pipe. Changing the fluid pressure or volume in such a reservoir will cause a change in the pipe stiffness, thus effecting a controlled reflection or echo according to the present invention.
Another embodiment includes controlling the one or more downhole packers 124 to interrupt the transmission path. This technique according to the present invention might be employed when using either the pipe 104 or earth as the transmission medium.
The description of the present invention provided thus far has focused on embodiments used in a production well system. The invention, however, is useful in other applications. For example, a measurement-while-drilling system could include a two-way borehole communication apparatus according to the present invention. FIG. 6 is one MWD embodiment according to the present invention. FIG. 6 is an elevation view of a drilling system 600 in a measurement-while-drilling (MWD) arrangement according to the present invention. As would be obvious to one skilled in the art, a completion well system would require reconfiguration; however the basic components would be the same as shown. A conventional derrick 602 supports a drill string 604 , which can be a coiled tube or drill pipe. The drill string 604 carries a bottom hole assembly (BHA) 606 and a drill bit 608 at its distal end for drilling a borehole 610 through earth formations.
Drilling operations include pumping drilling fluid or “mud” from a mud pit 622 , and using a circulation system 624 , circulating the mud through an inner bore of the drill string 604 . The mud exits the drill string 604 at the drill bit 608 and returns to the surface through the annular space between the drill string 604 and inner wall of the borehole 610 . The mud drives the drilling motor (when used) and it also provides lubrication to various elements of the drill string.
A sensor 612 and a controllable reflector 614 are positioned on the BHA 606 . The sensor 612 may be any sensor suited to obtain a parameter of interest of the formation, the formation fluid, the drilling fluid or any desired combination or of the drilling operations. Characteristics measured to obtain to desired parameter of interest may include pressure, flow rate, resistivity, dielectric, temperature, optical properties tool azimuth, tool inclination, drill bit rotation, weight on bit, etc. The output of the sensor 612 is sent to and received by a downhole control unit (not shown separately), which is typically housed within the BHA 606 . Alternatively, the control unit may be disposed in any location along the drill string 604 . The controller further comprises a power supply (not shown) that may be a battery or mud-driven generator, a processor for processing the signal received from the sensor 612 . The reflector 614 may be any of the embodiments as described with respect to FIGS. 4A-B, or any other configuration meeting the intent of the present invention.
The downhole controller controls the acoustic reflector 614 to induce in the drill pipe 604 an acoustic wave signal representative of the sensed parameter. The reflected acoustic wave travels through the drill pipe fluid 604 , and is received by an acoustic receiver 616 disposed at a desired location on the drill string 604 , but which is typically at the surface. The receiver 616 , preferably a hydrophone when the transmitting medium is fluid, converts the acoustic wave to an output representative of the wave, thus representative of the measured downhole parameter. The converted output is then transmitted to a surface controller 620 , either by wireless communication or by any conductor suitable for transmitting the output of the receiver 616 . The surface controller 620 further comprises a processor 622 for processing the output using a program and an output device 624 such as a display unit for real-time monitoring by operating personnel, a printer, or a data storage device.
The foregoing description is directed to particular embodiments of the present invention for the purpose of illustration and explanation. It will be apparent, however, to one skilled in the art that many modifications and changes to the embodiment set forth above are possible without departing from the scope and the spirit of the invention. It is intended that the following claims be interpreted to embrace all such modifications and changes.
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The present invention provides a semi-passive two-way borehole communication system and method. The system includes a surface source signal generator for generating an acoustic signal. The acoustic source signal is transmitted downhole, and a downhole controllable reflector reflects a portion of the source signal back toward the surface. The reflector is controlled such that an echo signal is created, which contains information to be carried to the surface. A surface receiver is used to detect the echo signal, and a surface controller is used to decode the echo signal.
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This application is a continuation, of application Ser. No. 566,674, filed Aug. 13, 1990 now abandoned.
BACKGROUND OF THE INVENTION
This invention relates generally to asphaltic roofing covering, and more particularly to a shingle provided with an adhesive component for securing portions of overlapping or underlying shingles thereon and the process specifically adapted to apply such an adhesive component.
In the present state of shingle manufacturing, adhesive is provided at a few points on the underside surface of shingle tab portions. Heat from the environment, more particularly from the sun, activates the adhesive to allow bonding of shingle surfaces. Prior art type shingles provide adhesive in the form of spaced apart rectangular bands, the rectangular designations being an incident of the manner of sealant application.
It is an object of this invention to provide a shingle with an adhesive component which will secure shingle portions to one another and provide improved drainage of entrained rain water and resistance to wind blow-off, and resistance to shingle distortion caused by internal stresses.
It is a further object of the present invention to provide a shingle with an adhesive configuration which will realize increased effective linear coverage of sealant across the width of a shingle using only partial material coverage.
It is another object of the invention to provide a process for applying sealant or adhesive material to a shingle surface whereby geometries of adhesive bands can be maintained.
Another object of the present invention is to provide a roof system comprising shingles having novel adhesive construction.
Other objects and advantages of the present invention will be readily apparent to those skilled in the art from a reading of the following brief description of the drawings, detailed description of the preferred embodiment and the appended claims.
SUMMARY OF THE INVENTION
In accordance with the principles of the present invention, a roofing shingle is provided with a novel adhesive band component. The adhesive bands are located either preferably on the underside surface of shingle tabs or, alternatively on the top surface of shingle butt portions, and provide a means for securing overlapping shingles to each other. The adhesive components of the shingle surface is preferably activated by environmental heating supplied by the sun, so that adhesion of overlapping shingle tab and butt surfaces is accomplished. The adhesive is provided in band configurations wherein at least one band has an angular edge or the equivalent, thereby creating a generally sloped space between adhesive bands. Such configurations provide improved shingle stability and holding properties due to effective improved drainage of entrained rain water and greater resistance to wind blow-off and greater resistance to shingle distortion caused by internal stresses. The adhesive bands may be aligned such that there is a zone of adhesive spanning horizontally across a shingle surface which provides increased effective linear sealant coverage. Wind blow-off is greatly minimized because, especially in the instance of full effective linear coverage, the adhesive acts to provide a barrier to exclude wind and other elements from passing into the space between shingle layers Shingle distortion, such as lifted corners, etc. is also greatly minimized. The invention also related to the process whereby adhesive is applied to a shingle surface in a specific geometrical patterns by utilizing an applicator wheel specifically adapted to handle adhesive surface tensions and viscosities in order to maintain the desired configuration. The shingles provided may be overlapped to form a roof system of superior strength and durability resulting from the operation of the novel adhesive configuration and patterns.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
FIG. 1 is a top plan view of a shingle of this invention.
FIG. 2 is an enlarged fragmentary plan view of an alternative shingle construction.
FIGS. 3 and 4 are enlarged fragmentary plan views of other alternative shingle constructions.
FIG. 5 discloses a roof system comprising shingles of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings in detail, reference is first made to FIG. 1, which illustrates a roofing shingle 1 which is generally constructed from asphalt or other suitable roofing material.
The roofing shingle 1 comprises a butt portion 2 and tab portions 3. Tab portions are separated from one another by intervening slots 4 which are defined by a pair of shingle tab side edges 17 and 18. The slots extend starting at the point of intersection 20 of a shingle tab bottom edge 5 and a shingle tab side edge 17 or 18, and end at a point 6 where the tab portion joins the butt portion, so that the end of the slot is preferably defined by a lower edge 6 of the butt portion.
Shingle butt portions are defined laterally by a pair of side edges 21 and 22, and by the upper edge 23 of the shingle 1 and the upper edge as shown as an imaginary line 14, of the tab portion. Shingle butt portions of successive shingles may be placed laterally adjacent to one another, such that a shingle butt edge 22 of one shingle is in contact with the butt edge 21 of another shingle. Successive shingles may be placed next to each another in a similar manner with butt edges 21 and 22 adjoining other shingle butt edges in the normal practice of making a shingled roof as shown in FIG. 5. The tab portions 3 have side edges 7 of a shingle 1. The side edges 7 will preferably be recessed as shown from the shingle butt edges 21 and 22 such that when the butt edges 21 and 22 of two shingles are in lateral contact with each other, the shingle tab edges 7 will function as one of the shingle tab side edges 17 or 18 to form a slot 4, in conventional manner.
A shingle 1 is provided with a band zone 8 having an area spanning horizontally across the bottom of the shingle tab portions, beneath imaginary line 10. The band zone is located on the underside of the shingle tab portions, as shown in dotted lines in FIG. 1 and comprises adhesive material. Alternatively or additionally, a band zone 12 may be located on the top surface of a shingle butt portion, on the granules thereof, preferably near to the end adjoining the tab portion as represented in FIG. 1 as the area between a pair of imaginary lines 13 and 14.
Adhesive zones 11 are provided on the underside surface of shingle tabs 3 within the band zone 8, as seen in FIG. 1.
The adhesive zones 11 are provided with structural geometries conducive to promoting high performance in the shingle art FIG. 1 shows an arrangement of adhesive zone configurations 11 in band 8 represented by parallelogram shapes having generally angular parallel side edges 27 and 28, separated by a space 26 therebetween. The shingles may be secured to a roof or mounting surface by nailing. Nailing zones located by imaginary lines 24 are provided on the butt portion 2 in the areas above the termination point 6 of the slots 4 defining shingle tabs.
With particular reference to FIG. 2, it will be seen that a shingle 101 is provided, having a butt portion 102 and a plurality of tab portions 103. Above the slots 104 that form the spaces between adjacent tab portions 103, it will be seen that an imaginary line 114 appears, and thereabove, another imaginary line 113, defining therebetween a band 112 having a plurality of adhesive zones 117 on an upper surface of the shingle 101, as shown. In addition thereto, there is provided a band 108 between the lower edge 105 of tab portions and imaginary line 100, as shown, and within which band there are provided a plurality of adhesive zones 111, shown in dotted lines, indicating their presence on the lower surface of the shingle 101. The adhesive zones 111, like those 11 of the embodiment of FIG. 1, are of parallelogram configuration.
The adhesive zones 111 and 117 are each spaced from adjacent zones within their respective bands 108 and 112. It will be seen that the horizontal dimension "X" as measured from one end of a given adhesive zone 111 to the opposite end of that zone 111, together with the similar dimension "X" for the other adhesive zones 111 in the same band, that comprise the band portion of FIG. 2 that is defined by the measurement "L" in the aggregate, are of a dimension at least as great as the dimension "L", and in the embodiment of FIG. 2, are even greater than that dimension "L". The above relationship can be expressed in a formula, such that the aggregate length of the individual zones in a portion of the band relative to the length of the portion of the band is defined as:
ΣX≦L
where Σ X=the aggregate length or sum of the individual lengths of the adhesive zones, each being measured horizontally from their horizontal left-most point to their horizontal right-most point; and where L=the length of the portion of the band of the adhesive zones from the left-most end of a left-most zone in a said band portion to the right end of a right-most zone of said band portion. Thus, along a given band portion such as that designated by the letter "L", there is no location therealong, at which an imaginary line crossing through the band perpendicular to the horizontal band 108, in the plane of the adhesive zones 111, at which such imaginary perpendicular line 121 would not intersect an adhesive zone 111. As can be seen with reference to the adhesive zones 117 in band 112, the same condition is existant. It will also be noted that a strip of release paper or film 109 is present in overlying relation to the adhesive zones 111 of band 108, and that such a strip, if desired, could overly the upper surface of the shingle 101, in the vicinity of the band 112, to likewise protect the adhesive zones 117 during packaging and shipment, but that the same release paper or film 109 would be removed prior to installation of the shingle 101, as is conventional. It will also be understood that, while two bands 108, 112 of adhesive zones 111, 117, are disclosed in the embodiment of FIG. 2, it will be commonplace, and in many instances preferable, that only one such band of adhesive zones is utilized, either at the location of band 108, or at the location of band 112, as desired.
It will also be apparent that various details of shingle construction, such as are embodied in FIG. 1, may also be utilized with respect to FIG. 2, and that the same need not be duplicated herein.
With particular reference now to FIG. 3, it will be seen that another embodiment of a shingle 201 is disclosed, having a butt portion 202 and tab portions 203. The tab portions 203 are separated by slots 204, as set forth above. It will also be understood that beneath an imaginary line 200 in the tab portions 203, there is provided a band 208 of a plurality of adhesive zones 211. The adhesive zones 211 likewise represent an alternative arrangement in which the aggregate dimension defined by the length "X'" for the plurality of adhesive zones 211 within the band portion "L'" are at least as great as, and preferably greater than the dimension "L'" between one end of one zone to the opposite end of another zone in the same band portion when measured horizontally, such that there is no location along that band portion at which an imaginary line 221 could cross through the band in a direction perpendicular to the horizontal band and in the plane of the adhesive zones without intersecting an adhesive zone 211.
With respect to the embodiments of FIGS. 1 and 2, it will be seen that the spaces 26, 115 and 126 between adjacent adhesive zones are non-perpendicular to the horizontal band, and comprise a plurality of parallel sloped openings through the band. With respect to the embodiment of FIG. 3, such openings 226 are generally sloped, given the elliptical configurations of the zones 211. It will be understood that such openings 26, 115, 126, 226, allow for escape of moisture from between overlying shingles of the type illustrated in FIG. 5 , rather than being trapped above the sealing zones indicated. Successive courses of shingles are thus able to breathe, but without allowing any substantial direct invasion of air, wind or the like in a direction perpendicular to the bands 8, 108, 112, 208, etc., and with respect to the embodiments of FIGS. 2 and 3, without allowing any space for direct invasion of the bands 108, 208, by wind or the like, in a direction perpendicular to that of the horizontal bands; namely, in a direction such as that indicated by the arrows 121 or 221.
With reference now to the embodiment of FIG. 4, it will be seen that another alternative shingle design 301 is provided, with butt and tab portions 302, 303, respectively, with a band zone 308 for application of adhesive zones 311 thereto, at the lower end of the tab portions 303. The application of adhesive to the band portion 308 in FIG. 4, is like that in band portion 08 of FIG. 2, except that the acute angles in the parallelogram configurations of adhesive zones 311 on the under side of the tab portions 303 of shingle 301 are significantly more acute than with respect to comparable acute angle portions of the parallelogram configurations 111 of FIG. 2. In some respects, the arrangement of FIG. 4 provides a more preferred embodiment, in that it allows for an even more acutely sloped spacing 326 between adjacent adhesive zones 311 than in FIG. 2, and additionally allows for an aggregate length of the individual zones "X'" in FIG. 4 being even greater than the length "L'" measured horizontally from one end of one zone to an opposite end of another zone in a band portion. Typical of such an acute angle "a" might be 17°, as for example, where the height of the parallelogram is a unit of approximately one, and the length of a base line is a unit of approximately three. It will be understood that the illustration of FIG. 4 is not to scale, but is intended to be representative, only. It will likewise be apparent that various other angular relationships may be used, more greatly or in lesser amounts, acute, and even that other configurations other than parallelogram configurations may be used for the adhesive application.
With reference to FIG. 5, it will be seen that there is illustrated a roof deck comprising a shingled roof of a plurality of shingles of the type discussed above. In FIG. 4 it will be seen that nailing zones 24 are indicated to show how shingles are secured to a roofing surface 45. As aforesaid, the strips 109 or the like which cover the adhesive zones of an adhesive band are removed before application, to allow adhesive in adhesive zones to secure tab and butt portions of a pair of shingles in two successive courses, to adhere to each other to resist wind lift-up and the like.
It will be apparent from the foregoing that while the preferred form of the invention is recited as being that of a shingle, that roof coverings of other types other than shingles may be utilized, such as rolled roofing or the like, in which the same adhesive arrangements as are disclosed herein may be satisfactorily utilized. Furthermore, while shingles in accordance with this invention are recited as having a plurality of tab portions, in the preferred embodiment, it will be understood that a single tab portion may be utilized with a single butt portion, for a given shingle.
It will also be apparent that the precise geometric arrangement of the adhesive zones within any given band of adhesive may vary, such as taking on circular, elliptical, parallelogram, trapezoidal, triangular, configurations or the like, that such variations are within the spirit and scope of the invention as recited in the claims, and are intended to be representative only, in that such adhesive zones may take any number of configurations, provided that they allow a passage for venting of moisture, while at the same time preventing tab lift-up by access to any significant discontinuity in the adhesive zones in an adhesive band.
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A shingle or other roof covering is provided, comprising a tab portion and a butt portion. The shingle surface is provided with a band zone, in which adhesive zones are applied. The band zones run the entire width of a shingle, and are preferably located either on the underside surface of the tab portions, or on the top surface of butt portions The adhesive pattern is so that shingle lifting due to wind is resisted, but so that moisture can escape between overlapped shingles when the adhesive secures them together.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a CMOS bandgap voltage reference and, more particularly, to a CMOS bandgap voltage reference which utilizes cascoded MOS devices to provide increased temperature stability of the bandgap voltage reference.
2. Description of the Prior Art
The bandgap voltage reference, since introduced by Widlar, has become widely used as a means for providing a reference voltage in bipolar integrated circuits. In general, the bandgap reference relies on the principle that the base to emitter voltage, V BE , of a bipolar transistor will exhibit a negative temperature coefficient, while the difference of base to emitter voltages, ΔV BE , of two bipolar transistors will exhibit a positive temperature coefficient. Therefore, a circuit capable of summing these two voltages will provide a relatively temperature independent voltage reference. One such circuit arrangement is disclosed in U.S. Pat. No. 4,429,122 issued to R. J. Widlar on Feb. 3, 1981. In CMOS technology, the basic Widlar arrangement may be directly applied, since bipolar devices may be created using standard CMOS processes. However, the bipolar devices available in CMOS are not as stable as those directly developed in bipolar technology, and additional control requirements are needed to provide a relatively temperature stable bandgap reference. U.S. Pat. No. 4,287,439 issued to H. Leuschner on Sept. 1, 1981, discloses one exemplary CMOS bandgap arrangement. Here, the circuit utilizes two substrate bipolar transistors with the emitter of one being larger than the other. The transistors are connected in an emitter follower arrangement with resistors in their respective emitter circuits from which a voltage is obtained to generator the bandgap reference. A later arrangement, disclosed in U.S. Pat. No. 4,380,706 issued to R. S. Wrathall on Apr. 19, 1983, relates to an improvement of on the Leuschner circuit wherein an additional transistor is inserted between the output of the amplifying stage and the substrate bipolar transistors to provide an output voltage of twice the bandgap voltage.
There exist many factors which affect the performance of these and other CMOS bandgap references. One factor not addressed by these prior art arrangements is the temperature dependence of the resistors used in association with the substrate bipolar transistors to provide the needed ratio between the emitter currents. Therefore, true temperature stability cannot be achieved without addressing this problem. One solution is disclosed in U.S. Pat. No. 4,375,595 issued R. W. Ulmer et al on Mar. 1, 1983. In the Ulmer et al arrangement, switch capacitors are used at the inputs associated with V BE and Δ VBE to sample both voltages. Proper selection of the capacitor ratio provides a weighted sum of both voltages to the amplifier inputs which will be substantially independent of temperature. This particular solution to the resistance-related temperature coefficient problem, however, requires an external clock source and relies on the proper selection of the capacitor values used. The need remains, therefore, for a CMOS bandgap reference which provides increased temperature stability in relation to the resistor-based temperature coefficient which is relatively easy to implement and does not require external circuitry.
SUMMARY OF THE INVENTION
The problem remaining in the prior art has been solved in accordance with the present invention which relates to a CMOS bandgap voltage reference and, more particularly, to a CMOS bandgap reference which utilizes cascoded MOS devices to provide increased temperature stability of the bandgap reference as related to the temperature coefficient of the resistors used in the reference circuit.
It is an aspect of the present invention to utilize cascoded MOS devices disposed between the substrate bipolar resistors and a power supply to such augment the value of the bandgap current to a level where only relatively small resistors are needed to provide the desired bandgap voltage level. Since p+ diffusion resistors have a better temperature coefficient than the larger P tub resistors, the associated temperature stability is significantly reduced over prior art arrangements.
Another aspect of the present invention is to provide a constant current source at a minimal increase (the addition of one MOS transistor) in circuit complexity.
A further aspect of the present invention relates to providing a bandgap reference which can operate at lower supply voltages by correctly sizing the transistors used to form the cascode arrangement.
Other and further aspects of the present invention will become apparent during the course of the following discussion and by reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring now to the drawings, where like numerals represent like parts in several views:
FIG. 1 illustrates a basic prior art CMOS bandgap voltage reference;
FIG. 2 illustrates an exemplary CMOS bandgap voltage reference formed in accordance with the present invention; and
FIG. 3 illustrates an alternative CMOS bandgap voltage reference formed in accordance with the present invention which can operate at lower supply voltages than the arrangement illustrated in FIG. 2.
DETAILED DESCRIPTION
Bandgap voltage references are frequently used in many integrated circuits. As CMOS technology becomes more and more prevalent, the need for a bandgap reference which can be formed using CMOS processes has become essential. A exemplary prior art CMOS bandgap reference 10 is illustrated in FIG. 1. A pair of bipolar transistors 12 and 14 are npn substrate transistors, where both collectors are coupled together and connected to a first power supply, denoted VDD in FIG. 1. In formation, the n-type substrate itself is defined as the collector regions, a p-type well formed in the substrate defines the base regions of transistors 12 and 14, and n-type diffusions in the p-type well form the emitters of transistors 12 and 14. It is to be noted that transistors 12 and 14 could also be pnp transistors, which would thus utilize a p-type substrate and diffusions and an n-type well. A complete description of this formation process can be found in the article "Precision Curvature-Compensated CMOS Bandgap Reference", by B. Song et al appearing in IEEE Journal of Solid-State Circuits, Vol. SC-18, No. 6, December 1983 at pp. 634-43. The base to emitter voltage of transistor 12, denoted V BE12 , is applied as a first, positive input to an operational amplifier 16. The detailed internal structure of operational amplifier 16 has not been shown for the sake of simplicity, since there exist many different CMOS circuits capable of performing the difference function of operational amplifier 16. A resistor 18 is connected between the emitter of transistor 12 and the output of operational amplifier 16. A resistor divider network comprising a pair of resistors 20 and 22 is connected between the emitter of transistor 14 and the output of amplifier 16, where the interconnection of resistors 20 and 22 is applied as a second, negative input to operational amplifier 16, as shown in FIG. 1. The bandgap voltage reference, V BG , measured across the terminals as shown, can be represented by the equation ##EQU1## where V T is the thermal voltage kT/q, I s12 is the saturation current of transistor 12 and I s14 is the saturation current of transistor 14. In order to provide a temperature coefficient which will be substantially equal to zero, large-valued resistors (on the order of 100k) are needed to keep the bandgap current (I 12 +I 14 ) at a reasonable level while still providing a substantially zero temperature coefficient. In MOS technology, the actual p-type tub is used to form resistors of such large magnitude, where a problem with this lies in the fact that p-tub resistors are well known in the art to exhibit a very large temperature coefficient. Therefore, the temperature coefficient of p-tub resistors 18, 20, and 22 will significantly degrade the temperature coefficient of bandgap voltage reference 10.
FIG. 2 illustrates a cascode bandgap voltage reference 30 formed in accordance with the present invention which overcome the problem related to the temperature coefficient of the p-tub resistors. As shown, resistors 18 and 20 of FIG. 1 are replaced with resistors 32 and 34, respectively, where resistors 32 and 34 are on the order of 15-20k, instead of 100k as was the case for the prior art arrangement. Therefore, resistors 32 and 34 may be formed from small p+ diffusions, which due to their decreased resistivity, exhibit a temperature coefficient which is significantly less than that associated with p-tub resistors. To compensate for the decreased resistor size, the present invention utilizes a cascode MOS circuit 36 connected as shown in FIG. 2, where the individual transistors forming circuit 36 are sized to provide the required level for the bandgap voltage. In particular, circuit 36 includes a pair of MOS transistors 40 and 42 connected in series between resistor 32 and VSS, where the drain of transistor 40 is connected to resistor 32, the source of transistor 40 is connected to the drain of transistor 42, and the gate of transistor 40 is coupled to the output of operational amplifier 16. The gate of transistor 42 is coupled to its drain, and the source of transistor 42 is connected to VSS. Circuit 36 further includes a pair of MOS transistors 44 and 46 connected in a like manner between resistor 34 and VSS, where the gate of transistor 44 is connected to the gate of transistor 40 and the gate of transistor 46 is connected to the gate of transistor 42. As shown in FIG. 2, transistors 44 and 46 are formed to have a width-to-length (Z/L) ratio n times greater than that of transistors 40 and 42. As shown below, the n factor provides the compensation for the decrease in resistor size as compared with prior art arrangements. In particular, the bandgap voltage, V BG , of circuit 30 can be defined by the following equation ##EQU2## Comparing equations (1) and (2), it can be seen that utilizing a bandgap reference circuit formed in accordance with the present invention results in substituting the factor n(R 34 /R 32 ) the prior art factor R 22 /R 20 . Therefore, if, n=10, the value of the needed resistors may be decreased from approximately 100K to approximately 10K, thus allowing low temperature coefficient p+ diffusion resistors to be utilized in place of high temperature coefficient p-tub resistors.
An added advantage of utilizing the cascode MOS arrangement of the present invention is that a constant current source may also be realized from merely adding one additional transistor to the above-described circuit. As shown in FIG. 2, an MOS transistor 50 may be included where the gate of transistor 50 is connected to the gates of transistors 42 and 46, and the source of transistor 50 is connected to VSS. Transistor 50, as shown, comprises a Z/L ratio m times larger than transistors 40 and 42. The current flowing through transistor 50, denoted I BIAS , is defined by the following expression ##EQU3## An additional advantage of the present invention arises from the fact that the output of operational amplifier 16 does not have to sink the bandgap current, as does the prior art arrangement of FIG. 1. Instead, the output of operational amplifier 16, as stated above is coupled to cascode circuit 36 at the gate terminals of transistors 40 and 44.
The minimum range between supply voltages VDD and VSS for the circuit of FIG. 2 can be expressed as
(VDD-VSS).sub.min =V.sub.BG +V.sub.TH(n) +2V.sub.ON, (4)
where V TH (n) is defined as the threshold voltage for transistors 44 and 46 and V ON is also associated with transistors 44 and 46. In order to operate at lower supply voltages, a ratioed cascode current mirror, included in the circuit illustrated in FIG. 3, may be utilized to eliminate the V TH (n) term from equation (3). As shown, a current mirror formed from a pair of MOS transistors 62 and 64 supply a like current I' to the drain terminals of a pair of transistors 66 and 68, respectively. Transistor 66 is connected between transistor 62 and VSS, where the gate of transistor 66 is connected to the gates of transistors 42 and 46. The gate to source voltage, V GS , of transistor is equal to the quantity V TH (n) +V ON . In order to eliminate the V TH (n) component, transistor 68, as shown in FIG. 3, is chosen to comprise a Z/L ratio which is one-fourth that of transistors 40 and 42. Therefore, it follows that V GS of transistor 68 is equal to the quantity V TH (n) +2V ON . Since the drain to source voltage, V DS , for both transistors 44 and 46 has been altered to equal V ON , the minimum voltage difference between VDD and VSS can be expressed as ##EQU4##
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A CMOS bandgap voltage reference which is temperature stable is disclosed. The large temperature-dependent p-tub resistors of prior art arrangements are replaced with relatively small, temperature stable p+ diffusion resistors. The increase in current level needed to compensate for the decrease in resistor value is provided by a simple cascode MOS circuit located between the ratioing resistors and the VSS potential.
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RELATED PATENTS AND APPLICATIONS
U.S. Patent Documents
6,355,865
March 2002
Elmstrom
2003/0121075
June 2003
Barham, Warren S.
2003/0163852
August 2003
Barham, Robert; et al.
6,759,576
July 2004
Zhang, et al.
2006/0137044
June 2006
Lanini; Brenda; et al.
OTHER REFERENCES
American Diabetes Association website—accessed Mar. 17, 2008 Bassett, Mark J. (editor), 1986, Breeding Vegetable Crops, AVI Publishing Company, Inc.
Central Intelligence Agency website—accessed Mar. 17, 2008
Florida Cooperative Extension Service, Institute of Food and Agricultural Sciences, University of Florida, HS1079, January 2007
Glich et al., (Eds), 1993, Methods in Plant Molecular Biology & Biotechnology, CRC Press
Harvard School of Public Health website—accessed Mar. 17, 2008
Maynard, D. N. (editor), 2001, Watermelon Characteristics, Production and Marketing, ASHS Press
National Agricultural Statistics Service of USDA—January 2006
Rhodes & Dane, 1999, Gene List for Watermelon, Cucurbit Genetics Cooperative Report 22:71-77
University of Sydney—Glycemic Index and GI database—accessed Mar. 17, 2008
Zhang, Xing-ping & Jiang, Yi, 1990, Edible Seed Watermelons ( Citrullus lanatus (Thunb. Matsum. Nakai) in Northwest China, Northwestern Agricultural University, China.
FIELD OF THE INVENTION
This invention is in the field of watermelon breeding, specifically relating to diploid watermelon plants producing fruit with reduced sugar content, and also serving the function of pollinating triploid watermelon plants for the commercial production of seedless watermelon fruit.
BACKGROUND OF THE INVENTION
Watermelon is an important horticultural crop with over 137,000 acres grown in the United States in 2005. The leading watermelon producing states are Florida, Georgia, Texas, and California with a combined total of 86,300 acres. (National Agricultural Statistics Service of USDA—January 2006)
The popularity of seedless (triploid) watermelon has increased over the last decade. During peak watermelon production in the U.S. market in 2005 and 2006, seeded watermelons only comprised 22% of the market and averaged four to five cents less per pound (Florida Cooperative Extension Service, Institute of Food and Agricultural Sciences, University of Florida, HS1079, January 2007).
Population of the United States is estimated at over 300 million as of July 2007 (Central Intelligence Agency website).
Of the 20.8 million Americans with diabetes, 90 to 95 percent have type 2 diabetes. (American Diabetes Association website). This amounts to 7% of the total population of the United States.
The glycemic index (GI) is a ranking of foods on a scale from 0 to 100 according to the extent to which they raise blood sugar levels after eating. Foods with a GI of 70 or above are considered high GI foods. Watermelon is rated at 72 which is considered a high GI. (University of Sydney Glycemic Index and GI database)
Glycemic index in watermelon can be lowered by decreasing its sugar content.
Lower GI foods have been shown to help control type 2 diabetes and improve weight loss. (Harvard School of Public Health—website)
The goal of plant breeding is to combine in a single variety or hybrid various desirable traits. Desirable traits may include resistance to diseases and insects, tolerance to heat and drought, reducing the time to crop maturity, greater yield, and better agronomic quality. Other desired traits may include particular nutrient content, color, fruit shape, as well as taste characteristics.
As with many different plants, watermelon contains a fruit part and a plant part. Each part contains different traits that are desired by consumers and/or growers, including such traits as flavor, texture, disease resistance, and appearance traits such as shape and color. Reduced sugar is a highly desirable trait for consumers with type 2 diabetes. The seedless trait in the watermelon fruit is also highly desired by consumers. Extended flowering in diploid watermelon plants is a trait sought after by growers of seedless watermelon.
Seeded watermelon plants are diploid and can be self-pollinated either by bees or by hand.
Seedless watermelon plants are triploid and must be pollinated by the pollen of diploid watermelon plants. The two primary methods currently in practice to pollinate seedless watermelon plants are; 1) planting traditional hybrid diploid varieties (e.g. Sangria produced by Syngenta, Inc.) in dedicated rows and harvesting and selling both the diploid fruit and the seedless fruit, or 2) inter planting between triploid watermelon plants within rows of triploid plants special pollenizer plants (e.g. SP-1 produced by Syngenta, Inc.), with plant characteristics especially favorable for pollination, which produce non-marketable fruit due their poor fruit quality, in particular a thin explosive rind making it difficult to harvest and transport the fruit. Due to the non-marketable fruit that these special pollenizer plants produce, they are generally referred to as “Non-Harvestable Pollenizers”.
The present invention recognizes the need to provide consumers with type 2 diabetes a watermelon with reduced sugar and therefore with less total carbohydrates, and a lower glycemic index. The present invention also recognizes that a method of producing reduced sugar watermelons is needed that reduces the economic risk of producing this product which has a relatively limited market (less than 7% of the total market).
BRIEF SUMMARY OF THE INVENTION
The present invention uses a novel diploid watermelon to provide a product to the consumer segment, which includes those suffering from type 2 diabetes in an economical manner. According to the invention, there is provided a novel reduced sugar watermelon (hereinafter referred to as “dual purpose reduced sugar watermelon”) and a method for producing it in an economical manner by using it as a pollenizer for seedless watermelon production. In other words, it will be produced as a byproduct of seedless watermelon production.
In addition to reduced sugar, the present invention includes a dual purpose reduced sugar watermelon with the following additional fruit traits enabling the successful production and marketing of this watermelon; 1) relatively firm flesh desired by consumers, 2) tough rind thereby reducing breakage of fruit during harvesting and transport, 3) rind color distinguishable from other watermelon fruit currently in the market in the United States, and 4) small fruit enabling consumers to purchase a “single portion”. The small fruit also helps to increase flowering, which contributes to the invention's second purpose as a pollenizer for seedless watermelon production.
The present invention further includes a dual purpose reduced sugar watermelon comprising a plant with the following characteristics favorable for its second purpose as a pollenizer for seedless watermelon production; 1) extended flowering duration providing pollen to seedless watermelon plants over an extended time period, 2) thin leaves thereby shading seedless watermelon plants located in close proximity to a lesser degree, and 3) long thin sprawling vines providing pollen over a larger surface area.
Also included in this present invention is a method of producing reduced sugar watermelons as a byproduct making the reduced sugar watermelon crop more economically feasible. This is accomplished by using the reduced sugar watermelon plant as a pollenizer for seedless watermelon production. The reduced sugar watermelon plants can be planted within seedless watermelon fields as a pollenizer in any of the currently practiced manners, and the fruit of the reduced sugar watermelon can be harvested and sold.
The dual purpose reduced sugar watermelon of the invention is further enhanced by including resistance to various pests and herbicides via conventional plant breeding methods or genetic transformation.
The dual purpose reduced sugar watermelon of the invention is further enhanced by various flesh colors including orange or yellow or white or red via conventional plant breeding methods or genetic transformation.
DETAILED DESCRIPTION OF THE INVENTION
Development of Dual Purpose Reduced Sugar Watermelon
According to the present invention, a watermelon OW824 is selected having the characteristics of an extended flowering duration, small leaves with deep, non-overlapping leaf lobes, a long sprawling vine, firm flesh, tough rind, and low sugar content. In this example, the fruit of OW824 is relatively large, the rind and flesh are very firm, the seed size is very big, and the flesh is white. OW824 is a publicly available edible seed watermelon variety generally referred to as Xinjiang Edible Seed Watermelon.
Also according to the invention, a watermelon Mickylee (PI 601307) is selected for its rind color which is distinguishable from other watermelon fruit on the market in the United States. In this example, Mickylee has a firm red flesh, light green rind, and weighs 4 to 5 Kg. Mickylee is publically available from the USDA—AMS National Genetic Resources Program.
Also according to the invention, diploid inbred watermelon line GSX-26, a proprietary Gold Seed Co. breeding line is selected for its small size (average weight of 1.5 Kg.). In this example, GSX-26 has fruit with the following characteristics; jubilee type striped rind pattern, thin rind, sweet red flesh, oval shape with small seeds. The plant is of medium vigor, high fruit set, and with very early maturity.
The first step was to cross Mickylee to GSX-26, and then hybrid progeny were crossed to OW824 to form a three way cross.
This three way cross generated progeny having the characteristics of the dual purpose reduced sugar watermelon of the present invention as described in more detail below.
The initial cross of Mickylee X GSX-26 was made during the spring of 2005 in Israel. This hybrid was further crossed with OW824 in Summer 2005 in Israel. The three-way cross produced was self-pollinated in spring 2006 in Israel. The F2 generation was grown in the summer of 2006. Individuals with the set of traits required for the dual purpose reduced sugar watermelon were successfully identified and self-pollinated in the F2 population. A total of 4 selections were made. The 4 F3 lines were grown in Israel in Spring 2007 for further selection and evaluation. 1 F3 line was identified to best meet our breeding goals and advanced to the F4 generation. This one line, Escort-4, called 121-14, is fixed for every trait concerned. Escort-4 contains the traits that are illustrative of the traits of the dual purpose reduced sugar watermelon of the invention. Other examples of dual purpose reduced sugar watermelon lines with similar characteristics were 121-5 with yellow/pink flesh, 121-7 with white flesh, and 121-11 with slightly larger fruits and a different rind color.
Fruit: The fruit of the dual purpose reduced sugar watermelon, e.g. of Escort-4, has approximately ⅓ less sugar content compared to the most popular diploid varieties currently marketed. Fruit of Escort-4 and the most popular diploid variety currently on the market called Sangria (Syngenta, Inc.) were harvested at full maturity on May 7, 2008, and tested for Total Soluble Sugars (TSS) for comparison purposes as shown in Table 1 below. In this comparison, fruit of Escort-4 had an average TSS content of 32% less than Sangria.
TABLE 1
Escort-4
% TSS
Sangria
% TSS
Fruit #1
9.5
Fruit #1
12.8
Fruit #2
9.1
Fruit #2
13.4
Fruit #3
8.6
Fruit #3
12.7
Fruit #4
8.8
Fruit #4
13.6
Fruit #5
8.5
Fruit #5
12.6
Fruit #6
8.6
Fruit #6
13.7
Fruit #7
8.9
Fruit #7
13
Fruit #8
8.3
Fruit #8
12.7
Fruit #9
10.1
Fruit #9
12.5
Fruit #10
8.4
Fruit #10
14
Average
8.9
Average
13.1
The flesh of the dual purpose reduced sugar watermelon, e.g. of Escort-4, is relatively firm. The flesh pressure when measured by a penetrometer (Model No. FT011 of Wagner Instruments, Greenwich, Conn. 06836) is in the range of approximately 2 lbs./inch to approximately 4 lbs./inch. The average flesh pressure is approximately 3 lbs./inch.
In addition, the fruit of the dual purpose reduced sugar watermelon, e.g. of Escort-4, compared to one of the more popular “non-harvestable” diploid pollenizers on the market called SP-1 (Syngenta, Inc.), has a much tougher rind, which resists breakage as opposed to the brittle fruit rind of SP-1 that splits easily and therefore can not be shipped easily if desired. Brittleness is conferred by a gene e (explosive rind, thin, and tender rind, bursting when cut (Rhodes & Dane, 1999, Gene List for Watermelon, Cucurbit Genetics Cooperative Report 22:71-77). The fruit of this invention does not contain this e gene and therefore has the ability to be harvested and transported long distances with minimal damage. For comparison purposes, fully mature fruit of Escort-4 and SP-1 were harvested on May 7, 2008 and measured for rind breakage pressure by a penetrometer (Model No. FT327 with a tip FT516— 5/16 diameter of Wagner Instruments, Greenwich, Conn. 06836). The Escort-4 fruit broke at 16-22 lbs./in., whereas fruit of SP-1 broke at 7-10 lbs./in. The rind of Escort-4 resists more than double the pressure as compared to SP-1. See TABLE 2 below.
TABLE 2
Breakage
Breakage
Pressure
Pressure
Escort-4
(Lbs./Inch)
SP-1
(Lbs./Inch)
Fruit #1
22.5
Fruit #1
9.5
Fruit #2
16
Fruit #2
8.5
Fruit #3
17
Fruit #3
7.5
Fruit #4
21
Fruit #4
10
Fruit #5
19.5
Fruit #5
7
Fruit #6
21
Fruit #6
8
Fruit #7
18.5
Fruit #7
7.5
Fruit #8
17.5
Fruit #8
7.5
Fruit #9
18
Fruit #9
8.5
Fruit #10
17
Fruit #10
9.5
Average
18.8
Average
8.3
The fruit of the dual purpose reduced sugar watermelon of the invention, e.g. of Escort-4, can be distinguished from the fruit of all of the most popular commercially available seedless watermelon varieties marketed in the United States. The rind color of the dual purpose reduced sugar watermelon is preferably light green with slightly noticeable very thin medium green lines.
Preferably, the fruit size of the dual purpose reduced sugar watermelon, e.g. of Escort-4, is small being approximately in the range of about 5 to about 7 inches long, and in the range of about 4 to about 5 inches wide. Small fruit size was selected to decrease the load on the plant, thereby extending the duration of plant growth and flower production. Another advantage of the small fruit size is that it can be marketed as a single serving fruit providing an option for individuals wanting to enjoy watermelon without having the excess from a typically large fruit. The fruit of the dual purpose reduced sugar watermelon weighs approximately in the range of about 2 to about 7 lbs, preferably about 2 to about 6 lbs. The average weight for the fruits of the dual purpose reduced sugar watermelon is preferably about 4.0 lbs.
Flowering: The plants of the dual purpose reduced sugar watermelon, e.g. of Escort-4, are very vigorous and continue flowering over a relatively long period. The plant of this invention begins flowering approximately 7 days earlier than diploid reference variety Sangria. It continues to flower for approximately 7 weeks, which is when the most common seedless watermelon varieties finish harvesting. It therefore flowers during the entire flowering period of seedless watermelons currently in the market, thereby providing a continuous supply of diploid watermelon pollen to seedless watermelon plants during the critical time period.
Leaf: The leaves of the dual purpose reduced sugar watermelon, e.g. of Escort-4, are similar to the Xinjiang Edible Seed Watermelon. The leaves of the dual purpose reduced sugar watermelon preferably have a surface area approximately in the range of about 20 to about 70 cm 2 , preferably about 22.5 to about 50 cm 2 . The leaves of the dual purpose reduced sugar watermelon preferably have deep, non-overlapping leaf lobes. These thin leaves shade seedless watermelon plants located in close proximity to a lesser degree than diploid watermelon Sangria, which is a variety favored by many growers.
Vine: The vines of the dual purpose reduced sugar watermelon, e.g. of Escort-4, are long, thin, and sprawling similar to the Xinjiang Edible Seed Watermelon. Length of vine at first harvest is approximately 1.7 to 2.3 meters. Diameter of the vine is approximately 4 to 6 mm at the second node. The long sprawling vine provides pollen to seedless watermelon plants over an extended surface area.
Other Traits: The dual purpose reduced sugar watermelon, e.g. Escort-4, can be used either as donor of the set of traits disclosed above, or as the recurrent parent to develop additional dual purpose reduced sugar watermelon lines. In accordance with the invention, the dual purpose reduced sugar watermelon contains traits of disease resistance (e.g. Fusarium wilt , Anthracnose, Gummy Stem Blight, Powdery Mildew, and Bacterial Fruit Blotch), insect resistance (e.g. cucumber beetle, aphids, white flies and mites), salt tolerance, cold tolerance, and/or herbicide resistance added. In addition, the dual purpose reduced sugar watermelon contains various flesh colors (e.g. orange or white or yellow or red). These traits can be added to existing lines by using either the conventional backcrossing method, pedigree breeding method or genetic transformation. The methods of conventional watermelon breeding are taught in several reference books, e.g. Maynard, D. N. (editor), 2001, Watermelon Characteristics, Production and Marketing, ASHS Press; and Bassett, Mark J. (editor), 1986, Breeding Vegetable Crops, AVI Publishing Company, Inc. General methods of genetic transformation can be learned from published references, e.g. Glich et al., (Eds.), 1993, Methods in Plant Molecular Biology & Biotechnology, CRC Press.
Forms of the Dual Purpose Reduced Sugar Watermelon: Once the dual purpose reduced sugar watermelon lines are developed, several forms of dual purpose reduced sugar watermelon varieties can be used in commercial watermelon production. Specifically, these forms of dual purpose reduced sugar watermelon varieties include: (1) Open Pollinated Variety: The stable lines of the dual purpose reduced sugar watermelon are grown in isolated fields, at least 2,000 meters from other watermelon varieties. Pollination is conducted in the open fields by bees. Seeds are harvested from the seed production field when the fruit and seeds are fully developed. The seeds are dried and processed according to standard watermelon seed handling procedures. (2) Hybrid Variety: Two dual purpose reduced sugar watermelon lines, the male and female parents, are planted in the same field. Hand pollination is conducted. Only the seed from the female parent line is harvested and sold to the commercial grower for use.
Method of producing reduced sugar watermelons as a byproduct: In order to produce the reduced sugar watermelons in an economical manner the dual purpose reduced sugar watermelon can be used as a pollenizer for seedless watermelon production. It can be planted as a pollenizer in both of the most common currently practiced methods, which are; 1) planting the dual purpose reduced sugar watermelon in separate dedicated rows before and after every 2nd row of seedless watermelon plants, and the seedless watermelon fruit and the reduced sugar watermelon fruit would then be harvested and sold, or 2) inter planting between triploid watermelon plants with no dedicated space for the dual purpose reduced sugar watermelon plants within the same rows as the seedless watermelon plants between every 2nd or 3rd or 4th or 5th plant. Both the seedless watermelon fruit and the reduced sugar watermelon fruit would then be harvested and sold. Therefore, a dedicated field for production of reduced sugar watermelons is not necessary.
Deposit
Applicant has made a deposit of at least 2500 seeds of the Dual Purpose Reduced Sugar Watermelon line Escort-4 at The National Collections of Industrial and Marine Bacteria Limited (NCIMB), Ferguson Building, Craibstone Estate, Bucksburn, Aberdeen AB21 9YA, Scotland, UK under number NCIMB 41542 in order to illustrate the invention. This deposit of the Dual Purpose Reduced Sugar Watermelon line Escort-4 will be maintained in the NCIMB depository, which is a public depository, for a period of 30 years, or 5 years after the most recent request, or for the effective life of the patent, whichever is longer, and will be replaced if it becomes nonviable during that period. Additionally, applicant has satisfied all the requirements of 37 C.F.R. sections 1.801-1.809, including providing an indication of the viability of the sample. Applicant imposes no restrictions on the availability of the deposited material from the NCIMB; however, applicant has no authority to waive any restrictions imposed by law on the transfer of biological material or its transportation in commerce. Applicant does not waive any infringement of its rights granted under this patent.
The foregoing invention has been described in detail for purposes of clarity and understanding. However, it will be obvious that certain changes and modifications such as single gene modifications and mutations, somaclonal variants, variant individuals selected from large populations of the plants of the instant inbred and the like may be practiced within the scope of the invention, as limited only by the scope of the appended claims. Thus, although the foregoing invention has been described in some detail in this document, it will be obvious that changes and modifications may be practiced within the scope of the invention, as limited only by the scope of the appended claims.
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The invention relates to a diploid watermelon having fruit with approximately ⅓ lower sugar content than common watermelons found in the market place, and plant characteristics favorable for use as a pollenizer for commercial production of seedless watermelons. In addition to reduced sugar, fruit characteristics of the invention include a tough rind, firm flesh, distinct rind color, and small fruit. The watermelon plant of the invention has the characteristics of extended flowering duration, thin leaves, and long sprawling vines. The invention combining the above mentioned fruit and plant characteristics can serve the dual purpose of producing reduced sugar watermelon fruit, and pollinating seedless watermelons. This will in effect produce reduced sugar watermelons which are beneficial for consumers with type 2 diabetes as a byproduct of commercial seedless watermelon production making the product more economically feasible.
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TECHNICAL FIELD
[0001] The present invention relates to the field of catalytic hydrogenation and, more particularly, to the use of specific Ru complexes with cyclopentadienyl derivatives, as one of the ligands, in 1,4-hydrogenation processes for the reduction of sorbol into the corresponding Z-alkene, as major product.
PRIOR ART
[0002] Selective 1,4-hydrogenation of conjugated dienes, in general, into their Z-alkene is a very interesting reaction in organic chemistry, since it renders accessible a number of compounds which are obtained in general with a poor selectivity.
[0003] One of the mandatory and characterizing elements of such processes is the catalyst or the catalytic system. The development of useful catalysts or catalytic systems for the 1,4-hydrogenation of sorbol into the corresponding Z-alkene is still an important, difficult and unpredictable task in chemistry. The chemical industry is always eager for higher selectivity, as well as to maintain a high conversion or yield.
[0004] From the prior art it is known that sorbic acid can be hydrogenated into the corresponding Z-alkene in the presence of [(Cp*)RuCO(phosphine)](anion) or [(Cp*)RuCO(sorbic acid)](anion) complexes, (Cp* representing a C 5 Me 5 or pentamethyl-cyclopentadienyl ligand; see Driessen et al, in Chem.Commun., 2000, 217 or in J.Organomet.Chem, 1998, 141), however the yields (conversions×selectivity) are quite low.
[0005] Furthermore, in EP 1394170, it is reported the cisoid hydrogenation of sorbic acid and sorbol using as catalytic systems the complex [(Dienyl)Ru(acyclic diene)](anion) (in particular [(Cp*)Ru(sorbic acid)](anion) or [(Cp*)Ru(sorbol)](anion). In this document it is expressively reported that the use of cyclic diene, instead of acyclic diene, is highly detrimental to the overall yield. The only conditions displayed as providing good yields require nitromethane as solvent, the latter being relatively toxic and hazardous for industrial applications. Finally, Table 4 of said document shows that the addition of Lewis acids is highly detrimental to the yields.
[0006] Therefore, there is a need for processes using alternative catalytic systems systems possibly providing high selectivity and/or conversions.
DESCRIPTION OF THE INVENTION
[0007] In order to overcome the problems aforementioned, the present invention relates to processes for the catalytic reduction by 1,4-hydrogenation, using molecular H 2 , of sorbol (I) into the corresponding Z-alkene (II) (i.e. Z-hex-3-en-ol) characterized in that said process is carried out in the presence of at least an acidic additive of the type specified further below, the catalyst or pre-catalyst being a ruthenium complex comprising as ligand a cyclopentadienyl derivative.
[0008] The invention's process is shown in Scheme 1:
[0000]
wherein compound (II) is in a Z configuration.
[0010] A particular embodiment of the invention is a process for the catalytic reduction by 1,4-hydrogenation, using molecular H 2 , of sorbol of formula
[0000]
into the corresponding Z-alkene, of formula
[0000]
[0012] wherein the isomer of configuration Z is predominant;
said process being characterized in that it is carried out in the presence of at least one ruthenium catalyst or pre-catalyst of formula
[0000] [Ru(C 5 Me 5 )(COD)(L′) n ]X (III)
[0015] wherein C 5 Me 5 represents pentamethyl-cyclopentadienyl, COD a cyclooctadiene ligand and X represents a non coordinated anion, n represents 2, 1 or 0 and L′ represents a solvent; and
at least an acidic additive of the type described further below, preferably in a total amount of about 0.1, or even 0.2, to 100 molar equivalents, relative to the compound (III).
[0017] Concerning compound (II), since it is an olefin, it can be obtained in the form of a mixture of two isomers, i.e. the one having a configuration Z (Z-alkene (II)) or the one having a configuration E (E-alkene (II′))
[0000]
[0018] It is understood that according to the invention the alkene obtained is in the form of a mixture Z-alkene and E-alkene, wherein the ratio Z-alkene/E-alkene (Z/E) is above 1. According to a particular embodiment, said ratio is above 10 or even above 20. In another particular embodiment, said Z/E ratio can be above 30 or even above 35, and in some cases ratio of above 45 or more can be obtained. In any case the presence of the acidic additive in the prescribed concentration range allows to improve said ratio.
[0019] The substrate (I), due to the fact that it is a diene, can be in the form of a mixture of its three configuration isomers, i.e. the (Z,Z), (E,Z) and (E,E) isomers. According to a particular embodiment of the invention, said substrate can be essentially in the form of its (Z,Z) isomer (e.g. comprising at least 99% w/w of the isomer (Z,Z)).
[0020] The process of the invention is characterized by the use, as catalyst or pre-catalyst (hereinafter referred to as complexes unless specified otherwise), of a specific type of ruthenium complex as [Ru(C 5 Me 5 )(COD)(L′) n ]X, as defined above.
[0021] According to a particular embodiment of the invention, L′ can be acyclic or cyclic non aromatic ketones or esters, such as acetone or methyl acetate. The ketone can be coordinated in its enolic form.
[0022] The COD ligand can be any isomer of cyclooctadiene, namely cycloocta-1,5-diene (1,5-COD), cycloocta-1,4-diene (1,4-COD), cycloocta-1,3-diene (1,3-COD).
[0023] Particular examples of the non-coordinated anion X are ClO 4 − , R 1 SO 3 − , wherein R 1 is a chlorine of fluoride atom or an C 1 -C 8 fluoroalkyl or fluoroaryl group, BF 4 − , PF 6 − , SbCl 6 − , SbF 6 − , or BR 2 4 − , wherein R 2 is a phenyl group optionally substituted by one to five groups such as halide atoms or methyl or CF 3 groups.
[0024] According to a preferred embodiment of the invention, the anion is BF 4 − , PF 6 − , ClO 4 − , C 6 F 5 SO 3 − , BPh 4 − , CF 3 SO 3 − or yet B[3,5-(CF 3 ) 2 C 6 H 4 ] 4 − , even more preferably BF 4 − .
[0025] As examples of the complex (III) one may cite the following: [Ru(C 5 Me 5 )(1,3-COD)]BF 4 .
[0026] In a general way, the complexes of formula (III) can be prepared and isolated prior to their use in the process according to the general methods described in the literature (for example see F. Bouachir et al.; Organometallics, 1991, pg 455).
[0027] It is also understood that the complex of formula (III) can also be obtained in situ from complexes which have a similar formula and are cationic or anionic according to the standard knowledge of a person skilled in the art. For example, reaction can be run using [Ru(C 5 Me 5 )(COD)Y] (Y being F, Cl, Br or I and method for preparation having been described by P.J. Fagan et al. in Organometallics, 1990, 9, pg 1843-1852) as precursors in the presence of the substrate and silver or tallium salts).
[0028] To carry out the processes of the invention it is required also to use at least an acidic additive. By “acidic additive” it is meant a compound capable of providing at least one proton to the catalytic cycle. Said acidic additive is preferably an organic or inorganic acid having a pK a comprised between 0.8 and 7, but in the case of phenols or boron derivatives said pK a can range up to 10.
[0029] Furthermore, said acidic additive and can be selected from the group consisting of:
a compound of formula R 3 (3-x)MO(OH) x , wherein R 3 is a R 4 or R 4 O group wherein R 4 is a C 1 -C 10 group, M is P or As and x is 1 or 2; and a boron derivative of formula R 3 B(OH) 2 , wherein R 3 is as defined above; and phenol or a phenol substituted by up to three C 1 -C 4 alkyl, alkoxy or carboxylic groups, nitro groups or halogen atoms; and a C 1 -C 12 mono-carboxylic non-amino acid; and a HOOCCH═CHCOOH di-acide, and the tetronic acid.
[0035] By “mono-carboxylic non-amino acid” it is meant here a mono-carboxylic acid which is not substituted by a primary, secondary or tertiary amino group or heteroaromatic nitrogen derivatives.
[0036] According to a particular embodiment, said R 3 (3-x) MO(OH) x acids can be a derivative wherein R 3 is a C 1 -C 8 alkyl or alkoxyl group or a C 1 -C 8 phenyl or phenoxyl group optionally substituted, M is P or As and x is 1 or 2.
[0037] Similarly said R 3 B(OH) 2 acids can be those wherein R 3 is a C 1 -C 8 alkyl or alkoxyl group or a C 1 -C 8 phenyl or phenoxyl group optionally substituted.
[0038] According to another embodiment of the invention, said acid can be the phenol or a phenol substituted by one C 1 -C 4 alkyl, alkoxy or carboxylic group, a nitro group or a halogen atom.
[0039] Furthermore, according to another particular embodiment of the invention, said acidic additive can be a mono-carboxylic acid of formula R 5 COOH, wherein R 5 represents a C 1 -C 12 hydrocarbon group or a C 1 -C 12 halogenated or per-halogenated hydrocarbon group, optionally substituted by one alcohol group or one or two ether or ester groups. According to a further embodiment, said carboxylic acid is advantageously selected from the group consisting of:
a carboxylic acid of formula R 5 COOH, wherein R 5 represents a halogenated or per-halogenated C 1 -C 8 hydrocarbon group; a R 6 CH(OR 6 ) group, R 6 being a hydrogen atom or a C 1 -C 6 hydrocarbon group; a C 1 -C 12 hydrocarbon group, optionally substituted by one or two ether or ester groups, the optional substituent being by one two or three C 1 -C 4 alkyl, alkoxy or carboxylic groups, or nitro groups or halogen atoms.
[0043] One can cite, as non-limiting examples, of said acidic additive the following: (BuO) 2 PO(OH), ( t BuO) 2 PO(OH), (PhO) 2 PO(OH), (PhCH 2 O) 2 PO(OH), t BuPO(OH) 2 , Ph 2 PO(OH), PhPO(OH) 2 , PhAsO(OH) 2 , (Me) 2 AsO(OH), CF 3 COOH, HCF 2 COOH, maleic or fumaric acid, glycolic acid, pyruvic acid, sorbic, acetic or oleic acid, tetronic acid, C 6 H 13 B(OH) 2 , PhB(OH) 2 , p-OMe-benzoic, benzoic or p-(COOMe)-benzoic acid, phenol, 3,5-dimethoxy-phenol or 2-methoxy-phenol. Of course, other suitable acidic additives responding to the above description can be used.
[0044] According to another embodiment of the invention, said acidic additive can be selected from the group consisting of:
a compound of formula R 3 2 MO(OH) or R 3 MO(OH) 2 , wherein R 3 is a C 1 -C 6 alkyl or alkoxyl group or a C 1 -C 8 phenyl or phenoxyl and M is P or As; and maleic or glycolic acid and an halogenated or per-halogenated C 1 -C 7 mono-carboxylic acid.
[0047] As previously mentioned the processes of the invention consist in the hydrogenation of a substrate using a ruthenium complex and an acidic additive. A typical process implies the mixture of the substrate with the ruthenium complex, at least one acidic additive and optionally a solvent, and then treating such a mixture with molecular hydrogen at a chosen pressure and temperature.
[0048] The complexes of the invention, an essential parameter of the process, can be added to the reaction medium in a large range of concentrations. As non-limiting examples, one can cite as complex concentration values those ranging from 0.01 mol % to 5 mol%, the molar percentage being relative to the amount of substrate. Preferably, the complex concentration will be comprised between 0.03 mol % to 2 mol %. It goes without saying that the optimum concentration of complex will depend, as the person skilled in the art knows, on the nature of the latter, on the nature of the substrate, on the nature of the solvent and on the pressure of H 2 used during the process, as well as the desired time of reaction.
[0049] Useful quantities of acidic additive, added to the reaction mixture, may be comprised in a relatively large range. Apart from the one above cited, one can cite, as non-limiting examples, total amounts ranging between 0.5 to 50 molar equivalents, relative to the complex, preferably 0.8 to 20, and even more preferably between about 2 and about 10 molar equivalents.
[0050] The hydrogenation reaction can be carried out in the presence or absence of a solvent. When a solvent is required or used for practical reasons, then any solvent current in hydrogenation reactions can be used for the purposes of the invention. Non-limiting examples include non-aromatic solvents such as C 1 -C 12 non aromatic ketones, esters, alkanes ethers, chlorinated alkanes and alcohols or mixtures thereof. According to an embodiment of the invention the solvent is advantageously selected amongst the C 1 -C 12 alkyl ketones, esters, ethers or chlorinated alkanes and mixtures thereof. In particular and as non-limiting examples one may cite the following: acetone ethyl acetate, MTBE, THF, iso-propyl acetate, Et 2 O, dichloromethane, 1,2-dichloethane, EtOH, MeOH, pentane, hexane. The choice of the solvent can be done as a function of the nature of the complex and the person skilled in the art is well able to select the solvent most convenient in each case to optimize the hydrogenation reaction.
[0051] In the hydrogenation process of the invention, the reaction can be carried out at a H 2 pressure comprised between 10 5 Pa and 80×10 5 Pa (1 to 80 bars) or even more if desired. Again, a person skilled in the art is well able to adjust the pressure as a function of the catalyst load and of the dilution of the substrate in the solvent. As examples, one can cite typical pressures of 1 to 30×10 5 Pa (1 to 30 bar).
[0052] The temperature at which the hydrogenation can be carried out is comprised between 0° C. and 120° C., more preferably in the range of between 40° C. and 100° C. Of course, a person skilled in the art is also able to select the preferred temperature as a function of the melting and boiling point of the starting and final products as well as the desired time of reaction or conversion.
EXAMPLES
[0053] The invention will now be described in further detail by way of the following examples, wherein the temperatures are indicated in degrees centigrade and the abbreviations have the usual meaning in the art.
[0054] All the procedures described hereafter have been carried out under an inert atmosphere unless stated otherwise. Hydrogenations were carried out in open glass tubes placed inside a stainless steel autoclave. H 2 gas (99.99990%) was used as received. All substrates and solvents were distilled from appropriate drying agents under Ar. NMR spectra were recorded on a Bruker AM-400 ( 1 H at 400.1 MHz, 13 C at 100.6 MHz) spectrometer and normally measured at 300 K, in CDCl 3 unless indicated otherwise. Chemical shifts are listed in ppm.
EXAMPLE 1
Hydrogenation Processes According to the Invention
Typical Hydrogenation Reaction Procedure
[0000]
2,4-Haxanedienol, solvent, [Ru(C 5 Me 5 )(COD)]X and the acidic additive according to the invention were loaded altogether under inert atmosphere an autoclave and the mixture was purged at room temperature with nitrogen (2 bars, 3 times) and then hydrogen (2 bars, 3 times) under stirring. The autoclave was then pressurized to the desired hydrogen pressure and heated at the desired temperature. The reaction was followed by hydrogen absorption monitoring and/or GC analysis sampling. The ruthenium catalyst was easily removed by distillation on residues and product isomers mixture was usually recovered in more than 90% molar yield.
[0056] The results obtained are summarized in the following tables.
[0000]
TABLE 1
influence of the acidic additive and of its
presence on hydrogenation selectivity
Ratio
Acidic additive
1,4-Selectivity
“cis”-alkene/“trans”-alkene
none
>98%
90/10
Benzoic acid
>98%
93/7
(C 6 H 13 )B(OH) 2
>98%
93.5/6.5
Acetic acid
>98%
94/6
Sorbic acid
>98%
95/5
Fumaric acid
>98%
95.5/4.5
Glycolic acid
>98%
96/4
(PhO) 2 P(O)(OH)
>98%
96.5/3.5
(PhCH 2 O) 2 P(O)(OH)
>98%
97/3
(Ph)As(O)(OH) 2
>98%
97/3
((tBu)P(O)(OH) 2
>98%
97/3
(Ph)P(O)(OH) 2
>98%
97.5/2.5
trifluoroacetic acid
>98%
97.5/2.5
(Me) 2 As(O)(OH)
>98%
98/2
(Ph) 2 P(O)(OH)
>98%
98/2
((BuO) 2 P(O)(OH)
>98%
98.5/1.5
Maleic acid
>98%
99/1
cathecol
>98%
94/6
p-cresol
>98%
94/6
pentafluorophenol
>98%
94/6
2,4-dichloro-6-
>98%
96/4
nitrophenol
2-methoxyphenol
>98%
97/3
[0000]
TABLE 2
influence of the acidic additive and of its
presence on hydrogenation selectivity
influence of the anion X
Presence of
Ratio
diphenylphosphonic
“cis”-alkene/
X
acid
1,4-Selectivity
“trans”-alkene
BF 4 −
no
>98%
90/10
BF 4 −
yes
>98%
98/2
ClO 4 −
no
>98%
82/18
ClO 4 −
yes
>98%
97/3
CF 3 SO 3 −
no
>98%
90/10
CF 3 SO 3 −
yes
>98%
98/2
PF 6 −
no
>98%
90/10
PF 6 −
yes
>98%
98/2
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The present invention relates to the use of Ru complexes, having a pentamethyl-cyclopentadienyl and a cyclooctadine as ligands, together with some acidic additives for improving the selectivity in the 1,4-hydrogenation of sorbol into the corresponding Z-alkene as major product.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a United States Non-Provisional Utility Patent Application claiming the benefit of Italian Patent Application Number TO2012A000651 filed on 25 Jul. 2012, which is incorporated herein in its entirety.
TECHNICAL FIELD
[0002] The present invention relates to a hub-bearing assembly for a tilling disc.
BACKGROUND ART
[0003] As is well known, tilling discs are usually mounted rotatably on respective spindles projecting from the frame of a plough or other agricultural machine.
[0004] WO 2002/019791 A discloses a hub-bearing assembly for rotatably mounting a tilling disc about an axis of rotation. The assembly comprises an annular hub having an axially extended tubular portion defining a generally cylindrical housing and a radially outer flange for fixing to a disc. In the housing is mounted a bearing unit comprising an outer ring, one or two inner rings and a dual set of rolling elements interposed between the outer and inner rings. In other solutions, the outer ring of the bearing is integrated into the flanged hub, forming therewith a single piece.
[0005] During use, impacts suffered by the disc against stones and similar damage the raceways of the bearing and shorten its working life.
[0006] It is therefore an object of the invention to create a hub-bearing assembly for a tilling disc capable of remedying the above-mentioned disadvantage.
DISCLOSURE OF INVENTION
[0007] It is therefore an object of the invention to create a hub-bearing assembly for a tilling disc capable of remedying the above-mentioned disadvantage.
[0008] This and other objects and advantages, which will be better understood hereafter, are achieved according to an aspect of the invention by a hub-bearing assembly for rotatably mounting a tilling disc about an axis of rotation, the hub-bearing assembly comprising:
an annular hub including:
an axially extending tubular portion defining a generally cylindrical housing, and a radially outer flange for mounting a disc;
a bearing unit mounted within the housing and comprising an outer ring, a pair of inner rings and a dual set of rolling elements, interposed between the outer ring and the inner rings; and an elastic damping body arranged in the housing and radially interposed between the hub and the outer ring of the bearing unit.
[0014] Other advantageous features are defined in the dependent claims.
[0015] Briefly, the hub-bearing assembly comprises an elastic damping body radially interposed between the hub and the outer ring of the bearing unit. The elastic damping body absorbs part of the dynamic stresses coming from impacts of the disc against stones. These stresses, no longer being fully transferred to the bearing and its rolling elements, do not noticeably damage the raceways. According to some preferred embodiments, the relative movements between the bearing unit and the housing formed from the hub for the bearing are limited due to the forced mounting of the elastic body between the bearing and the hub and owing to particular shapes taken by the outer surface of the outer bearing ring and by the housing of the hub in which the bearing unit is accommodated by means of the interposition of the elastic damping body.
BRIEF DESCRIPTION OF DRAWINGS
[0016] A description will now be given of a few preferred, but not limiting, embodiments of the invention. Reference is made to the attached drawings, in which:
[0017] FIG. 1 is a view in axial section of a tilling disc mounted rotatably about a spindle by means of a hub-bearing assembly according to an embodiment of the invention;
[0018] FIG. 2 is a perspective view of the disc with the hub-bearing assembly and spindle of FIG. 1 ; and
[0019] FIG. 3 is an enlarged view, in partial axial section, of the hub-bearing assembly and spindle of FIG. 1 .
DETAILED DESCRIPTION
[0020] Making reference now to the drawings, a hub-bearing assembly according to an embodiment of the invention, indicated in its entirety 10 , serves for mounting a disc A in freely rotatable manner about an axis of rotation x defined by a spindle B projecting in cantilever from a machine or an agricultural implement (not illustrated), such as for example a plough, a harrow or similar. The characteristics of the disc A, which may be of any known type, for example a disc for ploughing or a disc for sowing (suitable for opening furrows in a previously ploughed terrain), are not significant for the purposes of understanding the present invention and will therefore not be described here in detail.
[0021] The assembly 10 comprises a hub 20 , a bearing unit 30 housed in the hub 20 and an elastic damping body 40 interposed between the hub and the bearing unit.
[0022] The hub 20 , of overall annular form, has an axially extended principal tubular portion 21 , which defines within itself a generally cylindrical housing 22 for the bearing unit 30 . The housing 22 is delimited radially by a substantially cylindrical inner wall 22 a, described below. Throughout the present description and in the claims, the terms and expressions indicating positions and orientations such as “radial” and “axial” are to be taken to refer to the central axis of rotation x of the bearing unit 30 .
[0023] From a first axial end of the tubular portion 21 of the hub there extends a radially outer flange 23 having a plurality of axial bores 24 for mounting the disc A. From a second axial end of the tubular portion 21 there extends a radially inner flange 25 which axially delimits the housing 22 on the side further from the disc.
[0024] The bearing unit 30 is a bearing unit of the so-called first generation, i.e. without radially projecting flanges. The bearing unit 30 comprises a rotatable outer ring 31 , a pair of inner rings 32 , 33 mounted side by side on the spindle B and a dual set of rolling elements 34 , 35 , in this example balls, interposed between the outer ring 31 and the inner rings 34 , 35 . The rotatable outer ring 31 has a substantially cylindrical radially outer wall 31 a, more fully described below.
[0025] The inner rings 32 , 33 are axially locked in position against a shoulder C on the spindle by means of a spacer D forcefully fitted onto the spindle, which is preloaded through a ring-nut (not illustrated) according to a per se known arrangement.
[0026] The inner flange 25 extends radially towards the spindle, and provides a radial surface 25 a for abutting a radial surface 31 c of the outer ring 31 of the bearing. In the embodiment illustrated, the flange 25 further forms an annular recess 26 , facing towards the bearing, suitable for accommodating a sealing device schematically indicated E, designed to slide against the spacer D or against another element integral with the spindle B in order to hermetically seal the housing 22 of the bearing towards the outside.
[0027] The elastic damping body 40 allows the disc A to elastically absorb the impacts which it receives during use, and to limit damage, undesired movements and the appearance of play which the bearing unit may undergo as a result of impacts transmitted by the disc.
[0028] The elastic damping body 40 is comprised of a tubular sleeve of elastomeric material, radially interposed between the substantially cylindrical wall 22 a of the housing 22 and the radially outer surface 31 a of the outer ring 31 of the bearing.
[0029] In a preferred embodiment, the elastic body 40 is fabricated at a preliminary stage, for example by extrusion or hot forming, and is then forcibly introduced (cold pressed) into a cylindrical gap located between the surfaces 22 a and 31 a, after the bearing unit has been introduced into the housing 22 .
[0030] The elastic body 40 has a tubular wall 41 having a radial thickness which, in the undeformed condition, i.e. before the introduction of the body 40 between the walls 22 a and 31 a , is preferably greater than a dimension or radial distance which separates the surface 31 a from the wall 22 a. Due to this arrangement, the elastic body 40 remains elastically compressed in radial directions between the housing 22 of the hub and the outer bearing ring 31 .
[0031] According to an alternative embodiment, the elastic body 40 is fabricated by injecting elastomeric material in the fluid state into the cylindrical gap located between the surfaces 22 a and 31 a, after the bearing unit has been introduced into the housing 22 .
[0032] In the illustrated embodiment, the elastic body 40 has an axial length greater than the axial length of the outer ring 31 of the bearing, so as to ensure an elastic damping effect on the bearing unit for stresses transmitted thereto by the hub according to any direction or angle.
[0033] To allow a uniform elastic response, the radial thickness of the tubular wall 41 is preferably constant. In order to guarantee correct positioning of the elastic body 40 , an annular groove 27 is formed in the housing 22 . The annular groove 27 extends into the inner flange 25 at the axial end of the wall 22 a located, in use, further from the disc A. The annular groove 27 steadily accommodates an edge 42 of the elastic body 40 .
[0034] Preferably, the wall 22 a is not perfectly cylindrical but has a relief projecting in a radially inner direction, in this example a relief 22 b in the form of an annular ridge, suitable for favoring a steady axial positioning of the elastic body 40 with respect to the housing 22 and the hub 20 . In this example, the relief 22 b is shaped as an annular ridge which extends circumferentially around the substantially cylindrical inner wall 22 a. In the particular embodiment illustrated, also the radially outer surface 31 a of the outer ring 31 is not perfectly cylindrical but provides a radial recess 31 b preferably in the form of an annular channel or groove extending circumferentially, with the object of favoring a stable relative axial positioning of the elastic body 40 with respect to the bearing unit. In order to maintain a uniform level of compression in the body 40 , it is preferable that the radial relief 22 b and the radial recess 31 b should be aligned in a same radial plane, so as to maintain a constant radial distance between the facing surfaces 22 a and 31 a. Advantageously, the relief 22 b is located in an axially intermediate position between two radial planes P 1 , P 2 in which lie the two sets of rolling elements 34 , 35 .
[0035] In a preferred embodiment, the annular groove 31 b is formed in a particularly convenient manner if the outer ring 31 is fabricated starting from steel tube cut and subjected to cold rolling so as to form the annular groove 31 b . The specific form illustrated of the annular groove 31 b is not to be considered limiting, since grooves of different profile, for example of square profile, can also be effective for axially locking the outer ring 31 . The material of the damping body 40 , being elastically deformable, makes it possible to adapt the shape of the body 40 to that of the annular groove 31 b.
[0036] In a preferred embodiment, the elastic damping body 40 is axially retained between the hub and the outer ring of the bearing simply as a result of the elastic compression to which the body 40 is subjected, without necessitating further retaining means, such as for example the application of adhesive. The elastic damping body 40 is held even more stably as a result of the relief 22 b, which generates a further radial compression stress, favoring the axial retention of the elastic body 40 .
[0037] It is to be understood that the invention is not limited to the embodiments here described and illustrated, which are to be considered examples of the assembly; it will be clear to experts in the field that various changes may be made to the functions and configuration of the elements described in the exemplary embodiment, without departing from the scope of the invention as defined in the attached claims and their equivalents.
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A hub-bearing assembly is disclosed, wherein the hub-bearing assembly is used for rotatably mounting a tilling disc about an axis of rotation is disclosed. The hub-bearing assembly comprises an annular hub comprising an axially extending tubular portion defining a cylindrical housing and an outer flange for mounting a disc, a bearing unit mounted in the housing, and an elastic damping body arranged in the housing and radially interposed between the hub and an outer ring of the bearing unit.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] The application claims the benefit of U.S. Provisional Patent Application No. 61/489,647, filed May 24, 2011, which is hereby incorporated by reference herein in its entirety.
TECHNICAL FIELD
[0002] The disclosed subject matter relates to microplate assemblies for flux determination by gradient monitoring and methods for using same.
SUMMARY
[0003] Microplate assemblies for flux determination by gradient monitoring and methods for using same are provided. In accordance with some embodiments, microplate assemblies are provided, the assemblies comprising a microplate well portion that forms a microplate well and that includes at least one sensor in the microplate well that responds to analyte in the well. In accordance with some embodiments, methods for determining a cell consumption or production rate, also referred to as the flux, of an analyte are provided, the methods comprising: positioning a cell in a microplate well having at least one sensor located within the well; providing analyte to the microplate well at a controlled rate; detecting a response of the sensor to the analyte in the microplate well; and determining a cell consumption or production rate of the analyte based on the response of the sensor to the analyte. The flux follows from the gradient of analyte generated in the microwell.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1 is a diagram of a microplate assembly portion in an opened position in accordance with some embodiments.
[0005] FIG. 2 is a diagram of a microplate assembly portion in a closed position in accordance with some embodiments.
[0006] FIG. 3 is a diagram of a microplate assembly portion having optical-capillary sensors in accordance with some embodiments.
[0007] FIG. 4 is a diagram of a microplate assembly portion having a multi-lumen-optical-capillary sensors in accordance with some embodiments.
DETAILED DESCRIPTION
[0008] Microplate assemblies and methods for using same are provided.
[0009] In accordance with some embodiments, a cell consumption or production rate of an analyte can be detected by collecting a series of one or more luminescence (fluorescence or phosphorescence) images each taken within a medium of a microplate well.
[0010] In accordance with some embodiments, a microplate assembly is provided. FIG. 1 illustrates an example of a portion 100 of a microplate assembly in accordance with some embodiments. As shown, portion 100 includes a microplate lid portion 102 and a mircoplate well portion 104 . The microplate lid portion 102 can be removably placed on top of the microplate well portion 104 , and, in some embodiments, as described below, microplate lid portion 102 can be omitted from the microplate assembly.
[0011] Portion 100 can be replicated any suitable number of times in the microplate assembly. For example, the microplate assembly can have 8, 16, 32, 64, etc. number of portions 100 arranged in any suitable fashion. Two or more of the microplate lid portions of the microplate assembly can be integrated into a single structure. Likewise, two or more of the microplate well portions of the microplate assembly can be integrated into a single structure.
[0012] As shown in FIG. 1 , the microplate lid portion 102 can include an analyte reservoir 106 , an analyte inlet channel 108 , an analyte outlet channel 110 , and a diffusive membrane 112 . The microplate well portion 104 can include a microplate well 114 , a transparent substrate 116 forming the bottom of the well, a first sensor 118 , a second, optional sensor 120 , and a third, optional sensor 122 .
[0013] The analyte reservoir in the microplate lid can be filled with a known concentration of analyte in fluid via the analyte inlet channel at a desired rate. Fluid in the analyte reservoir can be removed via the analyte outlet channel at a desired rate. Thus, for example, an analyte-containing fluid in the analyte reservoir can be replenished at a fixed, known concentration via the analyte inlet and analyte outlet channels that run to each analyte reservoir in the microplate lid. Analyte in the reservoir can also exit the reservoir into the microplate well 114 via the diffusive membrane 112 . Analyte which diffuses through the membrane can mix without creating appreciable turbulence into the microplate well 114 and thus can provide a known concentration of analyte at the membrane boundary independent of a cell consumption or production rate in the well. This known, fixed concentration along with one or more sensors inside microplate well 114 can be used to determine the analyte gradient within the well.
[0014] Microplate well 114 can have any suitable shape. Sensors 118 , 120 , and 122 can be any suitable sensors, such as fluorescent sensors that operate by optical fluorescent response (which may include changes in color, intensity or decay time of a fluorophore) in response to analyte.
[0015] In some embodiments, first sensor 118 can be located at the plane of the cells at the bottom of the well, first optional sensor 120 can be placed at some intermediate height, and second optional sensor 122 can be placed just below the analyte reservoir. Although cells 124 and sensor 118 are illustrated as being in the same region at the bottom of the well in FIGS. 1 and 2 , the cells and the sensor can be physically separated from each other or can be in contact with each other (e.g., such as the cells being located on a biocompatible thin film sensor on which the cells are growing).
[0016] Although three sensors 118 , 120 , and 122 are illustrated in FIG. 1 , any suitable number of sensors (including only one) can be used in some embodiments, and those sensors can be at any suitable locations within the well.
[0017] In some embodiments, rather that integrating one or more sensors with the walls of the microplate well, optical sensors can be provided as illustrated in FIGS. 3 and 4 . As shown in FIG. 3 , optical sensors 302 can be provided at the tips 304 of optical capillaries 306 . Any suitable capillary, such as commercially available capillaries, can be used in some embodiments. Stimuli can be delivered through the central tube of the capillary and optical readout of the sensor can be achieved through the capillary wall. As shown in FIG. 4 , optical sensors 302 can be provided at the tips 304 of multi-lumen optical capillaries 406 in order to provide sensors at different heights. Any suitable multi-lumen capillary, such as commercially available capillaries, can be used in some embodiments.
[0018] During use, one or more cells 124 can be placed in well 114 in any suitable fashion, such as at the bottom of the well on top of transparent substrate 116 . The cells can then be exposed to analyte. Examples of analyte can include any soluble gas, ions, small molecules, nanoparticles, drugs, biomolecules, and microorganisms that reside at or below the lowest sensor location, for example cells 124 adhered to the transparent substrate 116 at the bottom of microplate well 114 . Images of the sensors at or above this analyte plane can then be captured to measure the gradient of analyte in the microplate well 114 from which the analyte consumption rate can be determined.
[0019] In some embodiments, as mentioned above, delivery of analyte to the cells in the well can occur as the analyte permeate through the diffusive membrane of the lid portion. In some embodiments, if the analyte under study is a liquid borne analyte, and the lid is in place, the liquid borne analyte can be held at a constant value within the analyte reservoir by controlling the flow of analyte in channels 108 and 110 . By controlling the concentration of analyte in the reservoir, the amount of analyte being delivered to the well can be controlled. In some embodiments, images of the fluorescent sensors can then be captured (e.g., from below microplate well via a suitable detector positioned below the transparent substrate).
[0020] As mentioned above, in some embodiments, microplate lid portion 102 can be omitted from the microplate assembly. For example, in some embodiments, if the analyte under study is a gas, the gas is present in the atmosphere, and a standard partial pressure is sufficient, then a microplate lid can be omitted from microplate portion 100 . Without the microplate lid (possible for atmospheric equilibrating gases), an image of the fluorescent sensors can be captured from above the microplate well (because the lid is omitted) or below the microplate well (via the transparent substrate), for example.
[0021] Once steady state is reached between the two contributions to analyte concentration within the microplate well (i.e., the influx/efflux from the diffusive membrane and the opposite efflux/influx from the cell(s)), then, in accordance with Fick's Laws of diffusion, a linear gradient in the microplate well will exist. Because the concentration is known in the analyte reservoir, by measuring the analyte concentration at at least one position within the microplate well, the linear gradient slope of the analyte in the well, and hence the consumption rate, can be determined. In some embodiments, by measuring the slope at multiple positions, further confidence about the absolute consumption rate of the cell(s) can be determined.
[0022] The extracellular flux rate of an analyte in the steady state may be determined by observation of the gradient of its concentration. In the steady state, the analyte concentration gradient above cells in a well can be linear as seen below in Equation 3. It may therefore not be necessary to measure this gradient in the vicinity of the cells and thereby risk damaging them. Measuring the analyte concentration at different depths within the well can be used to verify the linearity of the gradient, and hence both validate the steady state assumption and calculate the gradient by simple linear regression of the observed concentration values against the position of the sensor. The sensor may be moved or multiple fixed sensors may be used.
[0023] Equations:
[0024] (1) Fick's second law
[0000]
∂
C
∂
t
=
D
∂
2
C
∂
2
z
[0025] (2) Steady state condition
[0000]
D
∂
2
C
∂
2
z
=
0
[0026] (3) General solution to Eq. 1
[0000]
C=az+b.
[0027] (4) Boundary conditions
[0000] C ( h )=α P O 2 ,cells ; C (0)=α P O 2 ,surface
[0028] (5) Specific solution to Eq. 1
[0000]
C
=
α
[
P
O
2
,
cells
-
P
O
2
,
surface
]
h
·
z
+
α
P
O
2
,
cells
[0029] (6) Fick's first law
[0000]
J
=
-
D
∂
C
∂
z
[0030] (7) Combination of Eq. 5 and Eq. 6
[0000]
J
=
-
D
α
[
P
O
2
,
cells
-
P
O
2
,
surface
]
h
[0031] (8) Rate from flux
[0000]
{dot over (Q)}=J·A
[0032] (9) Respiration rate from gradient
[0000]
Q
.
=
-
(
D
·
A
·
α
)
α
[
P
O
2
,
cells
-
P
O
2
,
surface
]
h
DEFINITION OF TERMS
[0000]
C Concentration of Analyte (O 2 , pH, . . . ) in units of mol/m 3
t Time in units of s
z Position. Depth below surface of media column above the cells in units of m
D Diffusion coefficient (material constant) in units of m 2 /s
a,b Constants to be determined by boundary conditions
h Height of media column above the cells in units of m
α Analyte solubility coefficient. O 2 in media at 37° and standard pressure is reported as 0.94
P O 2 ,depth Partial pressure of analyte in units of millimeters of mercury.
J Diffusion flux in units of mol/m 2 .s
A Area of media column above the cell(s) in units of m 2
{dot over (Q)} Rate of analyte consumption or production. The respiration rate of the cell(s) in units of mole/s
[0044] In accordance with some embodiments, this technique can be used to measure atmospheric equilibrated dissolved oxygen consumption rates. In some embodiments, this technique can additionally or alternatively be used to measure the differences in cell consumption rates between cell types (cancerous vs. normal) and also between differing growth morphologies on 2D planar untreated surfaces vs. treated surfaces (poly-L-lysine, fibronectin, and laminin) and 3D scaffolds of aligimatrix.
[0045] Any suitable mechanism for capturing images of the sensors can be used, such as a plate reader, an imaging cytometer, an optical microscope, etc. Through the sensor images, homogeneous fluid analyte consumption rate can be measured.
[0046] For example, in some embodiments, the consumption rate can be measured from a single image by determining the difference in the brightness of two sensors at different heights in the well, dividing by their height difference, and multiplying by constants. Imaging the number of cells in each well can be used in some embodiments to bin the responses according to isolated cell numbers and thus cell-cell interactions can be considered.
[0047] In some embodiments, there may be extracellular fluxes for which the concentration is so small that the approach above is not capable of measuring a response. In such situations, optical sensors can be placed in direct contact with light-guiding fibers coupled to high sensitivity photo-counting diodes. In this approach, images are not being acquired, but rather light levels of the sensors are being acquired, from which images can be inferred. Conversely, light levels can be inferred from images with appropriate calibration.
[0048] For example, in some embodiments, real time in situ control with a moving light-guiding capillary can be used. In such an approach, a specialized lid with multiple light-guiding capillaries attached can be placed over a microwell array. Next, the array can be placed in an imager (e.g., such as an upright fluorescence microscope, an imaging cytometer, a modified microarray plate scanner, etc.). Stimuli can then be introduced at will. Excess media can be allowed to drain so that its level is less than or equal to height of mircowell. Then, one can wait for cell response, which can take minutes in some embodiments. The lid can then be slowly raised and images periodically taken. Finally, the change in sensor brightness between images can be measured and fit by linear regression to determine analyte flux rate.
[0049] For example, in some embodiments, real time in situ control with a static multi-lumen light-guiding capillary can be used. In such an approach, a specialized lid with multiple light-guiding capillaries attached can be placed over a microwell array. Next, the array can be placed in an imager (e.g., an upright fluorescence microscope, an imaging cytometer, a modified microplate scanner, etc.). Stimuli can then be introduced at will. Excess media can be allowed to drain so that its level is less than or equal to height of mircowell. Then, one can wait for cell response, which can take minutes in some embodiments. The difference in photon counts from the light-guiding capillaries can be determined and fit by linear regression to determine analyte flux rate.
[0050] In some embodiments, the microwells and sensors can be produced by standard high throughput MEMS-type manufacturing. Any suitable technology can be used. For example, in some embodiments, one or more of the following technologies can be used to produce the microwells: replicate molding or soft lithography; repeated aligned photomasked lithography; reactive ion etching; etc. The diffusion constants of the microenvironment in the microplate well 114 should be dominated by the media diffusion, and not diffusion through surrounding materials microplate 104 and diffusive membrane 112 . In the case of soft lithography with absorptive or emissive porous polymers, an additional coating might be required to ensure this condition. Sensors can be deposited by either additional photolithography or vapor phase deposition followed by barrier lift-off.
[0051] In some embodiments, any suitable solid phase sensor can be used. For example, hydrogel non-leeching fluorescent sensors for O 2 and pH as published in “SENSORS AND ACTUATORS B-CHEMICAL,” volume 147, issue 2, pages 714-722, Jun. 3, 2010, which is hereby incorporated by reference herein in its entirety, can be used in some embodiments. In some embodiments, these sensors can be mixed into a single matrix so long as their absorption and emission are compatible with the optical detection approach. In some embodiments, the sensitivity of these embedded sensors can be enhanced by resonant photonic behavior, for example, these sensors may act like micro-ring resonators which would be capable of measuring single-molecule changes.
[0052] In some embodiments, any suitable capillaries can be used. For example, in some embodiments, light-guiding capillaries, such as light-guiding fused silica capillaries, can be used. Light-guiding fused silica capillaries are commercially available, for example, from Polymicro Technologies, http://www.polymicro.com. Capillaries are available with dimensions appropriate for narrow single-cell appropriate microwells. Furthermore, published methods and commercial fittings exist for connecting both fluids and excitation/detection to these optical capillaries. In some embodiments, these capillaries can be prepared by dipping a pressurized (to keep the central channel free of sensor material) capillary tip into the appropriate sensor material, followed by curing.
[0053] In some embodiments, the methods and/or processes described herein for flux determination by gradient monitoring can be performed using any suitable devices. For example, in some embodiments, one or more computers, optical detectors/cameras/imagers, fluid controllers, robotic arms, and/or any other suitable devices can be used to place cells into a well, control the exposure of the cells to analyte, capture images of the sensors, and/or perform the calculations of flux, gradient, etc. A computer used for such purpose can be any of a general purpose device such as a computer or a special purpose device such as a client, a server, controller, etc. Any of these general or special purpose devices can include any suitable components such as a processor (which can be a microprocessor, digital signal processor, a controller, etc.), memory, communication interfaces, display controllers, input devices, etc.
[0054] In some embodiments, any suitable computer readable media can be used for storing instructions for performing the processes described herein. For example, in some embodiments, computer readable media can be transitory or non-transitory. For example, non-transitory computer readable media can include media such as magnetic media (such as hard disks, floppy disks, etc.), optical media (such as compact discs, digital video discs, Blu-ray discs, etc.), semiconductor media (such as flash memory, electrically programmable read only memory (EPROM), electrically erasable programmable read only memory (EEPROM), etc.), any suitable media that is not fleeting or devoid of any semblance of permanence during transmission, and/or any suitable tangible media. As another example, transitory computer readable media can include signals on networks, in wires, conductors, optical fibers, circuits, any suitable media that is fleeting and devoid of any semblance of permanence during transmission, and/or any suitable intangible media.
[0055] Although the invention has been described and illustrated in the foregoing illustrative embodiments, it is understood that the present disclosure has been made only by way of example, and that numerous changes in the details of implementation of the invention can be made without departing from the spirit and scope of the invention, which is only limited by the claim which follows. Features of the disclosed embodiments can be combined and rearranged in various ways.
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Microplate assemblies and methods for using same are provided. In accordance with some embodiments, microplate assemblies are provided, the assemblies comprising a microplate well portion that forms a microplate well and that includes at least one sensor in the microplate well that responds to analyte in the well. In accordance with some embodiments, methods for determining a cell consumption rate of an analyte are provided, the methods comprising: positioning a cell in a microplate well having at least one sensor located within the well; providing analyte to the microplate well at a controlled rate; detecting a response of the sensor to the analyte in the microplate well; and determining a cell consumption rate of the analyte based on the response of the sensor to the analyte.
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This application is a continuation of Ser. No. 08/134,827, filed Oct. 12, 1993, and now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a method and a system for transmitting signals between groups of data acquisition devices and a central station by means of concentration units.
More particularly the method and the system of the invention relates to seismic prospecting, where a large quantity of signals have to be transferred to a central station such as a recording truck and are picked up by a large number of receivers such as geophones, arranged in contact with the ground above a geological formation to be studied, in response to seismic signals transmitted by a seismic source and reflected by the subsoil discontinuities.
2. Description of the Prior Art
Current seismic prospecting methods include using acquisition devices distributed over several kilometers for collecting the signals received by at least one receiver, for digitizing and storing the signals in a local memory before they are transmitted in real or delayed time to a central station through a transmission channel such as a cable, an optical fiber, a radio channel, etc.
Various seismic data transmission systems are used to connect acquisition devices to a central station. Links may be provided by cables, radio channels, via one or several possible relays; cable and radio links may also be combined as shown for example in patents FR-2,599,533 corresponding to U.S. Pat. No. 4,815,044; 2,538,561 corresponding to U.S. Pat. No. 4,979,512; 2,511,772 corresponding to U.S. Pat. No. 4,583,206 or 2,627,652 corresponding to U.S. Pat. No. 4,908,803.
French Patent 2,511,772 describes a transmission system in which a central station communicates directly with a first array of acquisition devices by means of a first radio channel and, by means of a second radio channel, with a radiorelay which communicates with a second array of acquisition devices by means of a third radio channel. This mixed layout allows easy adaptation to topography changes or to radio link difficulties in zones where seismic exploration surveys are carried out.
French Patent 2,627,652 describes a semisequential transmission system allowing simultaneous communication of groups of seismic acquisition devices with a central station by means of several radio transmission channels of different frequencies. In each group, the devices are respectively allocated different serial numbers according to their location in the field. Each one of them determines the difference between its own serial number and a serial number received by radio and which is the number assigned to the first device of the group to which it belongs and it transmits the data which have been recorded thereby.
It is thus possible, with a single order, to control the semisequential transmission, towards the central station, of data coming from determined groups of acquisition devices.
The digitized data acquired by the acquisition boxes in the field are generally transmitted for example by series of 32 or 64 digital words included in a transmission frame and the transmitter waits for an acknowledgement signal from the central station before the emission of a new series of words. This transmission mode is relatively slow.
SUMMARY OF THE INVENTION
The transmission method according to the invention allows transmission to a central control and recording station, by means of a predetermined number n of concentration units, of digitized data stored in a plurality of seismic data acquisition devices distributed in an acquisition zone, these data corresponding to signals received by sensors and coming from discontinuities of a geological formation in response to seismic signals transmitted in the subsoil by a seismic source. The method comprises:
dividing at least part of the acquisition devices into a number of groups at least equal to the number n of concentration units, each unit including at most a number of acquisition devices;
assigning to each group (Gi) a determined number of specific radio transmission frequencies, the number being less than the number of devices defined for each group, the acquisition devices of a single group and the associated concentration unit (Ci) being provided each with a radio transmission device on at least one of the specific frequencies;
subdividing each group into subgroups of acquisition devices utilizing the same transmission frequency, for all the groups of acquisition devices, and assigning different serial numbers to the acquisition devices of a single subgroup;
sending from the central station a single transmission order to all the concentration units and to all the acquisition device, and
transmitting signals successively by means of all the acquisition devices of a single subgroup during staggered emission windows, each acquisition device delaying the emission window thereof by a time interval depending on its serial number in the subgroup to which it belongs, the transmissions of all the subgroups of any of the various groups being performed within a time interval.
If the acquisition devices are each provided each with a transmission device for transmitting on several different frequencies, the method may comprise sending an order to all the devices of a single group allowing switching of the transmission frequency to a determined frequency so as to assign them to a determined subgroup.
The method may further comprise sending an order allowing different serial numbers to be assigned to all the acquisition devices of each of the subgroups.
According to an embodiment, at least part of the concentration units is provided with radio communication devices for communicating with the central station at a frequency distinct for each one of the units, the signals received at the same time from the acquisition devices of the various subgroups which are be transmitted to the central station are transmitted successively by using this distinct frequency.
According to another embodiment, at least part of the concentration units may be connected to the central station by means of at least one material transmission channel.
The transmission system implementing the method according to the invention comprises a determined number n of concentration units each provided with a device for communicating with the central control and recording station and with a radio transmitter-receiver set for communicating simultaneously on several different frequencies each with a group of acquisition devices.
Each acquisition device of a single group includes a storage for storing a serial number, transmitter-receiver means for operation on at least one determined transmission frequency, a decoder for decoding orders transmitted by the control and recording station, a clock for generating a time scale which is substantially the same for all the acquisition devices of the array, and a processing set allowing demarcation of an emission window and staggering thereof by an interval depending on the serial number assigned to the device, to read the data acquired in the storage and to transmit them at the determined frequency.
With the invention, a single order allows control of the transmission to the control and recording station of all of the data stored in the array of acquisition devices distributed in the field by means of a limited number of transmission frequencies. The control and recording station receives simultaneously streams of signals (coming from the concentration units), each stream resulting from the sequencing of signals received simultaneously from acquisition devices of different subgroups of a single group, the devices of a single subgroup recognizing autonomously and automatically a certain priority order.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features and advantages of the transmission method and system according to the invention will be clear from reading the description hereafter of embodiments given by way of non limitative examples, with reference to the accompanying drawings in which:
FIG. 1 shows a first embodiment of the invention where all the exchanges between the acquisition devices, the concentration units and the central station are carried out by radio;
FIG. 2 shows an example of the embodiment of an acquisition device in accordance with the invention;
FIG. 3 shows an example of the embodiment of a concentration unit in accordance with the invention;
FIG. 4 shows another embodiment utilizing mixed transmission modes utilizing radio and non wireless transmission, and
FIG. 5 shows an example of the positioning of emission windows of several acquisition devices within a single group.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The seismic device shown in FIG. 1 includes seismic receivers R11 to Rpn spaced apart from one another and distributed over a zone to be explored so as to pick up the seismic waves reflected by subsoil discontinuities, in response to the transmission, in the ground, of seismic waves produced by a source S, and a central control and recording station 1. Each of these receivers R is most often made up of the electric interconnection of several lined-up elementary sensors g. All the receivers R11 to Rpn are connected to data acquisition devices BA11 to BApn for digitizing and for storing temporarily the seismic data collected by the associated receiver R.
The array of receivers R11 to Rpn is subdivided into n groups GA1, GA2 . . . GAn each including a number of p associated receivers and acquisition devices. Any group of order k for example comprises p receivers R1k, R2k . . . Rpk connected respectively to p acquisition devices BA1k, BA2k, BApk. A concentration unit C1 . . . Ck . . . Cn is associated with each group of receivers and acquisition devices. These units are arranged to relay respectively communications between the central station 1 and the devices of the associated group of devices GA1 . . . GAk . . . GAn. Each group Gi is assigned a number of q transmission frequencies fi1, fi2 . . . fiq, generally less than the number of p acquisition devices of the groups. Preferably, these frequencies are specific to each group. The devices of each group Gi are divided into q subgroups each including each several acquisition devices and each of the subgroups is assigned a frequency among the q specific frequencies fi1 to fiq available.
The transmission method which is implemented assigns a subgroup to each acquisition device and in assigning thereto a certain rank which sets the utilization rules for the transmission frequency f assigned to its subgroup.
For example, if any group GAk has 4 frequencies f1k, f2k, f3k, f4k, the devices of the group are numbered from 1 to p. The first frequency f1k is assigned to the devices numbered BA1 BA5k, BA9k, BA13k, etc, frequency f2k is assigned to the devices numbered BA2k, BA6k, etc; frequency f3k is assigned to the devices numbered BA3k, BA7k, etc, and frequency f4k is assigned to the devices numbered BA4k, BA8k, etc, with successive 4-device shifts in each subgroup. Furthermore, each device is also assigned an emission time of a determined duration. This time is calculated from the number of samples to be transmitted and from the data rate selected for the transmission. It ranges for example between about 0.12 s and 4 s.
Under these conditions, when, after seismic transmission-reception cycles, the devices of group Gk are given from the control and recording station, an emission order TB to transmit the seismic data which has been stored and when they are effectively ready to transmit from an initial instant t0 (FIG. 5), the first acquisition devices to transmit during the set interval T are devices BA1k, BA2k, BA3k and BA4k at the head of the respective subgroups thereof. By comparing their serial number with those of the leading devices, the following four devices BA5k to BA8k calculate that they have to shift their respective emission windows by an interval T increased by a safety interval dt sufficient to take into account possible disparities in the time base signals of the various devices. The following four devices, by means of an analogous comparison operation, shift their respective windows by an interval equal to 2(T+dt), etc.
The concentration units are arranged at relatively small distances for which the power required for the radio transmitters is low, about 100 mW for example or even less. Since the telecommunication regulations are not restricting for such low power, a great number of parallel communication channels is easily available between the various subgroups and the associated concentration unit. The number of higher powered radio channels which require a license may therefore be highly restricted.
Communications between the acquisition devices in the field and the central station may be speeded up if the data are transmitted without any interposed acknowledgement message. In this case, a well-known transmission method with interlacing and error checking is preferably selected so as to minimize the influence of possible disturbances such as that described in French patent 2,673,298.
Each of the acquisition devices includes for example as illustrated in FIG. 2 an acquisition unit 2 for amplifying the signals of the associated seismic receiver R, digitizing and storing them. In case several receivers are connected to the same device, the device further comprises a multiplexer at the top (not shown), as it is well-known in the art. Acquisition unit 2 is connected to a transmitter-receiver set 3 arranged for transmitting and receiving signals at a selected frequency depending on the group and on the subgroup to which the device concerned belongs.
The transmission-reception set 3 includes an oscillator 4 of the VCO type whose oscillation frequency is determined by application of a control voltage coming from a low-pass filter 5. The input of filter 5 is connected to the output of a frequency synthesizer circuit 6 of a well-known type including phase feedback loops (PLL) and a predivider allowing a programmable reduction factor to be applied to the reference frequency defined by a quartz crystal 7. Selection of this reduction factor is achieved by controlling selectively switches of an array of switches 8. The signal applied at the input of synthesizer circuit 6 is the signal of the VCO type oscillator 4.
Switching allows a specific frequency, among the nine frequencies available for each group G, to be assigned and may be performed by an operator at the time of the setting up of the acquisition devices in the field.
The signal delivered by acquisition unit 2 is applied to a coding element COD of the NRZ type for example, then amplified in an amplification stage 9 and applied at the "modulation" input of oscillator 4. The modulated carrier available at the output of oscillator 4 is applied to an amplification system including a pre-amplifier 10, a power amplifier 11 and a low-pass filter 12. The amplified signal is applied to a transmitter-receiver antenna 13 by means of an antenna duplexer of a well-known type. A radio receiver 14 receives the coded control signals coming directly from the central laboratory, encoded by a signal transmitted at a predetermined frequency common to all the acquisition devices, is also connected to antenna duplexer 13. Demodulation of the received signals is achieved by using a signal produced by the frequency synthesizer circuit 6. The demodulated signals coming from receiver 14 are decoded by decoder 15 and then applied to a micro-processing unit 16 including an arithmetic-logic unit 17 and a memory unit 18. Unit 17 includes an input port for the connection of an interface element 19 suited to the link type. It is for example possible to use an infrared optical receiver such as that described French Patent 2,602,875, which allows an operator to transmit instructions to the acquisition device without having to establish a wireline link therewith. Interface element 19 may also consist, as the case may be, of a radio receiver or of a connection for a transmission cable. A connection 20 is achieved between arithmetic-logic unit 17 and the array of switches 8, so that the transmission frequency may be changed at will.
The acquisition devices are for example placed in sealed boxes allowing them to be used in damp zones (lakes, bogs, forests, etc). The seismic equipment may for example include several hundred acquisition devices.
The processing unit 17 of each acquisition device is programmed to make the calculations necessary for the positioning of each emission window according to the serial number, the assigned frequency and the rank allocated to the device in the subgroup thereof. The data necessary for these positioning calculations may be fed into each device at the time of its setting up in the field for example, by means of an interface unit 19, or transmitted from central station 1 before the beginning of the planned seismic recording operations. This transmission of calculation data may in this case be performed by direct transmission or via concentration units C1 to Cn.
Processing unit 17 may be programmed to carry out all the operations necessary for allocating a transmission frequency and for the relative positioning of the emission windows from the serial number of the acquisition device in the field alone, which is introduced at the time of the setting thereof.
Each one of these concentration units Ci includes as illustrated in FIG. 3 radio receiver comprising q modules 201, 202 . . . 20q connected in parallel to an antenna 21 adjusted to the q frequencies fi1 to fiq assigned to the associated group Gi, to separate signals received simultaneously from q acquisition devices among the n of this group. After their separation, the signals received are placed into storage blocks 221, 222 . . . 22q of the FIFO type for example. These blocks are controlled by a synchronization module 23 for managing the simultaneous storing of the signals received and the sequential rereading thereof. The reading mode selected allows a set of q different signals received simultaneously from q acquisition devices of group Gi and stored to be converted into a stream of q successive signals which may be retransmitted on a single transmission channel such as a radio channel.
According to the embodiment of FIG. 4, n radio channels of respective frequencies F1 . . . Fk . . . Fn are used to achieve the sequential transmissions from the n concentration units C1 . . . Ck . . . Cn and central station 1. In this case, storage blocks 22 to 22q are connected to a radio transmitter 24 adjusted to the frequency Fk allocated to concentration unit Ck and connected to antenna 25 by means of a duplexer 26. The duplexer 26 also allows antenna 25 to be connected to a radio receiver 27 adjusted for example to frequency Fk so as to detect controls coming from central station 1.
According to the embodiment of FIG. 3, concentration units Ci are used which may either transmit or receive signals by a radio channel and by a non wireless material channel L such as a transmission cable or an optical fiber, in accordance with an implementation analogous to that described in the above-cited French Patent 2,511,772. When the application planned allows or requires it, at least a part C1, C2 . . . Ci of the concentration units is preferably connected to the central station by means of a common cable or fiber 28.
Without departing from the scope of the invention, at least part of the acquisition devices of a group such as group Gn in FIG. 3 may be connected to the associated concentration unit (Cn) by means of a material link.
Similarly, without departing from the scope of the invention, acquisition devices BA capable of acquiring by multiplexing the signals coming from several receivers R may be used.
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Seismic data acquisition devices (BA) distributed in an exploration zone are divided into n groups (GA1 to GAn) and, therein, into sub-groups having each a specific frequency for communicating with a concentration unit (Ck) which is connected to a central station (1) through Hertzian channels or cables or optical fibers. Acquisition devices in the various subgroups communicate simultaneously with the corresponding concentration unit (Ck) during predetermined emission windows. The concentration unit collects the signals received from the acquisition devices to transmit them in series to station (1). The acquisition devices are adapted for delaying their own emission window according to the rank which has been previously assigned thereto within the respective subgroups thereof.
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FIELD OF THE INVENTION
The present invention relates to a device within and a method processed by a Workflow Management System (WFMS). More particularly, the invention relates to a device and a method making resources/objects accessible to activities of said WFMS processing these resources/objects.
BACKGROUND OF THE INVENTION
A new area of technology with increasing importance is the domain of Workflow-Management-Systems (WFMS). WFMS support the modeling and execution of business processes. Business processes control which piece of work of a network of pieces of work will be performed by whom and which resources are exploited for this work, i.e. a business process describes how an enterprise will achieve its business goals. The individual pieces of work might be distributed across a multitude of different computer systems connected by some type of network.
The process of designing, developing and manufacturing a new product and the process of changing or adapting an existing product presents many challenges to product managers and engineers to bring the product to market for the least cost and within schedule while maintaining or even increasing product quality. Many companies are realizing that the conventional product design process is not satisfactory to meet these needs. They require early involvement of manufacturing engineering, cost engineering, logistic planning, procurement, manufacturing, service and support with the design effort. Furthermore, they require planning and control of product data through design, release, and manufacturing.
The correct and efficient execution of business processes within a company, e.g. development or production processes, is of enormous importance for a company and has significant influence on company's overall success in the market place. Therefore, those processes have to be regarded similar as technology processes and have to be tested, optimized and monitored. The management of such processes is usually performed and supported by a computer based process or workflow management system.
In D. J. Spoon: “Project Management Environment”, IBM Technical Disclosure Bulletin, Vol. 32, No. 9A, February 1990, pages 250 to 254, a process management environment is described including an operating environment, data elements, and application functions and processes.
In R. T. Marshak: “IBM's FlowMark, Object-Oriented Workflow for Mission-Critical Applications”, Workgroup Computing Report (USA), Vol. 17, No. 5, 1994, page 3 to 13, the object character of IBM FlowMark as a client/server product built on a true object model that is targeted for mission-critical production process application development and deployment is described.
In H. A. Inniss and J. H. Sheridan: “Workflow Management Based on an Object-Oriented Paradigm”, IBM Technical Disclosure Bulletin, Vol. 37, No. 3, March 1994, page 185, other aspects of object-oriented modeling on customization and changes are described.
In F. Leymann and D. Roller: “Business Process Management with FlowMark”, Digest of papers, Cat. No. 94CH3414-0, Spring COMPCON 94, 1994, pages 230 to 234, the state-of-the-art computer process management tool IBM FlowMark is described. The meta model of IBM FlowMark is presented as well as the implementation of IBM FlowMark. The possibilities of IBM FlowMark for modeling of business processes as well as their execution are discussed. The product IBM FlowMark is available for different computer platforms and documentation for IBM FlowMark is available in every IBM branch.
In F. Leymann: “A meta model to support the modeling and execution of processes”, Proceedings of the 11 th European Meeting on Cybernetics and System Research EMCR92, Vienna, Austria, Apr. 21 to 24, 1992, World Scientific 1992, pages 287 to 294, a meta model for controlling business processes is presented and discussed in detail.
The “IBM FlowMark for OS/2”, document number GH 19-8215-01, IBM Corporation, 1994, available in every IBM sales office, represents a typical modern, sophisticated, and powerful workflow management system. It supports the modeling of business processes as a network of activities; refer for instance to “Modeling Workflow”, document number SH 19-8241, IBM Corporation, 1996. As further information on Workflow Management Systems available in IBM sales offices one could mention: IBM MQSeries Concepts and Architecture, document number GH 12-6285; IBM MQSeries Getting Started with Buildtime, document number SH 12-6286; IBM MQSeries Getting Started with Runtime, document number SH 12-6287. This network of activities, the process model, is constructed as a directed, acyclic, weighted, colored graph. The nodes of the graph represent the activities or workitems which are performed. The edges of the graph, the control connectors, describe the potential sequence of execution of the activities. Definition of the process graph is via the IBM FlowMark Definition Language (FDL) or the built-in graphical editor. The runtime component of the workflow manager interprets the process graph and distributes the execution of activities to the right person at the right place, e. g. by assigning tasks to a work list according to the respective person, wherein said work list is stored as digital data within said workflow or process management computer system.
In F. Leymann and W. Altenhuber: “Managing business processes as an information resource”, IBM Systems Journal, Vol. 32(2), 1994, the mathematical theory underlying the IBM FlowMark product is described.
In D. Roller: “Verifikation von Workflows in IBM FlowMark”, in J. Becker und G. Vossen (Hrsg.): “Geschaeftsprozessmodellierung und Workflows”, International Thompson Publishing, 1995, the requirement and possibility of the verification of workflows is described. Furthermore the feature of graphical animation for verification of the process logic is presented as it is implemented within the IBM FlowMark product.
For implementing a computer based process management system, firstly the business processes have to be analyzed and, as the result of this analysis, a process model has to be constructed as a network of activities corresponding to the business process. In the IBM FlowMark product, the process models are not transformed into an executable. At run time, an instance of the process is created from the process model, called a process instance. This process instance is then interpreted dynamically by the IBM FlowMark product.
A user typically interacts with the workflow management system via a graphical end user that represents the tasks to be performed by the user as icons. Work for a particular task is started by the user by double-clicking on the appropriate icon which in turn starts the program implementing the activity.
It is important for the productivity of the user that the program complete its access to data as fast as possible to avoid delays in interacting with the user. In many cases WFMS are executed by a multitude of distributed computer systems accessing resources/objects which also are spread across the computer network. In such a distributed environment a user who controls execution of an activity assigned as a work item to him could suffer severe performance degradation until the system has been able to provide him with all required resources/objects. The problem becomes even worse if the activity has to access large resources/objects or if the activity requires access to a large number of resources/objects distributed across a large number of different computer systems.
Objective of the Invention
The invention is based on the objective of improving the performance of the access of a WFMS activity activated by a user to resources/objects required by said activity. It is an objective at the same time to optimize the communication traffic of an activity accessing resources/objects during execution.
Summary and Advantages of the Invention
The invention relates to one or a multitude of computer systems acting as a Workflow-Management-System (WFMS), wherein said WFMS comprises a process-model defining at least one process-activity managed and executed by said WFMS and wherein said WFMS comprises a WFMS-server, said WFMS-server performing navigation through said process-model and performing resolution. Resolution is done by selecting a next-process-activity to be executed by said WFMS, and by selecting a WFMS-agent to execute said next-process-activity. According to the present invention said computer system comprises a stager storing, after performing said resolution, resources required for execution of said next-process-activity from one or a multitude of source-locations at a WMF-staging-location. Said WFMS-agent uses said resources from said WFMS-staging-location for execution of said next-process-activity.
The technique proposed by the present invention significantly improves performance with respect to the access of an executing activity to resources accessed by said activity. This is due to the fact that all resources required by said activity can be stored to and made available by an arbitrary WFMS staging location being placed “closer” (in terms of access time, for instance due large bandwidth or huge processing power) to the system executing the activity. This increases the productivity of the user as the program completes its access to data as fast as possible to avoid delays in interacting with the user. The teaching of the present invention is of specific advantage as in many cases WFMS are executed by a multitude of distributed computer systems accessing resources/objects which also are spread across the computer network. In such a distributed environment a user who controls execution of an activity assigned as a work item to him could suffer severe productivity degradation until the system has been able to provide him with all required resources/objects; the present solutions avoids this. The advantages are also remarkable if the activity has to access large resources/objects or if the activity requires access to a large number of resources/objects distributed across a large number of different computer systems. Finally the present invention would reduce the network traffic as it is more economical to transfer a certain amount of data in a single bulk data transfer compared to the situation of transferring the same amount of data via a larger number of transfer requests. Moreover, the suggested teaching is flexible in the sense that it is not required to adapt the program implementing the activity in any way. The present invention does not enforce the stager to be a component of the WFMS (of course that could be the case), offering large spectrum of implementation possibilities. For instance, the stager could also be implemented as an “exit”.
Additional advantages are accomplished by a WFMS wherein said WFMS-agent stores output generated by execution of said next-process-activity at said WFMS-staging-location and said WFMS, after completion of said next-process-activity, stores said output to said source-location.
Due to such a teaching also the manipulative access to the resources is supported and experiences significant speed-up for write/modify access.
Additional advantages are accomplished if said storing of said output is performed by said stager.
As the stager takes care to write the generated output back to the original storage locations the present teaching is completely transparent to the level of programs implementing activities. The complexity of implementing such programs is therefore reduced. The staging facility has to be implemented once but can be exploited by all programs.
Additional advantages are accomplished by said WFMS, wherein said stager is called by said WFMS-server or by said WFMS-agent.
The WFMS-server or the WFMS-agent are the optimal instance to call the stager as both of them have the knowledge when one activity has terminated and the WFMS is ready to process the next activity according the process model. Thus the overall processing effort is minimized if either the WFMS server or the WFMS client is responsible for calling the stager. This is at least true as far as the stager is storing, after completion of said next-process-activity, the output to said source location. In a WFMS in which navigation is performed by the WFMS only, it might be a better choice to invoke the stager by the WFMS server. The latter approach would guarantee data consistency as the WFMS server would not invoke the next process activity before the stager has stored the output to the source location.
Additional advantages are accomplished if said resources comprise data and/or a program required for execution of said next-process-activity.
On one hand flexibility of the present teaching is increased, if no limitation is imposed upon the nature of the resources. On the other hand supporting both, data and code, makes the present approach open for object-oriented approaches. Even more, the present teaching could also be used to stage the program implementing the activity to be executed by a user to the WFMS staging location; thus the WFMS agent would be enabled to access that program faster for its execution.
Additional advantages are accomplished if said WFMS-staging-location is selected dynamically from a predefined set of WFMS-staging-locations. Moreover it is advantageous to select said WFMS-staging-location such that said resources can be accessed on said WFMS-staging-location with improved performance compared to an access from their source-location.
A dynamic selection process allows the WFMS to take into account for the selection all changes occurring within the WFMS up to the point in time of the selection. Moreover the selection can also consider the system load, transmission load within the network etc. for an optimal selection of an WFMS staging location.
Additional advantages are accomplished if said stager is located on said WFMS-server.
As the WFMS server stores the complete process model and the activities are parts of it, all knowledge required for the stager to perform its work is available on the WFMS server. If the WFMS server and the stager share a common system, communication overhead within a distributed environment is minimized.
According to a further embodiment of the invention said WFMS performs said resolution by further selecting a WFMS-client to control execution of said next-process-activity by a work-item and said WFMS providing said work-item to said WFMS-client. Additional advantages are accomplished by not presenting said work-item to a user before said resources have been stored to said WFMS-staging-location.
As a work item is presented to the user after the resources have been stored to the WFMS staging location (from where they can be accessed in an optimal way) the user will not realize the processing time (latency period) required to make the resources available at the WFMS staging sever. The user will fully enjoy the performance improvements.
According to a further embodiment of the invention, said process-activity has associated with it at least one input-container. Additional advantages are accomplished if said resources are determined from the contents of said input-container of said next-process-activity. Further advantages are achieved if said stager determines said resources.
These features of the present invention allow implementation of the invention within an existing WFMS with minimal modifications to the WFMS. As an input container already stores information regarding which data the corresponding activity will require for its processing, a separate stager could exploit this information for locating these resources, transferring and storing the resources on the WFMS staging location.
According to a further embodiment of the invention said WFMS-staging-location and said WFMS-agent are located on the same computer system, or said WFMS-client and said WFMS-agent are located on the same computer system, or said WFMS-staging-location, said WFMS-agent and said WFMS-client are located on the same computer system.
According to the various characteristics of the actual distributed processing environment the present teaching suggests instantiating the WFMS staging location, the WFMS agent and the WFMS-client on the same or different computer systems for achieving the best performance results. In most cases performance is optimal if the WFMS staging location, the WFMS agent and the WFMS-client are located on the same computer system.
According to a further embodiment of the invention access to said WFMS-staging-location is managed through a WMFS-staging-server.
With this feature the implementation of a stager could be simplified as the knowledge of how to access the resources staged to the WFMS staging location is provided by the separate WFMS staging server.
Another embodiment of the invention relates to a method of staging resources in a Workflow-Management-System (WFMS), wherein said WFSM comprises a process-model defining at least one process-activity managed and executed by said WFMS and said WFMS performs navigation through said process-model. The proposed method comprises a resolution-step, wherein a next-process-activity to be executed by said WFMS is selected, and wherein a WFMS-agent to execute said next-process-activity is selected. The proposed method further comprises a staging-step storing resources required for execution of said next-process-activity from one or a multitude of source-locations at a WMF-staging-location. Moreover the proposed method comprises a usage-step, wherein said WFMS-agent uses said resources from said WFMS-staging-location for execution of said next-process-activity.
With respect to the advantages achieved by said method features refer to the corresponding device features discussed above.
According to a further embodiment of the invention a method of staging resources is taught wherein in said usage-step said WFMS-agent is storing output generated by execution of said next-process-activity onto said WFMS-staging-location. In addition said method comprises a restore-step succeeding said usage-step, wherein after completion of said next-process-activity, said output is restored to said source-location.
With respect to the advantages achieved by said method features refer to the corresponding device features discussed above.
According to a further embodiment of the invention a method of staging resources is taught wherein said resources comprise data and/or a program required for execution of said next-process-activity.
With respect to the advantages achieved by said method features refer to the corresponding device features discussed above.
According to a further embodiment of the invention a method of staging resources is taught wherein in said staging-step said WFMS-staging-location is selected such that said resources can be accessed on said WFMS-staging-location with improved performance compared to an access from their source-location.
With respect to the advantages achieved by said method features refer to the corresponding device features discussed above.
According to a further embodiment of the invention, a method of staging resources is taught which comprises a work-item-presentation-step succeeding said staging-step and presenting a work-item to a user, said work-item allowing said user to control execution of said next-process-activity from a WFMS-client.
With respect to the advantages achieved by said method features refer to the corresponding device features discussed above.
According to a further embodiment of the invention, a method of staging resources is taught wherein in said staging-step said resources are determined from the contents of one or more input-containers of said next-process-activity, said input-containers being associated with said next-process-activity.
With respect to the advantages achieved by said method features refer to the corresponding device features discussed above.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram reflecting the first phase of the execution of an activity in a WFMS showing the creation of work items.
FIG. 2 is a diagram reflecting the second phase of the execution of an activity in a WFMS showing the execution of an activity implementation and its access to resource/objects by the activity implementation.
FIG. 3 shows the basic architecture of a WFMS for the support of clients and the execution of activity implementations.
FIG. 4 shows the improved architecture of a WFMS for the support of clients and the execution of activity implementations according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention is illustrated based on IBM's FlowMark workflow management system. Of course any other WFMS could be used instead. Furthermore the present teaching applies also to any other type of system which offers WFMS functionalities not as a separate WFMS but within some other type of system.
Throughout the specification the terms “resources” and “objects” are used interchangeably referring to any kind of data or programs or combinations thereof. While the term “object” is a terminology more focused on the object-oriented side, the term “resource” reflects the more traditional view.
Introduction
The following is a short outline on the basic concepts of a workflow management system based on IBM's FlowMark WFMS:
From an enterprise point of view the management of business processes is becoming increasingly important: business processes or process for short control which piece of work will be performed by whom and which resources are exploited for this work, i.e. a business process describes how an enterprise will achieve its business goals. A WFMS may support both the modeling of business processes and their execution.
Modeling of a business process as a syntactical unit in a way that is directly supported by a software system is extremely desirable. Moreover, the software system can also work as an interpreter basically getting as input such a model: The model, called a process model or workflow model, can then be instantiated and the individual sequence of work steps depending on the context of the instantiation of the model can be determined. Such a model of a business process can be perceived as a template for a class of similar processes performed within an enterprise; it is a schema describing all possible execution variants of a particular kind of business process. An instance of such a model and its interpretation represents an individual process, i.e. a concrete, context dependent execution of a variant prescribed by the model. A WFMSs facilitates the management of business processes. It provides a means to describe models of business processes (build time) and it drives business processes based on an associated model (run time). The meta model of IBM's WFMS FlowMark, i.e. the syntactical elements provided for describing business process models, and the meaning and interpretation of these syntactical elements, is described next.
A process model is a complete representation of a process, comprising a process diagram and the settings that define the logic behind the components of the diagram. Using various services provided by FlowMark these buildtime definitions of the process models are then converted into process templates for use by FlowMark at runtime. Components of a FlowMark process model are:
Processes
Activities
Blocks
Control Flows
Connectors
Data Containers
Data Structures
Conditions
Programs
Staff
Not all of these elements will be described below.
On this background a process, modeled by a process model within FlowMark, is a sequence of activities that must be completed to accomplish a task. The process is the top-level element of a FlowMark workflow model. In a FlowMark process, it can be defined as:
How work is to progress from one activity to the next
Which persons are to perform activities and what programs they are to use
Whether any other processes, called subprocesses, are nested in the process
Of course multiple instances of a FlowMark process can run in parallel.
Activities are the fundamental elements of the meta model. An activity represents a business action that is from a certain perspective a semantical entity of its own. With the model of the business process it might have a fine-structure that is then represented in turn via a model, or the details of it are not of interest at all from a business process modeling point of view. Refinement of activities via process models allows for both the modeling of business processes bottom-up and top-down. Activities, being steps within a process, represent pieces of work that the assigned person can complete by starting a program or another process. In a process model, the following information is associated with each activity:
What conditions must be met before the activity can start
Whether the activity must be started manually by a user or can start automatically
What condition indicates that the activity is complete
Whether control can exit from the activity automatically or the activity must first be confirmed as complete by a user
How much time is allowed for completion of the activity
Who is responsible for completing the activity
Which program or process is used to complete the activity
What data is required as input to the activity and as output from it
A FlowMark process model consists of the following types of activities: Program activity: Has a program assigned to perform it. The program is invoked when the activity is started. In a fully automated workflow, the program performs the activity without human intervention. Otherwise, the user must start the activity by selecting it from a runtime work list. Output from the program can be used in the exit condition for the program activity and for the transition conditions to other activities.
Process activity: Has a (sub-)process assigned to perform it. The process is invoked when the activity is started. A process activity represents a way to reuse a set of activities that are common to different processes. Output from the process can be used in the exit condition for the process activity and for the transition conditions to other activities.
The flow of control, i.e. the control flow through a running process, determines the sequence in which activities are executed. The FlowMark workflow manager navigates a path through the process that is determined by the evaluation to TRUE of start conditions, exit conditions, and transition conditions.
The results that are in general produced by the work represented by an activity are put into an output container, which is associated with each activity. Since an activity will in general be required to access output containers of other activities, each activity is associated in addition with an input container too. At run time, the actual values for the formal parameters building the input container of an activity represent the actual context of an instance of the activity. Each data container is defined by a data structure. A data structure is an ordered list of variables, called members, that have a name and a data type. Data connectors represent the transfer of data from output containers to input containers. When a data connector joins an output container with an input container, and the data structures of the two containers match exactly, the FlowMark workflow manager maps the data automatically.
Connectors link activities in a process model. Using connectors, one defines the sequence of activities and the transmission of data between activities. Since activities might not be executed arbitrarily they are bound together via control connectors. A control connector might be perceived as a directed edge between two activities; the activity at the connector's end point cannot start before the activity at the start point of the connector has finished (successfully). Control connectors thus model the potential flow of control within a business process model. Default connectors specify where control should flow when the transition condition of no other control connector leaving an activity evaluates to TRUE. Default connectors enable the workflow model to cope with exceptional events. Data connectors specify the flow of data in a workflow model. A data connector originates from an activity or a block, and has an activity or a block as its target. One can specify that output data is to go to one target or to multiple targets. A target can have more than one incoming data connector.
Conditions are the means by which it is possible to specify the flow of control in a process. In FlowMark process models logical expressions can be defined that are evaluated by FlowMark at runtime to determine when an activity may start, end, and pass control to the next activity. Start conditions are conditions that determine when an activity with incoming control connectors can start. The start condition may specify that all incoming control connectors must evaluate to TRUE, or it may specify that at least one of them must evaluate to true. Whatever the start condition, all incoming connectors must be evaluated before the activity can start. If an activity has no incoming control connectors, it becomes ready when the process or block containing it starts. In addition, a Boolean expression called transition condition is associated with each control connector. Parameters from output containers of activities having already produced their results are followed as parameters referenced in transition conditions. When at run time an activity terminates successfully, all control connectors leaving this activity are determined and the truth value of the associated transition conditions is computed based on the actual values of their parameters. Only the end points of control connectors the transition conditions of which evaluated to TRUE are considered as activities that might be executed based on the actual context of the business process. Transition conditions model thus the context dependent actual flow of control within a business process (i.e. an instance of a model). Business processes encompass long running activities in general; such activities need to be allowed to be interrupted. Thus, termination of an activity does not necessarily indicate that the associated task has been finished successfully. In order to allow the measurement of successfulness of the work performed by an activity, a Boolean expression called exit condition is associated with each activity. Only the activities the exit conditions of which evaluated to TRUE in the actual context are treated as successfully terminated. For determination of the actual control flow precisely the successfully terminated activities are considered. Thus the logical expression of an exit condition, if specified, must evaluate to TRUE for control to pass from an activity or block.
Beside describing the potential flow of control and data between activities, a business process model also encompasses the description of the flow of the activities itself among “resources” actually performing the pieces of work represented by each activity. A resource may be specified as a particular program, person, a role, or an organizational unit. At run time tasks are resolved into requests to particular persons to perform particular activities, resulting in workitems for that person. Staff assignments are the means to distribute activities to the right people in the sequence prescribed by the control flow aspect of a business process model. Each activity in a process is assigned to one or more staff members defined in the FlowMark database. Whether an activity is started manually by the user or automatically by the FlowMark workflow manager, and whether it requires user interaction to complete or completes automatically, a staff member must be assigned to it. FlowMark staff definition entails more than identifying people at your enterprise to the FlowMark database. For each person defined, you can specify a level, an organization, and multiple roles. These attributes can be used at run time to dynamically assign activities to people with suitable attributes.
Process definition includes modeling of activities, control connectors between the activities, input/output container, and data connectors. A process is represented as a directed acyclic graph with the activities as nodes and the control/data connectors as the edges of the graph. The graph is manipulated via a built-in, event-driven, CUA compliant graphic editor. The data containers are specified as named data structures. These data structures themselves are specified via the Data Structure Definition facility. FlowMark distinguishes three main types of activities: program activities, process activities, and blocks. Program activities are implemented through programs. The programs are registered via the Program Definition facility. Blocks contain the same constructs as processes, such as activities, control connectors etc. They are however not named and have their own exit conditions. If the exit condition is not met, the block is started again. The block thus implements a Do Until construct. Process activities are implemented as processes. These subprocesses are defined separately as regular, named processes, with all their usual properties. Process activities offer great flexibility for process definition. They not only allow one to construct a process through permanent refinement of activities into program and process activities (top-down), but also to build a process out of a set of existing processes (bottom-up). In particular, process activities help to organize the modeling work if several process modelers are working together. They allow the team members to work independently on different activities. Program and process activities can be associated with a time limit. The time limit specifies how long the activity may take. If the time is exceeded, a designated person is notified. If this person does not react within another time limit, the process administrator is notified. It not only helps to recognize critical situations, but also to detect process deficiencies as all notifications are recorded in an audit trail.
All data structures used as templates for the containers of activities and processes are defined via the Data Structure Definition Facility. Data Structures are names and are defined in terms of elementary data types, such as float, integer, or string and references to existing data structures. Managing data structures as separate entities has the advantage that all interfaces of activities and their implementations are managed consistently in one place (similar to header files in programming languages).
All programs which implement program activities are defined via the Program Registration Facility. Registered for each program is the name of the program, its location, and the invocation string. The invocation string consists of the program name and the command string passed to the program.
Before process instances can be created, the process model must be translated to ensure the correctness and completeness of the process model. The translated version of the model is used as a template when a process instance is created. This allows one to make changes to the process model without affecting executing process instances. A process instance is started either via the graphical interface or via the callable process application programming interface. When a process is started, the start activities are located, the proper people are determined, and the activities are posted onto the work list of the selected people as work items. If a user selects a work item, i.e. the activity, the activity is executed and removed from the work list of any other user to whom the activity has been posted. After an activity has executed, its exit condition is evaluated. If not met, the activity is rescheduled for execution, otherwise all outgoing control connectors and the associated transition conditions are evaluated. A control connector is selected if the condition evaluates to TRUE. The target activities of the selected control connectors are then evaluated. If their start conditions are TRUE, they are posted to the work list of selected people. A process is considered terminated if all end activities have completed. To make sure that all end activities finish, a dead path elimination is performed. It removes all edges in the process graph which can never be reached due to failing transition conditions. All information about the current state of a process is stored in the database maintained by the server. This allows forward recovery in case of crashes.
Activity Execution in WFMS
As already indicated above, WFMS support the definition and execution of business processes. Those business processes are made up of a set of activities which are handled by different people at different places; business processes are therefore processed in most cases in a distributed environment comprising a network of a multitude of computer systems. The activities are generally implemented via programs that the user interacts with and that manage data that is associated with the process. A user typically interacts with the workflow management system via a graphical end user that represents the tasks to be performed by the user as icons. Work for a particular task is started by the user by double-clicking on the appropriate icon which in turn starts the program implementing the activity.
The execution of an activity within a process is performed in two phases visualized in FIG. 1 and FIG. 2 . FIG. 1 shows the first phase in which staff resolution is performed. When a process is defined, each activity is assigned an expression (staff assignment) that describes who should perform the activity. The staff assignment is expressed as a query against the organizational database that is part of the workflow management system. When the workflow management system navigates to an activity, it uses that query to find the people who should perform the activity (staff resolution). A work item ( 101 , 102 , 103 ) is created for each of the selected persons. Depending on some settings, the work item is pushed immediately onto the work list ( 104 , 105 ) of a selected person, or will be made part of the user's work list as the result of an explicit request.
FIG. 2 shows the flow of control when the user starts a work item from the work list representing the second phase of execution of an activity. After double-clicking the work-item representing the execution request of the activity on the work list ( 201 ), the workflow management system materializes the input container ( 202 ) and/or output container ( 203 ) and activates the program ( 205 ) that implements the activity ( 204 ). The program that is executed typically determines its context by obtaining some or all of the fields in the input container, interacts with the user, retrieves or modifies some resources/objects ( 206 ), or date data for short, modifies the context by storing this information in the output container, and then terminates. This constitutes the completion of the activity, and navigation through the process graph continues.
It is obvious that the data access must be fast. Otherwise, the user is waiting unproductively before any interaction can be performed. Which data is accessed is typically determined from context information in an input container, such as the name of a file that contains the image to be displayed. The speed with which the data is retrieved or modified depends on the available bandwidth between the location where the data resides and the location where the program executes. The data, if there is only low bandwidth between the program and the data, should be brought to a place with high bandwidth before the program is invoked. That means the user should not see the appropriate work item before the appropriate objects have been staged to a place with high bandwidth or a place as “close as possible” (in terms of access time) to the system executing the activity. Moreover, the original data to be accessed by the activity might be stored on a multitude of different systems. Further improvements might be achieved by concentrating copies of that data for usage by the activity on a single nearby computer system.
The current application proposes a new approach as to how this can be achieved within a workflow management system.
The Staging Solution
It is important for the productivity of the user that the program complete its access to data as fast as possible to avoid delays in interacting with the user. It is almost mandatory, in particular in a distributed environment, that large objects be brought very close (staged) to the executing program before the user perform the associated task. The same holds if the activity requires access to a large number of resources/objects distributed across a large number of different computer systems. This specification proposes a flexible method that allows the exploiters of workflow management systems to specify which data should be staged to which place.
FIG. 3 shows the basic architecture of a workflow management system for the support of clients and the execution of activity implementations. WFMS Server, WFMS agent, and WFMS client represent three major components of the workflow management system. The WFMS server ( 301 ) performs navigation through the process graph to determine the set of next activities to be performed after completion of an activity, performs staff resolution for a selected activity, and creates work items for selected users. The WFMS client ( 302 ) manages the work items for the user and implements together with the WFMS server the push or pull of work items. When a work item is selected by a user, the WFMS client indicates this to the WFMS server, which then materializes the input container and/or output container ( 303 ), and sends the materialized containers and appropriate activity implementation information such as the name of the program to be executed to the WFMS agent ( 304 ). The WFMS agent ( 304 ) invokes the specified program ( 305 ), provides the appropriate containers to the invoked program, and accepts application programming interface requests from the program for retrieval of data from the input container and storing of data into the output container. Moreover, it accesses further data ( 306 ) depending on the nature of the activity and, if the program finishes, informs the WFMS server about completion, so that the server can continue navigation.
This architecture can be extended to support the staging of objects as shown in FIG. 4 . After the WFMS server ( 401 ) has performed staff resolution, it calls the stager ( 402 ) to move the resources/object(s) ( 403 ) to a pre-defined location, the WFMS staging location ( 408 ), such as the workstation of the selected user or to a LAN server to which the user has access. FIG. 4 shows an optional extension of that idea, wherein the resources/objects ( 403 ) are moved to a WFMS staging location whose access is managed by a separate WFMS staging server ( 404 ) (without a WFMS staging server the program ( 406 ) and the stager ( 402 ) would access the WFMS staging location ( 408 ) directly). The stager has access to the input container ( 405 ) with the same contents as will be passed to the program. This provides the staging program with the same amount of information as the program, so that the staging program can determine which object(s) should be moved. After the object has been successfully staged to the WFMS staging location, the WFMS makes the associated work item available to the WFMS client ( 407 ). When a work item is now selected by a user, the activity implementation ( 406 ) accesses the object(s) from the new location ( 408 ) at maximum speed.
When the activity implementation has completed, the WFMS agent ( 409 ) informs the WFMS server about this so that the WFMS server can continue navigation. If an object has been staged to a WFMS staging location, the WFMS server needs to perform two actions. First, it must call the staging program to copy the modified object back to the original place. Second, it must call the staging program to delete all copies of the object.
Clearly, the program that implements the activity and the staging program(s) that moves the objects close to the program need to be carefully designed and implemented together.
In the shown architecture, the stager is invoked by the WFMS server. Alternatively, the stager could be invoked by the WFMS client upon a request of the WFMS server.
Process Model Additions
Several additions to the process model of the workflow management system are required. The outlined proposal can be applied to most process models supported by workflow management systems. For illustrative purposes, the process meta model of IBM FlowMark is used. Therefore these extensions are specified in the FlowMark Definition Language (FDL), though any other type of specification could be used instead consistent with the proposed invention. It should be further mentioned that the extensions are only outlined to the extent of allowing a person skilled in the art to implement the additions. Further details are avoided.
According to the FlowMark FDL, each program that is the implementation of an activity is registered via the PROGRAM section. Keywords supplied in this section define the properties of the program for each of the operating system platform it is executing on. Further keywords need to be added that define which staging programs should be called and in which sequence. The following section of a FDL program registration shows the new keyword STAGER which is assigned the value of IMAGE.
This indicates that a staging program is invoked when an activity is implemented via this program and that the stager program has been registered under the name IMAGE.
The staging program itself must be registered with FlowMark together with all the properties that are needed to perform correct staging of the objects. Typical properties for such a program are:
The operating system on which the program is to be executed.
The name and path of the executable.
Whether it should be executed by the WFMS server or the WFMS client or some other places in the WFMS network.
The location where it should put the copied object(s); examples are: a separate WFMS Staging Location, the WFMS Agent, the WFMS Client, the WFMS Server or WFMS Staging Location managed by a separate WFMS Staging Server.
The following section of a stager registration shows the definition of a staging program.
In the spirit of having separate sections for each of the major pieces of the process model, a new section STAGER is introduced. This section keyword starts the definition of a staging program. The staging program is registered under the name IMAGE. This is the name which is used in the registration of programs, as shown in the previous figure. The OS2 keyword starts the definitions of the properties of the executable when the staging program is invoked in the OS/2 environment. In this case, the program is found in the directory IMAGE on the E: disk and the program name is IMGCOPY.EXE as identified via the PATH keyword.
The INVOCATION_MODE property indicates that the program is invoked on the server of the workflow management system.
The TARGET keyword starts the definition as to where the staging program should put the staged objects. Thus it identifies the WFMS staging location and the storage location within that system. In the example, the object is staged to the user's workstation (LOCATION USER) into the directory IMAGE on the E: disk as indicated by the PATH keyword; in this example case the WFMS staging location is identical with the WFMS Client.
In this example it is assumed that the object identification is maintained in the input container.
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The present invention relates to a device within and a method processed by a Workflow Management System (WFMS) making resources/objects accessible to activities of said WFMS processing these resources/objects. The Workflow-Management-System (WFMS) according the current invention comprises a WFMS-server said WFMS-server performs navigation through a process-model and performs resolution by selecting a next-process-activity to be executed by said WFMS, and by selecting a WFMS-agent to execute said next-process-activity. The current invention teaches a stager storing, after the WFMS performing said resolution, resources required for execution of said next-process-activity from one or a multitude of source-locations onto a WMF-staging-location. Afterwards the WFMS-agent uses said resources from said WFMS-staging-location for execution of said next-process-activity.
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CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] The present application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/103,858, filed Oct. 8, 2008, the contents of which are hereby incorporated by reference in their entirety, and claims priority from European Patent Application EP 08 017 644.9, filed Oct. 8, 2008, the contents of which are hereby incorporated by reference in their entirety.
BACKGROUND
[0002] The invention relates to a bone anchoring device, in particular to a polyaxial bone screw which is connected to two stabilization rods and to a stabilization device having such a bone anchoring device, in particular for the stabilization of the spinal column.
[0003] A dynamic stabilization device for bones, in particular for vertebrae, is described in US 2004/0049190 A1. The stabilization device includes two bone anchoring elements, at least one of which is a polyaxial bone screw and a rigid rod with a longitudinal axis connecting them. An elastic element is inserted between the two bone anchoring elements. The elastic element acts on the bone anchoring elements to exert a force in a direction of the longitudinal axis. One of the bone anchoring elements is fixedly connected to the rod to prevent translational movement of the rod and the other bone anchoring element is slidably connected to the rod.
[0004] EP 1 800 614 A1 describes a dynamic stabilization device for bones or for vertebrae having at least two bone anchoring elements and at least one connection element in the form of an elastic loop connecting the bone anchoring elements. In one embodiment, the bone anchoring element is in the form of a polyaxial bone screw having a receiving part which accommodates to two elastic loops each of which can be connected to a second bone anchoring element.
[0005] Based on the foregoing, there is a need to provide a bone anchoring device and a stabilization device comprising such a bone anchoring device which allows the dynamic stabilization of bone parts or vertebrae and which allows a variable design of elastic properties of the dynamic stabilization device.
SUMMARY
[0006] The provision of a modular double-rod, i.e. two rods, allows to design the bone anchoring device more compact in terms of the height of the bone anchoring device, since each rod can be designed smaller than a single rod. The low profile cross-section of two rods compared to one single rod has also the advantage that the stiffness of the rods is enhanced. The stability in view of bending or torsional loads of the double-rod system is also enhanced.
[0007] The dynamic properties of the stabilization device can be adjusted by selecting appropriate rods and/or adjusting the sliding motion of the rods by stops and/or dampening elements. The dynamic properties of the rods can vary. For example the rods can have the same or different elastic properties. They can be made of the same or different material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 shows a perspective side view of the stabilization device.
[0009] FIG. 2 shows a perspective exploded view of the stabilization device.
[0010] FIG. 3 shows an exploded view of the bone anchoring device according to a first embodiment.
[0011] FIG. 4 shows a perspective view of the bone anchoring device of FIG. 3 in an assembled state.
[0012] FIG. 5 shows a perspective view from the side of the first pressure element in a first embodiment.
[0013] FIG. 6 shows a perspective view of the second pressure element in a first embodiment.
[0014] FIG. 7 shows a partially sectional view of the bone anchoring device with the first and second pressure element according to the first embodiment.
[0015] FIG. 8 shows a partially sectional view of the bone anchoring device with the first and second pressure element according to a second embodiment.
[0016] FIG. 9 shows an exploded perspective view of the bone anchoring device with a first and second pressure element according to a third embodiment.
[0017] FIG. 10 shows a perspective view of the bone anchoring device of FIG. 9 in an assembled state.
[0018] FIG. 11 shows a perspective view of a rod according to another embodiment.
DETAILED DESCRIPTION
[0019] The invention is now described in detail with reference to the embodiment of the stabilization device shown in FIGS. 1 to 8 . The stabilization device includes a first polyaxial pedicle screw 1 , a second pedicle screw 2 and two rods 3 a , 3 b connecting them for stabilizing two adjacent vertebrae. The two rods 3 a , 3 b may be separate rods as shown in FIG. 2 . Alternatively, as shown in FIG. 11 , the rods 3 a , 3 b may be connected or formed in one-piece to define a single rod 3 .
[0020] On each rod a spring element 4 a , 4 b is provided and the rods 3 a , 3 b are connected by rod connectors 5 , 6 . The rods 3 a , 3 b are fixedly clamped in the second pedicle screw 2 and can slide through the first pedicle screw 1 as shown by the arrows. The sliding motion is limited by means of the rod connector 6 which connects the free ends of the rods 3 a , 3 b and acts as a stop. The springs 4 a , 4 b and the rod connector 5 limit the sliding motion of the rods 3 a , 3 b relative to the first pedicle screw 1 in the direction of the second pedicle screw 2 . The springs provide elastic dampening. The rod connectors 5 , 6 are sleeve shaped with two channels 5 a , 5 b , 6 a , 6 b , respectively, for guiding through the rods 3 a , 3 b . The distance of the channels corresponds to the distance of the rods in which they are guided through the pedicle screws. The rod connectors 5 , 6 connect the rod 3 a , 3 b by means of a press-fit connection i.e the diameter of the channels is selected such that the rods are firmly connected. The rod connectors 5 , 6 can be made of an elastomer material or any other body compatible material.
[0021] The springs 4 a , 4 b in this embodiment are shown as helical springs encompassing the rods 3 a , 3 b like sleeves. They can be made of any body compatible material, in particular of titanium, nickel titanium alloys, for example nitinol, or other materials.
[0022] The rods 3 a , 3 b exhibit a flexibility under forces having a component perpendicular to the rod axis, such as bending forces. For this purpose the rods are made of non-compressible materials, such as stainless steel, titanium, nickel titanium alloys, such as nitinol, PEEK or carbon reinforced PEEK or other body compatible materials.
[0023] It should be noted that the rod connectors and the springs are only examples for the function of connecting the two rods, providing a stop and providing a dampening to the sliding motion.
[0024] Next, the first pedicle screw 1 will be described in detail with reference to FIGS. 3 to 7 . The pedicle screw 1 comprises a screw element 10 with a threaded shank 11 and a spherically segment-shaped head 12 . At the free end of the head 12 a recess 13 is provided for engagement with a tool. The pedicle screw 1 further comprises a receiving part 20 with a first end 21 and a second 22 and a coaxial bore 23 extending from the first end in the direction of the second end. At the second end 22 the bore 23 tapers to provide an opening and a seat 24 for the screw, head 12 as shown in particular in FIG. 7 .
[0025] The receiving part 20 further comprises a recess 25 extending from the first end 21 in the direction of the second end 22 which provides a channel through the receiving part in a direction perpendicular to the bore axis of bore 23 for guiding through the rods 3 a , 3 b . The recess provides two free legs 26 a , 26 b . Near the first end 21 the free legs 26 a , 26 b have an internal thread 27 for cooperation with a fixation screw 30 . The screw element 10 and the receiving part 20 as well as the fixation screw 30 are made of a rigid body compatible material, such as a body compatible metal like stainless steel or titanium or a titanium alloy, such as nitinol.
[0026] For locking the head 12 and in consequence the angular position of the screw element 10 within the seat 24 of the receiving 20 a first pressure element 40 and a second pressure element 50 are provided. The first pressure element 40 and the second pressure element 50 also form guiding elements for guiding the rods 3 a , 3 b through the receiving part 20 . The first pressure element 40 has a substantially cylindrical body part 41 which is sized such that the first pressure element 40 can be inserted in the receiving part and moved in an axial direction within the bore 23 . At its side facing the head 12 of the screw element the first pressure element 40 comprises a cylindrical recess 42 shown in FIG. 7 in which a cylindrical insert 43 is provided. The insert 43 has on its side facing the head 12 of the screw element a spherical recess 44 the radius of which fits to the radius of spherical head 12 of the screw element.
[0027] The first pressure element 40 further comprises a cuboid body part 45 which is shaped so as to fit in the recess 25 of the receiving part 20 as shown in particular in FIGS. 3 and 4 . The width of the body part 45 corresponds to the width of the recess 25 and the length is selected such that the first pressure element is flush with the outer surface 28 of the receiving part 20 as shown in FIG. 4 . On its side opposite to the recess 42 the cuboid body part includes two cylinder segment-shaped recesses 46 a , 46 b the cylinder radius of which is slightly larger than the radius of the rods 3 a , 3 b . The recesses 46 a , 46 b extend perpendicular to the axis of the coaxial bore 23 of the receiving part 20 . The recesses 46 a , 46 b form channels for receiving the rods 3 a , 3 b . Since the recesses 46 a , 46 b are spaced apart from each other a rib 47 is formed between them. The depth of the recesses 46 a , 46 b is preferably slightly larger than the radius of the rods 3 a , 3 b . The first pressure element 40 also has a coaxial bore 48 for providing access to the head 12 of the screw element with a tool. Similarly, the cylindrical insert 43 has a coaxial bore 49 . The cylindrical body part 41 and the cuboid body part 25 are shown to be made in one piece so that cylindrical segment-shaped flanges 41 a , 41 b are provided on each side of the channel 46 a , 46 b . The flanges facilitate the guidance of the first pressure element 40 within the receiving part 20 . The cuboid body part 45 prevents rotation of the first pressure element within the receiving part once the first pressure element is inserted into the recess 25 .
[0028] The second pressure element 50 is substantially cuboid shaped with a width and length corresponding to that of the cuboid body part 45 of the first pressure element 40 . Therefore, it also fits into the recess 25 of the receiving part. On its long sides it comprises two cylindrical segment-shaped flanges 51 a , 51 b corresponding to the flanges 41 a , 41 b of the first pressure element. On its side opposite to the first pressure element 40 , the second pressure element 50 comprises a cylindrical recess 52 and a coaxial cylindrical projection 53 in which a corresponding ring-shaped projection 31 and a cylindrical recess 32 of the fixation screw 30 engage, as shown in FIG. 7 . Thereby, the fixation screw 30 can be rotatably connected to the pressure element 50 .
[0029] On its side facing the first pressure element, the second pressure element 50 comprises two longitudinal cylinder segment-shaped recesses 56 a , 56 b which are complementary in their size and distance to the channels 46 a , 46 b of the first pressure element. The channels 56 a , 56 b are spaced apart by a rib 57 .
[0030] In the assembled state shown in FIG. 7 the first pressure element presses via the insert 43 onto the head 12 . The second pressure element 50 presses onto the first pressure element 40 thereby providing closed channels for the rods 3 a , 3 b which are accommodated therein with a gap 60 to the wall of the channel. Since the fixation screw 30 is rotatably connected to the second pressure element, the fixation screw 30 can be tightened when the second pressure element 50 is inserted.
[0031] The first pressure element and the second pressure element can be made of a material which facilitates sliding of the rods 3 a , 3 b . For example, the pressure elements can be made of titanium or a nickel titanium alloy which is coated or of PEEK or carbon reinforced PEEK. The insert 43 is preferably made of the same material as the head 12 of the screw, for example of a body compatible metal. Instead of providing the insert 43 the first pressure element itself can have a spherical recess to press onto the head. Instead of providing the first and second pressure element of a material which facilitates sliding or which is coated or treated to facilitate sliding, the rods 3 a , 3 b themselves can have a surface which facilitates sliding, for example a coated or otherwise treated surface.
[0032] The second pedicle screw 2 shown in FIGS. 1 , 2 and 8 differs from the first pedicle screw 1 in the design of the first and second pressure elements. All other parts are identical and have the same reference numerals. Therefore, the description thereof is not repeated. The shape of the first pressure element 40 ′ and of the second pressure element 50 ′ of the second pedicle screw 2 is the same as that of the first pressure element 40 and the second pressure element 50 of the first pedicle screw 1 . However, the size of the channels 46 a ′, 46 b ′, 56 a ′, 56 b ′ is smaller than that of the channels of the first and second pressure element of the first pedicle screw. The radius of the channels is adapted to the radius of the rods 3 a , 3 b and depth of the channels is smaller than the radius of the rods 3 a , 3 b such that, as shown in FIG. 8 , in the assembled state the rods 3 a , 3 b are clamped between the first pressure element 40 ′ and the second pressure element 50 ′.
[0033] A second embodiment of the stabilization device is shown in FIGS. 9 and 10 without the rods. The second embodiment differs from the first embodiment described with reference to FIGS. 1 to 8 only in the shape of the first and second pressure elements 400 , 500 . The length of the channels 460 a , 460 b is smaller than the diameter of the cylindrical body part 410 . Therefore, the first pressure element 400 and the second pressure element 500 are arranged completely within the cylindrical bore 23 of the receiving part.
[0034] Modifications of the above described embodiments are conceivable. For example, the pedicle screws and the design of the pressure elements can be such that more than two rods can be accommodated. It is possible to use rods with different elastic properties. It is sufficient, if one of the pressure elements has the channels for guiding the rods, however, it is advantageous if the rods are guided from below and from the top by the channels. The shape of the lower part of the first pressure element can be flat, however, a shape adapted to the shape of the head of the screw 12 is advantageous for distributing the pressure onto the head.
[0035] The fixation element can be a two-part fixation screw wherein the first screw element of a bushing type presses onto the first pressure element for locking of the head 12 and a second screw element of a set screw type arranged within the first screw element presses onto the second pressure element for fixation of the rods in the embodiment shown in FIG. 8 .
[0036] The receiving part can be shaped as a top loader as shown in the figures or a bottom loader in which the screw element 10 is introduced from the bottom, i.e. the second end of the receiving part.
[0037] The shank of the screw element does not have to have a thread. It can be in the form of a hook, a nail or can have barb elements for anchoring in the bone.
[0038] The springs can be also provided adjacent the outer stop 6 . It is also conceivable that the rods themselves have an axial elastic spring portion.
[0039] In use, first the screw elements of the pedicle screws 1 , 2 which have been inserted into the receiving parts 20 are screwed into adjacent vertebrae. The first pressure elements can be preassembled so that after alignment of the receiving parts the rods 3 a , 3 b can be inserted into the receiving parts and the channels of the first pressure element, respectively. The rods 3 a , 3 b with the stops and the springs can be preassembled as well and can be inserted as a double-rod system. For specific clinical applications the first pedicle screw and the stop 6 points in the direction the patient's head. However, the arrangement of the pedicle screws depends on the specific clinical situation.
[0040] Next, after the receiving parts and the rods are aligned the angular position of the screw elements relative to the receiving parts is fixed by inserting the fixation screw together with the second pressure element and tightening the fixation screw. In the case of the second pedicle screw 2 as shown in FIGS. 1 , 2 and 8 the rods 3 a , 3 b are fixed simultaneously with the screw head 12 . In the case of the first pedicle screw only the head 12 of the screw element is fixed while the rods can still slide within the channels.
[0041] As shown in FIG. 1 the rods can slide through the receiving part of the first pedicle screw during flexion or extension of the spinal motion segment, whereby the sliding movement is limited by the rod connectors 6 and 5 acting as stops and dampened by the springs 4 a , 4 b . Simultaneously, the rods may experience bending forces and can bend to some extend provided by the flexibility of the material of the rods.
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A stabilization device for bone parts or vertebrae includes two bone anchoring devices for anchoring in the bone parts or vertebrae. At least one of the bone anchoring devices includes an anchoring element with an anchoring section for anchoring in a bone part or a vertebra and a head, and a receiving part for receiving a stabilization rod. The receiving part has a seat for receiving the head so that the head can pivot with respect to the receiving part. The stabilization device includes a first pressure element which is movable in the receiving part so that it can be pressed onto the head to lock the angular position of the head. The stabilization device includes at least two stabilization rod sections, and at least two guiding channels within the receiving part which have a distance from each other for guiding through the at least two stabilization rod sections so that the rod sections do not touch each other.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority to German Patent Application No. 102007047635.5 filed Oct. 4, 2007, which application is herein expressly incorporated by reference.
FIELD
The disclosure relates to a torque limiting coupling and, more particularly, to a torque limiting coupling rotatably arranged around a longitudinal axis. A coupling hub with circumferentially distributed apertures adjustably holds driving elements that extend parallel to the longitudinal axis. A coupling sleeve includes first recesses that correspond to the apertures. A switching disc is rotatably arranged between a connected position, where the driving elements engage the first recesses to transmit torque, and a freewheeling position relative to the coupling hub. The switching disc, if a predetermined nominal torque is exceeded, is transferred by a rolling movement of the driving elements from the connected position into the freewheeling position. The switching disc includes second recesses that correspond to the apertures. The second apertures are engaged by the driving elements in the freewheeling position. A first spring mechanism loads the switching disc in the circumferential direction towards the switching position. A second spring mechanism axially loads the switching disc and thus loads the driving elements indirectly towards the coupling hub.
BACKGROUND
Torque limiting couplings are sufficiently known from the state of the art. More particularly, they can be used very effectively to protect force- and/or torque-transmitting components of a driveline from critical loads. If the torque limiting couplings are overloaded, they are able to reduce or even completely interrupt transmission of forces or torque between the input end and the output end of a driveline. It goes without saying that such torque limiting couplings are available in a large number of designs.
For example, patent specification DE 102 01 988 C2 proposes a torque limiting coupling that makes it possible, if an overload occurs in a driveline with rotating parts, to interrupt the transmission of force and/or torque. After the elimination of the overload, the coupling enables subsequent automatic connection of the torque limiting coupling at a low connecting speed. Normally, the connecting speed amounts to approximately 100 rpm. If automatic connection of the torque limiting coupling is not desirable, it is possible, even at a very small number of revolutions, to maintain an emergency disconnection of the torque limiting coupling. This prevents automatic reconnection of the torque limiting coupling by actuating a suitable latch.
The torque limiting coupling described in DE 102 01 988 C2 has an emergency disconnection characteristic. Thus, components of a driveline are well protected in the case of an overload. In addition, it offers the possibility of preventing automatic re-connection of the torque limiting coupling when the speed is reduced.
With respect to the driveline torque transmitting components or if a driveline stoppage occurs, in some cases it is undesirable for a released torque limiting coupling not to be re-connected unless a massive reduction in speed, e.g. approximately 100 rpm, takes place. Especially in the case of short-term overloading, the cause of which is usually eliminated automatically, the working process is often interrupted for an unnecessarily long period if the speed in the driveline is reduced. Thus, the working machine subsequently must be restarted.
SUMMARY
It is therefore an object of the present disclosure to provide a torque limiting coupling that make it possible to achieve a higher re-connecting speed.
In accordance with the disclosure, the objective is achieved by providing an initially described torque limiting coupling wherein, in the connected position, a circumferential play is provided between the driving elements and the first recesses.
In practice, it has been found that by providing such a circumferential play between the driving elements and the first recesses, it is possible for a released torque limiting coupling to be re-connected at higher connecting speeds, in practice in excess of 100 rpm. The circumferential play formed between the driving elements and the first recesses can be used to prolong the insertion time of the driving elements into the first recesses during the re-engagement of the driving elements into the first recesses when transferring the driving elements from the freewheeling position into the connected position.
In this way, advantageously even at higher speeds, e.g. in excess of 100 rpm, the driving elements can enter the first recesses sufficiently deeply without being able, undesirably, to jump out of the first recesses. Thus, force and/or torque-locking can be achieved again between the input end and the output end of the driveline. The speeds described here refer to rotating parts in a driveline and, more particularly, to a torque limiting coupling that is able to rotate with the driveline at these speeds.
According to a first variant of an embodiment, the first recesses are longer in the circumferential direction than the driving element portions engaging the first recesses. Because the first recesses are longer in the circumferential direction than the driving elements engaging the first recesses, it is easy from a design standpoint to provide a circumferential play between the driving elements and the first recesses.
The term “portion” describes regions of the driving elements that, provided the torque limiting coupling is accurately connected, are arranged in the first recesses.
Furthermore, even if greater masses are to be driven, the present torque limiting coupling, after being disconnected, in an advantageous way, enables a more rapid speed increase, due to the increased re-connecting speed, without running the risk of the driving elements, due to their high mass inertia, being pushed too soon out of the first recesses. Thus, the starting time of the working machine can be considerably shortened.
It goes without saying that it is possible for differently designed driving elements to enable force and/or torque-locking, in the form of interaction, with the first recesses. For example, driving elements in the form of balls can be provided, as described, in the initially mentioned patent specification.
However, according to a preferred embodiment, the driving elements are in the form of rollers. The rollers are rotatable around axes of rotation that extend radially relative to the longitudinal axis. Rollers are advantageous as compared to the balls. The rollers are able to transmit higher torque values. Needless to say, the rollers can differ geometrically, for example, they can be drum-shaped or conical.
If the rollers are cylindrical, it is particularly easy to produce the corresponding first recesses in simple shape. As a result, other components of the first recesses are easy to produce.
The circumferential play between the driving elements and the first recesses is particularly easy to achieve with cylindrical rollers. Additionally, the first recesses include a surface contour with a concave curvature that differs, at least partially, from a convex curvature of the surface contour of the driving element and, more particularly, the roller surface.
If the driving elements are in the form of balls, it is advantageous if the circumferential extension of the surface contours of the recesses differs from a radial extension.
With the help of the above-described first recesses, more particularly, in cooperation with the driving elements, it is possible to provide an advantageous mechanism to transfer the driving elements into a connected position at a connecting speed in excess of 200 rpm. Additionally, at a connecting speed of 300 rpm. On the other hand, an advantageous mechanism provides prolong insertion time of the driving elements in the first recesses during the re-engagement of the driving elements in the first recesses when transferring the driving elements from the freewheeling position into the connected position.
Also, it is possible to modify the connection behaviour of existing torque limiting couplings. For example, one replaces a coupling sleeve with the first recesses with a coupling sleeve that includes recesses that, in the connected position, are provided with circumferential play relative to the driving elements.
Further advantages, objectives and characteristics of the present disclosure will be explained with reference to the following description of the attached drawings that diagrammatically illustrate torque limiting coupling with a coupling sleeve that includes recesses which are longer in the circumferential direction.
DRAWINGS
The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.
FIG. 1 is a longitudinal section view through a torque limiting coupling.
FIG. 2 is a further longitudinal section view along a sectional line E-E of FIG. 1 .
FIG. 3 is a cross-section view along a sectional line F-F of FIG. 1 .
FIG. 4 is a plan view of a coupling sleeve whose first recesses are longer in the circumferential direction.
FIG. 5 is a longitudinal section through the coupling sleeve according to FIG. 4 .
FIG. 6 is a perspective view of the coupling sleeve according to FIGS. 4 and 5 .
DETAILED DESCRIPTION
The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses.
The torque limiting coupling 1 shown in FIG. 1 is connected to a shaft journal (not illustrated) by splines 3 , defining a bore 2 , in a form-locking and rotationally fast way. The torque limiting coupling 1 and the shaft journal are able to rotate around a common axis of rotation 4 .
The torque limiting coupling 1 includes a coupling hub 5 slid onto the shaft journal. On its radial outside, the coupling hub 5 includes a concentrically extending coupling flange 6 . A total of eight apertures 7 are concentrically arranged around the common axis of rotation 4 . They are given reference numbers by way of example only (see FIG. 3 ).
The apertures 7 receive driving elements 8 . In this embodiment, the driving elements 8 are in the form of cylindrical rollers. The driving elements 8 are supported around the axis of rotation 10 of the driving elements 8 within the apertures 7 (see FIG. 3 ). In accordance with the double arrow 11 and depending on the connected/disconnected condition of the torque limiting coupling according to FIG. 1 , the driving elements 8 can be displaced in the apertures 7 . In the left hand side 12 , they are in the connected condition. In the right hand side 13 , they are in the freewheeling condition.
Primarily, in the operating condition, force and/or torque is transmitted by the torque limiting coupling. The driving elements are in their connected condition. The driving elements are pushed, by force, towards the left hand side 12 . The driving elements 8 are force-loaded by a spring-assisted switching disc 14 towards the left hand side 12 .
The switching disc 14 is permanently pressed by spring forces 17 of a plate spring package 18 , via a pressure bearing 15 and a pressure ring 16 , towards the concentrically rotating coupling flange 6 . The pressure ring 16 is rotationally secured and axially displaceably arranged on the coupling hub 5 . The switching disc 14 is rotatable relative to the pressure ring 16 via the pressure bearing 15 . Together with the pressure ring 16 , the switching disc 14 can be axially adjusted on the coupling hub 5 against the spring force of the plate spring package 18 . The plate spring package 18 is axially supported against the pressure ring 16 , on the one hand, and against a supporting ring 19 , on the other hand. A clamp package 20 is supported in the circumferential direction against the pressure ring 16 , on the one hand, and against the switching disc 14 , on the other hand. This loads the switching disc 14 into a rotational position relative to the pressure ring 16 . The rotational position corresponds to the connected position.
In the connected position or in the operating condition of the torque limiting coupling according to FIGS. 1 and 2 , the driving elements 8 are in a coupled position relative to a coupling sleeve 22 . The driving elements 8 are arranged at the coupling sleeve 22 in first recesses 23 of the torque limiting coupling 1 . The first recesses 23 are arranged at the coupling sleeve 22 . Thus, they extend concentrically around the common axis of rotation 4 .
A supporting ring 24 and an intermediate disc 25 secure the coupling sleeve 22 on the left hand side 12 at the coupling hub 5 . The coupling sleeve 22 includes threaded bores 26 that connect to a component (not shown) at the input end or output end.
FIG. 2 shows one of the first recesses 23 in a cross-sectional view. In this embodiment, the recesses 23 include a ladle-shaped surface contour 27 . Thus, a circumferential play 28 occurs between the driving elements 8 , which in this embodiment are provided in the form of cylindrical rollers 9 . The circumferential play 28 , if viewed in the circumferential direction of the coupling sleeve 22 , occurs on both sides of the cylindrical rollers 9 . This is due to the ladle-shaped surface contour 27 in the region of its vertex 29 , including a bottom region 30 of the first recesses 23 .
Under load conditions, the driving members 8 , depending on the direction of rotation, rest against one of the curved side regions 31 or 32 . The side regions 31 , 32 are located between the planar bottom region 30 and a planar running face 33 of the coupling sleeve 22 . The side regions 31 , 32 complete the ladle-shaped surface contour 27 .
If overloading occurs, the switching disc 14 is rotated relative to the coupling sleeve 22 around the common axis of rotation 4 . The second recesses 34 of the torque limiting coupling that are arranged at the switching disc 14 overlap the apertures 7 in the concentrically rotating coupling flange 6 . The switching disc 14 continues to be force-loaded in the circumferential direction by the clamp package 20 towards entering the connected position. The spring forces automatically displace back into its connected position as soon as overloading discontinues and as soon as the torque limiting coupling 1 rotates at a suitable speed.
Thus, in the case of overloading, the coupling sleeve 22 and the coupling hub 5 rotate relative to one another. The driving members 8 push the switching disc 14 against the spring forces 17 . The plate spring package 18 is compressed as a result. Thus, the driving members 8 can be displaced into the second recesses 34 of the switching disc 14 . As a result, the force-locking connection between the coupling sleeve 22 and the coupling hub 5 is interrupted. Once the driving members 8 have been moved into the second recesses 34 , the torque limiting coupling 1 is in a freewheeling position. Thus, the force and torque locking effect between an input end and an output end is interrupted. As a result, any damage to the driveline can be prevented.
Once the overload condition has been eliminated, it is possible, as described above, by reducing the speed, to transfer the coupling from the freewheeling position into the connected position 21 . Thus, the driving elements 8 can be displaced back into the first recesses 23 . In this embodiment, the recesses 23 include a ladle-like surface. Thus, a longer period of time is available for the driving elements 8 to enter the first recesses 23 before they abut one of the curved side regions 31 and 32 , respectively. This additional period of time ensures that the driving elements 8 can enter the first recesses 23 much more deeply, ideally completely.
The first recesses 23 , if viewed in the circumferential direction, are wider. This ensures that the driving elements 8 are able to enter the first recesses 23 in an operationally safe way at a substantially higher connecting speed. Thus, the torque limiting coupling 1 is ready for operation much sooner. To that extent, the first recesses 23 , with their ladle-like surface contours 27 , constitute an advantageous mechanism to prolong the insertion time of the driving elements into the first recesses 23 during the re-engagement of the driving elements 8 into the first recesses 23 , thus transferring the driving elements from the freewheeling position into the connected position.
The torque limiting coupling 1 includes a housing 35 that protects the above-mentioned components and assemblies of the torque limiting coupling 1 against influences of the environment 36 . When the housing 38 abuts the coupling sleeve 22 , it is held by a securing ring 37 on the coupling hub 5 .
In the cross-section through the concentrically rotating coupling flange 6 of the coupling hub 5 shown in FIG. 3 , it is easy to identify the apertures 7 that rotate concentrically around the common axis of rotation 4 . The driving elements 8 are arranged in the apertures 7 to rotate around their respective driving element axis 10 . Thus, the driving elements 8 can roll in a problem-free way on the planar running face 33 of the coupling sleeve 22 . The apertures 7 at the concentrically rotating coupling flange 6 are radially closed by the housing 35 . The housing 35 is slid over the coupling flange 6 and secured to the coupling hub 5 .
FIG. 4 illustrates the coupling sleeve 22 as viewed from the switching disc 14 . Similarly to the apertures 7 of the coupling hub 5 , the coupling hub 22 is provided with a total of eight first recesses 23 . The recesses 23 are arranged to extend concentrically around the common axis of rotation 4 . Running face segments 38 are arranged between the first recesses 23 . The running face segments 38 provide the planar running faces 33 at the coupling sleeve 22 .
The ladle-shaped surface contour 27 , via its curved side regions 31 and 32 , respectively, adjoins the running face segments 38 . Between the two curved side regions 31 and 32 , a planar bottom region 30 is provided at each ladle-shaped surface contour 27 .
In the longitudinal section through the coupling sleeve 22 , as illustrated in FIG. 5 , it is possible, in the region of two opposed recesses 23 A and 23 B, to identify in the upper region of the coupling sleeve 22 , a second curved side region 32 of the upper first recess 23 A. It is also easy to see the planar bottom region 30 . The running face segment 38 has its planar running face 33 adjoining the second curved side region 32 at the lower first recess 23 B in the lower region of the coupling sleeve 22 . At the lower first region 23 B, in the lower region of the coupling sleeve 22 , a first curved side region 31 of a ladle-shaped surface structure 27 is provided for the planar running face 33 of a running face segment 38 .
In the illustration of FIG. 6 , the coupling sleeve 22 is shown in a perspective view from the direction of the switching disc 14 . Thus, it very easy to identify the arrangement of the first recesses 23 with the ladle-shaped surface contours 27 and the running face segments 38 in an alternating arrangement.
The description of the disclosure is merely exemplary in nature and, thus, variations that do not depart from the gist of the disclosure are intended to be within the scope of the disclosure. Such variations are not to be regarded as a departure from the spirit and scope of the disclosure.
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In order to increase an automatic connecting speed at a torque limiting coupling, a torque limiting coupling ( 1 ) has a coupling hub ( 5 ). Driving elements ( 8 ) are adjustably held in the apertures and extend parallel to the longitudinal axis. A coupling sleeve has first recesses ( 23 ) corresponding to the apertures. A switching disc ( 14 ) is rotatably arranged between a connected position and a freewheeling position, relative to the coupling hub. The switching disc ( 14 ) can be transferred by a rolling movement of the driving elements ( 8 ) from the connected position into the freewheeling position. The switching disc ( 14 ) has second recesses ( 34 ) that engage the driving elements ( 8 ) in the freewheeling position. A first and second spring mechanism load the switching disc ( 14 ) in the circumferential and axial direction. Circumferential play ( 28 ) is formed between the driving elements ( 8 ) and the first recesses ( 23 ) in the connected position.
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BACKGROUND OF THE INVENTION
[0001] The invention relates to calendering of paper and to a method, wherein a paper web is passed through a nip formed by a heatable thermo roll and a backing roll.
[0002] In calendering, paper is pressed in the nip, whereby the surface of the paper in particular is moulded under the effect of mechanical work and heat. The purpose is to increase especially the smoothness of the paper, and to eliminate variations in thickness. However, in calendering, the paper is also compressed, which decreases the stiffness, the strength, and the opacity.
[0003] The plasticity of paper in calendering can be improved by increasing the temperature of the paper. In practice, this is effected so that one of the rolls of the nip is a heatable roll, a so-called thermo roll, which is against the surface of the web that is to be moulded. In the calendering methods used at present, the surface temperature of the thermo roll is in the range of the glass-transition temperature of the paper that is moulded, at the most. The glass-transition temperature is dependent on the paper grade. Moisture decreases the glass-transition temperature, which is why the paper is often moistened before calendering. Typically, the glass-transition temperature is within 150 . . . 250° C.
DESCRIPTION OF THE INVENTION
[0004] According to the independent claims, a calendering method and a calender have now been invented. Some embodiments of the invention are presented in the dependent claims.
[0005] Paper herein generally refers to a web-like material, which is manufactured of a fibre suspension. Thus, the paper can be actual paper, for example, such as printing paper, or paperboard.
[0006] The roll herein generally refers to a rotating member, such as a rotating roll and/or a revolving belt.
[0007] Paper that is manufactured of wood fibre contains various polymers: cellulose, hemicellulose, and lignin. In addition, coated paper can also contain other polymers, such as starch or synthetic polymers, such as polystyrene butadiene. The polymers are partly in a crystalline and partly in an amorphous form. The deformations that take place in the polymers of the paper depend on time and are partly non-reversible (visco-elastic). The macroscopic deformation of a visco-elastic material is a result of deformation processes on the molecular level. An increase in temperature accelerates the movement of the molecules and their segments and makes the amorphous phase quicker in reacting to an external force. In that case, as large permanent deformations can be achieved in the material by means of an external force of a shorter duration.
[0008] Below a certain temperature range characteristic to each polymer, the glass transition temperature range, the amorphous phase is in a glassy state. Hereby amorphous polymers and the amorphous parts of partly crystalline polymers have solidified and become hard and fragile. However, under an external force, in addition to the reversible deformation (an elastic component) in the glassy state, also permanent deformation (a viscous component) can take place, which is called plastic deformation. In the glass transition range, the portion of the viscous component of the amorphous phase increases considerably and all physical and mechanical properties undergo a strong change. The centre of the range is called the glass transition temperature.
[0009] Depending on the degree of crystallinity, the glass transition temperature of the cellulose in wood fibres is about 200 . . . 250° C., that of hemicellulose about 150 . . . 220° C., and that of lignin about 130 . . . 205° C. The glass transition temperatures of the synthetic polymers normally used in coatings are considerably lower than those of the biopolymers contained in wood fibres. For example, the glass transition temperature of styrene/butadiene latex, depending on the structure of the bond of the polymer, is about 0 . . . 70° C. The glass transition temperature of starch in dry conditions is about 100° C. The glass transition temperature is dependent on the plasticizing effect of water. A growth in moisture content decreases the glass transition temperature.
[0010] Above the glass transition range, there is the range of a rubbery state. With the temperature further increasing, a rubbery flow range is reached and, further, a viscous flow range.
[0011] In the method now invented, paper is calendered in the nip by a thermo roll, the surface temperature of which is above the glass transition range of the paper to be calendered, i.e. in the range of the rubbery state, in the rubbery flow range or in the viscous flow range. Correspondingly, the temperature can be, for example, about 250° C. at a minimum, about 300° C. at the minimum or about 350° C. at the minimum. A temperature of as much as 450° C. can be used. The upper limit should be about 550° C. The temperature is preferably within 300 . . . 400° C. At the temperatures according to the invention, the fibres of the surface are plasticized, whereby they are easier to mould, for example, to press into a flat form. The deformations are also more stable than at lower temperatures. At high temperatures, the surface of the paper can partly melt. Because of the plasticizing of the surface, moulding in the direction of the surface, such as a transition, increases.
[0012] The method according to the invention gives better smoothness, polish, and consistency to the surface of the paper. In that case, for example, the printability of the paper improves, because the printing ink sticks better to the surface. For coated grades, the amount of coating needed is reduced.
[0013] When so desired, the surface of the paper can also be moistened before the calendering nip to improve the plasticity. At temperatures according to the invention, however, moistening is generally not needed.
[0014] When so desired, the paper can be cooled after the nip.
[0015] Because the surface of the paper is easier to mould in the nip, lower nip pressures and shorter residence times can be used. In this way, particularly the compression of the paper decreases and the volume weight (bulk) is better maintained.
[0016] The calender can be a soft calender, for example. The calender can also be a multi-nip calender. In a traditional calender formed by two round rolls, the linear load can be 40 . . . 200 kN/m, for example. The calendering nip is preferably a so-called long nip, a revolving belt being provided at least on its one side, moving in the nip over a so-called shoe, wherein the other nip surface presses it. The distance travelled by the paper web in the nip can be, for example, 25 . . . 400 mm, such as 150 . . . 250 mm. The nip pressure can be 5 . . . 50 Mpa, such as 10 . . . 30 Mpa, for example, depending on the belt coating and the linear load. The residence time in the nip can be short.
[0017] The temperature of the paper web coming to the nip can be 30 . . . 100° C., for example. Generally, it is the better the lower the inner temperature of the paper is, as in that case there is less compression of the inner part of the paper. The other surface of the paper can be cooled. The formation of a temperature gradient in the calendering nip is influenced by transfer of heat from the thermo surface to the paper, transfer of heat inside the paper, and by transfer of heat from the backside to the counter surface. The compression pressure has a considerable effect on the heat transfer.
[0018] Moulding of the inner part of the paper can further be decreased by cooling the web surface on the side of the backing roll.
[0019] The method can be applied to both coated and uncoated paper and to both precalendering and finishing calendering. In precalendering, the intention is to particularly control the degree of roughness and porosity required by the coating.
[0020] The high temperature needed is best provided by means of oil or induction heating.
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The invention relates to a method for calendering of paper, comprising passing the paper web through a flip formed by a heatable thermo roll and a backing roll. The surface temperature of the thermo roll is above the glass transition range of the paper.
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